00 BPCL 41purchase Requisition

Engineering, Procurement and Construction Management
Consultancy Services - Stage-2 (EPCM-2) for Propylene Derivative

Petrochemical Project (PDPP) at BPCL Kochi Refinery
PURCHASE REQUISITION
(Document No : A842-PDE-VV-PR-6041-0041)
Page 1 of 704
Click on the Document Title to go to that section of the document
Table of Contents
Document Number Rev. Document Title Page
Number
A842-PDE-VV-PR- 0 PURCHASE REQUISITION 6
6041-0041
A842-PDE-VV-PDS 0 ANY OTHER DOCUMENT 10
A842-79-41-PDE- 2 A842-79-41-PDE-11044 85
11044
A842-79-41-PDE- 2 A842-79-41-PDE-11045 86
11045
A842-79-41-PDE- 2 A842-79-41-PDE-11046 87
11046
A842-79-41-PDE- 2 A842-79-41-PDE-11084 88
11084
A842-79-41-PDE- 2 A842-79-41-PDE-11085 89
11085
A842-79-41-PDE- 2 A842-79-41-PDE-11086 90
11086
A842-PDE-80-43- 0 JOB SKETCHES 91
SK-0003
PDPP-SDR-0001 1 PDPP-SDR-0001 92
A842-PDE-80-43- A MIXER/AGITATOR DATASHEET 117
DS-XXXX
6-12-0001 5 General specification for pressure vessels. 119
6-12-0002 7 Supplementary specification for carbon steel vessels. 132
6-12-0006 5 Supplementary specification for austenitic stainless steel vessels. 139
6-12-0011 7 Standard specification for boiler quality carbon steel plates. 146
6-12-0014 5 Standard specification for weldable structural quality steel plates 153
for tanks and vessels
6-12-0020 7 Standard specification for stainless steel plates. 157
6-14-0003 5 Installation procedure for trays and tower internals. 162
6-14-0017 3 General specification for wire mesh demisters 178
6-81-0001 2 Standard specification for Positive Material Identification (PMI) at 184
Supplier's Works
6-81-0011 3 ITP for pressure vessels / columns carbon steel. 192
6-81-0014 3 ITP for stainless steel pressure vessels/ columns 199
6-81-0060 3 ITP for wire mesh demisters. 206
6-82-0001 6 Standard specification for health, safety & environment (HSE) 211
management at construction sites
6-78-0001 1 Specification for quality management system requirements from 298
bidders
6-78-0003 1 Specification for documentation requirement from suppliers 305
A842-000-79-41- 0 PROCESS SPECIFICATION-FREE NUMBER FORMAT 314
PLS-01
6-26-0001 3 Standard specification for mechanical agitators 358
7-12-0001 5 Vessel tolerances. 370
7-12-0002 5 SUPPORT FOR HORIZONTAL VESSEL 372
7-12-0004 6 Skirt base details. 373
7-12-0005 5 Skirt opening details. 374
7-12-0006 5 Angle leg support. 376
7-12-0007 5 Pipe leg support. 378
7-12-0008 5 Bracket support for vertical vessel. 379
7-12-0009 6 Manhole with hinged cover. 380
7-12-0010 6 Manhole with davit. 382
7-12-0011 5 Ladder rungs for manhole/demister. 384
7-12-0013 6 Nozzle reinforcement and projection. 385
Page 2 of 704
Table of Contents
Number
7-12-0015 5 Standard bolt hole orientation. 387
7-12-0017 5 Sight glasses for pressure vessels. 388
7-12-0018 5 Internal flanges. 390
7-12-0019 5 Vortex breakers. 391
7-12-0023 6 Pipe davit. 392
7-12-0024 7 Lifting lug top head type (for vertical vessels / columns). 395
7-12-0025 5 Fire proofing & insulation supports. 396
7-12-0026 5 Earthing lug. 398
7-12-0027 5 Name plate. 399
7-12-0028 5 Manufacturer name plate. 400
7-12-0029 5 Bracket for name plate. 401
7-12-0030 4 Name plate for small equipment. 402
7-12-0032 4 Supports for internal feed pipe. 403
7-12-0033 4 Hot insulation supports for horizontal vessel. 405
7-12-0036 4 Typical details of wire mesh demister and its supports (for vessels 406
and columns).
7-12-0038 0 Allowable nozzle loads 410
6-51-0064 1 Specification for energy efficient medium voltage induction motors 414
6-81-1032 5 ITP for MV motors 426
7-52-0001 4 Instrument connection on vessel, standpipes and tanks. 432
7-52-0002 4 Instrument connection on pipes. 436
7-52-0035 3 Thermowell. 439
7-52-0036 3 Thermocouple / RTD assembly with thermowell. 442
A842-000-16-51- A DRAWING 443
IS45
A842-000-16-51- A DRAWING 444
IS59
7-52-0481 4 Level gauge on vessel. 445
6-52-0052 3 Standard specification for instrumentation of package units. 446
7-52-0101 2 Instrument support single instrument 520
7-52-0041 3 Orifice plates and flanges dimensional details. 523
6-52-0032 4 Standard specification for electronic / pneumatic instruments. 537
A842-000-16-51-DS- A DATA SHEET 553
1001
A842-000-16-51-DS- A DATA SHEET 554
1101
A842-000-16-51-DS- A DATA SHEET 555
2601
A842-000-16-51-DS- A DATA SHEET 556
3201
A842-000-16-51-DS- A DATA SHEET 557
4001
A842-000-16-51-DS- A DATA SHEET 558
3701
A842-000-16-51-DS- A DATA SHEET 560
2501
A842-000-16-51-DS- A DATA SHEET 561
3401
A842-000-16-51-DS- A DATA SHEET 562
0201
Final Vendor List 0 VENDOR LIST 563
MR-6041(14) Rev 0
Page 3 of 704
Table of Contents
Number
7-52-0036 4 Thermocouple / RTD assembly with thermowell. 570
7-52-0481 5 Level gauge on vessel. 571
A842-79-41-PDE- 4 A842-79-41-PDE-11044 572
11044
A842-79-41-PDE- 4 A842-79-41-PDE-11084 573
11084
A842-PDE-16-50- 0 JOB SPECIFICATION FOR AGITATORS 574
SP-6042
A842-PDE-16-50- 0 VENDOR DATA REQUIREMENTS 577
VR-6041
A842-PDE-16-51-SL- 0 MANDATORY SPARE PARTS 580
6041/0041
A842-PDE-16-51- 0 JOB SPECIFICATIONS 582
SP-6041/0041
A842-PDE-16-51- A VENDOR DATA REQUIREMENTS 592
VDR-6041/0039
A842-PDE-85-41-VL- 0 VENDOR LIST 595
6041-41
PDPP-DS-A405 1 PDPP-DS-A405 602
PDPP-DS-A505 1 PDPP-DS-A505 603
PDPP-DS-V405 1 PDPP-DS-V405 604
PDPP-SDR-0001 2 PDPP-SDR-0001 631
A842-80-43-LL-6041- 0 PR LIST OF ATTACHMENTS 655
0041
A842-80-43-SS- 0 PR SCOPE OF WORK AND SUPPY 659
6041-0041
A842-80-43-TR- 0 PR INSTRUCTIONS TO VENDOR 665
6041-0041
A842-PDE-80-43- 0 VDR FOR VDR COMPILATION 678
VDR-6041
A842-PDE-80-43- 0 MECHANICAL DATASHEETS 682
DS-3405
DS-3405A3
DS-3405A2
DS-3425
DS-3425A2
DS-3433
DS-3433A3
A842-PDE-80-43- 0 ENGINEERING DRAWINGS/SETTING PLAN 690
DS-3433A2
Page 4 of 704
Table of Contents
Number
DS-3432
DS-3432A3
DS-3432A2
DS-3431
DS-3431A2
DS-3505
DS-3505A3
DS-3505A2
DS-3525
DS-3525A2
DS-3411
DS-3411A2
Page 5 of 704
PURCHASE REQUISITION (TOP SHEET)
ITEM DESCRIPTION: PRESSURE VESSEL -CS (UP TO 25 MM), PRESSURE VESSEL -SS (UP TO 25MM)
This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced,
GROUP ITEM CODE: 01AA,01AE DESTINATION: As per Commercial Documents

DELIVERY PERIOD: As per Commercial Documents
DOCUMENT NUMBER
( Always quote the Document Number given below as reference )
A842 PDE VV PR 6041 / 0041 0 12/04/2017 80 43

copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.
JOB NO. UNIT/ MAIN DOC. SR. NO. REV. DATE DIVN. DEPT.
AREA COST CODE
ORIGINATOR
S133 Shree Satyanarayan Ind. Supp. Pvt. Ltd
VENDOR CODE VENDOR NAME

( FOI Number: 41 DATED 31/01/2017 )
NOTES :
1 This page is a record of all the Revisions of this Requisition.
2 The nature of the Revision is briefly stated in the "Details" column below, the
Requisition in its entirety shall be considered for contractual purposes.
REV. DATE BY CHK. APPD. DETAILS

0 12/04/2017 SA PVSS PVSS ISSUED FOR PURCHASE
This is a system generated approved document and does not require signature.
Project: PMC-2 FOR PROPYLENE DERIVATIVE

ENGINEERS INDIA LIMITED PETROCHEMICAL PROJE
Client: BPCL-KOCHI REFINERY
NEW DELHI
Sheet 1 of 4
Page 6 of 704
SR. NO. TAG NO./ DESCRIPTION QUANTITY
ITEM CODE/ [ ID. NO.]
01.00 Residual Design & Engineering of Vessels
including design of Agitators, procurement

of materials and bought out components,
fabrication including assembly/sub
assembly at shop, NDT, inspection, testing
at manufacturer's works, hydrotest,
surface preparation and application of
primer & finish paint, packing, delivery
of following equipment, supply of agitator

assembly alongwith ancillaries including
motor, gear box drives, mechanical seal,
Instrumentation and accessories, supply of
hoppers, supply of all mandatory /
commissioning spares & documentation as
per the enclosed EIL standard
specifications, instructions to vendors,
job specification, data sheets etc. and
other codes and standards attached or
referred
01.01 PDE-V-405 CATALYST MIXING DRUM 1 Nos
01.04 PDE-V-411 V-410 RECEIVER 1 Nos
01.06 PDE-V-425 WATER SURGE DRUM 1 Nos
01.07 PDE-V-431 V-440 FEED DRUM 1 Nos
01.08 PDE-V-432 OIL SEPERATOR 1 Nos
01.09 PDE-V-433 SCUM SEPERATOR 1 Nos
01.14 PDE-V-505 CATALYST MIXING DRUM 1 Nos
01.19 PDE-V-525 WATER SURGE DRUM 1 Nos
01.22 PDE-V-533 SCUM SEPERATOR 1 Nos
03.00 Transportation of vessels, hoppers &
agitator assembly alongwith ancillaries
including motor, gear box drives,
mechanical seal, Instrumentation and
accessories from Vendors work/ shop to
site (as per commercial part) for the
following as per the enclosed EIL standard
specifications, instructions to vendors,
job specification, data sheets etc
03.01 {03}PDE-V-405 For Sr. No. 01.01 1 Nos
03.04 {03}PDE-V-411 For Sr. No. 01.04 1 Nos
03.06 {03}PDE-V-425 For Sr. No. 01.06 1 Nos
03.07 {03}PDE-V-431 For Sr. No. 01.07 1 Nos
03.08 {03}PDE-V-432 For Sr. No. 01.08 1 Nos
03.09 {03}PDE-V-433 For Sr. No. 01.09 1 Nos
03.14 {03}PDE-V-505 For Sr. No. 01.14 1 Nos
03.19 {03}PDE-V-525 For Sr. No. 01.19 1 Nos
03.22 {03}PDE-V-533 For Sr. No. 01.22 1 Nos
08.00 Supervision (alongwith manufacturer of
Agitator) for erection/testing of agitator
assembly and installation/ Testing of
Instrumentation & Electrical items,
Hoppers, commissioning of items specified
at item 1.00 above, as per enclosed
REQUISITION NO. REV.
Client: BPCL-KOCHI REFINERY A842-PDE-VV-PR-6041 / 0041 0
NEW DELHI
Sheet 2 of 4
Page 7 of 704
SR. NO. TAG NO./ DESCRIPTION QUANTITY
ITEM CODE/ [ ID. NO.]
instructions to vendor (refer note-1)
08.01 {08}PDE-V-405 For Sr. No. 01.01 1 /diem rate

08.14 {08}PDE-V-505 For Sr. No. 01.14 1 /diem rate
09.00 Drawings and documents as per attached Lot
Vendor Data requirement for all supplies
and services covered above in Sr.Nos.1.00
to Sr.No.8.00
Unit rates for various items if any , shall be as included in the Commercial part
of the Purchase order.
Vendor to note that the numbers given in square '[]' and curly '{}' brackets are
not for their use and meant for store purpose only. Items shall be tagged as per
main equipment Tag No. only.

NEW DELHI
Sheet 3 of 4
Page 8 of 704
LIST OF ATTACHMENTS
REVISION
SL. REV. REV. REV. REV.

DOCUMENT TITLE DOCUMENT NO.
No.
DATE DATE DATE DATE
In case of any subsequent revision of MR or PR, only revised sheets of the

attachments listed above shall be issued alongwith the revision.
GENERAL NOTES:
1. FOR LIST OF ATTACHMENTS REFER "TABLE OF CONTENTS".

NEW DELHI
Sheet 4 of 4
Page 9 of 704
MITSUBISHI CHEMICAL CORPORATION CONFIDENTIAL
1 Customer Bharat Petroleum Corporation Limited
2 DRUM DATA SHEET Doc. No. PDPP-DS-V405-1
3 Project Name PDP Project
4 Item No. PDE-V-405 Job No. E029636001
5 Service Catalyst Mixing Drum No. Req'd Working 1 Spare 0 Total 1
6 Regulation - Location ( ) Indoor (X) Outdoor
7 Code ASME Sec.VIII Div.1
8 Type VERTICAL Shell I.D. / Shell Length mm 2800 / 5100
9 DESIGN CONDITIONS PAINTING
10 Section Shell Side Jacket Side Trace Side ( ) Yes ( ) No (X) C.S. only
11 Fluid Name P - -
12 Density kg/m3 896 - - WEIGHT
13 Operating Press. mmWC(g) ATM - - Erection kg @
14 o
Temp. C 35 - - Empty kg @
15 Design Press. mmWC(g) F.W. + 150 / - 50 (*1) - / - - / - Operating kg @
16 o
Temp. C 65 - -
17 Hydro.Test Press. mmWC(g) F.W. - - ACCESSORIES
18 Leak Test Press. mmWC(g) - - - (X) Name Plate with Saddle
19 Radiograph % By Code - - (X) Lifting Lug
20 Post Weld Heat Treatment By Code - - (X) Anchor(Set) Bolt & Nut
21 Corrosion Allowance mm 0 (for S.S.) - - (X) Earth Plate
22 Insulation None - - ( ) Support for Insulation
23 Volume Full m3 31.4 - - ( ) Platform & Ladder
24 Operating m3 15.8 / 8.0 (*2) - - ( ) Lug for Attachment
25 Retention Time min. - - - ( ) Sight Glass
26 (X) Agitator (*3)
27 MATERIAL ( ) Demister
28 Section Shell Side Jacket Side Trace Side ( ) Vortex Breaker
29 Shell 316 SS - - ( ) MH Balancer
30 Hopper 316 SS - - ( ) Internal Ladder
31 Nozzle 316 SS - -
32 Flange F316 SS - -
33 Gasket V#7010 or Eq. - -
34 Internal, Basket, Mesh 316 SS - -
35 External C.S. - -
36 Leg,Saddle - - -
37
38 REMARKS
39
40 '@' Marks to be decided by Vendor.
41 (*1) Design press. of Hopper : F.W. + 150 mmWC(g)
42 (*2) Upper Part / Lower Part
43 (*3) As for the specification of agitator, refer to "PDPP-DS-A405".
44
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61 LIST OF ATTACHED SHEETS
62 PDPP-DS-V405-2 Outline Sketch and List of Nozzle
63 PDPP-DS-V405-3 Detail of Nozzle and Hopper
64
65
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67
68
69
70
71 <1> 11 Mar. 2016 T.Tanaka M.Matsuyama J.Takahashi Revision up
72 <0> 17 Jan. 2016 T.Tanaka M.Matsuyama J.Takahashi Original
73 Rev. Date Prepared Checked Approved Description
Page 10 of 704
MITSUBISHI CHEMICAL CORPORATION
1 Doc. No. PDPP-DS-V405-2
2
DRUM DATA SHEET Project Name PDP Project
3 Job No. E029636001
4 Item No. PDE-V-405 Service Catalyst Mixing Drum
5
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8
CONFIDENTIAL
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54 NOZZLE LIST
55 Mark Size Q'ty Rating Service Mark Size Q'ty Rating Service
56 N1 2" 1 #150 SO-RF Liquid from OSBL T1 2" 1 #150 SO-RF TG
57 N2 3" 1 #150 SO-RF Over Flow L1 3" 1 #150 SO-RF LT
58 N3 2" 1 #150 SO-RF Liquid from Upper Part L2 3" 1 #150 SO-RF LT
59 N4 2" 1 #150 SO-RF Liquid to Lower Part G1a,b 2" 2 #150 SO-RF LG
60 N5 2" 1 #150 SO-RF Liquid to P-405 G2a,b 2" 2 #150 SO-RF LG
61 N6(*3) 2" 1 #150 SO-RF LN Inlet
62 N7 2" 1 #150 SO-RF LN Inlet X1 (*1) 1 #150 SO-RF Agitator Mount
63 N8~9 2" 2 #150 SO-RF MXA Inlet
64 N10~11 2" 2 #150 SO-RF Spare (w/Cover) MH1~2 24" 2 #150 SO-RF Manhole (w/Cover)
65 N12 - 1 - PTSA Inlet
66 HH1 6" 1 #150 SO-RF Handhole (w/Cover)
67 V1 4" 1 #150 SO-RF VENT
68 V2(*3) 2" 1 #150 SO-RF VENT
69 D1~2 2" 2 #150 SO-RF DRAIN
70
Page 11 of 704
2
3 Job No. E029636001
5
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CONFIDENTIAL
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Page 12 of 704
5 Service V-410 Receiver No. Req'd Working 1 Spare 0 Total 1
8 Type HORIZONTAL Shell I.D. / Shell Length mm 3200 / 6700
11 Fluid Name P - -
12 Density kg/m3 857 / 977 - - WEIGHT
13 Operating Press. mmHg 200 - - Erection kg @
14 Temp. °C 31 - - Empty kg @
15 Design Press. kg/cm2(g) 3.5 / F.V. - / - - / - Operating kg @
16 Temp. °C 65 - -
17 Hydro.Test Press. kg/cm2(g) By Code - - ACCESSORIES
18 Leak Test Press. kg/cm2(g) 3.5 - - (X) Name Plate with saddle
23 Volume Full m3 62.5 - - (X) Platform & Ladder (*1)
26 ( ) Agitator
28 Section Shell Side Jacket Side Trace Side (X) Vortex Breaker
30 Head 304 SS - - (X) Internal Ladder
34 Internal 304 SS - -
36 Leg,Saddle C.S. - -
37
38 REMARKS
39
41 (*1) Scope of supply is finalized in detailed engineering stage.
42 (*2) Light Liquid Part / Decanting Part
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63 PDPP-DS-V411-3 Detail of Nozzle
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Page 13 of 704
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3 Job No. E029636001
4 Item No. PDE-V-411 Service V-410 Receiver
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 6" 1 #150 SO-RF Liquid from E-412 T1 2" 1 #150 SO-RF TE
57 N2 2" 1 #150 SO-RF Liquid from E-413 L1a,b 2" 2 #150 SO-RF LT
58 N3 4" 1 #150 SO-RF Liquid to P-411A/B L2a,b 3" 2 #150 SO-RF LT
59 N4 4" 1 #150 SO-RF Liquid to P-412A/B G1a,b 2" 2 #150 SO-RF LG
60 N5 (*2) 1 #150 SO-RF Min. Flow(from P-411A/B) G2a,b 2" 2 #150 SO-RF LG
61 N6 (*2) 1 #150 SO-RF Min. Flow(from P-412A/B) P1 2" 1 #150 SO-RF PT
62 N7 2" 1 #150 SO-RF Equalization P2 2" 1 #150 SO-RF PG
63 N8 2" 1 #150 SO-RF LN Inlet
64 N9 2" 1 #150 SO-RF FCS Inlet MH1~2 24" 2 #150 SO-RF Manhole(w/Cover)
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Page 14 of 704
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CONFIDENTIAL
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Page 15 of 704
5 Service Inhibitor Drum No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name P - -
14 o
16 o
Temp. C 65 - -
36 Leg,Saddle - - -
37
38 REMARKS
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Page 16 of 704
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3 Job No. E029636001
4 Item No. PDE-V-415 Service Inhibitor Drum
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CONFIDENTIAL
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54 NOZZLE LIST
61 N6(*3) 2" 1 #150 SO-RF LN Inlet
63 N8~9 2" 2 #150 SO-RF MXA Inlet
65 N12 - 1 - Inhibitor Inlet
67 V1 4" 1 #150 SO-RF VENT
68 V2(*3) 2" 1 #150 SO-RF VENT
69 D1~2 2" 2 #150 SO-RF DRAIN
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Page 17 of 704
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CONFIDENTIAL
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Page 18 of 704
5 Service Water Surge Drum No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name P - -
15 Design Press. mmWC(g) F.W. + 150 / - 50 - / - - / - Operating kg @
16 Temp. °C 65 - -
18 Leak Test Press. mmWC(g) - - - (X) Name Plate with saddle
26 ( ) Agitator
30 Head - - - ( ) Internal Ladder
36 Leg,Saddle - - -
37
38 REMARKS
39
41 (*1) It shall be verified that V2 is larger than V1.
42 V1 : sum of volume for pipes under 10m from grade connected from LZ-441, LZ-451 and E-443
43 V2 : volume between LIL and level at end of insert pipes
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63 PDPP-DS-V425-3 Detail of nozzle
64 PDPP-DS-V425-4 Detail of Dam Baffle
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71 <1> 11 Mar. 2016 T.Tanaka M.Matsuyama J.Takahashi Revised as per PDP review meeting
Page 19 of 704
2
3 Job No. E029636001
4 Item No. PDE-V-425 Service Water Surge Drum
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 2" 1 #150 SO-RF Liquid from LZ-441 V1 3" 1 #150 SO-RF VENT
57 N2 2" 1 #150 SO-RF Liquid from LZ-451
58 N3 2" 1 #150 SO-RF Liquid from LZ-451 D1 2" 1 #150 SO-RF DRAIN
59 N4 2" 1 #150 SO-RF Liquid from V-471 D2 2" 1 #150 SO-RF DRAIN
60 N5 2" 1 #150 SO-RF Liquid from V-441
61 N6 2" 1 #150 SO-RF Liquid from LZ-416 L1a,b 2" 2 #150 SO-RF LT
62 N7 2" 1 #150 SO-RF Liquid from E-443 L2 3" 1 #150 SO-RF LT
63 N8 2" 1 #150 SO-RF Liquid from P-412A/B G1a.b 2" 2 #150 SO-RF LG
65 N10 2" 1 #150 SO-RF Liquid to P-425A/B
66 N11 (*2) 1 #150 SO-RF Min. Flow (From P-424A/B) MH1 24" 1 #150 SO-RF Manhole(w/Cover)
67 N12 (*2) 1 #150 SO-RF Min. Flow (From P-425A/B)
68 N13 3" 1 #150 SO-RF Over Flow HH1 6" 1 #150 SO-RF Handhole(w/Cover)
69 N14 2" 1 #150 SO-RF FCS Inlet
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Page 20 of 704
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3 Job No. E029636001
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Page 21 of 704
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Page 22 of 704
5 Service V-440 Feed Drum No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name P - -
13 Operating Press. kg/cm2(g) ATM - - Erection kg @
14 o
15 Design Press. kg/cm2(g) 3.5 / - - / - - / - Operating kg @
16 o
Temp. C 65 - -
18 Leak Test Press. kg/cm2(g) 3.5 - - (X) Name Plate with Saddle
24 Operating m3 25.0 - - ( ) Lug for Attachment
26 ( ) Agitator
28 Section Shell Side (*2) Jacket Side Trace Side (X) Vortex Breaker
37
38 REMARKS
39
42 (*2) All welding lines on the inner surface shall be smoothly finished by a grinder.
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Page 23 of 704
2
3 Job No. E029636001
4 Item No. PDE-V-431 Service V-440 Feed Drum
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 3" 1 #150 SO-RF Liquid from V-430 L1 3" 1 #150 SO-RF LT
58 N3 2" 1 #150 SO-RF Liquid to V-432 G1a,b 2" 2 #150 SO-RF LG
60 N5 (*2) 1 #150 SO-RF Min. Flow
61 N6 3" 1 #150 SO-RF Equalization MH1 24" 1 #150 SO-RF Manhole (w/Cover)
62 N7 4" 1 #150 SO-RF Over Flow
63 N8 3" 1 #150 SO-RF Gas from V-420
64
65 V1 4" 1 #150 SO-RF VENT
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Page 24 of 704
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Page 25 of 704
5 Service Oil Separator No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name P - -
16 Temp. °C 65 - -
25 Retention Time min. - - - (X) Sight Glass
26 ( ) Agitator
30 Head 304 SS - - ( ) Internal Ladder
37
38 REMARKS
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60
63 PDPP-DS-V432-3 Detail of Baffle
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Page 26 of 704
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3 Job No. E029636001
4 Item No. PDE-V-432 Service Oil Separator
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 2" 1 #150 SO-RF Liquid from V-420,V-430,V-431
57 N2 2" 1 #150 SO-RF Liquid to V-433
58 N3 2" 1 #150 SO-RF Liquid to LZ-611
60
61 V1 3" 1 #150 SO-RF VENT
62 D1 2" 1 #150 SO-RF DRAIN
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Page 27 of 704
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Page 28 of 704
11 Fluid Name P - -
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
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Page 29 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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54 NOZZLE LIST
57 N2 2" 1 #150 SO-RF Liquid from OSBL L1a 3" 1 #150 SO-RF LT
58 N3 3" 1 #150 SO-RF Liquid to P-441A/B L1b 3" 1 #150 SO-RF LT
59 N4 2" 1 #150 SO-RF Liquid to V-425 L2a,b 2" 2 #150 SO-RF LT
60 N5 (*2) 1 #150 SO-RF Min. Flow G1a,b 2" 2 #150 SO-RF LG
61 N6 2" 1 #150 SO-RF Equalization G2a,b 2" 2 #150 SO-RF LG
62 N7 2" 1 #150 SO-RF LN,FCS Inlet P1 2" 1 #150 SO-RF PT
63 P2 2" 1 #150 SO-RF PG
64
65 MH1 24" 1 #150 SO-RF Manhole (w/Cover)
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Page 30 of 704
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3 Job No. E029636001
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Page 31 of 704
11 Fluid Name P - -
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
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43
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Page 32 of 704
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54 NOZZLE LIST
56 N1 8" 1 #150 SO-RF Liquid from E-452A/B T1 2" 1 #150 SO-RF TE
57 N2 2" 1 #150 SO-RF Liquid from E-453 L1a 1" 1 #150 SO-RF LT
58 N3 2" 1 #150 SO-RF Liquid from P-401A/B L1b 3" 1 #150 SO-RF LT
60 N5 (*2) 1 #150 SO-RF Min. Flow P1 1" 1 #150 SO-RF PT
62 N7 2" 1 #150 SO-RF LN,FCS Inlet
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Page 33 of 704
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3 Job No. E029636001
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Page 34 of 704
11 Fluid Name P - -
16 Temp. °C 65 - -
28 Section Shell Side (*3) Jacket Side Trace Side ( ) Vortex Breaker
36 Leg,Saddle - - -
37
38 REMARKS
39
45
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Page 35 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 2" 1 #150 SO-RF Liquid from P-401A/B T1 2" 1 #150 SO-RF TG
61 N6(*3) 2" 1 #150 SO-RF MXA Inlet
62 N7 2" 1 #150 SO-RF MXA Inlet X1 (*1) 1 #150 SO-RF Agitator Mount
63 N8~9 2" 2 #150 SO-RF MXA Inlet
67 V1 4" 1 #150 SO-RF VENT
68 V2(*3) 2" 1 #150 SO-RF VENT
69 D1~2 2" 2 #150 SO-RF DRAIN
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Page 36 of 704
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CONFIDENTIAL
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Page 37 of 704
11 Fluid Name P - -
14 o
16 o
Temp. C 65 - -
36 Leg,Saddle - - -
37
38 REMARKS
39
41 (*1) Design press. of hopper : F.W. + 100 mmWC(g) / F.V.
44
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Page 38 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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54 NOZZLE LIST
61 N6~7 2" 2 #150 SO-RF MXA Inlet
62 N8~9 2" 2 #150 SO-RF Spare (w/Cover) X1 (*1) 1 #150 SO-RF Agitator Mount
64 MH1~2 24" 2 #150 SO-RF Manhole (w/Cover)
65 V1 4" 1 #150 SO-RF VENT
66 V2(*3) 2" 1 #150 SO-RF VENT HH1 6" 1 #150 SO-RF Handhole (w/Cover)
67 D1~2 2" 2 #150 SO-RF DRAIN
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Page 39 of 704
2
3 Job No. E029636001
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CONFIDENTIAL
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Page 40 of 704
11 Fluid Name P - -
12 Density kg/m3 (*1) - - WEIGHT
13 Operating Press. mmHg (*1) - - Erection kg @
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
39
41 (*1) Operating Condition:
42 Case BA HA
43 Fluid Density kg/m3 856/977 860/989
44 Operating Press. mmHg 200 105
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Page 41 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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54 NOZZLE LIST
55 Mark Size Q'ty Rating Service Mark Size Q'ty Rating
58 N3 2" 1 #150 SO-RF Liquid from P-503A/B L2a,b 2" 2 #150 SO-RF LT
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Page 42 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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Page 43 of 704
11 Fluid Name P - -
14 o
16 o
Temp. C 65 - -
36 Leg,Saddle - - -
37
38 REMARKS
39
44
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Page 44 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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54 NOZZLE LIST
61 N6~7 2" 2 #150 SO-RF MXA Inlet
65 V1 4" 1 #150 SO-RF VENT
67 D1~2 2" 2 #150 SO-RF DRAIN
68
69
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Page 45 of 704
2
3 Job No. E029636001
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CONFIDENTIAL
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Page 46 of 704
11 Fluid Name P - -
o
14 Temp. C (*1) - - Empty kg @
o
16 Temp. C 65 - -
26 ( ) Agitator
36 Leg,Saddle - - -
37
38 REMARKS
39
42 Case BA HA
44 Operating Temp. °C 31 37
46 V1 : sum of volume for pipes under 10m grade connected from LZ-541, LZ-551 and E-543.
50
51
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Page 47 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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53
54 NOZZLE LIST
60 N5 2" 1 #150 SO-RF Liquid from V-571 L1a,b 2" 2 #150 SO-RF LT
62 N7 2" 1 #150 SO-RF Liquid from LZ-516 L3 3" 1 #150 SO-RF LT
64 N9 2" 1 #150 SO-RF Liquid from V-541 G2a,b 2" 2 #150 SO-RF LG
65 N10 2" 1 #150 SO-RF Liquid to P-524
66 N11 2" 1 #150 SO-RF Liquid to P-525A/B MH1 24" 1 #150 SO-RF Manhole(w/Cover)
67 N12 (*2) 1 #150 SO-RF Min. Flow
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Page 48 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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Page 49 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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Page 50 of 704
11 Fluid Name P - -
12 Density kg/m3 884(BA) / 866(HA) - - WEIGHT
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
39
43
44
45
46
47
48
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Page 51 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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39
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53
54 NOZZLE LIST
61 N6 3" 1 #150 SO-RF Equalization
62 N7 3" 1 #150 SO-RF Over Flow MH1 24" 1 #150 SO-RF Manhole (w/Cover)
63 N8 3" 1 #150 SO-RF Gas from V-520
64
65 V1 3" 1 #150 SO-RF VENT
66
67
68
69
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Page 52 of 704
2
3 Job No. E029636001
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CONFIDENTIAL
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Page 53 of 704
11 Fluid Name P - -
o
14 Temp. C 35 - - Empty kg @
o
16 Temp. C 65 - -
26 ( ) Agitator
37
38 REMARKS
39
41
42
43
44
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47
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Page 54 of 704
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3 Job No. E029636001
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CONFIDENTIAL
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57 N2 2" 1 #150 SO-RF Liquid to V-533
60
61 V1 3" 1 #150 SO-RF VENT
62 D1 2" 1 #150 SO-RF DRAIN
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5 Service Scum Separator No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name P - -
o
14 Temp. C 35 - - Empty kg @
o
16 Temp. C 65 - -
26 ( ) Agitator
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2
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4 Item No. PDE-V-533 Service Scum Separator
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CONFIDENTIAL
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54 NOZZLE LIST
57 N2 2" 1 #150 SO-RF Liquid to P-533
58 N3 2" 1 #150 SO-RF Liquid to V-507
61
62 V1 3" 1 #150 SO-RF VENT
63 D1 2" 1 #150 SO-RF DRAIN
64
65 L1 3" 1 #150 SO-RF LT
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11 Fluid Name P - -
13 Operating Press. mmHg 25(BA) / 16(HA) - Erection kg @
16 Temp. °C 65 - -
26 ( ) Agitator
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38 REMARKS
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54 NOZZLE LIST
57 N2 2" 1 #150 SO-RF Liquid from OSBL,P-503A/B L1a,b 3" 2 #150 SO-RF LT
61 N6 2" 1 #150 SO-RF Equalization G2a,b 2" 2 #150 SO-RF LG
62 N7 2" 1 #150 SO-RF LN,FCS Inlet P1 2" 1 #150 SO-RF PT
63 P2 2" 1 #150 SO-RF PG
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11 Fluid Name P - -
13 Operating Press. mmHg 12(BA) / 7(HA) - - Erection kg @
14 Temp. °C 31(BA) / 30(HA) - - Empty kg @
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
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2
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CONFIDENTIAL
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53
54 NOZZLE LIST
57 N2 2" 1 #150 SO-RF Liquid from E-553 L1a 1" 1 #150 SO-RF LT
58 N3 2" 1 #150 SO-RF Liquid from P-401A/B, L1b 3" 1 #150 SO-RF LT
59 P-501A/B G1a,b 1" 2 #150 SO-RF LG
60 N4 4" 1 #150 SO-RF Liquid to P-551A/B P1 1" 1 #150 SO-RF PT
61 N5 (*2) 1 #150 SO-RF Min. Flow P2 1" 1 #150 SO-RF PG
62 N6 2" 1 #150 SO-RF Equalization
63 N7 2" 1 #150 SO-RF LN,FCS Inlet MH1 24" 1 #150 SO-RF Manhole (w/Cover)
64
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11 Fluid Name P - -
14 o
16 o
Temp. C 65 - -
28 Section Shell Side (*3) Jacket Side Trace Side ( ) Vortex Breaker
36 Leg,Saddle - - -
37
38 REMARKS
39
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2
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5
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CONFIDENTIAL
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53
54 NOZZLE LIST
56 N1 2" 1 #150 SO-RF Liquid from P-501A/B T1 2" 1 #150 SO-RF TG
61 N6~7 2" 2 #150 SO-RF MXA Inlet
65 V1 4" 1 #150 SO-RF VENT
67 D1~2 2" 2 #150 SO-RF DRAIN
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5 Service No.1 Knock Out Drum No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name PVG - -
12 Density kg/m3 1.06 - - WEIGHT
14 Temp. °C AMB - - Empty kg @
16 Temp. °C 65 - -
26 ( ) Agitator
27 MATERIAL (X) Demister
37
38 REMARKS
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2
3 Job No. E029636001
4 Item No. PDE-V-611 Service No.1 Knock Out Drum
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 14" 1 #150 SO-RF PVG Inlet MH1 18" 1 #150 SO-RF Manhole (w/Cover)
57 N2 14" 1 #150 SO-RF PVG Outlet
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Page 70 of 704
Page 71 of 704
5 Service No.1 ITY Knock Out Drum No. Req'd Working 1 Spare 0 Total 1
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
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2
3 Job No. E029636001
4 Item No. PDE-V-613 Service No.1 ITY Knock Out Drum
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CONFIDENTIAL
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54 NOZZLE LIST
56 N1 6" 1 #150 SO-RF PVG Inlet
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Page 73 of 704
5 Service No.2 ITY Knock Out Drum No. Req'd Working 1 Spare 0 Total 1
16 Temp. °C 65 - -
26 ( ) Agitator
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38 REMARKS
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3 Job No. E029636001
4 Item No. PDE-V-614 Service No.2 ITY Knock Out Drum
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CONFIDENTIAL
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56 N1 8" 1 #150 SO-RF PVG Inlet
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Page 75 of 704
5 Service Condensate Drum No. Req'd Working 1 Spare 0 Total 1
11 Fluid Name SCL,SCM - -
16 Temp. °C 115 - -
21 Corrosion Allowance mm 3.0 (for C.S.) - - ( ) Earth Plate
22 Insulation HOT - - (X) Support for Insulation
26 ( ) Agitator
29 Shell C.S. - - ( ) MH Balancer
30 Head C.S. - - (X) Internal Ladder
31 Nozzle C.S. - -
32 Flange C.S. - -
34 Internal C.S. - -
37
38 REMARKS
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2
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4 Item No. PDE-V-751 Service Condensate Drum
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CONFIDENTIAL
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56 N1 4" 1 #150 SO-RF SCM from PDE-400/500 T1 2" 1 #150 SO-RF TG
57 N2 6" 1 #150 SO-RF SCL from PDE-500 L1a,b 3" 2 #150 SO-RF LT
58 N3 8" 1 #150 SO-RF SCL from PDE-400 G1a,b 2" 2 #150 SO-RF LG
59 N4 2" 1 #150 SO-RF SCL from E-751
60 N5 6" 1 #150 SO-RF Over Flow MH1 24" 1 #150 SO-RF Manhole (w/Cover)
61 N6 (*1) 1 #150 SO-RF Min. Flow
62 N7 6" 1 #150 SO-RF WDM Inlet
64 N9 6" 1 #150 SO-RF Vapor to E-751
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2
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4 Item No. PDE-V-751 Service Condensate Drum
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Page 78 of 704
2 AGITATOR DATA SHEET Doc. No. PDPP-DS-A405
4 Item No. PDE-A-405 Job No. E029636001
5 Service V-405 Agitator No. Req'd Working 1 Spare 0 Total 1
7 Code -
8 Type Propeller No. of Stage 1
9 OPERATING CONDITION
10 Liquid Name P Operating in Empty Tank ( ) Yes (X) No
11 Liquid Volume / B.H.P.
12 Press.(Nor. / Des.) kg/cm2(g) ATM / F.W. + 150 / -50 mmWC(g) Min. m3 / kW /
13 Temp.(Nor. / Des.) °C 35 / 65 Nor. m3 / kW /
14 Mixing Time - Max. m3 / kW 15.8 / Min. 5.5
15 MIXING CONDITION VESSEL DESCRIPTION
16 Material for Mixing BUOH / PTSA Item No. V-405
17 Charge kg/Batch 14200 Doc. No. PDPP-DS-V405
18 Flow Rate kg/h - Type Vertical
19 Temp. °C 35 Size I.D. mm 2800
20 Viscosity mPa s 2.7 HLL-Btm mm 2380
21 Density kg/m3 896 Flange Size / Rating @ / #150 SO-RF
22 CONSTRUCTION VESSEL ARRANGEMENT SKETCH
23 Mfr. -
24 Entering (X) Top ( ) Btm ( ) Side
25 Impeller Type Propeller
26 No. of Stage 1
27 Diameter mm 650
28 No. of Blade 3
29 Speed rpm @
30 Rotation(View from Driver) ( ) CW ( ) CCW (X) @
31 Baffle No. of Baffle -
32 Dimension mm -
33 Spacing from Wall mm -
34 Draft Tube Length mm -
35 Diameter mm -
36 Coil ( ) Yes (X) No
37 Power Transmission ( ) Direct (X) Gear ( ) V-belt ( ) @
38 Shaft Seal Type (X) Packing ( ) Mech. ( )@
39 Sealing Fluid -
40 Temp./Press. °C / kg/cm2(g) - / -
41 Cooling Water
42 C.W. Jacket l/min. ( ) Yes ( ) No (X) @ /
43 Stuff. Box l/min. ( ) Yes ( ) No (X) @ /
44 Pedestal l/min. ( ) Yes ( ) No (X) @ /
45 Temp./Press. °C / kg/cm2(g) 26 / 7.5
46 MATERIAL
47 Impeller 316 SS Gasket V#7010 or Eq.
48 Shaft 316 SS O-Ring -
49 Shaft sleeve 316 SS Shaft Seal V#8132 or Eq.
50 Mounting Flange 316 SS
51 ACCESSORIES
52 (X) Coupling (X) Mounting Flange (X) Shaft Sleeve MOTOR
53 (X) Coupling Guard (X) Mounting Gasket (X) Gasket Supplied by @
54 ( ) Pressure Unit (X) Bolt & Nut (X) Special Tool (If need) Mounted by @
55 ( ) Auxiliary Piping (X) Reducer Mfr. @
56 PAINTING Type @
57 ( ) Yes ( ) No (X) C.S. only Rated Output / Amp. kW / A @ / @
58 Pole / Revolution P / rpm @ / @
59 WEIGHT Phase / Cycle / Volt P / Hz / V 3 / 50 / 415
60 Erection kg @ Exp.Proof Class (*2)
61 Empty kg @ Bearing @
62 Operating kg @ Lubricating @
63 REMARKS A-weighted sound pressure level
64 (equip. side 1m) dBA 85
65 '@' Marks to be decided by Vendor. REDUCER
66 (*1) Estimated mounting nozzle height is 150mm. Mfr. @
67 (*2) Refer to "HAZARDOUS AREA CLASSIFICATION PLAN" Type Gear
68 Reduction ratio @
69 Revolution In / Out rpm @
70
Page 79 of 704
7 Code -
16 Material for Mixing BUOH / HQ Item No. V-415
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 550
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
Page 80 of 704
7 Code -
16 Material for Mixing BA / MQ Item No. V-455
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 550
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
Page 81 of 704
7 Code -
16 Material for Mixing 2EHOH / PTSA Item No. V-505
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 450
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
Page 82 of 704
7 Code -
16 Material for Mixing 2EHOH / NCR Item No. V-515
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 600
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
Page 83 of 704
7 Code -
16 Material for Mixing HA / MQ Item No. V-555
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 500
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
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EQUIPMENT
DIVISION
Page 91 of 704
CHAPTER-5
SPECIAL DESIGN REQUIREMENT
CONFIDENTIAL
CLIENT: Bharat Petroleum Corporation Limited

PROJECT NAME: PDP Project
JOB No. E029636001 PREPARED BY H.Kawasaki
DATE: 17 Jan. 2016 CHECKED BY M.Matsuyama
SCALE: NONE APPROVED BY J.Takahashi
1 11 Mar. 2016 Revised H.K. M.M. J.T. DOC. No. PDPP-SDR-0001 REV. 1
No. DATE DESCRIPTION PRED CHKD APVD
REVISION
Page 92 of 704
MITSUBISHI CHEMICAL CORPORATION PDP Project
REVISION 1
11 Mar. 2016
CONTENTS
5.1 COMMON NOTICE………………………………………………………………… 4
5.1.1 General ……………………………………………………………………… 4
5.1.2 Distinctive Features of AA/AE Process …………………………………… 4

5.1.2.1 Polymerization
5.1.2.2 Odor
5.1.3 Analysis ……………………………………………………………………… 4
5.2 DESIGN REQUIREMENT FROM PROCESS FEATURES…………………….. 5
5.2.1 General ……………………………………………………………………… 5
5.2.2 Equipment ……………………………………………………………………… 5

5.2.2.1 General
5.2.2.2 Reactor
5.2.2.3 Column
5.2.2.4 Heat Exchanger
5.2.2.5 Drum
5.2.2.6 Tank
5.2.2.7 Pump
5.2.3 Piping …………………………………………………………………………… 11
5.2.4 Insulation and Tracing ……………………………………………………… 13

5.2.4.1 General
5.2.4.2 Requirement for Insulation and Tracing
5.2.4.3 Recommended Specifications
5.2.5 Civil …………………………………………………………………………… 16
5.2.6 Vendor List ……………………………………………………………………… 18

5.2.6.1 Mandatory Vendor
5.3 CONSIDERATIONS FOR DETAILED ENGINEERING………………………… 19
5.3.1 General ……………………………………………………………………… 19
5.3.2 Project Design Basis ……………………………………………………… 19
5.3.3 Battery Limit Conditions ……………………………………………………… 19
5.3.4 Piping & Instrument Diagram (P&ID) ………………………………………… 19
Page 2 of 25
CHAPTER-5 CONFIDENTIAL
Page 93 of 704
REVISION 1
11 Mar. 2016
5.3.4.1 Line Size

5.3.4.2 Insulation
5.3.4.3 Safety Valve
5.3.4.4 Breather Valve
5.3.4.5 Spectacle Blind
5.3.4.6 Spill Back Line for Vacuum System
5.3.4.7 Restriction Orifice
5.3.5 General Plot Plan and Equipment Plot Plan ……………………………… 21
5.3.6 Hazardous Area Classification ……………………………………………… 21
5.3.7 Equipment ……………………………………………………………………… 21

5.3.7.1 General
5.3.7.2 Column
5.3.7.4 Tank
5.3.7.5 Pump
5.3.7.6 Vacuum System
5.3.7.7 Desuperheater
5.3.7.8 Hoist
5.3.7.9 Spare Parts for Equipment
5.3.8 Piping …………………………………………………………………………… 23
5.3.9 Instrument ……………………………………………………………………… 24
5.3.10 Electrical ……………………………………………………………………… 24
5.3.11 Civil …………………………………………………………………………… 24
5.3.12 Others …………………………………………………………………………… 24
Page 3 of 25
Page 94 of 704
REVISION 1
11 Mar. 2016
5.1 COMMON NOTICE
5.1.1 General
This document provides the information to achieve safe and stable operation of
Acrylate plant and shall be referred / accommodated in detailed engineering.
5.1.2 Distinctive Features of AE Process

AE process has following two distinctive features which are caused by the
handling material’s properties especially for Acrylic Acid and Acrylate.
- Polymerization
- Odor
Hence, AE PLANT shall be designed strictly to avoid occurrence of these
phenomena.
The polymerization of Acrylic Acid and Acrylate causes blockage in the equipment
and piping. To avoid the polymerization, countermeasures shown as below shall
be taken into account for the process equipment and piping which have possibility
to make polymerization.
- Stagnation of liquid shall be minimized
- Condensation shall be avoided
- Inhibitors and air shall be provided adequately to process liquid
- Contamination of foreign objects causing polymerization shall be avoided
5.1.2.2 Odor
Since Acrylic Acid and Acrylate have foul odor, countermeasures against leakage
shall be incorporated in the plant design.
5.1.3 Analysis
Acrylic Acid and Acrylate are easy to polymerize. Analysis itself is a point of vital
importance for stable operation with good product and polymerization prevention,
as the analysis result leads to the correct operation conditions. Analytical
requirements and information, such as “Chemicals to analyze”, “Sampling point”,
“Frequency of sampling”, “Analytical method for raw materials or stream products”
and so on, are referred to “Chapter 22 ANALYSIS EQUIPMENT INFORMATION”.
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5.2 DESIGN REQUIREMENT FROM PROCESS FEATURES
5.2.1 General
This paragraph describes design requirement from process features which shall
be accommodated in detailed engineering stage.
5.2.2 Equipment
5.2.2.1 General
(1) For welding on internals and inner surfaces of equipment, double fillet welding or
full penetration and continuous butt welding shall be used without gaps. Socket
welds are not allowed for any of the equipment. After welding, be sure to
thoroughly finish and clean the welding lines to ensure that there are no adverse
affects on the product quality. All welding lines on the inner surfaces of equipment
must be smoothly finished by a grinder. Moreover, all welding lines that contact
the process fluid should be finished by acid-pickling and rinsed with fresh water
(e.g., boiler feed water) to remove particles and dust on the surfaces.
(2) All butt joints in the shell and head shall be welded by full penetration welding
without backing strip for process equipment. This requirement shall also apply to
the welded joints between the bodies and nozzles. Even a small gap may lead to
the accumulation of stagnant fluid and which may cause polymerization.
(3) Gap, crevice and/or groove on any joint of equipment shall not be provided to
prevent the stagnation of fluid has possibility of polymerization. For this purpose,
such as Bell-and-Spigot type joint or Tang-and-Groove flange shall not be applied.
Unless otherwise specified in PDP documents, Modified Male and Female type
flange (refer to Fig.-1 below) is preferable for equipment girth flanges or heat
exchanger channel head flanges with PTFE solid sheet gasket under the vacuum
condition.
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Fig.-1: Modified Male and Female Flange (Typical)
Gasket
Gasket
Equipment Girth Flange Heat Exchanger Channel Head Flange
(4) Dead space (the part which has possibility of fluid stagnation) in equipment shall
not be allowed to prevent the polymerization. Any design changes in detailed
engineering stage leading to make dead space shall not be allowed without
permission of LICENSOR. This change includes, for instance, the addition of
nozzles or the change of instrument type, etc.
(5) Weep holes for internals and devices on equipment shall be provided for complete
drainage.
5.2.2.2 Reactor
Esterification Reactor
To prevent polymerization in the reactor, spray of process liquid with inhibitors
shall be provided for all inner surfaces in gas phase zone of the reactor including
agitator installation nozzles. Actual arrangement of spray nozzle location shall be
designed and finalized in detailed engineering stage according to process
requirements specified on the reactor data sheet.
5.2.2.3 Column
(1) Column and internals shall be designed so as to remove polymers easily which
might be formed and accumulated inside. Following structures are applied to the
design in detailed engineering stage;
Minimum dead space
Welding with smooth finished structure for not removable internal parts
Bolt and nut tighten structure for removable internal parts
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(2) The levelness of trays and trough-type distributors shall be as shown below.
Inside Tower Diameter (mm) Max Levelness (mm),(Note 1)
1500 and under 2
from 1501 up to 2500 3
from 2501 up to 4000 4
from 4001 up to 5000 5
Note 1: “Levelness” refers to the difference between the highest point and the
lowest point out of at least 5 equivalently spread points.

(1) Shell & Tube Heat Exchanger
For all vertical heat exchangers, at least five (5) numbers’ tubes including those
weldment on upper side shall have no projection from tube sheet surface which is
shown in the right side [Type-B] of Fig.-2 below so as to perform good drainage
and minimize remaining liquid on the tube sheet. Tube arrangement with this
requirement is referred to EQUIPMENT DATA SHEET.
Fig.-2 Upper Tube End of Vertical Heat Exchanger
[ Type-A ] [ Type-B ]
Standard Type For 5 tubes
(2) Tank Cooler

In PDP, heat duties of tank coolers are estimated values as LICENSOR’s own
practice. These values shall be verified / modified according to radiation heat from
sun light, corresponding line length, final selected insulation thickness, heat input
from selected pump and etc. in detailed engineering stage. In case verified heat
duties are different from the values of PDP, heat duties of tank coolers shall be
modified in detailed engineering stage with notification to LICENSOR for the
review.
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5.2.2.5 Drum
Feed nozzles of liquid from overhead condenser and vent condenser to reflux
drum shall be connected to side of shell and lower than LLL (Low Liquid Level) as
shown in Fig.-3. Unless otherwise specified in P&ID or EQUIPMENT DATA
SHEET, inner pipe shall not be provided to prevent polymerization.
Fig.-3: Liquid Inlet Nozzle of Reflux Drum
From Condenser
Reflux Drum
5.2.2.6 Tank
(1) Tank roofs with butt welding or double fillet welding as shown in Fig.-4 below shall
be applied.
Fig.-4: Fillet Welding of Tank Roof
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(2) In order to eliminate dead space from tank inner surface, following construction
shown in Fig.-5 shall be applied.
Roof rafters shall be installed above roof (outside of tank)
Roof plate and shell plate shall be welded and smoothed
Fig.-5: Structure of Tank Roof
(3) Liquid circulation lines for the tank shall be installed to achieve good mixing for
minimizing temperature difference and inhibitors maldistribution at any part of tank
inside.
5.2.2.7 Pump
(1) Mechanical seal system
(a) Mechanical seal system for the process pumps might have leakage trouble by
polymerization of process liquid and crystallization of inhibitors in process liquid.
Hence, the most suitable mechanical seal system shall be selected for such fluid
properties. TANKEN SEAL SEIKO Co., Ltd. or John Crane are required as
mechanical seal Vendor because LICENSOR has many experiences applying
their mechanical seals for Acrylate process pumps.
(b) Following table gives reference specifications about mechanical seals for
process pumps in the existing and/or the past licensed plant.
Fluid BA / HA HE
Single Single
Type
Stationary Stationary
Seal face WC/WC WC/WC
Back metal Titan Hastelloy-C
Secondary seal O ring (Chemraz) Metal bellows
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(c) Mechanism of mechanical seal trouble on Acrylate process pumps is

presumed as follows.
Generated heat in-between mechanical seal faces of process pump induces
polymer film. This polymer film grows up and expands gap of seal faces. As the
result, leakage of process fluid from mechanical seal occurs.
To prevent this trouble, LICENSEE is recommended to request manufacturers
that following considerations to be taken into account to pump and mechanical
seal design.
For pump manufacturers:
To reduce the rotating speed of shaft (for reboiler pump and HE
decomposer bottom pump)
For mechanical seal manufacturers:
To reduce the seal balance ratio
To reduce the spring pressure
It is also good idea for realizing low-heat-generating mechanical seal system that
the limitation of seal balance and spring pressure is applied as minimum values as
possible in the heat generation calculation.
(2) Motor shall be connected directly with pump. Any kind of reducer, especially belt
reducer, shall not be installed to prevent belt trouble.
(3) Double fillet welding or full penetration welding shall be applied to nozzles'
connections of pump contacts with process fluid. Threaded connection with seal
welding and / or socket welding shall not be applied.
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5.2.3 Piping
(1) For welding of process piping, full penetration and continuous butt welding shall
be used. Socket welds are not allowed. Projection of weld metal into pipe bore
shall be minimized. Welding by GTAW (Gas Tungsten Arc Welding) for first layer
of all process piping is required except for the double welding. After welding, be
sure to thoroughly finish and clean the lines to ensure that there are no adverse
affects on the product quality.
Moreover, all piping welding lines of more than 20” diameter that contact the
process fluid shall be finished smoothly by a grinder and acid-pickling, and rinsed
with fresh water to remove particles and dust on the surface.
(2) Flange quantities in piping system shall be minimized for process line except for
flanges necessary for facilitate cleaning, maintenance and inspection.
(3) For process liquid lines, piping slopes shall be designed to ensure the complete
drainage of the process liquid from the drain nozzles. For gas and/or vapor lines,
“no pocket” piping layout shall be designed to ensure the complete drainage of
process liquid condensate from gas and/or vapor.
(4) “Min.” in the P&ID represents the constructive minimum distance requirement for
piping. The minimum distance construction of piping prevents polymerization by
reducing the stagnation in piping which might become a dead end. EPC
Contractor shall carefully comply with the minimum distance construction
specified on the P&ID in detailed engineering stage. As a best way, the fittings
such as flange (WN Flange or Stub-end for Lap joint) and tees should be welded
directly to construct minimum distance. When the adjustment of the distance
between them is necessary, the short pipe piece can be inserted under the above
mentioned purpose. In this case, the enough consideration for the practical
fabrication procedure shall be done. A target value of the “Min.” distance from
COP (Center of Pipe) to flange face is shown as follows.
Main Pipe Min. Distance
Size [mm]
1”or less Not more than 100
1_1/2”-4” Not more than 200
6” or above Not more than 300
(5) Liquid circulation lines shall be installed to pipe line between process area and
tank yard area for BA, HA and HE services to prevent blockage caused by
stagnation of liquid. Required specifications for these lines are as follows.
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Circulation Required Specifications

lines for
Fluid Velocity [m/s] Pipe Size
BA More than 0.02 ---
HA More than 0.06
HE More than 1.0 2” or above
(6) For polymerization service lines, length of bypass lines for FI and CV shall be
minimum distance to minimize stagnation of liquid. These lines will be shown as
Fig.-6-I in P&ID. But these lines shall be designed as Fig.-6-II and Fig.-6-III in
detailed engineering stage.
In addition to the above, for the services which has possibilities to include solid
particles, lines to / from FI and CV shall be branched / connected horizontally to
the main lines as similar arrangement as Fig.-6-II and Fig-6-III.
Fig.-6-I: Piping around Flow Meter and Control Valve in P&ID
Min. Min.
Min. Min. Min.
FI
Fig.-6-II: Piping around Area Flow Meter and Control Valve
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Fig.-6-III: Piping around Flow Meter (excluded area) and Control Valve
(7) All drain nozzles shall be straight line until drain valve.
(8) Length of forced circulation reboiler loop line and film evaporator bottom line shall
be shortened to reduce retention time because it affects process performance.
(9) Air Distributer for reboiler circulation line shown in P&ID shall be finalized in
detailed engineering stage referring to schematic drawing shown in “Chapter 16.8
PIPING PARTS INFORMATION”. Requirement (hole size and numbers) for each
nozzle is shown on P&ID.
(10) Strainer washing box for washing of strainer element shall be provided near
process pump strainer on Grade. Schematic drawing of strainer washing box are
referred to “Chapter 16.8 PIPING PARTS INFORMATION”. Actual location of
strainer washing box shall be decided in detailed engineering stage referring to
“Chapter 12. GENERAL PLOT PLAN” and “Chapter 13. EQUIPMENT PLOT
PLAN”.
5.2.4 Insulation and Tracing
5.2.4.1 General
This paragraph describes insulation and tracing requirements to prevent the
condensation of process fluids in equipment, piping, and instrument piping.
Installation required portion of tracing and/or insulation are shown in P&ID and/or
EQUIPMENT DATA SHEET individually in process requirement point of view.

Steam tracing shall be provided on process lines and equipment to prevent
polymer formation due to condensation of process vapor and to prevent increasing
of heavy end liquid viscosity. LLS or MS tracing systems shall be applied to the
process lines and equipment as they are specified in P&ID and EQUIPMENT
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DATA SHEET.
(a) Selection of LLS or MS tracing system
These systems are to prevent condensing of process vapor (e.g. in distillation
column shell or inside of overhead lines) and/or increasing HE viscosity. Selection
either LLS tracing system or MS tracing system are specified in P&ID and
EQUIPMENT DATA SHEET in accordance with operating temperature of process
fluid.
(b) Thermal insulation slip
Thermal insulation slip (referring to Fig.-7 bellow) shall be installed between tracer
and process line to avoid local heating of process line.
Fig.-7 Thermal insulation slip (For Reference)
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Followings are recommended specifications and information referring to
LICENSOR’s existing plant and/or past licensed plants. Detailed configuration of
tracing system shall be decided by EPC Contractor in detailed engineering stage.
(1) Tracing Line Specifications
Pipe Carbon steel NPS 1/2
Tube Copper or Stainless steel OD 10mm / ID 8mm
(2) Arrangement on process pipe
Pipe Parallel along with process pipe
Tube Spiral along with process pipe (refer to Fig.-8 below)
Fig.-8 Spiral Installation (For Reference)
(3) In general, NPS 1/2 carbon steel tracing pipe is applied for all tracing systems,
however only in case carbon steel pipe is not possible to install relatively tangled
portion such as around instruments equipment, OD 10mm / ID 8mm tube can be
used as alternative.
(4) Tracing line specifications (tracer size and quantities) with respect to each
process line size and length are shown in following tables as LICENSOR’s past
experiences. Required tracing line quantities shall be verified and determined
according to site conditions considering with actual selected insulation
specifications in detailed engineering stage.
(a) Steam Tracing
Steam Tracing
Process Line (NPS)
(LLS,MS)
Tracer size Quantity

Less than 2" NPS 1/2 2
3" to 8" NPS 1/2 4
10" to 16" NPS 1/2 6
18" to 28" NPS 1/2 8
30" or 36” NPS 1/2 10
38” to 44” NPS 1/2 12
44” to 50” NPS 1/2 14
More than 50” NPS 1/2 Pitch=200mm
Note: Length of steam tracer pipe should be less than 30m/loop.
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(5) Typical installation arrangement

Basically flow direction in tracer should be as follows.
Steam: Down flow
Typical installations for Steam tracing is referred to following diagrams (Fig.-9).
Fig.-9 Typical installation diagram for

Steam tracing (For Reference)
Steam Tracing
(6) Flanges and connections for tracers should be installed at the same place of
process lines’ flanges so as to facilitate piping / equipment maintenance. Also joint
of tracer is recommended to be placed outside of process line insulation.
5.2.5 Civil
Liquid Acrylic Acid (AA) and Solid or Solution of Para Toluene Sulfonic Acid
(PTSA) have corrosive property. Anticorrosive countermeasures for civil structure
are required to consider for the following places having chance of exposing to AA
or PTSA. (For example, Acid resistant concrete)
(a) Mandatory Place
Inside of WW Pit and Oil Pit
(b) Recommended Place
On the surfaces of concrete or civil structure around AA or PTSA handling
equipment (especially for pump base).
Inside of trench around AA or PTSA handling equipment
Corrosivities of AA and PTSA against structural materials are referred to following
table.
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Corrosivities of AA and PTSA (For Reference)

corrosivity
Water not
Solubility in Relative reinforced
Phase Name Formula pH absorptivity reinforce brick wood steel aluminum
Water humidity concrete
concrete
(%)
liquid acrylic acid CH2CHCOOH yes 1 to 2 - Yes strong medium medium weak strong weak
Pala toluene
liquid sulｆonic acid CH3C6H4SO3H yes 1 to 2 - yes strong strong medium medium strong strong
solution
Pala toluene
solid CH3C6H4SO3H yes 1 to 2 - yes strong strong medium medium strong strong
sulｆonic acid
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5.2.6 Vendor List

Following Vendors shall be selected to achieve AE process performance.
(1) Film Evaporator

KOBELCO ECO-SOLUTION CO., LTD JAPAN
(2) Tray (Column Internals)

KOCH ASIA PACIFIC JAPAN
(3) Pump Mechanical Seal

TANKEN SEAL SEIKO CO., LTD JAPAN
John Crane INTERNATIONAL
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5.3 CONSIDERATIONS FOR DETAILED ENGINEERING
5.3.1 General
This paragraph describes considerations and/or study items shall be performed in
detailed engineering stage referring to PDP. In general, descriptions in this
paragraph are not strongly related to process requirements, therefore this
paragraph does not contain the descriptions listed in the Paragraph 5.2 above.
Any design changes related to process requirements specified in PDP shall be
informed to LICENSOR for the review and the approval in case the design
changes are executed in detailed engineering stage.
5.3.2 Project Design Basis

PROJECT DESIGN BASIS (“Chapter 1. PROJECT DESIGN BASIS”) is prepared
based on the latest information of this project. Some items might be updated, if
required.
5.3.3 Battery Limit Conditions

BATTERY LIMIT CONDITONS (shown in “Chapter 1. PROJECT DESIGN BASIS”)
is prepared based on the latest (and/or estimated) design results by LICENSOR.
Some items shall be reviewed / updated according to the information during
5.3.4 Piping & Instrument Diagram (P&ID)
5.3.4.1 Line Size

(1) All line sizes are specified on P&ID as estimated line sizes based on the estimated
piping route, it shall be verified and finalized based on the piping routing plan
during detailed engineering stage. However circulation lines between process
area and tank yard for HE services have limitations as process requirements
referring to “Section 5.2.3 (4)” hereinabove. These limitations shall be considered
in finalization of line size in detailed engineering stage.
(2) Size of pump minimum flow lines in P&ID are described as “XX”. They shall be
finalized based on pump vendor information.
5.3.4.2 Insulation
Insulation thickness is specified in Line List based on “Chapter 2. DESIGN
CRITERIA”, it shall be verified and finalized in detailed engineering stage
according to selected insulation material and/or LICENSEE’s standards.
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(1) Safety valve design is executed based on API STD 520 & 521 in PDP referring to
“Chapter.3 DESIGN CRITERIA”. It shall be verified / finalized in accordance with
the local regulations and/or LICENSEE’s standards.
(2) Number of safety valve is specified on P&ID based on minute of meeting of Kick
off meeting. It should be modified based on local regulations (necessity of spare
safety valve, upstream/downstream block valve, bypass valve, mechanical
interlock etc.), if required.

Breather valve design for atmospheric tank is executed based on API STD 2000
referring to “Chapter.3 DESIGN CRITERIA”. It shall be verified / finalized in
accordance with applicable laws, codes, local regulations, and/or LICENSEE’s
standards in the detailed engineering stage.

Spectacle blinds’ position described in P&ID is based on the view point of
operability and maintainability. It should be reviewed / modified in detailed
engineering stage according to the requests by laws, codes and regulations, if
necessary. However, some of spectacle blinds are for prevention of fluids
contamination. In case spectacle blind needs to be removed from original position
described in P&ID of PDP, LICENSEE shall notify this intention to LICENSOR for
the review.

In detailed engineering stage, spill back line for vacuum system shall be designed
carefully because available pressure drop of this line is restricted. Followings are
design guidelines.
Size of spill back line is to be reviewed and finalized according to actual piping
routing plan so that maximum flow rate can be passed through this line within
available pressure drop. Maximum flow rate and available pressure drop are
referred to the corresponding vacuum system DATA SHEET in PDP. And
available pressure drop is considered as “Delivery pressure – Suction pressure”
referring to the each data specified in the DATA SHEET.

Restriction orifice differential pressure is based on the estimated value. It shall be
verified / finalized in detailed engineering stage.
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5.3.5 General Plot Plan and Equipment Plot Plan

(1) Plot plan and elevation is prepared as conceptual layout and process requirement
is shown in Chapter 12. GENERAL PLOT PLAN” and “Chapter 13. EQUIPMENT
PLOT PLAN”. It shall be modified, updated and finalized based on the actual
allowable plot area and the final equipment sizes. In case plot plan and elevation
is to be modified, LICENSEE shall inform this intention to LICENSOR for the
review.
(2) Tie-in point location in PDP is recommended and estimated location by
LICENSOR. Location shall be reviewed and finalized in detailed engineering
stage according to LICENSEE’s actual needs.
(3) Catwalks, operation deck, platform and spiral stairs for tanks are provided in
consideration of operability and maintainability. However these can be modified in
accordance with LICENSEE’s standards and/or experience.
5.3.6 Hazardous Area Classification

This drawing is prepared based on API RP 505. Any requirements other than the
above such as laws, codes and regulations shall be verified / modified in detailed
engineering stage.
5.3.7 Equipment
5.3.7.1 General
In general, process requirements are specified in EQUIPMENT DATA SHEET of
PDP. However, specifications (such as dimension of parts, nozzle position, nozzle
orientation, etc.) other than specified in EQUIPMENT DATA SHEET shall be
decided in detailed engineering stage considering with its purpose or operability,
maintainability and etc. In case these specifications are to be decided by
LICENSEE or EPC Contractor, its relative position shall be kept as process
requirements described in the EQUIPMENT DATA SHEET of PDP.
5.3.7.2 Column
(1) Column diameter is specified as preliminary sizes, it shall be verified based on the
process requirements described in data sheet and shall be modified accordingly, if
necessary.
(2) Feed inlet nozzles and reboiler return nozzles shall be verified based on the
process requirements which is described in data sheet and shall be modified
based on vendor’s information in detailed engineering stage, if necessary.
(3) Tray plate shall be designed that tray plate is tighten with bolt, nut and washers so
as to set and remove easily.
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(1) Thermal rating design of all shell & tube type heat exchangers are carried out by
LICENSOR, no more additional thermal design is required.
(2) Any modification in accordance with LICENSEE’s standards shall be executed in
detailed engineering stage, if necessary. However, in case modifications will be
carried out, it shall be done keeping the process requirements described in the
data sheet in PDP.
5.3.7.4 Tank
Design of “Air Foam Chambers” for all required tanks shall be executed in detailed
engineering stage.
5.3.7.5 Pump
(1) Pump head specified on data sheet is calculated based on the estimated piping
length and number of fittings etc., it shall be verified and finalized based on the
piping routing plan in detailed engineering stage. Design pressure for equipment
and instrument shall be modified according as final shut off pressure in detailed
engineering stage.
(2) Motor rated output specified on data sheet is preliminary figure, it shall be verified
and finalized based on the vendor’s information.
(3) Pump capacities (Minimum, Normal and Design) specified on data sheet do not
include any minimum flow rate, it shall be requested pump vendor to specify the
required minimum flow rate.
(4) Estimated system and size of cooling water lines and flushing lines for pump were
specified on P&ID. It shall be verified / finalized in detailed engineering stage.
5.3.7.6 Package Unit

In general, any description in PDP documents (such as data sheet, PFD, P&ID
and so on) are prepared in the view point of process requirements by LICENSOR.
Modifications for mechanical configurations and pipings etc. according to vendor’s
information, LICENSEE’s standards and/or good engineering practice by any
parties shall be accommodated in detailed engineering stage. However, in case
modifications will be carried out, it shall be done keeping the process
requirements described in the data sheet in PDP.
Minimum flow rates for desuperheater are based on PDE-400 operation assuming
PDE-500 is under switch operation. Minimum condition shall be finalized in
detailed engineering stage considering operation case.
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5.3.7.8 Hoist
Hoist is recommended to install in operability point of view. EPC Contractor shall
finalize specifications of hoist considering with shape of inhibitor paper bag,
Vendor’s information and final plot plan in detailed engineering stage.
Recommended location to install hoist is;
Above Inhibitor / PTSA drum (for lifting up of inhibitor paper bag)

Any spare parts for equipment are not specified in data sheet. LICENSOR’s
recommended spare parts for continuous operation are shown below.
Construction spare parts and operation spare parts other than shown below shall
be decided by LICENSEE in accordance with LICENSEE’s standards or the
selected vendor’s information.
(a) Film Evaporator Wipers
Full set spare of film evaporator wipers for PDE-E-554 should be prepared for
replacement.
(b) Mechanical Seal Units
100% complete set of spare parts for mechanical seal units for all process
pumps with mechanical seal shall be prepared for replacement.
(c) Strainer Elements
Strainer elements for special bucket type should be prepared for replacement.
Recommended amount is one for each size.
5.3.8 Piping
(1) In general, mechanical design of piping shall be performed in accordance with
ASME B31.3.
(2) In detailed engineering stage, thermal stress analysis of piping should be
conducted which operating temperature shown in line list exceeds 100 deg.C. For
piping which the results of the analysis show excess in allowable stress or
moment and considered to have detrimental distortion, the piping systems shall
be designed so that they have adequate flexibility by installing expansion joints or
reinforcing equipment nozzles, etc.
(3) If low point drain nozzles other than specified in P&ID of PDP are found necessary
to install according to actual piping routing plan in detailed engineering stage, it
shall be added in consideration of complete drainage from the pipelines after the
shutdown operation.
(4) Equipotential bonding shall be provided considering the requirement of local
regulations, laws or LICENSEE’s standards in detailed engineering stage.
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(5) Details of Air Regulator for process vent gas line shown in P&ID shall be finalized
in detailed engineering stage referring to schematic drawing shown in “Chapter
16.8 PIPING PARTS INFORMATION”.
5.3.9 Instrument
(1) All pressure data on pump discharge line are specified based on estimated pump
head calculation, it shall be reviewed and finalized accordingly based on the
piping routing plan in detailed engineering stage.
(2) Elevation (static head) is not considered for the pressure data in the Instrument
List. The pressure data shall be finalized in detailed engineering stage considering
with its installed elevation.
(3) Minimum flow rates for PDE-700 are based on PDE-400 operation assuming
5.3.10 Electrical
Motor List
All motor outputs mentioned on motor list is estimated figures, it shall be reviewed
and finalized based on vendor’s information in detailed engineering stage.
5.3.11 Civil
(1) Base Level is assumed as EL +/- 0m and set as floor level of Process Area, Pipe
Rack and Intermediate Tank Yard Area in PDP. Actual altitude of each level shall
be decided in detailed engineering stage.
(2) Anti-vibration design for structure and for foundation of rotating equipment shall be
provided in accordance with the selected vendor’s information (dynamic load etc.).
5.3.12 Others
(1) Firefighting system
Firefighting system (including air foam chamber for tanks) shall be designed by
EPC Contractor in detailed engineering stage in accordance with applicable laws,
codes, local regulations, and/or LICENSEE’s standards.
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(2) Hose Station, Eye Washer and Safety Shower

(a) Numbers and locations of hose station, eye washer and safety shower shall be
designed in detailed engineering stage considering with personnel safety,
operability, LICENSEE’s standards and so on. LICENSOR’s recommended
numbers and locations are shown below as each type described in P&ID.
(I) Type A (For Process Yard and Intermediate Tank Yard)

(i) Grade (Process Yard)
Hose length should be 10m and Hose Station should be put in every 15 ~ 20
m.
(ii) Above 1st Floor
Hose Station should be put in every 30 ~ 40 m.
(iii) Intermediate Tank Yard
(II) Type B (For Column)

Hose Station should be put in every plat form installed man hole.
(b) Eye washer and safety shower should be installed nearby sample box and
strainer washing box for operator’s safety as recommendation of LICENSOR.
Refer to Attachment 1.
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REV
DATA SHEET NO.
MIXER DATA SHEET A842-PDE-80-43-DS-XXXX X
SHEET 1 OF 2
1.0 PROJECT : PDPP SERVICE
2.0 CUSTOMER M/s BPCL KOCHI DUTY :
3.0 JOB NO. A842 ITEM NO. : NO. REQD.

4.0 UNIT NO. PDE MANUFACTURER :
5.0 LOCATION KOCHI, KERALA MAKE / TYPE / SIZE :

5.1 AREA CLASSIFICATION
6.0 OPERATING CONDITIONS
6.1 PURPOSE :
6.2 OPERATION : FLOW RATE THROUGH VESSEL: (m3/hr)
6.3 BATCH OPERATION TIME : RETENSION TIME (HR):
6.4 CONTINOUS FLOW RATE REQUIRED WITHIN THE TANK (min.) m3/hr RATED : MAX. :
6.5 OPERATING PRESSURE (Kg/cm² g) : OPERT. TEMP(°C) : SOLIDS PRESENT : TYPE & SIZE:
6.6 FOAM TENDENCY : SOLUBILITY :
6.7 DEGREE OF AGITATION ABRASION :
6.8 CORROSIVE PRODUCTS SETTLING :
6.9 PROCESS LIMITATION (IF ANY) : NONE H.P. TIP SPEED SPACE TORQUE SEE NOTES
7.0 PRODUCTS TO BE MIXED (IN SEQUENCE)
PERCENTAGE COMPOSITION VISCOSITY (CST) DENSITY

7.1 S.NO. COMPONENT
BY VOLUME BY WEIGHT AT OPER TEMP. AT 15°C AT OPER. TEMP. AT 15°C
7.2 AVERAGE PROPERTIES OF MIX
8.0 CONSTRUCTION
8.1 VESSEL : ITEM NO. : DRG. NO. SUPPLY BY OTHERS BY VENDOR LINING NO YES
8.2 VOLUME: DIA/SIDE (mm) : HEIGHT/LENGTH (mm) : THICKNESS (mm)
8.3 TOP : OPEN : CLOSED TYPE FLAT DISHED MIXER MOUNTING NOZZLE SIZE (mm DIA.):
8.4 BOTTOM : FLAT DISHED CONICAL DEPTH OF BOTTOM FROM WLF/TANGENT LINE (mm) :
8.5 BAFFLES : NO YES VENDOR TO SUGGEST TYPE NO. : SIZE(L x W x T)/DIA (mm)
8.6 BAFFLE SPACING FROM WALL (mm) : HEATING COILS PROVIDED : NO YES SIZE
8.7 LIQUID LEVEL (INCH FROM WELD/TANGENT LINE) : NORMAL : MIN. MAX.
8.8 MOUNTING SPACE FOR MIXER AVAILABLE AMPLE RESTRICTED (mm) ACTUALLY REQD. (mm)
8.9 MIXER : LOCATION SIDE ENTRY TOP ENTRY BOTTOM ENTRY PORTABLE MOTOR/GEARBOX MOUNTING: HORIZONTAL VERTICAL
8.10 MOUNTING : CLAMPED FLANGED MOUNTING ANGLE : INSTALLATION HEIGHT REQUIRED: mm
8.11 SHAFT SEAL : MECH SEAL STUFF. BOX LABYRINTH SEAL VAPOR SEAL
8.12 MAKE TYPE : CLASS SIZE :
8.13 MTRL. NO. OF RINGS : LANTERN RINGS YES NO
8.14 SHUT-OFF DEVICE WITH : (A) TANK FULL YES NO (B) UNDER PRESSURE YES NO
9.0 MATERIALS (SEE NOTE 5)
9.1 IMPELLER : SHAFT : SHAFT SLEEVE :
9.2 TANK AUX. TANK COUPLING : BAFFLES :
9.3 MTG. FLANGE STEADY BEARING : BOLTS
9.4 GASKET: STABILIZER RING : HIGH SPEED COUPLING :

9.5 H.S. CPLG GUARD :
10.0 CHARACTERISTICS
10.1 IMPELLER TYPE : NO. DIA. (mm) SPEED (RPM) :
10.2 BLADES TYPE : NO. PITCH : WIDTH (mm) :

10.3 MINIMUM SUBMERGENCE CLEARANCE FROM (A)THE BOTTOM OF IMPELLER TO TANK BOTTOM (mm) B) SIDEWALLS (mm)
10.4 SHAFT DIA (mm) : SOLID PIPE SCH (A) INSIDE TANK (B) AT THE BEARINGS / IN STOOL CHROME PLATING : YES NO
10.5 LENGTH FROM MIXER FLANGE (mm) : TOTAL LENGTH (mm) : ROTATION FROM IMP. END : .CW .CCW
10.6 STABILIZER :
10.7 DRIVE UNIT : TRANSMISSION TYPE GEAR BELT DIRECT COUPLED AGMA S.F. : LUBRICATION : FORCED SPLASH
10.8 TYPE OF G. BOX/BELT : MAKE : RPM : INPUT / OUTPUT PERMISS. LOAD : THRUST (KG) RADIAL(KG)
10.9 DISPOSITION OF RED. UNIT : HORIZONTAL VERT. INCLINED C/C DISTANCE : SPEED RATIO :
10.10 HIGH SPEED COUPLING : TYPE : MAKE : H.S. COUPLING GUARD : NO YES
10.11 LOW SPEED COUPLING : TYPE : MAKE : AUX. TANK COUPLING : NO YES TYPE
10.12 ELECTRIC MOTOR : K.W. : SYN. RPM : RPM AT FULL LOAD :

10.13 MAKE : VOLTS / PHASE / CYCLES :
10.14 ENCL : MTG. (A) HORIZ. VERT. (B) FOOT FLANGE
10.15 FRAME SIZE : INSULATION CLASS
10.16 MTG. FLANGE : (A) TANK SIZE RATING : FACING :

10.17 (B) MIXER SIZE RATING : FACING :
X
NO. DATE REVISION BY CHK APP
This drawing and the design it covers are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced, copied, loaned, exhibited, nor
used except in the limited way and private use permitted by any written consent given by the lender to the borrower. CONFIDENTIAL Property of ENGINEERS INDIA LTD. To be used or reproduced only with the written
permission of Engineers India Ltd.
FORMAT NO. 4-1646-0102 REV. 2 (20.12.2011) A4-210 X 297
Page 117 of 704

DATA SHEET NO. REV
MIXER DATA SHEET A842-PDE-80-43-DS-XXXX X
SHEET 2 OF 2
11.0 PERFORMANCE
11.1 HORSE POWER ABSORBED : (A) WITH BAFFLE: (B) WITHOUT BAFFLES : POWER NO. USED
11.2 BASIS OF POWER CALCULATION :
11.3 EFEECT OPER. TIME : RECYCLE TIME TANK-TURN-OVER RATE :
11.4 CRITICAL SPEED OF MIXER (RPM) OPERATING SPEED AS PERCENTAGE OF CRITICAL SPEED :
11.5 SEAL FLUSHING : YES NO API PLAN SEAL COOLING (SEE NOTE-6): REQUIRED NOT REQUIRED
11.6 EFFECTIVE SPHERICAL RADIUS OF AGITATION : THEO : (mm)
11.7 GUARANTEE FURNISHED : MECHANICAL PERFORMANCE SMOOTH OPERATION
12.0 TESTING
12.1 S.NO. TEST REQUIRED WITNESSED CERTI. REQD. REMARKS

1 MATERIAL CHECK
2 DIMENSIONAL CHECK
3 MECH. RUNNING TEST ON AIR AT SHOP
4 PERFORMANCE TEST WITH WATER AT SHOP
5 PERFORMANCE TEST AT SITE
6 STATIC BALANCE
7 DYNAMIC BALANCE
8 SHUT-OFF
13.0 MISCELLANEOUS
13.1 MAX. LOAD ON MTG FLANGE DURING OPERATION : FORCES MOMENTS

13.2 WEIGHTS (Kgs) : MIXER : DRIVER : ACCESSORIES : TOTAL :
14.0 SCOPE OF SUPPLY
14.1 MIXER UNIT WITH ALL NECESSARY ACCESSORIES AND APPURTENANCES

14.2 ELECTRIC MOTOR MOTOR CANOPY
14.3 GEAR REDUCER BELT DRIVE MOTOR STARTER
14.4 MIXER MTG. FLANGE MTG. FLANGE GASKET AND A SET OF BOLTS
14.5 AUX. TANK COUPLING LOW SPEED COUPLING
14.6 HIGH SPEED COUPLING H.S. COUPLING GUARD
14.7 SHAFT SEAL AS SPECIFIED BELT DRIVE GUARD
14.8 ANGUL. MOUNTING PIECE SPARE PARTS
14.9 SPECIAL TOOLS FOR MAINTENANCE INSPECTION AND TESTING
14.10 DRIVER ENGG. COORDINATION AND SHOP ASSEMBLY WITH DRIVER OPERATING MANUAL/CATALOGUE
14.11 FIELD ASSEMBLY TYPICAL SKETCH WITH BID
14.12 DOCUMENTS AND DATA AS SPECIFIED
NOTES :
1 BIDDER SHALL FURNISH ALL RELEVANT DATA FOR EACH MIXER ALONG WITH THE BID AS PER VENDOR DATA REQUIREMENTS.
2 BIDDER TO CONFIRM IF DYNAMIC BALANCING TEST IS A REQUIREMENT FOR THIS ITEM
3 BIDDER TO FURNISH THE EXACT MATERIAL INDICATING DESIGNATION ETC. FOR ALL MATERIALS QUOTED
4 BIDDER TO FURNISH LIST OF TWO (2) YEARS OPERATION SPARES AND INDICATE IF COMMISIONING SPARES WILL BE REQUIRED.
5 CORROSION ALLOWANCE EQUAL TO SPECIFIED FOR VESSEL/TANK SHALL BE CONSIDERED FOR EACH EXPOSED SURFACE.
6 ALL INSTRUMENTS/EQUIPMENTS/ACCESSORIES REQUIRED FOR SEAL COOLING TO MEET BATTERY LIMIT CONDITIONS SHALL BE SUPPLIED BY VENDOR
7 REFERENCE DOCUMENTS:
X
NO. DATE REVISION BY CHK APP
This drawing and the design it covers are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced, copied, loaned, exhibited, nor
used except in the limited way and private use permitted by any written consent given by the lender to the borrower. CONFIDENTIAL Property of ENGINEERS INDIA LTD. To be used or reproduced only with the written
permission of Engineers India Ltd.
FORMAT NO. 4-1646-0102 REV. 2 (20.12.2011) A4-210 X 297
Page 118 of 704

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Page 161 of 704
INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS FOR TRAYS AND TOWER
INDIA LIMITED 6-14-0003 Rev. 5
INA?f toron ) IA GoN of InOla uneertaiong) INTERNALS Page 1 of 16
(r4. C.1 cl *C<G1 ei

. 1;frfif-2TTI:RT
cr) I
INSTALLATION PROCEDURE FOR

TRAYS AND TOWER INTERNALS
f
REVISED AND RE-ISSUED AS STANDARD
5 29.10.2014 VDY IK/ SKM
SPECIFICATION
REVISED AND RE-ISSUED AS STANDARD
4 11.03.2010 AK SKM/HCN AKG ND
SPECIFICATION
REAFFIRMED AND RE-ISSUED AS
3 22.07.2004 AK KKG RKA SKG
STANDARD SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 162 of 704

ENGINEERS
22-dg
14.11771 c./~ M1 vcmi
INDIA LIMITED
in Govt of InOta Undertakingt
FOR TRAYS AND TOWER
INTERNALS
6-14-0003 Rev. 5
Page 2 of 16
Abbreviations:
BB Bolting Bar
D/C Downcomer
M/W Manway
TSR Tray Support Ring
SOME IMPORTANT GUIDELINES
SLOTS Slots are provided for adjustments of the tray segments. Vessels are made
to manufacturing tolerances which are fully accounted for in Distillation
Tray design.
CLEARANCES Clearances between Deck Beams/Downcomers from Support Rings are

provided to ensure that the trays fit the vessels without modification to
parts. POSITION tray deck beams and downcomers with equal clearances
at each end.
SPACINGS Spacings of loose beams or deck plates shown on drawings are TYPICAL
for perfectly round and sized vessels. The vessels may not be perfect, so
spacings will need to be ADJUSTED.
INSTALLATION INSTRUCTIONS ON THE FOLLOWING PAGES SHOULD BE READ

CAREFULLY.
Heat and Mass Transfer Standards Committee
Convenor: Sh. Amit Prakash
Members: Sh. Mandip Kapoor

Sh. Inder Kumar
Sh. Ratan Lal (Projects)
Sh. G. K. Iyer (Const.)
Page 163 of 704

ENGINEERS
INDIA L1MITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
IA Govt ol India UndertakIngt
INTERNALS Page 3 of 16
CONTENTS
1.0 INTRODUCTION 4
2.0 ORDER OF INSTALLATION 4
3.0 FITTING MAJOR BEAMS 6
4.0 FITTING DOWNCOMERS & EXIT WEIRS 7
5.0 FITTING DECK PLATES: INTEGRAL BEAM DESIGN 9
6.0 SUPPORT PLATES 11
7.0 BED LIMITERS 12
8.0 DISTRIBUTORS/REDISTRIBUTORS 12
9.0 FLASHING FEED GALLERY 14
10.0 LIQUID COLLECTOR/CHIMNEY/ACCUMULATOR TRAY 15
11.0 LATTICE GIRDERS 15
12.0 TIGHTENING OF BOLTS AND CLAMPS 15
13 .0 LEAK TESTING 16
14.0 REMOVAL OF LINSEED OIL COATING FROM CARBON STEEL TRAYS AND
INTERNALS 16
15.0 INSTALLATION CHECKLIST & REPORTING FORMATS 16
Page 164 of 704

■
31 ENGINEERS
Og.,102e- g INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
nreasaTassr) IA Govf Of Ind. Undertakog) INTERNALS Page 4 of 16
1.0 INTRODUCTION
The purpose of this specification is to help in effecting satisfactory installation of EIL-

designed trays and tower internals in the minimum time.
Whether installation involves a small number of trays, tower internals or is a large complex
involving thousands of components, it is vital that care is taken to ensure efficient handling
and assembly of tray components.
This specification should be used only as a "General Guide". The work in each tower and for
each tray/tower internal should be carried out in accordance with General Arrangement
Drawings prepared for specific tray/tower internal.
An adequate number of components with installation spares, where applicable, are supplied
for every assembly. Significant time and Cost can be saved by efficient storage and usage of
such components.
2.0 ORDER OF INSTALLATION
These instructions are based upon the following order of installation:
2.1 Review the drawings provided for respective tray/tower internals. It is an important aid for
installation. The drawings show the relative position of each component and corresponding
item number. After all trays/tower internals are uncrated, identify each piece of the tray/tower
internal with the item number w.r.t. its location on the General Arrangement Drawing.
2.2 Ensure that protective oil coating is removed from carbon steel tray/tower internal parts prior
to initiating installation of trays and tower internals in the tower. (For suggested procedure
for removal of linseed oil coating, refer clause 14.0 of this specification).
2.3 Check levelness of tray support rings & various dimensions of bolting bar welded to the
tower to ensure that these are as per relevant drawings and within specified tolerances. In
case of any deviation observed, refer this to EIL-HMTD. Levelness of support ring and other
dimensions of bolting bar shall be recorded in Format attached in EIL Specification No. 6-
14-0016.
2.4 Trays
2.4.1 Work upwards from lowest tray in tower.
2.4.2 Fit/complete installation (including welding) of lattice girder, if any.
2.4.3 Fit and leak test seal pan below bottom tray, if provided.
2.4.4 Fit major beam, if any.
2.4.5. Fit downcomer for bottom tray.
2.4.6 Fit support beam (if any) for bottom tray.
2.4.7 Fit deck plates for bottom tray except man way deck plate. (However proper fitment of man
way decks plate shall be ensured).
2.4.8 Leak test recessed seal pans, wherever provided.
2.4.9 Fit/install lattice girder/major beam, if required, for tray above bottom tray.
Page 165 of 704

ENGINEERS
$1
1g-
ar IMeg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
1.11771 excm, .3721,
71, IA Govt of Inda Undertaking)
2.4.10 Fit downcomers for tray above bottom tray.
2.4.11 Fit beams and decks for tray above bottom tray except man way deck plate. (However proper
fitment of man way decks plate shall be ensured).
2.4.12 Fit each successive tray as above.
2.4.13 Remove all the foreign material and ensure that trays are clean and unobstructed for proper
performance.
2.5 Tower Internals
2.5.1 Work upward from bottom most bed in the tower.
2.5.2 Fit/install lattice girder/major beam, if any.
2.5.3 Install (including welding and leak testing) vapour distributor/chimney tray/accumulator tray,
if any.
2.5.4 Install support plate/support grid.
2.5.5 Pack the tower with random packings in accordance with EIL spec. 6-14-0011 titled
"Specification for Packing the Tower".
In case bed is provided with proprietary packings/grid/structured packings, follow the

instructions provided by the supplier. Successive layers of grid/structured packings may
require to be rotated by specific angle as mentioned in supplier's drawings/procedure for
installation.
2.5.6 Install the bed limiter/hold down grid wherever specified in drawings, in case of random
packings
Install bed retainer/distributor support grid, in case of structured packings.
2.5.7 Install distributor/redistributor, Leak test pan/trough type distributor/redistributor and hydro
test spray header, if specified, on the drawings.
2.5.8 Fit the pre-distributor/feed pipe.
2.5.9 Repeat from paragraph 2.5.2 to 2.5.8 above, for the next bed.
2.5.10 Remove all the foreign material from respective tower internal. Ensure that the same are
clean and un-obstructed for proper performance.
Page 166 of 704

■
31 ENGINEERS
INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
mlaRr.1) IA Govt of Incla Undertakog) INTERNALS Page 6 of 16
3.0 FITTING MAJOR BEAMS
3.1 Carefully place shims, as necessary, under major beams to bring top of beam exactly in level
with tray support ring (Refer sketch 3.1.1). Tack weld/bolt shims in position.
NOTE: Depth of stool is always designed to allow for minimum shim thickness of 3 mm
(although this may be taken up in vessel or tray manufacturing tolerances).
TOP OF SUPPORT RING &

THICKNESS TRAY DECK
PLATE MAJOR BEAM SHALL BE
IN SAME LEVEL
THICKNESS
et... OF CLAMP
BEAM
THICKNESS
y s
PROVIDE SHIMS
AS NECESSARY
SKETCH No. 3.1.1

(C BEAM SHOWN, MAJOR BEAM MAY BE OF OTHER SHAPES ALSO)
3.2 Line-up down comer bolting bars, if fitted, on beam with downcomer bolting bars attached to
vessel wall. See sketch No. 3.2.1.
UNE—UP BOLTING VESSEL WALL

BAR THIS SIDE BOLTING BAR
VESSEL WALL
BOLTING BAR
MAJOR BEAM
MAJOR BEAM UNE—UP BOLTING

MAJOR BEAM
BOLTING BAR BAR THIS SIDE
BOLTING BAR
SKETCH No. 3.2.1
Page 167 of 704

■31 ENGINEERS
A GoN of InON Undeftaking)
4.0 FITTING DOWNCOMERS & EXIT WEIRS
4.1 Where no down comer support stools are provided
(a) Top section of downcomers for one tray fitted by:
i) Level exit weir base (top) with top of support ring and/or support beam top
surface.
ii) Bolting securely in position.
(b) Fit bottom downcomer sliding plate into position, position bottom of plate in
downcomer support bracket while fitting on tray below. Check clearance under
downcomer bottom edge. See Sketch No. 4.1.1.
HORIZONTAL SLOTS
IN BOLTING BAR D/C THICKNESS
EQUAL TO BEAM
TRAY DECK
END CLEARNCE TO BE IN
THICKNESS
SAME LEVEL
EXIT WEIR
25 x 11 VERTICAL EXIT WEIR

SLOT IN D/COMER I
TOP D/C SECTION
— —F
25x11 HORZ. SLOT BOTTOM D/C

IN TOP D C APRON SECTION
25x11VE . SLOT IN D/C RETAINING
BOTTOM D/C APRON
BRACKET
TRAY DECK
FIT STANDARD TRAY
THICKNESS
EDGE CLAMP WHEN UNDER D/C CLEARANCE
BOLTING IS OMITTED
IN BOTTOM PIECE OF TOLERANCE ± 3
DOWNCOMER.
SKETCH No. 4.1.1
4.2 Where downcomer support stool is provided
(a) Place shims, as necessary, under top downcomer section to bring exit weir base (top)
exactly in level with support ring and/or lattice girder/major beam (if provided) and
then bolt downcomer sections including exit weir securely. Tack weld/bolt shims in
position.
(b) Fit bottom-sliding plate of downcomer in position in downcomer support bracket, set
clearance under downcomer plate within plus or minus 1/8" (3mm). The clearance
obtained should be maintained as near constant across the width as possible (See
Sketch No. 4.2.1).
Page 168 of 704

ENGINEERS
$'gLIE IC1Ws INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
IA Govt ol Incha Undertak■ng) INTERNALS Page 8 of 16
HORIZONTAL SLOTS
IN BOLTING BAR D/C THICKNESS
EQUAL TO BEAM
TRAY DECK
END CLEARNCE TO BE IN
THICKNESS
SAME LEVEL
EXIT WEIR
25 x 11 VERTICAL EXIT WEIR

SLOT IN D/COMER I HEIGHT
TOP D/C SECTION I
BEAM END L
CLEARANCE j_
25x11 HORZ. SLOT PLACE SHIMS BOTTOM D/C

IN TOP D/C APRON AS REQUIRED
SECTION
25x11VERT. SLOT IN D/C RETAINING
BOTTOM D/C APRON
BRACKET
TRAY DECK
Fff STANDARD TRAY
THICKNESS
EDGE CLAMP WHEN UNDER D/C CLEARANCE
BOLTING IS OMI1TED
IN BOTTOM PIECE OF TOLERANCE ± 3
DOWNCOMER.
SKETCH No. 4.2.1
4.3 Use of Washer & Location of Nut
Unless otherwise specified on drawing, two washers (one on bolt head side & one on nut
side) shall be used for every bolt. The nut shall be provided towards the side accessible from
Tray man way. Lock nuts shall not be provided on clamp/bolting for Man way deck plate.
Nuts for supporting pipes (i.e. U clamps) shall be kept loose so as to have free
movement/expansion of the pipe.
4.4 Downcomer Vent Tubes
Vent Tubes are standard feature in Three (3) / Four (4) pass trays.
(a) Fit one top section of center/off-center downcomer as in paragraph 4.1/4.2 and then
position tube as shown in Sketch 4.4.1.
(b) Fit top section of opposite downcomer.
(c) Place shims, as necessary, between vent tube flanges and tighten the bolts.
Page 169 of 704

01nz ENGINEERS
v.1 20. lA Govt o11n0ia Undertakogt
D/C BOLTING BAR

ON VESSEL WALL
TOP D/C
VENT TUBE
SHIMS AS
NECESSARY
SKETCH No. 4.4.1
4.5 Downcomer Bracer Panels
After downcomer sections have been fitted, position bracer panels and bolt securely.
4.6 Adjustable Exit Weirs
Bolt loosely into position after down comer has been leveled and tightly secure. Weir top
edge then to be leveled upto desired height and bolts tightened securely. Unless otherwise
specified on the drawings, adjustable weirs to be set at mid point.
5.0 FITTING DECK PLATES: INTEGRAL BEAM DESIGN
5.1 Measure distance across area of deck to be installed at 90° to run of minor beams. See Sketch
No. 5.1.1
SKETCH No. 5.1.1
Page 170 of 704

ENGINEERS
$.
1g faWg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
171QT r1rane d513:12ffil) I A Govt of Incha Undertaking)
5.2 Compare measurement taken in paragraph 5.1 with dimensions stated on tray General
Arrangement Drawings.
5.3 If comparison shows measured distance GREATER than shown on drawings, INCREASE 25
mm typical spacing difference - see Sketch No. 5.3.1.
25 mm NOMINAL GAP
TO BE OPENED OR CLOSED
(MAX 27mm, MIN 23mm)
20/23/25mm NOMINAL OVERLAP

INTEGRAL BEAM
SKETCH No. 53.1
5.4 If distance measured is SMALLER than shown on drawings, DECREASE 25mm typical
spacing between the deck plates to absorb the difference - EXCEPT at each side of man way
section, which must remain at 25 mm to allow man way clamps to operate properly. See
Sketch No. 5.3.1.
5.5 Position deck plates as required from paragraph 5.3 to 5.4 on support ring and/or down comer
top flange.
5.6 Position deck plates centrally along their length i.e. leave EQUAL clearance at each end.
NOTE: Edge clamps must be orientated correctly (see Sketch No. 5.6.1). Stud/pin of all tray
edge clamps are provided with screwdriver slot and center punch mark as aid in
installation and fitting of edge clamps properly. Slot shall be in radial direction,
while punch mark be towards center of the tower.
II II
II I
I
II II
CLAMPS STUDS TO BE PUSHED

CLAMP ORIENTED 90*
AGAINST SUPPORT RING
TO VESSEL WALL
SKETCH No. 5.6.1

Page 171 of 704

ENQNEERS
gigz-Jr0fmg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
1.177, ,fe,cnf, C51~) IA Govt of Inda Undertalongt
5.7 Position man way plate in place to check that this can be put in position from top as well as
bottom of tray without fouling or interfering with man way beam clamp or adj acent tray deck
plate.
5.8 Remove man way plate and keep it on the tray or in downcomer area so that tray man ways
are accessible for inspection of trays.
5.9 Bubble cap trays, seal pans, draw off etc. shall be leak tested to ensure that drop in water
level does not exceed the specified limit mentioned in the drawing. In case the leakage
exceeds the allowable limit, consult EIL-HMTD.
5.10 Proceed with installation of next tray.
5.11 Tray man way plate shall be clamped in position only after all the trays installed in the tower
have been inspected, tested and approved by competent authority.
6.0 SUPPORT PLATES
6.1 Gas Distribution Support Plate
6.1.1 Start installation with the short piece of decicing and work across the tower. When gasketing
is specified, place the gasket on the support ring. If a mid span is required, place gasket on
the mid span also. Install the support ring clamps in the deck sections; leave the clamps loose.
Place the deck section on the support ring. Place the minor beam against the edge of the deck.
Minor beams are not always required (see drawing). Install the adjacent deck section. Install
the bolting through the deck section and through the minor beams when provided. When
gasketing is required between the deck sections, the bolts should also go through the gasket.
Tighten the bolting. Continue this procedure until all deck sections are installed.
For some applications, liquid downcomer tubes are provided which hang below the deck
sections. The downcomer tubes may or may not be removable (check drawing provided).
6.1.2 When the tubes are removable they should be installed before the deck sections are installed
on the support ring.
6.1.3 For various applications, riser tubes with covers are provided (which may or may not be
removable). When the tubes or covers are removable, install the tubes with the gaskets and
bolting provided as the deck sections are being installed. When the gas riser tube covers are
removable, ensure that they are fastened firmly in place.
6.1.4 After all deck plates are installed; rotate clamps under support ring and tighten clamps.
Ensure that all gasketing is in proper position.
6.1.5 Remove all foreign material so that the support plate is clean and unobstructed for proper
performance.
6.2 Gas Injection Support Plate
6.2.1 Place the sections in position on top of the support ring starting with the shorter sections at
one side of the tower. Proceed across the tower. Make sure all sections are making proper
contact with the support ring. The sections shall be equally spaced so that the gap between
sections is uniform.
Ensure that at any location on the support plate, gap is not large enough for the random
packings to pass through.
Forrnat No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved
Page 172 of 704

+31 ENGINEERS
OgZIT 02-dg ' INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
I.27f twzn, erfi Jcrasaal I A Go. of Inoia Undertaking)
6.2.2 When clamps are required, the clamps are to be assembled in position as the sections are set
in place. Tighten clamps after sections are properly positioned.
6.2.3 Remove all foreign material so that the support plate is clean and unobstructed for proper
performance.
7.0 BED LIMITERS
7.1 After the Bed Limiter is uncrated, identify each section of the Bed Limiter with the tag
number. The tag numbers locate the relative position of the sections.
7.2 Install the packing in the tower upto the depth of the minor beams from the support ring, as
shown on the drawing provided.
7.3 Install the minor beams to the support ring as shown on the drawing in their correct
positions. Finish installing the tower packing such that packings level is same as the top of
the minor beams and support ring/support cleats.
7.4 Install the screened Bed Limiters sections. Some of the sections may require tray clamps (see
drawings). If tray clamps are required, install them in the sections before installing the
sections on the support ring/support cleats.
7.5 Bolt all the sections with the hardware provided, as shown on the drawings.
7.6 Ensure removal of all foreign materials so that the bed Limiter is clean and unobstructed for
proper performance.
7.7 Ensure that the packings do not fly from the gaps. If so, adjust/reduce the gap.
8.0 DISTRIBUTOR/REDISTRIBUTOR
8.1 Orifice/Deek Type
8.1.1 Start installation with the short piece of deck and working across the tower. Place the gasket
on the support ring. Install the support ring clamps in the deck sections; leave the clamps
loose. Place the deck sections on the support ring. Place the minor beam, if provided, against
the edge of the deck. Gasketing is to be installed on both sides of the minor beam. Install the
bolting through the deck sections, gasketing and minor beams. Tighten the bolting. Continue
this procedure until all deck sections are installed.
8.1.2 Some applications require covers or hats over the gas riser area. Install the same.
8.1.3 When specified, the distributor shall be leak tested after installation.
8.1.4 Ensure that all foreign materials are removed so that the distributor/redistributor is clean and
unobstructed for proper performance
8.2 Trough Type Liquid Distributor/Redistributor
8.2.1 Review the drawing provided with the distributor/redistributor plate.
8.2.2 Install the tray clamps (wherever provided) loosely in the deck sections and the end closing
plates. If the plate is equipped with a center sump (see drawing), install the center sump first.
8.2.3 For some low-flow applications, gasketing is provided with the plate. If gasketing is required
(see drawing), place the gasket along with the support ring and sump top edges.
Page 173 of 704

ENQNEERS
02-dg
' ) INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
17.M7T 0traol0n. (A Govt of ioo.a Undertalongt
8.2.4 To install the main deck of the distributor/redistributor, begin by placing the short deck
section in its proper position on the support ring. Using the tag numbers as a guide, place the
adjacent deck section on the support ring. Bolt the deck sections together with the proper end
closing plates. If gasketing is provided with the plate, ensure providing gaskets in the joints
between the deck sections and the end closing plates. Tighten the bolting at these joints to
minimize leakage.
Some applications require covers or hats over the gas riser area. If covers are required, install
the same. Continue this, until the entire distributor/redistributor is installed.
8.2.5 After the plate is assembled on the support ring, rotate the tray clamps under the support ring
and tighten the clamps. Ensure gasketing (if required) is in proper position.
8.2.6 If parting box(es) are provided with the distributor, install the parting box brackets to the
parting box(es), then bolt this assembly in proper position on the distributor/redistributor.
8.2.7 Remove all foreign materials so that distributor/redistributor is clean and unobstructed to
ensure proper performance.
8.2.8 For some applications, distributors are provided with leveling screws. Level the troughs
wherever leveling screws are provided to bring within level as specified in the respective
drawings.
8.2.9 Leak test the distributor, wherever specified on the drawing.
8.3 Lateral Type Dishibutor/Redishibutors
8.3.1 If mounting clips have not been previously welded to the tower wall this is to be done before
installing distributor. The drawing provided for the job will show the proper position of the
mounting clips. Layout and weld the clips in position.
8.3.2 Place the laterals in position resting on top of the bed limiter.
8.3.3 If the tower is larger than 1250 mm I D , support members are provided. When support
members are provided, they are to be installed next. Loosely bolt the support members to the
mounting clips. Lift laterals and loosely bolt laterals to support members.
8.3.4 Place the gasketing provided on top of the lateral flanges in the proper position.
8.3.5 Place header in position and loosely bolt header to clips. Then assemble bolting through
header, gasket and lateral flange. Be sure to keep gasket in proper position. Tighten lateral
flange bolting. Leave other bolting loose.
8.3.6 Install connecting pipe and flange gaskets to header and inlet nozzle. Tighten pipe flange
bolting.
8.3.7 Tighten all bolting on support members.
8.3.8 Ensure to remove all foreign materials so that the distributor is clean and unobstructed for
proper performance.
8.4 Spray Nozzle Distributor
8.4.1 Review the drawing provided with the distributor.
Page 174 of 704

ENGINEERS
02-'eg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
•>■wn ,wowerA,rom) IA Govt of India Unclertak.g) INTERNALS Page 14 of 16
8.4.2 If mounting clips have not been previously welded to the tower wall, this is to be done before
installing the distributor. The drawing provided for the job will show the proper position of
the mounting clips layout. Weld the clips in position.
8.4.3 Check to see that all the piping is clean and unobstructed inside.
8.4.4 Place the laterals in position resting on top of the bed limiter.
8.4.5 Place header in position and loosely bolt to wall clip. Assemble the bolting and gasket at the
inlet flange. Tighten inlet flange bolting.
8.4.6 Place the lateral pipes in position and loosely bolts to wall clips. Assemble the bolting and
gasket at the flange end. Tighten the flange bolting.
8.4.7 Secure the wall clip bolting as shown on the drawing provided.
8.4.8 Hydro tests the spray header, without spray nozzles, if specified on the drawings.
8.4.9 Assemble the spray nozzles to the header and lateral assembly as shown on the drawing
provided.
If the spray nozzles are threaded, it is recommended that an anti seize pipe thread compound
be used for installation.
If the spray nozzles are flanges, use gaskets and tighten the bolting securely.
8.4.10 The bolting provided at end of pipe (i.e. for U clamps) shall be kept loose so as to have free
movement/expansion of the pipe.
8.4.11 Check the spray pattern visually by running the pump with water. If spray pattern is
defective, replace the spray nozzle with spare spray nozzles supplied.
9.0 FLASH1NG FEED GALLERY
9.1 Review the drawing provided with the Flashing Feed Gallery plate.
9.2 Install the tray clamps loosely in the sections that go on the support ring.
9.3 For most applications, gasketing is required and is provided with the plate. When gasketing is
required, place the gasket along with the support ring.
9.4 Place the first section on the support ring and snug up the tray clamps enough to hold it in
place. Place the adjacent section on the support ring with a gasket between the two sections.
Bolt the two sections together. Install all the sections on the support ring in a similar manner.
Tighten the tray clamps and the bolting to ensure leak free operation.
In some instances, where a high gallery wall is required, more sections are provided which
need to be bolted on top of the first row of sections. If angle braces are provided, they are to
be bolted to the first row of sections. It is advisable to bolt them in place before the upper
sections are installed.
After all the sections are bolted tightly together and all the joints are gasketed, install all
bracing when required, as shown on the drawing provided. Attach wall clips as shown on the
drawing, when required.
Remove all foreign materials so that the Flashing Feed Gallery is clean and unobstructed to
ensure proper performance.
Page 175 of 704

31 ENQNEERS
FOR TRAYS AND TOWER
Iu faWg
lafWf rarcnIcf tuf.34m-41)
INDIA LIMITED
(A Govt of Incha Undertakog)
INTERNALS
6-14-0003 Rev. 5
Page 15 of 16
10.0 LIQUID COLLECTOR/CHIMNEY/ACCUMULATOR TRAYS
10.1 Review the drawing provided with the collector plate.
10.2 Start installation with the short piece of decking and work across the tower.
10.3 Collector/Chimney/Accumulator trays may be provided with gaskets or may be of seal welded
construction to achieve leak tight joints.
10.4 In case trays are provided with gaskets, place the gasketing on the support Ring. Install the
support ring clamps in the deck sections and end closing plates. Leave the clamps loose.
Attach the proper end closing plate with gasket to each end of the deck sections by bolting
through the deck section, gaskets and end closing plate. Tighten the bolting. Continue this
procedure until all sections are installed.
10.5 After deck plates are installed, rotate clamps under support ring and tighten clamps. Ensure all
gasketing, when required, is in proper position.
10.6 In case of seal welding, welding to be completed after assembly of deck plates and before
building the riser height. After completion of floor level assembly and seal welding, leak test
the tray to locate deficiency of seal welding and ensure leak tightness.
Install next level of risers to build-up riser height, seal weld and leak test. Continue till tray
assembly, seal welding and leak testing is complete.
10.7 Place gas riser covers in position and bolt covers to gas riser using the bolting provided.
Tighten the bolts.
10.8 Install a vortex breaker in the draw off nozzle, if required.
10.9 Remove all foreign materials so that collector is clean and unobstructed to ensure proper
performance.
11.0 LATTICE GIRDERS
Lattice girders, where utilized, will be of a special design to suit the job. Lattice girders are
normally provided to support Two trays/internale (i.e. top lip/flange of each primary member
supporting one tray/internal). Lattice girders are supplied in segments so as to enable
individual segment pass through the tower manhole, for final installation and welding inside
the tower.
It is to be ensured that out of levelness of primary members is within 2 mm and is in level

with respective support rings.
Do not install tray, unless installation (including welding) of Lattice Girder is complete.
12.0 TIGHTENING OF BOLTS & CLAMPS
While tightening bolts & clamps, care should be exercised to apply proper force to avoid
deformation in clamps. A spanner with a lever arm of 200 mm (8 inch) maximum should be
employed so as to apply a torque of approximately 15 ft. Lbs. for tightening of bolts, studs &
clamps of M10 size; torque of 18-22 ft. Lbs. for tightening of bolting/clamps of M12 size and
torque of 24-36 ft. Lbs. for tightening of bolting/clamps of M16 size.
Page 176 of 704

ENGINEEFZS
$1g-ar OfMg INDIA LIM1TED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
1«1771 kwo,41ovaotr.0 IA Govt of Inda Undertak.g) INTERNALS Page 16 of 16
13.0 LEAK TESTING
(a) Preferred Method
Bubble caps, Collector/Accumulator trays, Distributors/Redistributors and other liquid

holding portion of other trays such as seal pans, draw off pans, recessed seal pans etc.
shall be leak tested with water. Drain holes/orifices shall be temporarily plugged
during testing. These holes are to be kept open during operation (unless otherwise
stated on the drawing). Leakage rate (i.e. fall in liquid level) shall not be more than the
value specified on the drawing. If leakage rate is excessive or a small area has a leak
rate which is appreciable, deck section shall be loosened and gasketing to be
repositioned to stop leakage.
(b) Alternate Method
If filling the plate with water is not practical, spot leak testing should be done. Using a
small stream of water from a hose, pour water on the joints and see if leakage occurs.
The main joints to check are the joints at support ring. A small liquid pool will occur.
If leakage occurs loosen the bolting and reposition the gasketing to stop the leakage.
If leak testing cannot be done, all gaskets should be closely inspected to assure proper
gasket sealing. This can be done with a small diameter wire by probing the joint or by
light testing the joint. If holes/gaps are found, loosen joints and reposition gasket to
obtain proper sealing.
14.0 REMOVAL OF LINSEED OIL COATING FROM CARBON STEEL TRAYS AND
TOWER INTERNALS
14.1 Prepare 10% caustic soda solution at about 80°C in a trough.
14.2 Immerse Tray or Tower Internal component coated with linseed oil for about 10 minutes.
14.3 Remove the component, scrub with wire brush using sand followed with rinse in clean
potable water for 15 minutes.
14.4 Repeat rinse in potable water two more times.
15.0 INSTALLATION CHECK LIST & REPORT1NG
After completion of Installation of each tray/tower internal, review the installation and report
the same in accordance with EIL specification for Review of Site Installation of Tower
internale (Specification No. 6-14-001 6).
Page 177 of 704

STANDARD SPECIFICATION No.
101 ENGINEERS GENERAL SPECIFICATION
fgeir fMfgitg INDIA LIMITED FOR WIRE MESH DEMISTERS 6-14-0017 Rev. 3
>Ten ofemit' im aflOrs0 IA Goot of India Undertaking)
Page 1 of 6
*111-111-ti i cl i 1 kill
GENERAL SPECIFICATION
FOR WIRE MESH DEMISTERS
07.11.2013 REVISED & ISSUED AS STANDARD

3 7t11 Sc
SPECIFICATION
REAFFIRMED & REISSUED AS STANDARD
2 17.09.2008 VDY HCN AKG VC
SPECIFICATION
REVISED & ISSUED AS STANDARD
1 22.08.2003 SK HCN RKA SKG
SPECIFICATION
0 07.05.1997 ISSUED AS STANDARD SPECIFICATION HCN SKK RKA AS
Standards Standards
Rev. Committee Bureau
Prepared Checked
No. by by
Approved by
Page 178 of 704

ENGINEERS GENERAL SPECIFICATION
Ogar Oil&
I .TIM ere4g7 .1,R35711
INDIA LIMITED
(A Goof of Ind.) Undertaking)
Rev. 3
Page 2 of 6
Abbreviations:
ASME : American Society of Mechanical Engineers
AISI : American Iron and Steel Institute
AIA : Authorized Inspection Agency
TIG : Tungsten Insert Gas
Heat & Mass Transfer Standards Committee
Convenor: Mr. Amit Prakash
Members: Mr. Inder Kumar

Mr. Mandip Kapoor
Mr. Ratan Lal (Projects)
Mr. GK Iyer ( Construction )
Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0
Page 179 of 704

0 el ENGINEERS GENERAL SPECIFICATION
fa5leg
etront maga,'
INDIA LIMITED
IA Govt of InMa Undeffak,o9) WIRE MESH DEMISTERS
6-14-0017 Rev. 3
Page 3 of 6
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 MATERIAL 4
4.0 DESIGN & FABRICATION 4
5.0 SPARES 5
6.0 INSPECTION & TESTING 5
7.0 PACKING & FORWARDING 5
8.0 GUARANTEE 6
9.0 DOCUMENTATION 6
10.0 AS BUILT DOCUMENTATION 6
Page 180 of 704

t_Silfazie-i ENGINEERS GENERAL SPECIFICATION
ligar taliteg INDIA LIMITED 6-14-0017 Rev. 3
Uif'~f i4 JOCA.if (A GovI of India Undertaking) FOR WIRE MESH DEMISTERS
Page 4 of 6
1.0 SCOPE
This specification covers the general requirements for design, fabrication, inspection and
supply of knitted wiremesh assemblies (Demisters) in duly packed condition.
The demister assembly(ies) shall consist of wiremesh pad, top and bottom holding grids,
major beams (if specified), bolting/clamps/tie rods/J-bolts/spacer pipes and any other
components which are essential to complete the demister assembly to be installed on supports
welded inside the vessel.
2.0 REFERENCES
Following documents/standards/specifications in their latest edition shall form the basis of

design, fabrication, inspection, testing and acceptance of the demister:
Demister data sheet As per Material Requisition

6-14-0009 Packing, Marking and Shipping Specifications for
Trays and Tower Internals
7-12-0036*/Licensor's standards - Details of Wire Mesh Demister Supports (as
applicable)
7-12-0001 Vessel Tolerances
ASME Sec. II Material Specifications
ASME Sec. VIII Div.I Boiler and Pressure Vessel Code
ASME Sec. IX Welding Qualifications
AISI Material Specification for Wires, Spacer Rods etc.
(* Standard 7-12-0036 shall be used for reference only. Final design of demister supports shall
be as per vendor design standards/calculations and shall be submitted to EIL for review prior
to start of fabrication.)
3.0 MATERIAL
All the material used for fabrication & supply of Demister shall be new & of first quality and
shall be duly supported with material test certificates.
4.0 DESIGN & FABRICATION
4.1 Basic details such as demister specification (surface area, voidage, and bulk density), material
of construction, supporting arrangement, manhole size etc. shall be as per drawings/
specification furnished by EIL.
4.2 In the General Arrangement drawing Demister Vendor shall indicate the following outside
dimensions (incase of square / rectangular demister) / diameter:
a) The oversized outside dimensions / diameter to take care of the tolerances/column ovality
defined in applicable Code / EIL Standard 7-12-0001/ drawings for snug fitment. These
dimensions / diameter shall be used for shop inspection of the demister mock up
assembly.
b) The final fit-up dimensions / diameter.
4.3 Demister assembly shall be designed for a net upward thrust of 100 kg/m2 (uniform) due to the
vapour loadings. The assembly should also be able to withstand a concentrated live load of 60
kg at mid point of any of the demister sub-assembly/component.
In addition to the above loading, demister shall be designed to withstand the additional
pressure surges, if specified.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved
Page 181 of 704

k3111 ENGINEERS GENERAL SPECIFICATION
22- es
5fgai cream „prom, INDIA LIMITED
(A Govt of India Undertaking)
WIRE MESH DEMISTERS
6-14-0017 Rev. 3
Page 5 of 6
4.4 All demister sub-assemblies shall be sized to facilitate installation inside the column/vessel
through the manhole. These shall rest on support ring/cleats welded inside vessel/column by
others.
4.5 Tentative details of the support rings/cleats, mid span beams (wherever required) grid details
& fixing arrangements shall be as given in the referenced documents listed in clause 2.0.
Vendor is advised to follow the same for the design/fabrication in their scope of work. Vendor
may, however, suggest any improvement in the design. Such suggestions will however be
reviewed/ approved by EIL/Client and can be followed by the vendor only on written
acceptance by EIL/Client.
4.6 All internal bolting shall be minimum M10 size and shall be compatible with Demister
material. All bolting shall be provided with locknuts.
4.7 Welding
All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG
welding is preferred. Welding wherever required, is to be done by qualified and approved
welders using the suitable fillers and fluxes recommended for materials used for the
fabrication.
5.0 SPARES
5.1 Constructional Spares
Following constructional spares shall be supplied:
Fasteners - bolts, nuts, clamps, spacer pipes, - 10% (minimum 4 Nos. of each type/size)
J-bolts etc.
5.2 Operational Spares
In addition to Constructional spares as indicated above, vendor shall also supply following
operational spares:
Fasteners - bolts, nuts, clamps, spacer pipes, - 10% (minimum 4 Nos. of each type/size)
J-bolts etc.
6.0 INSPECTION AND TESTING
6.1 The material, fabrication and trial assembly shall be Inspected by the EIL/Client and/or their
AIA.
6.2 Complete demister assemblies (along with grids) and Beams etc. shall be assembled as floor
mock-up & shall be offered for final inspection. Assembly shall be checked for oversized
dimensions as per the approved drawing.
7.0 PACKING & FORWARDING
The individual components shall be marked with proper item/part number as given in the
drawings to facilitate identification at site. Demister shall be wrapped in polythene and
supplied in wooden cases for damage free transportation. For all other requirements refer EIL
Specification No. 6-14-0009.
Page 182 of 704

ENGINEERS GENERAL SPECIFICATION
5'1:
gar tle-e-g w INDIA LIMITED
Wert eiCarre ZINJER/5,
11 IA Govt of India Undettahing)
6-14-0017 Rev. 3
Page 6 of 6
8.0 GUARANTEE
Vendor shall guarantee the design, performance (i.e. separation efficiency, and pressure drop),
material, fabrication and workmanship for the demisters for the period as outlined in General
Purchase Conditions.
9.0 DOCUMENTATION
Documents/drawings shall be furnished as per the 'Vendor Data Requirement' enclosed with
requisition / feed document. All the drawings prepared by the vendor shall be on AUTOCAD.
10.0 AS BUILT DOCUMENTATION

Nos. and type of documents to be supplied as 'As-built' document shall be per 'Vendor Data
Requirement' enclosed with requisition / feed document.
Shop changes made by Vendor after approval of drawings under Code-1 by EIL and
deviations granted in deviation permits, if any, shall be marked in hard copy of drawings
which shall then be stamped 'As-built' by the vendor. These 'As-built' drawings shall be
reviewed and stamped by Authorised Inspector also. Vendor shall prepare scanned image files
of all marked-up 'As-built' drawings. Vendor shall also incorporate the above changes in the
native soft files of the drawings.
Authorised Inspector shall ensure/certify completeness of Vendor's Final/As-built documents

before equipment dispatch.
In addition, vendor shall also incorporate site changes, if any, based on mismatch observed at
site and resubmit the 'As-built' documents.
Page 183 of 704

tg
I
151fRiseA ENGINEERS FOR POSITIVE MATERIAL
si at efaleg INI NA LIMITED
/A “nul na. Lnden.,), IDENTIFICATION (PMI) AT
6 - 81 - 0001 Rev. 2
SUPPLIER'S WORKS Page I of 8
covingii 4
c 1T
,flcomoict) TIPTth LI 111

f'6g itta-vr
FOR
POSITIVE MATERIAL
IDENTIFICATION
(PMI)
AT SUPPLIER'S WORKS
40D ., 15,
2 20.10.11 REVISED AND RE-ISSUED AKC DM
1 15.07.08 REVISED AND RE-ISSUED

NKR SSL SKP VC
0 07.12.00 ISSUED AS STANDARD SPECIFICATION AKC AKB AKB MI
Standards Standards
Rev. Prepared Checked Committee Bureau
No Date Purpose
by by Convenor Chairman
Approved by
Formal No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 184 of 704

STANDARD SPECIFICATION STANDARD SPECIFICATION No.
151Mae? - le.' ENGINEERS FOR POSITIVE MATERIAL
imegver INDIA LIMITED
yin eRaWanJelwill Govl of India Undertakno IDENTIFICATION (PM I) AT
6-81-0001 Rev. 2
SUPPLIER'S WORKS Page 2 of 8
Abbreviations:
API American Petroleum Institute

AS Alloy Steel
LSTK Lump Sum Turn Key
PMI Positive Material Identification
Sch Schedule
SS Stainless Steel
TPI or TPIA Third Party Inspection Agency
Inspection Standards Committee
Convenor: Mr.AK Chaudhary
Members: Mr. SS Lotay

Mr. SC Gupta
Mr. RK Singh
Mr. Rajeev Kumar
Mr. Anoop Goel
Mr. G Suresh
Mr. G Poornachandra Rao
Mr. MP Jain (Projects)
Page 185 of 704

151M4-e?fte ENGINEERS FOR POSITIVE MATERIAL
Ogrir tfigtegW INDIA LIMITED
Gorl of India undertaking} IDENTIFICATION (PMI) AT
6-81-0001 Rev. 2
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE DOCUMENTS 4
3.0 DEFINITIONS 4
4.0 PMI EXAMINATION 5
5.0 ACCEPTABLE METHODS FOR PMI 5
6.0 EXTENT OF PMI EXAMINATION 6
7.0 RECORDING AND DOCUMENTATION 7
8.0 MARKING 7
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
Page 186 of 704

ft/ ENCJNEERS FOR POSITIVE MATERIAL
beire,altateg ‘60
'- -1 INDIA LIMITED 6-81-0001 Rev. 2
IDENTIFICATION (PMT) AT
1.0 SCOPE
1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at the Supplier's works on Metallic Materials procured either directly by the
Owner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.
1.2 Any post order deviation from this specification must be approved by Owner/EIL in the
Deviation/ Waiver Permit format (No. 5-0000-0180-F1) enclosed with Material Requisition.
1.3 This specification covers the procedures and methodology to be adopted to assure that the
chemical composition of the material is consistent with the material specifications as specified
in purchase documents using 'Alloy Analyzer' at the time of final inspection before dispatch.
1.4 The scope of this specification shall include but shall not be limited to Positive Material
Identification (PMI) to be performed on Materials listed below:
1.4.1 For alloy Steel materials as below:

Alloy Steel Pipes including Clad Pipes
Alloy Steel Flanges & Forgings
Alloy Steel Fittings including Clad Fittings
Alloy Steel Fasteners
Alloy Cast & Forged steel valves
Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)
Longitudinal Pipe & Fittings Welds.
Gaskets (for Ring Type Joints)
1.4.2 For Carbon Steel materials as below:

All Carbon Steel Piping items under NACE or HIC or H2
Carbon Steel flanges and valves (Rating 900# and above)
Carbon Steel Pipes & fittings for following thicknesses:
Size 1"- 2" NB : Sch 160 & above
Size 3" NB : Sch XS & above
Size 4" - 12" NB : Sch 120 & above
Following items shall be excluded from scope of PMI examination.
Gaskets other than for Ring Type Joints

Internal Components of Valves
1.5 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In
case of any defective materials being found at site, the Supplier shall be responsible to effect
replacement of such defective materials at project site without any delays to the satisfaction of
EIL site RCM (Resident Construction Manager).
2.0 REFERENCE DOCUMENTS
2.1 API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program for
New and Existing Alloy Piping Systems.
3.0 DEFINITIONS
3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referred
items. This definition shall also include any sub-Supplier or manufacturer on whom a sub-order
is placed by the Supplier.
Page 187 of 704

SaIRCIELM—; ENGINEERS FOR POSITIVE MATERIAL
Par taiReZ VW INDIA LIMITED 6-81-0001 Rev. 2
IDENTIFICATION (PM I) AT
3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat and
Heat treatment lot.
3.3 Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionally
added to enhance mechanical or physical properties and/or corrosion resistance.
4.0 PMI EXAMINATION
4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of this
Specification Approval of PMI Procedure shall be obtained from Owner/EIL/TPIA prior to
commencing manufacture/ inspection of product.
4.2 PMI examination of materials is independent of any certification, markings or colour coding
that may exist and is aimed at verifying that the alloy used are as per specified grades.
4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to
cutting to ensure maintenance of identification on off-cuts.
4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or alloy
material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from
ferro-magnetic materials.
4.5 PMI examination is subject to surveillance inspection by Owner/EIL/TPIA.
5.0 ACCEPTABLE METHODS FOR PMI
5.1 The method used for PMI examination shall provide a quantitative determination of the alloying
elements like chromium, nickel, molybdenum or vanadium in Alloy Steel items.
5.2 Instruments or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of alloying elements
present.
5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or
"Optical Emission" type each capable of verifying the percentage of alloy elements within
specified range.
5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.
5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the
specified range.
5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources etc., and the data of the last service shall be stated on
the PMI Report Form (Sample enclosed).
5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginning
and end of each shift. Instrument must be checked against known standard for each alloy type
to be inspected during the shift.
Page 188 of 704

ISillaZreq e ENGINEERS FOR POSITIVE MATERIAL
s'Ig7e2eg W
INDIA UMITED
Govt a Inaa Undenakingi IDENTIFICATION (PMI) AT
6-81-0001 Rev. 2
5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use as
a random spot check on the instrument calibration.
5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or
abrasive paper. No permanent marks, which are injurious to the usage of product in service, are
acceptable.
5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence
instrument.
5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer
being used. Modification of these procedures if any must be approved by Owner/EIL.
5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may
perform the examination. Otherwise PMI examination shall be sub-contracted to an independent
testing agency approved by EIL.
5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejection
note shall be issued.
6.0 EXTENT OF PMI EXAMINATION
Following sampling plans shall be applicable for PMI examination of various items.
Flanges, Fittings 100%

Valves, RTJ Gaskets
Pipes 100% (for pipes procured from traders).
2 random samples drawn from each

Size/Heat/Lot (for pipes procured directly from mills)
C. Fasteners
Lot Size Sample Size
Upto 100 2% (Min 2)

101 to 500 1% (Min 3)
501 and above 0.5% (Min 5)
Note:
For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as
weldments.
Whenever any sample drawn to PMI test on the basis of percentage selection in B & C
above, fails to meet specification requirements, 100% of items of lot shall be tested for
PMI.
Page 189 of 704

i.311-aelti . ENGINEERS FOR POSITIVE MATERIAL
ogrir EiRtegi INDIA LIMITED
IA Go' at India Undertaking) IDENTIFICATION (PMI) AT
6-81-0001 Rev. 2
7.0 RECORDING AND DOCUMENTATION
The results of PMI examination shall be recorded in a Report Format as enclosed with this
specification.
8.0 MARKING
8.1 All alloy materials tested by PMI shall be identified using either of the following methods by
indicating "PMI OK"
Bar Code/Hologram Sticker

A low stress stamp marking
Page 190 of 704

012-ael ie ENGINEERS FOR POSITIVE MATERIAL
st",ar &Reg W INDIALIMTED 6-81-0001 Rev. 2
GOA Of India undertakng) IDENTIFICATION (PMI) AT
POSITIVE MATERIAL IDENTIFICATION REPORT Page of

BULK MATERIALS
Project: Client Job No.
PMI Report No. Supplier/Sub-Supplier
Purchase Order No. Testing Agency
Purchase PMI Location

Requisition No:
Bulk Item Type (as per Requisition)
Material Specification/Grade
Number of items in Lot
Requisition Item No./ Description Major content, Weight Percent Remarks

Accept/Reject
Element Cr Mo Ni V
Specified Range
Actual observations
Instrument Type / ID
Last Service Date Witnessed By

Inspection Agency
Page 191 of 704

INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
k31 ENGINEERS FOR 6-81-0011 Rev. 3
INDIA LIMITED
erednedia (A Govt of India Undertaking)
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 1 of 7
copsil 1-ael ,‹ tuRT / c4;1(14-1-1

ftteur a Iteur
INSPECTION AND TEST PLAN

FOR
PRESSURE VESSELS/ COLUMNS CARBON STEEL
kVilIP—
t'
3 09.09.2013 REVISED AND RE-ISSUED TKK RKS / SCG DMr—.
2 15.07.2011 REVISED AND RE-ISSUED HP SCG AKC DM
1 28.09.2007 REVISED AND RE-ISSUED PD RB MVKK VC
0 10.12.2002 ISSUED FOR IMLEMENTATION NKN SPS AKB GRR
Convenor Chairman
Rev. Prepared Checked Standards Committee Standards Bureau
Date Purpose
No. by by
Approved by
Page 192 of 704

5 ENGINEERS FOR 6-81-0011 Rev.3
ftar 7,1, m JVCD.,
eic,
INDIA LIMITED
IA Goer or Incite Undertaking)
Abbreviations:
CEIL Certification Engineers International Limited MRT Mechanical Run Test

CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing
CE Carbon Equivalent NPSH Net Positive Suction Head
DFT Dry Film Thickness PO Purchase Order
DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization
DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record
ERTL Electronics Regional Test Laboratory PR Purchase Requisition
FCRI Fluid Control Research Institute PMI Positive Material Identification
HT Heat Treatment RT Radiography Testing
HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking
ITP Inspection and Test Plan TC Test Certificate
IP Ingress Protection TPI or TPIA Third Party Inspection Agency
IHT Intermediate Heat Treatment UT Ultrasonic Testing
IC Inspection Certificate VDR Vendor Data Requirement
IGC Inter Granular Corrosion WPS Welding Procedure Specification
MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification
MTC Material Test Certificate
Convenor : Mr. S C Gupta
Members:
Mr. R.K. Singh Mr. Rajeev Kumar Mr. Himangshu Pal

Mr.Neeraj Mathur Mr. T Kamalakannan Mr. Deepak Gupta (Project)
Mr. Mayank Jain
Page 193 of 704

k31
ENGINEERS
Ogar lat5reg w INDIA LIMITED FOR 6-81-0011 Rev.3
tarnR elecnre,51,1,15.1, IA Govt 01 India Undertaking)
1.0 SCOPE
This Inspection and test plan covers the minimum testing requirements of Pressure vessels/ Columns carbon steel
PO/PR/ Standards referred there in/ Job specifications /approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedures
Hydro test ,heat treatment,

Procedure R
1.1 NDT, hot forming and other Documented procedures. 100% - H
documents
Procedures
Procedure R-Existing
1.2 WPS/ PQR /WPQ Documented procedures. 100% - H
documents W-New
2.0 Materials inspection
Page 194 of 704

ENGINEERS
INDIA LIMITED FOR 6-81-0011 Rev.3
IA Govt of India Undertaking)
SCOPE OF INSPECTION
SL QUANTUM
SUPPLIER
Plates, pipes, Forgings,

Expansion Bellows, Fittings,
As per PR/Purchase H R
2.1 Fasteners, Gaskets, etc (As 100% Mill TC H
Specification
applicable)
3.0 In process inspection

Review of test certificates,
markings Material
Materials identification for - H H
3.1 visual & dimensional inspection, 100% clearance
plates, pipes (pressure parts) record
identity correlation & transfer of
identity
Material identification for Review of test certificates, Material
3.2 forgings, fittings, fasteners, markings 100% clearance - H R
gaskets (pressure parts) Identity correlation. record
Non pressure parts (including Material test
3.3 Review of test certificates 100% W R R
internals, supports etc.) certificate
NDT Reports /
NDT of weld seam as applicable 100% H H R
Films
Inspection of formed
3.4 components (cold or hot NDT ( dished ends and tori cone)
formed) for cracks on inside & outside 100% Inspection
i
H H R
surfaces in knuckle zone and report
edges.
Page 195 of 704

ENGINEERS
ligar 254-
dg INDIA LIMITED FOR 6-81-0011 Rev.3
(11109 ert-MTE 051079M) IA Govt 01 India Undettaktngt
SCOPE OF INSPECTION
SL QUANTUM
SUPPLIER
HT chart review as applicable 100% HT Chart W W R
Inspection
Test coupon as applicable 100% H H W
report
Visual & dimensional (min.
100% Inspection
thickness, profile, ovality etc ) H H H
report
inspection
100% Batch test
3.5 Welding consumable Chemical & mechanical properties W R R
certificates
Visual & dimensional inspection,
Inspection
weld edge, root gap, offset, 100% - W
Weld edge preparation & set check list
3.6 alignment, cleanliness etc
up of pressure parts
NDT of weld edges as applicable
for cracks, laminations or 100% NDT Reports - W R
segregations
Intermediate inspection of Inspection
3.7 Visual/ inter pass temperature 100% - W -
welds report
4.0 Final inspection
Visual and dimensional Visual/ dimensions, completeness
inspection (internals & of assembly and weld visual for Inspection
4.1 100% - H H
externals) including welds reinforcement, undercuts, Surface report
(before PWHT as applicable) defects, etc.
Page 196 of 704

ENGINEERS
laf54- g INDIA LIMITED FOR 6-81-0011 Rev.3
wren' eteoredt13traMi IA Govt of India Undertaking)
SCOPE OF INSPECTION
SL QUANTUM
SUPPLIER
Each Inspection
4.2 PMI (AS/SS components) Chemical check W R
component report
4.3 Air test of pads Leak check 100% Test report - W R
Trial assembly of internals and

Dimensions, completeness of Inspection
4.4 column/vessel sections as 100% - H RW
assembly and alignment report
applicable
PWHT as applicable 100% HT chart W R

4.5
Inspection of completed welds
NDT Reports /
NDT as applicable 100% - W R
RT Films
Hardness check on all welds, 100% Inspection

4.6 Hardness - W RW
HAZ as applicable report
Production test coupon as As per Inspection

4.7 Production test coupon testing - H H
applicable spec/drg. report
4.8 Hydrostatic test Leak check 100% Test report - H H
5.0 Painting
Page 197 of 704

ENGINEERS
sfig-ar 0154-eg INDIA LIMITED FOR 6-81-0011 Rev.3
tan7 knreee avattli (A Govt of India Undertaking)
SCOPE OF INSPECTION
SL QUANTUM
SUPPLIER
Visual inspection (after surface
preparation and final painting for Inspection
5.1 Final painting 100% - H
workmanship, uniformity) DFT report
check
6.0 Documentation and IC
Final stamping, review of IC /

Verifying stamping details and
6.1 inspection documents and 100% Inspection - H H
review of inspection documents
issue of IC reports
Verification & compilation of
Final
6.2 Final documents as per PR inspection & test records for 100% - H H
dossier
submission to customer
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)),
R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
NOTES (As applicable):
1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be
applicable.
(Unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
Page 198 of 704

ENGINEERS
INDIA LIMITED FOR 6-81-0014 Rev. 3
ofroxe , (A Govt of India Undeflaking,
STAINLESS STEEL PRESSURE VESSELS / COLUMNS Page 1 of 7
,t-le),ti \Lao tiTR:r coio44ti

fttuur a trtaTur

FOR
STAINLESS STEEL PRESSURE VESSELS / COLUMNS
3 09.09-2013 REVISED AND RE-ISSUED TKK KS DM
2 15.07.2011 REVISED AND RE-ISSUED HP SCG AKC DM
1 15.07.08 REVISED AND RE-ISSUED

NKR SSL SKP VC
0 19.07.02 ISSUED FOR IMPLEMENTATION NKN SPS AKB GRR
Convenor Chairman
Rev. Prepared Checked Standards Committee Standards Bureau
Date Purpose
No. by by
Approved by
Format No. 8-00-0001-F7 Rev. 0 Copyright El L — All rights reserved
Page 199 of 704

ENGINEERS
51?-ar laf5i-eg INDIA LIMITED FOR 6-81-0014 Rev 3
7 eic,
1.17, Pre JC.5.1 IA Govt of India Undertaking)
Abbreviations:
CEIL Certification Engineers International Limited MRT Mechanical Run Test

CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing
CE Carbon Equivalent NPSH Net Positive Suction Head
DFT Dry Film Thickness PO Purchase Order
DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization
DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record
ERTL Electronics Regional Test Laboratory PR Purchase Requisition
FCRI Fluid Control Research Institute PMI Positive Material Identification
HT Heat Treatment RT Radiography Testing
HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking
ITP Inspection and Test Plan TC Test Certificate
IP Ingress Protection TPI or TPIA Third Party Inspection Agency
IHT Intermediate Heat Treatment UT Ultrasonic Testing
IC Inspection Certificate VDR Vendor Data Requirement
IGC Inter Granular Corrosion WPS Welding Procedure Specification
MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification
MTC Material Test Certificate
Convenor : Mr. S C Gupta
Members:
Mr. R.K. Singh Mr. Rajeev Kumar Mr. Himangshu Pal

Mr.Neeraj Mathur Mr. T Kamalakannan Mr. Deepak Gupta (Project)
Mr. Mayank Jain
Page 200 of 704

ENGINEERS
2154-es INDIA LIMITED FOR 6-81-0014 Rev 3
10 Govt Al India Undertaking)
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Pressure vessels/ Columns stainless steel
PO/PR/ Standards referred there in/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SCOPE OF INSPECTION
QUANTUM
SL NO. STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedures
Hydro test ,heat treatment, NDT,
Procedure
1.1 hot forming, and other Documented procedures. 100% - H R
Documents
Procedures
Procedure R-Existing
1.2 WPS/ PQR /WPQ Documented procedures. 100% - H
documents W-New
2.0 Materials Inspection

Plates, pipes, forging,
fittings , etc Mill test
2.1 (Supplier / sub supplier to As per PR / Purchase specification 100% certificates and H H R
arrange TPIA Certification) TPI reports
Expansion Bellows, Fasteners,

As per PR/Purchase
2.2 Gaskets, etc (As applicable) 100% Mill TC H H R
Specification
Page 201 of 704

k̀ilif-aziel ENGINEERS
Ogzir taijteg INDIA LIMITED FOR 6-81-0014 Rev 3
INRR armor Jr21.11 IA Govt A India Undertaking)
SCOPE OF INSPECTION
QUANTUM
SUPPLIER
3.0 In process inspection
Review of test certificates, markings
Materials identification for visual & dimensional inspection, Material
3.1 100% - H H
plates, pipes (pressure parts) identity correlation & transfer of clearance record
identity
Material identification for
Review of test certificates, markings Material
3.2 forgings, fittings, fasteners, 100% H R
identity correlation . clearance record
gaskets (pressure parts)
Non pressure parts (including Material test
3.3 Review of test certificates 100% W R R
internals, supports etc.) certificate
NDT report/RT
NDT of weld seam as applicable 100% W W R
films
DPT (dished ends and tori cone) for
100% Inspection
cracks on inside & outside surfaces in W W R
report
knuckle zone and edges.
Solution Annealing as applicable 100% HT chart W W R
Inspection of formed components As per
3.4 Hardness check as applicable Inspection report W W R
(Cold or hot formed) requirement
Test coupon Tensile, IGC / Micro

100% Inspection report W W W
etching as applicable
Visual & dimensional (min. thickness, Inspection

100% H H H
profile, ovality etc ) inspection report
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL - All rights reserved
Page 202 of 704

ENGINEERS
$fgaI fa5t&G
E ~wINDIA LIMITED FOR 6-81-0014 Rev 3
1.17n ,107-+Yer ‘7,1,70,./ IA 000 01 India Undenakindi
SCOPE OF INSPECTION
QUANTUM
SUPPLIER
Chemical & mechanical properties 100% Batch test
3.5 Welding consumable W R R
including IGC certificates
Visual & dimensional inspection, weld
Inspection
Insp
edge, root gap, offset, alignment, 100% W R
check list
3.6 Weld edge preparation & set up cleanliness etc
of pressure parts
DPT of weld edges as applicable for Inspection
100% - W R
cracks, laminations or segregations check list
3.7 Intermediate Inspection of Welds Visual/ DPT for weld root 100% Inspection report W R
4.0 Final inspection
Visual/ dimensions, completeness of

Visual and dimensional
assembly and weld visual for Inspection
4.1 inspection (internals & externals) 100% - H H
reinforcement, undercuts, surface report
rt
including welds
defects, etc.
Each
Inspection
4.2 PMI Chemical check component - W RW
report
and weld
4.3 Air test of pads Leak check 100% Test report - W R
Trial assembly of internals and

Dimensions, completeness of assembly Inspection
4.4 column/vessel sections as 100% - H H
and alignment report
applicable
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — AII rights reserved
Page 203 of 704

15111a_At.-1 ENGINEERS
$1=g-ari&Wg INDIA LIMITED FOR 6-81-0014 Rev 3
1.7F, c`feage 051.3rglr. (A Govl ai Indo Undertaking)
SCOPE OF INSPECTION
QUANTUM
SUPPLIER
PWHT as applicable 100% HT chart W R
Hardness test as applicable 100% Inspection report - W R

4.5
Inspection of completed welds
Production test coupon testing including
100% Inspection report - H H
IGC and micro etching as applicable
NDT report/RT
NDT as applicable 100% - W R
films
4.6 Water Quality Check Chloride Content 100% Inspection report - H R
4.7 Hydrostatic test Leak check 100% Test report - H H

Pickling/ passivation (inside and
4.8 outside surface) , drying of Visual inspection for cleanliness 100% Inspection report - W R
equipment
Drying and Nitrogen Filling (as
4.9 Nitrogen Pressure 100% Inspection report - W -
applicable)
5.0 Painting
Visual inspection (after surface

Final painting for carbon steel
5.1 preparation and final painting for 100% Inspection report - H -
portion (As applicable)
workmanship, uniformity) DFT check
Page 204 of 704

k31 _.1 ENGINEERS
fg-af 1a15rdg INDIA LIMITED FOR 6-81-0014 Rev 3
(A Govf of India Undeflok ,og)
SCOPE OF INSPECTION
QUANTUM
SUPPLIER
6.0 Documentation and IC
Final stamping, review of Name plate/ rub-

Verifying stamping details and review
6.1 inspection documents and issue 100% off and - H H
of inspection documents
of IC inspection reports
Verification & compilation of inspection
.C.
6.2 Final documents as per PR & test records for submission to 100% - H H
doQssier
customer
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review,
W-Witness (Give due notice, work may proceed after scheduled date).
NOTES (as applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable.( unless otherwise
agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
Page 205 of 704

Page 206 of 704
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Page 207 of 704

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Page 210 of 704

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS HEALTH, SAFETY &
6-82-0001 Rev. 6
aarn 122 51
INDIA LIMITED
IA Govt of India Undertak.ng)
ENVIRONMENT MANAGEMENT
AT CONSTRUCTION SITES Page 1 of 87
1-11-1 ul -f-zffl 'zr{

WkcIT 1141<ui
3T4tT9' irq
STANDARD SPECIFICATION FOR

HEALTH, SAFETY & ENVIRONMENT
(HSE) MANAGEMENT
AT CONSTRUCTION SITES
6 26/02/2014
REVISED & UPDATED SM J RKD SC
5 19/12/2012 REVISED & UPDATED SM SM RKD DM
4 13/02/2008 REVISED & UPDATED AS RK SCB VC
3 17/07/2007 REVISED & UPDATED AS MPJ VNP VC
2 11/08/2005 REVISED & UPDATED MPJ MPJ VNP VJN
Standards Standards
Comm ittee Bureau
Rev Date Purpose Prepared by Checked by Convenor Chairman
Approved by
Page 211 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
Abbreviations:
AERB : Atomic Energy Regulatory Board

ANSI : American National Standards Institute
BARC : Bhabha Atomic Research Centre
BS : British Standard
EIL : Engineers India Limited
ELCB : Earth Leakage Circuit Breaker
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning
ESI : Employee State Insurance
GCC : General Conditions of Contract
GM : General Manager
GTAW : Gas Tungsten Arc Welding
HOD : Head of Department
HSE : Health, Safety & Environment
HV : High Voltage
IS : Indian Standard
IE : Indian Electricity
JSA : Job Safety Analysis
LOTO : Lock Out & Tag Out
LPG : Liquefied Petroleum Gas
LSTK : Lump Sum Turn Key
MV : Medium Voltage
PPE : Personal Protective Equipment
RCM : Resident Construction Manager or Site-in-Charge, as applicable
ROW : Right of Way
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
TBM : Tool Box Talks
Construction Standards Committee
Convenor : Sh. RK Das, ED(Construction)
Members : Sh. M.Deshpande, GM (C)

Sh. M. Natarajan, GM (C&P)
Sh Rakesh Nanda, DGM (Piping)
Sh. S Mukherjee, DGM (Construction)
Sh. Janak Kishore, DGM (Projects)
Sh. D. Jana, AGM (Construction)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
Page 212 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
CONTENTS
CLAUSE TITLE PAGE NO.
1.0 Scope 5
2.0 References 5
3.0 Requirement of Health, Safety and Environment (HSE) Management 5
System to be complied by Bidders
3.1 Management Responsibility 5
3.1.1 HSE Policy & Objective 5
3.1.2 Management System 5
3.1.3 Indemnification 6
3.1.4 Deployment & Qualification of Safety 6
Personnel
3.1.5 Implementation, Inspection & Monitoring 7
3.1.6 Behavior Based Safety 8
3.1.7 Awareness 9
3.1.8 Fire prevention & First-Aid 9
3.1.9 Documentation 9
3.1.10 Audit 10
3.1.11 Meetings 10
3.1.12 Intoxicating drinks & drugs and smoking 11
3.1.13 Penalty 11
3.1.14 Accident/Incident investigation 14
3.2 House Keeping 14
3.3 HSE Measures 15
3.3.1 Construction Hazards 15
3.3.2 Accessibility 16
3.3.3 Personal Protective Equipments (PPEs) 16
3.3.4 Working at height 17

3.3.5 Scaffoldings 18
3.3.6 Electrical installations 19
3.3.7 Welding/Gas cutting 21
3.3.8 Ergonomics and tools & tackles 22
3.3.9 Occupational Health 22
3.3.10 Hazardous substances 23
3.3.11 Slips, trips & falls 23
3.3.12 Radiation exposure 23
3.3.13 Explosives/Blasting operations 24
3.3.14 Demolition/Dismantling 24
3.3.15 Road Safety 24
3.3.16 Welfare measures 25
3.3.17 Environment Protection 25
3.3.18 Rules & Regulations 26
Contd to page 4 …
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HEALTH, SAFETY &
6-82-0001 Rev. 6
CONTENTS (contd. from page 3)
3.3.19 Weather Protection 26

3.3.20 Communication 26
3.3.21 Confined Space Entry 27
3.3.22 Heavy Lifts 27
3.3.23 Key performance indicators 27
3.3.24 Unsuitable Land Conditions 28
3.3.25 Under Water Inspection 28
3.3.26 Excavation 28
3.4 Tool Box talks 29
3.5 Training & Induction Programme 30
3.6 Additional safety requirements for working Inside a running 31
3.7 Self Assessment and Enhancement 32
3.8 HSE Promotion 32
3.9 LOTO for isolation of energy source 32
4.0 Details of HSE Management System by Contractor
4.1 On Award of Contract 33
4.2 During Job Execution 33
4.3 During short listing of the sub-contractors 34
5.0 Records 35
Appendices
1. Standards/Codes on HSE Appendix-A
2. Details of First AID Box Appendix-B
3. Types of Fire Extinguishers & their Appln. Appendix-C
4. Indicative List of statutory Acts & Rules Appendix-D
5. Construction Hazards and their mitigation Appendix-E
6. Training subjects / topics Appendix-F
7. Construction Power Board ( typ) Appendix-G
8. List of HSE procedures Appendix-H
Attachments (Reporting Formats)
I. Safety Walk through Report HSE-1 Rev.0
II. Accident/Incident Report HSE-2 Rev.0
III. Suppl. Accident/Incident Investigation Report HSE-3 Rev.0
IV. Near Miss Incident Report/Dangerous occurrence HSE-4 Rev.0
V. Monthly HSE Report HSE-5 Rev.0
VI. Permit for Working at height HSE-6 Rev.0
VII. Permit for Working in Confined Space HSE-7 Rev.0
VIII. Permit for Radiation work HSE-8 Rev.0
IX. Permit for Demolishing/ Dismantling HSE-9 Rev.0
X Daily Safety Checklist HSE-10 Rev.0
XI Housekeeping assessment & compliance HSE-11 Rev.0
XII Inspection of temporary electrical booth / installation HSE-12 Rev.0
XIII Inspection for scaffolding HSE-13 Rev.0
XIV Permit for erection / modification & dismantling of HSE-14 Rev.0
scaffolding
XV Permit for heavy lift/critical erection HSE-15 Rev.0
XVI Permit Energy Isolation & De-Isolation HSE-16 Rev 0
XVI Permit for Excavation HSE-17 Rev 0
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HEALTH, SAFETY &
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1.0 SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/Vendors including their sub-contractors/sub vendors
during construction.
This specification is not intended to replace the necessary professional judgment needed to
design & implement an effective HSE system for construction activities and the contractor is
expected to fulfill HSE requirements in this specification as a minimum. It is expected that
contractor shall implement best HSE practices beyond whatever are mentioned in this
specification.
Requirements stipulated in this specification shall supplement the requirements of HSE

Management given in relevant Act(s)/legislations, General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where different
documents stipulate different requirements, the most stringent shall apply.
2.0 REFERENCES
The document should be read in conjunction with following:
- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers Act,
- Indian Factories Act
- Job (Technical) specifications
- Relevant International / National Codes (refer Appendix-A for standards/codes on HSE)
- Relevant State & National Statutory requirements.
- Operating Manuals Recommendation of Manufacturer of various construction Machineries
3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT

SYSTEM TO BE COMPLIED BY BIDDERS
3.1 Management Responsibility
3.1.1 HSE Policy & Objectives
The Contractor should have a documented HSE policy duly & objectives to demonstrate
commitment of their organization to ensure health, safety and environment aspects in their line
of operations.
HSE Policy of the contractor shall be made available to Owner / EIL at the place of execution of
specific contract works, as a valid document.
3.1.2 Management System
The HSE management system of the Contractor shall cover the HSE requirements &
commitments to fulfill them, including but not limited to what are specified under clause 1.0
and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan from EIL /
Owner prior to commencement of any site works. Corporate as well as Site management of the
Contractor shall ensure compliance of their HSE Plan at work sites in its entirety & in true
spirit.
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3.1.3 Indemnification
Contractor shall indemnify & hold harmless, Owner/EIL & their representatives, free from any
and all liabilities arising out of non-fulfillment of HSE requirements or its consequences.
3.1.4 Deployment & qualifications of Safety personnel
The Contractor shall designate/deploy various categories of HSE personnel at site as indicated
below in sufficient number. In no case, deployment of safety Supervisor / Safety Steward shall
substitute deployment of Safety Officer / Safety Engr what is indicated in relevant statute of
BOCW Act i.e deployment of safety officer/Safety Engineer is compulsory at project site. The
Safety supervisors, Safety stewards etc. would facilitate the HSE tasks at grass root level for
construction sites and shall assist Safety Officer / Engineers.
a) Safety Steward
For every 250 workmen, one safety steward shall be deployed.
As a minimum, he shall preferably possess School leaving Certificate (of Class XII with
Physics & Chemistry etc.) and trained in fire-fighting as well as in safety/occupational
health related subjects, with minimum two year of practical experience in construction
work environment and preferably have adequate knowledge of the language spoken by
majority of the workers at the construction site.
b) Safety Supervisor
For every 500workmen, one safety Supervisor shall be deployed.
As a minimum, he shall possess a recognized Degree in Science (with Physics &

Chemistry) or a diploma in Engg. or Tech. with minimum Two years of practical
experience in construction work environment and should possess requisite skills to deal
with construction safety & fire related day-to-day issues.
c) Safety Officer / Safety Engineer
One for every 1000 workers or part thereof shall be deployed.
Safety officer/Engineer Should Possess following Qualification & Experience :
(i) Recognized degree in any branch of Engg. or Tech. or Architecture with practical
experience of working in a building or other construction work in supervisory
capacity for a period of not less than two years, or possessing recognized diploma in
any branch of Engg. or Tech with practical experience of building or other
construction work in supervisory capacity for a period of not less than five years.
(ii) Recognized degree or diploma in Industrial safety with one paper in Construction
Safety
(iii) Preferably have adequate knowledge of the language spoken by majority of the
workers at the construction site.
Alternately
(i) Person possessing Graduation Degree in Science with Physics & Chemistry and
degree or diploma in Industrial Safety (from any Indian institutes recognized by
Page 216 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
AICTE or State Council of Tech. Education of any Indian State) with practical
experience of working in a building, plant or other construction works (as Safety
Officer, in line with Indian Factories Act, 1958) for a period of not less than five
years, may be considered as Safety Officer, in case Owner/Client of the project
agrees for /approves the same.
d) HSE In-Charge
In case there is more than one Safety Officer at any project construction site, one of them,
who is senior most by experience (in HSE discipline), may be designated as HSE In-
Charge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of Client and contractors.
In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like
the Building and Other Construction Workers’ Regulation of Employment and Conditions
of Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same shall be
followed.
Contractors shall ensure physical availability of safety personnel at the place of specific
work location, where Hot Work Permit is required / granted. No work shall be started at
any of the project sites until above safety personnel & concerned Site Engineer of
Contractor are physically deployed at site. The Contractor shall submit a HSE organogram
clearly indicating the lines of responsibility and reporting system and elaborate the
responsibilities of safety personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and furnish
Bio-Data/ Resume/ Curriculum Vitae of the safety personnel as above for EIL/Owner’s
approval, at least 1 month before the mobilization. The Contractor, whenever required,
shall arrange submission of original testimonials/certificates of their Safety personnel, to
EIL/Owner (for verification/scrutiny, etc.)
Imposition / Realization of penalty shall not absolve the Contractor from his/her
responsibility of deploying competent safety officer at site.
Adequate planning and deployment of safety personnel shall be ensured by the Contractor
so that field activities do not get affected because of non-deployment of competent &
qualified safety people in appropriate numbers.
3.1.5 Implementation, Inspection/Monitoring
 The Contractor shall be fully responsible for planning, reporting, implementing and
monitoring all HSE requirements and compliance of all laws & statutory requirements.
 The Contractor shall also ensure that the HSE requirements are clearly understood &
implemented conscientiously by their site personnel at all levels at site.
 The Contractor shall ensure physical presence of their field engineers / supervisors, during
the continuation of their contract works / site activities including all material transportation
activities. Physical absence of experienced field engineers / supervisors of Contractor at
critical work spot during the course of work, may invite severe penalization as per the
discretion of EIC, including halting / stoppage of work.
 Contractor shall furnish their annual Inspection Plan, with regard to project issues /subjects,
frequency and performers to EIL/Owner.
 The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.
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HEALTH, SAFETY &
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 The Contractor shall ensure important safety checks right from beginning of works at every
work site locations and to this effect format No: HSE-10 “Daily Safety Check List” shall
be prepared by field engineer & duly checked by safety personnel for conformance.
 The Contractor shall carry out inspection to identify various unsafe conditions of work
sites/machinery/equipments as well as unsafe acts on the part of
workmen/supervisor/engineer while carrying out different project related works.
 Adequate records for all inspections shall be maintained by the Contractor and the same
shall be furnished to EIL/Owner, whenever sought.
 The Contractor shall not carry-out work by engaging single worker anywhere without any
supervisor anytime during day or night.
 To demonstrate involvement/commitment of site management of Contractor, at least one
Safety Walk through in a month shall be carried out by Contractor’s head of site (along
with his area manager/field engineers) and a report shall be furnished to EIL/Owner as per
format No: HSE-1” Safety walk through report” followed by compliance for unsatisfactory
remarks.
 As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected,
tested and examined by competent people (approved by concerned State authorities) before
being used at site and also at periodical interval (e.g. during replacement,extension,
modification, elongation/reduction of machine/parts, etc.) as per relevant statutes. Hydra,
cranes, lifting machinery, mobile equipments / machinery / vehicles, etc. shall be inspected
regularly by only competent / experienced personnel at site and requisite records for such
inspections shall be maintained by every contractor. Contractor shall also maintain records
of maintenance of all other site machinery (e.g. generators, rectifiers, compressors, cutters,
etc.) & portable tools/equipments being used at project related works (e.g. drills, abrasive
wheels, punches, chisels, spanners, etc.). The Contractor shall not make use of arbitrarily
fabricated ‘derricks’ at project site for lifting / lowering of construction materials.
 Site facilities /temporary. installations, e.g. batching plant, cement godown, DG-room,
temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc.
and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motor
cycle/bicycle-shed, site washing facilities, First-aid centers, urinals/toilets, etc. should be
periodically inspected by Contractor (preferably utilizing HR/Admn. personnel to inspect
site welfare facilities) and records to be maintained.
3.1.6 Behaviour Based Safety
 The contractor shall develop a system to implement Behaviour-Based Safety (BBS)

through which work groups can identify, measure and change the behaviours of employees
and workers
 The BBS process shall include the following:
- Identify the behaviours critical to obtaining required safety performance.
- Communicate the behaviours and how they are performed correctly to all
- Observe the work force and record safe/at risk behaviours. Intervene with workers
to give positive reinforcement when safe behaviours are observed. Provide
coaching/correction when at risk behaviours are observed
- Collect and record observation data
- Summarize and analyze observation data
- Communicate observation data and analysis results to all employees
- Provide recognition or celebrate when safe behaviour improvements occur
- Change behaviours to be observed or change activators or change consequences as
appropriate.
- Communicate any changes to workforce
 Contractor through its own HSE committee shall implement the above process.
 The necessary procedures and reporting formats shall be developed by the contractor for
approval by EIL/Owner.
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HEALTH, SAFETY &
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 The HSE committee of contractor shall observe individual’s behavior for safe practices
adapted for utilization/execution of work for following as a minimum:-
- PPE
- Tools & equipment
- Hazard Identification & control
- House keeping
- Confined space entry
- Hot works
- Excavation
- Loading & unloading
- Work At height
- Stacking & storage
- Ergonomics
- Procedures
3.1.7 Awareness and Motivation
 The Contractor shall promote and develop awareness on Health, Safety and Environment
protection among all personnel working for the Contractor.
 Regular awareness programs and fabrication shop / work site meetings at least on monthly
basis shall be arranged on HSE activities to cover hazards/risks involved in various
operations during construction.
 Contractor to motivate & encourage the workmen & supervisory staff by issuing /
awarding them with tokens/ gifts/ mementos/ monetary incentives / certificates, etc.
 Contractor shall assess & recognize the behavioral change of its site engineers / supervisors
periodically and constantly motivate / encourage them to implement HSE practices at
project works
3.1.8 Fire prevention & First-Aid
 The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer
Appendix-B for details), trained personnel/nurse (male) to administer First Aid, stand-by
Ambulance vehicle and
 The Contractor shall arrange installation of fire protection measures such as adequate
number of steel buckets with sand & water and adequate number of appropriate portable
fire extinguishers (Refer Appendix-C for details) to the satisfaction of EIL/Owner.
 The Contractor shall deploy trained supervisory personnel / field engineers to cater to any
emergency situation.
 In case the number of workers exceeds 500, the Contractor shall position an Ambulance /
vehicle and nurse on round the clock basis very close to the worksite.
 The Contractor shall arrange FIRE DRILL at each site at least once in three months,
involving site workmen and site supervisory personnel & engineers. The Contractor shall
maintain adequate record of such fire drills at project site
3.1.9 Documentation
The Contractor shall evolve a comprehensive, planned and documented system covering the
following as a minimum for implementation and monitoring of the HSE requirements and the
same shall be submitted for approval by owner/EIL.
- HSE Organogram
- Site specific HSE Plan
- Safety Procedures, forms and Checklist. Indicative list of HSE procedures is attached as
Appendix :H
- Inspections and Test Plan
- Risk Assessment & Job Safety Analysis for critical works.
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HEALTH, SAFETY &
6-82-0001 Rev. 6
 The monitoring for implementation shall be done by regular inspections and compliance of
the observations thereof. The Contractor shall get similar HSE requirements implemented
at his sub-contractor(s) work site/office. However, compliance of HSE requirements shall
be the responsibility of the Contractor. Any review/approval by EIL/Owner shall not
absolve contractor of his responsibility/liability in relation to fulfilling all HSE
requirements.
3.1.10 Audit
The Contractor shall submit an Audit Plan to EIL/Owner indicating the type of audits and
covering following as minimum:
 Internal HSE audits regularly at least on quarterly basis by engaging internal qualified
auditors (viz safety officers/Construction personnel having 5 years experience in
construction safety and Lead Auditor Course :OSHA 18001certification).
 External HSE audits regularly at least on every six months by engaging qualified external
auditors (viz safety officers/Construction personnel having 10 years experience in
construction safety and Lead Auditor Course :OSHA 18001certification).
All HSE shortfalls/ non-conformances on HSE matters brought out during review/audit, shall be
resolved forthwith ( generally within a week) by Contractor & compliance report shall be
submitted to EIL/Owner.
In addition to above audits by contractor, the contractor’s work shall be subjected to HSE audit
by EIL/Owner at any point of time during the pendency of contract. The CONTRACTOR shall
take all actions required to comply with the findings of the Audit Report and issue regular
Compliance Reports for the same to OWNER/ EIL till all the findings of the Audit Report are
fully complied.
Failure to carry-out HSE Audits & its compliance (internal & external) by Contractor, shall
invite penalization.
3.1.11 Meetings
 The Contractor shall ensure participation of his top most executive at site (viz. Resident
Construction Manager / Resident Engineer / Project Manager / Site-in-Charge) in Safety
Committee / HSE Committee meetings arranged by EIL/Owner usually on monthly basis
or as and when called for. In case Contractor’s top most executive at site is not in a
position to attend such meeting, he shall inform EIL/Owner in writing before the
commencement of such meeting indicating reasons of his absence and nominate his
representative – failure to do so may invite very stringent penalization against the specific
Contractor, as deemed fit in Contract. The obligation of compliance of any observations
during the meeting shall be always time bound. The Contractor shall always assist
EIL/Owner to achieve the targets set by them on HSE management during the project
implementation.
 In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most
executive at site on weekly basis and maintain records. Such internal HSE meetings shall
essentially be attended by field engineers / supervisors (& not by safety personnel only) of
the Contractor and its associates. Records of such internal HSE meetings shall be
maintained by the Contractor for review by EIL/Owner or for any HSE Audits.
 Agenda of internal HSE meeting should broadly cover: -
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HEALTH, SAFETY &
6-82-0001 Rev. 6
a) Confirmation of record notes / minutes of previous meeting

b) Discussion on outstanding subjects of previous points / subjects, if any
c) Incidents / Accidents (of all types) at project site, if any
d) Current topics related to site activities / subjects of discussion
e) House keeping
f) Behavioral Safety
g) Information / views / deliberations of members / site sub Contractors
h) Report from Owner / Client
i) Status of Safety awareness, Induction programs & Training programs
The time frame for such HSE meeting shall be religiously maintained by one and all.
3.1.12 Intoxicating drinks & drugs and Smoking
 The Contractor shall ensure that his staff members & workers (permanent as well casual)
shall not be in a state of intoxication during working hours and shall abide by any law
relating to consumption & possession of intoxicating drinks or drugs in force.
 The Contractor shall not allow any workman to commence any work at any locations of
project activity who is/are influenced / effected with the intake of alcohol, drugs or any
other intoxicating items being consumed prior to start of work or working day.
 Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
 The Contractor shall ensure that all personnel working for him comply with “No-Smoking”
requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition
tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be
allowed inside the project / plant complex.
 Smoking shall be permitted only inside smoking booths exclusively designated &
authorized by the Owner/EIL.
3.1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-
compliances and also for repeated failure in implementation of any of the HSE provisions,
EIL/Owner may impose stoppage of work without any cost & time implication to the Owner
and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative

limit of
2.0% (Two percent) of the contract value for Item Rate or Composite contracts with an overall
ceiling of 1, 00, 00, 000 (Rupees One crore)
0.5% (Zero decimal five percent) of the contract value for LSTK, OBE, EPC, EPCC or Package
contracts with an overall ceiling of 10, 00.00.000 (Rupees ten crores)
This penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
EIL/Owner. The same shall be binding on the Contractor. Imposition of penalty does not make
the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations is
specified below:
Page 221 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
Sl.
Violation of HSE norms Penalty Amount
No.
1. For not using personal protective equipment Rs 500/- per day/ Item / Person.
(Helmet, Shoes, Goggles, Gloves, Full body harness,
Face shield, Boiler suit, etc.)
2. Working without Work Permit/Clearance Rs 20000/- per occasion
3 Execution of work without deployment of requisite Rs. 5000/- per violation per day
field engineer / supervisor at work spot
4. Unsafe electrical practices (not installing ELCB, Rs 10000/- per item per day.
using poor joints of cables, using naked wire without
top plug into socket, laying wire/cables on the roads,
electrical jobs by incompetent person, etc.)
5. Working at height without full body harness, using Rs. 10000/- per case per day.
non-standard/ rejected scaffolding and not arranging
fall protection arrangement as required, like hand-
rails, life-lines, Safety Nets etc.
6. Unsafe handling of compressed gas cylinders (No Rs 500/- per item per day.
trolley, jubilee clips double gauge regulator, and not
keeping cylinders vertical during storage/handling,
not using safety cap of cylinder).
7. Use of domestic LPG for cutting purpose / not using Rs. 3000/- per occasion.
flash back arresters on both the hoses/tubes on both
ends.
8. No fencing/barricading of excavated areas / Rs. 3000/- per occasion.
trenches.
9. Not providing shoring/strutting/proper slope and not Rs.5, 000/- per occasion.
keeping the excavated earth at least 1.5M away from
excavated area.
10. Non display of scaffold tags, caution boards, list of Rs.1000/- per occasion per day
hospitals, emergency services available at work
locations.
11. Traffic rules violations like over speeding of Rs. 2000/- per occasion per day
vehicles, rash driving, talking on mobile phones
during vehicle driving, wrong parking, not using seat
belts, vehicles not fitted with reverse horn / warning
alarms / flicker lamps during foggy weather.
12. Absence of Contractor’s RCM/SIC or his Rs10000/- per meeting.
nominated representative (prior approval must be
taken for each meeting for nomination) from site
HSE meetings whenever called by EIL/Owner &
failure to nominate his immediate deputy (in the site-
organogram) for such HSE meetings.
13. Failure to maintain HSE records by Contractor Rs 10000/- per month.
Safety personnel, in line with approved HSE
Plan/Procedures/Contract specifications..
14. Failure to conduct daily site safety inspection (by Rs.10000/- per occasion.
Contractor’s safety engineers/safety officers),
internal HSE meeting, internal HSE
Awareness/Motivation Program, Site HSE Training
and HSE audit at predefined frequencies (as
approved in HSE Plan).
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Sl.
Violation of HSE norms Penalty Amount
No.
th
15. Failure to submit the monthly HSE report by 5 of Rs. 10000/- per occasion and Rs.
subsequent month to Project’s Engineer-in-Charge / 1000/- per day of further delay.
Owner
16. Poor House Keeping Rs. 5000/- per occasion per subject
17. Failure to report & follow up accident (including Rs. 20000/- per occasion
Near Miss) reporting system within specific time-
frame.
18. Degradation of environment (not confining toxic Rs10000/- per occasion
spills, spilling oil/lubricants onto ground)
19. Not medically examining the workers before Rs 5000/- per occasion per worker
allowing them to work at height / to work in
confined space / to work in shot-blasting / to work
for painting / to work in bitumen or asphalt works,
not providing ear muffs while allowing them to work
in noise polluted areas, made them to work in air
polluted areas without respiratory protective devices,
etc.
20. Violation of any other safety condition as per job Rs. 5000/- per occasion
HSE plan / work permit and HSE conditions of
contract (e.g. using crowbar on cable trenches,
improper welding booth, not keeping fire
extinguisher ready at hot work site, unsafe rigging
practices, non-availability of First-Aid box at site,
not using hood with respiratory devices by blaster
for shot//grit blasting, etc.)
21. Failure to carry-out Safety audit in time (internal & Rs. 20,000/- per occasion
external), close-out of identified shortfalls of
Observations of Safety Aspects(OSA),etc
22. Carrying out sand blasting instead of grit/shot Rs. 50,000/- per day
blasting
23. Failure to deploy adequately qualified and Rs. 10000/- per day per Officer
competent Safety Officer
24. Utilization of hydra/ back-hoe loader for material Rs 25,000/- per occasion
shifting or any other unauthorized /unsafe lifting
works
25. Any incident / accident at project site has been Rs 10,00,000/-per occasion
caused because of willful negligence or gross
violation of safety measures / provisions on the part
of the Contractor or any of its sub-agencies
26. Any violation not covered above To be decided by EIL/Owner.
 The Contractor shall make his field engineers/supervisors fully aware of the fact that they
keep track with the site workmen for their behavior and compliance of various HSE
requirements. Safety lapses / defects of project construction site shall be attributable to the
concerned job supervisor / engineer of the Contractor, (who remains directly responsible
for safely executing field works). For repeated HSE violations, concerned job supervisor /
engineer shall be reprimanded or appropriate action, as deemed fit, shall be initiated (with
an information to EIL & Owner) by the concerned Contractor.
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Contractor shall initiate verbal warning shall be given to the worker/employee during his first
HSE violation. A written warning shall be issued on second violation and specific training shall
be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on
the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall
call for his forthright debar from the specific construction site. A record of warnings for each
worker/employee shall be maintained by the Contractor, like by punching their cards / Gate
passes or by displaying their names at the Project entry gate. Warnings, penalizations,
appreciations etc. shall be discussed in HSE Committee meetings by site Head of the
Contractor.
3.1.14 Accident/ Incident investigation
All accidents / incidents shall be informed to EIL/Owner at least telephonically by Contractor

immediately and in writing within 24 hours on Format No. HSE-2 as applicable , by Contractor.
Thereafter, a Supplementary Accident / Incident investigation Report on Format No. HSE-3
shall be submitted to EIL/Owner within 72 hours. Near Miss incident(s),Dangerous
accidents/incident shall also be reported on Format No. HSE-4 within 24 hours. The accident/
incident shall be investigated by a team of Contractor’s senior Site personnel (involving Site-in-
Charge or at least by his deputy) for establishing root-cause and recommending corrective &
preventive actions. Findings shall be documented and suitable actions taken to avoid
recurrences shall be communicated to EIL/Owner. Owner/EIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help
and cooperation in this regard. EIL/Owner shall have the right to share the content of this report
with the outside world.
3.2 House Keeping
The Contractor shall ensure that a high degree of house keeping is maintained and shall ensure
inter alia; the followings:
a) All surplus earth and debris are removed/disposed off from the working areas to designated
location(s).
b) Unused/surplus cables, steel items and steel scrap lying scattered at different places within
the working areas are removed to identify location(s).
c) All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
d) Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and
bricks etc shall not be allowed on the roads to obstruct free movement of men &
machineries.
e) Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.
f) Water logging on roads shall not be allowed.
g) No parking of trucks/trolleys, cranes and trailers etc shall be allowed on roads, which may
obstruct the traffic movement.
h) Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working
areas.
i) Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
within the plant area/ or these materials shall be transported with top surface wet.
j) The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing.
k) At least two exits for any unit area shall be assured at all times – same arrangement is
preferable for digging pits / trench excavation / elevated work platforms / confined spaces
etc.
l) Welding cables and the power cable must be segregated and properly stored and used .The
same shall be laid away from the area of movement and shall be free from obstruction.
m) Schedule for upkeep/cleaning of site to be firmed up and implemented on regular basis
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The Contractor shall carry-out regular checks (minimum one per fortnight) as per format No:
HSE-11 for maintaining high standard of housekeeping and maintain records for the same.
3.3 HSE Measures
3.3.1 Construction Hazards
The Contractor shall ensure identification of all Occupational Health, Safety & Environmental
hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor
shall carry out Job Safety Analysis (JSA)/Risk Analysis specifically for high risk jobs/crtical
jobs like
a) Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation
etc.) & hot works.
b) Work in confined space,
c) Deep excavations & trench cutting (depth > 2.0 mts.)
d) Operation & Maintenance of Batching Plant.
e) Shuttering / concreting (in single or multiple pour) for columns, parapets & roofs.
f) Erection & maintenance of Tower Crane.
g) Erection of structural steel members / roof-trusses / pipes at height more than 2.0 Mts. with
or without crane.
h) Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
of 100T capacity.
i) All lifts using 100T Crane plus mechanical pulling.
j) All lifts using two cranes in unison (Tandem Lifting).
k) Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
l) Laying of pipes (isolated or fabricated) in deep narrow trenches – manually or
mechanically.
m) Maintenance of crane / extension or reduction of crane-boom on roads or in yards.
n) Erection of any item at >2.0 Mts. height using 100T crane or of higher capacity
o) Hydrostatic test of pipes, vessels & columns and water-flushing.
p) Radiography jobs (in-plant & open field)
q) Work in Live Electrical installations / circuits
r) Handling of explosives & Blasting operations
s) Demolishing / dismantling activities
t) Welding / gas cutting jobs at height (+2.0 Mts.)
u) Lifting / placing roof-girders at height (+2.0 Mts.)
v) Lifting & laying of metallic / non-metallic sheet over roof/structures.
w) Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with & without using
cranes
x) Calibration of equipment, instruments and functional tests at yards / work-sites.
y) Operability test of Pump, Motors (after coupling) & Compressors.
z) Cold or Hot works inside Confined Space.
aa) Transportation & shifting of ODC consignments into project areas.
bb) Working in “charged/Live” elect. Panels
cc) Stress Relieving works (Electrically or by Gas-burners).
dd) Pneumatic Tests
ee) Card board blasting
ff) Chemical cleaning
and take feedback from EIL/Owner. The necessary HSE measures devised shall be put in to
place, prior to start of an activity & also shall be maintained during the course of works, by the
Contractor. Copies of such JSAs shall be kept available at work sites by the Contractor to enable
all concerned carrying out checks / verification.
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A list of typical construction hazards along with their effects & preventive measures is given in
Appendix-E.
3.3.2 Accessibility
 The Contractor shall provide safe means of access(in sufficient numbers) & efficient exit to
any working place including provisions of suitable and sufficient scaffolding at various
stages during all operations of the work for the safety of his workmen and EIL/Owner.
 The Contractor shall implement use of all measures including use of “life line”, “fall-
arresters”, “retractable fall arresters” , “safety nets” etc. during the course of using all safe
accesses & exits, so that in no case any individual remains at risk of slip & fall during their
travel.
 The access to operating plant / project complex shall be strictly regulated. Any person or
vehicle entering such complex shall undergo identification check, as per the procedures in
force / requirement of EIL/Owner.
 Accessibility to ‘confined space’ shall be governed by specific system / regulation, as
established at project site.
3.3.3 Personal Protective Equipments (PPEs)
 The Contractor shall ensure that all their staff, workers and visitors including their sub-
contractor(s) have been issued (records to be kept) & wear appropriate PPEs like nape strap
type safety helmets preferably with head & sweat band with ¾” cotton chin strap
(made of industrial HDPE), safety shoes with steel toe cap and antiskid sole, full body
harness (CЄ marked and conforming to EN361), protective goggles, gloves, ear muffs,
respiratory protective devices, etc. All these gadgets shall conform to applicable IS
Specifications/CE or other applicable international standards. The Contractor shall
implement a regular regime of inspecting physical conditions of the PPEs being issued /
used by the workmen of their own & also its sub-agencies and the damaged / unserviceable
PPEs shall be replaced forthwith.
 Owner/EIL may issue a comprehensive color scheme for helmets to be used by various
agencies. The Contractor shall follow the scheme issued by the owner/EIL and shall choose
any colour other than white (for Owner) or blue (for EIL) All HSE personnel shall
preferably wear dark green band on their helmet so that workmen can approach them for
guidance during emergencies. HSE personnel shall preferably wear such dresses with
fluorescent stripes, which are noticeable during night, when light falls on them.
 For shot blasting, the usage of protective face shield and helmets, gauntlet and protective
clothing is mandatory. Such protective clothing should conform relevant IS Specification.
 For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to EIL &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at all time.
 An indicative list of HSE standards/codes is given under Appendix-A.
 Contractor shall ensure procurement & usage of following safety equipments/ accessories
(conforming to applicable IS mark / CE standard) by their staff, workmen & visitors
including their subcontractors all through the span of project construction / pre-
commissioning/ Commissioning:-‘
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a. PPEs (Helmet, Spectacle, Ear-muff, Face shield, Hand gloves, Safety Shoes, Gum
boot)
b. Barricading tape / warning signs
c. Rechargeable Safety torch (flame-proof)
d. Safety nets (with tie-chords)
e. Fall arresters
f. Portable ladders (varying lengths)
g. Life-lines (steel wire-rope, dia not less than 8.0 mm)
h. Full body harness (double lanyard)
i. Lanyard
j. Karabiner
k. Retractable fall arresters (various length)
l. Portable fire extinguishers (DCP type) – 5 kg capacity
m. Portable Multi Gas detector
n. Sound level meter
o. Digital Lux meter
p. Fire hoses & flow nozzles
q. Fire blankets / Fire retardant cloth (with eyelets)
3.3.4 Working at height
 The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints as specified in the attached permit (Format No. HSE-6). He
shall also undertake to ensure compliance to the conditions of the permit during the
currency of the permit including adherence of personal protective equipments. Contractor’s
Safety Officer shall verify compliance status of the items of permit document after
implementation of action is completed by Contractor’s execution / field engineers at work
site. Job Safety Analysis (JSA) for specific works at height duly commented by
EIL/Owner, shall be kept attached with particular Permit for Work (PFW) at site for ready
reference & follow-up.
 Such PFW shall be initially issued for one single shift or expected duration of normal work
and extended further for balance duration, if required. EIL/Owner can devise block-permit
system at any specific area, in consultation with project specific HSE Committee to specify
the time-period of validity of such PFW or its renewal. This permit shall be applicable in
areas where specific clearance from Owner’s operation Deptt. /Safety Deptt. is not
required. EIL / Owner’s field Engineers/Safety Officers/Area Coordinators may verify and
counter sign this permit (as an evidence of verification) during the execution of the job.
 All personnel shall be medically examined & certified by registered doctor, confirming
their ‘medical fitness for working at height. The fitness examination shall be done once in
six months.
 In case work is undertaken without taking sufficient precautions as given in the permit, EIL
/Owner Engineers may exercise their authority to cancel such permit and stop the work till
satisfactory compliance/rectification is arranged made. Contractors are expected to
maintain a register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.
 The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his
workers. Fall arresters are to be used while climbing/descending tall structures or vessels /
columns etc. These arresters should lock automatically against the anchorage line,
restricting free fall of the user. The device is to be provided with a double security opening
system to ensure safe attachment or release of the user at any point of rope. In order to
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avoid shock, the system should be capable of keeping the person in vertical position in case
of a fall.
 The Contractor shall ensure that Full body harnesses conforming EN361 and having
authorized CЄ marking is used by all personnel while working at height. The lanyards and
life lines should have enough tensile strength to take the load of the worker in case of a fall.
One end of the lanyard shall be firmly tied with the harnesses and the other end with life
line. The harness should be capable of keeping the workman vertical in case of a fall,
enabling him to rescue himself.
 The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping
roofs in order to reduce the chances of slippages and falls.
 The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of
fall from height is present. The safety net, preferably a knotted one with mesh ropes
conforming to IS 5175/ ISO 1140 shall have a border rope & tie cord of minimum 12mm
dia. The Safety Net shall be located not more than 6.0 meters below the working surface
extending on either side up to sufficient margin to arrest fall of persons working at different
heights.
 In case of accidental fall of person on such Safety Net, the bottom most portion of Safety
Net should not touch any structure, object or ground.
 The Contractor shall ensure positive isolation while working at different levels like in the
pipe rack areas. The working platforms with toe boards & hand rails shall be sufficiently
strong & shall have sufficient space to hold the workmen and tools & tackles including the
equipments required for executing the job. Such working platforms shall have mid-rails, to
enable people work safely in sitting posture.
3.3.5 Scaffoldings & Barricading
 Suitable scaffoldings shall be provided to workmen for all works that cannot be safely done
from the ground or from solid construction except such short period work that can be safely
done using ladders or certified (by 3rd party competent person) man-basket. When a ladder
is used, an extra workman shall always be engaged for holding the ladder.
 The Contractor shall ensure that the scaffolds used during construction activities shall be
strong enough to take the designed load. Main Contractor shall always furnish duly
approved construction-design details of scaffold & SWL (from competent designers) free
of charge, before they are being installed / constructed at site. Owner/EIL reserves the right
to ask the Contractor to submit certification and or design calculations from his Head office
/ Design/ Engineering expert regarding load carrying capacity of the scaffoldings.
 All scaffolds shall be inspected by a competent Scaffolding Inspector of the Contractor. He

shall paste a GREEN tag (duly signed by competent Scaffolding Inspector) on each
scaffold found safe and a RED tag (duly signed by competent Scaffolding Inspector) on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be permitted to be used
and Scaffolds with RED ones shall immediately be made inaccessible. Work being found
continuing on scaffolds with RED tag shall be considered unauthorized work by Contractor
and may invite penalization from EIL/Owner. For every 120-125 m2 /m3 area / volume or
its parts thereof minimum one TAG shall be provided.
 The Contractor shall ensure positive barricading (indicative as well as protective) of the
excavated, radiography, heavy lift, high pressure hydrostatic & pneumatic testing and other
such areas. Sufficient warning signs shall be displayed along the barricading areas.
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 Scaffolding shall be constructed using foot seals or base plates only.
3.3.6 Electrical installations
 All electrical installations/ connections shall be carried out as per the provisions of latest
revision of following codes/standards, in addition to the requirements of Statutory
Authorities and IE/applicable international rules & regulations:
- OISD STD 173 : Fire prevention & protection system for electrical installations
- SP 30 (BIS) : National Electric Code
 All electrical installations shall be approved by the concerned statutory authorities.
 All temporary electrical installations / facilities shall be regularly checked by the

licensed/competent electricians of the Contractor and appropriate records shall be
maintained in format no: HSE-12” Inspection of temporary electrical booth/installation at
project construction site”. Such inspection records are to be made available to EIL/Owner,
whenever asked for.
3.3.6.1 The Contractor shall meet the following requirements:
a. Shall make Single Line Diagram (SLD) for providing connection to each equipments &
machinery and the same (duly approved by EIL/Owner) shall be pasted on the front face of
DBs (distribution boards) or JBs (Junction boxes) at every site. ( A typical Switch Board
Sketch is attached as Appendix -G )
b. Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per provisions
of the latest revision of the Indian Electrical/ applicable international regulations.
c. Shall deploy qualified & licensed electricians for proper & safe installation and for regular
inspection of construction power distribution system/points including their earthing. A
copy of the license shall be submitted to EIL / Owner for records. Availability of at least
one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be
ensured at site round the clock to attend to the normal/emergency jobs.
d. All switchboards / welding machines shall be kept in well-ventilated & covered shed/ with
rain shed protection. The shed shall be elevated from the existing ground level to avoid
water logging inside the shed . Installation of electrical switch board must be done taking
care of the prevention of shock and safety of machine.
e. No flammable materials shall be used for constructing the shed. Also flammable materials
shall not be stored in and around electrical equipment / switchboard. Adequate clearances
and operational space shall be provided around the equipment.
f. Fire extinguishers and insulating mats shall be provided in all power distribution centers.
g. Temporary electrical equipment shall not be employed in hazardous area without obtaining
safety permit.
h. Proper housekeeping shall be done around the electrical installations.
i. All temporary installations shall be tested before energizing, to ensure proper earthing,
bonding, suitability of protection system, adequacy of feeders/cables etc.
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j. All welders shall use hand gloves irrespective of holder voltage.
k. Multilingual (Hindi, English and local language) caution boards, shock treatment charts and
instruction plate containing location of isolation point for incoming supply, name &
telephone No. of contact person in emergency shall be provided in substations and near all
distribution boards / local panels.
l. Operation of earth leakage device shall be checked regularly by temporarily connecting

series test lamp (2 bulbs of equal rating connected in series) between phase and earth.
ELCB tester /test meter shall be used for testing ELCBs
m. Regular inspection of all installations at least once in a month. (Ref. Format HSE-12).
3.3.6.2 The following features shall also be ensured for all electrical installations during construction
phase by the contractor:
 Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch shall not
exceed 1.5 M. The main switch shall be connected to the point of supply by means of
armoured cable.
 The outgoing feeders shall be double or triple pole switches with fuses / MCBs. Loads in a
three phase circuit shall be balanced as far as possible and load on neutral should not
exceed 20% of load in the phase.
 The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type.
Use of rewirable fuses shall be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.
 All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.
 All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be
provided with socket caps.
 Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5
mm2 copper shall be used for all single phase hand tools.
 Only metallic distribution boxes with double earthing shall be used at site. No wooden
boxes shall be used.
 All power cables shall be terminated with compression type cable glands. Tinned copper
lugs shall be used for multi-strand wires / cables.
 Cables shall be free from any insulation damage.
 Minimum depth of cable trench shall be 750 mm for MV & control cables and 900 mm for
HV cables. These cables shall be laid over a sand layer and covered with sand, brick & soil
for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of buried trench route.
When laid above ground, cables shall be properly cleated or supported on rigid poles of at
least 2.1 M high. Minimum head clearance of 6 meters shall be provided at road crossings.
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 Under ground road crossings for cables shall be avoided to the extent feasible. In any case
no under ground power cable shall be allowed to cross the roads without pipe sleeve.
 All cable joints shall be done with proper jointing kit. No taped/ temporary joints shall be
used.
 An independent earthing facility should preferably be established within the temporary

installation premises. All appliances and equipment shall be adequately earthed. In case of
armoured cables, the armour shall be bonded to the earthing system.
 All cables and wire rope used for earth connections shall be terminated through tinned
copper lugs.
 In case of local earthing, earth electrodes shall be buried near the supply point and earth
continuity wire shall be connected to local earth plate for further distribution to various
appliances. All insulated wires for earth connection shall have insulation of green colour.
 Separate core shall be provided for neutral. Earth / Structures shall not be used as a neutral
in any case.
 ON/OFF position of all switches shall be clearly designated / painted for easy isolation in
emergency.
3.3.7 Welding/ Gas cutting
 Contractor shall ensure that flash back arrestors conforming to BS: 6158 or equivalent are
installed on all gas cylinders as well as at the torch end of the gas hose, while in use.
 All cylinders shall be mounted on trolleys and provided with a closing key. Empty &
filled-up gas cylinders shall be stored separately with TAG, protecting them from direct
sun or rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be
maintained at the gas cylinder stores. Stacking & storing of compressed gas cylinders shall
be arranged away from DG set, hot works, Elect. Panels / Elec. boards, etc
 The burner and the hose placed downstream of pressure reducer shall be equipped with
Flash Back Arrester/Non Return Valve device.
 The hoses for acetylene and oxygen cylinders must be of different colours. Their
connections to cylinders and burners shall be made with a safety collar.
 At end of work, the cylinders in use shall be closed and hoses depressurized.
 Cutting of metals using gases, other than oxygen & acetylene, shall require written
concurrence from Owner.
 All welding machines shall have effective earthing at least at distinctly isolated two points.
 In order to help maintain good housekeeping, and to reduce fire hazard, live electrode bits
shall be contained safely and shall not be thrown directly on the ground.
 The hoses of Acetylene and Oxygen shall be kept free from entanglement & away from
common pathways / walkways and preferably be hanged overhead in such a manner which
can avoid contact with cranes, hydra or other mobile construction machinery.
 Hot spatters shall be contained / restricted appropriately (by making use of effective fire-
retardant cloth/fabric) and their flying-off as well as chance of contact with near-by
flammable materials shall be stopped.
 The Contractor shall arrange adequate systems & practices for accumulation / collection of
metal & other scraps and remnant electrodes and their safe disposal at regular interval so as
to maintain the fabrication and other areas satisfactorily clean & tidy.
 All gas cylinders must have a cylinder cap on at all times when not in use.
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3.3.8 Ergonomics and tools & tackles
 The Contractor shall assign to his workmen, tasks commensurate with their qualification,
experience and state of health.
 All lifting tools, tackles, equipment, accessories including cranes shall be tested
periodically by statutory/competent authority for their condition and load carrying capacity.
Valid test & fitness certificates from the applicable authority shall be submitted to
Owner/EIL for their review/acceptance before the lifting tools, tackles, equipment,
accessories and cranes are used.
 The contractor shall not be allowed to use defective equipment or tools not adhering to
safety norms.
 Contractor shall arrange non-sparking tools for project construction works in operating
plant areas / hydrocarbon prone areas.
 Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or
Aerial Work Platforms (mobile or stationary) to avoid ergonomical risks and workmen
shall be debarred to board such elevated platform during the course of their shifting /
transportation.
 Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use)
to minimize overloading risk. SLI shall have capability to continuously monitor and
display the load on the hook, and automatically compare it with the rated crane capacity at
the operating condition of the crane. The system shall also provide visual and audible
warnings at set capacity levels to alert the operator in case of violations.
 The contractor shall be responsible for safe operations of different equipments mobilized
and used by him at the workplace like transport vehicles, engines, cranes, mobile ladders,
scaffoldings, work tools, etc.
 The Contractor shall arrange periodical training for the operators of hydra, crane,
excavator, mobile machinery, etc. at site by utilizing services from renowned
manufacturers
3.3.9 Occupational Health
 The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
 For surface cleaning operations, sand blasting shall not be permitted even if not explicitly
stated elsewhere in the contract.
 To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
shall not contain Thorium.
 Appropriate respiratory protective devices(hood with respiratory devices) shall be used to

protect workmen from inhalation of air borne contaminants like silica, asbestos, gases,
fumes, etc.
 Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulling
of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting
equipments.
 For jobs like drilling/demolishing/dismantling where noise pollution exceeds the specified
limit of 85 decibels, ear muffs shall be provided to the workers.
 To avoid work related upper limb disorders (WRULD) and backaches, Display Screen
Equipments' workplace stations shall be carefully designed & used with proper sitting
postures. Power driven hand-held tools shall be maintained in good working condition to
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minimize their vibrating effects and personnel using these tools shall be taught how to
operate them safely & how to maintain good blood circulation in hands.
 The Contractor shall arrange health check up (by registered medical practitioner) for all the
workers at the time of induction. Health check may have to be repeated if the nature of duty
assigned to him is changed necessitating health check or doubt arises about his wellness.
EIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding, Radiography,
Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-ups shall be
conducted by registered Medical practitioner and records are to be maintained by the
Contractor.
 The Contractor shall ensure vaccination of all the workers including their families, during
the course of entire project span.
3.3.10 Hazardous substances
 Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, anti-
termite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good ventilated
area. These containers shall be labeled with the name of the materials highlighting the
hazards associated with its use and necessary precautions to be taken. Respective MSDS
(Material Safety Data Sheet) shall be made available at site & may be referred whenever
problem arises.
 Where contact or exposure of hazardous materials are likely to exceed the specified limit or
otherwise have harmful effects, appropriate personal protective equipments such as gloves,
goggles/face-shields, aprons, chemical resistant clothing, respirator, etc. shall be used.
 The work place shall be checked prior to start of activities to identify the location, type and
condition of any asbestos materials which could be disturbed during the work. In case
asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured
and the matter shall be reported immediately to EIL/ Owner.
3.3.11 Slips, trips & falls
The contractor shall establish a regular cleaning and basic housekeeping programme that covers
all aspects of the workplace to help minimize the risk of slips, trips & falls. The contractor shall
take positive measures like keeping the work area tidy, storing waste in suitable containers &
harmful items separately, keeping passages, stairways, entrances & exits especially emergency
ones clear, cleaning up spillages immediately and replacing damaged carpet/ floor tiles, mats &
rugs at once to avoid slips, trips & falls.
3.3.12 Radiation exposure
 All personnel exposed to physical agents such as ionizing & non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with adequate
shielding or protection commensurate with the type of exposure involved.
 For Open Field Radiography works , requirements of Bhabha Atomic Research Centre
(BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
 The Contractor shall implement an effective system of control (as described in the AERB
regulations) at site for handling radiography-sources & for avoiding its misuse & theft.
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 The contractor shall generate the Format No: HSE-8 “Permit for radiation work” before
start of work.
 In case the radiography work has to be carried out at day time, suitable methodology to be
used so that other works, people are not affected.
3.3.13 Explosives/Blasting operations
 Blasting operations shall be carried out as per latest Explosive Rules (Indian / International)
with prior permission. The Contractor shall obtain license from Chief Controller of
Explosives (CCoE) for collection, transportation, storage of explosives as well as for
carrying out blasting operations.
 The Contractor shall prepare exclusive method statement (in cognizance with statutory
requirements) for diffusing unfired explosives, if any, at project site before carrying out
actual task. Nowhere blasting shall be carried out by the Contractor or its agency without
the involvement of competent supervisor and licensed blaster / shot blaster.
3.3.14 Demolition/ Dismantling
 The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work
to guard against unsafe working practices.
 The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, if required as directed by
EIL/ Owner at no extra cost.
 Before carrying out any demolition/ dismantling work, the contractor shall take prior
approval of EIL/Owner and generate the Format No.HSE-9. For revamp jobs in operating
plants where location of underground utilities is not known with certainty, the contractor
shall depute an experienced engineer for supervision and shall make adequate arrangements
for Fire fighting & First-Aid during the execution of these activities.
 The Contractor shall arrange approved Job Safety Analysis (JSA) / Method Statement for
the specific demolition / dismantling task and corresponding action plan commensurate
with hazards / risks associated therein. In no case any activity related to demolition /
dismantling shall be carried out by the Contractor without engaging own supervision / field
engineer.
3.3.15 Road Safety
 The Contractor shall ensure adequately planned road transport safety management system.
 The vehicles shall be fitted with reverse warning alarms & flashing lights / fog-lights and
usage of seat belts shall be ensured.
 The Contractor shall also ensure a separate pedestrian route for safety of the workers and
comply with all traffic rules & regulations, including maintaining speed limit of 20 kmph
or indicated by owner for all types of vehicles / mobile machinery. The maximum
allowable speed shall be adhered to.
 In case of an alert or emergency, the Contractor must arrange clearance of all the routes,
roads, access. The Contractor shall deploy sufficient number of traffic controllers at project
site routes / roads/ accesses, to alert reversing movement of vehicles & machinery as well
as pedestrians.
 Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also
to & from the labour colony to & from project sites.
 Hydras shall only be allowed for handling the materials at fabrication/ storage yards and in
no case shall be allowed to transport the materials over project / plant roads.
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 The Contractor shall not deploy any such mobile machinery / equipments, which do not
have competent operator and / or experienced banks-man / signal-man. Such machinery /
equipments shall have effective limit-switches, reverse-alarm, front & rear-end lights etc.
and shall be maintained in good working order.
 The Contractor shall not carry-out maintenance of vehicles / mobile machinery occupying
space on project / plant roads and shall always arrange close supervision for such works.
 For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
loading / unloading of pipes, movement of side booms, movement of vehicles on the ROW,
etc.
 Contractor’s shall arrange /install visible road signs, diversion boards, caution boards, etc
on project roads for safe movement of men and machinery.
3.3.16 Welfare measures
Contractor shall, at the minimum, ensure the following facilities at work sites:
 A crèche at site where 10 or more female workers are having children below the age of 6
years.
 Adequately ventilated / illuminated rooms at labour camps & its hygienic up-keeping.
 Reasonable canteen facilities at site and in labour camps at appropriate location depending
upon site conditions. Contractor shall make use of “industrial” variety of LPG cylinder &
satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of
wastes from canteens & urinals /toilets shall also be made and regular review shall be made
to maintain the ambience satisfactorily hygienic & shall also comply with all applicable
statutory requirements.
 Adequately lighted & ventilated Rest rooms at site (separate for male workers and female
workers).
 Urinals, Toilets, drinking water, washing facilities, adequate lighting at site and labour
camps, commensurate with applicable Laws / Legislation.
3.3.17 Environment Protection
Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment. Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste materials,
such as metals, plastics, glass, paper, oil & solvents. The waste that cannot be minimized,
reused or recovered shall be stored and disposed of safely. In no way, toxic spills shall be
allowed to percolate into the ground. The contractor shall not use the empty areas for dumping
the wastes.
The contractor shall strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases,
harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need
arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other
waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A
discharge plan suggesting the methods of treating the waste before discharging shall be
submitted to EIL/Owner for approval.
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For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This
fertile soil shall be placed back on top after backfilling.
For offshore construction barges, arrangements shall be made for safe disposal of human, food
& other wastes and applicable laws in this regard shall be followed.
3.3.18 Rules & Regulations
All persons deployed at site shall be knowledgeable of and comply with the environmental laws,
rules & regulations relating to the hazardous materials, substances and wastes. Contractor shall
not dump, release or otherwise discharge or disposes off any such materials without the express
authorization of EIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is
given under Appendix-D.
3.3.19 Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, rain, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun
screen lotions, respirators, dust masks, etc. and rearranging/ planning the construction activities
to suit the weather conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle in the form
of temporary shelter shall be made at site.
3.3.20 Communication
All persons deployed at the work site shall have access to effective means of communication so
that any untoward incident can be reported immediately and assistance sought by them.
All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
For information to all, typical subjects that should be communicated are: -
Inside the company (Top to down)
a. Quality Policy
b. HSE Policy contents
c. Environment Policy
d. HSE Objectives
e. Safety Cardinal Rules
f. HSE Target – reached or missed
g. Praises & Warnings to personnel for HSE Management
h. Safety Walk Through Reports and safety defects / shortfalls (by management)
i. HSE Audit results
j. Revised Statutory Health & Safety provisions, if any
k. H & S publicity
l. Suggestions
Inside the Company (Bottom to up)
a. Complaints
b. Compliances on safety defects / shortfalls
c. Suggestions
d. Proposals for changes & improvements
e. HSE Reports (including near-miss reports)
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3.3.21 Confined Space Entry
The contractor shall generate a work permit (Format No. HSE -7) before entering a confined
space. People, who are permitted to enter into confined space, must be medically examined &
certified by registered doctor, confirming their ‘medical fitness for working in confined space’.
All necessary precautions mentioned therein shall be adhered to. An attendant shall be
positioned outside a confined space for extending help during an emergency. All appropriate
PPEs and air quality parameters shall be checked before entering a confined space. It shall be
ensured that the piping of the equipment which has to be opened is pressure- free by checking
that blinds are in place, vents are open and volume is drained. Inside confined space works, only
electrical facilities / installations of 24V shall be permitted. Contactor shall ensure usage of safe
& suitable arrangement of oxygen supply for individual workmen (during the course of work in
confined space), if oxygen concentration is found to be less than 19.5% (v/v) there.
3.3.22 Heavy Lifts
 The contractor shall submit detailed rigging studies plan for EIL/ Owner approval prior to
lifting equipment which cannot be erected with a crane of approx. 100 MT capacity due to
constraints of its dimensions, location of foundation height, approach & weight.
 Contractor shall generate the format no:HSE-15 “Permit for heavy lift/critical erection”
 Prior to actual lifting activities, contractor shall check the validity of the crane inspection
certificate issued by statutory/ competent authority. This requirement shall also apply to all
rigging equipments utilized for the job.
 The contractor shall, at all times, be responsible for all rigging activities.
 The Contractor shall ensure medical fitness of all workmen who are engaged / involved in
erection of equipments, vessels etc. and such fitness checks shall be carried-out every six
months interval with the help of a registered medical practitioner & record shall be
maintained
 Adequate safety measures such as positive barricading, usage of appropriate PPEs, permit
to work, etc. shall be taken during all heavy or critical lifts.
 For lifting any material (irrespective of shape, size or volume), at any height, it is always
advisable to prepare a Plan of Erection (PoE) taking into consideration hazards & risks
associated therein – this can enable people to put their own experiences of various natures
& side-by-side establish a practical method for risk-free erection / lifts. The contractor shall
prepare PoE & shall document the same, when risks are identified as “medium” or “high”
and the same shall be approved by its competent / qualified engineer.
3.3.23 Key Performance Indicators
The contractor shall measure an activity in both leading & trailing indicators for statistical and
performance measurement. The activities pertaining to key performance indicators are covered
in Monthly HSE Report (Format No. HSE-5). The contractor shall try to achieve a statistically
fair record and strive for its continual improvement.
Leading Indicators viz:-:
- Number of Safety Inductions carried-out at site (for workmen & staff members)
- Number of HSE inspections carried out
- Number of “Safety Walk Through” carried-out by site-head.
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- Number of HSE shortfalls / lapses identified per contractor & closed-out in time.
- Number of Safety Meetings conducted (in-house / with contractors)
- Number of HSE Audits made (internal & external) vis-à-vis non conformances raised
- Number of HSE Awareness / Motivational program conducted by contractors
- Number of HSE Trainings conducted at site for supervisors & workmen
- Study of Near miss case reported
- Encouragements / Awards / Recognitions to workmen, job supervisors & field engineers.
- Suggestions for improvement
Trailing Indicators viz:-:
- Calculation of HSE statistics viz frequency rate, severity rate, LTA free manhours,etc
- Analysis of incidents / accidents (nature, severity, types etc.)
- Study of Incident / Accident with respect to :-
 Variety
 Period of the year / project span
 Timings of the incident / accident
 Age profile of victims
 Body parts involved
 Penalty levied for causing incident / accident
3.3.24 Unsuitable Land Conditions
Contractor shall take appropriate measures and necessary work permits/clearances if work is to
be done in or around marshy areas, river crossings, mountains, monuments, etc. The Contractor
shall make right assessment and take all necessary action for developing work areas to make
them safe & suitable for crane operations or other vehicular movement before carrying out any
project related activity / operation. Contractor shall take all necessary actions to make the
surroundings of its site establishments (site office, stores, lay-down area etc.) work-worthy
safe and secure.
3.3.25 Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection arrangements
and shall posses communication facilities like cellular phones, wireless, walkie-talkie. All
divers used for seabed surveys, underwater inspections shall have required authorized license,
suitable life saving kit. Number of hours of work by divers shall be limited as per regulations.
EIL/ Owner shall have the right to inspect the boat and scrutinize documents in this regard.
3.3.26 Excavation
The Contractor shall obtain permission from competent authorities prior to excavation wherever
required.
The Contractor shall locate the position of buried utilities (water line, cable route, etc.) by
referring to project / plant drawing / in consultation with EIL/Owner. The Contractor shall start
digging manually to locate the exact position of buried utilities & thereafter use mechanical
means.
The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance equal to depth
of pit (whichever is more)
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The Contractor shall maintain sufficient “angle of repose” during excavation – shall also
provide slope or suitable bench as decided by EIL / Owner.
The Contractor shall arrange “battering” or “benching” wherever required for preventing
collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth
collapse due to heavy rain / influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid “underpinning” / under-cutting to prevent collapse of chunk of earth
during excavation
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of
excavated pits / trenches.
The Contractor shall arrange strengthening of “shoring” & “strutting” proactively to avoid
collapse of earth / edges due to vehicular movement in close proximity of excavated areas / pits
/ trenches, etc.
3.4 Tool Box Talks (TBT)
Contractor shall conduct daily TBT with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBT is to be conducted
by the immediate supervisor of the workers
The Contractor shall conduct TBT before start of every morning or evening shift or night shift
activities, for alerting the workers on specific hazards and their appropriate dos & don’ts. The
Contractor shall provide sufficient rests to the site workmen and their foremen to avert fatigue
& thereby endangering their lives during the course of site works.
TOOL BOX TALK RECORDING SHEET

Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name Signature Section
Remarks, in any
The topics during TBT shall include
- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards/events/instruction/orders, etc.
The above record can be kept in local language, which workers can read. These records shall be
made available to EIL/ Owner whenever demanded.
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3.5 Training & Induction Programme
 Initial induction of workers into Construction oriented activities and appraising them about
the methodology of works and how to carry-out safely and the same should not be inter
mixed with Tool Box Talks or HSE Training. In this regard careful action should be made
& maintained for imparting HSE induction to every individual, irrespective of his
task/designation/level of employment, whereas, HSE Training should be imparted to
specific person/group of people who are to carry-out that specific task more than once – for
example, Riggers must be trained for working at heights, welders must be trained for work
in confined space, fitters/carpenters, mesons must be trained for work at heights, etc.
 Contractor shall conduct Safety induction programme on HSE for all his workers and
maintain records. The Gate Pass shall be issued only to those workers who successfully
qualify the Safety induction programme.
 The Contractor shall brief the visitors about the HSE precautions which are required to be
taken before their proceeding to site and make necessary arrangements to issue appropriate
PPEs like Aprons, hard hats, ear-plugs, goggles & safety shoes etc., to his visitors. The
Contractor shall always maintain relevant acknowledgement from visitor on providing him
brief information on HSE actions.
 Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about
- Potential hazards to which they may be exposed at their workplace

- Measures available for prevention and elimination of these hazards
The topics during training shall cover, at the minimum: -
- Why safety should be considered during work - explanation

- Education about hazards and precautions required
- Employees’ duties & responsibilities
- Emergency and evacuation plan
- HSE requirements during project activities
- Fire fighting and First-Aid
- Use of PPEs
- Occupational health issues – dos & don’ts
- Local laws on intoxicating drinks, drugs, smoking in force
- Common environmental subjects – lighting, ventilation, vibration, smoke/fumes etc.
 Records of the training shall be kept and submitted to EIL/ Owner.
 The Contractor shall make regular program for conducting Safety Training on various
topics related to various activities & their safe-guarding utilizing experienced persons /
outside agency / faculty. A program for Safety Training (indicative list as per Appendix –F)
shall be furnished by the Contractor in its HSE Plan .
 For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner/EIL.
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3.6 ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING

PLANT
As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant:
a) Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined Space
from Owner in the prescribed format.
b) The contractor shall monitor record and compile list of his workers entering the operational
plant/unit each day and ensure & record their return after completing the job.
c) Contractor’s workers and staff members shall use designated entrances and proceed by
designated routes to work areas only assigned to them. The workers shall not be allowed to
enter units' area, tanks area, pump rooms, etc. without work authorization permit.
d) Work activities shall be planned in such a way so as to minimize the disruption of other
activities being carried out in an operational plant/unit and activities of other contractors.
e) The contractor shall submit a list of all chemicals/toxic substances that are intended to be
used at site and shall take prior approval of the Owner.
f) Specific training on working in a hydrocarbon plant shall be imparted to the work force and
mock drills shall be carried out for Rescue operations/First-Aid measures.
g) Proper barricading/cordoning of the operational units/plants shall be done before starting

the construction activities. No unauthorized person shall be allowed to trespass. The height
and overall design of the barricading structure shall be finalized in consultation with the
Owner and shall be got approved from the Owner.
h) Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i) Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of critical
activities.
j) Emergency evacuation plan shall be worked out and all workmen shall be apprised about
evacuation routes. Mock drill operations may also be conducted.
k) Flammable gas test shall be conducted prior to any hot work using appropriate measuring
instruments. Sewers, drains, vents or any other gas escaping points shall be covered with
flame retardant tarpaulin.
l) Respiratory devices shall be kept handy while working in confined zones where there is a
danger of inhalation of poisonous gases. Constant monitoring of presence of Gas/
Hydrocarbon shall be done.
m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on live
lines and work on corroded tank roof.
n) Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be done.

Closing of valve will not be considered sufficient for isolation.
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o) Welding spatters shall be contained properly and in no case shall be allowed to fall on the
ground containing oil. Similar care shall be taken during cutting operations.
p) The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe
and got it approved from Safety Department of the Owner.
q) Plant air should not be used to clean any part of the body or clothing or use to blow off dirt
on the floor.
r) Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's
plant operation personnel.
s) Experienced full time safety personnel shall be exclusively deployed to monitor safety
aspects in running plants.
3.7 Self Assessment And Enhancement
The contractor shall develop a method of check & balance through self assessment &
enhancement techniques and shall explore the opportunities for continual improvement in the
HSE system.
3.8 HSE Promotion
The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops/seminars/training programmes, celebrating HSE awareness weeks &
National Safety Day, conducting quizzes & essay competitions, distributing pamphlets, posters
& material on HSE, providing incentives for maintaining good HSE practices and granting
incentives / bonus for completing the job without any lost time accident.
3.9 Lock Out and Tag Out (LOTO) for isolation of energy source
 Contractor shall follow the LOTO/Isolation procedure of owner for all energy source
isolations installed/under purview by /of owner ie. “Brown field”
 For all the other energy source (not under purview of client/owner) i.e “Green field”
Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel,
electrical panels from the energy source covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic,

chemical, thermal, gravitational, radiation and other forms of stored or kinetic
energy.
- Establishing the energy isolation devices viz: manually operated electrical circuit
breakers, disconnection switches, blind flanges, etc
- Installation of Lock Out devices for preventing the inadvertent release of stored
energy and Tag Out devices ( “Danger”, “Do Not operate” or Do not Remove” tags)
to indicate that testing, maintenance or servicing is underway and the device cannot
be operated until the tag out device is removed.
- Lock Out and Tag out log book
- Permit for isolation and de-isolation of energy source as per format NO: HSE-16
- Availability of competent persons like experienced operators at substations, pump
house, units, etc, ; supervisors,etc.
 Contractor shall ensure that all the sources are locked out and tagged properly before giving
clearance to start the job.
 After the completion of job, contractor shall ensure all tools and tackles are removed
and nobody is present in the working area and signing on LOTO log book.
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 Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person carrying out
the task shall himself carry the key for the lock in /Lock out.
4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
4.1 On Award Of Contract
The Contractor shall submit a comprehensive Health, Safety and Environment Plan or
programme for approval by EIL/Owner prior to start of work. The Contractor shall participate in
the pre-start meeting with EIL/Owner to finalize HSE Plans which shall including the
following:
- HSE policy & Objectives

- Job procedure to be followed by the Contractor for construction activities including
handling of equipments, scaffolding, electric installations, etc. describing the risks
involved, actions to be taken and methodology for monitoring each activity. Indicative list
of procedures is enclosed as Annexure-H
- EIL/Owner review/audit requirement.
- Organization structure along with responsibility and authority, on HSE activities.
- Administrative & disciplinary steps involving implementation of HSE requirements
- Emergency evacuation plan/ procedures for site and labour camps
- Job Safety Analysis for high risk jobs
- Procedures for reporting & investigation of accidents and near misses.
- HSE Inspection
- HSE Training programmes at project site
- HSE Awareness programmes, at project site
- Reference to Rules, Regulations and statutory requirements.
- HSE documentation viz reporting, analysis & record keeping.
4.2 During Job Execution
Contractor shall implement approved Health, Safety and Environment management programme
including but not limited to as brought out under para 3.0. Contractor shall also ensure:
 to arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act, etc, as applicable.
 to arrange all HSE permits before start of activities (as applicable), like permits for hot
work, working at heights (Refer Format No. HSE-6), confined space (Refer Format No.
HSE-7), Radiation Work Permit (Refer Format No. HSE-8), Demolishing/ Dismantling
Work Permit (Refer Format No. HSE-9),Permit for erection/modification & dismantling of
scaffolding(Refer Format No:HSE-14), Permit for heavy lift/critical erection (Refer Format
No:HSE-15) ,Permit for energy Isolation & De-isolation” (HSE-16) ,storage of chemical /
explosive materials & its use and implement all precautions mentioned therein. In this
regard, requirements of Oil industry Safety Directorate Standard No. Std -105 "Work
Permit Systems” shall be complied with while working in existing Oil or Gas processing
plants. List of the persons involved shall be maintained as annexure to the work permit
issued for a particular activity.
 to submit, timely, the completed checklist on HSE activities in Format No.HSE-1, Monthly
HSE report in Format No.HSE-5 (use of web based package (www.eil.co.in/conthse) is
compulsory wherever the facility is available else a hard copy is to be submitted), accident/
incident reports, investigation reports etc. as per EIL/Owner requirements. Compliance of
instructions on HSE shall be done by Contractor and informed urgently to EIL/Owner.
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 that his top most executive at site attends all the Safety Committee/HSE meetings arranged
by EIL/Owner and carries out safety walk through regularly. Only in case of his absence
from site that a second senior most person shall be nominated by him, in advance, and
communicated to EIL/Owner for performing the above tasks.
 display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various do’s & don’ts, etc.
 provide posters, banners for safe working to promote safety consciousness.
 identify, assess, analyze & mitigate the construction hazards & incorporate relevant control
measures before actually executing site works. (HIRAC = Hazard Identification, Risk
Analysis and Control).
 arrange testing, examination, inspection of own as well as borrowed construction

equipments / machinery (stationary & mobile) before being used at site and also at
periodical interval, through own resources and also by 3rd party competent agencies (as
deemed fit in statutes). Records of such test, examination etc. shall be maintained & shall
be submitted to EIL/Owner as & when asked for.
 carryout audits/inspection (internal & external) at his works as well as sub contractor works
as per approved HSE plan/procedure/programme & submit the compliance reports of
identified shortfalls for EIL/Owner review.
 arranging HSE training for site workmen (of his own & sub contractors) through internal or
external faculty at periodical intervals.
 assistance & cooperate during HSE audits by EIL/Owner or any other 3rd party and submit
compliance report.
 generate & submit of HSE records/report as per this specification.
 apprise EIL/Owner on HSE activities at site regularly.
 carry-out all dismantling activities safely, with prior approval of EIL/Owner representative.
 The Contractor shall ensure that “Hot works” and painting works do not continue at the
same place / location at project site for which chance or probability of “fire” incident
exists.
4.3 During Short Listing Of The Sub-Contractors
The contractor shall review the HSE management system of the sub-contractors in line with the
requirements given in this specification. The contractor shall be held responsible for the
shortcomings observed in the HSE management system of the sub-contractor(s) during
execution of the job.
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5.0 RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following reporting
formats/:
Safety Walk Through Report HSE-1

Accident/ Incident Report HSE-2
Supplementary Accident/ Incident Investigation report HSE-3
Near Miss Incident Report HSE-4
Monthly HSE Report HSE-5
Permit for working at height HSE-5
Permit for working in confined space HSE-7
Permit for radiation work HSE-8
Permit for demolishing/ dismantling HSE-9
Daily Safety checklist HSE-10
House keeping Assessment & compliance HSE-11
Inspection of temporary electrical booth/installation HSE-12
Inspection for scaffolding HSE-13
Permit for erection/modification &dismantling of scaffolding HSE-14
Permit for heavy lift/critical erection. HSE-15
Permit for Energy isolation and de-isolation. HSE-16
Permit for Excavation HSE-17
Inspection reports of Equipment/tools/tackles *
Report of Toolbox talks As indicated in
specification
PPE issue report/register *
Site inspection reports *
Training records *
(*) The formats shall be developed in consultation with EIL/Owner
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APPENDIX-A
(Sheet 1 of 2)
A. IS CODES ON HSE
SP: 53 Safety code for the use, Care and protection of hand operated tools.
IS: 838 Code of practice for safety & health requirements in electric and gas welding
and cutting operations
IS: 1179 Eye & Face precautions during welding, equipment etc.
IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 1989 (Pt -II) Leather safety boots and shoes
IS: 2925 Industrial Safety Helmets
IS: 3016 Code of practice for fire safety precautions in welding & cutting operation.
IS: 3043 Code of practice for earthing
IS: 3764 Code of safety for excavation work
IS: 3786 Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents
IS: 3696 Safety Code of scaffolds and ladders
IS: 4083 Recommendations on stacking and storage of construction materials and
components at site
IS: 4770 Rubber gloves for electrical purposes
IS: 5121 Safety code for piling and other deep foundations
IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557 Industrial and Safety rubber lined boots
IS: 5983 Eye protectors
IS: 6519 Selection, care and repair of Safety footwear
IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293 Safety Code for working with construction Machinery
IS: 8519 Guide for selection of industrial safety equipment for body protection
IS: 9167 Ear protectors
IS: 11006 Flash back arrestor (Flame arrestor)
IS: 11016 General and safety requirements for machine tools and their operation
IS: 11057 Specification for Industrial safety nets
IS: 11226 Leather safety footwear having direct moulded rubber sole
IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage
system
IS: 13367 Code of practice-safe use of cranes
IS: 13416 Recommendations for preventive measures against hazards at working place
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APPENDIX-A
(Sheet 2 of 2)
B. INTERNATIONAL STANDARDS ON HSE
Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092,

BS 1542, BS 679, DIN 4646/ 58311
Safety Shoes : ANSI Z 41.1, AS 2210, EN 345
Hand Gloves : BS 1651
Ear Muffs : BS 6344, ANSI S 31.9
Hard Hat : ANSI Z 89.1/89.2, AS 1808 , BS 5240, DIN 4840
Goggles : ANSI Z 87.1
Face Shield : ANSI Z 89.1
Breathing Apparatus : BS 4667, NIOSH
Welding & Cutting : ANSI Z 49.1
Safe handling of compressed: P-1 (Compressed Gas Association Gases in cylinders 1235
Jefferson Davis Highway,
Arlington VA 22202 - USA)
Full body harness : EN-361
Lanyard : EN-354
Karabiner : EN-362 and EN-12275
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APPENDIX-B
DETAILS OF FIRST AID BOX
------------------------------------------------------------------------------------------------------------------------
SL. DESCRIPTION QUANTITY
NO.
------------------------------------------------------------------------------------------------------------------------
1. Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs.
2. Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing) 6 Pcs.
3. Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs.
4. Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5. Cotton Wool (20 gms packing) 4 Pkts.
6. Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8. Ammonia Solution (20 ml.) 1 Bottle
9. A Pair of Scissors 1 Piece
10. Adhesive Plaster (1.25 cm X 5 m) 1 Spool
11. Eye pads in Separate Sealed Pkt. 4 pcs.
12. Tourniqut 1 No.
13. Safety Pins 1 Dozen
14. Tinc. Iodine/ Betadin (100 ml.) 1 Bottle
15. Polythene Wash cup for washing eyes 1 No.
16. Potassium Permanganate (20 gms.) 1 Pkt.
17. Tinc. Benzoine (100 ml.) 1 Bottle
18. Triangular Bandages 2 Nos.
19. Band Aid Dressing 5 Pcs.
20. Iodex/Moov (25 gms.) 1 Bottle
21. Tongue Depressor 1 No.
22. Boric Acid Powder (20 gms.) 2 Pkt.
23. Sodium Bicarbonate (20 gms.) 1 Pkt.
24. Dressing Powder (Nebasulf) (10 gms.) 1 Bottle
25. Medicinal Glass 1 No.
26. Duster 1 No.
27. Booklet (English & Local Language) 1 No. each
28. Soap 1 No.
29. Toothache Solution 1 No.
30. Vicks (22 gms.) 1 Bottle
31. Forceps 1 No.
32. Note Book 1 No.
33. Splints 4 Nos.
34. Lock 1 Piece
35. Life Saving/Emergency/Over-the counter Drugs As decided at site
-----------------------------------------------------------------------------------------------------------------
Box size: 14" x 12" x 4"
-----------------------------------------------------------------------------------------------------------------
Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.
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APPENDIX-C
TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS
Fire
Extinguisher
Multi purpose
Fire Water Foam CO2 Dry Powder
(ABC)
Originated from can control can control

  minor surface 
paper, clothes, wood minor surface
fires fires
Inflammable liquids
like alcohol, diesel,     
petrol, edible oils,
bitumen
Originated from
gases like LPG,     
CNG, H2
Electrical fires     
LEGEND :  : CAN BE USED
 : NOT TO BE USED
Note: Fire extinguishing equipment must be checked at least once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next inspection date is
given. Type of extinguisher shall clearly be marked on it.
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APPENDIX-D
List of Statutory Acts & Rules Relating to HSE
- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules
- The Petroleum Act and Petroleum Rules
- The Workmen Compensation Act
- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
- The Indian Electricity Act and Rules
- The Indian Boiler Act and Regulations
- The Water (Prevention & Control & Pollution) Act
- The Water (Prevention & Control of Pollution) Cess Act
- The Mines & Minerals (Regulation & Development) Act
- The Air (Prevention & Control of Pollution) Act
- The Atomic Energy Act
- The Radiation Protection Rules
- The Indian Fisheries Act
- The Indian Forest Act
- The Wild Life (Protection) Act
- The Environment (Protection) Act and Rules
- The Hazardous Wastes (Management & Handling) Rules
- The Manufacturing, Storage & import of Hazardous Chemicals Rules
- The Public Liability Act
- The Building and Other Construction Workers (Regulation of Employment and Condition of service)
Act
- Other statutory acts Like EPF, ESIS, Minimum Wage Act.
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APPENDIX-E (Sheet 1 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES
TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
(A) Falling into pit Personal injury Provide guard rails/ barricade with warning
EXCAVATION signal
Provide at least two entries/ exits.
Pit Excavation Provide escape ladders.
upto 3.0m Earth Collapse Suffocation/ Provide suitable size of shoring and strutting, if
Breathlessness required.
Buried Keep soil heaps away from the edge equivalent to
1.5m or depth of pit whichever is more.
Don't allow vehicles to operate too close to
excavated areas. Maintain at least 2m distance
from edge of cut.
Maintain sufficient angle of repose. Provide
slope not less than 1:1 and suitable bench of 0.5m
width at every 1.5m depth of excavation in all
soils except hard rock.
Battering/benching the sides.
Contact with Electrocution Obtain permission from competent authorities,
buried electric Explosion prior to excavation, if required.
cables Locate the position of buried utilities by referring
Gas/ Oil to plant drawings.
Start digging manually to locate the exact
Pipelines position of buried utilities and thereafter use
mechanical means.
Pit Excavation Same as above Can cause Prevent ingress of water
beyond 3.0m plus drowning situation Provide ring buoys
Flooding due to Identify and provide suitable size dewatering
excessive rain/ pump or well point system
underground
water
Digging in the Building/Structure Obtain prior approval of excavation method from
vicinity of may collapse local authorities.
existing Building/ Loss of health & Use under-pining method
Structure wealth Construct retaining wall side by side.
Movement of May cause cave-in Barricade the excavated area with proper lighting
vehicles/ or slides. arrangements
equipments close Persons may get Maintain at least 2m distance from edge of cut
to the edge of cut. buried. and use stop blocks to prevent over-run
Strengthen shoring and strutting
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APPENDIX-E: (Sheet 2 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Narrow deep Same as above May cause severe Battering/benching of sides
excavations for plus injuries or prove Provide escape ladders
pipelines, etc. Frequent cave-in fatal
or slides
Flooding due to May arise drowning Same as above plus
Hydro- static situation Bail out accumulated water
testing Maintain adequate ventilation.
Rock by Improper May prove fatal Ensure proper storage, handling & carrying of
excavation handling of explosives by trained personnel.
blasting explosives Comply with the applicable explosive acts &
rules.
Uncontrolled May cause severe Allow only authorized persons to perform
explosion injuries or prove blasting operations.
fatal Smoking and open flames are to be strictly
prohibited
Scattering of Can hurt people Use PPE like goggles, face mask, helmets etc.
stone pieces in
atmosphere
Rock excavation Entrapping of May cause severe Barricade the area with red flags and blow siren
by blasting persons/ animals. injuries or prove before blasting.
(Contd) fatal
Misfire May explode Do not return to site for at least 20 minutes or
suddenly unless announced safe by designated person.
Piling Work Failure of pile- Can hurt people Inspect Piling rigs and pulley blocks before the
driving beginning of each shift.
equipment
Noise pollution Can cause deafness Use personal protective equipments like ear
and psychological plugs, muffs, etc.
imbalance.
Extruding Can hurt people Barricade the area and install sign boards
rods/casing Provide first-aid
Working in the Can cause Keep sufficient distance from Live-Electricity as
vicinity of 'Live- electrocution/ per IS code.
Electricity' Asphyxiation Shut off the supply, if possible
Provide artificial/rescue breathing to the injured
(B) Air pollution by May affect Wear respirators or cover mouth and nose with
CONCRETING cement Respiratory System wet cloth.
Handling of Hands may get Use gloves & other PPE.
ingredients injured
Protruding Feet may get Use Provide platform above reinforcement for
reinforcement injured movement of workers.
rods.
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APPENDIX-E : (Sheet 3 of 12)
TYPE OF EFFECT OF
HAZARD HAZARD
Earthing of Can cause Ensure earthing of equipments and proper
electrical electrocution/ functioning of electrical circuit before
mixers, asphyxiation commencement of work.
vibrators, etc.
not done.
Falling of Persons may get Use hard hats
materials from injured Remove surplus material immediately from work
height place.
Ensure lighting arrangements during night hours
Continuous Cause tiredness of Insist on shift pattern
pouring by same workers and may Provide adequate rest to workers between
gang lead to accident. subsequent pours.
Revolving of Parts of body or Allow only mixers with hopper
concrete mixer/ clothes may get Provide safety cages around moving motors
vibrators entrapped. Ensure proper mechanical locking of vibrator
Super-structure Same as above Shuttering/props Avoid excessive stacking on shuttering material
plus may collapse and Check the design and strength of shuttering
Deflection in prove fatal material before commencement of work
props or Rectify immediately the deflection noted during
shuttering concreting.
material
Passage to work Improperly tied and Ensure the stability and strength of passage
place designed before commencement of work.
props/planks may Do not overload and stand under the passage.
collapse
(C) Curtailment and Persons may get Use PPE like gloves, shoes, helmets, etc.
REINFOR- binding of rods injured Avoid usage of shift tools
CEMENT Carrying of rods Workers may get Provide suitable pads on shoulders and use safety
for short injured their hands gloves.
distances/at and shoulders. Tie up rods in easily liftable bundles
heights Ensure proper staging.
Checking of Rods may cut or Use measuring devices like tape, measuring rods,
clear distance/ injure the fingers etc.
cover with hands
Hitting projected Persons may get Use safety shoes and avoid standing
rods and injured and fell unnecessarily on cantilever rods
standing on down Avoid wearing of loose clothes
cantilever rods.
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TYPE OF EFFECT OF
HAZARD HAZARD
Falling of material May prove fatal Use helmets
from height Provide safety nets
Transportation of Protruded rods may Use red flags/lights at the ends

rods by trucks/ hit the persons Do not protrude the rods in front of or by the side
trailers of driver's cabin.
Do not extend the rods 1/3rd of deck length or
1.5m whichever is less
(D)WELDING Welding radiates Radiation can Use specified shielding devices and other PPE of
AND GAS invisible damage eyes and correct specifications.
CUTTING ultraviolet and skin. Avoid thoriated tungsten electrodes for GTAW
infra-red rays
Improper Explosion may occur Move out any leaking cylinder
placement of Keep cylinders in vertical position
oxygen and Use trolley for transportation of cylinders and
acetylene cylinders chain them
Use flashback arrestors
Leakage/ cuts in May cause fire Purge regulators immediately and then turn off
hoses Never use grease or oil on oxygen line
connections and copper fittings on acetylene lines
Inspect regularly gas carrying hoses
Always use red hose for acetylene & other
fuel gases and black for oxygen
Opening-up of Cylinder may burst Always stand back from the regulator while
cylinder opening the cylinder
Turn valve slowly to avoid bursting
Cover the lug terminals to prevent short
circuiting
Welding of tanks, Explosion may occur Empty & purge them before welding
container or pipes Never attach the ground cable to tanks, container
storing flammable or pipe storing flammable liquids
liquids Never use LPG for gas cutting
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CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES …(Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
(E) Ionizing Radiations may react Ensure Safety regulations as per BARC/AERB
RADIOGRAPHY radiation with the skin and can before commencement of job.
cause cancer, skin Cordon off the area and install Radiation warning
irritation, dermatitis, symbols
etc. Restrict the entry of unauthorized persons
Wear appropriate PPE and film badges issued by
BARC/AERB
Transpor-tation Same as above Never touch or handle radiography source with
and Storage of hands
Radiog-raphy Store radiography source inside a pit in an
source exclusive isolated storage room with lock and
key arrangement. The pit should be approved by
BARC/AERB.
Radiography source should never be carried
either in passenger bus or in a passenger
compartment of trains.
BARC/AERB has to be informed before source
movement.
Permission from Director General of Civil
Aviation is required for booking radio isotopes
with airlines.
Loss of Radio Same as above Try to locate with the help of Survey Meter.
isotope Inform BARC/AERB (*)
(F) ELECTRICAL Short circuiting Can cause Use rubberized hand gloves and other PPE
INSTALLATION Electrocution or Fire Don't lay wires under carpets, mats or door ways.
AND USAGE Allow only licensed electricians to perform on
electrical facilities
Use one socket for one appliance
Ensure usage of only fully insulated wires or
cables
Don't place bare wire ends in a socket
Ensure earthing of machineries and equipments
Do not use damaged cords and avoid temporary
connections
Use spark-proof/flame proof type field
distribution boxes.
(*) Atomic Energy Regulatory Board (AERB),

Bhabha Atomic Research Centre (BARC)
Anushaktinagar, Mumbai – 400 094
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TYPE OF EFFECT OF
ACTIVITY
HAZARD HAZARD
PREVENTIVE MEASURES
Do not allow open/bare connections
Provide all connections through ELCB
Protect electrical cables/equipment's from water
and naked flames
Check all connections before energizing
Overloading of Bursting of system Display voltage and current ratings prominently
Electrical can occur which with 'Danger' signs.
System leads to fire Ensure approved cable size, voltage grade and
type
Switch off the electrical utilities when not in use
Do not allow unauthorized connections.
Ensure proper grid wise distribution of Power
Improper laying Can cause Do not lay unarmoured cable directly on ground,
of overhead and electrocution and wall, roof of trees
underground prove fatal Maintain at least 3m distance from HT cables
transmission All temporary cables should be laid at least 750
lines/cables mm below ground on 100 mm fine sand
overlying by brick soling
Provide proper sleeves at crossings/ inter-
sections
Provide cable route markers indicating the type
and depth of cables at intervals not exceeding
30m and at the diversions/termination
(G) FIRE Small fires can Cause burn injuries In case a fire breaks out, press fire alarm system
PREVENTION become big ones and may prove fatal and shout "Fire, Fire"
AND and may spread Keep buckets full of sand & water/ fire
PROTECTION to the extinguishing equipment near hazardous
surrounding locations
areas Confine smoking to 'Smoking Zones' only.
Train people for using specific type of fire
fighting equipments under different classes of fire
Keep fire doors/shutters, passages and exit doors
unobstructed
Maintain good housekeeping and first-aid boxes
(for details refer Appendix-B)
Don't obstruct assess to Fire extinguishers.
Do not use elevators for evacuation during fire.
Maintain lightening arrestors for elevated
structures
Stop all electrical motors with internal
combustion
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TYPE OF EFFECT OF
HAZARD HAZARD
Move the vehicles from dangerous locations
Remove the load hanging from the crane booms
Remain out of the danger areas.
Improper It may not Ensure usage of correct fire extinguisher meant
selection of Fire extinguish the fire for the specified fire (for details refer Appendix-
extinguisher C).
Do not attempt to extinguish Oil and electric
fires with water. Use foam cylinders/CO2/sand
or earth.
Improper storage Same as above Maintain safe distance of flammable substances
of highly from source of ignition
inflammable Restrict the distribution of flammable materials
substances to only min. necessary amount
Construct specifically designed fuel storage
facilities
Keep chemicals in cool and dry place away from
heat. Ensure adequate ventilation
Before welding operation, remove or shield the
flammable material properly
Store flammable materials in stable racks,
correctly labeled preferably with catchment
trays.
Wipe off the spills immediately
Short circuiting Same as above Don't lay wires under carpets, mats or door ways
of electrical Can cause Use one socket for one appliance.
system Electrocution Use only fully insulated wires or cables
Do not allow open/bare connections
Provide all connections through ELCB
Ensure earthing of machineries and equipments
(H) Crossing the Personal injury Obey speed limits and traffic rules strictly
VEHICULAR Speed Limits Always expect the unexpected and be a
MOVEMENT (Rash driving) defensive driver
Use seat belts/helmets
Blow horn at intersections and during
overtaking operations.
Maintain the vehicle in good condition
Do not overtake on curves, bridges and slopes
Adverse weather Same as Above Read the road ahead and ride to the left
condition Keep the wind screen and lights clean
Do not turn at speed.
Recognize the hazard, understand the defense
and act correctly in time.
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TYPE OF EFFECT OF
HAZARD HAZARD
Consuming Same as above Alcohol and driving do not mix well. Either
alcohol before choose alcohol or driving.
and during the If you have a choice between hitting a fixed
driving object or an on-coming vehicle, hit the fixed
operation object
Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
Do not force the driver to drive fast and round the
clock.
Do not day dream while driving
Falling objects/ May prove fatal Ensure effective braking system, adequate
Mechanical visibility for the drives, reverse warning alarm..
failure Proper maintenance of the vehicle as per
manufacturer instructions
(I) PROOF Bursting of May cause injury Prepare test procedure & obtain EIL/owner's
TESTING piping and prove fatal approval
(HYDROSTATI Collapse of Provide separate gauge for pressurizing pump
C /PNEUMATIC tanks and piping/equipment
TESTING) Tanks flying off Check the calibration status of all pressure
gauges, dead weight testers and temperature
recorders
Take dial readings at suitable defined intervals
and ensure most of them fall between 40-60% of
the gauge scale range
Provide safety relief valve (set at pressure
slightly higher than test pressure) while testing
with air/ nitrogen
Ensure necessary precautions, stepwise increase
in pressure, tightening of bolts/nuts, grouting, etc.
before and during testing
Keep the vents open before opening any valve
while draining out of water used for hydro-testing
of tanks.
Pneumatic testing involves the hazard of released
energy stored in compressed gas. Specific care
must therefore be taken to minimize the chance
of brittle failure during a pneumatic leak test.
Test temperature is important in this regard and
must be considered when the designer chooses
the material of construction.
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TYPE OF EFFECT OF
HAZARD HAZARD
A pressure relief device shall be provided, having
a set pressure not higher than the test pressure
plus the lesser of 345 KPa (50 psi) or 10% of the
test pressure.
The gas used as test fluid, if not air, shall be
nonflammable and nontoxic.
(J) Person can fall May sustain severe Provide guard rails/barricade at the work place
WORKING AT down injuries or prove Use PPE like full body harness, life line, helmets,
HEIGHTS fatal safety shoes, etc.
Obtain a permit before starting the work at height
above 3 meters
Fall arrest and safety nets, etc. must be installed
Provide adequate working space (min. 0.6 m)
Tie/weld working platform with fixed support
Use roof top walk ladder while working on a
slopping roofs
Avoid movement on beams
May hit the Keep the work place neat and clean
scrap/material Remove the scrap immediately
stacked at the
ground or in
between
Material can fall May hit the workers Same as above plus
down working at lower Do not throw or drop materials or equipment
levels and prove from height. I.e. do not bomb materials
fatal All tools to be carried in a tool-kit
Bag or on working uniform
Remove scrap from the planks
Ensure wearing of helmet by the workers
working at lower levels
(K) CONFINED Suffocation/ Unconsciousness, Use respiratory devices, if reqd.
SPACES drowning death Avoid over crowding inside a confined space
Provide Exhaust fans for ventilation
Do not wear loose clothes, neck ties, etc
Fulfill conditions of the permit
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TYPE OF EFFECT OF
HAZARD HAZARD
Check for presence of hydrocarbons, O2 level
Obtain work permit before entering a confined
space
Ensure that the connected piping of the
equipment which is to be opened is pressure
free, fluid has been drained, vents are open and
piping is positively isolated by a blind flange
Presence of Inhalation can pose Same as above plus

foul smell and threat to life Check for hydrocarbon and Aromatic compounds
toxic before entering a confined space
substances Depute one person outside the confined space for
continuous monitoring and for extending help in
case of an emergency
Ignition/ flame Person may sustain Keep fire extinguishers at a hand distance
can cause fire burn injuries or Remove surplus material and scrap immediately
explosion may occur Do not smoke inside a confined space
Do not allow gas cylinders inside a confined
space
Use low voltage (24V) lamps for lighting
Use tools with air motors or electric tools with
max. voltage of 24V
Remove all equipments at the end of the day
(L) Failure of load Can cause accident Avoid standing under the lifted load and within
HANDLING lifting and and prove fatal the operating radius of cranes
AND moving Check periodically oil, brakes, gears, horns and
LIFTING equipments tyre pressure of all moving machinery
EQUIPMENTS Check quality, size and condition of all chain
pulley blocks, slings, U-clamps, D-shackles, wire
ropes, etc.
Allow crane to move only on hard, firm and
leveled ground.
Allow lifting slings as short as possible and
check gunny packings at the friction points
Do not allow crane to tilt its boom while moving
Install Safe Load Indicator
Ensure certification by applicable authority
Page 260 of 704

HEALTH, SAFETY &
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TYPE OF EFFECT OF
HAZARD HAZARD
Overloading of Same as above Safe lifting capacity of derricks and winches
lifting written on them shall be got verified
equipments The max. safe working load shall be marked on
all lifting equipments
Check the weight of columns and other heavy
items painted on them and accordingly decide
about the crane capacity, boom and angle of
erection
Allow only trained operators and riggers during
crane operation.
Overhead Can cause Do not allow boom or other parts of crane to
electrical wires electrocution and come within 3m reach of overhead HT cables
fire Hook and load being lifted shall preferably
remain in full visibility of crane operators.
(M) Person can fall Person May sustain Provide guard rails for working at height
SCAFFOLDI down severe injuries and Face ladder while climbing and use both hands.
NG, prove fatal Ladders shall extend about 1m above landing for
FORMWOR easy access and tying up purpose
K Do not place ladders against movable objects and
AND maintain base at 1/4 unit of the working length of
LADDERS the ladder.
Suspended scaffolds shall not be less than 500
mm wide and tied properly with ropes
No loose planks shall be allowed
Use PPE, like helmets, safety shoes,etc
Failure of Same as above Inspect visually all scaffolding materials for
scaffolding stability and anchoring with permanent
material structures.
Design scaffolding for max. load carrying
capacity.
Scaffolding planks shall not be less than 50X250
mm full thickness lumber or equivalent. These
shall be cleated or secured and must extend over
the end supports by at least 150mm and not more
than 300mm
Don't overload the scaffolds
Do not splice short ladders to make a longer one.
Vertical ladders shall not exceed 6m.
Material can Persons working at Remove excess material and scrap immediately
fall down lower level gets Carry the tools in a tool-kit bag only
injured Provide safety nets
Page 261 of 704

HEALTH, SAFETY &
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TYPE OF EFFECT OF
HAZARD HAZARD
(N) Personal Can cause injury or Do not take rest inside rooms built for welding
STRUCTUR negligence and casualty machines or electrical distribution system.
AL WORKS danger of fall Avoid walking on beams at height
Wear helmet with chin strap and full body
harness while working at height.
Use hand gloves and goggles during grinding
operations
Cover or mark the sharp and projected edges
Do not stand within the operating radius of
cranes
Lifting/ slipping Same as above Do not stand under the lifted load
of material Stack properly all the materials. Avoid slippage
during handling
Control longer pieces lifted up by cranes from
both ends
Remove loose materials from height
Ensure tightening of all nuts & bolts
(O) Erection/ Can cause injury Do not stand under the lifted load
PIPELINE lowering failure Do not allow any person to come within the
WORKS radii of the side boom handling pipes
Check the load carrying capacity of the lifting
tools & tackles
Use safe Load Indicators
Use appropriate PPEs
Other Same as above Wear gum boots in marshy areas
Allow only one person to perform signaling
operations while lowering of pipes
Provide night caps on pipes
Provide end covers on pipes for stoppage of pigs
while testing/ cleaning operations
(P) Pollution in Can cause personal Ensure the blasting is done in enclosed shed.
GRIT neighboring injury Keep safe distance while blasting operations.
BLASTING area, hit by grits Wear positive pressure blast hood or helmet
and high with view –window, ear-muff/plug, gloves,
pressure air overall or leather coat /apron, rubber shoes.
Page 262 of 704

HEALTH, SAFETY &
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APPENDIX-F
TRAINING SUBJECTS / TOPICS

(For contractors’ personnel)
1. The Law & Safety – Statutory Requirement / Applicable statutes / Duties of employer / employee
2. Policy & Administration – Why HSE? / Duties & Responsibilities of Safety Personnel at project
site / Effect of incentive on accident prevention
3. HSE & Supervision – Duties of Supervisor / HSE integrated supervision / Who should be held
responsible for site accidents?
4. Safety Budget / Cost of Accidents – Direct costs / Indirect costs
5. Hazard Identification / Type of hazards / HIRAC
6. Behavioural Safety & Motivation
7. Housekeeping – Storage / Stacking / Handling of materials / Hydra handling
8. Occupational Health in Construction sector
9. Personal Protective Equipments – Respiratory & Non- respiratory
10. Electricity & Safety – ELCB / Fuse / Powered tools / Project illumination
11. Handling of Compressed Gas – Transportation / Storage / FBAs / Fire prevention
12. Machine Safety – Machine guarding / Maintenance
13. Transportation – Hazards & risks in transp. of materials / ODC consignments
14. Cranes & Other Lifting machinery – Legal requirements vis-à-vis essential safety requirements.
15. Communication – HSE Induction / TBTs / Safety Committee / Safety meeting / Safety
propaganda / Publicity.
16. Excavation – Risks & Dangers / Safety measures
17. Working at Heights – Use of ladder / Work on roofs / Scaffolds / Double harness lanyards / Life-
line / Fall arrester / Safety Nets / Floor openings
18. Hazards in Welding & important safety precautions
19. Gas Cutting – Hazards & safety measures
20. Fire prevention & fire protection
Page 263 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
APPENDIX - G
CONSTRUCTION POWER BOARD( typ)
Page 264 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
APPENDIX-H
LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:-
A. HSE Management Procedures:
 HSE Risk Management (including JSA/HIRA)

 HSE Legal Compliance and Other Requirements
 HSE Objectives & Performance
 HSE Training and Competence (including Induction)
 HSE Motivation & Award Scheme
 HSE Audits
 HSE Meetings
 HSE Sub Contractor Management
 HSE Emergency Management
 HSE Incidents Reporting and Management
 HSE Reports
 HSE Management System Review
 HSE Change Management
 HSE procedure for Behaviour based Safety
 First Aid & Management
 Roles, Responsibility, accountabilities and Authorities
B. Job procedures/Safe Operating procedures
 Setting Up Site & Signage’s

 Handling of Electrical Appliances
 Working at Height
 Confined Space Entry
 Permit to Work (including hot works)
 Housekeeping
 Lifting Operations
 Transportation of materials including Manual Handling
 Compressed Air Tools and Units
 Earthmoving Operations & excavation
 Scaffolding
 Fire Prevention/Protection
 Hazardous Substance handling & Storage
 Radiation Hazard
 Personal Protective Equipment
Page 265 of 704

HEALTH, SAFETY &
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FORMAT NO. : HSE-1 REV 0

(Sheet 1 of 6)
SAFETY WALK-THROUGH REPORT
(Name & signature of walk through performer to be inserted at the bottom of each page)
Project : _____________ Report no. : ___________
Date : _____________ Contractor : ___________
Inspection by :_____________ Owner : ___________
Frequency : Monthly Job no. : ___________
Note : Write ‘NA’ wherever the item is not applicable

Non
SL. Satisafctory
ITEM satisfactory/ Remarks Action
NO. / Yes
No
1. HOUSEKEEPING
a) Waste containers provided and used
b) Sanitary facilities adequate and Clean
c) Passageways and Walkways Clear
d) General neatness of working areas
e) Other
2. PERSONNEL PROTECTIVE EQUIPMENT
a) Goggles; Shields
b) Face protection
Hearing protection
Foot protection
e) Hand protection
f) Respiratory Masks etc.
g) Full body harness conforming to CЄ, EN 361
h) Hard hat (HDPE)
i) Other
3. EXCAVATIONS/OPENINGS
a) Openings properly covered or barricaded

b) Excavations shored
c) Excavations barricaded
d) Overnight lighting provided
e) Other
Safety walk-through performer (Name & Signature)……………………………………………..
Page 266 of 704

HEALTH, SAFETY &
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(Sheet 2 of 6)
Non
SL. Satisafctory
ITEM satisfactory/ Remarks Action
NO. / Yes
No
4. WELDING & GAS CUTTING
a) Gas cylinders chained upright
b) Cables and hoses not obstructing
c) Screens or shields used
d) Flammable materials protected
e) Live electrode bits contained properly
f) Fire extinguisher (s) accessible
g) Other
5. SCAFFOLDING & BARRICADING
a) Fully decked platforms
b) Guard and intermediate rails in place
c) Toe boards in place
d) Adequate shoring
e) Adequate access
f) Positive barricading for critical activities
g) Installation of warning signs
h) Other
6. LADDERS
a) Extension side rails 1 m above
b) Top of landing
c) Properly secured
d) Angle + 700 from horizontal
e) Other
Safety walk-through performer (Name & Signature)……………………………………………..
Page 267 of 704

HEALTH, SAFETY &
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(Sheet 3 of 6)
Non
SL. Satisafctory
ITEM satisfactory Remarks Action
NO. / Yes
/No
7. HOISTS, CRANES AND DERRICKS
a) Condition of cables and sheaves OK
b) Condition of slings, chains, hooks and eyes

O.K.
c) Inspection and maintenance log-books
maintained
d) Outriggers used
e) Reverse horn installed / active / coupled with

gear
f) Signs/barricades provided
g) Signals observed and understood
h) Qualified operators
i) Other
8. MACHINERY, TOOLS AND EQUIPMENT
a) Proper instruction
b) Safety devices
c) Proper cords
d) Inspection and maintenance
e) Other
9. VEHICLE AND TRAFFIC
a) Rules and regulations observed
b) Inspection and maintenance
c) Licensed drivers
d) Other
Safety walk-through performer (Name & Signature)………………………………………
Page 268 of 704

HEALTH, SAFETY &
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(Sheet 4 of 6)
Non
SL. Satisafctory
NO. / Yes
/No
10. TEMPORARY FACILITIES
a) Emergency instructions posted
b) Fire extinguishers provided
c) Fire-aid equipment available
d) Secured against storm damage
e) General neatness
f) In accordance with electrical requirements
g) Other
11. FIRE PREVENTION
a) Personnel trained & instructed to make use

of facility
b) Fire extinguishers checked periodically &
record maintained
c) No smoking in Prohibited areas.
d) Fire Hydrants not obstructed Clear
e) Other Regular fire drill conducted
12. ELECTRICAL
a) Use of 3-core armored cables everywhere
b) Usage of 'All insulated' or 'double-insulated'

electrical tools
c) All electrical connection are routed through
ELCB
d) Natural Earthing at the source of power
(Main DB)
e) Continuity and tightness of earth conductor
f) Effective covering of junction boxes, panels

and other energized wiring places
g) Ground fault circuit interrupters provided
h) Prevention of tripping hazards maintained
f) DCP extinguishers arranged & licensed

electrician engaged at site
Safety walk-through performer (Name & Signature)…………………………………………
Page 269 of 704

HEALTH, SAFETY &
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(Sheet 5 of 6)
Non
SL. Satisafctory
NO. / Yes
/No
14. HANDLING AND STORAGE OF
MATERIALS
a) Safely stored or stacked
b) Passageways clear / free from obstructions
c) Fire fighting facility in place
15. FLAMMABLE GASES AND LIQUIDS
a) Containers clearly identified / protected from
fire
b) Safe storage & transportation arrangement
made
c) Fire extinguishers positioned nearby
d) Facilities kept away from electric spark, hot
spatters & ignition source.
16. WORKING AT HEIGHT
a) Approved Erection plan and work permit in
place
b) Safe access, Safe work platform & Safety
nets provided
c) Life lines, Fall arrester, Full body harness
and with double lanyards used;
d) Health Check record available for workers
going up?
e) Protective handrails arranged around floor
openings
17. CONFINED SPACE
a) Work Permit obtained from requisite
authority
b) Test for toxic gas and sufficient availability
of oxygen conducted & status
c) Supervisor present at site & at least one
person outside the confined space for
monitoring deputed
d) Availability of safe means of entry, exit and
ventilation (register for entry & exit
maintained)
e) Fire extinguisher and first-aid facility
ensured
f) Lighting provision made by using 24V Lamp
g) Proper usage of PPEs ensured
18. RADIOGRAPHY
a) Proper storage and handling of source as per
BARC/ AERB guidelines (authorized
radiographer available)
b) Work permit obtained
Page 270 of 704

HEALTH, SAFETY &
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(Sheet 6 of 6)
Non
SL. Satisafctory
NO. / Yes
/No
c) Cordoning of the area done
d) Use of appropriate PPE's ensured
e) HSE training to workers/supervisors
imparted during the fortnight (indicate topic)
f) Minimum occupancy of workplace ensured
19. HEALTH CHECKS
a) All Workers medically examined and found

be fit for working at heights (slinging,
rigging, painting etc.)
in confined space
in excavation / trenching
in shot blasting
b) Availability of First Aid box with contents
c) Proper sanitation at site, office and labour
camps
d) Arrangement of medical facilities.
e) Measures for dealing with illness at site &
labour camps.
f) Availability of Potable drinking water for
workmen & staff.
g) Provision of crèches for children.
h) Stand by vehicle / ambulance available for

evacuation of injured
20. ENVIRONMENT
a) Chemical and Other Effluents properly
disposed
b) Cleaning liquid of pipes disposed off
properly
c) Seawater used for hydro-testing disposed off
as per agreed procedure
d) Lubricant Waste/Engine oils properly
disposed
e) Waste from Canteen, offices, sanitation etc
disposed properly
f) Disposal of surplus earth, stripping materials,
Oily rags and combustible materials done
properly
g) Green belt protection
Page 271 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 1 of 3)
ACCIDENT / INCIDENT REPORT
(To be submitted by Contractor after every Incident / Accident within 24 hours to EIL/ Owner)
Report No.: ____________________________ Date: ______________________

Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________
Non-disabling injury (Non- Hospitalized but resumed duty before end of 48 hrs
LTA)
Disabling injury (other LTA) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTA): Death / Expiry
First Aid case (non LTA) Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: - ______
Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c.operator
Engineer Manager Other/specify
Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify
Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above
Location where the incident happened: ___________________________________________

______________________________________________________________________________
Page 272 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 2 of 3)
Activity / Works that was continuing during incident / accident: -

Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify
What exactly the victim was doing just before the incident / accident? ....................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify
Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)
Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify
Page 273 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 3 of 3)
Medical Aid provided: - (indicate specific aids / treatment etc.)-

………………………………………………………………………………………………………….
…………………………………………………………………………………………………………..
-------------------------------------------------------------------------------------------------------------------------
Actions taken to prevent recurrence of similar incident / accident: ………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
……………………………………………………………………………………………………………
………………………………………………………………………………………………………...
_____________________________________________________________________________
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
Safety Officer Site Head / Resident Construction Manager

(Signature and Name) (Signature and Name)
Stamp of Contractor
To : Owner
: RCM/Site-in-charge EIL (3 copies)
Divisional Head (Constn) through RCM

Project Manager, EIL, through RCM
Page 274 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 1 of 5)
SUPPLEMENTARY INCIDENT / ACCIDENT INVESTIGATION REPORT

TICK THE APPROPRIATE ONE AS APPLICABLE (furnish within 72 hours)
Supplementary to Incident / Accident Report No: ______ (Copy enclosed)
Report No.: ____________________________ Date: ______________________
Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________
Non-disabling injury (Non- Hospitalized but resumed duty before end of 48 hrs
LTA)
Disabling injury (other LTA) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTA): Death / Expiry
First Aid case (non LTA) Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: - ______
Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c.operator
Engineer Manager Other/specify
Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify
Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above
Location where the incident happened: ___________________________________________

______________________________________________________________________________
Page 275 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 2 of 5)
Activity / Works that was continuing during incident / accident: -
Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify
What exactly the victim was doing just before the incident / accident? ....................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Particular of tools & tackles being used and condition of the same after incident/accident:
…………………………………………………………………………….........................................
………………………………………………………………………………………………………
Description of Incident/Accident (How the incident was caused):
……………………………………………………………………………………….
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify
Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify
Page 276 of 704

HEALTH, SAFETY &
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(Sheet 3 of 5)
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)
Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify
Name & Designation of person who provided First-Aid to the victim: ---------------------------------------
Name & Telephone number of Hospital where the victim was treated_________________________
Mode of transport used for transporting victim – Ambulance / Private car / Tempo / Truck / Others
How much time taken to shift the injured person to Hospital________________________________
In case of FATAL incident, indicate clearly the BOCW Registration No. of the victim
/Company……………………………………………………………………………………………
Comments of Medical Practitioner, who treated / attended the victim/injured (attached / described
here)_____________________________________________________________________
What actions are taken for investigation of the incident, please indicate clearly – (Video film /
Photography / Measurements taken etc……………………………………………………………..)
Immediate cause (Please tick the right applicable) –

Hazardous methods or Poor housekeeping Inadequate or improper
procedures inadequately PPE
guarded
Environmental hazards improper Working on dangerous
(excess noise/ space illumination/Moving on oval equipment
constraint/ inadequate surface
ventilation
Page 277 of 704

HEALTH, SAFETY &
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(Sheet 4 of 5)
Failure to secure Horse-play Failure to use PPE
Inattention to surroundings Improper use of hands & By-passing safety devices

body-parts
Unsafe mixing or placement Bypassing standard Failure in communication
of tools & tackles procedures
Operating without authority Improper use of equipment drug or alcoholic
or tools & tackles influence
excessive haste Others(specify)
Basic cause
Over confidence Impulsiveness over-exertion

Faulty judgement or poor Failing to keep attention Nervousness & Fear
understanding constantly
Fatigue Defective vision Ill health or sickness
Slow reaction Others(specify)
Root cause
Inadequate Engg Improper Design Inadequate Planning &

organization
Inadequate knowledge Inadequate skill Inadequate training
Inadequate supervision Improper work procedure Inadequate compliance
with standard
Substandard performance Inadequate maintenance Improper inspection
Others(specify)
Loss of man days and impact on site works, (if any) –
Remarks from Contractor’s Safety Officer / Engineer –
Was the victim performing relevant tasks for which he was engaged /employed? Yes / No
Was the Supervisor present on work-site during the incident? Yes / No
Have the causes of incident rightly identified? Yes / No
Cause of Accident was_____________________________________________________________
Page 278 of 704

HEALTH, SAFETY &
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(Sheet 5 of 5)
Remedial measures recommended by Safety Officer of Contractor for avoiding similar incident in
future
: ………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
……………………………………………………………………………………………………………
………………………………………………………………………………………………………...
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
_____________________________________________________________________________
Safety Officer Site Head / Resident Construction Manager

Stamp of Contractor
To : Owner
: RCM// Site-in-charge of EIL (3 copies)
Project Manager EIL, through RCM
Page 279 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
NEAR MISS INCIDENT/ DANGEROUS OCCURRENCE SUGGESTED PROFORMA

(to be submitted within 24 hours)
 Near Miss : Human injury escaped & no damage to property, equipment

or interruption to work.
 Dangerous Occurrence: Damage to property, equipment or interruption of work, but not
resulting in personal injury/illness, e.g. Fire incident, collapse of structure, crane failure,
etc
Report No.: _________________
Name of Site: _________________________ Date: ______________________
Name of work: __________________________ Contractor: __________________
__________________________________________________________________________________
Incident reported by :
Date & Time of Incident :
Location :
__________________________________________________________________________________
Brief description of incident
__________________________________________________________________________________
Probable cause of incident
__________________________________________________________________________________
Suggested corrective action
__________________________________________________________________________________
Steps taken to avoid recurrence Yes No
To : Owner
: RCM/Site-in-charge EIL (3 copies)

Project Manager EIL, through RCM
Page 280 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by each Contractor)
Actual work start Date: _______________ For the Month of: __________________
Project: ____________________________ Report No: ________________________
Name of the Contractor: ______________ Status as on : ______________________
Name of Work : _____________________ Job No : __________________________
(Contractor in consultation with EIL shall generate the reports through web based
package(www.eil.co.in/conthse) only.
UPTO
THIS
ITEM PREVIOUS CUMULATIVE
MONTH
MONTH
1) Average number of Staff & Workmen
(average daily headcount, not man days)
2) Man-hours worked
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
7) Number of Lost Time Accidents (LTA) Fatal
Other LTA
8) Number of Loss Time Injuries (LTI) Fatalities
Other LTI
9) Number of Non-Loss Time Accidents
10) Number of First Aid Cases
11) Number of Near Miss Incidents
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to accidents

15) LTA Free man-hours i.e. LTA free man-hours counted from the
Last LTA (enter date: ……….)
16) Frequency Rate (No. of LTA per 2 lacs man-hours worked)
17) Severity Rate (No. of man days lost per 2 lacs man-hours
worked)
18) Loss Time Injury Frequency (No. of LTI per 2 lacs man-hours
worked)
19) No. of activities for which Job Safety Analysis (JSA) completed
20) No. of incentives/ awards given
21) No. of occasions on which penalty imposed by EIL/ Owner
22) No. of Audits conducted
23) No. of pending NCs in above Audits

24) Compensation cases raised with Insurance
25) Compensation cases resolved and paid to workmen
26) Whether workmen compensation policy taken Yes No
27) Whether workmen compensation policy is valid Yes No
28) Whether workmen registered under ESI Act, as applicable Yes No
Remarks, if any
Date:
Prepared by Safety Officer Approved by Site Head / Resident Construction Manager
To : - OWNER
- RCM EIL (2 copies)
Page 281 of 704

HEALTH, SAFETY &
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PERMIT FOR WORKING AT HEIGHTS (ABOVE 2.0 METER)
(In duplicate to be issued daily for site and for office)
Permit No…………….. Name of Main Contractor……………………
Name of work executing agency / sub agency / vendor:…………………………………………………...
Date……………… Exact Location of work……………………………………
Nature of work ……………………………………..Duration of work (from) ………… (to) ……….......
Number of workers covered within this permit……………………………………………………………
(List enclosed with name & gate pass numbers.)
Sl. Status of compliance

Items / Subjects
No. (Yes / No)
1 Work areas / Equipments inspected
2 Work area cordoned off
3 Adequate lighting is provided
4 Precautions against public traffic taken
5 Concerned persons in & around have been alerted & cautioned
Hazards / risks involved in routine / non-routine task assessed and control
6
measures have been implemented at specific task
7 ELCB provided for electrical connection & found working
8 Ladder safely attached / fixed
9 Scaffoldings are checked and TAGs are found used correctly
10 Working platforms are provided and are found sound /safe for use
Safe access & egress arrangements (e.g. ladders, fall arresters, life-lines etc.)
11
are satisfactorily incorporated
a. Openings on platform / floors are effectively cordoned / covered
12
b. Safety Nets are provided wherever required
Use of following safety gadgets by people working at area under this permit, is
checked and found satisfactory -
Safety helmet
13 Safety harness (full body) with double lanyard
Safety Shoes
Safety gloves
Safety goggles
14 Housekeeping of work area found satisfactorily tidy / clean & clear
Adequate measures have been taken for works being continued at the ground
15
level, when simultaneous works are permitted overhead at that very location.
16 Materials are not thrown from heights on to ground
17 Medical examination of workers are made & found satisfactory
Responsible job engineer / supervisor found physically present at work spot for
18
overall administration of work as well as safety of people.
Above items have been checked & compliance has been found in place. Hence work is permitted to
start / continue at the above-mentioned location. Work shall not start till identified lapses are rectified.
Additional Precautions, if any …………………………………………………………….

……………………………………………………………………………………………..
Work Permit issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer
AT THE END OF THE DAY/WORK:

All works at height are completed & workmen have returned safely from work location at
(time)………….. (date)……………
(Sig. Contractor Engineer)
Page 282 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
CONFINED SPACE ENTRY PERMIT

Project site ___________________________ Sr.No. _________________________
Name of the work ______________________ Date ___________________________
Name of Contractor ____________________ Nature of work ___________________
Exact location of work _____________
Safety Requirements POSITIVE ISOLATION OF THE VESSEL IS MANDATORY

(A) Has the equipment been ?
Y NR Y NR Y NR
  Isolated from   water flushed &/or   radiation sources
power/steam/air steamed removed
  isolated from liquid or   Man ways open &   proper lighting
gases ventilated provided
  depressurized &/or   cont. inert gas flow  
drained arranged
  blanked/ blinded/   adequately cooled  
disconnected
(B) Expected Residual Hazards
  lack of O2   combustible gas/ liquid   H2S / toxic gases
  corrosive chemicals   pyrophoric iron / scales   electricity / static
  heat/ steam / frost   high humidity   ionizing radiation
     
(C) Protection Measures
  gloves   ear plug / muff   goggles / face shield
  protective clothing   dust / gas / air line mask   personal gas alarm
  grounded air duct/blower   attendant with SCBA/air   rescue
/AC mask equipment/team
  Fire fighting arrangements   safety harness & lifeline   communication
equipment
     
Authorization / Renewal (It is safe to enter the confined space)
Signature Time Signature
No. of Contractor's Contractor's From To Workman
persons Name of persons allowed Supervisor Safety Officer
allowed
Permit Closure :
(A) Entry  was closed  stopped  will continue on ...
(B)  Site left in a safe condition  Housekeeping done
(C) Multilock  removed  key transferred

 Ensured all men have come out  Man-ways barricaded
Remarks, if any:
Page 283 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
RADIATION WORK PERMIT
Project : Sr.No. :
Name of the work : Date :
Name of site contractor : Job No. :
Location of work :
Source strength :
Cordoned distance (m) :
Name of Radiography agency : Approved by Owner/EIL
No. of workers engaged :

The following items have been checked &compliance shall be ensured during currency of the
permit:
S. No. Item description Done

Safety regulations as per BARC/AERB ensured while source in use/in transit & during
storage
Area cordoned off / safe working platform provided
Lighting arrangements for working during nights ensured
Warning signs/ flash lights installed
Cold work permit taken (if applicable)
PPEs like film badges, dosimeters used
Additional precautions, if any ______________________________________________________
(Radiography Agency’s BARC/AERB authorized Supervisor)
Permission is granted.
Permit is valid from ___________ AM/PM ____________ Date to ___________ AM/PM _________
Date
(Signature of permit issuing authority of site contractor)
Name :Designation: Date:

Permit renewal:
Sign of issuing authority with
Permit extended up to Additional precautions required, if any
date (of site contractor)
Date Time
Work completed/ stopped/ area cleared at ________ Hrs of Date ______________

(Sign. of permit issuing authority)
Name & Signature of site contractor:
Page 284 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

DEMOLISHING/DISMANTLING WORK PERMIT
Project : Sr.No. :
Name of contractor : Job No. :
Name of sub-contractor : No. of workers to be engaged:

Line No./ Equipment No./ Structure to be dismantled :

Location details of dismantling/ demolition with sketch : (clearly indicate the area)
The following items have been checked &compliance shall be ensured during currency of the
permit:
S. Item description Done Not

No. Applicable
Services like power, gas supply, water, etc. disconnected
Dismantling/ Demolishing method reviewed & approved
Usage of appropriate PPEs ensured
Precautions taken for neighbouring structures
First-Aid arrangements made
Fire fighting arrangements ensured
Precautions taken for blasting
(Contractor’s Supervisor) (Contractor’s Safety Officer)
Permission is granted.
(Permit issuing authority)
Name :
Date :
Completion report :
Dismantling/ Demolishing is completed on _____________ Date at ____________ Hrs.
Materials/ debris transported to identified location Tagging completed (as applicable)
Services like power, gas supply, water, etc. restored
(Permit issuing authority)
CONTRACTOR’s NAME
Page 285 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
DAILY SAFETY CHECKLIST

(To make use of before start of day’s work)
Project : Sr.No. :
Description of Job decided to perform : -
 Use of PPE / Safety Gadgets
Sl. Compliance Sl. Compliance (Yes

PPEs PPEs
No (Yes / No) No / No)
1 Safety Helmets 6 Face Shield
2 Safety Shoes 7 Full body harness
3 Hand Gloves 8 Fall Arrest System
4 Dust Musk 9 Safety net
Horizontal life-line made
5 Safety Goggles 10 of steel wire, (dia not
less than 8.0 mm.)
(Serial No. 1 & 2 are compulsory for everyone. Specify & ensure use of other safety gadgets as required for the job)
 Identify following important unsafe conditions: -
Sl. No Conditions Yes / No

1 Access to work site / emergency escape clear
2 Soil / Loose earth kept away from excavated pit / slope / ladder provided
Electrical wire / welding lead lying entangled on ground / welding m/c. booth
3
accessible
4 Elevated work platform / open ends are protected
Ground area cordoned off before lifting works or erection at height / ground
5
area checked & cordoned-off before start of height works
Structural members / erected pipes / wooden boards/pieces etc. are safely
6 anchored at heights and are not likely to fall down on people when working
beneath
Rope ladders tied-up on tall steel structures, long before are removed to get
7
rid of their use
8 Any Other
 Indicate actions taken, if status of any of the above items is found “No”
………………………………
……………………………………………………………………………………………………………….
 Specific Safety guidelines / precautions, if any (communicated thro’ TBT)

……………………………
………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
 Above conditions and PPE compliances are checked by undersigned and correct status are indicated after
verification
Inspected by Verification By
Contractor Engineer Contractor Safety Officer
Page 286 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 1 of 2)
HOUSEKEEPING ASSESSMENT & COMPLIANCE
Project : Sr.No. :
Name of contractor : Fortnightly
Sl Satisafctory/ Non
No.
Subjects of Review Remarks Action
Yes satisfactory/No
1. Cleanliness at the Main entry / access of site
2. Ground condition / floor areas free from water-
logging / oil spillage
3. Ground & elevated floors free from rubbish /
wastes / accumulated debris / scraps.
4. Manholes / openings are covered / fenced
5. Trenches are barricaded / walkways are in place
6. Drains are cleaned / not choked / not occupied
by dumped materials
7. Sufficient CAUTION boards / instructions
displayed
8. Construction machinery are maintained &
parked in orderly manner.
9. Movement of site people are not obstructed
because of dumping / storing of construction
materials
10. Access / egress to Electrical Distribution Boards
/ Panels clear from wires / cables / earth-strips
etc.
11. Electrical panel rooms / sheds / MCC / Control
rooms / Substations etc. are clean & tidy and not
used for storing dress / clothes, tiffin-box or
bicycles.
12. Passage behind Elec. panels are free for access
13. Fire extinguishers / fire-buckets are accessible
without any difficulty.
14. Stair-steps, platforms & landings are clear & tidy
15. Sheds / rooms & work areas have got sufficient
illumination as well as ventilation
16. Cables / Wires / welding leads are routed /
hanged appropriately & are not creating unsafe
condition.
17. Stacking / storing of insulation materials or their
packing.
18. Removal or cleanliness of left-over sand,
concrete, brick-bats, insulation-materials, excess
earth, wastes etc.
19. Storing / stacking of sand, metal chips, re-bars,
steel pipes, valves, fittings etc.
20. One escape route at ground & minimum two
escape routes at elevation available,
Page 287 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 2 of 2)
Sl Satisafctory/ Non
No.
Subjects of Review Remarks Action
Yes satisfactory/No
21. Captions / Posters / Slogans on various safety
instructions are displayed legibly in local
language
22. Cable trenches are water-free or regular
arrangement for taking out accumulated water
exists.
23. Windows of rooms / offices are regularly
cleaned
24. Facilities for cycle sheds, drinking water,
washing, rest-rooms etc. are maintained in tidy
manner.
25. Toilet, Urinals, Canteen / kitchen / pantry etc.
are maintained & free from obnoxious smell.
26. Construction tools / tackles are stored
systematically - the items are tagged / tested /
certified by competent third party.
27. Sufficient numbers of Dust-bins / Waste-bins
found at site and are regularly emptied.
Additional remarks, if any -

………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
……………………………………
Page 288 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
INSPECTION OF TEMPORARY ELECTRICAL BOOTH / INSTALLATION

Project : Sr.No. :
Sub Station No:/Booth No Location:
SL
SUBJECTS OBSERVATION (YES /NO) ACTION TAKEN
NO
Switchboards installed properly are in order and
1
protected from rain & water-logging.
Adequate illumination provided for switchboard
2 operation during night hours & the lamps are protected
from direct human contact.
Voltage ratings, DANGER signs, Shock-Treatment-
3
Chart displayed in the installation / booth
Fire extinguisher (DCP or CO2) & Sand Bucket kept in
4
close vicinity of Switchboards
Valid License & Competent Electrician / Wireman
5 available & name/ license no. displayed at booth /
installation.
General housekeeping in & around booth / installation
6
found in order.
7 Cable-route-markers for U/G cables provided.
Monthly inspection report of Electrical hand tools
8
available in booth / installation.
9 Insulated Mat provided in front of Elec. Panels.
10 Rubber hand gloves available/ used by Electricians
Availability of CAUTION boards for shutdown & / or
11
repairing works.
All incoming & outgoing feeders have proper MCCB /
12
HRC fuses / Switches.
Switchboards “earthed” at two distinctly isolated
13
locations.
Switchboards have adequate operating space at the front
14
face & at the rear face too.
15 All connections provided through 30mA ELCB.
16 Testing records of all ELCBs available at site
17 Only industrial type plugs & sockets are used.
Temporary connections are 3-core double insulated &
18 free from cuts & joints and 3rd core is earthed at both
ends
Socket boards are properly mounted on stand &
19
protected from water ingress.
Electrical equipments operating above 250V have two
20
earthing / double earthing.
All incoming / outgoing cables are properly glanded &
21
terminated with “lugs”.
22 Switch-boards are of industrial variety / type.
Sketch for installation / connection (SLD) made &
23
pasted & other safety labels/display boards
24 Labeling of incoming / outgoing feeders made.
25 All hand lamps are protected from direct contact.
26 All electrical cable / joints are in safe condition
Page 289 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(Sheet 1 of 2)
INSPECTION FOR SCAFFOLDING
Project : Sr.No. :
Sl. Actions
Description Yes No N.A
No taken
1 Whether work permit is obtained to take up work at height above 1.5 Mts?
Whether atmospheric condition is “stormy” or “raining” and works at
2
heights have been permitted?
3 Whether steel pipes scaffoldings are used for units /off-site areas?
Whether scaffolding has been erected on rigid/firm/leveled surfaces /
4 ground? Whether “foot-seals” or “base-plates” are used beneath the up-
rights (vertical steel pipes)
Whether scaffold construction is as per IS specification with toe-board and
5
hand-rails (top-rail as well as mid-rail)?
Whether distance between two successive up-rights are less than 2.5 Mts
6 (height of scaffold & load carrying capacity governs the distance between
two uprights)
Whether all uprights are extended at least 900 mm above the top most
7
working platform (to enable fitting of handrails)?
Whether vertical distance of two successive ledgers is satisfactory?
8
(varying between 1.3 Mts. To 2.1 Mts)
Whether the peripheral areas of working at height are cordoned-off? (for
9
avoiding accident to people arising out of dropped / deflected materials)
10 Whether platform is provided? Is it safely approachable?
Whether end of scaffold platform / board are extended beyond transoms?
11
(125mm to 150 mm)
Whether CE / IS approved quality and worthy conditioned full-body safety
12 harness (with double lanyard & karabiners) are used while working at
heights?
Whether life-line of safety harness is anchored to an independent secured
13
support capable of withstanding load of a falling person?
Whether the area around the scaffold is cordoned off to prohibit the entry of
14
unauthorized person / vehicle?
Whether clamps used are of good condition, of adequate strength and free
15
from defects?
16 Whether ladder is placed at secured and leveled surface?
17 Whether water-pass and oil-spills are avoided around the scaffold structure?
18 Whether ladder is extended 1.5mts. above the landing point at height?
19 Whether more than one access/egress provided to the scaffold?
Whether ladder used are of adequate length and overlapping of short
20
ladders avoided?
Whether metallic ladders are placed much away from near-by electrical
21
transmission line?
22 Whether rungs of ladder are inspected and found in good order?
23 Whether fall-arresters provided on both the access/egress routes?
Whether diagonal (cross) bracings are provided at regular interval on the
24
scaffold?
Whether working platform on the scaffold has been made free from “jolt”
25
or “gap”?
Whether tools or materials are removed after completion of the day’s job at
26
heights?
Whether a valid Permit for Work (PFW) is obtained before taking up work
27
over asbestos or fragile roof?
28 Whether sufficient precaution is taken while working on fragile roof?
Page 290 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
(Sheet 2 of 2)
Sl. Actions
Description Yes No N. A
No taken
Whether provision is made to arrange duck ladder, crawling board for
29
working on fragile roof?
Whether scaffold has been inspected by qualified civil engineers prior to
30
their use?
Whether the scaffolding has been designed for the load to be borne by the
31
same?
Whether the erection and dismantling of the scaffolding is being done by
32
trained persons and under adequate supervision?
Whether safety net with proper working arrangement and life-line has
33
been provided?
Whether TAGS (Green for acceptable and Red for incomplete/unsafe
34
scaffolds) are used on scaffolds?
Whether sufficient illumination is provided in and around the scaffold
35
and access?
Whether emergency rescue / response arrangements are made in place
36
Page 291 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(sheet 1 of 2)
PERMIT FOR ERECTION / MODIFICATION & DISMANTLING OF SCAFFOLDING
Project : Sr.No. :
Nature of activities : Duration: From………To…………
SL. NOT
SUBJECTS / ITEMS DONE REMARKS
No. DONE
Specific task of Erection / Modification / Dismantling of scaffolds,
1 identified & TAGGED accordingly (before as well as after carrying-
out jobs).
People engaged in doing the job are identified & are certified by Job Names to be
2
Engineer of Main Contractor as experienced / trained. noted
Concerned persons are alerted by the Job Engineer of Main Contractor
3 in connection with possible hazards & what the workmen MUST do /
MUST not do.
Verification by Job Engineer of Main Contractor made for confirming
that all persons permitted to carry-out the jobs are making use of
4
Helmet, Safety Shoes, Goggles, Gloves & Double lanyard safety
harness and other relevant PPEs.
5 Area of work is effectively cordoned-off / barricaded / illuminated.
For taking-up / lowering down Scaffolding members / clamps /
couplings etc. appropriate ropes / pulleys/ chains etc. have been
6
arranged for use (not to throw any item) & the same have been
verified as “fit for purpose”.
Items / members of scaffold, being lowered are removed from the area
7
& stacked correctly.
Ropes, chains, pulley blocks etc. being used for lifting or lowering
scaffold items, are inspected by the Job Engineer & their certifications
8
as well as physical conditions have been found O.K, before signing
this PERMIT.
Safety Net / Life-line / Fall Arresters etc. are arranged in position and
9 Job Engineer has found working conditions favourable for activities to
start.
Scaffold erection or dismantling tasks are being supervised by
10
Experienced Engineer / Competent person.
Only competent & experienced people have been selected / engaged in
11
Scaffolding erection, modification or dismantling tasks.
Adequate & effective actions for traffic and movement of people
12
around the cordoned-off area taken to avoid inadvertent incident
13 Working platforms are protected with handrails & toe-boards.
14 Access & Exit (for reach & escape) are safe for use by people.
Tools, tackles to be used for above jobs are verified by job Engineers
15 of Main contractor as genuinely good and tied-up at height (to prevent
their fall).
16 Site important Telephone Nos. are made known to everyone
SOP (Safe Operating Procedure) for the specific task is made &
17
followed too.
18 Emergency vehicle has been arranged at work locations.
 This permit for work shall be available at specific work location all the time.
 After completion of work, permit shall be returned to safety cell of main contractor, without fail.
 This Permit shall be issued maximum upto (Monday to Sunday).
 Additional Precautions, if any
…………………………………………………………………………………………………………………
 ACCORD OF PERMISSION (to be ticked) - YES ( ) / NO ( )
Contractor Engineer Contractor Safety Officer]
Page 292 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6

(sheet 2of 2)
Everyday Site working conditions & performance of workmen shall be assessed / checked by Contractor
Site Engr. and Safety Officer shall verify the same .
Name / Sign. MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY

Site
Engr.
Safety
Off.
Page 293 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
PERMIT FOR HEAVY LIFT/CRITCAL ERECTION
Project : Sr.No. :
Nature of activities : Duration: From………To…………
Location of work : Name /Type of crane :
Equipment/Structure to be erected: Wt. of equipment/ structure to be erected :
SL. COMPLIANCE STATUS
Description of Item
NO. Remarks
Yes No Not applicable
1) Is the crane type suitable for lift or as per erection
procedure?
2) Is the crane have the correct number of counterweights
fitted?
3) Availability of Load Certification of crane from
authorized agency.
4) Is the load chart of crane available in carne cabin/or with
Crane operator?
5) Is the device to check the Wind speed in crane is working?
Is the safety features in crane are working?
6) Availability of Load certification of slings and other
accessories from authorized agency
7) Availability of Licensee/certificate for crane operator from
authorized agency.
8) Availability of approved JSA for the subject activities.
9) Availability of approved erection/rigging procedures.
10) Availability of temporary gratings/ platforms for critical
lifting(as applicable)
11) Tool Box conducted before erection?
12) Has the area been cordoned off?
13) Are the authorized persons during erection are identified?
14) Does each person identified for erection understand their
roles and responsibilities?
15) Is the ground on which crane will rest or outrigger support
are correct?
16) Is hard stand requirement (if any) complied?
17) Is the communication system (viz walkie talkies,etc are
working properly?
18) If more than one crane is lifting the load, is an
Intermediate rigger will supervise the lift?
19) If there is other obstruction within the operating radius of
the crane, have correct precautions been taken to prevent
collision?
20)
All the persons are wearing the requisite PPE?
Inspected & Issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer
Page 294 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
PERMIT FOR ENERGY ISOLATION & DE-ISOLATION
Project : Sr.No. :
ENERGY ISOLATION PERMIT
 Clearance required from:…..Hrs ………Date To …. ..Hrs ….Date
 Name of equipment/ energy source etc ………………………………………………………………….
 Nature of job to be done: ……………………………………………………………………………….
 Area………………………….Location:…………………………………………………………………..
PERMIT VALIDATION PERFORMING AUTHORITY

I hereby authorize the …………..personnel(performer) The work and precautions will be carried out under my
to isolate the above equipment/energy source from all overall responsibility.(Testing/execution engineer)
sources of power and handover the equipment/energy
source for maintenance/repair.
Signature: Date:
Issuing authority Name:
Area –Incharge/RCM
Signature: Date:
Name:
SAFETY PRECAUTIONS FOR CLEARANCE NORMALISING AFTER CLEARANCE

1. Notify workers of intent to de- energize 1. Notify workers of intent to re- energize
2. Obtain lock,tag or locking/tagging devices 2. Conduct visual inspection to confirm that the
3. Shut down ,de energize, dissipate any danger zone is clear of workers
residual energies. 3. Conduct visual inspection to confirm that tools
4. Apply lock ,tag and locking and/or tagging ,equipments danger zone is clear of workers
devices 4. Reposition the safety devices(interlocks,
5. *Any other job specific precautions valves, guards, covers ,sensors, as applicable, etc)
6. Verify effectiveness of lockout by 5. *Any other job specific normalizing details
attempting to restart. 6. Remove lock, tag and locking and/or tagging
7. Proper PPE is ensured devices.
7. Re energize.
I certify that the energy source mentioned above is 8. Confirm system is operating properly& safely
isolated from all sources and is safe to start the work. I certify that the energy source mentioned above is
isolated from all sources and is safe to start the work.
Tag No:…… Lock No:………….
Tag No:…… Lock No:………….
Issuing authority Issuing authority
Area –Incharge/RCM Area –Incharge/RCM
Signature: Date: Signature: Date:
Name: Name:
(*to be included by contractor in consultation with (*to be included by contractor in consultation with
EIL/owner) EIL/owner)
ENERGY DE-ISOLATION PERMIT
PERMIT VALIDATION PERFORMING AUTHORITY
I hereby authorize the …………..personnel(performer) I herby certify that the equipment/energy source
to de- isolate the above equipment/energy source from mentioned above has been de-isolated and is ready for
all sources of power and handover the equipment/energy normal operation.(Testing/execution engineer)
source for normal operation..
Issuing authority Signature: Date:

Area –Incharge/RCM Name:
Signature: Date:
Name: Countersigned by Issuing authority
Page 295 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
PERMIT FOR EXCAVATION (depth 2m and above)

(Sheet 1of 2)
Project : Sr.No. :
Job Description : Location:
Size of excavation :
SL. COMPLIANCE STATUS Remarks

Description of Item
NO. Yes No Not
applicable
1) Suitable and sufficient risk assessments and method statements
has been carried to ensure that the work shall be undertaken in
accordance with specification and standard.
2) Are plans/details of underground services available and the
same has been reviewed?
3) Has survey done to locate the services/obstacles, etc.
4) Has the live services (electrical, water line, air line, telephone
line,etc) has been disabled for carrying out the job.
5) Is adequate barriers/fences to protect the excavation are in
place?
6) Is Adequate warning signs are in place?
7) Is Assessment of ground conditions done and remedial action (if
any) taken?
8) Safe access / egress (e.g. ramp / steps / ladders etc.) provided for
site workmen & supervisors.
9) Is the excavation work being undertaken in proximity of
structure, etc ? If Yes, it’s effect is considered?
10) Availability of competent person for supervising the excavation
work?
11) Adequate safe arrangement to prevent collapse of edges (e.g.
shoring / strutting / benching / sloping etc.) made at site.
12) Hard barricades (at least 1.0M away from edge & for excavation
near site access roads) with warning signs/caution boards are
provided
13) Accumulation / passage-ways of water at periphery of
excavation / trench stopped/ restricted.
14) Is the equipment being used for excavation has been checked for
adequacy and is in good working condition having all the safety
features?
15) Age & fitness of workmen ensured by medical test before
engagement in job ?
16) Arrangement of Monitoring of possible oxygen deficiency or
obnoxious gases done & action taken?
PERMIT GRANTED - Yes / No
Name & Signature of Site Engr Name & Signature of Safety Officer
Contractor (Initiator) Contractor (Issuing authority)
Page 296 of 704

HEALTH, SAFETY &
6-82-0001 Rev. 6
PERMIT FOR EXCAVATION

(Sheet 2of 2)
NOTES: -
1. Slopes or benches for excavation beyond 2.0M depth shall be designed & approved by Contractor’s site
head.
2. Excavated earth to be kept at least 1.5M away from edges
3. Safety helmets, Safety shoes or gum-boots, gloves, goggles, Face shield, Safety Harness shall be essential
PPEs.
4. Permit shall be made in duplicate and original shall be available at site of work.
5. Permit shall be issued for maximum one week only (Monday to Sunday)
6. After completion of works, permit shall be closed & preserved for record purpose
GRANT OF PERMIT AND EXTENSIONS
Issuing authority
Initiator (site Review by EIL /
Sl. Validity period Working Time (Safety Officer
Engr. of Main Owner (Remarks
No. From ____To ____ From _____To _____ of Main
Contractor) with date
Contractor)
1.
2.
3.
4.
5.
6.
7.
Additional safety instructions if any: -

1.
2.
3.
Page 297 of 704

SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
ENGINEERS MANAGEMENT SYSTEM 6-78-0001 Rev. 1
lakgINDIA LIMITED REQUIREMENTS FROM
mren ewaire mjvam) (A Gavt at India Undertaking)
BIDDERS Page 1 of 7
64)(11 Chrlf qui ciall -51-04ff

u tea aliikrrat t ?drift'
SPECIFICATION FOR QUALITY

MANAGEMENT SYSTEM
REQUIREMENTS FROM BIDDERS
QMS QMS
1 12.03.15 General Revision Standards Standards MPJ SC
Committee Committee

QMS QMS
0 04.06.09 Issued as Standard Specification Standards Standards SCT ND
Committee Committee
Standards Standards
Committee Bureau
Rev. Checked
Date Purpose Prepared by Convener Chairman
No by
Approved by

Page 298 of 704

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
INDIA LIMITED SYSTEM 6-78-0001 Rev. 1

lft2 (AG'"ind'Undelt6ung) REQUIREMENTS FROM BIDDERS Page 2 of 7
Abbreviations:
CV Curriculum Vitae
ISO International Organization for Standardization
MR Material Requisition
PO Purchase Order
PR Purchase Requisition
QA Quality Assurance
QMS Quality Management System
QMS Standards Committee
Convener: Mr. M.P. Jain
Members: Mr. A.K. Chaudhary (Insp.)

Mr. S.K. Kaul (C&P)
Mr. R.K. Trivedi (Engg.)
Mr. Ravindra Kumar (Const.)
Mr. Tilak Raj (Projects)
Mr. Vinod Kumar (CQA)

Page 299 of 704

Igar llks INDIA LIMITED SYSTEM 6-78-0001 Rev.
Oiren
'A
Govt
At ' nth' Und"k"V) REQUIREMENTS FROM BIDDERS Page 3 of 7
CONTENTS
Clause Title Page

No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
4.0 QUALITY MANAGEMENT SYSTEM — GENERAL 4
5.0 QUALITY SYSTEM REQUIREMENTS 4
6.0 AUDITS 7
7.0 DOCUMENTATION REQUIREMENTS 7
Page 300 of 704

el ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

$1g-zg faReg INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1
own 120.2 .I J40.9) IA GOVt of India Undertaking) REQUIREMENTS FROM BIDDERS Page 4 of 7
1.0 SCOPE
This specification establishes the Quality Management System requirements to be

met by BIDDER for following purpose:
• QMS requirements to be met by suppliers/contractors after award of work/

during contract execution.
2.0 DEFINITIONS
2.1 Bidder
For the purpose of this specification, the word "BIDDER" means the person(s), firm,
company or organization who is under the process of being contracted by EIL /
Owner for delivery of some products (including service). The word is considered
synonymous to supplier, contractor or vendor.
2.2 Project Quality Plan
Document tailored from Standard Quality Management System Manual of BIDDER,

specifying how the quality requirements of the project will be met.
2.3 Owner
Owner means the owner of the project for which services / products are being
purchased and includes their representatives, successors and assignees.

6-78-0002 Specification for Documentation Requirements from
Contractors
6-78-0003 Specification for Documentation Requirements from Suppliers
4.0 QUALITY MANAGEMENT SYSTEM — GENERAL
Unless otherwise agreed with EIL / Owner, the BIDDER proposed quality system
shall fully satisfy all relevant requirements of ISO 9001 "Quality Management
Systems — Requirements." Evidence of compliance shall be current certificate of
quality system registration to ISO 9001 or a recent compliance audit recommending
registration from a certification agency. The quality system shall provide the
planned and systematic control of all quality related activities for execution of
contract. Implementation of the system shall be in accordance with BIDDER'S
Quality Manual and PROJECT specific Quality Plan.
5.0 QUALITY SYSTEM REQUIREMENTS

5.1 BIDDER shall prepare and submit for review / record, Project Quality Plan / Quality
Assurance Plan for contracted scope / job. The BIDDER'S Quality Plan shall
address all of the applicable elements of ISO 9001, identify responsible parties
within BIDDER'S organization, for the implementation / control of each area,
reference the applicable procedures used to control / assure each area, and verify
the documents produced for each area. The Project Quality Plan shall necessarily
define control or make reference to the relevant procedures, for design and
engineering, purchase, documentation, record control, bid evaluation, inspection,
production/manufacturing, preservation, packaging and storage, quality control at

Page 301 of 704

INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

(A Gavt of India undertaking' REQUIREMENTS FROM BIDDERS Page 5 of 7
construction site, pre-commissioning, commissioning and handing over (as

applicable) in line with contract requirement and scope of work.
5.2 BIDDER shall identify all specified or implied statutory and regulatory requirements
and communicate the same to all concerned in his organization and his sub
contractor's organization for compliance.
5.3 BIDDER shall deploy competent and trained personnel for various activities for
fulfillment of PO / contract. BIDDER shall arrange adequate infrastructure and work
environment to ensure that the specification and quality of the deliverable are
maintained.
5.4 BIDDER shall do the quality planning for all activities involved in delivery of order.
The quality planning shall cover as minimum the following:
Resources
Product / deliverable characteristics to be controlled.
Process characteristics to ensure the identified product characteristics are
realized
Identification of any measurement requirements, acceptance criteria
Records to be generated
Need for any documented procedure
The quality planning shall result into the quality assurance plan, inspection and test
plans (ITPs) and job procedures for the project activities in the scope of bidder.
These documents shall be submitted to EIL/Owner for review/approval, before
commencement of work.
5.5 Requirements for sub-contracting / purchasing of services specified in contract /

tender shall be adhered to. In general all outsourced items will be from approved
vendors of EIL. Wherever requirements are not specified, or approved sub vendors
do not exist, the sub-contractor shall establish and maintain a system for purchasing
/ sub-contracting to ensure that purchased product / service conforms to specified
requirements. Criteria for selection of sub-contractor, evaluation, re-evaluation,
maintenance of purchasing data and verification of purchased product (sub-
contractor services), constitute important components of this requirement.
5.6 BIDDER shall plan and carry production and service provision under controlled
conditions. Controlled conditions shall include, as applicable
the availability of information that describes the characteristics of the product

the availability of work instructions
the use of suitable equipment
the availability and use of monitoring and measuring devices
the implementation of monitoring and measurement
the implementation of release, delivery and post-delivery activities
5.7 BIDDER shall validate any processes for production and service provision where
resulting output cannot be verified by subsequent monitoring and measurement.
This includes any process where deficiencies become apparent only after the
product is in use or service has been delivered.
5.8 BIDDER shall establish a system for identification and traceability of product /
deliverable throughout product realization. Product status with respect to inspection
and testing requirements shall be identified.

Page 302 of 704

ei ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
lge.ji id5fez INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

Oren erRRIZ .71.1.113,70 IA Govt of India undettaking) REQUIREMENTS FROM BIDDERS Page 6 of 7
5.9 BIDDER shall identify, verify, protect and safeguard EIL / Owner property (material /
document) provided for use or incorporation into the product. If any Owner / EIL
property is lost, damaged or otherwise found to be unsuitable for use, this shall be
reported to the EIL / Owner.
5.10 BIDDER shall ensure the conformity of product / deliverable during internal
processing and delivery to the intended destination. Requirements mentioned in the
tender shall be adhered to.
5.11 BIDDER shall establish system to ensure that inspection and testing activities are
carried out in line with requirements. Where necessary, measuring equipments
shall be calibrated at specified frequency, against national or international
measurement standards; where no such standard exists, the basis used for
calibration shall be recorded. The measuring equipments shall be protected from
damage during handling, maintenance and storage.
5.12 BIDDER shall ensure effective monitoring, using suitable methods, of the processes
involved in production and other related processes for delivery of the scope of
contract.
5.13 BIDDER shall monitor and measure the characteristics of the product/deliverable to
verify that product requirement has been met. The inspection (stage as well as
final) by BIDDER and EIL / Owner personnel shall be carried out strictly as per the
ITPs forming part of the contract. Product release or service delivery shall not
proceed until the planned arrangements have been satisfactorily completed, unless
otherwise approved by relevant authority and where applicable by Owner / EIL.
5.14 BIDDER shall establish and maintain a documented procedure to ensure that the
product which does not conform to requirements is identified and controlled to
prevent its unintended use or delivery
5.15 All non-conformities (NCs) / deficiencies found by the BIDDER'S inspection /

surveillance staff shall be duly recorded, including their disposal action shall be
recorded and resolved suitably. Effective corrective and preventive action shall be
implemented by the BIDDER so that similar NCs including deficiencies do not recur.
5.16 All deficiencies noticed and reported by EIL / Owner shall be analyzed by the
BIDDER and appropriate corrective and preventive actions shall be implemented.
BIDDER shall intimate EIL / Owner of all such corrective and preventive action
implemented by him.
5.17 BIDDER should follow the standards, specifications and approved drawings.
Concessions/Deviations shall be allowed only in case of unavoidable circumstances.
In such situations Concession/deviation request must be made by the BIDDER
through online system of EIL eDMS. URL of EIL eDMS is
http://edocx.eil . co . in/vportal.
5.18 BIDDER shall have documented procedure for control of documents.
5.19 All project records shall be carefully kept, maintained and protected for any damage
or loss until the project completion, then handed over to EIL / Owner as per contract
requirement (Refer Specification Nos. 6-78-0002 - Specification for Documentation
Requirements from Contractors and 6-78-0003 - Specification for Documentation
Requirements from Suppliers), or disposed as per relevant project procedure.
Page 303 of 704


ei MANAGEMENT SYSTEM
IftJr
kif51ft. INDIA LIMITED 6-78-0001 Rev. 1
wirer riraxem3Tmil (A Goof of India UndertakIngi
REQUIREMENTS FROM BIDDERS Page 7 of 7
6.0 AUDITS
BIDDER shall plan and carry out the QMS audit for the job. Quality audit programme
shall cover design, procurement, construction management and commissioning as
applicable including activities carried out by sub-vendors and sub-contractors. This
shall be additional to the certification body surveillance audits carried out under
BIDDER'S own ISO 9001 certification scheme.
The audit programmes and audit reports shall be available with bidder for scrutiny
by EIL / Owner. EIL or Owner's representative reserves the right to attend, as a
witness, any audit conducted during the execution of the WORKS.
In addition to above EIL, Owner and third party appointed by EIL/Owner may also
perform Quality and Technical compliance audits. BIDDER shall provide assistance
and access to their systems and sub-contractor / vendor systems as required for this
purpose. Any deficiencies noted shall be immediately rectified by BIDDER.
7.0 DOCUMENTATION REQUIREMENTS
BIDDER shall submit following QMS documents immediately after award of work
(Within one week) for record / review by EIL / Owner.
Organization chart (for complete organization structure and for the project)
Project Quality Plan/Quality Assurance Plan
Job specific Inspection Test Plans, if not attached with PR
Job Procedures
Inspection/Test Formats
In addition to above QMS documents, following documentation shall be maintained

by the BIDDER for submission to EIL / Owner on demand at any point of time during
execution of the project.
Quality Manual
Certificate of approval for compliance to ISO: 9001 standard
Procedure for Control of Non-conforming Product
Procedure for Control of Documents
Sample audit report of the QMS internal and external audits conducted during
last one year
Customer satisfaction reports from at least 2 customers, during the last one
year
Project QMS audit report
Technical audit reports for the project
Corrective action report on the audits
Documents as specified above are minimum requirements. BIDDER shall submit

any other document/data required for completion of the job as per EIL/Owner
instructions.
Page 304 of 704

SPECIFICATION FOR STANDARD SPECIFICATION No.

∎31 ENGINEERS DOCUMENTATION
ligar lafgesW INDIA LIMITED 6-78-0003 Rev. 1
(411W1 292,51V MIJ‘10571) Govt o India Undertalongj
REQUIREMENTS FROM
SUPPLIERS Page 1 of 8
affr irewufat 74ER

*mat t feitu
SPECIFICATION FOR
DOCUMENTATION REQUIREMENTS
FROM SUPPLIERS
C)(415----2
QMS QMS
1 12.03.15 General Revision Standards Standards SC
Committee Committee
QMS QMS
0 04.06.09 Issued as Standard Specification Standards Standards SCT ND
Committee Committee
Standards Standards
Comm ifte Bureau
Date Purpose Convener Chairman
No by by
Approved by
Page 305 of 704

SPECIFICATION FOR STANDARD SPECIFICATION
(t,ft. ENGINEERS
1i laWGNIIY INDIA LIMITED
ogire, efiTIWAnowAl (A Govt of Into Undertaking(
DOCUMENTATION
REQUIREMENTS FROM
No.
6-78-0003 Rev. 1
Abbreviations:
DCI - Document Control Index

eDMS - Electronic Document Management System
FOA Fax of Acceptance
HOD Head of Division / Department
IC Inspection Certificate
IRN Inspection Release Note
ITP Inspection and Test Plan
LOA Letter of Acceptance
MOU Memorandum of Understanding
MR Material Requisition
PO Purchase Order
PR Purchase Requisition
PVC Polyvinyl Chloride
QMS Quality Management System
TPIA Third Party Inspection Agency
URL Universal Resource Locator
QMS Standards Committee
Convener: Mr. M.P. Jain
Members: Mr. A.K. Chaudhary (Insp.)

Mr. S.K. Kaul (C&P)
Mr. R.K. Trivedi (Engg.)
Mr. Ravindra Kumar (Const.)
Mr. Tilak Raj (Projects)
Mr. Vinod Kumar (CQA)
Page 306 of 704


ei ENGINEERS DOCUMENTATION No.
Oaez idiWIeg INDIA LIMITED 6-78-0003 Rev. 1
011E71 ewaxedaagem)

(A Govt of India Undertaking) REQUIREMENTS FROM
CONTENTS

Clause Title Page
No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
4.0 DOCUMENTATION REQUIREMENTS 4
Attachments
Format for completeness of Final Documentation Format No. 3-78-0004

Page 307 of 704

dol ENGINEERS DOCUMENTATION No.
5'gzir tlf5ltu INDIA LIMITED 6-78-0003 Rev. 1
I.VOM (A Govt of Intha Undertakongt REQUIREMENTS FROM
1.0 SCOPE
This specification establishes the Documentation Requirements from Suppliers.
All documents/data against the PO / PR / MR shall be developed and submitted to
EIL/Owner by the suppliers for review / records, in line with this specification.
2.0 DEFINITIONS
2.1 Supplier
For the purpose of this specification, the word "SUPPLIER" means the person(s),
firm, company or organization who is under the process of being contracted by EIL /
Owner for delivery of some products (including service). The word is considered
synonymous to bidder, contractor or vendor.
2.2 Owner
Owner means the owner of the project for which services / products are being
purchased and includes their representatives, successors and assignees.
6-78-0001 Specification for Quality Management System Requirements

from Bidders
4.0 DOCUMENTATION REQUIREMENTS
4.1 Documents/Data to be Submitted by the Supplier
4.1.1 The Supplier shall submit the documents and data against the PO/PR/MR as per the
list given in respective PO/PR/MR.
4.1.2 Review of the supplier drawings by EIL would be only to review the compatibility with
basic designs and concepts and in no way absolve the supplier of his
responsibility/contractual obligation to comply with PR requirements, applicable
codes, specifications and statutory rules/regulations. Any error/deficiency noticed
during any stage of manufacturing/execution/installation shall be promptly corrected
by the supplier without any time and cost implications, irrespective of comments on
the same were received from EIL during the drawing review stage or not.
4.1.3 Unless otherwise specified, submission of documents for Review/Records shall

commence as follows from the date of Fax of Intent / Letter of Intent/ Fax of
Acceptance (FOA)/ Letter of Acceptance (LOA):
QMS - 1 week
Drawing/Document Control Index - 2 weeks
Other Documents/Drawings - As per approved Drawing/Document Control
Index/Schedule
4.1.4 Documents as specified in PO/PR/MR are minimum requirements. Supplier shall

submit any other document/data required for completion of the job as per EIL/Owner
instructions.

Page 308 of 704

ENGINEERS DOCUMENTATION No.
'7f 11 INDIA LIMITED 6-78-0003 Rev. 1
I OfiTt cYeawlnn (A Govt of India UndenakIngi REQUIREMENTS FROM
4.2 Style and Formatting
4.2.1 All Documents shall be in ENGLISH language and in M.K.S System of units.
4.2.2 Before forwarding the drawings and documents, contractor shall ensure that the
following information are properly mentioned in each drawing:
Purchase Requisition Number
Name of Equipment / Package
Equipment / Package Tag No.
Name of Project
Client
Drawing / Document Title
Drawing / Document No.
Drawing / Document Revision No. and Date
43 Review and Approval of Documents by Supplier
4.3.1 The Drawing/Documents shall be reviewed, checked, approved and duly

signed/stamped by supplier before submission. Revision number shall be changed
during submission of the revised supplier documents and all revisions shall be
highlighted by clouds. Whenever the supplier require any sub-supplier drawings to be
reviewed by EIL, the same shall be submitted by the supplier after duly reviewed,
approved and stamped by the supplier. Direct submission of sub-supplier's drawings
without contractor's approval shall not be entertained.
4.4 Document Category
4.4.1 Review Category
Following review codes shall be used for review of supplier Drawings/Documents:
Review Code 1 No comments. Proceed with manufacture/

fabrication as per the document.
Review Code 2 Proceed with manufacture/fabrication as per
commented document. Revised document
required.
Review Code 3 Document does not conform to basic
requirements as marked. Resubmit for review
R Document is retained for Records. Proceed
with manufacture/fabrication.
V Void
4.5 Methodology for Submission of Documents to EIL/Owner
4.5.1 Document Control Index (DCI)
Supplier shall create and submit Document Control Index (DCI) for review based on
PO/PR/MR along with schedule date of submission of each drawing/document on EIL
eDMS. The DCI shall be specific with regard to drawing/document no. and the exact
title. Proper sequencing of the drawings/documents should be ensured in schedule
date of submission.

Page 309 of 704


r1.7
-14 ENGINEERS DOCUMENTATION No.
51g-a feff5leg INDIA LIMITED 6-78-0003 Rev. 1
1.17,124ifflsrefloJOORI1 IA GUN. of India Undertaking, REQUIREMENTS FROM
4.5.2 Submission of Drawings/Documents

Drawings/documents and data shall be uploaded on the EIL eDMS Portal as per DCI.
The detail guidelines for uploading documents on EIL eDMS Portal are available on
following URL
http://edocx.eil.co.in/vportal
4.5.3 Statutory Approvals
Wherever approval by any statutory body is required to be taken by Supplier, the

Supplier shall submit copy of approval by the authority to EIL.
4.5.4 Details of Contact Persons of Supplier
After placement of order supplier shall assign a Project Manager for that order. The
details are to be filled online through the portal. The details include e-mail address,
mailing address, telephone nos., fax nos. and name of Project Manager. All the system
generated emails pertaining to that order shall be sent to the assigned Project
Manager.
4.5.5 Schedule and Progress Reporting
Supplier shall submit monthly progress report and updated procurement, engineering
and manufacturing status (schedule vs. actual) every month, beginning within 2 weeks
from FOA/LOA. In case of exigencies, EIL/Owner can ask for report submission as
required on weekly/fortnightly/adhoc basis depending upon supply status and supplier
shall furnish such reports promptly without any price implication. Format for progress
report shall be submitted by the Supplier during kick off meeting or within one week of
receiving FOA/LOA, whichever is earlier.
4.5.6 Quality Assurance Plan/Inspection and Test Plan

Inspection and test plans (ITP) attached if any, to the MR/PR are to be followed.
However for cases wherein ITPs have not been attached with MR/PR, Supplier shall
submit within one week of receiving FOA/LOA, the Quality Assurance Plan for
manufacturing, covering quality control of critical bought out items/materials,
inspection & testing at various stages of production, quality control records and site
assembly & testing as may be applicable to the specific order and obtain approval
from concerned Regional procurement Office of EIL/third party inspection agency, as
applicable.
For Package equipment contracts, the supplier shall prepare a list of items/
equipments and their inspection categorization plan for all items included in the scope
of supply immediately after receipt of order and obtains approval for the same from
EIL. The items shall be categorized into different categories depending upon their
criticality for the scope of inspection of TPIA and/or EIL.
4.5.7 Inspection Release Note (IRN)/ Inspection Certificate (IC)
IRN/ IC shall be issued by EIL Inspector/ third party inspection agency on the basis of
successful inspection, review of certificates as per specifications & agreed quality plan
(as applicable) and only after all the drawings/documents as per DCI are submitted
and are accepted under review code-1 or code R. Supplier shall ensure that necessary
documents/manufacturing and test certificates are made available to EIL/TPIA as and
when desired.

Page 310 of 704

ENGINEERS DOCUMENTATION No.
Ogell 0151jeg INDIA LIMITED 6-78-0003 Rev. 1
1.127, owtore o43frosso IA Govt of India Unclettalong) REQUIREMENTS FROM
Note: Non fulfilling above requirement shall result into appropriate penalty or with-
holding of payment as per conditions of PO/PR/MR.
4.5.8 Transportation Plan

Transportation Plan for Over Dimensional Consignments (ODC), if any, shall be
submitted within 2 weeks of receiving FOA/LOA, for approval. Consignment with
parameters greater than following shall be considered as over dimensional.
Dimensions: 4 meters width x 4 meters height x 20 meters length
Weight : 32 MT
4.6 Final Documentation

4.6.1 As Built Drawings
Shop changes made by Supplier after approval of drawings under `Code 1' by EIL and
deviations granted through online system , if any, shall be marked in hard copies of
drawings which shall then be stamped 'As-built' by the supplier. These 'As-built'
drawings shall be reviewed and stamped by EIL Inspector/ TPIA also. Supplier shall
prepare scanned images files of all marked — up 'As — built' drawings. Simultaneously
Supplier shall incorporate the shop changes in the native soft files of the drawings
also.
4.6.2 As Built Final Documents
As built final documents shall be submitted as listed in PO/PR/MR.
4.6.3 Packing/Presentation of Final Documents
Final Documents shall be legible photocopies in A4, A3 size only. Drawings will be
inserted in plastic pockets (both sides transparent, sheet thickness minimum 0.1 mm)
with an extra strip of 12 mm wide for punching so that drawings are well placed.
Final Documentation shall be bound in Hard board Plastic folder(s) of size 265 mm x
315 mm (101 /2 inch x 12 1 /2 inch) and shall not be more that 75 mm thick. It may be of
several volumes and each volume shall have a volume number, index of volumes and
index of contents of that particular volume. Where number of volumes are more,
90mm thickness can be used. Each volume shall have top PVC sheet of minimum
0.15 mm thick duly fixed and pressed on folder cover and will have 2 lever clip. In
case of imported items documents, 4 lever clip shall also be accepted. All four corners
of folders shall be properly metal clamped. Indexing of contents with page numbering
must be incorporated by supplier. Spiral/Spico bound documents shall not be
acceptable. As mentioned above, books should be in hard board plastic folders with
sheets punched and having 2/4 lever clips arrangement.
Each volume shall contain on cover a Title Block indicating package Equipment Tag
No. & Name, PO/Purchase Requisition No., Name of Project and Name of Customer.
Each volume will have hard front cover and a reinforced spine to fit thickness of book.
These spines will also have the title printed on them. Title shall include also volume
number (say 11 of 15) etc.
4.6.4 Submission of Soft Copies
Supplier shall submit to EIL, the scanned images files as well as the native files of
drawings/documents, along with proper index.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—AIL rights reserved
Page 311 of 704

(L:ED'D ENGINEERS No.
lig ar idf5les
I MT
C,'
INDIA UMITED
riernfO7IJOCFAI IA Govt of India Undertaking)
DOCUMENTATION
REQUIREMENTS FROM 6-78-0003 Rev. 1
In addition to hard copies, Supplier shall submit electronic file (CD-ROM) covering soft
copies of all the final drawings and documents, all text documents prepared on
computer, scanned images of all important documents (not available as soft files), all
relevant catalogues, manuals available as soft files (editable copies of drawings/text
documents, while for catalogues/manuals/proprietary information and data, PDF files
can be furnished).
All the above documents shall also be uploaded on the EIL eDMS portal.
4.6.5 Completeness of Final Documentation
Supplier shall get the completeness of final documentation verified by EIUTPIA and
attach the Format for Completeness of Final Documentation (Format No. 3-78-0004)
duly signed by EIL Inspector or TPIA as applicable to the document folder.

Page 312 of 704

COMPLETENESS OF FINAL
fEr) ENGINEERS DOCUMENTATION
$afg7:11 tel5leg
Men eRali• 4,30.0
INDIA LIMITED
(A Gort of hula Undertakog)
COMPLETENESS OF FINAL DOCUMENTATION
Name of Supplier/Contractor
Customer
Project
EIL's Job No.
Purchase Order No./
Contract No.
Purchase Requisition No./

Tender No. Rev. No. :
Name of the Work/

Equipment
Tag. No.
Supplier's/ Contractor's
Works Order No.
Certified that the Engineering Documents/ Manufacturing & Test Certificates submitted by the
supplier are complete in accordance with the Vendor Data Requirements of Purchase
Requisition.
Signature Signature
Date Date
Name Name
Designation Designation
Department Department
Supplier/Contractor EIL/TPIA
arTilittl/APPROVED
gTffTeR/ Sig
eilegiltk
tvi . ...........
.....
4/ Name: ......... .. . ......
..................
f4-41--/ Date: ..... ••••••• .... ......
Format No. 3-78-0004, Rev. 1/ 12.03.2015 Copyright EIL — All rights reserved
Page 313 of 704

JOB SPECIFICATION JOB SPECIFICATION No.
FOR SURFACE PREPARATION AND A842-000-79-41-PLS-01
PROTECTIVE COATING Rev.0
PDP PROJECT BPCL KR PAGE 1 OF 44
JOB SPECIFICATION FOR

SURFACE PREPARATION AND
PROTECTIVE COATING
(NEW CONSTRUCTION)
0 02-03-2016 ISSUED AS JOB SPECIFICATION SRIDHAR SRIDHAR S. GHOSAL
Rev.
Date Purpose Prepared by Reviewed by Approved by
No
Page 314 of 704

Abbreviations:
AS : Alloy Steel
CS : Carbon Steel
DFT : Dry Film Thickness
DM : De-mineralized
GI : Galvanized Iron
ID : Internal Diameter
IRN : Inspection Release Note
LTCS : Low Temperature Carbon Steel
MS : Mild Steel
NB : Nominal Bore
OD : Outside Diameter
RCC : Reinforced Cement Concrete
SS : Stainless Steel
WFT : Wet Film Thickness
Page 315 of 704

CONTENTS
SL. DESCRIPTION PAGE

NO NO.
1.0 General…………………………………………………………………………………. 4
2.0 Scope…………………………………………………………………………………… 4
3.0 Reference Codes & Standards……………………………………………………….... 6
4.0 Equipment……………………………………………………………………………… 7
5.0 Surface Preparation, Shop Primer, Coating Application & Repair and 7
Documentation..
6.0 Paint Materials………………………………………………………………………….. 15
7.0 Coating Systems selection criteria……………………………………………………... 19
8.0 Coating System for Gratings, Rolling & Stationery Ladders, Spiral Stairways and
Hand Rails in All Location……………………………………………………………... 21
9.0 Coating System for Offsite Area (Inland Plants)………………………………………. 22
10.0 Coating System For Unit Areas as well as DM, CPP, Cooling Tower of Inland Plants
and for All Areas (Unit, Offsite, DM, CPP, etc.) of Coastal Plants……………………. 23
11.0 Coating System for Effluent Treatment Plant (ETP)…………………………………... 25
12.0 External Coating Systems for Uninsulated Carbon Steel and Low Alloy Steel Storage
Tanks (For All Plant Locations, Coastal or Inland) - All Process Units & Off-Sites …. 26
13.0 Internal Coating Systems for Carbon Steel and Low Alloy Storage Tanks - All
Process Units & Off-Sites……………………………………………………………… 28
14.0 Coating Systems for External Side of Underground Carbon Steel Plant Piping and
Underground Vessels…………………………………………………………………... 30
15.0 Coating Under Insulation (Coastal Or Inland Plants). All Units Areas & Off-Sites…… 31
16.0 Coating System for Carbon Steel Components of Coolers / Condensers (Internal
Protection) for Fresh Water Service……………………………………………………. 32
17.0 Coating System (Internal Protection) for Galvanized or Non Ferrous or Stainless
Steel/ Duplex Stainless Steel Components of Coolers/ Condensers for Fresh Water
Service….......................................................................................................................... 32
18.0 Storage………………………………………………………………………………….. 32
19.0 Paint colour code for piping and equipment ……...…………………………………… 32
20.0 Recommended paint color code ………………...……………………………………. 35
21.0 Painting for civil defense requirements………………………………………………… 40
22.0 Selection of paint materials …………………………………...……………………….. 41
23.0 Quality Control, Inspection and Testing ………………………………………………. 42
24.0 Guarantee……………………………………………………………………………….. 46
Page 316 of 704

1.0 GENERAL
1.1 This technical specification shall be applicable for the work covered by the contract, and
without prejudice to the provisions of various international codes of practice, standard
specifications etc. It is understood that contractor shall carry out the work in all respects with
the best quality of materials and workmanship and in accordance with the best engineering
practice and instructions of Engineer-In-Charge.
1.2 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor.
Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
1.3 This specification covers the requirement for protective coating for new construction.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the
following.
2.1.1 This specification defines the requirements for surface preparation, selection and application
of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts,
steel structures, external & internal protection of storage tanks for all services and chimneys
if any. The items listed in the heading of tables of paint systems is indicative only, however,
the contractor is fully responsible for carrying out all the necessary painting, coating and
lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting
 All uninsulated Carbon Steel & Alloy Steel equipments like vessels, Columns, storage
Tanks, Exchangers if any, parts of boilers etc.
 All uninsulated carbon steel and low alloy plant and related piping, fittings and valves
(including painting of identification marks), furnace ducts and stacks.
 All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping and if
any other insulated items present.
 All items contained in a package unit as necessary.
 All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms etc.
 Flare lines, external surfaces of MS chimney with or without refractory lining and
internal surfaces of MS chimney without refractory lining. (If present)
Page 317 of 704

 Identification of colour bands on all piping as required including insulated aluminium

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

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

hazardous service.
 Supply of all primers, paints and all other materials required for painting (other than
Owner supplied materials)
 Over insulation surface of equipments and pipes wherever required.
 Painting under insulation for carbon steel, alloy steels and stainless steel as specified.
 Painting of pre-erection/fabrication and Shop primer.
 Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the
field/site before and after erection as required.
 All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP
plant.
 Quality control, testing and inspection during all stages of work (surface preparation,
application of coating and testing of furnished coating).
2.2.2 The following surfaces and materials shall not require painting in general. However, if there
is any specific requirement by the OWNER/LICENSOR, the same shall be painted as per the
relevant and applicable specifications.
a. Uninsulated austenitic stainless steel.

b. Plastic and/or plastic coated materials
c. Non-ferrous materials like aluminum, Cu-Ni alloy
d. Galvanized steel.
In general Galvanized steel doesn’t require painting. However if as per OWNERs

instructions, contractual or for colour coding requirement painting is essential, then coating
system in table 8.0 shall be followed.
2.3 Documents
2.3.1 The contractor shall perform the work in accordance with the following documents issued to
him for execution of work.
a. Bill of quantities for piping, equipment, machinery and structures etc.
b. Piping Line List.
c. Painting specifications including special civil defense requirements.
Page 318 of 704

2.4 Unless otherwise instructed, final paint coating (i.e., application of field primer,
wherever required, intermediate and top coats) on pre-erection/ shop primed
equipments shall be applied at site, only after all welding, testing on systems are
completed as well as after completion of steam purging wherever required.
2.5 Changes and deviations required for any specific job due to clients requirement or otherwise
shall be referred to EIL for deviation permit.
3.0 REFERENCE CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, latest editions of the following codes and standards are applicable for the work
covered by this contract.
IS-5 : Colour coding

RAL DUTCH : International Standard for colour shade (Dutch Standard)
IS-101 : Methods of test for ready mixed paints and enamels
IS-2379 : Indian Standard for Pipe line identification-colour code
ISO-12944 : Corrosion Protection of steel Structures by Protective Paint
System
ASTM-Vol 6.01&6.03 : American standard test methods for Paints and Coatings.
ANSI A 13.1 : Scheme for identification of piping systems: American
National Standards Institution
SSPC : Steel Structures Painting Council
3.2 Surface Preparation Standards
The latest editions of any of the following standards shall be followed for surface
preparation:
3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for Preparation of steel substrates before
application of paints and related products. This standard contains photographs of the various
standards on four different degrees of rusted steel and as such is preferable for inspection
purpose by the Engineer-In-Charge.
3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).
3.2.3 National Association of Corrosion Engineers, U.S.A., (NACE).
3.2.4 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
3.4 The paint manufacturer's instructions shall be followed as far as practicable at all times for
best results. Particular attention shall be paid to the following:
a. Instructions for storage to avoid exposure as well as extremes of temperature.
b. Surface preparation prior to painting shall be followed as per Table 8.0 to 16.0 of
this standard shall be followed.
Page 319 of 704

c. Mixing and thinning.
d. Application of paints and recommended limit on time intervals in between coats.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all
equipments, scaffolding materials, shot & grit blasting equipments & air compressors etc.
required to be used shall be suitable for the work and all in good order and shall be arranged
by the contractor at site and in sufficient quantity. The manufacturer’s test certificates / data
sheets for all the above items shall be reviewed by Engineer-in-charge at site before start of
work.
4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack systems
except that the Engineer-In-Charge may allow the hand mixing of small quantities at his
discretion in case of specific requirement for touch up work only.
5.0 SURFACE PREPARATION, SHOP PRIMER COATING APPLICATION & REPAIR

AND DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed, depending on condition of surface to be painted and as
instructed by Engineer-In-Charge. Adhesion of the paint film to surface depends largely on
the degree of cleanliness of the metal surface. Proper surface preparation contributes more to
the success of the paint protective system.
a. Abrasive blast cleaning

b. Mechanical or power tool cleaning
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and
dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per
provisions of relevant tables given elsewhere in this specification. The minimum acceptable
standard, in case of thermally sprayed metal coatings, in case of mechanical or power tool
cleaning it shall be St. 3 or equivalent. In case of blast cleaning it shall be Sa 2-1/2 as per
Swedish Standard SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning
shall be Sa 3 as per Swedish Standard in case thermally sprayed metal coatings.
Before surface preparation by blast cleaning, the surface shall be degreased by aromatic
solvent to remove all grease, oil etc.
5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning shall not be
performed where dust can contaminate surfaces undergoing such cleaning or during humid
weather conditions having humidity exceed 85%. In case of internal coating of storage tanks,
dehumidifier shall be used, to control humidity level below 60%. Dehumidifier should
depress the dew point of air in the enclosed space, sufficient enough so as to maintain it 3⁰C
below the metal substrate temperature during centre period of blasting and coating
application. During the interval time between application of primer coat and subsequent
intermediate and top coats or between blast cleaning completion and start of application of
Page 320 of 704

primer coat, dehumidifier unit should be in continuous operation to ensure that no

condensation occurs on substrate.
Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25
grains per pound of air per hour. Dehumidifier should have capacity of at least 2 air changes
per hour of the enclosed space. All necessary psychometric data should be collected by
contractor for the given site conditions before starting operation of dehumidifier to ensure
that desired values of dew point, moisture content in enclosed scope is achieved.
Dehumidification to be maintained round the clock for surface preparation and painting till
the total coating application is over.
Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed
to the satisfaction of the technical representative of the paint manufacturer interested with
quality assurance for the work. In case the dehumidifier breaks down in middle of the job, the
same shall be replaced at the risk and the cost of the contractor and the entire unfinished
work shall be repeated.
5.1.4 The Engineer in-charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances the
contractor shall remove the equipment and replace the same with another equipment to
provide satisfactory results without any additional cost to the owner.
5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray/ air assisted conventional spray if recommended by the paint manufacturer on
dry surface. This should be done immediately and in any case within 4 hours of cleaning of
surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall
have the liberty to control the time period, at his sole discretion and/or to insist on re-
cleaning, as may be required, before primer application is taken up. In general, during
unfavorable weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose
particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush.
Acid etching with 10-15% HCL solution for about 15 minutes shall be carried and surface
must be thoroughly washed with water to remove acid & loose particles and then dried
completely before application of paint.
5.2 Procedure for Surface Preparation
5.2.1 Air Blast Cleaning with abrasives
The surfaces shall be blast cleaned using one of the abrasives like angular chilled cast iron or
steel grit, copper slag or Nickel slag, A12O3 particles at pressure of 7kg/cm2 at an appropriate
distance and angle depending of nozzle size maintaining constant velocity and pressure.
Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16 – G42
conforming to SSPC AB1 and S250 grade size of steel shots (maximum) to obtain a desired
surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the
range of G16 – G24. The combination of steel grits and shots shall be normally in the ratio of
3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet
the requirements of SSPC AB1. Compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the
materials for liners. Nozzles orifice may vary from 3/16” to ¾”. On completion of blasting
Page 321 of 704

operation, the blasted surface shall be clean and free from any scale or rust and must show a
grey white metallic luster. Primer/first coat of paint shall be applied within 4 hours of surface
preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible
vacuum collector shall be installed for collecting the abrasives and recycling.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding
wheels or rotating steel wire- brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and /or washed by water or steam and thoroughly dried with
compressed air jet before application of paint.
5.3 Non-Compatible Shop Coat Primer
For equipments on which application of total protective coating (Primer + Intermediate + top
coat) is carried out at shop, compatibility of finish coat with primer should be checked with
paint manufacturer. If the shop coat is in satisfactory condition showing no major defect upon
arrival at site, the shop coat shall not be removed.
5.4 Shop coated equipments (coated with Primer & finishing coat) should not be repainted unless
paint is damaged. Repair shall be carried out as per Table 7.2 of paint systems depending
upon compatibility of paint.
5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means
of power tool brush cleaning or hand tool cleaning and then spot primed before applying one
coat of field primer unless otherwise specified. If shop primer is not compatible with field
primer then shop coated primer should be completely removed before application of selected
paint system for particular environment.
5.6 For Package units/equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer’s standard can be followed after review.
As mentioned in section 2.4, all coating application at field (field primer, intermediate and
top coat) on equipments, structures, piping, etc, shall be carried out only after its erection and
all welding, testing, steam purging (wherever carried out) have been completed.
5.7 Coating Procedure and Application
All paint coatings shall be applied by airless spray excepting at the following special
cases where application can be carried out by brush subject to suitability of the
application of the paint product by brush.
- Spot repair
- Stripe coating on edges
- Small bore parts not suitable for spray application.
Irregular surfaces such as sharp edges, welds, small brackets, and interstices may stripe
coated to ensure specified DFT is achieved. Paint manufacturer recommendation
should be followed before deciding for brush application.
Page 322 of 704

5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
exists, when the steel surface temperature is less than 5oF above dew point when the relative
humidity is greater than 85% or when the temperature is below 40oF and when the
ambient/substrate temp is below the paint manufacturer’s recommended temperature of
application and curing. De-humidifier equipment shall be used to control RH and Dew point.
The paint application shall not be done when the wind speed exceeds 20km per hour.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous
film uniform thickness free of probes. Any spots or areas missed in application shall be
recoated and permitted to dry before the next coat is applied. Applied paint should have the
desired wet film thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding
coat. Material shall be considered dry for recoating when an additional coat can be applied
without the development of any detrimental film irregularities, such as lifting or loss of
adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval.
5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage
of the surface. The tinting material shall be compatible with the material and not detrimental
to its service life and shall be recommended by the original paint manufacturer.
5.7.6 Airless spray application shall be in accordance with the following procedure: as per steel
structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An air compressor or
electric motor is sued to operate a pump to produce pressures of 1000 to 6000 psi. paint is
delivered to the spray gun at this pressure through a single hose within the gun, a single paint
stream is divided into separate streams, which are forced through a small orifice resulting in
automization of paint without the use of air. This results in more rapid coverage with less
over spray. Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks
paint from any container, including drums. The unit shall have in built agitator that keep the
paint uniformly mixed during the spraying. The unit shall consist of in built strainer. Usually
very small quantity of thinning is required before spray. In case of high build epoxy coating
(two pack). 30:1 pump ratio and 0.020-0.023” tip size will provide a good spray pattern.
Ideally fluid hoses should not be less than 3/8” ID and not longer than 50 ft to obtain
optimum results.
In case of gun choking, de-choking steps shall be followed immediately.
5.7.7 Brush application of paint shall be in accordance with the following:
a. Brushes shall be of a style and quality that will enable proper application of paint.
b. Round or oval brushes are most suitable for rivets, bolts, irregular surface, and
rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they
shall not have width over five inches.
Page 323 of 704

c. Paint shall be applied into all corners.

d. Any runs or sags shall be brushed out.
e. There shall be a minimum of brush marks left in the applied paint.
f. Surfaces not accessible to brushes shall be painted by spray, doubers, or sheepkin.
5.7.8 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be
ensured in the qualification trial.
5.8 Drying of Coated Surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered
dry for re-coating when another coat can be applied without the development of any film
irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat
should not exceed maximum specified for it as a first coat; if it exceeds the paint material has
possibly deteriorated or maxing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling,
blistering formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturer’s
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry
to the fullest extent practicable.
5.9 Spot Repair of Damaged Primer
5.9.1 Where pre erection shop primer has been damaged at isolated localized spots during handling
and transportation, or after erection / welding, the repair of damaged coating of pre-erection /
pre-fabrication or shop primer shall be done as given below and as per the Table 7.2 of this
specification.
5.9.2 Repair of damaged inorganic zinc silicate pre-erection / pre-fabrication or shop primer
(F9) after erection / welding in the design temperature of -90oC to 400oC and damaged
silicone aluminium (F-12) pre-erection / pre-fabrication or shop primer after erection /
welding for design temperature range of 401 – 550 °C.
Surface Preparation: Quickly remove the primer from damaged area by mechanical scraping
and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the
surface, if possible. Feather the primed surface over the intact adjacent surface surrounding
the damaged area by emery paper.
Primer coating: One coat of F-9 shall be applied wherever damage was observed on pre-
erection / pre fabrication or shop primer of inorganic zinc silicate coating (F-9). Similarly
one coat of F-12 shall be applied wherever damage observed on pre-erection / pre-
fabrication shop primer of silicone aluminium (F-12).
5.9.3 Wherever if damaged areas are found extensive and spread over large areas, then entire pre-
erection / pre-fabrication or shop primer shall be removed by blasting to achieve SSPC-SP-
10 then entire blasted surface shall be primed again with F-9 or F-12 as applicable for the
intended design temp. (See note under table 7.2).
Page 324 of 704

5.10 Paint Application
5.10.1 Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface
(SSPC-SP-10)
5.10.2 Shop priming / pre-erection priming with F9 or F12 shall be done only with airless spray.
5.10.3 Assessment of Painting Requirement
The paint system to be applied for a specific job shall be arrived at sequentially as given
below:
- Identify the environment from area classification details and chose the appropriate table.
- Identify the design temperature from the technical documents
- Identify the specific field paint system and surface preparation requirement from the above
identified table and temperature range.
- Identify the shop priming requirement from Table 7.1 based on compatibility of the above
paint system.
- Identify the need of repair of shop primer and execute as per Table 7.2.
5.11 Documentation / Records
5.11.1 A written quality plan with procedure for qualification trials and for the actual work
including test and inspection plan & procedure for approval before start of work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no of
coats and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness,
holiday detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
The coating applicator must maintain a job record consisting of all the information as per
5.11.2 -5.11.7 above as well as the approved procedure of work (5.11.1 above). The job
record consisting of information as required in accordance to 5.11.2 – 5.11.7 shall be entered
on daily basis and should be daily signed by Engineer-in-charge.
Page 325 of 704

TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL
Sl. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Manual or hand tool
cleaning
Removal of loose rust, loose ST.2 SSPC-SP-2 --

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

cleanliness. Removal of all clean surface can be
3.1 SA 3 SSPC-SP-5 NACE#1
visible rust. Mill scale, paint expected for prolong
& foreign matter 100% life of paint system.
cleanliness with desired
surface profile.
Near white metal The minimum
requirement for
Blast cleaning to near white chemically resistant
metal cleanliness, until at paint systems such as
least 95% of each element of epoxy, vinyl,
surface area is free of all polyurethane based
visible residues with desired and inorganic zinc
3.2 SA 2½ SSPC-SP-10 NACE#2
surface profile. silicate paints, also
for conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
Page 326 of 704

VARIOUS INTERNATIONAL
Sl. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Commercial Blast For steel required to
be painted with
Blast cleaning until at least conventional paints
two-third of each element of for exposure to
3.3 SA 2 SSPC-SP-6 NO.3
surface area is free of all mildly corrosive
visible residues with desired atmosphere for longer
surface profile. life of the paint
systems.
Brush-off Blast
Blast cleaning to white metal

3.4 cleanliness, removal of all SA 1 SSPC-SP-7 NO.4
visible rust, mill scale, paint
& foreign matter. Surface
profile is not so important
Page 327 of 704

6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on original printed
literature, along with the test certificate for all specified characteristics given in this
specification. All the paint materials shall be of first quality and conform to the following
general characteristics as per the tables 6.1, 6.2, 6.3 and 6.4.
PAINT MATERIALS
TABLE No. 6.1 PRIMERS
Sl. DESCRIPTION P-2 P-4 P-6 P-7

No.
Chlorinated Etch Epoxy zinc ZINGA,
rubber Zinc primer/wash phosphate primer LOCKTITE or
1 Technical name
Phosphate primer. primer ZRC
cold galvanizing
Single pack, air Two pack Two component One pack
drying chlorinated polyvinyl butyral polyamine cured Synthetic Resin
rubber based resin medium epoxy resin based zinc
medium cured with medium, galvanizing
2 Type and composition plasticised with phosphoric acid pigmented with containing min
unsaponifiable solution zinc phosphate. 92% of electrolytic
plasticizer, pigmented with zinc dust of
pigmented with zinc tetroxy 99.95% purity.
zinc phosphate. chromate.
3 Volume Solids % 40 ±3 10±1 50±1 37%
DFT (Dry Film
4 thickness) per coat in 40-45 8-10 40-50 40-50µ
microns
Theoritical covering
5 8-10 8-10 8-10 4m²/kg
capacity in M2/coat/ litre
Weight per litre in
6 1.3±0.05 1.2±0.05 1.4±0.05 2.67 kg at 15oC
kgs/litre
Touch dry at 30oC
7 30 minutes 2 hrs. After 30 min. 10 minutes
(minimum)
Hard dry at 30oC
8 8 hrs. 24 hrs. 8 hrs 24 hrs.
(maximum.)
9 Overcoating interval Min.: 8 hrs Min: 4-6 hrs. Min.:8hrs. Min.:4 hrs
Pot life at 30oC for two Not
10 Not applicable 6 - 8 hrs. Unlimited
component paints Applicable
Temperature (Resistance 60 oC NA 80oC 50oC
11
(minimum) Dry service Dry service Dry service Dry service
Page 328 of 704

PAINT MATERIALS
TABLE No. 6.2 FINISH PAINTS
Sl.
DESCRIPTION F-2 F-3 F-6A/B F-6C F-7
No
Acrylic Chlorinated High build coal
Epoxy-High Build Solvent less
1 Technical name Polyurethane rubber based tar epoxy
coating epoxy coating
finish paint finish paint coating.
Single pack F-6A Two-pack
Two pack, Two pack
plasticised Aromatic amine
cured with polyamide
Two-pack chlorinated cured epoxy resin
Amine cured epoxy
aliphatic rubber based medium suitably
Type and Adduct; resin blended
2 isocynate medium with pigmented.
composition catalyzed with coaltar
cured acrylic chemical and F-6B: polyamide
epoxy resin medium,
finish paint. weather cured epoxy resin
suitably suitably
resistant medium suitably
pigmented pigmented
pigments. pigmented
3 Volume Solids % 40 ± 3 38±2 60±3 99±1 65±3
DFT (Dry Film
4 thickness) per coat in 30-40µ 30-40 100-125µ 200-500 100-125µ
microns
5 capacity in 11-15 11-15 5-6 2-3 5.2-6.5
M2/coat/litre
Weight per liter in
6 1.15±0.03 1.15±0.03 1.42±0.03 1.40±0.03 1.40±0.03
kgs/litre
7 Touch dry at 30oC 30 minutes 30 minutes. 3 hrs. 3 hrs. 4 hrs.
Hard dry at 30oC
16 hrs
(max) 48 hrs
8 hrs
8 Full cure at 30oC (for 8 hrs 16 hrs
5 days
immersion/ high 5 days
temperature service)
Over-coating interval Min.12 hrs. Min.: Min.: Overnight Min.: 8 hrs. Min.: 24 hrs
9
at 30 oC Overnight Max.: 5 days Max.: 48 hrs. Max.: 5 days.
Pot life (approx.) at
6-8 hrs. Not
10 30oC for two 4-6 hrs 30 minutes 4-6 hrs.
applicable
component paints
Temperature 120oC(Dry
o o
Resistance 80 C 60 C service), 125oC
80oC
11 (minimum) Dry service Immersion 50oC Immersion
Dry service
min service (Immersion service
service)
Page 329 of 704

PAINT MATERIALS
Sl.
DESCRIPTION F-8 F-9 F-11 F-12
No
Self priming type Heat resistant
Heat resistant
surface tolerant synthetic medium
silicone
high build epoxy Inorganic zinc based two pack
1 Technical name Aluminium paint
coating (complete silicate coating Aluminium paint
suitable up to
rust control suitable up to
500oC dry temp.
coating). 250oC dry temp.
A two pack air
Two pack epoxy drying self curing
resin based solvent based
Heat resistant
suitable inorganic zinc Single pack
synthetic medium
pigmented and silicate coating with silicone resin
based two pack
2 Type & composition capable of minimum 80% zinc based medium
Aluminium paint
adhering to content on dry film. with Aluminium
suitable up to
manually The final cure of flakes.
250oC.
prepared surface the dry film shall
and old coating. pass the MEK rub
test.
3 Volume Solids % 78±3 60±3 38±0.03 20±2
DFT (Dry Film
4 thickness) per coat in 100-125 65-75µ 15-20µ 15-20µ
microns
5 capacity in M2/coat/ 6.0-7.2 8-9 10-12 8-10
litre
Weight per liter in
6 1.41±0.03 2.3±0.03 0.95±0.03 1.00±0.03
kgs/litre
Touch dry at 30oC
7 3 hrs. 30 minutes. 3 hrs. 30 minutes.
(maximum)
Hard dry at 30oC
(maximum) 24 hrs 12 12 hrs 24 hrs
8 Full cure 30oC (for
immersion /high 5days NA NA NA
temperature service)
Min.: 12 hrs .at
9 Over-coating interval Min.: 10 hrs Min. 24 hrs Min.: 24 hrs
20oC & 50 % RH
Pot life at 30oC for two
10 90 minutes. 4-6 hrs. Not applicable Not applicable
component paints
Temperature 80 oC 400 oC 250oC 500oC
11
Resistance (minimum) Dry service Dry service Dry service Dry service
Page 330 of 704

PAINT MATERIALS
Sl.
DESCRIPTION F-14 F-15 F-16 F-17
No
Ambient temperature
curing Poly Siloxane
Two-component Two component
coating/High build
Epoxy phenolic solvent free type
cold applied inorganic
coating cured with high build epoxy
copolymer based
Polyamine cured Polyamine adduct phenolic/novalac
1 Technical name aluminium coating
coal tar epoxy hardener system epoxy phenolic
suitable for under
(primer + coating cured with
insulation coating of
intermediate coat Polyamine adduct
CS and SS piping for
+ finish paint) hardener system
high temperature
service.
Two pack ambient Two component
Specially
temperature curing solvent free type
formulated Suitable for high
epoxy phenolic high build epoxy
polyamine cured temperature service
coating system phenolic/novalac
2 Type & composition coal tar epoxy and under insulation
suitable for epoxy phenolic
suitable for coating for CS, alloy
application under coating cured with
application under steel and SS
insulation of Polyamine adduct
insulation
CS/SS piping hardener system
3 Volume Solids % 70±3 70±3 60±2 98-100
DFT (Dry Film
4 thickness) per coat in 100-125 75-100 75-100 125- 150
microns
5 capacity in M2/coat/ 5-8 4-5 7.0- 9.0 6.5 - 8
litre
Weight per liter in
6 1.45±0.03 1.65±0.03 1.3 1.7
kgs/litre (mix paint)
Touch dry at 30oC
7 4 hrs 3 hrs 1 hr 2 hrs
(maximum)
Hard dry at 30oC
(maximum) 24 hrs 24 hrs 16 hrs 24 hrs
8 Full cure 30oC (for
immersion /high 168 hrs (7 days) 168 hrs (7 days) - 168 hrs (7 days)
temp. service)
Over-coating interval Min. 6 hrs Min. 36 hrs Min.16 hrs Min. 16 hrs
9
Max.5 days Max.21 days Max. Not applicable Max.21 days
Pot life at 30oC for
10 two component 4 hrs 4-6 hrs 1 hr 1 hr
paints
Temperature -45oC to 150oC
-45oC to 125oC
Resistance under insulation & Up to 6000C -45oC to 150oC for
11 under insulation
immersion (Note: 5) immersion service
And immersion
NOTES (for tables 6.1 to 6.4):
1 Covering capacity and DFT depends on method of application. Covering capacity specified above is theoretical. Allowing
the losses during application, min specified DFT should be maintained.
Page 331 of 704

2. All primers and finish coats should be cold cured and air drying unless otherwise specified.
3 All paints shall be applied in accordance with manufacturer's instructions for surface preparation, intervals, curing and
application. The surface preparation, quality and workmanship should be ensured. In case of conflict between this
specification and manufacturer’s recommendation, the same shall be clarified through EIL.
4 Technical data sheets for all paints shall be supplied at the time of submission of quotations.
5 F-16: Ambient temperature curing poly siloxane Coating or high build cold applied inorganic co-polymer based
aluminium coating. Inert polymeric matrix paint product with applicable temperature range of -180 to 650deg C is also
comes under this category
7.0 COATING SYSTEMS SELECTION CRITERIA
The coating system (External) should be selected based on the Plant location as given below:
Classification based on Plant Location:
a) Plant located in Inland area (more than 50 km from coast)

Environment Classification – Industrial
- For offsite areas : Table 9.0 to be followed
- For all UNITs, DM, CPP & Cooling Tower etc: Table 10.0 to be followed
b) Plant located on sea coast or within 50 km from sea coast;

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

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

done as per Table 7.2.
Page 332 of 704

TABLE 7.1: LIST OF PRIMERS & FINISH COATS COVERED IN TABLE NOS. 8 to 18.0
PRIMERS
P-2 Chlorinated rubber zinc Phosphate Primer
P-4 Etch Primer/Wash Primer
P-6 Two component Epoxy Zinc Phosphate Primer cured with polyamine hardener
Single pack, cold galvanizing compounds containing minimum 92% electrolytic zinc in dry film.
P-7
make ZINGA, LOCKTITE (of HENKEL) or ZRC
F-9 Two component Inorganic Zinc Silicate coating
FINISH COATS / PAINTS

F-2 Two component Acrylic – Polyurethane finish paint
F-3 Chlorinated Rubber finish paint
F-6A High Build Epoxy finish coating cured with polyamine hardener
F-6B High Build Epoxy finish coating cured with polyamide hardener
F-6C Solvent less Epoxy Coating cured with poly amine hardener
F-7 High build Coal Tar epoxy coating cured with polyamine hardener
F-8 Self priming surface Tolerant High Build epoxy coating. cured with polyamine hardener
F-11 Heat resistant synthetic medium based Aluminium paint
F-12 Two component Heat resistant Silicone Aluminium paint.
F-14 Specially formulated coal tar epoxy coating. cured with polyamine hardener
F-15 Two component Epoxy phenolic coating cured with Polyamine adduct hardener system
Engineered Epoxy poly Siloxane Coating or high build cold applied inorganic co-polymer based
F-16
aluminium coating
Two component solvent free type high build epoxy phenolic/novalac epoxy phenolic coating cured
F-17
with Polyamine adduct hardener system
Page 333 of 704

TABLE 7.2 REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER

AFTER ERECTION/WELDING
For all un-insulated CS, LTCS & low allow steel items in all Environments
Total DFT
Sl. Surface
Design Temp. in oC Coating System in Microns Remarks
No. Preparation
(min.)
7.2.1 -90 to 400 SSPC-SP-3 1 coat of F-9 65-75 See note

below and
7.2.2 401 to 550 SSPC-SP-3 1 coat of F-12 20 clause 5.9.3
NOTES:
1 The application and repair of pre-erection/pre-fabrication or Shop Primer given in above tables
shall be done for all the items to be painted. In case the damages of primer are severe and spread
over large area, entire primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces
to be primed again with F-9 or F-12 as applicable.
TABLE 8.0 COATING SYSTEM FOR GI HAND RAILS & GI ITEMS WHICH REQUIRE
COLOUR CODING- All locations
Design
Sl. Total DFT
Temp. in Coating System
No. o in Microns (min.)
C
Hot Dip Galvanizing * to 80-85 microns (600-610
80 microns of finish coat
gm/m2)as per IS 4759, 2629, 4736, 2633 +
8.1 Up to 60 (excluding the thickness of
1 coat of P-6 @ 40µ DFT/coat + 1 coat of F-2 @ 40
galvanizing )
microns DFT/coat
NOTES:
1 Galvanization thickness mentioned here is indicative. However Galvanization of respective

items shall be as per other Standards/Job specifications attached elsewhere in the contract.
2 Repair of the damaged area of galvanized coatings due to welding during erection shall be
carried out as per recommended practice IS 11759 using cold galvanizing spray process.
Organic Paint systems are not acceptable for repair.
3 After repair of damaged galvanized coating by Cold Galvanized, the repaired area shall be top
coated with paint system as given in Table 8.0 above (i.e., 1 coat of P-6 @ 40µ DFT/coat + 1
coat of F-2 @ 40µ DFT/coat).
4 Suggested Cold Galvanizing manufacturers are ZINGA, LOCKTITE or Z.R.C.
Page 334 of 704

TABLE 9.0 COATING SYSTEM FOR OFFSITE AREA (INLAND PLANTS)

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

Surface Preparation
Sl. Design (Post-erection / Field) Final DFT
& Pre-erection/Shop Remarks
No. Temp. oC in Microns
Primer Primer Finish Coat
(min.)
SSPC-SP-10; No over-coating
9.1 -90 to -15 1coat of F-9 @ None None 65-75 over F-9 is
65-75µ DFT/coat allowed
1 coat of F-6B@
SSPC-SP-10; 1 coat of
9.2 100 µ + 1 coat of
-16 to 80 1coat of F-9 @ P-6 @40 245-255
F-2 @ 40µ
65-75µ DFT/coat µ
DFT/coat
SSPC-SP-10; 2 coats of F-11 @
9.3 81 to 250 1coat of F-9 @ None 20µ DFT/coat; 105-115
65-75µ DFT/coat (2x20=40)
SSPC-SP-10; 2 coats of F-12 @
9.4 251 to 400 1coat of F-9 @ None 20µ DFT/coat 105-115
65-75µ DFT/coat (2x20=40) F-12 shall be
ambient
2 coats of F-12
SSPC-SP-10; temperature
@20-25µ
9.5 401 to 550 1coat of F-12 @ None 60-75 curing type
DFT/coat
20-25µ DFT/coat
(2x20=40)
* Flare line within unit or offsite areas shall be coated as per Clause 10.3 of Table 10.0, having
finish coat of 2 coats of F-12.
NOTES:
1 The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2 If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
3 In case of Paint systems as per Sl. Nos. 9.5 and 9.6, the color bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
4 All coating system including surface preparation, primer, and finish coat for piping shall be done
at field only.
Page 335 of 704

TABLE 10.0 COATING SYSTEMS FOR UNIT AREAS AS WELL AS DM, CPP,
COOLING TOWER OF INLAND PLANTS AND FOR ALL AREAS (UNIT,
OFFSITE, DM, CPP, etc.) OF COASTAL PLANTS
For external surfaces of un-insulated and above ground (atmospheric exposure) structures, piping,
vessels, equipments, external surface of MS chimney/stacks, RCC chimney, internal surface of MS
chimney without refractory lining, towers, columns, pumps, compressors, blowers etc. of carbon steel,
LTCS & low alloy steels (note-1)
Surface Preparation & Coating System Total DFT

Design Pre-erection/Shop (Post-erection / Field) in
Sl. Remarks
Temp. in oC Primer Microns
No. Primer Finish Coat
(min.)
SSPC-SP-10; a) No over-
10.1 -90 to -15 1coat of F-9 @ None None 65-75 coating to be
65-75µ DFT/coat done on
F-9 as it will
2 coats of F-6B lead to mud
@ 100 µ cracking.
DFT/coat + 1
SSPC-SP-10; 1 coat of P-6
coat of F-2 @ b) F-12 shall
10.2 -14 to 80 1coat of F-9 @ @ 40 µ 345-355
40µ DFT/coat; be ambient
65-75µ DFT/coat DFT/coat
(2x100 + 40= temperature
240) curing type
c) Finish coat
including
2 coats of F-12 primer
SSPC-SP-10; @ 20µ compatible
10.3 81 to 400 1coat of F-9 @ None DFT/coat 105-115 with finish
65-75µ DFT/coat 2x20=40 coat (i.e. field
primer) shall
be applied at
site only.
Finish
2 coats of F-12 coating is not
SSPC-SP-10; permitted at
@ 20µ
10.4 401 to 550 1coat of F-12 @ None 60 equipment
DFT/coat;
20µ DFT/coat manufacture
(2x20=40)
shop.
NOTES:
1. The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2. If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
Page 336 of 704

3. For external surface of MS chimney with or without refractory lining and for internal surface
without refractory lining, paint system as per 10.3 above shall be followed.
4. For external surface of RCC Chimney, 2 coats of F-6B @ 100µ DFT/coat to obtain total DFT of
200 µ shall be applied after proper surface preparation as per guidelines in 5.1.6.
5. In case of paint systems as per Sl. Nos. 10.3 and 10.4, the colour bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
6. All coating system including surface preparation, primer, finish coat for piping shall be done at
site/field only.
Page 337 of 704

TABLE 11.0 COATING SYSTEMS FOR EFFLUENT TREATMENT PLANT (ETP)

Sl. Design Temp. DFT in
Surface Preparation Remarks
No. in oC Primer Finish Coat Microns
(min.)
For External Surfaces of C.S./M.S. items: Screens, Walk way bridges, Baffles, Dual media filters,
11.1 Vertical pumps, piping in treated effluent sump, bio sludge pump, Screw pump and pump house, CS
tanks, sumps and vessels.
2 coats of
F-6A @100µ
DFT/coat + 1
1 coat of F-9
coat of F-2 @
-14 to 80 SSPS-SP-10 @ 65-75µ 305-315 -
40µ
DFT/coat
DFT/coat;
(2x100+40=2
40)
For Internal Surfaces of CS/MS Items: Bio-sludge sump, Filter feed sump, Process sump, Sanitary
11.2
sump, Transfer sump, Sludge, Slop oil tank, scrapping mechanism in Clarifier
3 coats of
1 coat of F-9
F-6A @100µ
-14 to 80 SSPS-SP-10 @ 65-75µ 365-375 Note:1
DFT/coat
DFT/coat.
(3x100=300)
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc. in
11.3
Process sump, TPI separator (Process and Oil), Aeration Tank and Transfer sump etc.
Epoxy screed
lining shall be
Blast cleaning to SSPC-SP
applied as per
guide lines and Acid
specific
-14 to 80 etching with 10-15% HCl Epoxy Screed lining 3mm
manufacturer
acid followed by thorough
and Engineer-
water washing.
in-Charge
instructions
C.S/M.S Dual media filters (Internal), Chemical dosing tanks(internal) such as Di-Ammonium
11.4
Phosphate (DAP) and Urea
Natural
Rubber lining
shall be
Natural Rubber Lining applied as per
Up to 60 SSPC-SP-10 (As per IS 4682, Part 1) 4.5mm specific
manufacturer
and Engineer-
in-Charge
instructions
NOTES
1. The paint /coating manufacturers shall provide their Quality control test certificate of coating
materials (F-6A) for immersion service of the exposed effluent given in 11.2.
Page 338 of 704

TABLE 12.0 EXTERNAL COATING SYSTEMS FOR UNINSULATED CARBON STEEL

AND LOW ALLOY STEEL STORAGE TANKS (For all plant locations, coastal
or inland)
All Process Units & Off-sites
Total
Surface Coating system (Field)
DFT
Sl. Design Temp. Preparation (see note 1 below) in Remarks
No. in oC (Field)
Microns
Primer Finish Coat (min.)
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tank including top
12.1
side of external and internal floating roof and associated external structural works.
F-6 should
2 coats of F-6B @
1coat of F-9 @ 65-75µ be suitable
100µ DFT /coat + 1
SSPC-SP-10 DFT/coat + 1coat of P-6 for
12.1.1 -14 to 80 coat of F-2 @ 40µ 345-355
@ 40µ DFT/ coat ; occasional
DFT/ coat;
water
immersion
1 coat of F-15 primer @ 1 coat of F-15 finish

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

105
DFT/ coat
1coat of F-9@ 65-75µ or
12.1.3 151 to 500 SSPC-SP-10 Or -
DFT/coat 115
1 coat of F-16 @ 50 µ
DFT / coat
12.2 External surfaces of bottom plate (soil side) for all storage tanks.
F-7 should
be suitable
for
SSPC-SP-10 1 coat of F-9 @ 3 coats of F-7@ 100µ immersion
12.2.1 -14 to 80 365-375
65-75µ DFT/ coat DFT/coat (3x100=300) service of
the
products
given
1 coat of F-15 primer @
80µ DFT/ coat + 1 coat
SSPC-SP-10 1 coat of F-15 finish
12.2.2 81 to 150 of F-15 intermediate 240 -
coat @ 80µ DFT/ coat
coat @ 80µ DFT/coat ;
(80+80=160)
1 coat of F-16 @ 125 µ 1 coat of F-16 @ 125 µ
12.2.3 151 to 550 SSPC-SP-10 250 -
DFT /coat DFT /coat
12.3 For underside of the bottom plate (in case tank is not lifted during PWHT) (see Note 2c)
Page 339 of 704

For CS Products
SSPC SP-6 from
Commercial JOTUN or
Blast HI-TEMP
2 coats of inert
-180 to 650 1 coat of inert polymeric coatings or
12.3.1 polymeric matrix 350-400
For SS matrix coating @ 125 µ SK
coating @ 125 µ
SSPC SP-1 FORMULA
with non- TIONS are
chloride recommend
solvent ed.
NOTES
1. All paint coating application including primer for tankage shall be carried out at field after
erection and completion of all welding.
2. For underside of bottom plate :

a) Painting shall be carried out before laying of bottom plate for tanks with Non-Post Weld
Heat Treatment (PWHT).
b) For tanks with PWHT, painting shall be carried out after PWHT.
c) In case tank is not lifted during PWHT then painting shall be applied before laying of
bottom plate, clause no. 12.3.1 shall be followed.
Caution: PWHT temperature shall not exceed 650oC.
Page 340 of 704

TABLE 13.0 INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY
STORAGE TANKS & VESSELS
All Process Units & Off-sites

Coating system (Field) Total
Surface
(see note 1 below) DFT
Sl. Design Preparation
in Remarks
No. Temp. in oC (Field)
Primer Finish Coat Microns
(min.)
PETROLEUM PRODUCTS & INTERMEDIATES like LDO, HSD , GAS OIL, FEEDS of
FCC-PC, FCC-LCO, VGO-HDT, ISOM, DHDT, REFORMATE, DCU, NHT & GASOLINE,
NAPHTHA, ISOMERATE AND KEROSENE.
13.1
Underside of Floating roofs, internal surface of cone roof, inside of bottom plate, internal surfaces of
Bare shell for full height, underside of floating roof, oil side surfaces of deck plates, oil side surfaces of
pontoons, support structures and ladders etc.
13.1. 1 coat of F-9 @
-14 to 45 SSPC-SP-10 - 75 Note 2
1 75 µ DFT/coat
1 coat of F-15
intermediate coat @
13.1. 1 coat of F-15 primer @
46 to 90 SSPC-SP-10 80µ DFT/coat + 1 coat 240-300 -
2 80µ DFT/ coat
of F-15 finish coat @
80µ DFT/ coat;
POTABLE, SERVICE AND FIRE WATER
13.2
All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
2 Coats of F-6A @
13.2. 1 Coats of P-6 @
-14 to 60 SSPC-SP-10 100µ DFT/ Coat; 300-350 Note-4
1 100 µ DFT/coat;
(2x100=200)
DM WATER & CONDENSATES
13.3
2 coats of F-6C @
13.3. 1 Coats of P-6 @
-14 to 60 SSPC-SP-10 200µ DFT/ coat; 400-450 -
1 100µ DFT/coat;
(2x200=400)
1 coat of F-15
intermediate coat @
13.3. 1 coat of F-15 primer @ 80µ DFT/coat + 1 coat
61 to150 SSPC-SP-10 240-300 -
2 80µ DFT/ coat of F-15 finish coat @
80µ DFT/ coat;
(80+80=160)
HYDROCHLORIC ACID (HCl) 10 %
13.4
13.4.
-14 to 60 SSPC-SP-10 None Natural Rubber Lining 4.5 mm -
1
AGGRESSIVE SOLVENTS LIKE HEXANE, HEXENE, BENZENE, XYLENE AND TOLUENE
13.5
13.5. 1 coat of F-9 @ 75µ

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

13.6
Internal shell-full height, bottom plate, underside of roof and all accessories
Page 341 of 704

Amercoat
3 coats of vinyl
23 or
chloride co-polymer
13.6. equivalen
All SSPC-SP-10 None AMERCOAT 23 @ 225
1 t suitable
75µ /Coat;
for the
(3x75=225)
service
13.7 Inside pontoon and inside of double deck of all floating roofs
13.7. 1 coat of F-8 @ 100µ 1 coat of F-8 @ 100µ
-14 to 80 SSPC-SP-3 200 -
1 DFT/coat DFT/coat
WET SLOPS, AMINE solutions, SOUR WATER , WATER DRAW OFF
13.8
1 coat of F-15
intermediate coat @
13.8. 1 coat of F-15 primer @ 80µ DFT/coat + 1 coat
-14 to 90 SSPC-SP-10 240 -
1 80µ DFT/ coat of F-15 finish coat @
80µ DFT/ coat;
(80+80=160)
VACUUM RESIDUE, FUEL OIL , DRY SLOP, BITUMEN AND OTHER HIGH TEMPERATURE
HYDROCARBON LIQUIDS
13.9 Underside of floating roof, internal surface of cone roof, bottom plate, inside of bare shell – including
wetted and non wetted surfaces, oil side surfaces of deck plates, oil side surfaces of pontoons, roof
structures, structural steel and ladders
1 coat of F-17
intermediate coat @
13.9. 1 coat of F-17 primer 125µ DFT/coat + 1 coat
Up to 150oC SSPC-SP-10 375 Note:3
1 @ 125µ DFT/ coat of F-17 finish coat
@125µ DFT/ coat;
(125+125=250)
ALKALIS UP TO 50 % CONCENTRATION
13.10
2 Coats of F-6 A @
13.10 1 coat of F-15 primer @
Up to 60oC SSPC-SP-10 100µ DFT/coat; 280-100 -
.1 80µ DFT/ coat
(2x100=200)
NOTES
1. All paint coating application including primer shall be carried out after erection and completion
of all welding work at site.
2. F-6A should be suitable and resistant for immersion service for the respective Hydrocarbons.
3. This system can be used where maximum operating temperature is below 150oC and design
temperature is up to 200oC. Cases of operating temperature > 150oC are not covered in this spec,
such cases shall be covered in separate job specifications.
4 F-6 A shall be suitable for drinking water service and should have competent authority
certification.
Page 342 of 704

TABLE 14.0 COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND

CARBON STEEL PLANT PIPING AND UNDERGROUND VESSELS
Surface Coating system (Field)1 Total Final

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

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

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

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

14.3.3 151 to 400 --- 250 -
primer @ coat @125µ DFT/ coat
125µ DFT/
coat
1 Primer & Field painting including priming shall be in accordance with applicable
SOR/MR/PRs.
Page 343 of 704

TABLE 15.0 COATING SYSTEMS FOR UNDER INSULATION (COASTAL OR INLAND

PLANTS)
ALL UNITS AREAS & OFF-SITES
For insulated Piping, Equipments, Storage vessels, tanks, Columns etc of Carbon Steel, LTCS, Low
Alloy Steel & Stainless Steels
Paint system (Field)3 Total Final
Sl. Design Surface Preparation & DFT
No. Temp. in oC Pre-erection/Shop Primer 3 Primer Finish paint in Microns
(min.)
15.1 Carbon steel, LTCS and low allow steel Piping, Storage tanks, vessels, equipments etc
3 coats of F-15 @ 75µ
SSPC-SP-10;
DFT/coat
15.1.1 -45 to 125 1coat of F-9 @ None 305- 315
75µ DFT/coat
SSPC-SP-10;
1coat of F-9 @ 125-135
65-75µ DFT/coat for up to 400 oC 3 coats of F-12 @ 20µ
15.1.2 126 to 400 None DFT/coat
1 coat of F-12 @20µ DFT/coat for
400-450 oC 80-100
15.2 Stainless Steel, Alloy Steel, Alloy-20 Piping, Vessels &Equipments (Note:2)
1 coat of F-15
Sweep blasting/Light Blast clean
intermediate coat @
as per grade Sa-1.0, of Swedish
80µ DFT/coat + 1 coat
15.2.1 -30 to 125 Standards SIS-05-5900 (Latest) None 240
of F-15 finish coat @
(15-25µ surface profile)
80µ DFT/coat;
1 coat of F-15@ 80 µ DFT/coat
(80+80=160)
1 coat of F-16@ 125μ

15.2.2 126 to 500 1 coat of F-16@ 125μ DFT/coat None 250
DFT/coat
SSPC-SP-10
Inert polymeric matrix coating*@
125µ DFT/coat 2 coats of Inert polymer
for SS sweep blasting/Light Blast matrix coating* @
15.2.3 500-650 --- 375
clean as per grade Sa-1.0, of 125µ DFT/coat
Swedish Standards SIS-05-5900
(Latest)
15.3 Cyclic service of CS, LTCS, SS, & Alloy Steels
SSPC-SP-10
Inert polymeric matrix coating*@
125µ DFT/coat 2 coats of Inert polymer
for SS sweep blasting/Light Blast matrix coating* @
-180 to 650 none 250
clean as per grade Sa-1.0, of 125µ DFT/coat
Swedish Standards SIS-05-5900
(Latest)
NOTES
* Alternatively Thermally Sprayed Aluminium (TSA) @500 µ is acceptable up to 500deg C.

JOTATEMP-650 or equivalent are acceptable.
Page 344 of 704

1. The blast cleaning abrasives for SS and Alloy steel surfaces shall be SS grits/shots or Aluminium oxide
grits/shots.
2. For piping with cyclic temperature of -45 to125 deg.C Sr.No 15.2.1 is applicable.
3. Application of Primer, field paint & repair shall be in accordance with applicable SOR/MR/PRs.
TABLE 16.0 COATING SYSTEM FOR CARBON STEEL COMPONENTS OF COOLERS /

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

Surface Preparation
Sl. Design (Post-erection / Field) Final DFT
No. Temp. in oC in Microns
Primer Primer Finish paint
(min.)
1 coat of F-15 2 coats of F-15 @
16.1 Up to 80 oC SSPC-SP-10 240 -
@ 80 microns 80µ DFT/coat;
1 coat of Glass
Fibre Reinforced
16.2 80 to 140 SSPC-SP-10 --- 1500 -
Novolac epoxy of
1.5 mm DFT
TABLE 17.0 COATING SYSTEM (INTERNAL PROTECTION) FOR GALVANIZED OR

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

Surface Preparation
Sl. Design (Post-erection / Field) DFT
No. Temp. in oC in Microns
Primer Primer Finish paint
(min.)
1 coat of F-15 @ 1 coat of F-15 @
17.1 Up to 80 Sweep Blasting 160 -
80µ DFT/coat; 80µ DFT/coat;
1 coat of Glass
Fibre Reinforced
17.2 80 to 140 Sweep Blasting --- 1500 -
Novolac epoxy of
1.5 mm DFT
18.0 STORAGE
18.1 All paints and painting materials shall be stored only in rooms to be arranged by contractor
and approved by Engineer-in-charge for the purpose. All necessary precautions shall be
taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word “PAINT STORAGE – NO NAKED LIGHT –
HIGHLY INFLAMABLE” shall be clearly displayed outside. Manufacturer’s
recommendation shall be followed for storage of paint materials.
19.0 PAINT COLOUR CODE FOR PIPING AND EQUIPMENT
This specification covers the requirement of colour scheme for the identification of the
contents of the pipelines carrying fluids, storage tanks and equipment in refineries. The
following colour coding system has been made based on BPCL-KR input document
Page 345 of 704

19.1 IDENTIFICATION
The system of colour coding consists of a ground colour and secondary colour bands
superimposed over the ground colour. The ground colour identifies the basic nature of the
service and secondary colour band over the ground colour distinguishes the particular service.
The ground colour shall be applied over the entire length of the un-insulated pipes. For
insulated lines ground colour shall be provided as per specified length and interval to identify
the basic nature of service and secondary colour bands to be painted on these specified length
to identify the particular service. Above colour code is applicable for both unit and offsite
pipelines.
The following ground colour designation for identification of basis classification of various
important services shall be followed.
Post Office Red Fire protection materials

Off White / Aluminium Steam (all pressures)
Canary Yellow Chemicals and dangerous materials

Dark Admiralty Grey Crude oil, lube oil
Orange Volatile petroleum products (motor sprit and lighter)
Oxide red Non-Volatile petroleum products (kerosene and heavier,
including waxy distillates and diesel, gas oil)
Black Residual oils, still bottoms, slop oils and asphalts, fuel oil
Sky blue Water (all purities and temperatures)
Sea green Air and its components and Freon
Secondary colours: The narrow bands presenting the secondary colour which identifies the
specific service may be applied by painting or preferably by use of adhesive plastic tapes of
the specific colour.
19.2 COLOUR BANDS AND IDENTIFICATION LETTERING
19.2.1 The following specifications of colour bands shall be followed for identifying the piping
contents, size and location of bands & letters. The bandwidth and size of letters in legends will
depend to some extent upon the pipe diameter. Either white or black letters are selected to
provide maximum contrast to the band colour. Bands usually are 100 mm wide and regardless
of band width, are spaced 50 mm apart when two bands are employed.
Colour bands and size of lettering for piping:
Outside diameter of pipe Width of colour bands in Size of legend Letters in

or covering in mm mm mm
19 to 32 200 13
38 to 51 200 19
64 to 150 300 32
200 to 250 600 64
Over 250 800 89
Page 346 of 704

Contrast shall be provided between color field and legend for readability. Use of letters
standard style, in sizes, 1/2inch (13mm) and larger, is recommended. See above table for
specific size recommendations. For identification of materials in pipes of less than ¾ inch
(19mm) in diameter, and for valve and fitting identification, the use of permanently legible tag
is recommended.
In addition, ground colour as per specified length should be provided on insulated piping for
easy identification of nature of fluid, on which the colour bands should be painted for
identification of each service. The length of the ground colour should be 3 times the width of
normal bands or 2 meters, whichever is suitable depending on the length of the pipe.
Arrows shall be used to indicate direction of flow. Where flow can be in both directions,
arrows in both directions shall be displayed.
Positive identification of the contents of a piping system shall be by lettered legend, giving the
name of the contents in full or abbreviated form. Contents shall be identified by a legend with
sufficient additional details such as temperature, pressure, etc as are necessary to identify the
hazard. Legends shall be brief, informative, pointed and simple of greatest effectiveness.
Legends shall be applied close to valves or flanges and adjacent to changes in direction,
branches and where pipes pass through walls or floors, where it enters and emerges from road,
culvert and walkway overpasses, unit battery limits and at every 50m intervals on straight pipe
runs sufficient for identification. Identification may be accomplished by stencilling, the use of
tape, or markers. In any situation, the number and location of identification markers shall be
based on the particular piping system.
The letters will be in black on pipes painted with light shade colours and white on pipes
painted with dark shade colours to give good contrast.
Only writing of service name shall be done on stainless steel lines. Precautions should be taken
while painting by using low chloride content painting to avoid any damage to the stainless
steel pipes. It is preferable to use adhesive plastic tapes to protect stainless steel pipes.
Visibility:
Attention shall be given to visibility with reference to pipe markings. Where pipelines are
located above or below the normal line of vision, the lettering shall be placed below or above
the horizontal centreline of the pipe.
Size of letters stencilled / written for equipment shall be as given below:
Column and vessel : 150

mm (Height)
Pump, compressor and other machinery : 50 mm (Height)
In addition, the contents of the pipe and/or direction of flow may be further indicated by
arrows and legend. If a hazard is involved it must be identified clearly by legend.
Colour bands: The location and size of bands, as recommended, when used, shall be
applied to the pipe.
- On both sides of the valves, tees and other fittings of importance.

- Where the pipe enters and emerges from walls and where it emerges from road &
walkway overpasses, unit battery limits.
Page 347 of 704

- At uniform intervals along long sections of the pipe.

- Adjacent to tanks, vessels and pumps.
Colour band specification:
a) Bands at intervals of 50 meters for the long stretch of pipelines

b) Each pipe segment will have minimum one band indication, irrespective of length.
c) The bands shall also be displayed near walkways, both sides of culverts, tanks dykes,
tanks, vessels, suction and discharge of pumps / compressors, unit battery limit, near
valves of line, etc.
For alloy steel / stainless steel pipes and fittings in stores / fabrication yard, colour band
(Minimum ½” wide) should be applied along the complete length of pipe, bends / tees, side-
covered surface (on thickness) of flanges as well as valves as per the metallurgy.
Unusual or Extreme situations
When the piping layout creates or occurs in a limited area of inaccessibility or of extreme
complexity, such segments of layouts may require substitute techniques shall be limited to
such segments and shall not deviate from the concept of identification as defined above.
The specification for application of the complete Piping identification colour code, including
base and bands colours, are presented in the below table.
Sl. FIRST COLOUR SECOND

SERVICE GROUND COLOUR
No. BAND COLOUR BAND
I WATER
01 Drinking Water Sea Green French Blue Signal Red
02 DM Water Sea Green Gulf Red
03 Cooling Water Sea Green French Blue
04 Boiler Feed Water Sea Green Gulf Red
05 Steam Condensate Sea Green Light Brown
06 Raw Water Sea Green Oxide Red
07 Tempered Water Insulated With Green Band
08 Sour Water Sea Green Yellow
09 Stripped Water Sea Green Gulf Red
10 Fire Water Fire Red
11 Wash Water Sea Green Canary Yellow
12 ETP Treated water Sea Green Canary Yellow Canary Yellow
II STEAM
01 Very High Pressure Steam Aluminium To IS 2339 Signal Red
02 High Pressure Steam Aluminium To IS 2339 French Blue
03 Medium Pressure Steam Aluminium To IS 2339 Gulf Red
04 Low Pressure Steam Aluminium To IS 2339 Canary Yellow
05 Very Low Pressure Steam Aluminium To IS 2339 Grey
06 Low Medium Pressure Steam Aluminium To IS 2339 Light Brown
07 Condensate Aluminium To IS 2339 Grey Canary Yellow
Page 348 of 704

III AIR/OTHER GASES

01 Process Air Sky Blue Signal Red
02 Plant Air Sky Blue Silver Grey
03 Instrument Air Sky Blue French Blue
04 Nitrogen Canary Yellow Black
05 Oxygen Canary Yellow White
06 Freon Canary Yellow Light Grey Dark Violet
07 Sweet Fuel Gas Canary Yellow Grey
08 Sour Fuel Gas Canary Yellow Grey Dark Violet
09 Acid Gas Orange Grey
10 H2S Canary Yellow French Blue
11 Hydrogen Canary Yellow Signal Red French Blue
IV CHEMICALS
01 Caustic Smoke Grey Light Orange
02 Chlorine Canary Yellow Dark Violet Light Orange
03 Ammonia Canary Yellow Dark Violet
04 Corrosion Inhibitor Yellow Aluminium
05 Sulfolane Azure Blue Yellow
06 Mono Ethanol Amine Light Yellow Brown
07 Lean DEA Light Yellow Blue
08 Rich DEA Light Yellow Red
09 Lo-Cat Solution Canary Yellow Smoke Grey
10 Anti-Foam Light Yellow Grey
11 De-Mulsifier Light Yellow Black
12 DMDS Black Gulf Red
V HYDROCARBONS
01 LPG Dark Ad. Grey Brilliant Green Dark Violet
02 Naphtha Dark Ad. Grey Light brown Black
03 Benzene Dark Ad. Grey Canary Yellow
04 Toluene Orange Blue Green
05 Reformate Dark Ad. Grey Blue
06 LAN (Low Aromatic Naphtha) Dark Ad. Grey Brilliant Green
07 Mixed Aromatic Solvent Orange Brilliant Green
08 Motor Spirit (MS) Orange Blue
09 Heavy Naphtha Light Brown Brilliant Green Red
10 Kerosene Light Brown Brilliant Green Dark Violet
11 LGO (Light Gas Oil) Light Brown Brilliant Green
12 HGO (Heavy Gas Oil) Light Brown Brilliant Green
13 High Speed Diesel Light Brown Brilliant Green
14 ATF (Aviation Turbine Fuel) Light Blue White
15 VDO (Vacuum Diesel Oil) Light Brown Brilliant Green
16 VGO (Vacuum Gas Oil) Steel Grey Red
17 Slop Distillate Steel Grey Black Red
18 VR (Vacuum Residue) Steel Grey Black Green
Page 349 of 704

19 Slop Steel Grey Black

20 Crude Oil Light Brown Yellow
21 Fuel Oil Steel Grey Yellow
22 Flushing Oil Light Brown Yellow
23 Flare Line Heat Resistant Aluminium
24 Reduced Crude Oil Steel Grey Black Signal Red
25 LCO (Light Cycle Oil) Light Brown Brilliant Green Yellow
26 HCO (Heavy Cycle Oil) Light Brown Brilliant Green Light Orange
27 CLO (Clarified Oil) Steel Grey Black French Blue
28 Propylene Dark Ad. Grey Signal Red Black
29 Reject Olefin Dark Ad. Grey Light Grey French Blue
30 Butane Dark Ad. Grey Signal Red Light Brown
31 Iso Butylene Dark Ad. Grey Brilliant Green Gulf Red
32 SBPS Dark Ad. Grey White Gulf Red
33 MTO Light Blue Green
34 Bitumen Dark Grey Signal Red Brilliant Green
35 HAN Dark Ad. Grey Brilliant Green
36 Heavy Kerosene Light Blue Black
37 RLNG Canary Yellow Signal Red Light Brown
Sl. No. . SERVICE RECOMMENDED COLOUR CODE

VI INSULATED HYDROCARBON PIPING
01 IFO Supply 1 Black ground colour with 1 yellow band in centre
02 IFO Return 1 Black ground colour with 1 green band in centre
03 HPS 1 Black ground colour with 1 red band in centre
04 Bitumen 1 Black ground colour with 2 red band in centre
05 CLO 1 Black ground colour with 1 brown band in centre
06 VB Tar 1 Black ground colour with 2 brown band in centre
07 VR AM (Bitumen / VBU Feed) 1 Black ground colour with 1 blue band in centre
08 VR BH 1 Black ground colour with 2 blue band in centre
09 VAC Slop 1 Black ground colour with 1 white band in centre
10 Slop 1 Steel grey ground colour with 1 black band in centre
11 Crude Sweet 1 Light brown ground colour with 1 yellow band in centre
12 Crude Sour 1 Light brown ground colour with 1 orange band in centre
13 VGO / HCU Feed 1 Oxide red ground colour with 1 steel grey band in centre
14 OHCU Bottom / FCCU Feed 1 Oxide red ground colour with 2 steel grey band in centre
VII UNINSULATED EQUIPMENT, TANKS AND STRUCTURES

01 Heater Structure Dark Admiralty Grey
02 Heater Casing Heat Resisting Aluminium
03 Vessels & Columns Aluminium
Page 350 of 704

04 Hydrogen Bullets Pink

05 LPG Vessels White (Reflective Paint)
06 SO2 Canary Yellow
07 Heat Exchangers Heat Resisting Aluminium
08 FO Tank & Hot Tanks Black
09 All Other Tanks Aluminium / Off White
10 Caustic / Amine / Acid Tanks Golden Yellow
11 Sour Water Sky Blue
12 Outer Surface In Boiler House Heat Resisting Aluminium
13 Compressors & Blowers Dark Admiralty Grey
14 Pumps Navy Blue
15 Motors & Switch Gear Bluish Green
Hand Railing - Hand Railing Middle Rail,
16.1 Signal Red
Toe Plate
16.2 Hand Railing – Vertical Post Black
17.1 Ladder - Rungs Black
17.2 Ladder – Vertical & Cage Signal Red
18 Load Lifting Equipment & Mono Rails Etc. Leaf Brown
19 Steel Structure Dark Admiralty Grey
19.3 PAINTING COLOUR CODE FOR STRUCTURAL STEEL
1. GANTRY GIRDER & MONORAIL DARK GREEN
2. GANTRY GIRDER & MONORAIL STOPPER SIGNAL RED
3. BUILDING STRUCTURAL STEEL COLUMNS, DARK ADMIRALITY

BRACKETS, BEAMS, BRACINGS, ROOF TRUSS, GREY
PURLINS, SIDEGIRTS, LOUVERS, STRINGERS
4. PIPE RACK STRUCTURE & TRESTLES DARK ADMIRALITY

GREY
5. CHEQUERED PLATE (BOTH FACES) BLACK
6. GRATING GALVANSIED
7. LADDER RUNGS – BLACK

VERTICALS & CAGE – RED
8. HAND RAILINGS
- HANDRAIL, MIDDLE RAIL, TOE PLATE SIGNAL RED
- VERTICAL POST BLACK
Page 351 of 704

20.0 IDENTIFICATION OF VESSELS, PIPING ETC
20.1 Equipment number shall be stencilled in black or white on each vessel, column, equipment &
machinery (insulated or uninsulated) after painting. Line number in black or white shall be
stencilled on all the pipe lines of more than one location as directed by Engineer-In-Charge;
Size of letter printed shall be as below:
Column & Vessels - 150mm (high)

Pump, compressor & other machinery - 50mm (high)
Piping - 40-150 mm
20.2 Identification of Storage Tanks
The storage tanks shall be marked as detailed in the drawing.
21.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS:
Following items shall be painted for camouflaging if required by the BPCL

a. All Columns
b. All tanks in Offsites
c. Large Vessels
d. Spheres
21.2 Two coats of selected finishing paint as per defense requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
21.3 Method of Camouflaging
21.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all
matte finish).
Dark Green Light Green Dark Medium Brown

5 : 3 : 2
21.3.2 The patches should be asymmetrical and irregular.
21.3.3 The patches should be inclined at 30º to 60º to the horizontal.
21.3.4 The patches should be continuous where two surfaces meet at an angle.
21.3.5 The patches should not coincide with corners.
21.3.6 Slits and holes shall be painted in dark shades.
21.3.7 Width of patches should be 1 to 2 meters.
22.0 SELECTION OF PAINTING MATERIALS
Paint manufacturers are expected to conduct periodic evaluation/testing of products including

long term performance tests which shall include following
-Resistance to Moisture vapour permeability for 2000h (ASTM 2247)
Page 352 of 704

-Cyclic tests for 4200h (ISO7253 & ASTM D 5894-10)

-Resistance to DM water immersion (ASTM D870)
- Chemical Resistance test, ASTM D 1308/D 543/DIN 50905 Part4
-Water vapor transmission, ASTM D1653 & test method B section A -wet cup method,
3 weeks duration
Contractor shall submit MAR (Material Approval Request) along with datasheets, MSDS,
relevant information and Test results as indicated below including test results of long term
tests for all paint products against system indicated for approval.
Test Test Method

Specific gravity ASTM D 1475
Dipping properties ASTM D 823
Film characteristics -
Solids content by weight ASTM D 2369
Drying time ASTM D 1640
Flexibility ASTM D 1737/ D 522
Hardness ASTM D 3363
Adhesion ASTM D 2197
Abrasion resistance ASTM D 968/ D 1044
DFT/coat As per SSPC guidelines
Storage Stability ASTM D 1849
100% Humidity test, duration 2000 hrs, ASTM D 2247
% Zn in Dry film for Inorganic Zinc ASTM D 521
Silicate primer
Chemical Resistance test ASTM D 543
- 10% & 40% NaOH (applicable only for F-6A F-6C,F-7,
F-14, F-15 and F-17)
- 10% H2SO4 (applicable only for F-6A F-6C,F-7, F-14,
F-15 and F-17)
- 10 % Nitric Acid test (applicable only for F-15 and F-
17)
- Xylene, Acetone, Ethanol, Kerosine (applicable only for
F-6A, F-6C, F-9, F-15 and F-17)
- Sea water (applicable only for F-6A, F-6C, F-7, F-14,
F-15, F-17)
- 5% Ammonium sulphate and 5% Ferric
Chloride(applicable only for F-6A, F-6C, F-7, F-8, F-
13, F-14, F-17)
- Glacial acetic acid (applicable only for F-15 and F-17)
- MIBK test (applicable only for F-2, F-6 A/B/C, F-8, F-
9, F-15 and F-17)
Cyclic Test for the duration of 4200 h ISO 7253, ASTM 5894
Salt spray: 72h;Drying in air:16 h;
UV-A 340 nm weatherometer: 80 h
One cycle: 168 h
(25 cycles at 168 hours each cycle) (Applicable for all
except P2, F16, F11, F12, F14)
Resistance to water immersion (applicable only for F11, ASTM D 870
F12, F15, F16, F17)
Dry Heat Resistance test ASTM D 2485
Page 353 of 704

(Method B-applicable only for F-

9,F11,F12,F15,F16,F17)
(Method A- applicable only for P6, F2,F-6A/B/C,F7,F14)
Water vapor transmission, & test method B section A - ASTM D 1653
wet cup method, 3 weeks duration (applicable only for
F9, F11, F12, F16)
Thermal shock resistance test ASTM D 2485 - 91
(only for F-9, F-6, poly-siloxane)
The contractor shall be fully responsible for the quality of the paints meeting technical
requirements of the products as per approved datasheets. Along with the delivery of the paint
products, the contractor shall furnish batch wise test report from the manufacturer.
Once the paint material is supplied to site, In addition to the quality control system as
specified in section 13.0, for each product, the supplier shall organize random sampling and
testing in a third party laboratory as per discretion of the Engineer-in-charge. Failing to meet
the specified quality requirements may cause rejection of the paint products.
23.0 QUALITY CONTROL, INSPECTION AND TESTING
23.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and shall be
accompanied by manufacturer's test certificates. Paint formulations without certificates are not
acceptable (see section 12.0).
The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as follows:
(a) Surface preparation

(b) Primer application
(c) Each coat of paint
23.2 During surface preparation, following tests are to be carried out:
- Test for presence of oil/grease and contamination
The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following
procedure to validate absence of oil and grease contamination.
a) Visual inspection - Continue degreasing until all visible signs of contamination are
removed.
b) Conduct a solvent evaporation test by applying several drops or a small splash of
residue-free tri-chloromethane on the suspect area especially pitting, crevice corrosion
areas or depressed areas. An evaporation ring formation is indicative of oil and grease
contamination.
Continue degreasing and inspection till test is passed.
- Tests for surface finish of blasted surface shall be done by visual inspection using SSPC-
VIS1. Clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of
dust on blasted surface. Checks shall be done on each component at least once per 200
m2 of blasted surface and minimum of 3 checks per shift.
Page 354 of 704

- Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt
content shall be considered 20 mg/m2 (2 mg/cm2). Checks shall be done on each
component at least once per 200 m2 of blasted surface and minimum of 3 checks per
shift. In case salt exceeds specified limit, the contaminated surface shall be cleaned by
method as per Annexure-C of IS 12944-4 (water cleaning). After cleaning surface shall
be retested for salt after drying.
- Blast Profile Measurement:
The angular profile depth measurement shall be done by profile tape as per method
NACE Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer).
Spot measurement shall be carried out every 15m2 of blasted surface. At each spot three
measurements shall be taken over an area of 10 cm2 and average of measurements to be
recorded and reported.
If profile is <65 microns blasting shall continue till greater than 65 microns depth profile
is achieved.
- Tests for blasting media, blasting air
Blasting Media (For every fresh batch of media and one random test during blasting)
Blasting Media shall be visually inspected for absence of contamination and debris using
10 X magnification.
a) Inspection for the absence of oil contamination shall be conducted using following
procedure:
- Fill a small clean 200 ml bottle half full of abrasive.
- Fill the bottle with potable water, cap and shake the bottle.
- Inspect water for oil film/slick. If present, the blasting media is not to be used.
b) Soluble salt contamination if suspected shall be verified by method ASTM D 4940.

If present, media to be replaced.
c) Clean blasting equipment, especially pot and hoses, and then replace blasting media
and retest.
Test for Blasting Air (Once Daily before start of blasting and once at random during
blasting)
The air for blasting shall be free from moisture and oil. The compressor air shall be
checked for oil and water contamination per ASTM D 4285.
In addition to above, record should include type of shop primer already applied on equipment
e.g. zinc silicate, or zinc rich epoxy, or zinc phosphate.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be responsible
for making good any defects found during final inspection/guarantee period/defect liability
period as defined in general condition of contract. Dry film thickness (DFT) shall be checked
and recorded after application of each coat and extra coat of paint should be applied to make-
Page 355 of 704

up the DFT specified without any extra cost to owner, the extra coat should have prior
approval of Engineer-in-charge.
23.3 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
The shades of successive coats should be slightly different in colour in order to ensure
application of individual coats, the thickness of each coat and complete coverage should be
checked as per provision of this specification. This should be approved by Engineer-In-
Charge before application of successive coats.
The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile, gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector & protector whenever required for
checking in case of immersion conditions.
Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The thickness of
paint on test panels shall be determined by using gauge such as 'Elko meter'. The thickness of
each coat shall be checked as per provision of this specification. This shall be approved by
Engineer-In-Charge before application of paints on surface of chimney.
At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and without
any obligation to the owner, as it would be in the interest of the manufacturer to ensure that
both surface preparation and application are carried out as per their recommendations. The
contractor is responsible to arrange the same.
23.4 Final inspection of finished coating shall consist of measurement of:

1) Paint dry film thickness (DFT)
2) Adhesion
3) Holiday detection check as well as for finish and workmanship.
1) Coating DFT measurement shall be as per ISO 2808. Type II electromagnetic gauges
should be used for ferrous substrates. DFT gauge calibration, number of measurement
shall be as per SSPC-DA 2. Measured DFT shall be within + 10% of the dry film
thickness, specified in the specifications.
2) Adhesion of the primer to the steel substrate and intercoat adhesion of the subsequent
coat(s) after curing for at least a week after application of the topcoat shall be examined by
a knife test in accordance with ASTM D 6677. For the knife test, if the rating is better than
8, the adhesion is considered acceptable. The adhesion is destructive and tested areas shall
be repaired afterward using the spot repair procedure. Alternatively, the applicator may
perform the adhesion test on a steel panel coated using the same surface preparation and
coating application procedure as the work piece. Adhesion testing shall be carried out for
each component at least once per 200 m2 (2000 ft2) of coated surface.
3) Holiday testing shall be conducted in accordance with NACE SP 0188. For immersion
services, 100% of coated area shall be inspected for holidays. For atmospheric exposure,
10% of coated area which must include weld seams, corners and edges to be holiday
Page 356 of 704

tested. Voltage at which test is to be carried out will depend upon DFT of coating being
tested and shall be as per NACE SP 0188. Any holiday is unacceptable and should be
marked and repaired immediately.
The contractor shall arrange for spot checking of paint materials for Specific gravity, glow
time (ford cup) and spreading rate.
23.5 Final Inspection of coating system
A final inspection shall be conducted prior to the acceptance of the work. The coating
contractor and the facility owner shall both be present and they shall sign an agreed inspection
report. Such reports shall include:
General
- Names of the coating contractor and the responsible personnel
- Dates when work was performed
Coating Materials
- Information on coating materials being applied
- Condition of coating materials received
Environmental Conditions
- Weather and ambient conditions
- Coating periods
Surface Preparation
- Condition of surface before preparation
- Tools and methods used to prepare surface
- Condition of surface after preparation
Coating Application
- Equipment used
- Mixing procedure prior to application
- Coating application techniques used
Testing
- Type and calibration of inspection instruments used
- Type of quality control tests performed, and results
24.0 GUARANTEE
The contractor shall guarantee that the chemical and physical properties of paint materials used
are in accordance with the specifications contained herein/to be provided during execution of
work.
Page 357 of 704

Page 358 of 704
Page 359 of 704
Page 360 of 704
Page 361 of 704
Page 362 of 704
Page 363 of 704
Page 364 of 704
Page 365 of 704
Page 366 of 704
Page 367 of 704
Page 368 of 704
Page 369 of 704
Offr ENGINEERS
STANDARD No.
egeINDIA LIAM
VESSEL TOLERANCES 7-12-0001 Rev. 5
(A Govt. of India Undertaking'
Page 1 of 2
L-
O
—U-
r
REF. PLANE
ir4
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT A M/SC DM

4 08.09.2006 REAFFIRMED AND REISSUED AS STANDARD POREL DNN AKM VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 370 of 704
STANDARD No.
daMO ENGINEERS
INDIA MIMED
/A Govt. of India Undertakingl
VESSEL TOLERANCES 7-12-0001 Rev. 5
Page 2 of 2
NOTES
REFERENCE LINES SHALL BE LIGHTLY PUNCH—MARKED INSIDE AND OUTSIDE AROUND THE CIRCUMFERENCE OF
THE SHELL PLATE ON THE TANGENT LINES OF THE VESSEL
a) OUT OF ROUNDNESS (OVALITY) SHALL BE AS PER APPLICABLE CODE.
b) OUTSIDE CIRCUMFERENCE OF SHELL SHALL BE WITHIN THE FOLLOWING LIMITS.
10 mm FOR NOMINAL DIAMETER 1200 mm AND UNDER.
12 mm FOR NOMINAL DIAMETER 1201 mm THROUGH 2400 mm.
20 mm FOR NOMINAL DIAMETER ABOVE 2400 mm.
c) FOLLOWING TOLERANCES ON DIAMETER SHALL APPLY THROUGHOUT ITS LENGTH FOR VESSELS WITH TRAYS
AND / OR PACKING. (FOR CARTRIDGE TYPE TRAY REFER SPECIAL NOTE—E).
VESSEL NOM. DIA. TOLERANCE ON NOM. DIA.

2000 mm AND UNDER ± 0.5%
2001 mm TO 4000 mm GREATER OF ± 10 mm OR ± 0.35%
4001 mm TO 8000 mm GREATER OF t 14 mm OR ± 0.25%
ABOVE 8000 mm TO BE SPECIFIED ON VESSEL DRAWING.
TOLERANCE FOR LENGTH t 5 mm PER 3000 mm, MAXIMUM 15 mm.
OUTSIDE SURFACE OF CYLINDER MAY BE OUT OF ALIGNMENT / STRAIGHTNESS NOT MORE THAN 6 mm PER 6000 mm
STRAIGHT LENGHT, BUT NOT MORE THAN 20 mm FOR ANY LENGTH.
5. TOLERANCE FOR CENTRE TO CENTRE DISTANCE BETWEEN ANY PAIR OF INSTRUMENT CONNECTIONS TO BE AS FOLLOWS:—
DISTANCE BETWEEN NOZZLES : * 1 mm
ORIENTATION : * 1 mm
NOZZLE FACE INCLINATION : * 1/4°
ELEVATIONS FROM REFERENCE PLANE MAY VARY AS FOLLOWS:—
MANHOLE: ± 12 mm, NOZZLE t 6 mm, INTERNAL SUPPORTS: t 3 mm, EXCEPT THAT LOCATIONS OF MANHOLES
AND NOZZLES NEAR THE TRAY SHALL NOT VARY MORE THAN ± 3 mm FROM THE TRAY.
PROJECTION OF FLANGE FACE FROM SHELL CENTRAL LINE / TANGENT LINE MAY VARY + 5 mm FOR NOZZLES
AND ± 12 mm FOR MANHOLES.
CIRCUMFERENTIAL AND RADIAL DEVIATION OF NOZZLES, MANHOLES AND SUPPORTS FROM THE TRUE POSITION SHALL
NOT VARY MORE THAN ± 3 mm.
BOLT HOLE ORIENTATION OF NOZZLES MAY VARY ± 2 mm AT BOLT CIRCLE.
VERTICAL AND HORIZONTAL DEFLECTION OF NOZZLE FLANGE FACES FROM PLANES NORMAL TO NOZZLE CENTRE UNES
OR PARALLEL TO VESSEL CENTRE UNE SHALL NOT BE MORE THAN t 1/2?
ALL TOLERANCES OF TRAY SUPPORTS TO BE AS PER TRAY SPECIFICATIONS / DRAWING.
THE BASE RING BOLT CIRCLE DIAMETER MAY VARY t 5 mm. FOR ANY DIAMETER MEASURED AT POINTS 90' APART,
DISTANCE BETWEEN TWO CONSECUTIVE HOLES MAY VARY BY ± 5 mm.
a) DEVIATION OF SUPPORT BASE FROM HORIZONTAL MAY BE AS FOLLOWS:—
FOR VESSEL DIA. 1500 mm AND UNDER 3 mm
FOR VESSEL DIA. OVER 1500 mm TO 2000 mm 5 mm
FOR VESSEL DIA. OVER 5000 mm 10 mm
b) DEVIATION OF SUPPORT BASE FOR BRACKET TYPE SUPPORT / SADDLE SUPPORT FROM HORIZONTAL MAY BE ± 1?
DISTANCE BETWEEN CL TO CL OF SUPPORTS AND BOLT HOLES IN SUPPORTS FOR HORIZONTAL VESSELS MAY VARY ± 3 mm.
DISTANCE BETWEEN CENTRE UNE OF HORIZONTAL VESSEL AND BOTTOM OF SUPPORT MAY VARY ± 3 mm.
16. a) TOLERANCE FOR CENTRE TO CENTRE DISTANCE BETWEEN ANY PART OF EXTERNAL STRUCTURAL
ATTACHMENT SHALL NOT VARY MORE THAN t 3 mm.
b) TOLERANCE FOR DISTANCE FROM REFERENCE PLANE TO BASE OF VERTICAL SUPPORTS AND CENTRE LINE OF
SADDLE SUPPORT MAY VARY ± 6 mm.
SPECIAL NOTES
CUMULATIVE TOLERANCES ON CONSECUTIVE DIMENSIONS SHALL BE LIMITED BY OVERALL DIMENSIONAL TOLERANCES.
ALL TOLERANCES ARE FROM REFERENCE PLANE UNLESS OTHERWISE INDICATED.
INTERFERENCE BETWEEN INTERNAL AND EXTERNAL PARTS OR ANY RESTRICTION TO THE INTENDED FUNCTION OF ANY
PART SHALL BE KEPT IN VIEW WHERE TOLERANCES ARE CUMULATIVE.
SPECIFIC TOLERANCES FOR ANY PART SHOWN ON EIL DRAWING SHALL BE GIVEN PREFERENCE TO THOSE GIVEN
IN THIS STANDARD.
UNUSUALLY LARGE OR COMPLEX VESSELS MAY BE EXECUTED AS PER FABRICATOR'S STANDARD WHEN THE TOLERANCES
AS SHOWN ARE UNREASONABLE. IN SUCH INSTANCES FABRICATOR'S TOLERANCES & UMITS MUST BE SUBMITTED
FOR APPROVAL.
E. VESSEL UPTO AND INCLUDING 750 mm NOMINAL DIAMETER SHALL HAVE CARTRIDGE TYPE TRAY. FOLLOWING
TOLERANCES ON DIAMETER SHALL APPLY THROUGHOUT ITS LENGTH.
VESSEL NOMINAL DIAMETER TOLERANCE
500 mm AND UNDER VESSEL I.D. + 1 mm
501 mm TO 750 mm VESSEL I.D. ± 3 mm A
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL AKM/SC DM

No. by by
Approved by
Page 371 of 704
STANDARD No.
SUPPORT FOR
ORMO ENGNEERS
NDIA UWE)
IA Govt. of India Undertaking) HORIZONTAL VESSEL
7-12-0002 Rev. 5
Page 1 of 1
MAX. APPROX.
D LB H t../ L2 ie
TYPE SADDLE
L3 SADDLE
(M. TON) (KGS.)
10 150 10
D/18 OR 300 260 300 50 200 A 4.4 17
\ I 350 280 325 55 210 A 4.8 18
\ tii +
x _il 400 330 350 75 250 A 4.5 20
450 370 375 95 300 A 3.6 22
YM
11
-wwTs..
V) ''' OF 500 450 450 125 370 A 14.9 40
IIR0PERKM
L1 L/ 600 560 500 175 470 A 13.2 50
I 1 EARTHING Ir 170 it 700 650 550 225 570 A 11.0 55
2
. I =J 26 0 HOLES FOX 800 750 600 275 670 A 10.6 65
M 20 BOLTS 900 850 650 300 760 A 11.0 75
:
TYPE - A
IUD 1000
1200
950
1100
700
800
330
375
820
960
B
B
12.3
19.4
85
130
HOLE FOR 1400 1250 900 465 1150 B 19.7 140
SLIDING SUPPORT
1600 1450 1000 370 1300 C 23.3 165
1800 1600 1100 410 1450 C 39.1 260
D/18 2000 1750 1200 445 1600 C 43.5 290
O 9R
■ 2200 1950 1300 495 1800 D 49.1 295
i 110 111 2400 2150 1450 545 2000 D 53.5 390
ki iii
__.
..1 2600 2300 1550 585 2150 D 52.9 440
11 1
Li Li
N- II It
1 0
2800
3000
2500
2670
1650
1750
620
670
2300
2500
E
E
52.7
64.9
475
600
I- EARTHING 3200 2800 1850 710 2600 E 63.8 620
I 250
L
26 0 HOLES FOR 3400 3000 1950 760 2800 E 64.9 630
30 M 20 BOLTS
111111 3600 3200 2050 830 3000 E 60.5 725
TYPE - B
DUD ,
3800
4000
3350
3550
2150
2250
845
895
3150
3300
E
E
61.0
60.6
745
820
HOLE FOR
SLIDING SUPPORT
TYPE t1 t2 L3 t3
D/18 A 10 10 170 12
B 10 12 250 12
110 C 12 16 300 16
D 16 20 350 20
2-60 VENT
HOLE (TYP.) E 20 20 400 20
(REF. NOTE-5)
I L 1 I L1 I Li 140
EARTHING
I 250
L2
I 30 0 HOLES FOR
30 M 24 BOLTS
PARALLEL TO VESSEL
TYPE - C. D. E AXIS (TYP)
HOLE FOR
SLIDING SUPPORT
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
VESSEL DIAMETER 'D' REFERS TO THE OUTER DIAMETER OF THE SHELL.
FOR INTERMEDIATE DIAMETERS TAKE THE IMMEDIATE NEAREST DIAMETER SUPPORT.
WELDING SHALL BE DONE ALL AROUND AND SHALL BE CONTINUOUS FILLET WELD. WELD SIZE SHALL
BE 6 mm FOR VESSELS UPTO 1400 mm DIA. AND 8 mm FOR VESSELS ABOVE 1400 mm DIA.
PROVIDE 2 NO. 60 VENT HOLES IN SADDLE WRAPPER PLATE. THESE HOLES SHALL BE PROVIDED DIAGONALLY
OPPOSITE AND BE LEFT UNPLUGED AND SHALL BE FILLED WITH HARD GREASE ONLY.
WHERE EARTHING LUG CANNOT BE PUT AT AN ELEVATION OF 400 mm ABOVE THE SADDLE BASE PLATE
IT SHALL BE LOCATED AS HIGH AS POSSIBLE.
EARTHING LUGS ARE NOT TO BE PAINTED OR GALVANIZED.
DETAIL, DIMENSIONS AND NOTES IN ENGINEERING DRAWING TAKE PRECEDENCE OVER THOSE SHOWN HERE.
MATERIALS SHALL BE AS PER ENGINEERING DRAWING.
EARTHING LUG SHALL BE AS PER STANDARD 7-12-0026
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL e611'

RKT A M/SC DM
No. Date Purpose Convenor Chairman
by by
Approved by
Page 372 of 704
STANDARD No.
SKIRT BASE DETAILS 7-12-0004 Rev. 6
wriumwrosame (A Govt. of India Undertaking)
Page 1 of 1
CHAIR CAP
NOTCH GUSSET TO WASHER WELD AT SITE
CLEAR WELD CONTINUOUS RING
NOTCH GUSSET TO
CLEAR WELD
EARTHING LUG
ir
// BOLT 0
+ 3mm
H 20
//
W
n A K
AK +V BOLT 0
-17
I-
II BOLT 0
+ 12mm
L + 12mm
(ALL DIMENSIONS AND DETAILS ARE
BCD BCD SAME AS SHOWN FOR TYPE-2
BCD EXCEPT CONTINUOUS RING)
BOLT 0 + 12mm
[WIDE SLOT RADIUS
+ 6mm
TYPE-1 TYPE-2 SLOT DETAIL TYPE-3
(SEE NOTE-6) (FOR CONTINUOUS RING ONLY)
BOCTO t1 * t2 * t3 * Av B C E F H K L* W TYPE REMARKS

24 20 — 10 60 — — — — 250 75 165 10
1
27 20 — 10 60 — — — — 250 80 170 10
30 25 25 12 55 60 150 12 60 300 80 180 10
33 25 25 12 58 65 150 12 70 300 80 185 10
36 25 25 12 66 70 150 12 80 300 90 200 10
39 32 25 12 70 70 160 14 80 300 95 215 12
42 32 25 12 72 70 160 14 90 300 100 230 12
45 32 25 12 80 75 160 14 90 300 105 245 12 2
48 32 30 14 83 75 180 16 100 380 110 260 14 AND
52 38 30 14 87 80 180 16 110 380 110 275 14 3
56 38 30 16 91 85 180 18 120 380 115 280 14
60 38 35 18 95 85 200 20 120 430 125 285 14
64 38 35 18 104 90 200 25 130 430 135 300 16
68 42 40 20 108 90 220 25 140 450 145 320 16
72 42 40 20 112 95 220 25 150 450 150 340 16
NOTES
BOLT CIRCLE DIAMETER ( BCD ), NUMBER AND SIZE OF THE BOLTS SHALL BE AS PER ENGINEERING DRAWING.
* 3. DIMENSIONS t1, t2, t3 AND 'I: ARE TO BE CHECKED IN EVERY CASE.
IN CASE OF ANY CONFLICT THE ENGINEERING DRAWING SHALL GOVERN.
NUMBER OF BOLTS USED IS TO BE A MULTIPLE OF 4 AND BOLTS SHALL STRADDLE VESSEL NORTH—SOUTH
CENTRE LINE IN PLAN.
USE CONTINUOUS RING ( CHAIR CAP ) IF DISTANCE BETWEEN CONSECUTIVE BOLTS IS LESS THAN 400 mm.
CIRCULAR WASHER SHALL BE SHIPPED LOOSE AND WELDED AT SITE AFTER ANCHOR BOLTS ARE IN POSITION.
♦ 8. PREFERRED DIMENSION 'A'
EARTHING LUG SHALL BE LOCATED BETWEEN THE ANCHOR BOLTS AND SHALL BE AS PER STANDARD 7-12-0026.
WHEN THE ANCHOR CHAIR CAP IS NOT CONTINUOUS, THE BASE PLATE SHALL BE SUITABLY STIFFENED USING
REMOVABLE STRUCTURAL SECTIONS (BEAM/SPIDER) AT SITE DURING ERECTION.
t*/
6 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT M/SC DM
No. by by
Approved by
Page 373 of 704
.C110Eet/IINGNEEI6
dliturletuleGNIFINDIA
oimmumwommose
UMITED
(A Govt. of Indio Undertaking)
SKIRT OPENING DETAILS 7-12-0005 Rev. 5
Page 1 of 2
N
PAD ALL AROUND
SEE NOTE-7
REF. SHE 2 FOR

COVER PLT. DETAIL
SKIRT
INSIDE 100NB SCH. 40
40 PIPE VENI
SKIRT
EQUISPACED INSIDE
BASE PLATE
ACCESS OPENING PLAN VENT

(SEE NOTE-5)
ACCESS OPENING/PIPE OPENING/

VENT OPENING (TYPICAL)
SKIRT
80x6THK. PLATE
INSIDE
cv II 2mm(TENTATIVE)
CHECK FOR PIPE
THERMAL EXPANSION.
MALLER OF tx+2
OR 14mm (FOR PIPE
SSEE NOTE-6)
OR INSULATED PIPE+10
SEE NOTE-10
PIPE OPENING VIEW A VIEW A FLARED SKIRT

(HOT TYPE VESSEL) (COLD TYPE VESSEL)
5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserve
Page 374 of 704

0.401 4"XeWhINGNEERS SKIRT OPENING DETAILS
OBZIPPleSNIFINDIALIMITED
mom mime (A Govt. of Indio Undertaking)
7-12-0005 Rev. 5
illoamPO
Page 2 of 2
6 WIDE SLOT FOR
2-120 HANDLE
3-50 PINS-15 LG
EQUISPACED
VIEW—Q
VIEW—P
NOTES (HOT TYPE VESSEL) (COLD TYPE VESSEL)
ACCESS OPENING SHALL BE LOCATED BETWEEN ANCHOR BOLTS WHEREVER POSSIBLE.
ACCESS OPENING IS NOT TO BE BLOCKED BY BOTTOM HEAD.
SKIRT DIAMETER ACCESS OPENING DIA.(D) NO. OF ACCESS OPENING
UP TO 1000 400 1
OVER 1000 UPTO 1500 450 1
OVER 1500 UPTO 3000 500 1
OVER 3000 500 2
SKIRT DIAMETER NO. OF VENT HOLES
UP TO 1000 2
OVER 1000 UPTO 2000 3
OVER 2000 4
MINIMUM SIZE OF PIPE SLEEVE IS 150NB SCH 40. USE SCH 40 UPTO 250NB PIPE SLEEVE. FOR 300NB AND
ABOVE, PIPE SLEEVE SHALL BE FABRICATED FROM PLATE.
ALL OPENINGS 300 DIA. AND ABOVE SHALL BE PROVIDE WITH REINFORCEMENT PADS ON INNER SURFACE OF SKIRT.
IN CASE OF CONFUCT ENGINEERING DRAWING SHALL GOVERN.
IN FLARED SKIRT, OPENING DETAIL IS SAME AS THAT FOR CYLINDRICAL SKIRT.
WOODEN BLOCK SHALL BE FIXED TO SLEEVE WITH TWO NO. OF WOOD SCREWS.
ACCESS OPENING/PIPE OPENING/VENT SHALL BE OF SAME MATERIAL AS THAT OF SKIRT.
ALL FILLET WELDS SHALL BE 6 mm MINIMUM.
* 13. PROJECTION OF SLEEVE/NECK SHALL BE GREATEST OF (30+INSULATION THK.), (30+FIRE PROOFING) & 50mm.
14. CENTER LINE OF ACCESS OPENING SHALL BE 850 MM (MINIMUM) ABOVE BOTTOM BASE RING FOR ANCHOR
BOLTS OF SIZE M45 & BELOW AND 1100 MM (MINIMUM) FOR ANCHOR BOLTS OF SIZE ABOVE M45. IF ANCHOR
CHAIR HEIGHT IS MORE THAN THAT OF GIVEN IN STANDARD. LOCATION OF ACCESS OPENING SHALL BE ESTABLISHED
SUITABLY.
1
5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT

No.
Date Purpose by by
Convenor Chairman
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserve
Page 375 of 704

STANDARD No.
eggir
ENGINEERS
fteINDIA LIMITED ANGLE LEG SUPPORT 7-12-0006 Rev. 5
/A Govt. of India Undertaking)
Page 1 of 2
PAD AS PER
ENGINEERING DRAWING
6 THK. COVER
PLATE
REF. TABLE ON
SHT. 2 OF 2 HOLE DIA.= BOLT DIA.
NOTCH TO + 6mm
CLEAR WELD
WELD UNE
TANGENT UN
SUPPORT BASE DETAIL
B.C.D.=VESSEL 0/D-50
NOTES
THIS STD. IS APPLICABLE FOR VESSEL DIAMETER UPTO AND INCLUDING 2000mm, MAXIMUM SHELL THICKNESS OF 20mm
AND MAXIMUM LENGTH (T.L. TO T.L.) OF 3000mm VESSELS BEYOND ABOVE RANGE REQUIRE SPECIAL CONSIDERATION.
3. FOR CALCULATION, FOLLOWINGS PARAMETERS HAVE BEEN CONSIDERED.
WIND PRESSURE 200 Kg/me
SHAPE FACTOR 0.7
BASIC SEISMIC CO—EFFICENT (a0 ) 0.08
SOIL FOUNDATION SYSTEM FACTOR (p) 1.5
IMPORTANCE FACTOR (I) 2.0
EMPTY WEIGHT WITH WIND LOADING OR HYDROSTATIC WEIGHT WITH SEISMIC LOADING.
4. HEIGHT AND NUMBER OF LEG SUPPORTS AND SIZE OF ANCHOR BOLTS SHALL BE AS PER ENGINEERING DRAWING.
MINIMUM BOLT SIZE SHALL BE M 20.
MAXIMUM INSULATION THICKNESS CONSIDERED IS 150 mm.
IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
EARTHING LUG SHALL BE AS PER STANDARD 7-12-0026.
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL R KM/SC DM

No. by by Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 376 of 704
STANDARD No.
IENGNEERS
fiSMO INDIA UMITED ANGLE LEG SUPPORT 7-12-0006 Rev. 5
IA Govt. of India Undertaking)
Page 2 of 2
LEG SUPPORT SIZES
LEG SIZE MAXIMUM ALLOWABLE

VESSEL NO.OF MAX. VESSEL LENGTH (T.L. TO T.L) UP TO AND INCLUDING 3.0 M BASE I(DLAIT
E SIZ (X) LOAD C(:1VESSEL
0/D(mm) LEGS
L = 1.5 M L = 2.0 M L = 2.5 M
500 3 ISA 100x100x8 ISA 100x100x10 ISA 110x110x15 170x170x16 THK. 40 1500
NOTES
FOR A VESSEL WITH MAXIMUM SUPPORT LEG HEIGHT OF 1500mm, FOLLOWING ALTERNATIVE
LEG SIZES MAY BE USED :—
ISA 65x65x8 WITH HYDROSTATIC WEIGHT UPTO 500 Kg.
ISA 80x80x8 WITH HYDROSTATIC WEIGHT 501 Kg. TO 1000 Kg.
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KM/SC DM

Page 377 of 704
STANDARD No.
PIPE LEG SUPPORT
ENGINMS
diaMO INDIA UMMED 7-12-0007 Rev. 5

IA Govt. of India Undertaking)
Page 1 of 1
6mm THK. COVER

PLATE
Y
NOTCH TO WELD UNE
CLEAR WELD
TANGENT UNE
S./
O
0
0_
to
NOTES
w ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
FOR DESIGN OF SUPPORT, FOLLOWINGS PARAMETERS HAVE BEEN CONSIDERED.
WIND PRESSURE 200 Kg/m2
SHAPE FACTOR 0.7
BASIC SEISMIC CO—EFFICENT (a0) 0.08
SOIL FOUNDATION SYSTEM FACTOR ( /3 ) 1.5
IMPORTANCE FACTOR (I) 2.0
EMPTY WEIGHT WITH WIND LOADING OR HYDROSTATIC WEIGHT
WITH SEISMIC LOADING.
HEIGHT AND NUMBER OF LEG SUPPORTS AND SIZE OF ANCHOR BOLTS
HOLE DIA = BOLT DIA +
SHALL BE AS PER ENGINEERING DRAWING.
MINIMUM BOLT SIZE SHALL BE M 20.
6rnn\ 91-11-E MAXIMUM INSULATION THICKNESS CONSIDERED IS 150 mm.
EARTHING LUG SHALL BE AS PER STANDARD 7-12-0026.
SUITABLE PAD FOR SS VESSEL SHALL BE PROVIDED.
SUPPORT BASE DETAIL
MAXIMUM ALLOWABLE LOAD PER LEG (Kgs)

LEG PIPE SIZE A B C E t MAXIMUM HEIGHT OF SUPPORT (L) IN METERS
2.0 2.5 3.0
50NB x EXTRA STRONG 120 230 140 36 20 2300 2050 1800
80NB x EXTRA STRONG 180 250 160 36 25 5700 5500 4900
100NB x EXTRA STRONG 230 310 185 42 25 9000 8600 8300
150NB x EXTRA STRONG 320 370 235 44 25 18500 18000 17500
0--64
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT KM/SC DM
No. by by
Approved by
Page 378 of 704
BRACKET SUPPORT FOR STANDARD No.
orfr
ftemm uyirrED
ENGNEERs
IA Govt. of India Undertaking) VERTICAL VESSEL
7-12-0008 Rev. 5
Page 1 of 1
1801 — 2000 650 500 400 550 25 14 350 50 0

z 0
z 550 60
3 3
1601 — 1800 600 450 350 500 25 14 300 50 g g,.., 540 55
,, 2„g
1401 — 1600 550 400 300 450 25 14 250 50 -t- D 2 540 50
re R
w1 z
1201 — 1400 500 350 250 450 25 12 200 25 w ,...
z 3
w—
Lo
z S 470 40
0 00
1001 — 1200 450 320 220 400 20 12 180 25 6 ,0 6 2 450 30
W W
801 — 1000 450 280 200 400 20 12 150 25 inj ig 450 25
MAXIMUM
VESSEL OUTSIDE DIA. A B C E F G H J Mew ANCHOR t v , ALLOWABLE

MA.
intu m VESSEL
-- WEIGHT
(TONNE)
1-60 VENT HOLE

25
•
REFER NOTE-3
(SEE ENGINEERING
DRAWING)
't's SHELL THK.
'X' O/D OF VESSEL

REFER NOTE-6
NOTES
NUMBER OF BRACKETS SHALL BE FOUR PER VESSEL
PAD THICKNESS SHALL BE AS PER ENGINEERING DRAWING.
FOR VESSELS UPTO 800 mm DIA. REFER ENGINEERING DRAWING.
5. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
'6. DISTANCE 'X' IS TO BE FINALISED CONSIDERING INSULATION THICKNESS, BOLT SIZE AND ERECTION
REQUIREMENT AND SHALL BE KEPT MINIMUM.
7. EARTHING LUG SHALL BE AS PER STANDARD 7-12-0026.
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT DM

Format No. 8 - 00 -0001 - F4 Rev.0 Copyright EIL - All rights reserved
Page 379 of 704
geINIDIA
Oliar LIMITED
MINERS
Govt. of India Undertaking)
MANHOLE WITH
HINGED COVER
STANDARD No.
7-12-0009 Rev. 6
Page 1 of 2
3—M16 SS d0 3 THK. WASHER

JACK SCREWS ON WELDED TO HINGE BAR
BOLT CIRCLE DIAMETER
(SEE NOTE-3) ./"."" 4 GAP
THK. WASHER
25 CLEAR
SS HINGE
BAR
MIN 3 THK. WASHER
80 C' 4 GAP
BLIND
M16 FLANGE
80 SS COTTER PIN
WITH 3THK. WASHER
1-3mm NPT
-J 120 0
TELL—TALE HOLE U-
N
I-
0
1 110 0
M16
0
20 0 ROD
SEE NOTE-2
slue
HANDGRIP DETAIL OF JACK SCREW
di 0
BLIND FLANGE
SLOPE TO FIT
PERIPHERY OF
W.N. OR S.O. MANHOLE FLG.
FLANGE R
W.N. OR S.O.
II d10
R
FLANGE
MIA9111
BLIND FLANGE
SIDE AND BOTTOM

MANHOLE TABS DETAILS TOP MANHOLE TABS DETAILS
f5C- (11'`')/
6 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT KM/SC DM
No.
Date Purpose by by
Convenor Chairman
Approved by
Page 380 of 704
STANDARD No.
ENIGINEERS MANHOLE WITH
figulMONDIA 1.11■01FE) IA Govt. of India Undertaking) HINGED COVER
7-12-0009 Rev. 6
Page 2 of 2
NOMINAL G t d R d1 L
FLANGE RATING
BORE
400 298 28 35 55 36 42
450 318 28 35 55 36 42
CLASS 150
500 348 28 35 55 36 42
600 406 28 35 55 36 42
400 324 28 35 55 36 42
450 355 28 35 55 36 42
CLASS 300
500 386 30 35 55 36 42
600 458 30 35 55 36 42
400 342 32 40 55 41 47
450 372 32 40 60 41 47
CLASS 600
500 406 36 40 60 41 47
600 470 36 40 75 41 47
400 352 32 40 60 41 47
450 394 32 40 65 41 47
CLASS 900
500 428 40 40 70 41 47
600 520 40 40 90 41 47
NOTES
WELD HINGE TABS AFTER TIGHTENING THE COVER WITH GASKET IN PLACE
AND MAINTAIN A LOOSE FIT OF HINGE BAR IN HINGE TABS.
BCD OF JACK SCREWS IS TO BE SUITABLY CHANGED IF MANHOLE
STUDS INTERFERE WITH JACK SCREWS.
IF SQUARE RODS ARE USED FOR HANDLES, THEIR EDGES SHALL BE ROUNDED OFF.
IN CASE OF CONFLICT, ENGINEERING DRAWING SHALL GOVERN.
ALL FILLET WELDS SHALL BE 6mm MINIMUM.
TELLTALE HOLE SHALL NOT BE PLUGED AND SHALL BE FILLED WITH
HARD GREASE ONLY.
THE MATERIAL OF COMPONENTS SHALL GENERALLY BE IS : 2062 UNLESS
OTHERWISE SPECIFIED ON ENGINEERING DRAWING. FOR LOW TEMPERATURE
SERVICES AND SERVICES ABOVE 425*C THE HINGE TABS AND HANDLE SHALL
BE OF SAME MATERIAL AS THAT OF SHELL.
6 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RK AKM/SC DM

No. by by
Approved by
Page 381 of 704
STANDARD No.
INGINEEIZS
eitiMOINDIA LIMMED (A Govt. of India Undertaking)
MANHOLE WITH DAVIT 7-12-0010 Rev. 6
Page 1 of 2
20 0 x 25 LG. SNAP
HEAD RIVET
B(OD)420 1.5 THK. S.S. WASHER

240 ROD
PIPE 'El' SCH. 80
0
0 30 VENT
1
1
6R 15
1NO. 60
DRAIN HOLE
DETAIL 'X'
TELL TALE HOLE
3N0.—M16 SS JACK SCREWS

ON BOLT CIRCLE DIAMETER
( SEE NOTE-3 )
DETAIL OF EYE BOLT
BUND
FLANGE
IM16
TYP. DETAIL FOR SR MANHOLE DETAIL OF JACK SCREW
jk4j6;.11?l''-
No. by by
Approved by
Page 382 of 704
Olar
STANDARD No.
ENGINEERS MANHOLE WITH DAVIT
geINIDIA LIAM 7-12-0010 Rev. 6
/A Govt. of India Undertaking)
Page 2 of 2
160 ROD FOR S.S. VESSEL

B(O0)+20 200 ROD FOR C.S. AND
PIPE 'B' SCH. 80 LOW ALLOY STEEL VESSEL
1.5 THK. VESSEL INSIDE
S.S. WASHER
1 0 THK. RIB 20R
8
260 350
(320)
40R NP4,
10V
ti DETAIL OF HAND GRIP
HAND GRIP
141"
0
I
— 1°N
N 20 0 x 25 LG. SNAP
250 HEAD RIVET
// PIPE 'A'
il \\
// \\
\\\
1/ \\ \ I I
/ \\ I I 0
II 1111 I I
— 30 VENT
\ 11 II
I I // ) 0
\\ // F—R
\ \ s.
\\
\\
\\
.■...--
1
1
//
ii
//
//
Y
------_ --------------
1 15
3N0.—M16 SS JACK SCREWS
ON BOLT CIRCLE DIAMETER 1NO. 60 )
(SEE NOTE-3) DRAIN HOLE
DETAIL 'Y'
1 N0.-3mm NPT
TELL TALE HOLE
CLASS 1,41ZBE) A (NB) B (NB)

.,
"nm-leg■-ing10000 400 50 NB SCH. 80 40
450 50 NB SCH. 80 40
150
200 ROD HANDLE 500 65 NB SCH. 40 50
200 200
600 65 NB SCH. 40 50
400 65 NB SCH. 40 50
450 65 NB SCH. 40 50
300
500 65 NB SCH. 40 50
NOTES
600 90 NB SCH. 40 80
DIMENSIONS IN BRACKETS ARE FOR CLASS 900. 400 80 NB SCH. 40 65
B.C.D. OF JACK SCREWS IS TO BE SUITABLY CHANGED IF MANHOLE
STUDS INTERFERE WITH JACK SCREWS. 450 90 NB SCH. 40 80
600
THE SLEEVE PIPE 'A' SHOULD BE IN TRUE VERTICAL POSITION WITHIN 500 125 NB SCH. 80 100
A TOLERANCE OF 2 1/2 DEGREE, AFTER WELDING TO THE FLANGE.
600 125 NB SCH. 80 100
EDGES SHALL BE ROUNDED OFF IF SQUARE ROD IS USED
FOR HANDGRIP. 400 125 NB SCH. 80 100
MATERIAL OF DAVIT COMPONENTS SHALL BE C.S. UNLESS OTHERWISE
SPECIFIED IN ENGINEERING DRAWING. 450 125 NB SCH. 80 100
900
ALL FILLET WELDS SHALL BE 6mm MINIMUM. 500 150 NB SCH. 80 125
THIS STANDARD IS NOT APPLICABLE FOR LOW TEMPERATURE SERVICES.
600 150 NB SCH. 80 125
taj•
No. by by
Approved by
Page 383 of 704
LADDER RUNGS FOR STANDARD No.
ENGINEERS
UNTED 7-12-0011 Rev. 5
(A Govt. of India Undertaking) MANHOLE / DEMISTER
Page 1 of 1
TOP OF DEMISTER
•!6!;!.9.■!VAtt;!..!..!■!•:•!.!•!..!•:•!..!•!....!•!•:•!•:•!..!•:•!
UM
DETAIL-X
HORIZONTAL VESSEL
V)
Z
7
CC TOP LADDER RUNGS EQUISPACED AT BOTH LEVELS O
o 2-NOS. FOR DIA. < 1000. 1=1
a"'
0
4-NOS. FOR 1000 < DIA. < 2000 I
cJ p) 1-
¢< 6-NOS. FOR 2000 < DIA. < 3000 0 W
—I I—
8-NOS. FOR DIA. > 3000 °
%.D
V) _j
HANDGRIP 175 175
350+1/2 MANHOL DIA. CU
MANHOLE
II
`1,
e) DETAIL-X
200
r DETAIL-X
F
175 175
200 (160) ROD FOR

VERTICAL VESSEL C.S. AND LOW ALLOY
STEEL (NOTE-7) Cu
2OR
HANDGRIP
NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
A 2. VARIATION IN SPACING BETWEEN LADDER RUNGS IS PERMITTED
IN CASE OF INTERFERENCE WITH SOME NOZZLE OR INTERNALS.
HOWEVER THE SPACING OF RUNGS SHALL BE EQUAL.
SQUARE RODS MAY BE USED FOR HANDGRIP / LADDER RUNGS.
IF FABRICATED FROM PLATE THE EDGES ARE TO BE ROUNDED OFF.
MATERIAL SHALL BE AS PER ENGINEERING DRAWING.
ORIENTATION OF LADDER RUNGS SHALL BE SAME AS OF MANHOLE.
7. DIMENSIONS SHOWN IN BRACKETS ARE FOR STAINLESS STEEL MATERIAL. r
du
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL T AKM/SC DM
Date Purpose by
Convenor Chairman
No. by Approved by
Page 384 of 704

STANDARD No.
NOZZLE REINFORCEMENT
ENGN33IS
111111171,1111,11MIND (A Govt. of loft Undertaking) AND PROJECTION
Page 1 of 2
0
1
5-
1-30 NPT TELLTALE HOLE
(REFER NOTE-7)
O
F—
L (WIDTH OF PAD) C) PROJECTION 'A' SEE NOTE-4,5,9800

NOMINAL OUTSIDE
PIPE SIZE DIAMETER SHELL WELD SHELL WELD CLASS 150 CLASS 300 CLASS 600 CLASS 900
EFF.=0.85 EFF.=1.0
BELOW 3" STANDARD - - 150 150 150 150
3" 88.9 40 45 200 200 200 200
4" 114.3 50 60 200 200 200 200
6" 168.3 70 85 200 200 200 250
8" 219.0 95 110 200 200 250 250
10" 273.0 115 135 200 200 250 300
12" 323.8 135 160 200 200 250 300

14" 355.6 150 175 250 250 250 300
16" 406.4 170 200 250 250 250 300
18" 457.2 195 225 250 300 300 350
20" 508.0 215 250 250 300 300 350
24" 609.6 255 300 250 300 300 400
26" 660.4 285 330 250 300 350 450
28" 711.2 305 355 250 300 350 450
30" 762 325 380 250 300 400 450
32" 812.8 350 405 300 350 400 500
34" 863.6 370 430 300 350 400 500
36" 914.4 390 455 300 350 - -
38" 965.2 410 480 300 350 - -
40" 1016 435 505 300 350 - -
42" 1066.8 455 530 300 400 - -
44" 1117.6 475 555 300 400 - -
46" 1168.4 500 585 300 400 - -

48" 1219.2 520 610 300 400 - -
6 07.06.2013 REVISED AND REISSUED AS STANDARD NIKHIL RKT/SC DM
5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL

No. by by
Approved by
Fnrmat Nn 8-110-n0(11-F4 RPV fl r.nnvrinht Fit - All rinhts msprvori
Page 385 of 704

STANDARD No.
NOZZLE REINFORCEMENT
INGINEERS
MR wow staxiso (A Govt. of India Undertaking)
AND PROJECTION
Page 2 of 2
NOTES
C) 3. WIDTH IS MINIMUM AND SHALL BE CHECKED AGAINST CODE REQUIREMENT. CHECK REINFORCEMENT REQUIREMENT FOR
ALL EXTERNAL PIPING LOADING ALSO.
4. NOZZLE PROJECTIONS ARE BASED ON INSULATION THICKNESS EQUAL TO 75mm. FOR INSULATION THICKNESS
GREATER THAN 75mm, THE NOZZLE PROJECTION IS 'A' + [INSULATION THICKNESS(mm)-75].
5. PROJECTION 'A' FOR SELF—REINFORCED NOZZLE SHALL BE BASED ON DESIGN OF REINFORCEMENT SUBJECT TO
MINIMUM REQUIREMENTS AS PER THIS STD.
6. EXTEND PAD LOCALLY FOR MANHOLE DAVIT SUPPORT, IF REQUIRED.
7. EXTERNAL REINFORCING PADS SHALL HAVE A MINIMUM OF 1 NO. TELL—TALE HOLE EXCEPT THAT PADS FOR
NOZZLES GREATER THAN 10"NB(250NB) SHALL HAVE MINIMUM TWO NOS. TELL—TALE HOLES AND NOZZLES IN
EXCESS OF 36"NB (900NB) SHALL HAVE 4 NOS. TELL—TALE HOLES. PAD INSTALLED IN SECTIONS SHALL HAVE
ATLEAST ONE TELL—TALE HOLE PER SECTION. TELL—TALE HOLES ON REINFORCEMENT PADS SHALL BE
EQUALLY SPACED IN CIRCUMFERENTIAL DIRECTION OF PAD.
8. TELL—TALE HOLE SHALL NOT BE PLUGGED AND SHALL BE FILLED WITH HARD GREASE ONLY, AFTER
HYDROTEST/PNEUMATIC TEST OF EQUIPMENT.
9. o) FOR COLUMNS & VERTICAL VESSELS, PROJECTION OF NOZZLE ON TOP HEAD SHALL BE 400mm MINIMUM FROM
OUTSIDE.
b) FOR HORIZONTAL VESSELS, PROJECTION OF NOZZLES ON TOP SIDE OF SHELL SHALL BE 300mm MINIMUM FROM
OUTSIDE.
10. PROJECTIONS ARE BASED ON ASME 816.5 FLANGES FOR UPTO AND INCLUDING 24"NB NOZZLES AND ASME 816.47
SERIES 'B' FLANGES FOR NOZZLE SIZES ABOVE 24"NB.
.1 1
6 07.06.2013 REVISED AND REISSUED AS STANDARD NKL RKT/SC DM
5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT

No. by by
Approved by
Format Nn 8-nn-onni-F4 Rpv n nonvrinht FII - All rinhts rpsprypri
Page 386 of 704

STANDARD No.
derfa INDIA maw

lb13\aSEERS STANDARD BOLT HOLE ORIENTATION 7-12-0015 Rev. 5
amegi.wegammo (A Govt. of India Undertaking)
Page 1 of 1
HORIZONTAL VESSEL
(ELEVATION)
q_
VERTICAL VESSEL
(PLAN)
NOTES
ANY DEVIATION FROM THIS ARRANGEMENT WILL BE INDICATED IN ENGINEERING DRAWING.
BOLT HOLES TO STRADDLE CENTRE LINES INDICATED ( BY q. ) ABOVE.
5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT

No. by by
Approved by
Page 387 of 704

STANDARD No.
601NDIA LIMITED
ENGINEERS SIGHT GLASSES FOR
7-12-0017 Rev. 5
Oturqr
(A Govt. of Indio Undortoking)
PRESSURE VESSELS
Page 1 of 2
I NO.-3mm NPT
TELL—TALE HOLE GLASS
tfl
15
SS OR CS SHELL HEAD CLAD SHELL HEAD P No.-14 HOLES
SIZE I G R H t C P h STUD SIZE L

(NB) - SI
DESIGN PRESSURE < 10 Kg / cm2g
50 152 50 92 38 24 91 10 20 120.5 4 19 M 16 75 23 25
100 230 100 157 38 29 156 16 28 190.5 8 19 M 16 85 23 25
50 165 50 92 38 27 91 14 20 127 8 19 M 16 82 23 25
100 255 100 157 40 37 156 22 28 200 8 22 M 20 105 25 29
GLASS
1 N0.-3mm NPT
TELL—TALE HOLE
SEE VESSEL DRG.
SIZE 0 FLG. X R T G D t W C P h STUD SIZEI L S

(NB) I.D.
50 152 62 78 92 24 30 50 91 10 20 120.5 4 19 M 16 100 28
100 230 116 135 157 29 38 100 156 16 28 190.5 8 19 M 16 115 28
DESIGN PRESSURE . 20 Kg / cm2g
50 165 62 84 92 27 38 50 91 14 20 127 8 19 M 16 110 28
100 255 116 146 157 37 53 100 156 22 28 200 8 22 M 20 145 32
THE ABOVE ARRANGEMENT IS APPLICABLE FOR THE FOLLOWING CONDITIONS.

DESIGN PRESSURE 20 Kg/cm2g
DESIGN TEMPERATURE < 200•C
III) MAXIMUM TEMPERATURE DIFFERENTIAL 140*C
( AMBIENT TO FLUID )
5 30.07.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM I SC DM

Page 388 of 704
STANDARD No.
ENGNEERS SIGHT GLASSES FOR
fit INDIA LIMTED 7-12-0017 Rev. 5
(A Govt. of Indio Undortoldng)
PRESSURE VESSELS
Page 2 of 2
16NOS.-15 0 HOLES 16NOS.—M12

TAPPED HOLES
16
39R
1110.-3mm NPT
TELL-TAIL
HOLE
COVER FLANGE GLASS GASKET PAD FLANGE

(NOTE-9)
THE ABOVE ARRANGEMENT IS APPLICABLE FOR THE FOLLOWING CONDITIONS.

DESIGN PRESSURE . 5.0 Kg/cm2g
DESIGN TEMPERATURE 200'C
III) MAXIMUM TEMPERATURE DIFFERENTIAL . 140*C
( AMBIENT TO FLUID )
NOTES
TYPE OF SIGHT GLASS SHALL BE TOUGHENED BOROSILICATE AND SHALL BE TESTED
AS PER IS : 5428 / BS 3463.
FOR APPLICATION OUTSIDE THE LIMITS SPECIFIED ON THE STANDARDS, MANUFACTURER'S
PROVEN DESIGN FOR THE COMPLETE SIGHT GLASS ASSEMBLY SHALL BE USED.
UNLESS OTHERWISE SPECIFIED, GASKET MATERIAL SHALL BE COMPRESSED ARAMIDE GASKET OR
COMPRESSED FIBRE ASBESTOS—FREE GASKET.
THE INDICATED SIGHT GLASS THICKNESSES ARE MINIMUM. NEGATIVE TOLERANCE IS NOT PERMITTED.
REFER ENGINEERING DRAWING FOR TYPE AND MATERIAL OF NOZZLE COMPONENTS.
GLASS AND SEAT FACE SHALL BE POLISHED PERFECTLY.
9. PROVIDE GASKET ON EITHER SIDE OF SIGHT GLASS.
5 30.07.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT A M / SC DM

No. by by
Approved by
Page 389 of 704
STANDARD No.
ENGNEERS INTERNAL FLANGES
OM/I(ANDIA UMRED Govt. of India Undertaking)
7-12-0018 Rev. 5
Page 1 of 1
O.D.
B.C.D.
I.D. REFER NOTE-4
18 DIA. HOLES
FOR M16 BOLTS
THICKNESS OF
NOMINAL NUMBER FLANGE t
PIPE SIZE I.D. B.C.D. O.D.
OF BOLTS CARBON S. STEEL
(mm)
STEEL OR MONEL
40 51 110 160 4 16 10
50 63 120 170 4 16 10
80 92 150 200 4 16 10
100 117 180 230 4 16 10
150 171 240 290 4 16 10
200 222 290 340 8 20 12
250 276 350 400 8 20 12
300 327 400 450 8 20 12
350 358 430 480 12 24 16
400 409 480 530 12 24 16
450 460 530 580 12 24 16
500 511 580 630 12 24 16
600 612 680 730 12 24 16
NOTES
* 3. FILLET SIZE IN BRACKET ARE FOR STAINLESS STEEL / MONEL.
FULL FACED GASKETS SHALL BE USED.
DIMENSIONS EXCEPT THICKNESS FOR INTERNAL FLANGES OF SIZE 25NB OR LESS SHALL BE AS PER
ASME 816.5 CLASS 150. FLANGE THICKNESS AND FACING SHALL BE EQUIVALENT TO 4 NB LANGE
COVERED IN THIS STANDARD. 2 14-4
5 30.07.2011 REAFFIRMED AND REISSUED AS STANDARD POREL AK / SC '' DM
Page 390 of 704
STANDARD No.
BsICNEERS
WA LIMITS) VORTEX BREAKERS 7-12-0019 Rev. 5
Man VIRINVINOMPINI (A Govt. of Indio Undertaking)
Page 1 of 1
to
4=1
w
0 50
z
50 FOR NOZZLES UPTO 250 NB
AND 80 FOR NOZZLES ABOVE
250 NB
60 DRAIN HOLE FLUSH

WITH VESSEL WALL ---CLAD/WELD OVERLAYED NOZZLE
(TYP)
UNLINED NOZZLE (TYP.)
TYPE — 1A TYPE — 2A
FOR NOZZLE NB 100
3D0
60 DRAIN HOLE FLUSH

PLAN VIEW FOR
WITH VESSEL WALL 1B AND 2B
TYPE — 1B TYPE — 2B
FOR NOZZLE NB < 100
ALLOY / ALLOY CLAD/ CONCRETE LINED

VESSEL CARBON STEEL/LOW ALLOY STEEL ALLOY LINED
MATERIAL (NOTE-3b)
CORROSION
ALLOWANCE 1.5 3 4.5 6 — —
THICKNESS 't' 6 8 12 14 5 5
WELD SIZE 'W' 6 6 8 8 5 5
NOTES
3.a) FOR ALLOY LINED VESSELS, THE BAFFLE MATERIAL SHALL BE SAME AS ALLOY LINING.
b) FOR CONCRETE LINED VESSELS, THE BAFFLE MATERIAL SHALL BE ALLOY AS SPECIFIED
IN ENGINEERING DRAWING.
REFER ENGINEERING DRAWING FOR DIMENSION 'B'.
DENOTES NOMINAL BORE SIZE OF SUBJECT NOZZLE.
5 30.07.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT DM

Page 391 of 704
STANDARD No.
lagE1eMENGINEERS
eg fiffleellir (AINDIA LIMITED PIPE DAVIT 7-12-0023 Rev. 6
(WM Govt. of India Undertaking)
Page 1 of 3
DETAIL-Z LOCKING PIN

DETAIL-X
A (NOTE-3) POSITIONING PLATE LOCKING PLATE
10 THK. (DETAIL 'K') DETAIL-Y
NAME PLATE 60'
a •
W
L_
r=• ANGLE SIZE 'SI X IX TAPPED HOLE
o a- Z WITH M16 BOLT
In co
L. 0
N mw
ANGLE SIZE 'S'
DETAIL IN TOP BRACKET
SHT. 2 aq
TOP OF PLATFORM
I
HAND
RAILING
z
TAPPED HOLE 1
WITH M16 DOLT 8
PIPE cu
SIZE 'D' 1 DETAIL-70 0
DETAIL — W
, TOP OF
I PLATFORM
1.--1)DAVIT SUPPORT
HAND RAILING
4Q N
(TYPE-1) (TYPE-2)
65
DEVIT FOR TOP DEVIT FOR SIDE TO SUIT
MOUNTED PLATFORM MOUNTED PLATFORM PIPE O/D.
8-180 HOLES
A (MAX) B CAPACITY PIPE SIZE ANGLE SIZE R1 R2 r t EQUISPACED
Cm) (rim) Ckgs.) D S
500 100NBxSCH.160 75x75x6 75 60 10 20
1000 1000 150NBxSCH.80 100x100x8 110 60 12 25 160 LOCKING
I'2—
PIN
(Ci
500 150NBxSCH.80 100x100x8 110 60 10 20
2000 1000 200NBxSCH.80 150x150x10 140 60 12 25
0
0 LOCKING PLATE
:: 500 200NBxSCH.80 150x150x10 140 60 10 20
/.
3000 1000 200NBxSCH.160 150x150x12 140 60 12 25 DETAIL—X DETAIL—Y
R1
3 THK. DEFLECTOR CONE
D (NB) D1
100 120
150 175
POSITIONING 200 225
PLATE
DETAIL—Z (DAVIT EYE)
DETAIL—K
DETAIL—P
4---
6 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KM / SC DM
5 12.10.2006 REAFFIRMED AND REISSUED AS STANDARD POREL RKG AKM VC
No. by
Approved by
Page 392 of 704

STANDARD No.
laNzieMENGINEF_RS
*Iges Of5legNW (AINDIA LIMITED PIPE DAVIT 7-12-0023 Rev. 6
Men Govt. of India Undertaking)
Page 2 of 3
LOCKING PLATE LOCKING PIN LOCKING PIN

LOCKING PLATE
TOP OF PLATFORM TOP OF PLATFORM
—
EXTENSION ANGLE
DETAIL- —-
LOCKING ARRANGEMENT OF DAVIT PIPE LOCKING ARRANGEMENT OF DAVIT PIPE

PASSING THROUGH PLATFORM PASSING THROUGH SIDE OF PLATFORM
CHAIN
(MIN. 350 LG.)
REF, LEVEL
ISMC 100
018 HOLE RADIUS TO SUIT GUSSET FOR BOTTOM

PIPE O.D. SUPPORT ONLY
ELEVATION
50 (TYP)
PLATFORM (NOTE-8
N\
EXTENSION ANGLE REF. AXIS

BY MECH. CONTRACTOR
DETAIL — Q
80
25NB SCH.80 INS. THK.
PIPE SLEEVE +300
030x10 THK.
PLAN (TOP BRACKET)
020 TURNING
12 THK.
REF. AXIS
in
PLAN (BOTTOM BRACKET)

TURNING HANDLE DETAIL DAVIT SUPPORT ..../
6 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AIM447C DM
No. by by
Approved by
Page 393 of 704

STANDARD No.
IfilfazieM ENGLI INEERS
ejr fafflegNIF INDIA MITED PIPE DAVIT 712-0023 Rev. 6
(A Govt. of Indio Undortoldng)
Page 3 of 3
170
17 60 15 25 10 20 17
to
2 CAPACITY KGS
NAME PLATE
NOTES
NAME PLATE
MATERIAL STAINLESS STEEL 2mm THICK.
NAME PLATE IS TO BE TACK WELDED TO THE DAVIT PIPE.
THE LETTERS AND NUMBERS SHALL HAVE RAISED POLISHED FACE.
BACKGROUND SHALL BE BLACK.
DIMENSION 'A' SHALL BE SUCH THAT THE DAVIT EYE EXTENDS PREFERABLY BY 900 mm OUTSIDE PLATFORM.
REFER ENGINEERING DRAWING FOR DIMENSIONS A, B, C, E, CAPACITY OF DAVIT AND INSULATION THICKNESS.
THE DAVIT USED SHALL CLEAR HANDRAIL OF THE EQUIPMENT.
MATERIAL OF PIPE SHALL BE A-53 / IS:1978 OR EQUIVALENT AND STRUCTURAL PARTS SHALL BE IS:2062 GR.B
OR EQUIVALENT.
FOR THIN WALLED EQUIPMENT, DESIGNER SHALL ANALYSE THE STIFFNESS OF SHELL AT THE BRACKET LOCATIONS.
DETAIL DIMENSIONS AND NOTES IN ENGINEERING DRAWING TAKE PRECEDENCE OVER THOSE SHOWN HERE.
LOCKING PLATE (DETAIL —Y), LOCKING PIN (DETAIL —X) WITH CHAIN, POSITIONING PLATE (DETAIL —K), DEFLECTOR
CONE (DETAIL—P) AND LOCKING SUPPORT CHANNEL (DETAIL —Q) SHALL BE SUPPLIED LOOSE BY FABRICATOR AND
WELDED AT SITE BY MECHANICAL CONTRACTOR.
FOR LOW TEMPERATURE SERVICE, BRACKET DETAILS SHALL BE AS PER EIL STD. 7-12-0034
13. IN CASE DIMENSIONS 'B' IS BEYOND THIS STANDARD, IT IS RECOMMENDED TO INSTALL PIPE DAVIT
ON STRUCTURAL PLATFORM.
t-/
-1(j491Ak.
6 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT KM / SC
DM

Page 394 of 704

LIFTING LUG STANDARD No.
laRtze ENGINEERS
TOP HEAD TYPE 7-12-0024 Rev. 7
fafRegNIFINDIA LIMITED
iiiw ecReelVaX3,10543) (A Govt. of Indio Undertaking)
(FOR VERTICAL VESSELS / COLUMNS) Page 1 of 1
SECTION XX
MAX. ERECTION WT. OF VESSEL (TONNES) 410 25 45 90 140 180

THICKNESS OF PLATE (MINIMUM) T 12 28 40 50 70 80
WIDTH W 200 230 300 400 500 610
LENGTH L 400+E 460+E 580+E 750+E 900+E 1080+E
DIAMETER OF HOLE D 60 75 75 100 130 150
HEIGHT OF NOTCH & SIDE WELD H 130 130 150 200 250 300
RADIUS OF NOTCH R 40 40 50 75 90 100
WELD SIZE ( SEE NOTE 5 ) A 10 14 20 30 38 46
BOTTOM OF BRACE TO TOP OF LUG F 200 230 300 400 500 600
BOTTOM OF BRACE TO T.L OF HEAD E SEE NOTE 2
T.L. OF VESSEL TO BOTTOM OF LUG B 200 230 280 350 400 480
C 30 40 50 70 90 100
TOP OF LUG TO Q OF HOLE J 90 90 115 150 180 230
K 30 40 50 70 80 100
NO. OF LUGS 2 2 2 2 2 2
NOTES
*2. DIMENSION 'E' IS TO BE DETERMINED BY THE SHAPE OF HEAD IN CONJUNCTION WITH DIMENSION 'K'.
DETAIL, DIMENSIONS AND NOTES GIVEN IN ENGINEERING DRAWING TAKE PRECEDENCE OVER THOSE SHOWN HERE.
FOR THIN WALLED EQUIPMENTS, DESIGNER SHALL ANALYSE THE STIFFENESS OF SHELL AT THE LIFTING LUG LOCATION.
IF PADS ARE USED ON STAINLESS STEEL EQUIPMENTS THE SIZE OF FILLET WELD BETWEEN SHELL AND STAINLESS
STEEL PAD SHALL BE ANALYSED.
MATERIAL SHALL BE COMPATIBLE WITH HEAD MATERIAL.
FOR INTERMEDIATE ERECTION WEIGHT, NEXT HIGHER SIZE OF LIFTING LUG SHALL BE USED.
LIFTING LUG SHALL BE MACHINED TO COVER OFFSET BETWEEN OUTER DIAMETERS OF SHELL AND HEAD.
7 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL I

*IA
RKT F AKM SC DM

Date Purpose by by
Convenor Chairman
No. Approved by
Page 395 of 704

FIRE PROOFING STANDARD No.
15MAZIEqENGINIEER.S
faglegVOY INDIA LIMITED AND 7-12-0025 Rev. 5
IMAM FRWIU ter MAAR) (A Govt. of India Undertaking)
INSULATION SUPPORTS Page 1 of 2
M6 x 4OLG. G.I. BOLTS 2-M6 BOLTS

6 DIA. HOLE FOR VESSEL DIAMETER ABOVE 600, TACK WELDED AT 600 PITCH x25LG. G.I.
(TYP•) PROVIDE 30X6 THK. FLATS WITH BOLTS AND
60 HOLE AT NUTS (TYP.)
10 TYP HEIGHT EQUAL TO INSULATION 600 PITCH
THK. AT 600 CIRCULAR PITCH
100 MIN. (TYP.) NOTE-7)
CORRUGATED
SHEET
10 DIA. LOOSE 3 THK. X 20 0.D
RING (TYP.) 100 MIN. NEOPRENE WASHER
S 2 THK. ALUMINIUM
WASHER
T.L
r•J
À'
3 THK.
ASBESTOS SHEET
6 THK. ANGLE RINGS
VIEW - 'A'
(WELD ENDS)
8 THK. T-CLEATS AT
1000 PITCH(MINIMUM
3 CLEATS PER RING)
10
(TP)
010 HOLE ON
DETAIL—X ANGLE LEG
(FOR HOT INSUSLATED VESSELS)
(WHERE => 40) VIEW — 'B'
INSULATION
THICKNESS (S)
N W.L o b
T.L
600 MIN. FOR VESSELS

INSULATED FOR TEMP.
ABOVE 400'C.
r•-■ ry r J W.L.
5 X COLD INSULATION
THICKNESS ( MIN 600MM)
a_
7
1=-J b
M12 SQUARE NUTS TACK WELD
ON INSIDE AND OUTSIDE OF PIPE G
SKIRT ‘111SUPPORT
SKIRT ON 450 TRIANGULAR PITCH
FOR FIRE PROOFING (SEE DETAIL-Y) ANGLE LEG
(REFER NOTE-8) SUPPORT
M12 SQUARE NUTS TACK

WELDED AS SHOWN IN
SEC.D-D FOR FIRE PROOFING
(REFER NOTE-8)
DETAIL—Y
SECTION 'C—C'
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD DM

No. by by
Approved by
Page 396 of 704

STANDARD No.
INPIZIEgMENIGINEERS FIRE PROOFING
fs' WWIEPIegilir INDIA LIMITED AND 7-12-0025 Rev. 5
E9210121BTWO (A Govt. of India Undertaking)
INSULATION SUPPORTS Page 2 of 2
2 NOS. 100 HOLES IN

PROVIDE ONE HEAT BREAK T—CLEAT / RING FOR 14.1
M6 X 25 LG G.I. BOLTS w 0
BETWEEN TWO CLEATS (TYP) w
AND NUTS. to z
AIR POCKET
6 THK. FLAT (FOR VESSEL TEMP.
10
ABOVE 400T)
3 THK.
ASBESTOS SHEET
8 THK. T—CLEATS AT 40X6 THK. FLAT

1000 PITCH(MINIMUM WITH 60HOLES
3 CLEATS PER RING)
500 PITCH
10 TYP.
6 THK.
SUPPORT RING
WITH 6 DIA.
HOLE AT 600
* = (C OLD INSULATION THICKNESS — 50 MM) PITCH
= 5 0 MM (MIN)
VIEW — 'P' DETAIL — 'Z'
DETAIL-X
(FOR COLD INSULATED VESSELS)
M6 x 40LG. G.I. BOLTS

CORRUGATED TACK WELDED AT 600 PITCH B1
"SHEET 60 HOLE AT
3 THK. X 20 0.D 600 PITCH
NEOPRENE WASHER
S 2 THK. ALUMINIUM
WASHER
6 THK. ANGLE RINGS

IN SEGMENTS
6 THK. T—CLEATS AT
10 1000 PITCH (MINIMUM
2 CLEATS PER SEGMENT) VIEW - 'Al'
(TYP)
10mm GAP
DETAIL-X
(FOR HOT INSULATED VESSELS) (rY1')
(WHERE S < 40)
NOTES VIEW - 'Bl

ALL DIMENSIONS ARE IN mm.
FOR MATERIAL SPECIFICATION REFER ENGINEERING DRAWING.
'R' SHALL BE EQUAL TO 175mm FOR VESSELS UPTO 3000mm DIAMETER AND 300mm FOR VESSELS ABOVE 3000mm
DIAMETER.
DETAILS, DIMENSIONS AND NOTES ON ENGINEERING DRAWING SHALL TAKE PRECEDENCE OVER THOSE SHOWN HEREIN.
CLIPS SHALL CLEAR WELD SEAMS AND INSULATION RINGS SHALL BE SUITABLY NOTCHED INCASE OF INTERFERENCE
WITH NOZZLES/ATTACHMENTS.
ONLY T—CLEATS WITH ASBESTOS SHEET AND G.I. BOLTINGS, ANGLE RING ALONG WITH TACK WELDED BOLTS, INSULATION
SUPPORT CLEATS WELDED TO EQUIPMENT, LOOSE RINGS & M12 NUTS SHALL BE SUPPLIED BY EQUIPMENT FABRICATOR.
a) FOR COLD INSULATED VESSELS CLEATS ON DISHED ENDS ARE NOT REQUIRED.
b) FOR COLD INSULATED VESSELS CLEATS ON SHELL ARE TO BE PROVIDED IF COLD INSULATION THICKNESS IS MORE
THAN 60mm.
FOR UNINSULATED VESSELS SQUARE NUTS SHALL BE PROVIDED FOR ENTIRE HEIGHT OF SUPPORT (SKIRT, PIPE/ANGLE LEG).
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD

Page 397 of 704
STANDARD No.
15iiitaEqM ENGINEERS
fafReg EARTHING LUG 7-12-0026 Rev. 5
FE0 W
41gen INDIA LIMITED
(..1921751¢tef3ACI (A Govt. of Indio Undertaking)
Page 1 of 1
10 THK. PLATE
VESSEL PART
tr.)
N
14 DIA. HOLE
(FOR M12 BOLT)
75 25
NOTES
ALL EQUIPMENTS SHALL BE PROVIDED WITH TWO(2) EARTHING
LUGS, UNLESS OTHERWISE STATED.
3.(a) EARTHING LUGS SHALL BE LOCATED DIAMETRICALLY OPPOSITE ON
NORTH—SOUTH CENTER LINE ON SKIRT SUPPORTED EQUIPMENTS,
ON ANY TWO(2) LEGS OF THREE(3) LEG SUPPORTED VERTICAL VESSEL,
ON DIAMETRICALLY OPPOSITE LEGS OF FOUR(4) LEG SUPPORTED
VERTICAL VESSEL AND ON EACH SADDLE OF HORIZOTAL VESSEL.
TWO(2) EATHING LUGS ARE TO BE LOCATED ON EACH SADDLE OF
HORIZONTAL VESSEL OF LENGTH GREATER THAN 20 METERS.
FOR SPHERE, TOTAL 4 — NOS. OF EARTHING LUGS SHALL BE PROVIDED
PREFERABLY ON DIAMETRICALLY OPPOSITE AND EQUALLY SPACED LEGS.
(SPHERES ARE USUALLY PROVIDED WITH LEGS IN NUMBERS WHICH ARE
MULTIPLE OF 4 FOR THE SYMMETRY)
DO NOT WELD EARTHING LUG ON PRESSURE PART.
6. MATERIAL OF CONSTRUCTION SHALL BE CARBON STEEL.
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL • RKT AKM / SC DM

Page 398 of 704
STANDARD No.
18iatER7 ENGINEERS
,Ig ej. &Aft INDIA LIMITED
INIURFIEVWC1X3,111.1.1) (A Govt. of Indio Undertaking)
NAME PLATE 7-12-0027 Rev. 5
Page 1 of 1
"CE
co
1
6 .. z 1-
Li,
I- u_
<
1- Y 0 E
0
<
E
—.1 csj
ce Zt
w
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o
w o
cc I _1
w 1— 1—
w Ww
I- 0 Y i—
o T I- 0 v)
a
w 0 IX V)
tr) L.LI CO U)
La 0 w
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1
Li -4Z
1—
cr)
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°)
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Lo 1-- 1 o
Z a co w — N Li,
_1 CD CO
w _J 1
w < _1 N _1
< 2 J _1
V) < 0 <
(/) I CC I
Z 0 V-) < (1)
0 Z 0
U) o Lu WW..
1-- Z
<
0 ,- n
W
w ix
0 CL
V 0_
m
E cr
Y L.L1 L.Li LO
(/) _1
_I C<C) <
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MI < CO Z O Z
0
Z .— C■I ri 4 6 tO
/ 11. , ^
4.0 0
2/Vvt'4
KT
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL 44.4) AKM / SC DM

No. by by
Approved by
Page 399 of 704

-
STANDARD No.
15iffazle ENGINEERS
e...111E1f5teg INDIA LIMI TED MANUFACTURER NAME PLATE 7-12-0028 Rev. 5
(llETI FIUME 115r3911771) (A Govt. of Indio Undertaking)
Page 1 of 1
I-
fY
CO
)-
W
_1
m
1.5
L...; V)
C.) o
Q 0_
Li_
I-
o o Li
w Z I—
=
La 5
Zi cc o_
0 Li)
a. = La
0
co
i a
M
—7"
Z I-
La La
I- VI 1..J La.
I- IX 0
fi)IX C E
t,_ ix
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taJ
in 0 0 a u.
i—
W La 0
W 0
CZ CD I J
La I—
i— La
X - Lai La
1
I- -I
x
< I- 6 (n
'-
0
V)
0 0
w
< 0
ct)mw
Lai IX 0
-I ILI _i J
Z 0
= ix le
• I-Li
ce
0 z
LL 4'1
0 I 1-
E m -1 le a) V)
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4 " L.
Z
z ,, 1.-
< m
0
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V) __I co
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La le ..„ I
IX 0
Q 0 i —I
< -J N _1
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_1 vi 4I 0 ..t
V1 m I cc Z
Z 0 in ..t v)
= ..:
v, Z o
Li) ce = Lai Z 1-61
Z Lai 0 I-
5 < I-
w
m
i— ce
1- 0 0_
1—
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X
La La
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ll- 41
I- < < CO Z IX Z
0
Z Csi Iii 4 ui (IS
,/0/49-4-1"/ 5/44-k
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM / SC DM

Page 400 of 704

STANDARD No.
1 legOINDIA LIMITED
ge4151Wt7-1e7
(NM meow wawa) (A Govt. of Indio Undertaking)
BRACKET FOR NAME PLATE 7-12-0029 Rev. 5
Page 1 of 1
0
—J
V)
10 R
BRACKET
NAME PLATE
0
r-
4-
N
EIL NAME PLATE
o 0:
+
N
0
N
0
MANUFACTURER NAME PLATE
<TYP
2V •
200
230
NOTES
I. ALL DIMENSIONS ARE IN inn UNLESS OTHERWISE STATED.
2, BRACKET MATERIAL SHALL BE SAME AS SHELL MATERIAL.
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT PKM / SC DM

No. by by
Approved by
Page 401 of 704

STANDARD No.
15i1WieditENIGNEERS
NAME PLATE
41gatafflegwiNDR LIMITED FOR 7-12-0030 Rev. 4
men 0E44E10139MR) (A Govt. of kidio Undertaking)
SMALL EQUIPMENT Page 1 of 1
1"1' 0
125
M IS NAME OF MANUFACTURER
DESIGNED BY I I OWNER I
cs,
ITEM NO. I I JOB NO. I rs,
, P.O. NO. I I YEAR OF FABRICATION I
(.1
D in CODES I INSPECTED BY I ,
IN N. I
DESIGN PRESSURE I I DESIGN TEMPERATURE I
CORROSION ALLOW. I I RADIOGRAPHY I
cs,
TEST PRESSURE I I EMPTY WEIGHT I
rs,
4,st- I
4" DATE OF TEST I
el
5R
4.50 HOLE 2
28 26 28
BRACKET
NAME /
PLATE
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED.
ALL LETTERS, BLOCKS AND BORDERS SHALL BE RAISED POLISHED FACE.
BACKGROUND SHALL BE BLACK.
NAME PLATE SHALL BE TACK—WELDED TO THE BRACKET. WHERE NOT POSSIBLE
IT MAY BE RIVETTED.
NAME PLATE SHALL BE OF STAINLESS STEEL OF 2mm THICK.
BRACKET MATERIAL SHALL BE SAME AS SHELL MATERIAL.
4
3
31.08.2011
12.10.2006
REAFFIRMED AND REISSUED AS STANDARD
REAFFIRMED AND REISSUED AS STANDARD
POREL
POREL
A41
KT
RKG
A.D‘>)
kAAr914/1"/
KM / SC
AKM
DM
VC
No. by by
Approved by
Page 402 of 704
SUPPORTS STANDARD No.
laftetitErsiGINEaS
dgar faMegvir INDIA UMIT1ED FOR 7-12-0032 Rev. 4
INET! meow =mom) to Govt. of India Undertaking)
INTERNAL FEED PIPE Page 1 of 2
SEE
VESSEL DRG. 00
TYPE—IA
100
VENT HOLE
(6+2xC.A.)
50 TO 75 THK. MIN. FLAT
AS PER
PIPE SIZE
I I '• 25 R
£
TYPE-1
INTERNAL FEED PIPE FOR HORIZONTAL VESSEL
SPARGER/FEED PIPE SUPPORT
NOTE TYPE—IA IS APPLICABLE FOR LARGE THERMAL EXPANSION (AIR / GAS SERVICE)
(6+2xC.A.)
THK. MIN. FLAT
TYPE-2
INTERNAL SPLASH FEED PIPE FOR HORIZONTAL VESSEL
65
15 0 HOLE IN PIPE CLEAT (6+2xC.A.)
& 30 LONGx15 WIDE SLOTTED THK. MIN. FLAT
HOLE IN SHELL CLEAT
SUPPORT CLEAT
FOR VERTICAL VESSEL
TYPICAL DETAIL OF BOLTING CLEATS
4 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL

3 12.10.2006 REAFFIRMED AND REISSUED AS STANDARD POREL RKG
Page 403 of 704
STANDARD No.
SUPPORTS
lig ILIANifAsam
(A Govt. of Indio Undertaking)
FOR
INTERNAL FEED PIPE
7-12-0032 Rev. 4
Page 2 of 2
3MM
CLEARANCE
REINFORCEMENT PAD
(NOTE-6)
TYPE—A
(FOR PIPES UPTO 250NB)
TS
20 MIN. D (NB) 50
SHELL
11
II
REINFORCEMENT PAD L
(NOTE-6)
10 N•F
0.5G
If)
TYPE—B
(FOR PIPES ABOVE 250NB)
INTERNAL FEED PIPE FOR VERTICAL VESSEL/COLUMN
T
PIPE N.B. BOLT SIZE E F G
D CA=O CA=1.5 CA=3 CA=5 CA=7
50 — 80 M 12 6 10 12 16 20 60 40 60
100 — 200 M 16 10 14 16 20 25 100 50 100
250 — OVER M 16 14 18 20 25 28 150 100 150
NOTES
IN CASE OF CONFLICT VESSEL ENGG. DRAWING SHALL GOVERN.
MATERIAL OF CLEATS SHALL BE AS PER VESSEL ENGG. DRAWING.
ALL FILLET WELDS TO BE ALL AROUND & SIZE OF WELDS ARE (6+1xC.A.) MINIMUM UNLESS OTHERWISE STATED.
ALL INTERNAL BOLTS SHALL BE MIN. M 12 SIZE AND OF STAINLESS STEEL WITH DOUBLE NUTS.
REINFORCING PAD SHALL BE LARGER BY 50mm ALL AROUND THAN BRACKET CLEATS. NO PAD IS REQUIRED FOR
VESSELS WITH WALL THICKNESS GREATER THAN 25mm.
)?•./
4 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL K 4/KM / SC DM

Page 404 of 704

STANDARD No.
15iatadat ENGINEERS HOT INSULATION SUPPORTS
lgar fatalegWINDIA LIMITED FOR 7-12-0033 Rev. 4
(A Govt. of India Undertaking)
HORIZONTAL VESSEL Page 1 of 1
* 600
INSULATION 8 THK. LOOSE FLAT
THK. (S) * 8 THK. LOOSE 60 HOLES
FLAT RING *
eli 3—I AI
100
15
—I IF(TYR) I
loco
ti
II KT#
REQUIRED
FOR VESSEL
HAVING
FOR VESSEL HAVING DIAMETER DIAMETER
SEE DETAIL -Z ABOVE >2000
ABOVE 600 PROVIDE 30x6 THK.
CLEAT WITH HEIGHT EQUAL TO
INSULATION THICKNESS AT 600
CIRCULAR PITCH 100 LOOSE GALVANIZED
RING (TYP.)
6 0 HOLE
/AT 600 PITCH `B' 'B' 2NO. 6 DIA. HOLES
' I VESSEL PER SEGMENT
tINSIDE
Li
10 T.L FOR DETAIL-X
'A'
10
G.I. BOLTS & NUTS

(N•)
8 THK. RING IN
3 SEGMENTS
8 THK. T-CLEAT AT VIEW—À'
1000 SPACING
(MIN. 3 PER RING-
FOR DETAIL-X ONLY) DETAIL—'Z' (PLAN)
DETAIL—'X'/ DETAIL—'Y'
(SEE NOTE-6)
2N0. 10 WIDE 10 DIA. HOLE IN

SLOTS IN T-CLEAT FLAT RING
NOTES VIEW '13—B'

ALL DIMENSIONS ARE IN mm.
FOR MATERIAL SPECIFICATION REFER ENGINEERING DRAWING.
DETAILS, DIMENSIONS AND NOTES ON ENGINEERING DRAWING
SHALL TAKE PRECEDENCE OVER THOSE SHOWN HEREIN.
CLEATS SHALL CLEAR WELD SEAMS AND IN CASE OF INTERFERENCE WITH
NOZZLES/ATTACHMENTS, INSULATION RINGS SHALL BE NOTCHED/MODIFIED SUITABLY.
5. ONLY T-CLEATS WITH ASBESTOS SHEET, G.I. BOLTING, INSULATION SUPPORT CLEATS
AND LOOSE RING/FLAT SHALL BE SUPPLIED BY THE EQUIPMENT FABRICATOR.
* 6. FOR INSULATION THICKNESS (5) 40mm AND LESS, ONLY RINGS AND FLATS IN PIECES
SHALL BE DIRECTLY WELDED TO SHELL/HEAD, AS SHOWN IN DETAIL-'Z'.
i51q,v4
4 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KTkjit A M / SC DM
Page 405 of 704

TYPICAL DETAIL OF WIREMESH STANDARD No.
ENGINEERS
Ifgartaf5teg
( ems,
INDIA LIMITED DEMISTER AND ITS SUPPORTS 7-12-0036 Rev. 4
(A Govt of India Undertaking)
(FOR VESSELS AND COLUMNS ) Page 1 of 4
0 I.D.
'-SUPPORT BEAM SIZE & NOS. AS

PER TABLE-3 OF SHT. 4 OF 4
SUPPORT GUSSETS ©1500 (MIN. 4 NOS.)

ORIENTATION-BY VESSEL VENDOR.
150 150 150 60/ariE ROD
SEE DETAIL SEE DETAIL -,t.r

REF. SHT 2 OF 4 REF. SHT 2 OF 4
60/Q TIE ROD
(REMOVABLE FROM BOTTOM) (REMOVABLE FROM TOP)
300 SPACING
25 (TYP.)
UPPER
GRATING UPPER 2
GRATING
V1
1OR LOWER
GRATING
LOWER 0
120 HOLE GRATING
0 IN CLAMP 15NB SCH.40s
M10 BOLT PIPE SLEEVE
SUPPORT WELDED WITH
30 WITH NUTS
RING GRID I
90 M10 BOLT 30 0
0
DETAIL-V 60 SUPPORT
(REMOVABLE THROUGH BOTTOM) VIEW - tV1' 122
RING
DETAIL-W
* SEE GENERAL NOTE-4
(REMOVABLE THROUGH TOP)
TYPE-A
4 01.10.2013 REVISED AND REISSUED AS STANDARD GCP : SC
3 27 01 2009 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM SKG
Prepared Checked Stds. Committee Stds. Bureau

Rev.
No. by by
Approved by
Format Nn 9-0n-onni-F4 RAN./ n Cnnvrinht Fit - All rinhts rpsprvp,r1
Page 406 of 704

t3tlc jt4 ENGINEERS
faOteg INDIA LIMITED DEMISTER AND ITS SUPPORTS 7-12-0036 Rev. 4
1.11Ve1 eternreasl.eivnell IA Govt of India Undertaking)
0 I.D.
UPPER
GRATING
SUPPORT BEAM SIZE & NOS.

AS PER TABLE-3
LOWER (DETAILS AS PER SHT.4 OF 4)
GRATING20
UPPORT
BEAM 25x6 THK. FLAT
DETAIL-U TACK
(REMOVABLE THROUGH TOP) WELD
C•1
—1150 150 6 0/OROD

* SEE GENERAL NOTE-4
SEE DETAIL – 'Z' 2-100 HOLES
SEE DETAIL –'U'
60/0 TIE ROD (REMOVABLE THROUGH BOTTOM) (REMOVABLE THROUGH TOP)

0300 SPACING
(TYP.)
120 HOLE FOR M10
BOLT WITH NUTS
0500 PITCH (MIN.)
50 t 50
0 11 ' Zl'
NOTCH
25X25
11 P,- A/11A
_I IBM=
!II!
1 411
14 30
4
14.
WELD
NOTCH 25 90
25X25
VENT HOLE 01250
(MIN. 4NOS.) DETAIL-Z
M 2 BOLT RETAINER PLATE
(MIN.) IN SEGMENTS
50 tl
50 r 50_
DETAIL- X DETAIL-Y
(REMOVABLE THROUGH BOTTOM) (REMOVABLE THROUGH TOP)
VENT HOLE 120 HOLE
DETAIL IN CLAMP
M10 BOLTS
FOR C 200 NO GUSSETS ARE READ.
TYPE-B WITH NUTS
FOR C > 200 MINIMUM 4 GUSSETS SHALL BE PROVIDED.
01250 (MIN. 4 NOS.)
4 01.10.2013 REVISED AND REISSUED AS STANDARD GC P
3 27.01.2009 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM S KG

No. by by
Approved by
Format No R-00-01101-F4 Rpv Convrinht F - All rinhtR rpsprvpri
Page 407 of 704

t31 el ENGINEERS
g)-ar fdtWieg INDIA LIMITED DEMISTER AND ITS SUPPORTS 7-12-0036 Rev. 4
(xr-err eleameashiqsr.4) (A Goof of India Undertaking)
40 WIDE x
MINIMUM 4 NOS. SUPPORT

CLEATS (65x40xt)
EQUALLY SPACED
(t AS PER TABLE-1)
(NOT TO BE FOLLOWED FOR
TRAYED/PACKED COLUMNS)
SECTION X—X
TYPE—C
NOTES
1. THIS TYPE IS APPLICABLE FOR VESSELS WITH REMOVABLE COVERS.
2. GRATING FRAME AND HOLD DOWN BARS TO BE MADE FROM 25 X 6 THK. PLATE.
4 01.10.2013 REVISED AND REISSUED AS STANDARD GCPL Sc
3 27.01.2009 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM SKG

Rev.
No. by by
Approved by
Fnrmat Nn a-nn-on01-F4 Rpv fl C:nnvrinht Fll - All rinhts rpsprvpri
Page 408 of 704

eliaeleiENGINEERS
t3
$ifgar tif5teg INDIA LIMITED
(MR7f ereaverrnordrA) (A Govt of Indo Undertaking)
DEMISTER AND ITS SUPPORTS 7-12-0036 Rev. 4
11
150
BOLT WITH DOUBLE NUTS

BOLT WITH DOUBLE NUTS SECTIONAL VIEW
WITH SLOTTED HOLES IN
WITH SLOTTED HOLES IN OF BEAM CLEAT AND HOLES IN
CLEAT AND HOLES IN BEAMS (REFER TABLE —3)
BEAMS (REFER TABLE —3)
(
11211211114FAIPIWIIIIII%
111•30
1
4101. 1a1111111111
SECTION A—A SECTION D—D SECTION— B—B
TABLE-1 TABLE-2
CORROSION SUPPORT CLEAT/RING THICKNESS (t) CORROSION MIN. FILLET

ALLOWANCE CARBON & LOW ALLOY STAINLESS STEEL® ALLOWANCE WELD SIZE
UPTO 3000 0 ABOVE 3001 0 UPTO 3000 0 ABOVE 3001 0 0 6

0 6 10 1.5 8
1.5 10 14 6 10 3.0 10
3.0 12 16 6.0 12
6.0 18 22 SECTION— C—C
® IF CORROSSION ALLOWANCE IS SPECIFIED TABLE-3 (REFER NOTE-4)
IN VESSEL DRG. THEN ADD 2xCA
VESSEL I.D.(D)/ NO. OF

T HOLE
CARBON STEEL AND S. STEEL BOLT SLOTTED NO OF BOLT
DEMISTER SUPPORT
H LOW—ALLOY STEEL SIZE E W
EFFECTIVE BEAM
CORROSSION ALLowna
(ADD 2xCA) SIZE HOLE TYPE—A TYPE—B
DIA. (0)
0.01.5 3.0 6.0
UPTO 1800 —
1801 < 3600 1 150 M16 18X30 20 1 30 90
3601 < 5400 2 200 6 10 12 18 6 M16 18X30 20 2 35 125
5401 < 7200 3 300 M20 22X36 24 2 50 175
7201 < 9000 4 400 M24 26X40 28 50 325
GENERAL NOTES
2. DEMISTER TYPE AND MATERIAL SHALL BE AS PER VESSEL DRAWING.
3. ALL INTERNAL BOLTS SHALL BE STAINLESS STEEL, OTHER MATERIALS SHALL BE
AS PER VESSEL DRAWING.
4. WIDTH AND LENGTH OF EACH DEMISTER PIECE SHALL BE DECIDED BY VENDOR.
HOWEVER THE WIDTH OF EACH PIECE SHALL BE SUCH THAT THE SAME CAN PASS THROUGH
THE MANHOLE. THE LENGTH OF EACH PIECE SHALL NOT EXCEED 2.5 M.
5. ANY DETAIL SHOWN IN VESSEL DRAWING SHALL BE GIVEN PREFERENCE
TO THAT OF STANDARD.
6. WIDTH OF SUPPORTING RING SHALL BE DECIDED BY VENDOR BASED ON LOADING
7. DEMISTER PAD SHALL BE SUPPLIED SUITABLY OVER SIZED FOR SNUG' FITTING.
4 01.10.2013 REVISED AND REISSUED AS STANDARD GCPA., SC
K
3 27.01.2009 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM SKG

No. by by
Approved by
Format No s-nn-nnni-F4 RPV n Cnnvrinht Fll - All rinhts msPrvPrl
Page 409 of 704

STANDARD No.
ENGINEERS ALLOWABLE NOZZLE LOADS
Ogzu laW5 INDIA LIMITED
(afreFr oirasrt .151,3,1,15.1) IA Govt of India Undertaking)
7-12-0038 Rev. 0
Page 1 of 4
MC
FL
NOTES: —
1. THIS STANDARD COVERS ALLOWABLE NOZZLE LOADS FOR PRESSURE VESSELS & COLUMNS ONLY.
2. EACH PROCESS NOZZLE OF VESSELS SHALL BE ANALYZED FOR THE LOADS PROVIDED IN THIS
STANDARD.
3. THESE LOADS SHALL BE CONSIDERED TO BE ACTING SIMULTANEOUSLY WITH INTERNAL/EXTERNAL
DESIGN PRESSURE. ALLOWABLE STRESS SHALL BE AS PER APPLICABLE DESIGN CODE.
4. STRESS CALCULATIONS SHALL BE CARRIED OUT AS PER WRC BULLETIN N0. 107/297. WRC 107
SHALL BE USED FOR NOZZLES ON DISHED ENDS AND WRC 297 SHALL BE USED FOR NOZZLES
ON CYLINDRICAL SHELL.
5. IN CASE OF FAILURE DUE TO WRC, FEM ANALYSIS / PD 5500 ANALYSIS CAN BE CARRIED
OUT TO ESTABLISH THE ADEQUACY OF PROVIDED CONFIGURATION.
0 31.07.14 ISSUED AS STANDARD GCP KA RKT SC

No. by by
Approved by
Page 410 of 704

STANDARD No.
ENGINEERS
$'g-ar 21 -e
1 -g. 4
1.12'ff ,-1,m,,121513405.1)
INDIA LIMITED
(A Govt ind.a Underlak.9)
ALLOWABLE NOZZLE LOADS
7-12-0038 Rev. 0
Page 2 of 4
CARBON STEEL AND LOW ALLOY STEEL EQUIPMENTS

(CLASS 150 AND CLASS 300)
NOZZLE MT ML MC
FA FL FC
SIZES
(Kgf) (Kgf) (Kgf) (Kgf—m) (Kgf—m) (Kgf—m)
(DN)
50 135 200 200 50 40 30
80 202 300 300 112 90 67
100 270 400 400 200 160 120
150 405 600 600 450 360 270
200 540 800 800 800 640 480
250 675 1000 1000 1250 1000 750
300 810 1200 1200 1800 1440 1080
350 945 1400 1400 2450 1960 1470
400 1080 1600 1600 3200 2560 1920
450 1215 1800 1800 4050 3240 2430
500 1350 2000 2000 5000 4000 3000
600 1620 2400 2400 7200 5760 4320
650 1755 2600 2600 8450 6760 5070
700 1890 2800 2800 9800 7840 5880
750 2025 3000 3000 11250 9000 6750
800 2160 3200 3200 12800 10240 7680
850 2295 3400 3400 14450 11560 8670
900 2430 3600 3600 16200 12960 9720
950 2565 3800 3800 18050 14440 10830
1000 2700 4000 4000 20000 16000 12000
1050 2835 4200 4200 22050 17640 13230
1100 2970 4400 4400 24200 19360 14520
1150 3105 4600 4600 26450 21160 15870
1200 3240 4800 4800 28800 23040 17280
1250 3375 5000 5000 31250 25000 18750
1300 3510 5200 5200 33800 27040 20280
1350 3645 5400 5400 36450 29160 21870
1400 3780 5600 5600 39200 31360 23520
1450 3915 5800 5800 42050 33640 25230
1500 4050 6000 6000 45000 36000 27000
0 31.07.14 ISSUED AS STANDARD \651p KA RKT SC

No. by by
Approved by
Page 411 of 704

STANDARD No.
1ifaf-A5 INDIA LIMITED (A Govt of Incha Undeltaking)
7-12-0038 Rev. 0
Page 3 of 4
CARBON STEEL AND LOW ALLOY STEEL EQUIPMENTS

(CLASS 600 AND ABOVE)
NOZZLE
FA FL FC MT ML MC
SIZES
(DN)
50 168 250 250 62 50 37
80 253 375 375 140 112 84
100 337 500 500 250 200 150
150 506 750 750 562 450 337
200 675 1000 1000 1000 800 600
250 843 1250 1250 1562 1250 937
300 1012 1500 1500 2250 1800 1350
350 1181 1750 1750 3062 2450 1837
400 1350 2000 2000 4000 3200 2400
450 1518 2250 2250 5062 4050 3037
500 1687 2500 2500 6250 5000 3750
600 2025 3000 3000 9000 7200 5400
650 2193 3250 3250 10562 8450 6337
700 2362 3500 3500 12250 9800 7350
750 2531 3750 3750 14062 11250 8437
800 2700 4000 4000 16000 12800 9600
850 2868 4250 4250 18062 14450 10837
900 3037 4500 4500 20250 16200 12150
950 3206 4750 4750 22562 18050 13537
1000 3375 5000 5000 25000 20000 15000
1050 3543 5250 5250 27562 22050 16537
1100 3712 5500 5500 30250 24200 18150
1150 3881 5750 5750 33062 26450 19837
1200 4050 6000 6000 36000 28800 21600
1250 4218 6250 6250 39062 31250 23437
1300 4387 6500 6500 42250 33800 25350
1350 4556 6750 6750 45562 36450 27337
1400 4725 7000 7000 49000 39200 29400
1450 4893 7250 7250 52562 42050 31537
1500 5062 7500 7500 56250 45000 33750
0 31.07.14 ISSUED AS STANDARD GCP KA RKT SC

Date Purpose by
Convenor Chairman
No. by Approved by
Page 412 of 704

STANDARD No.
5fgU
- faW5 INDIA LIMITED 7-12-0038 Rev. 0
la4TO 051.3,
1-55N) IA Govt of India Untleftaking)
Page 4 of 4
STAINLESS STEEL EQUIPMENTS

(ALL CLASSES)
NOZZLE MT ML MC
FA FL FC
SIZES
(DN)
50 135 200 200 50 40 20
80 202 300 300 112 90 45
100 270 400 400 200 160 80
150 405 600 600 450 360 180

200 540 800 800 800 640 320
250 675 1000 1000 1250 1000 500
300 810 1200 1200 1800 1440 720
350 945 1400 1400 2450 1960 980
400 1080 1600 1600 3200 2560 1280
450 1215 1800 1800 4050 3240 1620
500 1350 2000 2000 5000 4000 2000
600 1620 2400 2400 7200 5760 2880
650 1755 2600 2600 8450 6760 3380
700 1890 2800 2800 9800 7840 3920

750 2025 3000 3000 11250 9000 4500
800 2160 3200 3200 12800 10240 5120
850 2295 3400 3400 14450 11560 5780
900 2430 3600 3600 16200 12960 6480
950 2565 3800 3800 18050 14440 7220
1000 2700 4000 4000 20000 16000 8000
1050 2835 4200 4200 22050 17640 8820
1100 2970 4400 4400 24200 19360 9680
1150 3105 4600 4600 26450 21160 10580
1200 3240 4800 4800 28800 23040 11520

1250 3375 5000 5000 31250 25000 12500
1300 3510 5200 5200 33800 27040 13520
1350 3645 5400 5400 36450 29160 14580
1400 3780 5600 5600 39200 31360 15680
1450 3915 5800 5800 42050 33640 16820
1500 4050 6000 6000 45000 36000 18000
0 31.07.14 ISSUED AS STANDARD C CP KA RKT SC

No. by by
Approved by
Page 413 of 704

SPECIFICATION STANDARD SPECIFICATION No.
, k31 ENGINEERS FOR
$iga fèiffl-
eg INDIA LIMITED ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
1.12M ~I, 4,1 JvA,N, IA Govt of Ind,a Underlaking)
VOLTAGE INDUCTION MOTORS Page 1 of 12
d»71E. -gurg
Wf"kil 11
fqw
SPECIFICATION
FOR
ENERGY EFFICIENT
MEDIUM VOLTAGE
INDUCTION MOTORS
REVISED & ISSUED AS STANDARD

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

Standards Standards
Rev. Checked Committee Bureau
Date Purpose Prepared by Convenor Chairman
No by
Approved by
Page 414 of 704

■
31 ENGINEERS FOR
fa;1W5 w INDIA LIMITED
1.177T s'1,,
,q51.7~1) ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
Abbreviations:
AL Aluminium
BASEEFA British Approvals Service for Electrical Equipment in Flammable Atmospheres
BIS Bureau of Indian Standards
BS British Standards
CEA Central Electricity Authority
CIMFR Central Institute of Mines and Fuel Research
CPRI Central power research institute
CT Current Transformer
CU Copper
DGMS Directorate General of Mines Safety
DOL Direct On Line
EIL Engineers India Limited
ERTL Electronics Regional test laboratory
FM Factory Mutual
FRP Fiber Reinforced Plastic
IEC International Electro-technical Commission
IEEE Institute of Electrical & Electronics Engineers
IP Ingress Protection
IS Indian Standard
JEC Japanese Electro-technical Committee
KLPL Karandikar laboratories Pvt. Ltd.
LCIE Laboratoire Central des Industries Electriques
NEMA National Electrical Manufacturers Association
PESO Petroleum and Explosive Safety Organisation
PO Purchase Order
PVC Poly Vinyl Chloride
RPM Revolutions per Minute
UL Underwriter's Laboratories
VFD Variable Frequency Drive
VDE Verband Deutscher Elektrotechniker
Electrical Standards Committee
Convenor: Mr. B.R. Bhogal
Members: Ms. S. Anand

Mr. Parag Gupta
Mr. M.K. Sahu
Mr. A.K. Chaudhary (Inspection)
Ms. N.P. Guha (Project)
Page 415 of 704

--1 ENGINEERS FOR
gzx Wes
i
INWR 290O 2151JY4M,
w INDIA LIMITED
ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 GENERAL REQUIREMENTS 5
4.0 OPERATING CONDITIONS 5
5.0 PERFORMANCE 6
6.0 CONSTRUCTION DETAILS 7
7.0 MISCELLANEOUS ACCESSORIES 10
8.0 CRITICAL SPEEDS 10
9.0 PAINTING 10
10.0 INSPECTION AND TESTING 11
11.0 CERTIFICATION 11
12.0 PACKING AND DESPATCH 11
Page 416 of 704

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

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

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

electrical machines.
Page 417 of 704

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

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

specified in datasheet.
b) Motors shall be designed for re-acceleration under full load after a momentary loss of
voltage with the residual voltage being 100% and is in phase opposition to the applied
voltage.
c) Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds
under cold conditions and 8 seconds under hot conditions. In addition, Locked Rotor
Page 418 of 704

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

No. of consecutive start-ups with initial temp. of the
3
motor at ambient level (cold)
No. of consecutive start-ups with initial temp. of the
2
motor at full load operating level (hot).
4.4 Direction of Rotation
Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided for
motors, direction of rotation for which the motor is designed shall be permanently indicated by
means of an arrow. Directional arrow should be manufactured from corrosion resistant material.
When a motor is provided with bi-directional fans, a double-headed arrow should be provided.
Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the
terminals UVW are connected to a power supply giving a terminal phase sequence in the order
UVW. Counter-clockwise rotation of the motor shall be obtained by connecting the power
supply to terminals so that the phase sequence corresponds to the reversed alphabetical
sequence of the terminal letters. Ample space shall be provided at the terminal box for
interchanging any two external leads for obtaining the reverse phase sequence.
5.0 PERFORMANCE
5.1 Motors shall be rated for continuous duty (Si), unless otherwise specified.
5.2 Unless specified, the starting current (as % rated current) shall be limited to maximum 600-
700% (based on number of poles and KW rating) as per IS 12615:2011, subject to IS tolerance
5.3 In particular cases, when the starting current is to be limited, care shall be taken such that the
design values of torque meets the load requirement while at the same time complying to clause
4.3 above of this specification. Unless otherwise specified the minimum pull-up torque of
motors, at rated voltage & frequency shall be minimum 50% of the rated full load torque.
5.4 In particular cases, when the starting with reduced voltage is specified, care shall be taken such
that the design values of torque meets the load requirement while at the same time complying to
clause 4.3 above of this specification.
5.5 Starting torque and minimum torque of the motor shall be compatible with the speed torque
curve of the driven equipment under specified starting and operating conditions.
In case where characteristics of driven equipment are not available while selecting the motor,
minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be 90%
of rated value for motors above 75 kW.
5.6 The breakdown torque at the rated voltage shall be not less than 175% of the rated load torque
with no negative tolerance. Unless otherwise agreed, the breakdown torque shall not exceed
300% of the rated load torque.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 419 of 704

ENGINEERS FOR
IA GoN oi Unde■tak.91 ENERGY EFFICIENT MEDIUM
In case of motors driving equipment with pulsating loads (e.g. reciprocating compressors,
crushers, ball mills) the minimum value of pull out torque at 75% of the rated voltage shall be
more than the peak value of pulsating torque and the current pulsation shall be limited to 40%.
5.7 Motors fed by variable frequency drive shall additionally meet the following requirements.
5.7.1 The motors shall be suitable for the current wave forms produced by the power supply including
harmonics generated by the drive. The necessary coordination by motor manufacturers with
drive manufacturers regarding harmonics generated by VFD shall be taken care and
incorporated in motor design suitably.
5.7.2 The motors shall be designed to operate continuously at any speed over the range as per process
requirement with minimum range as 10-100% of rated speed or as specified in data sheet. The
characteristics shall be baked on the application — in terms of constant torque / variable torque as
per the driven equipment. Additional cooling fan shall be provided if required to limit the
temperature rise to specified limits, alternatively option of applying suitable de-rating may be
considered.
5.7.3 The motors shall withstand torque pulsation resulting from harmonics generated by the solid
state power supply.
5.7.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.
5.8 The minimum values for performance characteristics of these motors shall be as given in the
tables 1, 2 & 3 of IS 12615-2011 for 1E2 motors, subjected to tolerance as per IS/IEC. Motor
meant for application with VFD, the efficiency value can be one class lower as per IS.
6.0 CONSTRUCTIONAL DETAILS
6.1 Windings
6.1.1 Unless otherwise specified, motors shall be provided with class 'B' insulation as a minimum. In
case of motors with class 'F' insulation, the permissible temperature rise above the specified
ambient temperature shall be limited to those specified in the applicable Indian standards for
class 'B' insulation.
6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated.
Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for
operating satisfactorily in humid and corrosive atmospheres.
6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In this
respect, particular care shall be taken for the stator windings for direct-on-line starting squirrel
cage motors. Insulation shall be provided between coils of different phases that lie together.
Core laminations must be capable of withstanding burnout for rewind at 350 °C without damage
or loosening.
6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the
joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses.
6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star
connection may be accepted. In case of motors with star-delta starting, the motor windings shall
be fully insulated for delta connection.
Page 420 of 704

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

2.2 kW and below 2.5 cu
3.7 kW 6 cu
5.5 kW 10 cu
7.5 kW 16 cu
9.3 kW 16 cu
11.0 kW 16 cu
15.0 kW 50 Al.
18.5 kW 70 Al
22.0 kW 70 Al
30.0 kW 95 Al
37.0 kW 120 Al
45.0 kW 150 Al
55.0 kW 240 Al
75.0 kW 2x95 Al
90.0 kW 2x120 Al
110.0 kW 2x240 Al
125.0 kW/132 kW 2x240 Al
160.0 kW 2x240 Al
6.2.6 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed
between the purchaser and manufacturer.
Page 421 of 704

ENGINEERS FOR
rr fa2es
1.12,f elvostVO51,~11
INDIA LIMITED
IA Govt of Indo Undertalong) ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
6.3 Motor Casing and Type of Enclosure
6.3.1 The minimum degree of motor enclosures including terminal boxes and bearing housing shall
be IP-55 as per IS.
6.3.2 Motors for outdoor use shall be suitable for installation and satisfactory operation without any
protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal of
condensed moisture except in case of flameproof motors (Type Ex d/Exde).
6.3.3 A11 internal and external metallic parts, which may come into contact with cooling air, shall be
of corrosion resistant material or appropriately treated to resist the corrosive agents, which may
be present in the atmosphere. Screws and bolts shall be of rust proof material or protected
against corrosion.
6.3.4 Unless otherwise agreed, motors shall have standard frame sizes (min.) for various output
ratings as stipulated in IS.
6.4 Bearing and Lubrication
6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be
chosen to provide a minimum L-10 rating life of 5 years, (40, 000 hours) at rated operating
conditions
(The L-10 rating life is the number of hours at constant speed that 90% of a group of identical
bearings will complete or exceed before the first evidence of failure).
6.4.2 The bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft
expansion. Motors designed to handle external thrust from the driven equipment shall be
supplied with a thrust bearing at the non-driving end.
6.4.3 In cases such as pumps for hot liquids where the driven equipment operates at high
temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient
ventilation of the bearing and disperse the heat transmitted from the driven equipment by
conduction or convection.
6.4.4 Bearings shall be capable of grease injection from outside without removal of covers with
motors in the running conditions. The bearing boxes shall be provided with necessary features
to prevent Loss of grease or entry of dust / moisture e.g. labyrinth seal/ oil seal/ V seal. Where
grease nipples are provided, these shall be associated, where necessary, with appropriately
located relief devices, which ensure passage of grease through the bearings.
6.4.5 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5
years of trouble-free service without the necessity of re-lubrication.
6.5 Cooling System
All motors shall be self ventilated, fan cooled. Fans shall be corrosion resistant or appropriately
protected. They shall be suitable for motor rotation in either direction without affecting the
performance of the motor. If this is not possible for large outputs, it shall be possible to reverse
the fan without affecting the balancing of the motor.
For motors operating in hazardous area, the fans shall be of an anti-static non-sparking material.
Page 422 of 704

ENG1NEERS FOR
Ogzrr
Mt c-lecnrc' 411
w INDIA LIMITED ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
6.6 Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration Level
and long service life for the bearings. Die cast aluminum rotors for motors in hazardous areas
may be accepted provided the same are type tested and approved by competent authorities.
6.7 Shaft Extension
Motors shall be provided with a single shaft extension with key-way and full key. Motor shaft
shall be sized to withstand 10 times the rated design torque.
6.8 Lifting Hooks
A11 motors weighing more than 30 kg. shall be provided with lifting hooks of adequate capacity.
6.9 Earth Terminals
Two earth terminals located preferably on diametrically opposite sides shall be provided for
each motor. Necessary nuts and spring washers shall be provided for earth connection.
7.0 MISCELLANEOUS ACCESSORIES
7.1 Anti-Condensation Heaters
All motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters,
sized and located so as to prevent condensation of moisture during shutdown periods.
For motors with heaters installed in hazardous atmospheres (Zone - 1 or Zone - 2), such heaters
shall conform to the provisions of applicable Indian Standards and temperature classification
specified in the motor data sheet.
The heater leads shall be brought out, preferably, to a separate terminal box which shall be of
the same specification and grade of protection as the main terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate that the
heater supply shall be isolated before carrying out any work on the motor.
7.2 Name Plates
In addition to the motor rating plate, a separate number plate for motor tag number shall be
fixed in a readily visible position. This number shall be as per the motor data sheets.
8.0 CRITICAL SPEEDS
The first actual critical speed of stiff rotors shall not be lower than 120 % of the synchronous
speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed; the
second actual critical speed shall be above 120 % of the synchronous speed.
9.0 PAINTING
A11 metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy based
final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All unpainted steel parts
shall be suitably treated to prevent rust formation. If these parts are moving elements, then these
shall be greased.
Page 423 of 704

ENGINEERS FOR
f laZ5 la INDIA LIMITED 6-51-0064 Rev. 1
Govt o7 Indo Undertaking) ENERGY EFFIC1ENT MEDIUM
10.1 All tests shall be carried out at manufacturer's shop under his care and expense.
10.2 The manufacturer shall submit all internal test records of the tests carried out by him on the
bought-out items, motor sub-assembly and complete motor assembly.
10.3 The manufacturer shall carry out the following routine and acceptance tests as per applicable
Standards/ITP on all the motors.
a) Visual check (Nameplate, terminal box location, terminal type, clearance, size, entries,
space adequacy & gland size, direction of rotation etc.)
b) Dimension check (shaft height etc.)
c) Cable glands, cable lugs size and no. of entries in terminal box.
d) Winding resistance
e) No load test & measurement of voltage, speed, current, power input
f) Measurement of starting torque, starting current, full load torque, breakdown torque
g) Reduced voltage starting & running
h) Insulation resistance before and after high voltage test
i) High voltage
i) Vibration
10.4 The manufacturer shall submit the following type test certificates (one sample from each
type/rating):
a) Full load test & measurement of voltage, current, power slip, power factor, bearing,
noise
b) Efficiency & pf at 100%, 75% and 50% load
c) Temperature rise test
d) Momentary overload test
e) Vibration
f) Noise Level
g) Over speed
h) Measurement of starting torque, starting current, full load torque.
10.5 For VFD fed motors, all tests as specified in the VFD specification shall be followed in addition
to the above.
11.0 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ BASEEFA/ LCIE/ UL/ FM/ KLPL or
equivalent). All indigenous motors shall conform to Indian standards and shall be certified by
recognised testing agencies. A11 motors (indigenous & imported) shall also have valid statutory
approvals (e.g. PESO, DGMS etc). as applicable for the specified location. All indigenous
fiameproof motors shall have valid BIS license and marking as required by statutory authorities.
12.0 PACKING AND DESPATCH
A11 the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/rail or
trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases
to prevent damage to the finish. Crates/cases shall have skid bottom for handling. Special
notations such as `Fragile', `This nide up', `Center of gravity', Weighe, Òwner's particulars',
`PO Nos.' etc. shall be clearly marked on the package together with other details as per purchase
order.
Page 424 of 704

ENGINEERS FOR
fg".2x w INDIA LIMITED 6-51-0064 Rev. 1
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elvOrt'4, (A Govt ot InOla Undertahmg) ENERGY EFFICIENT MEDIUM
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature,
unless otherwise agreed.
Page 425 of 704

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Page 430 of 704

* Measurementswill bemade inaccord ancewith standardJEC(Logarithmicproporti onmethod II & Iasperrotor design) .
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Page 433 of 704

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Page 434 of 704

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z
z
ti"AON Z000-ZS-L S3cIld NONOIIO3NNOO
'oN ativaNVIS
0 00 rn J. 1,1
11
113131AI MOTH
Cb
t21
31770N/121111N3A
C
0.A91:I L3- L.000-00-9*clisl)et.uioj

V /A Z E3 rn ■
,; c: 65 v /A V /A V /A
CA 0, -q
■ • > .-4 PO tTi CA 0, cl, 0, CA 0, V
ci, 0,
CD
CD c
o on '-' a cc rr o c, o c, c, c, o c,
4t , 4k c,
4t o
4k o c> CD CD CD
4t 4t 4t 4t 4L
..... .-
1":! :',,.: w 2,,'
. uo .,■'
;7;7 ;.1'7
. .11 :37:
on on -1 CA .1 "Irl LO
-ri r) n r- n
n
r r- p0
r- . r- .
CD CD X CD 70 CD CD 70
C7 C7 C7 C7 u 0 C7
'A" FLGD
P P * * • * *
A" SCRD*
PROCESS
CONNECTION
...
2" FLGD.
::37
,
." ,■'0 1:".- . 1
''-!
''. W ';',7
, 7
3 3
on C4 n1 cn "< -in. nn GO
r) (-) r- n 2 r- . r- . n
r- Pc C) 7o ,,, 70
CD C7 0 CJ 0 --3 C)
VALVE
C)
'A" FLGD
* * • * ...-, 0
'A" SCRD*
.- .-
;:r. ;;F: w ,":3: u'.3 w w
,',7, Z.7
.. .3: 1
LO Ln n1 LO hl nn nn
nn "T1 n r) ,-. r) r- . , , t-
r-
c) r"
C 70 ,
0 x 4
C C) C)
2" FLGD
P P :.- P C7 C7
'A" SCRD
T
'A" SCRD
C) P
WHERE PIPINGCLASS RECOMMENDS
CONNECTION
FIRST BLOCKINSTRUMENTS
SCRDCONNECTION ..
-- -.
3 4, .":,:f.3 Qa ;.„.:' ;;;.7
. 3
7.7
;:',7 ::...7 .3 l'.̀
.
'
.
I. Go Go ' on " Ln „ 3 1
r-
P, p ,1 -,1 r) (-, -1
r- il (::J c E E P:, El
c) c
P P 1..- P 0 u a • P„ u
__
2" FLGD.
t! ...! :37
LO C4 vu ...‹ . 3 3 l'' ,;,Z
!..,',.
r- 1` P2 2 P P. P. cc on a
C) aa 65 0 tr- cn C 0 C C
Y2" SW
%" BW
VALVE
P -3 0 CI c
'A" FLGD
P l'
-'i C
INSTRUMENT CONNECTION ON PIPES
... ...
;.. .c ..;‹ ^': ;;;Z, W. ,,;.r w w w ua La ;')..7.
cn cn -n un -n .-1 .:1 .11 ce,
n (..) r- () r- r- r- r a ()
r- r" 7s pD3 C) xi C) C) C) C) C) 20
2" FLGD
0 C) C7 C7 C7 C7 :7 0 C7 C) V Z7
'A" SCRD
'A" SCRD
'A" SCRD
C7 P
'ING CLASS RECOMMENDS
CONNECTION
FIRST BLOCK INSTRUMENTS
BW # CONNECTION
..- --
:;"‹ 1",
! .
"3:,
'
. (J'i '33! w Is: ;:37 ;:',,.'
3 ;73'-
,
t137, 1 „ 3 :
nn ,, .., nn nn
-n n1 'f=";
r r r r r r =" c4
c)
c) c c
r0
c c o c) i,-i x c)
2" FLGD.
0
'A" FLGD
Puuoc) *uu
'" SCRD*
P P
PROCESS
'A" SCRD**
CONNECTION
'
,.;‹ ;-...,: 1-;,..-, .,.'3 "Ea

,..< .
,,.-: ';'....t...3 .■.373 1".. 3 ::,3: ;1"!
3
.11 .71 `11'T1 nn nn nn a a
t- r- r r" nn r 2r' r r a r r r-
c.) c) c),c2,C)cncc)c)c)c)c)
FIRST
BLOCK
c
'A" FLGD
A" FLGD
c :.--, C7 .-.- C7 C7 0 0 C) C7
'A" FLGD
p
CD
CD
NJ
0
- --
." ;.',.7. ;.,u. ;.;,-, L'..! t'f< '"i. w L., 3.,..t L..) ::;.7
.
„ nn C n1 ni=1 -.6 h6 -.6 ,,
h,
.noN Z000-Z9-L
n1 ,-, r (-.) r' r-

'(e'2) r-- r- r- ,
.oN a avaNvis
r c) C) c c C) C) x
.1
2" FLGD
c-) C7 p C7 ? C7 Z7 C7 C7 p
'A" SCRD
'A" SCRD
'A" SCRD
0 P
CONNECTI
Copyright EIL — All rightsreserved

INSTRUMENTS
ON
WHERE PIPINGCLASS RECOMME NDS
FLGDCONNECTION
VALVE
Page 437 of 704

▪
'0 Oa -4 ON to 41. Lo t,
..) --
C
lewiod
(.01 4:a. L.)
<5>
ORIFICE
(FLGD ) <5>
+ + * 4t * "Iv . .; > "11
FLOW METER
FLOW METER
ORIFICE (DIA-
THERMOWELL
* X'-'-rO
PHGRAMSEAL)
+
SEAL PRESSURE
rrI '-3 CM'X
c4 .,„
cn > E.-;) "il >
DIAPHGRAM SEAL
/A V
FLOWMETER ++
TYPEOF
INSTRUMENTS <5>
c:r"rn ; Z cs O,
XJ .-< C, CD
[DP INSTRUMENTS <5>

DIAPHGRAM SEAL D.P.
(-) (./) > V) H>OZ
— , _ r, r, C, C,
# 009 <
INSTRUMENTS
0'AO/AL3-1000-00-8
#009
7r ii 0 --] CA m = -1 ' -7.,. 12 -4 xt 4k
AVERAGINGPITOT TUBE
DIAPHGRAM(CHEMICAL)
_PRESSUREINSTRUMENTS
PRESSUREINSTRUMENTS
rZ,..,-1:1 cliF5S2c4=
INSTRUMENTS (SCRD.) <5>

r; Z ni r-
0r- rl c Po C) rrl .5
mH r)._,°7JmCHn
-, -r., ----
:C '0 >H z ..- .e■
. 1):',.! l'iZ.! ,7,.
,
H3,2r1-Jmr44
r, 2 z r- c) ..4 po
m cnm - e-,HHrZC c) r) (-)
> ,1 r- cn - cn z cD P.
z c) 'z' 'd PC
m,2rHu,r,-, c) x)
0
3" FLGD
3" FLGD.
3" FLGD.
'A" SCRD*
PROCESS
*
3/4" SCRD**
%"SW/BW#
c) ,_ n(-) 24=z 0 a
IT' ,...., .n C: r- m , -1 > H
r- crl
CONNECTION
CY.° '-2- P,.-lS 2, ;:rz

H2 , u mcz3,mc
HcA „...-t.,4„..m .-3 _
OH u 7:,==1'4>pc :.', 1-,:z.! ,;z ,' ,;z
4po z rri - - En rri, ..:
cA
cn (4 0 -cl H
m= m m
-orri c zz, r- aa Ca
-tlz HcA P'' 0
VALVE
3" FLGD 6a
3" FLGD.
3/4" SCRD*
*
3/4"SW/BW#
OH P V V
FIRST BLOCK
(4,
(BY INST)
z r-n1 0
CLADDED PIPES
(n r- Z (4
Y>rcxr) 4c4Mm -
r q m >n -3 ,;;Z: 7. t...,.■
m M2Z"-j= cn ^ri
cn xJ -000 m
n ,-ri r) r
c ...›....,
(4. r- XI 0
—3 C.) 0
WHERE PIPING CLASS SPECIFIES
3" FLGD
3" FLGD
3" FLGD
3 " FLGD
'A" SCRD
V2" SCRD
,-,
SCRD.
>2=-7
'A" SCRD.
-t, z o m2 P P 5?
r
CONNECTION
poz,
INSTRUMENTS
F i
0, cA rn - r)
U 700H H
-to ,r
‹ c4 > -
c,, m z g
a c ,.-
cr X 0 t-r1 C/)
H rri til0H I ' 0
Xi 0 ..n > P:J
C
3" FLGD
3" FLGD
3" FLGD
o
3" FLGD
3" FLGD
3" FLGD
3" FLGD
> .:J'
'A" SCRD*
...
PROCESS
K C c., ct' h
tri 0
rri H (4
:c
Z --
CONNECTION
H cn cn >
0 t-
r r-
> :',..'
.-3
1A
o 5' r
: vi
O . . .
?:' z v)
= < `-0 oa
VALVE
3"FLGD
3" FLGD
m
3/4" FLGD
a
1 1/4"FLGD
'A" SW/BW
'A" SW/BW
CD 7y
' " SW/BW
r
FIRST BLOCK
<
(BY INST)
rrl rn
< c
S3dId NO NO1133NNO3IN3IN I11:11SNI
rn
CI =
,...,
r r1 ....
CEMENT LINED PIPES
X w0 C: ,.."7 .■
's7. .,7
rrl PO > ..,z :. .1
(n C) r- Cl) CA cn . .
H <n (-) n n
e P zJ zi
5 c
3" FLGD
3" FLGD
3" FLGD
WHERE PIPING CLASSSPECIFIES
'A" SCRD
0 0
3" FLGD+
ti, c 0
0, p c
INSTRUMENTS
.< CO .-
'-'
K 0 n1
m-i K
r) 2 m
z
x --
0 !
-3 „Z .1:
1A
-1
.11
z P r,
F--)' 0 r” c)
> 0 c)
1" FLGD
1" FLGD
3" FLGD
3" FLGD
0
3" FLGD.
r- 0
PROCESS
0
' " FLGD
C)
n >
CONNECTION CONNECTION
o c.)
z t-1-1
X H
ul
n u, --.
H = "r1
O > . '
,
1 ' t-'
?c1 r- r
r-
VALVE
C
1" FLGD
1" FLGD
3" FLGD
I" FLGD
0
3" FLGD.
cc
(BY INST)
1 'A" FLGD
m 0
FIRST BLOCK
2 up
rn
-0 Ca
za 0
2 Ca
C)
..;Z
n
-nau Z000-Z9-L
0 -,1 C . .
C)
.oN auvaNvis
RUBBER/TEFLON LINED PIPES
-c, r- x
C)
3" FLGD
WHERE PIPINGCLASS SPECIFIES
3" FLGD
'"SCRD
'A" SCRD
3" FLGD.
'A" SCRD
3" FLGD+
C C
INSTRUMENTS
pamasai spAi IIV—113114 6pAdo0

CONNECTION
Page 438 of 704

Oln-a-eifith ENGINEERS STANDARD No.
azit 'Meg Ter INDIA LIMITED THERMOWELL 7-52-0035 Rev. 3
1.11271MORMMORI) IA Gm of India Underwonw
Page 1 of 3
cZ 34 mm CHAIN
ct• 1/2"NPT r_
FOR CHAIN TERMINATION

(ONLY FOR TEST THERMOWELL) PLUG WITH CHAIN
45 mm
FULL PENETRATION WELD

I VT FLANGE

NO WELD MATERIAL
PROJECTION BEYOND RF
ID 11 mm
BORE TO BE CONCENTRIC
WITH 0.D. WITHIN 10% OF
WALL THICKNESS
18 mm
(1)
NOTES - 1. THIS STANDARD IS APPLICABLE FOR ;

TEMPERATURE GAUGES, BEADED TEMPERATURE ELEMENTS AND DUPLEX TEMPERATURE ELEMENTS.
THERMOWELL UPTO 1500 CLASS AS PER ASME OR EQUIVALENT.
TYPE OF FLANGE SHALL BE RTJ FOR RATING (AS PER ASME CLASS) > 600.
DP TEST SHALL BE CARRIED OUT FOR ALL WELD JOINTS.
4. CHAIN AND PLUG SHALL BE APPLICABLE ONLY FOR TEST THERMOVVELLS.
3 21-03-12 ter 4--v" DTh-'
REVISED & REISSUED Manoj G RI5/J S M)
2 21-08-06 REVISED & REISSUED MN TGM PM VJN
Rev. Stds. Committee
Date Prepared Checked Stds. Bureau
No. Purpose Convenor
by by Chairman
Format No. 8-00-0001-F4 Rev.O Approved by
Copyright EIL - Al rights reserved
Page 439 of 704

1511=4-a-eite, STANDARD No.
ENGINEERS
DReg ie INDIA LIMITED
MET MaR a51300,10 (A GOvl Of WM Undertgo001
THERMOWELL 7-52-0035 Rev. 3
Page 2 of 3
0 34 mm CHAIN
r_ 00 I's 1.0z"
q 1/2"NPT
•
•
••
Min
4!)
N
FOR OW TERMINATION PLUG WITH CHAIN
(ONLY FOR TEST THERMOWELL) 45 mm

1 1/7 FLANGE
ABM
6R
NO WELD MATERIAL
OD 21 mm
z
ID 7 mm
WRH O.D. WRMIN 10% OF
WALL THICKNESS
JO 16 mm
NOTES - 1. THIS STANDARD IS APPLICABLE FOR ;

SINGLE TEMPERATURE ELEMENT.
THERMOWELL UPTO 1500 CLASS AS PER ASME OR EQUIVALENT.
TYPE OF FLANGE SHALL BE RTJ FOR RATING (AS PER ASME CLASS) > 600.
4. CHAIN AND PLUG SHALL BE APPLICABLE ONLY FOR TEST THERMOWELLS.
2116,-,)
3 21-03-12 REVISED & REISSUED rtm. Cit SL MS p hi
2 21-06-06 REVISED & REISSUED MN TOM PM VJN
by by
Approved by
Format No. 8-00-0001-F4 Rev.O
Copyright EIL - All rights reserved
Page 440 of 704

STANDARD No.
safteiela ENGINEERS
au WaveINDIA LIMITED BUILT-UP THERMOWELL
1.4.1
7-52-0035 Rev. 3
Page 3 of 3
0 34 mm
45 mm
WELD

2' FLANGE

NO WELD MATERIAL
MACHINE TAPER TO BE CONCENTRIC

1Nt T 11 INSIDE DIAMETER WITHIN 10%
OF WALL THICKNESS
WITH O.D. WITHIN 10% OF
WALL THICKNESS
BAR STOCK
0 18 mm
NOTES:-
TYPE OF FLANGE SHALL BE RTJ FOR RATING (AS PER ASME CLASS) >
3 21-03-12 REVISED & REISSUED e‘anoj R JMS
by by
Approved by
Format No. 8-00-0301-F4 Rev.O Copyright EIL • AI rights reserved
Page 441 of 704

THERMOCOUPLE / RTD STANDARD No.
ENGINEERS
i 5
INDIA LIMITED ASSEMBLY 7-52-0036 Rev. 3
WITH THERMOWELL
ravage e5 J4o534) IA Govt of India Undeftakong)
Page 1 of 1
1/2" NPT
(NOTE-1)
CHAIN
UNION 1/2" NPT
NIPPLE 1/2" NPT
(NOTE-2)
THERMOWELL
NOTE - 1. IN THE CASE OF DUPLEX THERMOCOUPLE/RTD, TWO INDEPENDENT

CABLE ENTRIES SHALL BE PROVIDED.
2. FLANGE TYPE, SIZE AND RATING SHALL BE AS PER DATA SHEET.
3 19-07-11 Revised & Reissued Manoj

TAM" RP/JS DM
2 22-07-05 Reaffirmed and Reissued MN AKG PM VJN
No. Date Purpose by by
Convenor Chairman
Approved by
Page 442 of 704
LIST OF ITEMS
CODE DESCRIPTION SIZE ENDS QTY. UNIT CODE DESCRIPTION SIZE ENDS QTY. UNIT
Page 443 of 704

LIST OF ITEMS
Page 444 of 704

STANDARD No.
s@itRa-eg ENGINEERS LEVEL GAUGE
NPA I IAG4A&Incliallndertaking)
ON VESSEL Page 1 of 1
P - BY PIPING
I- BY INSTRUMENTATION
V- BY INSTRUMENT VENDOR
LIST OF ITEMS
7 NIPPLE 1/2" TH X PL 4 No
48 FLANGE 2" X 3/4" FL X TH (Rod) 2 Ne
51 CAP 1/2" TH 2 Ne
210 GATE VALVE 1/2" SW 2 Ne
n 44,..
12-10-11 Revised and Reissued Mano /J
3 07-08-06 Reaffirmed and Reissued MN TGM PM VJN
Page 445 of 704

Ogar0154'dg
.
ala_it4 ENGINEERS
INDIA LIMITED
INSTRUMENTATION OF
PACKAGE UNITS
6-52-0052 Rev. 3
,A Govt of Indla Undertaking) Page 1 of 58
Ada fry
*o-t-§al21mm ITFTW fq fff -kmRT

INSTRUMENTATION OF PACKAGE
UNITS
3 16.03.15 REVISED AND REISSUED
2 29.06.09 REVISED AND REISSUED

RG RP TGM ND
1 25.06.97 REVISED AND REISSUED. RK BRS RB AS
0 30.06.86 ISSUED AS STANDARD SPECIFICATION. RK RB AKV AK

Standards Standards
Committee Bureau
No by by
Approved by
Page 446 of 704

ENGINEERS INSTRUMENTATION OF
&
$'1gal• faiW
IA Govt of India Undeflaking) PACKAGE UNITS Page 2 of 58
Abbreviations:
AARH •. Arithmetic Average Roughness Height

AC :. Alternating Current
AWG American Wire Gauge
CPU Central Processing Unit
CRCA .: Cold Rolled Cold Annealed
DCS •. Distributed Control System
DPDT :. Double Pole Double Throw
DPST :. Double Pole Single Throw
DTM Device Tool Manager
DVD Digital Versatile Disc
EDDL Electronic Device Description Language
FDT .: Field Device Tool
FF :. Foundation Fieldbus
FISCO :. Fieldbus Intrinsically Safety Concept
FNICO •. Fieldbus Non-Incendive Concept
HART •. Highway Addressable Remote Transducer
HIC Hand Indicating controller
HMI Human Machine Interface
HT .• High Tension
110 •. Input /Output
IP •. Ingress Protection
IU •. Interface Unit
LAS •. Link Activity Scheduler
LED Light Emitting Diode
LT Low Tension
MAWP .• Maximum Allowable Working Pressure
MCB :. Miniature Circuit Breaker
MCC •. Motor Control Center
MR •. Material Requisition
NB -. Nominal Bore
NC Normally Close
NO Normally Open
NPT National Pipe Threads
NPTF •. National Pipe Threads Female
NPTM •. National Pipe Threads Male
P&ID -. Piping and Instrumentation Diagram
PID :. Proportional, Integral and Derivative
PLC •. Programmable Logic Controller
PTC •. Performance Test Code
PTFE :. Poly Tetra Fluoro Ethylene
PVC :. Poly Vinyl Chloride
RAM :. Random Access Memory
RB •. Rockwell Hardness in B Scale
RTD :. Resistance Temperature Detector
Page 447 of 704

n31 ENGINEERS INSTRUMENTATION OF
Oe.11 tlf5ieg INDIA LIMITED 6-52-0052 Rev. 3
IvIten eivtutzmatmissif Govt of India UrvIertaktng) PACKAGE UNITS Page 3 of 58
RTU Remote Terminal Unit

SOV • Solenoid Valve
SPDT • Single Pole Double Throw
TFT • Thin Film Transistor
TMR Triple Modular Redundant
UPS • Uninterrupted Power Supply
URV Upper Range Value
WC Water Column
Instrumentation Standards Committee
Convener : Mr. Rajiv Gupta
Members : Mr S Bhowal
Mr M Nandi
Mr R K Gupta
Ms Rima Kundu
Mr S Mahesh Kumar
Ms. N.P.Guha (Proj.)
Page 448 of 704

43* ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
sl ar Wes
g
NV, rieaxt
INDIA LIMITED
IA Govt of hrhA Unde,taong) PACKAGE UNITS Page 4 of 58
CONTENTS
PART I GENERAL SPECIFICATION OF INSTRUMENTATION 5
1.0 GENERAL 6
2.0 DESIGN PHILOSOPHY 12
3.0 SPARES PHILOSOPHY 19
4.0 GENERAL SPECIFICATION OF INSTRUMENTS 20
5.0 LIST OF DOCUMENTS ATTACHED 46
PART II SPECIFICATION FOR MATERIAL, INSTALLATION, TESTING AND

COMMISSIONING 47
1.0 INSTALLATION MATERIALS 48

2.0 INSTALLATION 54
3.0 TESTING AND CALIBRATION 56
4.0 COMMISSIONING 58
ANNEXURES:
ANNEXURE — I MATERIAL SELECTION CHART

ANNEXURE — II BLANK FORMATS
Page 449 of 704

0 e1 ENGINEERS INSTRUMENTATION OF
OQzll taRcg INDIA LIMITED
6-52-0052 Rev. 3
n AVIRot ottratte On avast. Govt Ind. unciertakog) PACKAGE UNITS Page 5 of 58
PART I
GENERAL SPECIFICATION OF
INSTRUMENTATION
Page 450 of 704

$1g-ar laf5teg INDIA LIMITED 6-52-0052 Rev. 3
r.tea v/vore attow)i) IA GovtofIndia Undertaking) PACKAGE UNITS Page 6 of 58
1.0 GENERAL
1.1 Scope
1.1.1 This specification together with the attachments covers the design and engineering of
instruments, control systems, accessories and materials, along with special test equipments,
where the supply is part of a package being supplied by vendor. This specification is general
and all instruments/systems included may not be required for the proposed package. The
scope shall be as defined in the scope of supply of Instrumentation.
1.1.2 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc.
if any, will be indicated in Scope of Supply of Instrumentation and Job Specification of
Instrumentation included in the material requisition.
1.1.3 This specification provides only the qualitative specifications of commonly used
instruments. Specifications of Instruments not covered in this specification shall be
submitted by vendor for review by Purchaser.
1.1.4 Vendor shall be fully responsible for design, material selection, sizing and selection of the
proper instruments for their system. The compliance to this specification does not absolve
the vendor of the responsibility towards contractual obligations with regards to
completeness, proper selection, satisfactory operation and easy maintenance of the unit.
1.1.5 All items, as offered, shall be field proven and should have completed trouble free
satisfactory operation for a period of minimum 6 months on the bid due date in the similar
application with the process conditions similar to those as specified in the purchaser's data
sheets. Items with proto-type design or items not meeting provenness criteria specified
above shall not be offered
1.1.6 In the event of any conflict between this specifications, data sheets, related standards, codes
etc., the vendor shall refer the matter to the purchaser for clarification and only after
obtaining the same should proceed with the manufacturing/engineering of the item in
question. DCS/ PLC is not included in this specification. Vendor shall refer specifications
attached separately in case DCS/ PLC is included in scope of supply.
1.2 Bids
1.2.1 Vendor shall provide the following information along with their offer:
Compliance to Complete Material Requisition/Tender.
Utility requirements including Power consumption and Instrument air supply

consumption. The offer shall indicate the power requirement for Uninterrupted Power
Supply (UPS), Non-UPS and DC power clearly indicating the locations for each.
Estimated heat load for the equipment located in control room.
Control room size and layout (Tentative)
1.2.2 Vendor shall clearly define the operational philosophy proposed, which shall be in line with
requirements specified in the job specification. Vendor shall also clearly indicate the
provision of control panels and control systems required for the package along with offer.
1.2.3 Documents like Instrument list and typical specifications and any other details if submitted
by vendor in their bid, shall not be reviewed and shall be retained for records only. All such
details shall be submitted by vendor only after the finalisation of P&ID (Piping and
Instrument Diagram) during detail engineering. No implication shall be admissible on the

Format No. 8-00-0001-F1 Rev. 0 Copyright EL — All rights reserved
Page 451 of 704

Og.r..1101Wteg INDIA LIMITED 6-52-0052 Rev. 3
IA Govt of InOta UndettakIngt PACKAGE UNITS Page 7 of 58
basis of these documents and vendor shall be responsible for completeness and correctness
of the same with respect to Purchase Requisition/Tender.
1.2.4 Vendor's offer, catalogues, drawings, instrument manuals etc. shall be in English.
1.2.5 In addition to mandatory spares, commissioning and consumables indicated elsewhere in

this specification, Vendor shall also quote recommended spares for 2 years normal operation
for the complete instrument and control system for the offered package.
1.3 Applicable National/International Standards:
1.3.1 Design and terminology shall comply, as a minimum, with the latest edition of following
codes, standard practices and publications, unless otherwise specified:
AGA American Gas Association, Gas Measurement Committee
Report No.3 Orifice Metering of Natural Gas and Other Related
Hydrocarbon Fluids — Concentric, Square-Edged Orifice
Meters
Report No.7 - Measurement of Natural Gas by Turbine Meter
AG181 Foundation Fieldbus System Engineering Guidelines
ASME American Society of Mechanical Engineers.

1.20.1 Pipe Threads.
16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24
Metric/Inch Standard
16.47-B Large diameter Steel Flanges: NPS 26 Through NPS 60
Metric/Inch Standard
16.20 Ring Joint Gaskets and Grooves for Steel Pipe Flanges.
ANSI/FCI American National Standards Institute/Fluid Controls Institute

70.2 Control valve seat leakage classification.
API American Petroleum Institute

RP 520 Sizing, Selection and Installation of Pressure Relieving
System in Refineries.
Part-I - Sizing and Selection
Part-II - Installation
RP 521 Guide for Pressure Relieving and Depressurising Systems.
RP 526 Flanged Steel Safety Relief Valves.
RP 527 Seat Tightness of Pressure Relief Valves.
MPMS Manual of Petroleum Measurement Standards.
RP 551 Process Measurement Instrumentation.
Part 1 - Process Control and Instrumentation.
RP 552 Transmission Systems
RP 554 Process Instrumentation and Control
RP 555 Process Analysers
S 2000 Venting Atmospheric and low pressure storage tank.
S 670 Machinery Protection Systems
ASME American Society of Mechanical Engineers.

ASME Boiler and Pressure Vessel Code (BPVC), Section VIII,
Division 1: Rules for Construction of Pressure Vessels.
PTC 19.3 TW :2010 & ERATA 2012
THERMOWELLS Performance Test
MFC-3M Measurement of Fluid Flow in Pipes using Orifice, Nozzle
and Venturi

Page 452 of 704

tgz1T tte--'
eg INDIA LIMITED 6-52-0052 Rev. 3
1.1¢F, eironeffoJoso•i) (A Go. of WO UndeffOk,o9) PACKAGE UNITS Page 8 of 58
MFC-14M Measurement of Fluid Flow in Pipes using Small Bore

Precision Orifice Meters
ASTM American Society for Tests and Materials

BS British Standards
EN 50288-7 Multi Element Metallic Cables used in Analogue and Digital
Communication and Control — Part-7 : Sectional
specification for Instrumentation and Control cables
EN 10204 Inspection Document for Metallic Products
IBR Indian Boiler Regulations.
IEC International Electrotechnical Commission.

60079 Electrical Apparatus for Explosive Gas atmosphere.
60085 Electrical Insulation — Thermal Evaluation and Designation
60332 Tests on electric and optical fibre cables under fire conditions
- Part 1-1: Test for vertical flame propagation for a single
insulated wire or cable - Apparatus
Parts and Sections
60529 Classification of degree of protection provided by enclosures.
60534-2 Industrial Process Control Valves-Flow capacity.
60584-2 Thermocouples — Tolerances
60751 Industrial Platinum Resistance Thermometer and Platinum
Resistance Sensors
61285 Industrial Process Control Safety of Analyser Houses
61000-4 Electromagnetic compatibility for Industrial Process
measurement and Control equipment
61158 Foundation Fieldbus Specifications
61804-3 Functional blocks for process control — part 3 Electronic
Device Description Language (EDDL)

IS Indian
Standard
5 Colours for ready mixed paints.
319 Specification for free cutting Brass bars, rods and sections
1239 Mild steel tubes, tubulars and other wrought steel fittings
1271 Specification of Thermal Evaluation and Classification of
Electrical Insulation
1554 PVC insulated (heavy duty) electric cables-working
Part I voltage upto and including 1100V
2074 Ready mixed paints, air drying, red oxide- zinc chrome.
3624 Specification for pressure and vacuum gauges
5831 PVC insulation and sheath of electric cables
7358 Specifications for Thermocouples
8784 Thermocouple compensating cables

ISA International Society of Automation
S-5.2 Binary logic diagrams for process operations.
S 7.0.01 Quality standard for Instrument Air
S-75.xx Standards related to Control Valves
ISO 5167 Measurement of fluid flow by means of orifice plates, nozzles and venturi
tubes inserted in circular cross-section conduits
ITK Interoperability Test Kit (latest version)

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1
k3 ENGINEERS INSTRUMENTATION OF
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.W1 03/1 (A Gov/ of India Untlertakolg) PACKAGE UNITS Page 9 of 58
NACE National Association of Corrosion Engineers
NEC National Electric Code
NEMA National Electrical Manufacturer's Association
NFPA-496 National Fire Protection Association - Purged and pressurised enclosures for
electrical equipment
OSHA Occupational Safety and Health Authorit.
SAMA Scientific Apparatus Maker's Association

1.4 Drawing and Data
1.4.1 Detailed drawings, data and catalogues required from the vendor shall be as per Vendor
Data Requirement attached elsewhere in the Material Requisition / Tender.
1.4.2 The minimum requirements expected from the various documents listed in Vendor Data
Requirement shall be as follows:
1.4.2.1 Document Control Index (DCI)
This document lists out all drawings and documents prepared and/or submitted by vendor to
purchaser after placement of order through vendor portal. Following information shall be
available in this document:
Name and number of each drawing and document listed.
Expected and Actual date of submission to purchaser.
c) Review category of the documents
1.4.2.2 Instrument Index
Instrument Index lists out all instruments appearing on the P&ID without any exception. It
is a basic instrument document which is necessary for the smooth execution of a job and is
also a reference document after the completion of job. Instrument Index shall be prepared in
EIL Format. In case, any other format is used, it must contain all information as listed in
this format as a minimum.
1.4.2.3 Sub Vendor List (for Instruments and Accessories)
This document shall list out all instrument items and accessories including control system
along with the name of the sub-vendors from whom vendor is likely to procure these items.
Instrument Sub-vendor shall meet the enlistment conditions of Ell, approval at the time of
placing the order on sub-vendor for the Project Approved Vendor List. The EIL approval
conditions are available with the Sub-Vendors. Vendor shall follow the approval
requirement.
For Instruments / items not covered in the vendor list, Vendor shall get approval from
purchaser/ owner for the vendors proposed, prior to the placement of order. In such cases the
sub-vendors suggested shall be manufacturer of repute and it shall meet the provenness
criteria specified in this document.
1.4.2.4 Instrument Sizing Calculations
Instrument sizing calculations provide information regarding sizing (as per standards
specified else-where in this document), type, selection and other related information.

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51:4231a5teg
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Following sizing calculations shall be applicable, in general, duly approved by the authority
indicated in Vendor's Standard Quality Plan;
Control valve including noise and velocity.

Pressure relief valves/pilot operated pressure relief valves/rupture disc/breather
valve/flame arrester.
Flow element including orifice plates, averaging pitot tubes, venturi, flow nozzle etc.
Utility consumption calculation including power supply (UPS/Non UPS), Instrument
air, steam for tracing, cooling water, nitrogen etc.
Cable sizing calculations for power cables.
Intrinsically safe loop calculation for proper selection of cables considering various
entity parameters.
Segment loading calculations.
Thermowell wake frequency calculations as pe ASME PTC 19.3 TW-2010
1.4.2.5 Utility Requirements
This document lists out the following information regarding utilities required by the vendor;
List of utilities required i.e. Power (UPS, Non UPS), Instrument air, Cooling water,
steam for tracing, Nitrogen etc.
Location and estimated/actual requirement at each location. The requirement shall be
listed as minimum/normal/maximum.
Incase of AC power, the In-rush current with duration and power factor shall also be
indicated for each location.
In case of cooling requirement of any instrument/equipment, vendor shall provide the
detail of pressure/flow requirement with location.
1.4.2.6 Nozzle Elevation for Level Instruments
Nozzle elevation for level Instruments represent the nozzle elevation, nozzle sizes and
rating, requirement of stand-pipes, type of level instrument etc. for all the vessels, columns,
exchangers and tanks.
1.4.2.7 Purchase Requisition (PR)
Purchase Requisition shall contain following information as a minimum but updated in line
with the finally accepted offer of the successful vendor including:-
Instrument specifications including detailed instrument data sheet and special

requirements, if any
Testing and Inspection requirements
Vendor data requirements
Other related documents like Standard Specifications, Quality Assurance requirements etc.
1.4.2.8 Functional Schematics
Functional Schematics details out the functionality of all the loops shown on the P&ID
including their correlation. The schematic shows all the hardware necessary to configure a
loop including their physical location, their interconnection and important software blocks as
applicable to make a loop complete. Similar loops may be combined under the same
functional schematic.

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1.4.2.9 Logic Diagrams
Logic diagram is a logic representation of process interlock and shutdown system and details
out the functionality, in a schematic form, as either process cause and effect table shown on
the P&ID or in a separate write-up. The schematic shall be prepared based on ISA S5.2 — A
Binary Logic Diagrams for Process Operations and shall show the physical location of
Input/output devices, their interconnection with functional blocks, bench status of all
electrical devices etc. The schematic shall also be supplemented with operational
requirements like startup and process bypasses, reset and shut down push buttons, selector
switches, status lamp etc.
1.4.2.10 Segment Drawing
The FF segment drawing provides the complete segment design details indicating all the
devices of a segment, the Tag names, device control/monitoring functional requirements,
spur length, FF Junction box barriers connectivity, termination details, location of JB etc.
1.4.2.11 Instrument Loop drawings
Each loop shall have a separate Instrument Loop drawing which shall show each component
from field device to final receiver including physical location; initiating device, its terminal
number; junction box with its terminal number; cable number with pair number/polarity;
receiver instrument terminals/cabinet terminals; system functional blocks of loop in
simplified manner (without configuration details).
1.4.2.12 Control Room Layout
Control room layout drawing shall show the location of control panels, system cabinets,
marshalling racks and other auxiliary cabinets, consoles with monitors, hard wired consoles,
printers, non-system panels/cabinets including panels/cabinets for packages, LEL panel, fire
alarms panels or any other equipment required to be installed in control room. The layout
shall be prepared on control room architectural drawing and shall also show layout of
equipment in engineering room/computer room etc.
1.4.2.13 Panel Front Arrangement
This drawing shall show the arrangement of panel mounted instruments like indicating
instruments, alarm annunicator, indicating lamps, push buttons/switches etc. including their
approximate sizes and their mounting locations.
1.4.2.14 Configuration Diagram
This drawing is a graphical representation of all major hardwares required in a configurable

control system which are necessary to meet all the expected functional requirements.
1.4.2.15 Dynamic Graphic Display Drawings
These drawings provide a graphic representation of P&ID's arranged in a sequence which

when displayed on the HMI, shall provide easy and logical operational views.
1.4.2.16 Input/ Output Assignment
This document indicates the physical assignment of various I/O modules and their respective
channels to various physical inputs and outputs.
1.4.2.17 Instrument Duct/ Tray/ Trench Layout
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Instrument duct/tray trench drawing shows the routing of main instrument duct/tray trench in
the unit/plant. The drawing shall be prepared on plot-plan/ Equipment layout and shall show
the size, cross-section at various locations, general notes, symbols, reference drawings and
the control room entry.
1.4.2.18 Instrument Location Plans
Instrument Location Plans shall show the location of instruments, location of tapping points,
location of local panels, junction boxes, main cable trenches, instrument air distribution
scheme etc. These drawings are prepared on equipment layout drawings in 1:50 or 1:100
scale depending on density of instruments.
1.4.2.19 Instrument Cable Schedule
The instrument cable schedule shall show all instrument and power cables required for
complete instrumentation. The document shall show tag number, cable number, type, length
and size of cables, type of junction box, identity of local panel, control room panel/cabinet
location etc. The document shall also show the size of terminals considered for power
junction boxes and the dimensions of cable considered by the contractor.
The cable schedule document shall include all single & multi pair cables indicating
terminations of instruments, field junction boxes and respective termination in satellite rack
room cabinets. The instrument cable schedule shall be prepared on ElL format.
1.4.2.20 3D Modelling:
Whenever 3D modeling is included in package vendor's scope, it shall include the following
instrumentation items as a minimum:
Instrument Cable Duct.

Analyser shelter/ cabinet.
Local Control Panels.
Prefabricated Hook-ups
Gas Detectors
CCTV
Instrument Junction Boxes
Instrument Stanchions and Canopy
2.0 DESIGN PHILOSOPHY
2.1 Instrumentation shall be complete in every respect in accordance with latest approved
P&IDs for the safe, efficient and easy operation, start up and shut down of the plant.
2.2 All instruments and equipments shall be suitable for use in a hot, humid and tropical
industrial climate in which corrosive gases and/or chemicals may be present. As a
minimum, all instruments and enclosures in field shall be metallic construction, dust proof
and weatherproof to IP-65 as per IS/IEC-60529 and secure against the ingress of fumes,
dampness, insects and vermin. All external surfaces shall be suitably treated to provide
protection against corrosive plant atmosphere.
2.3 The design of electronic instruments shall be in compliance with the electromagnetic
compatibility requirements as per IEC 61000-4 'Electromagnetic compatibility for Industrial
Process measurement and Control equipment.

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n31 ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
Ifgar idtareg INDIA LIMITED
PACKAGE UNITS
1.1E'A 292tATUOT.AVA/ IA Govt of InOta Undertak.ng) Page 13 of 58
2.4 Instrument Requirements for Classified Area:
Certified Intrinsically Safe (IS) equipment as per IEC-60079-11 shall be used, in

general, in hazardous area, for conventional loops.
Field instruments in fieldbus loops shall be designed and certified as per the hazardous
area protection specified in Job Specification.
In case intrinsically safe equipment is not available, flameproof enclosures as per IEC-
60079-01 may be considered.
Junction boxes, cable glands and accessories required for flameproof instruments shall
also be certified flameproof.
All non flameproof panels and cabinets installed in classified area shall be purged as per
requirements specified in NFPA-496, as a minimum.
Other type of protection specified in IEC-60079 shall not be used.
2.5 Statutory Approvals
Contractor shall be responsible for obtaining all statutory approvals, as applicable, for
all instruments and control systems.
In addition, equipments/instruments/systems located in the hazardous area shall be

certified by the local statutory authorities for their use in the area of their installation. In
general following certification shall be given:
For all intrinsically safe/ FISCO/FINICO/ explosion proof/flameproof equipments/

instruments/systems or equipments with any other type of protection allowable as
per this package which are manufactured abroad and certified by any statutory
authority like Laboratorie Central Des Industries Electriques (LCIE), British
Approval Service for Electrical Equipment in Flammable Atmospheres (Baseefa),
Canadian Standards Association (CSA), Factory Mutual(FM), Underwriters
laboratories(UL) etc. for compliance to ATEX directives or other equivalent
standards. All these equipments/ instruments/systems shall additionally have the
approval of Petroleum and Explosives Safety Organisation (PESO)/ Chief
Controller of Explosives (CCE), Nagpur, if installed in INDIA and the same is
mandatory.
For all flame proof equipments manufactured locally (indigenously), the testing
shall be carried out by any of the approved test house like Central Institute of
Mining & Fuel research (CIMFR)/ Electronics Regional Testing Laboratory
(ERTL) etc. The equipment shall in addition bear the valid approval from
Petroleum and Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur and a valid BIS license.
iii) For all intrinsically safe equipment manufactured locally (indigenously), the
testing shall be carried out by any of the approved test house like Central Institute
of Mining & Fuel research(CIMFR)/ Electronics Regional Testing
Laboratory(ERTL) etc. The equipment shall in addition bear the valid approval
from Petroleum and Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur.
c) Approvals other than above shall neither be offered nor will these be acceptable.
2.6 Following units of measurement shall be applicable, unless indicated specifically otherwise:

Flow Liquid M3/11

Steam kg/h

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50Z:Eq ENGINEERS INSTRUMENTATION OF
51gaf Weg INDIA LIMITED 6-52-0052 Rev. 3
n oqR ,Neant CIA ,141,0, A GoK otino undertak.9) PACKAGE UNITS Page 14 of 58
Gas & Vapour Nm3/h

PressureNacuum Gauge kg/cm2g
mm of H2O
Vacuum kg/cm2
mm of H2O
Temperature °C
Level
Analysis
ppm
Conductivity micro siemens
Viscosity mPa.s (cP)
2.7 Local control loops shall be avoided. In case these are unavoidable, these shall be electronic
field mounted manual loading station only.
2.8 Ranges for instruments shall be selected in general, such that in normal process operation
the indication is between 35% to 65% of the range i.e. middle 30% of the full working
range.
2.9 Field mounted direct actuated Flow and Temperature switches shall not be used. Instead,
transmitters shall be used along with flow element/temperature element. Process switches
shall not be considered unless its use is unavoidable and the same shall be subject to
purchaser's approval. In case switch has been considered, same shall be provided with
sealed micro switch contacts rated for the specified application. Also contacts shall be SPDT
type unless otherwise specified. Contacts used in intrinsically safe applications shall be
suitable for the application.
2.10 Intrinsically Safe System Requirements (for Non Fieldbus Instruments)
Following points must be considered while designing an intrinsically safe system;
All intrinsic safety barriers shall be active type isolating barriers only, with three port
isolation.
Barriers must be selected based on entity concept. Cable parameters shall also be
considered while matching entity parameters.
Each instrument in the hazardous area and the intrinsic safe barrier shall be certified for
intrinsic safety by any statutory authority.
Each input and output in a loop shall have separate barrier. No barrier shall be shared
between two loops or input/outputs.
Any device required to be connected to any intrinsically safe loop in the hazardous side
permanently or temporarily shall also be certified intrinsically safe.
Configuration tools whenever required for any intrinsically safe item, which forms part
of the intrinsically safe item, shall also be certified intrinsically safe.
2.11 Power Supplies and their Distribution
a) Power supply shall be made available at the following voltage levels, unless otherwise
specified:
0 For Instruments, Control Systems, 240V AC/110V AC
Analyzers

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n31 ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
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OIRT ,12,V77 aRJQCITA)
INDIA LIMITED
IA Govt of India Undertaking) PACKAGE UNITS Page 15 of 58

Solenoid Valves, Relays, lamps 24V DC/110V DC ±10%/
240 AC/ 110 V AC UPS

Input interrogation voltage 24V DC/110V DC ±10%
0
Panel/cabinets lighting 240V AC Non-UPS ± 10%
In case 24 V DC is required for Input interrogation, relays and lamps, any other vendor
supplied instruments/ electronics), same shall be considered by the vendor using dual
redundant power packs (110 V AC to 24 V DC converter). 24 V DC feeders shall not be
provided by Purchaser unless indicated specifically in the job specifications.
All instruments, control systems (PLC and DCS) and analyser system shall be able to
operate at the following UPS specification:
Voltage level 240V AC/110V AC ± 10%

Frequency 50 Hz ±3 Hz
Switch over time : 5 milli seconds.
Power feeders shall be supplied to the vendor at only one location. All further
distribution within the package shall be taken care of by the vendor. Number and size of
power feeders shall be informed during detail engineering. Vendor shall provide
adequate number and size of terminals and cable glands required.
d) Instrument power circuits shall be individually protected and isolated from fault with
the help of fuses and DPST switches. Power supply to the individual instrument shall
be disconnected with the help of DPST switch and protected with the help of fuses.
Miniature circuit breakers (MCB's) may be selected in place of switch fuse unit in case
protection is provided for overload protection.
2.12 Alarm Philosophy
Alarms shall be provided to give audible and visual warning of any process and
machine malfunction in the package.
All trips shall have a pre-trip warning alarm in addition to alarm at the trip condition.
Package alarms including pre-trip warning alarms and trip alarms (shutdown alarms)
shall be annunciated on the local panel as per approved P&ID.
Rotating equipments shall have the status indication provided on the local panel as per
approved P&ID.
e) 'Fail-safe' type with normally closed alarm contacts shall be used.
2.13 All line or equipment mounted instruments like control valves, pressure relief valves,
thermo-wells, orifice flanges, level instruments etc., installed on pipes and vessels under
IBR shall be certified by IBR or their authorized representative.
2.14 Location of process connections shall be from the side or from the top of the process
equipment but not from the bottom. This requirement is applicable to both pipes and vessels.
The location of lower side connection for level measurement when necessary shall be
extended inside the equipment with the approval of purchaser to prevent plugging due to dirt
or other suspended solids. In addition, the connections shall be short, vertical or horizontal
and without any pockets.
2.15 Material of construction of instruments shall be as per the material selection chart, attached
as Annexure I of this specification, as a minimum. However vendor is responsible to ensure
that the selected material is consistent with temperature, pressure, corrosion conditions and
other process requirements.

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'
a ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
$T4Zif laWeg
INDIA LIMITED
my', twaxt ...5,... IA Govt 07 Groba Undenak,r,g ) PACKAGE UNITS Page 16 of 58
2.16 Field Transmitters
2.16.1 SMART Field Transmitters:
2.16.1.1 The field transmitters in all conventional loops shall be smart type only unless specified
otherwise. Field transmitters for flow, pressure, temperature, differential pressure and level
applications shall be yoke mounted type unless specified otherwise. Meter electronics used
for flow measurement etc. shall include all the associated items like pre-amplifier, converter,
transmitter, integrator, integral output meter etc.
2.16.1.2 Field transmitter shall be intrinsically safe and meter electronics shall be intrinsically safe, in
general. In case, intrinsically safe is not available from the approved vendor list enclosed
with this MR/tender, flameproof enclosure is acceptable. In case sensor/ pick up coil is
intrinsically safe, suitable barrier shall be provided and installed in flameproof enclosure.
2.16.1.3 These transmitters shall be 2 wire systems having 4 - 20 mA DC output with superimposed
digital signal having simultaneous analog and digital communication with HART
communication protocol, unless otherwise specified.
2.16.1.4 The transmitter shall be microprocessor based and it shall incorporate a non-volatile memory
which shall store complete configuration data of transmitter and sensor characterization. All
necessary signal conversions, including conversion to produce output with the required
protocol shall be carried out in the transmitter electronics. The configuration data of the
instruments shall be stored in a non-volatile memory such that this remains unchanged
because of power fluctuations or power off condition. In case vendor standard instrument
has battery backed RAM, vendor to ensure that battery drain alarm is provided as diagnostic
maintenance message.
2.16.1.5 Transmitter shall also run complete diagnostic subroutines and shall provide diagnostic
alarm messages for sensor as well as transmitter healthiness. In the event of detection
failure, the output shall be driven to a predefined value, which shall be field configurable.
2.16.1.6 Universal hand held configurator / terminal for the configuration and maintenance of
instruments with HART output shall be provided for all HART based smart instruments.
2.16.2 Fieldbus Field Transmitter and devices:
2.16.2.1 Fieldbus transmitters/ devices shall be provided, if specified, in fieldbus loops.
2.16.2.2 Field bus based transmitter/ devices shall meet the following requirements;
All instruments must satisfy the requirements of the fieldbus registration laboratory
with applicable checkmark like foundation field bus, profibus etc as specified in Job
Specification.
All instruments shall be polarity in-sensitive. Also transmitter shall be LAS capability.
Line plugging detection facility shall be provided, whenever specified in data sheet.
All instruments shall have Analog Input (AI) block and Proportional, Integration and
Differential (PID) control block, as a minimum.
All instruments must be interoperable and shall have valid interoperability test
clearance like ITK latest version for foundation field bus or equivalent for profibus PA,
as applicable.
The field bus instruments shall support peer to peer communication with two wire
communication and bus powered supply.
All instruments shall support EDDL or FDT/DTM requirements.

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Og en ttliteg INDIA LIMITED
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.AF,,,,AIA' AAJAA,A) IA Govt Ind Undertaking) PACKAGE UNITS Page 17 of 58
Internal software shall be configured by the vendor including the following information
such as serial number, Device Tag (Tag Number) and Process description
All instruments shall be capable of supporting incremental Device descriptor (DD) for
extra functionality and for software revisions in device memory.
Soft copy of the Device Descriptor (DD) files for configuring the FF device parameters
and common file format (CFF) files for integrating the device into the system shall be
provided by the bidder for offline configuration by System vendor immediately after
despatch.
Fieldbus based field indicator shall be able to indicate all signals available in the
fieldbus segment, selectively.
2.16.2.3 The fieldbus / devices provided shall be able to communicate with latest universal fieldbus
communicator.
2.16.3 Accuracy of transmitters (Pressure & Differential pressure), smart as well as fieldbus based
shall be as follows:
Type of Transmitter Range of Transmitter Accuracy for the rangeability of 1:10
Direct 760 mm WC and above Equal to or better than ±0.075%
Direct Less than 760 mm WC Equal to or better than ±0.15%
Diaphragm seal 500 mm WC and above Equal to or better than ±0.25%
Diaphragm seal Less than 500 mm WC Equal to or better than ±0.5%
The accuracy is defined as the combined effect of repeatability, linearity and hysteresis.
2.16.4 Transmitter shall update the output at least 8 times a second unless otherwise specified.
Unless specified otherwise in purchaser's specification, transmitter response time shall be as

follows:
For transmitter range of 760 mm WC and above, the response time shall be equal to or
better than 500 milliseconds.
For transmitter range below 760mm WC, the response shall be equal to or better than 1
second.
The response time of the transmitter shall be considered as the sum of dead time and 63.2%
step response time of the transmitter.
2.16.5 Unless specified otherwise, the over-range/static pressure protection of the transmitter shall
be as follows;
Over range/ static pressure <N1>

Range of Transmitter Pressure
Pressure Transmitter Differential
(kg/cm2) Transmitter (kg/cm2)
0 < (V < 250 mm WC 20 20
250 < ®< 1000 mm WC 45 52
1000 < ®< 5000 mm WC 45 70

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5000 < ®< 10000 mm WC 45 160
1 < ®< 10 kg/cm2 52 160
10 < 0 < 100 kg/cm2 160 210
> 100 kg/cm2 210 210
<N1> However if the Over range/ static pressure value specified above is less than the
maximum/ design pressure of service conditions, offered instrument shall be suitable for the
maximum/ design pressure.
2.16.6 Diaphragm seal DP transmitters in flow measurement with a DP of less than 250 mmWC
shall be avoided and alternate type of flow meters shall be provided for such cases suitable to
the process condition.
2.16.7 All transmitters shall have vent and drain facility and the same shall be provided with metallic
plugs. All the cable entries shall also be provided with metallic plugs.
2.17 Instrument Connections
2.17.1 The connections of instruments installed on vessels, tanks, standpipes and piping shall be as
per following EIL Standards.
7-52-0001 Instrument Connections on Vessels and tanks.

7-52-0002 Instrument connection on Piping.
2.17.2 Pneumatic instrument connections for signal and air supply shall be 1/4" NPT (F).
2.17.3 Electrical cable entry connection shall be 1/2" NPT (F)/ 3/4"NPT (F) as per the cable size.
Suitable cable gland shall be used.
2.17.4 End connections shall meet the following, unless, otherwise specified:
Threaded end connection shall be NPT as per ASME B1.20.1.

Flanged end connection shall be as per ASME B16.5 or ASME B16.47B or AWWA
C207 Cl D as per related Piping Specification.
When Flanges are Raised Face (RF) type, the face finish shall be as per ASME B 16.5
and shall be as follows:
125 AARH : 125 to 250 microinch AARH
63 AARH : 32 to 63 micro inch AARH
Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20 and
groove finish shall be as follows:
63 AARH : 32 to 63 micro inch AARH
2.18 Instrument Air Supply
2.18.1 Air supply at pressure specified elsewhere shall be made available to the vendor at the
battery limit for distribution to the instruments.
2.18.2 Pneumatic Instruments shall operate on air supply of 1.4 kg/cm2g and shall have
transmission and output signal of 0.2 to 1.0 kg/cm2g.

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15iF4TE? ENGINEERS INSTRUMENTATION OF
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Govt of India Undertaking) PACKAGE UNITS Page 19 of 58
2.18.3 Instrument air quality shall be as per ISA- S 7.0.01and free from corrosive, hazardous and
toxic contaminants.
2.19 Interface with Main Control Room
2.19.1 Wherever applicable, instrument junction boxes shall be provided as interface between
purchaser and vendor. Marshalling details between purchaser-vendor cabling shall be shown
with corresponding junction box termination number allocated against appropriate
purchaser's/vendor's instrument tag number in the format provided by purchaser.
2.19.2 Direct signals from package/package skid
All signals from package skid/battery limit to purchaser's control room shall be terminated
in the junctions boxes located at the battery limit. Separate junction boxes shall be used for
the following type of signals:
Fieldbus based Signals

Intrinsically Safe Analog Inputs/Outputs (4-20mA)
Non -intrinsically Safe Analog Inputs/Outputs (4-20mA)
Intrinsically Safe Thermocouple Inputs
Intrinsically Safe RTD Inputs
Intrinsically Safe contact Inputs
Non-Intrinsically Safe contact Inputs
Intrinsically safe contact Outputs
Non-Intrinsically Safe contact Outputs
DCS and PLC signals shall be further segregated and shall in no case be mixed up.
2.19.3 Repeat Signals from Package Local Panel
Where signals as indicated in Clause 2.19.2 is less in number and do not justify
separate junction boxes, all such signals may be routed via local control panel.
All such signals shall be terminated on separate terminal strips in the local control
panel. The terminal strips shall be segregated as per Clause 2.19.2.
c) Intrinsically safe barriers for all such signals, wherever required, shall be provided.
The above shall only be considered with prior approval from purchaser.
3.0 SPARES PHILOSOPHY
3.1 Mandatory Spares
Unless specified otherwise, the following mandatory spares shall be provided by vendor.
3.1.1 Predefined Mandatory Spares
Mandatory spares shall be ware-house spares and shall be supplied as loose items.
3.1.1.1 Higher of 10% or minimum one of each type (range, type, material and rating ) of complete
instruments for commonly used instruments such as transmitter, gauges, temperature
elements, switches, probes.

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3.1.1.2 For Control valve one set of packing and bonnet gasket with tag, one set of stem seal o-ring
for each actuator and piston o-ring additionally for each piston actuated valve, line bolting
(set of studs and nut) and set of gasket with each tag no.
3.1.2 Commissioning Spares
Vendor shall be responsible to supply all spares which are found necessary to replace while
performing pre-commissioning and commissioning activities and this includes system
oriented items (hardware / software).
3.1.3 Consumable spares
Vendor shall supply consumable spares for six months of normal operation.
3.1.4 Engineering Spares
3.1.4.1 For Control system, installed spare module of higher of 10% or minimum one of
input/output modules (including termination panels, if applicable) to enhance the system
functional requirements of control system.
3.1.4.2 For Hardwired console / Local control panel:
A minimum of 20% spare windows with alarm modules shall be provided in alarm
annunciator.
A minimum of 20% spare status lamps / switches / pushbuttons / terminals or one no of
each type, whichever is higher, shall be provided.
For pneumatic panels, 10% spare instrument air header branch lines and 15% spare
bulkheads and tapping points shall be provided in each panel.
Control panels shall have additional spare-space as per clause 4.2.8 of this specification.
3.2 Spares for 2 years normal operation
Vendor shall supply a list of recommended spare parts for each instrument and system
required for two (2) years of normal operation. These spares shall be quoted separately.
4.0 GENERAL SPECIFICATION OF INSTRUMENTS
4.1 Panel Board Instruments
4.1.1 Alarm Annunciator shall either be solid state type or microprocessor based programmable
type with plug in modules and integral power supply. Window display shall be back lighted
incandescent lamps or cluster LED type integral power supply. For window display with
back lighted incandescent lamps two numbers of incandescent lamps of minimum 5 watt
each shall be provided for each window. For cluster type LED display, the number of
LED's in the cluster matrix windows shall be sufficient to provide illumination level of at
least 150 lumens. The circuit shall be designed in such a way that removal/failure of one
lamp or LED from a window/ cluster shall not hamper functioning of that particular
window/display. The annunciator lamps shall be replaceable from the front of the enclosure
panel. In general, dedicated alarm logic module shall be used for each alarm input.
However, when micro processor based alarm Annunciator is offered failure of one
microprocessor shall not affect more than four alarm windows.
Intrinsically safe annunciator circuit, when used, shall have power supply unit in a safe area.
Annunciator alarm sequence shall be as per F3A of ISA.
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The design of the alarm annunciator system shall be such that transient alarms of less than
330 milliseconds duration shall be automatically rejected.
4.2 Panel Design
4.2.1 All panels shall be supplied in pre-tubed/pre-wired condition and shall be completely tested
at manufacturer's works prior to dispatch.
4.2.2 Panels shall be free standing type. Panels with instruments mounted on the front shall be
fabricated from 3 mm thick cold rolled steel sheet. If the same is not available, 4 mm thick
hot rolled steel sheet shall be used. All other panels shall be fabricated from 2mm thick cold
rolled steel sheet. Angle iron framework shall use a minimum section of 50 x 50 x 4 mm
angle. Panel painting procedure shall include blast cleaning, grinding, chemical cleaning,
surface finishing by suitable filler and two coats of high grade lacquer with wet blasting
wherever required. Two coats of paint in the panel colour shall be provided for non-glossy
high satin finish. Final coat shall be given after assembly at site.
Unless otherwise specified, exterior/interior portion of all panels and closed cabinets shall
have a colour as per RAL-7035. Channel base shall be of black colour.
4.2.3 Panel shall be enclosed cubicle type with each section of typically 2100 mm high, 1200 mm
wide and 800 mm deep mounted on 100 mm channel base.
4.2.4 Enclosed cubicle panels shall have removable hinged doors for easy maintenance and
accessibility of the instruments. Doors shall be double leaved type with handle and shall be
provided with lock and key. Adequate illumination shall be provided inside the panel. All
light fittings shall be suitable for 240 V, 50 Hz AC. Power supply greater than 240 V shall
also not enter the control panel.
4.2.5 All cable entries to the panel shall be from panel bottom only using cable glands of adequate
size. Cable gland plate thickness shall be a minimum of 3 mm cold rolled cold annealed
(CRCA) as a minimum. All unused cable entries must be plugged.
4.2.6 Space heater shall be provided where condensation is expected. The space heater provided
shall be with temperature cut off and manual control.
4.2.7 The design of panel shall incorporate provision for expansion by installing adequate spare
capacity. Each panel shall be designed to accommodate the following additional equipment,
as a minimum:
20% of panel front/inside mounted instruments including lamps, push buttons,

switches, relays etc.
20% additional power feeders each provided with switch fuse assembly.
20% additional spare windows in alarm annunciators.
20% spare cable entry points.
4.2.8 Panel layout shall be designed considering ease of operation. No push button or hand switch
shall be located below 600 mm. Instrument mounting heights, in general, shall be as follows:
Electronic Instruments Bottom row 1100 mm

Middle row 1350 mm
Top row 1600 mm
Annunciators 1950 mm
c) Electric push buttons/ 700 mm
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switches, lamps etc.

4.2.9 The internal panel layout shall be designed considering proper approach for instruments,
terminals and other accessories for maintenance, easy removal and online calibration. No
instrument, terminals, power distribution box etc shall be mounted on the panel side plates
inside the panel.
4.2.10 All lamps, status as well as alarm, shall be provided with lamp test facility. One single lamp
test push button shall be used for each panel. Logic for lamp test shall not be implemented
through relay logic in the panel.
4.2.11 Colour Scheme
Status Lamps
On/Open/Permissive Green
Off/Close/Emergency Red
Alarms
Normal/Pre-trip alarms Amber
Shutdown alarms Red
e) Push/Pull buttons
On/Open Green
Off/Close Red
Emergency shut-down (ESD) Red
(Push-button with cover/
Mushroom push button)
4.2.12 Panel Piping and Tubing
4.2.12.1 The instrument air header shall be adequately sized with 1/2" branches, SS packless isolation
valves and shall be complete with suitable dual filter-cum-air reducing station.
4.2.12.2 Panel tubing from the bulk head to the panel instruments and instrument air supply to the
panel instruments shall be of 6 mm x lmm thick SS 316L tubing.
4.2.12.3 The tubing shall be laid in plastic slotted ducts. Panel air header and tube fittings shall be of
SS 316.
4.2.12.4 Each tube shall be identified at both the terminating ends.
4.2.13 Panel Wiring
4.2.13.1 Open terminals shall generally be avoided. Terminal strips shall preferably be mounted in an
enclosure. Fused terminal may be used wherever necessary. All terminals shall be of
mechanical screw clamp/screwless type with pressure plates as per the job specification.
Self-insulating crimping wire lugs shall be used for all terminations on terminal blocks,
whereas forked tongue type or lug with eyehole type shall be used for termination on
screwed terminals such as on relays, push buttons, lamp etc. Terminal blocks shall be rated
for 600 V.
4.2.13.2 A minimum of 1 mm multi stranded PVC insulated copper conductor shall be used in
2
general. All wiring shall be laid in the PVC troughs. No trough shall be more than 70%
full.

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4.2.13.3 Wires carrying measurement signals associated with thermocouples, resistance

thermometers and other low level signals shall be routed in separate troughs/wire ways and
not alongwith power cables. Power wiring and control wiring shall be separated by not less
than 150 mm. The crossing, if unavoidable, shall be as close to right angles as possible.
4.2.13.4 Extension cables/wires shall be used for all thermocouple inputs. These wires shall be
routed in separate troughs/wire-ways.
4.2.13.5 All intrinsically safe wires shall be routed in separate wire ways from non-intrinsically safe
and power wiring. Intrinsically safe wiring and terminals shall be light blue in colour and
shall be separated from non-intrinsically safe terminals atleast by 50 mm.
4.2.13.6 All incoming power feeders shall be terminated on separate terminals suitable for the
incoming feeder size. These shall be located at the bottom of the panel and shall be suitably
covered for protection against accidental shorting and for human safety.
4.2.13.7 Power supply shall be made available at one point. Further power distribution network shall
be designed such that a single power fault in any instrument branch system shall not cause a
trip of the entire system. Each consumer shall be provided with a separate switch and fuse
for isolation and protection of the system.
4.2.14 Electrical Wiring
All the cabinets, consoles and panels shall be completely wired. Interconnections shall
preferably be done with the help of pre-tracked cables. Vendor may follow their standard
wiring practices, however the requirements specified herein must be complied.
All wiring shall conform to API RP 552- Transmission Systems. Different signal level
cables shall be routed with separation distances as recommended by code.
All wiring inside racks, cabinets, and back of the panels shall be housed in covered,
non-flammable plastic raceways arranged to permit easy assembly to various
instruments for maintenance, adjustments, repair and removal.
All wiring in the raceways shall be properly clamped. All incoming cable shall be
terminated by vendor at marshalling rack with cable glanding including supply of
cable glands. Total wiring cross-sectional area shall not exceed 50% of the raceway
cross sectional area.
Separate wiring raceways shall be used for power supply wiring, DC and low level
signal wiring, and intrinsically safe wiring. Parallel runs of AC and DC wiring closer
than 300mm shall be avoided.
Vendor can alternately offer prefabricated cables for interconnection between
different cabinets and panels.
Wire termination shall be done using self-insulating crimping lugs. More than two
wires shall not be terminated on one side of single terminal. The use of shorting links
for looping shall not be done.

g) No splicing is allowed in between wire / cable straight run.
4.2.15 Terminals and Terminal Blocks
Terminals shall be non-hygroscopic type made up of unbreakable, fire-retardant, safe

extinguishable, halogen free polyamide compound.
Terminals shall be suitable for wires up to 2.5 sq. mm base solid or stranded
conductor in general. For power cables, higher size terminals shall be used.
c) The metal parts of terminals shall be of high quality (pure electrolytic) copper and
shall be tin or nickel plated (of thickness up to 15 micron).
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The spring material for all terminals shall be chrome nickel spring steel of high tensile
strength and of excellent corrosion resistance. All terminal / terminal blocks shall be
DIN Rail mounted type and shall be easily removable. The size of the terminal blocks
/ terminals of different types shall be consistent and identical.
All terminal blocks shall be mounted on suitable anodised metallic or plastic stand-
off.
f) Terminal strips shall be arranged group-wise for incoming and outgoing cables
separately. Terminal blocks for intrinsically safe wiring shall be separate. 20% spare
terminals shall be provided, as a minimum, preferably in each terminal strip.
4.2.16 Following design philosophy shall be followed while deciding the internal layout of panels,
as a minimum;
Distance between terminal strip and 100 mm (min.)+ trough

side of the panel upto 50 terminals width
Distance between two adjacent terminal : 100mm (min.)+trough
strips width
Distance between gland plate and 300mm (min.)
bottom of the strip
Distance of terminal strip 100mm (min.)
from instrument/trough/panel top
4.3 Local Control Panel (LCP)
4.3.1 Local control panel for the package units shall be installed within the battery limit of the
package considering operational and maintenance requirements and accessibility. In case of
skid mounted packages, panel shall be located away from the skid.
In case local control panel is housed outdoor i.e. not in a local control room, it shall be
designed to meet IP-55 requirements. In addition, panel must be provided with a rain cum
sun shade/canopy.
4.3.2 Local control panel/panels shall be totally enclosed cubicles. Panel sizing shall be carried
out based on equipment being installed keeping in view the maintenance clearances and
easiness of operation. Although the panel dimensions shall be guided by the actual
requirements, typical dimensions shall be 2100 mm height x 1200 mm width x 1000 mm
depth. In any case, vendor shall not proceed with panel manufacturing before getting prior
approval from the purchaser.
4.3.3 Local control panels located in the hazardous area shall either be purged type or flame proof
Ex'd' or weather proof with Ex'd' components such as lamps, push buttons, switches etc. as
specified in job specification. In case pressurized panels are specified the same shall be
purged and pressurized as per NFPA 496 requirements to render space within the panel non
hazardous. For panels located in IEC Zone 2, hazardous area type Z purging shall be used
with a purge fail alarm in main control room. In case, panels are located in Zone 1, the
power shall be cut off on perssurisation failure as per x-purge requirements of NFPA-496.
An alarm shall be provided on local panel and a contact shall be provided for remote
annunciation, whenever the panel pressurization falls below 2.5 mm of H2O. A protective
device to protect the panel from over pressure must be provided.

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Lrr faiteg INDIA LIMITED 6-52-0052 Rev. 3
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4.3.4 Panel pressurisation with start-up panel purging scheme shall be fully automatic however it
shall be started manually from a push button. Solenoid valves and differential pressure
switch required for panel purging shall be flameproof, however other items like relays,
switches/pushbuttons, timers etc. shall be located in a flameproof housing. Other items like
valves, restriction orifice plates, dual filter regulators, pressure gauges, rotameters etc
required for pressurization shall also be located in the non-pressurized section of the panel.
4.3.5 It shall be possible to switch off incoming power to panel from panel front. All such power
on/off switches shall be flameproof type.
In addition, all those devices and terminals, which cannot be powered off from on/off
switches shall also be located inside flameproof enclosures.
4.3.6 All hinges, screws and other non-painted metallic parts shall be of stainless steel material.
4.3.7 All other requirements as specified in clause 4.2 of this specification shall also be applicable
for local control panels.
4.3.8 Whenever weatherproof local panel is provided by vendor for classified area, the Alarm
Annunciator shall be intrinsically safe and push button, lamps; selector switches shall be
flame-proof "Exd" type mounted on LCP. IS Barriers/ relays for IS alarm annunciator shall
be supplied by vendor along with IS annunciator and potential free non-flameproof contact
for the same shall be considered from the PLC / DCS/ control systems. The IS power supply
module for alarm annunciator shall be installed in a flameproof box in local panel by bidder.
For Lamps, wet contact shall be considered from the PLC/ control system and the lamp test
logic shall be realised in PLC/ control system. The Power supply distribution box inside the
Local Panel shall also be flame-proof "Exd'. IS PCs for display of loop powered indicators
shall be used in weather-proof local panels in case no. of tag local display more than Five
tags. The same IS PC can also be used for local display of vibration and temperature
monitoring system parameters at field instead of separate display unit at field. For 5 or less
number of tags for local indication, normal IS loop powered indicators shall be provided on
weather proof local panel.
Intrinsically Safe (IS) type with minimum 15" Display (Remote interactive PC terminal) unit
certified suitable for the hazardous area shall be mounted on the panel front of local control
panel of the package, wherever IS PC is considered. All local control panel mounted field
remote output indicators, wherever required as per approved P&IDs, shall be displayed in
this remote PC. Single serial interface (RS 485 with Modbus RTU protocol) corresponding
to these signals from control system shall be considered and vendor's scope shall include all
necessary converters, power supply module, connectors at both ends along with serial
communication cables for connecting to serial interface cards.
The PC terminal shall be equipped with necessary keyboard suitable for specified hazardous
area.
4.4 Local Gauge Board
4.4.1 Local gauge board shall be used to install skid-mounted instruments like pressure gauges,
temperature gauges and transmitters.
4.4.2 Location of local gauge boards, when provided, shall be decided to allow easy access at the
rear and front for all instruments and accessories for maintenance and operation.
4.4.3 Gauge board shall be constructed from 3 mm stainless steel sheet with other necessary SS
supporting structure.

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4.4.4 Local gauge board shall be supplied with all instruments installed and completely in
tubed/wired condition before shipment.
4.4.5 All pressure transmitters and gauges shall be provided with block and bleed valves securely
fastened. Identification tags shall be securely fastened for easy identification. Wherever local
temperature indicator is required with temperature transmitter, Loop powered indicator shall
be provided.
4.5 Temperature Instruments
4.5.1 Thermowells
All temperature elements shall be provided with thermowells fabricated out of bar stock
of minimum SS 316 material as per EIL Standard 7-52-0035. The base of the
thermowells shall be chosen to fit the instrument without air gap for minimizing
measurement lag.
Built-up thermowells shall be used in low pressure and low velocity services like in
fired heaters and also where thermowell immersion lengths greater than 500 mm are
required.
Immersion length of thermowells shall be as follows:
Line Size Immersion length

From 4" to 6" 280 mm
From 8" to 20" 320 mm
>20" and Vessels / columns 400 mm
In special applications, not covered above, vendor shall decide the immersion length
based on actual requirements. Immersion length is based on 200 mm length between
flange face and outer wall of pipe and 200 mm length between flange face and outer
wall of the vessel.
Any pipe line less than 4" nominal bore shall be blown to 4" size to install thermowell.
e) Thermowell flange and well material shall be as per material selection chart.
0 The vibration analysis shall be carried out as per PTC 19.3 TW:2010 (latest version)
and corrective measures shall be taken as necessary.
4.5.2 Temperature Gauges
Local temperature gauges shall be in general bimetallic type. The temperature bulb
shall be of stainless steel construction. The gauge connection shall be all angles
adjustable. Gas filled type shall be used when measuring range is beyond the limits of
Bimetallic gauge or thermowell length exceeds 550 mm or in applications involving
excessive vibrations. Mercury filled type temperature gauge shall not be used.
All local temperature gauges shall have 150 mm dial size. The bulb size shall be
selected to suit the thermowell.
Cases shall be minimum 304 SS and weatherproof to IP-65 as per IS/IEC-60529.
Temperature gauges shall have accuracy of ±1% URV (upper range value).
e) Bimetallic type dial thermometers shall be avoided where excessive vibrations are
enoniinterett, clich ac reriprnrating rnmpreccor clicrharr Only filled type with
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capillary extension shall be used in such cases. Capillary tubing shall be a minimum of
304 SS with stainless steel flexible armouring, and PVC covering over armour. Filled
type gauges shall be manufactured as per relevant SAMA class.
f) Thermometer stem adjustable gland with union connection and bushing shall be
suitable for 1/2" NPTF connection.
4.5.3 Temperature Elements
a) For remote temperature indication/recording/control/switch etc., resistance temperature

detector (RTD) shall be used upto 400 deg C (operating) and above 400 deg C
(operating) thermocouples shall be used. Elements shall be spring loaded, mineral
insulated and shall have stainless steel sheath as a minimum.
Thermocouple assemblies shall be furnished with weatherproof screw type heads as per
EIL Standard 7-52-0036.
Thermocouples shall be as per IEC-60584-2 and shall have a wire size of 18 AWG for
single and 20 AWG for duplex thermocouples. These shall be magnesium oxide (MgO)
filled grounded type, unless necessary otherwise. The type of thermocouple shall be
selected based on temperature. The selection of type shall be as per following
guidelines:
Copper-Constantan (ISA-Type-T) (-) 200 to 200°C

Chromel-Constantan (ISA-Type-E) (-) 200 to 600°C
lion- Constantan (ISA-Type-J) 0 to 600°C
Chromel-Alumel (ISA-Type-K) 600 to 1200°C
Platinum Rhodium-Platinum (ISA Type-S) 600 to 1600°C
The design of thermocouple assemblies shall be such that replacement on line is
possible.
RTD (Resistance Temperature Detecter) shall be platinum element 3 wire type with
100 ohms resistance at 0°C calibrated as per 1EC 60751. RTD shall be used within a
temperature range of -200 to 650°C. Three-wire system shall be adopted in connecting
the element.
0 RTD shall be used where accuracies of the order of 0.25% or better and smaller
measuring spans are required.
g) Duplex element sensors shall be supplied. Two separate cable entries shall be provided
with plugs.
4.5.4 Temperature Transmitter
Temperature transmitters shall have a built-in linearising function to produce an output

linear to temperature range.
The Temperature transmitters with RTD shall have an accuracy of 0.075% of URV as a
minimum for range above 350° C, 0.15% of URV for temperature range 350° C to 150°
C and 0.25% for calibrated range below 150° C.
The Temperature transmitters with cold junction compensation for thermocouple shall
have an accuracy of 0.25% of URV as a minimum for range above 350° C, 0.5% of
URV for temperature range between 350° C to 150° C and 0.75% for calibrated range
below 150° C.
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0 el ENGINEERS INSTRUMENTATION OF
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c) Transmitters shall be provided with dual compartment.
4.5.5 Burn out protection must be provided with temperature transmitters. Upscale or downscale
protection shall be decided based on its application to ensure fail-safe operation.
4.6 Pressure Instruments
4.6.1 Pressure Gauges
Pressure gauge dial shall be white with black figures. The dial face shall be marked
with pressure element material. Pointers shall have micrometer adjustment.
Pressure gauges shall be weatherproof with dial size of 150 mm and shall have features
like over range protection (at least 130% of max. operating pressure) and blowout
discs. Glass shall be shatter proof. Pressure gauge sensing element shall be of SS 316
and movement of SS 304, as a minimum.
Pressure gauges shall have an accuracy of ±1% of URV as a minimum. Differential

pressures gauges, diaphragm seal pressure gauges and draft gauges may have an
accuracy of ±2% of URV.
Over range protector and pulsation dampener, whenever used, shall be of SS 304, as a
minimum. Pulsation damepner shall be used for all pulsating services. It shall be
floating pin type, externally mounted and externally adjustable.
Pressure gauges with range 0-100 kg/cm 2g and more shall have safety type solid front
case.
Connection shall normally be 1/2" NPTM bottom.
Cases shall be minimum 304 SS and weatherproof to IP-65 as per IS/IEC-60529.
Ranges shall be so specified that the gauge normally operates in the middle third of the
scale and shall conform to IS-3624 standard dials, wherever possible.
Diaphragm seals shall be furnished where plugging of the element may occur or where
suitable material is not available in highly corrosive services. When chemical seals are
required, they shall be of the clean out type with flushing connection.
Where vibrations and pressure fluctuations are expected, glycerin filled type and
snubber shall be used.
k) Receiver pressure gauges for local transmitter output indication shall have 100 mm dial
with stainless steel element and 1/4" NPTM connection.
1) The pressure element shall be bourdon, diaphragm or bellows depending upon process
condition. Single diaphragm type Differential pressure gauges shall not be considered,
Instead double diaphragm type or bellows shall be considered.
4.6.2 Pressure/Differential Pressure Transmitters
Pressure/differential pressure transmitter shall have electronic state-of-art capacitance

or any other type of sensor meeting all functional specifications as per clause 2.16.
Element material for transmitters shall be 316 SS, as a minimum.
All transmitters shall have an integral output meter. Remote mounted meters may be
provided if required in addition.
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t_7 7- •) ENGINEERS INSTRUMENTATION OF
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c) Diaphragm seal element with capillary shall be used for congealing, corrosive and
highly viscous services.
4.6.3 Pressure Switches
Process switches shall not be considered unless its use is unavoidable and the same
shall be subject to purchaser's approval
Pressure switches shall have either diaphragm or bellow type of process element with
SS 316 material of construction as a minimum. Switch type shall be sealed micro-type
with contact rating suitable for specific application. Also contacts shall be SPDT type
unless otherwise specified. Contacts used in intrinsically safe applications shall be
suitable as per the process condition.
Pressure switches shall be blind type with 1/2 NPTF process connection and shall be
operative in full-specified range. The switch differential shall be selected as per
operating conditions.
Pressure switches shall have repeatability of ±0.5% of URV, as a minimum. Pressure

switch shall have over range protection of at least 130% of maximum working pressure.
The set pressure shall fall in the middle third (between 35% to 65%) of the adjustable
range in general. Set point shall be field adjustable.
4.7 Level Instruments
4.7.1 Level gauges
All gauge glasses shall be steel armoured reflex or transparent type with body and cover
material of forged carbon steel as a minimum and shall have tempered borosilicate glass
with asbestos or other suitable gasket. Transparent type of gauges shall be provided
with integral illuminators operating at 240 V 50 H z supply and shall be suitable for
electrical area classification specified. All gauge glasses must have a rating equal to or
more than the vessel design pressure and temperature.
Reflex type will be used for clean and colourless liquids, except liquids level interface.
For low temperature, low boiling point service, large chamber type will be used.
Transparent type will be used on acid, caustic, dirty or viscous, coloured liquids and
liquid interface. Transparent type with Mica or Kel-F shields shall be used for treated
water, boiler and condensate services, and for corrosive liquids, which will attack glass.
Tubular gauge glasses shall, in general, not be used in Hydrocarbon/hazardous services.
They may be used for non-hazardous services at ambient temperature and low pressures
(less than 10 kg/cm2g operating).
Large chamber gauges with frost shields shall be provided for cold services below 0° C.
Heating jacket shall be provided for viscous liquids with 1/2" flanged connection.
All gauges shall have top and bottom chamber connections, unless otherwise specified.
However side-side chamber connection is acceptable where nozzle installation is a
constraint. In addition each gauge shall be provided with ball check valves and pipe
union.
e) The visible range of level gauge shall be selected to cover the complete operating level
as well as measuring range of the other level instruments provided for the same
purpose. In general, the visible length and C to C distance of the top and bottom level
gauges shall be selected from the following:
Visible length Centre to Centre Length

Copyright EIL -All rights reserved
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IA Govt of India OnctertaAng) PACKAGE UNITS Page 30 of 58
220 470
470 720
720 970
980 1230
1230 1480
1490 1740
For side-side level gauge C to C distance shall be 10 mm less than visible length.
0 For level gauging in very viscous, corrosive liquids, liquids with crystals and high
pressure service, float operated magnetic gauges with 2" (50 mm) flanged end
connections, shall be used. C to C length of single magnetic level gauge shall not be
more than 2500mm.
4.7.2 Level Transmitter
Guided Wave Radar type instruments with external cage and side-side connections
shall normally be used for level and for interface level measurement upto 2400 mm.
Guided wave radar inst shall have ±3mm accuracy.
Differential pressure transmitter shall be used for level measurement above 2400 mm,
for services requiring purge or where liquid might boil in external portion.
Differential Pressure transmitters for use on corrosive or fouling service shall generally
be diaphragm wafer with extended filled capillary type. Flush or extended diaphragm
type differential pressure transmitter shall be considered for special applications only.
Diaphragm material shall normally be stainless steel or any other special alloy.
e) For sump levels, Guided wave radar or non- contact type radar level instrument shall be
used depending on the application within accuracy ± 3mm.
0 Generally for top mounted level transmitters, internal guided wave radar type
instruments shall be used for level measurement upto 3000mm. Above that non-contact
type radar shall be used.
g) Level transmitters shall meet all requirements specified in clause 2.16.
4.7.3 Other Special types of level instruments like ultrasonic, hydrostatic, nucleonic, capacitance,
conductivity type shall be used as necessitated by application requirements.
4.7.4 For high pressure steam drum application at least one number conductivity type (Hydrastep
or equivalent) level instrument shall be provided. Also level gauges shall be of bi-color type
for such application.
4.7.5 For solid level measurement, type of instrument shall be ultrasonic/

electromechanical/capacitance/nucleonic/non-contact type radar as per the process
condition. The actual type selection shall be carried out based on the provenness of the
selected type for similar type of application.
4.8 Tank Level Instruments
a) Each tank shall be provided with minimum 2 types of tank level instruments operating
on different principles like one servo and other one radar (Antenna) type.

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Radar type transmitter shall be provided with ±3 mm accuracy for storage tanks and ±1
mm for custody transfer. Whenever ±3.0 mm accuracy is required, process connection
on vessel/ tank/ equipment for non-contact radar gauge can be 4" with 4" Carbon Steel
/ Stainless Steel (depending on the pipe schedule requirement) still well. However
wherever ±1.0 mm accuracy is required (e.g. in custody application), process
connection on vessel/ tank/ equipment for non-contact radar gauge shall be 8" with 8"
Carbon Steel / Stainless Steel (depending on the pipe schedule requirement) still well.
For viscous service, nozzle connection shall be 24".
Servo type instruments shall have 6" process connection with 6" diameter still well,
with accuracy ±3 mm for storage tanks and ±1 mm for custody transfer. Raising or
lowering of displacer for calibration shall be possible on-line with the design of still-
well.
The wetted material like float, displacer, tape, wire etc. shall generally be 316 SS.
The accessories for servo-controlled level gauge shall include isolation ball valves for
pressurized tanks and calibration/maintenance chamber for all tanks. Each calibration
chamber shall be provided with a viewable window of blast proof glass. The
calibration chamber can be either integral to the instrument or separate. Whenever
calibration chamber is separate i.e. not integral to the tank level instrument, the material
of construction of calibration chamber shall be stainless steel. The calibration chamber
shall also permit insertion / removal of displacer for maintenance without removing the
instruments.
f) Servo and Radar type instruments shall be capable of providing serial output as per
vendor standard protocol or field bus protocol as per IEC-61158 in addition to analog
4-20 mA DC current output. These instruments shall also be capable of accepting input
from multi element tank temperature sensors (thermocouple/ RTD), water cut probes
and transmit the same as a part of serial signal from the transmitter. Multi-element tank
temperature sensors when used shall be provided with 3" stillwell and 3" process
connection.
4.9 Flow Instruments
The selection of flow measurement instruments shall be based on the requirement of

accuracy, repeatability, location, physical properties of the flowing fluids handled, pressure
drop and ease of maintenance.
In-line flow instruments shall have a direction of flow indication clearly marked and easily
visible in the final installed position.
Flow switches shall not be used without prior approval from the purchaser.
4.9.1 Orifice Plates
a) Flow measurement shall normally be carried out by using thin square edged concentric
orifice plate mounted between a pair of weld neck flanges of minimum 300 pounds
ANSI rating for line size 2" and above. Flange taps shall be used for line sizes upto 14"
while D-D/2 taps shall be used for line sizes more than 14". The material of the orifice
plates shall be normally 316 SS, as a minimum.
Quadrant edge or quarter circle orifice plates shall be used for highly viscous liquids
and for pipe Reynold number below 10,000.

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af-aeltii ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
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0.1, AGoo 0 Indo Unelettak.g) PACKAGE UNITS Page 32 of 58
Conical entrance type of orifice plates shall preferably be used for very highly viscous
liquids upto throat Reynolds number of 250. These plates shall be fabricated as per
Flow Measurement Hand Book by RW Miller.
Vent and Drain holes shall be provided for bore dia above 25.4 mm.
b) Sizing of orifice plate shall be carried out in accordance with ISO-5167 (Latest
Edition). For orifice plates not covered in ISO 5167, sizing methods shall be ASME
MFC-14M (latest Edition) or AGA Report No. 3 or 'Flow measurement-Engineering
Handbook' by RW Miller.
Honed metering runs or integral orifice type transmitter shall be used in line size with
1.5" (40 mm) nominal diameter or below.
Upstream and downstream straight length shall be provided based on maximum d/D
ratio of 0.75, in general. Where it is difficult to meet this requirement, the actual d/D
ratio can be considered for reducing the straight length as permitted by the codes. Flow
straighteners are to be considered, where straight runs are difficult to achieve otherwise.
f) Meter taps shall be horizontal for liquids, condensible vapours and steam. The taps
shall be on top for gas, non-condensible vapour, or liquids which boil at or below the
maximum design ambient temperature at operating pressure. Where piping clearances
are a factor, taps may be located upto 45 degree below the horizontal center line for
condensible vapour and liquid. The taps may be located upto 60 degree from vertical
for gas, non-condensible vapour and steam.
4.9.2 Venturi Flowmeters
Venturi shall be designed and constructed as per ISO 5167-4 (Latest Edition) or ASME
MFC-3M.
The Venturi Flow element shall be classical, machined, non truncated type.
c) Impulse piping connection for venturi tubes shall be provided with 1/2" NPTF
connection, unless otherwise specified in the data sheet.
Venturi tube shall be forged/cast construction in general. However fabricated

construction shall also be acceptable, wherever allowed as per ISO-5167.
Venturi tube shall be provided with Annular chamber / Piezo-metric Ring. Material of
construction of Annular chamber / Piezo-metric Ring shall be same as material of
Venturi tube.
Material of construction of Venturi tube shall be SS316 as a minimum. Material of

construction for Throat, Divergent section and Convergent section shall also be SS316
as a minimum. Flanges shall be provided as per the material specified in the datasheet.
Flow calibration for those Venturi tubes, which are necessitated due to their installations
outside the limits as defined in ISO 5167 for D (Pipe Inside Diameter), beta and
Reynolds numbers shall be considered in the base quote
4.9.3 Averaging Pitot Tube
Averaging pitot tube in general shall not be considered unless specifically required by the
purchaser. Averaging pitot tube shall meet the following requirements:
a) The flow sensor shall be continuous averaging velocity head producing type of pitot
tube with four or more equal averaging pitot tube sensing ports or continuous slots to

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suit line velocity profile. The sensor shall also incorporate a rear port for the
measurement of line static pressure.
Averaging pitot tube shall be of 3" flanged connection with isolation ball valve.
The insert retract mechanism shall be provided to allow on line removal and insertion
of the average Pitot tube under maximum pressure and flow condition.
Vibration analysis for each averaging pitot tube element shall be done for the indicated
flow condition to ensure that the averaging pitot tube is of sufficient thickness and
strength to withstand the vibration effects created due to Karman vortex shedding in the
fluid stream.
The free end of the averaging Pitot tube shall be pressure supported at the pipe wall.
However, for the large pipe sizes and where vibration analysis recommends the
requirement of end support, the end support/weld cap support shall be provided.
f) The offered averaging pitot tubes shall have ±1% accuracy of actual value and
repeatability of ±0.1% of actual value.
4.9.4 Variable area Flow Meters
Variable area flow meters or rotameters shall be provided as per the P&ID or where
rangeability in flow precludes the use of an orifice. Variable area flow meters shall be as per
ISA-RP 16.1, 16.2, 16.3, 16.4, 16.5 and 16.6. Metal tube rotameters shall be used for all
fluids. External devices for indicating or transmitting shall be magnetically coupled to the
float or extension.
Glass tube rotameters shall not be used unless it is necessitated for low range or for low
pressure utility services for local indication and where line size is 1-1/2" (40mm) or less
with the approval of purchaser.
Reducer shall be considered, in case the size of the flowmeter is less than the line size.
4.9.5 Mass Flow Meters
The mass flow meters shall meet the following requirement:
Flow meter shall be of in-line mounting design and shall be of flanged body
construction with stainless steel as minimum material of construction.
The mass flow meter shall be provided with the external flow tube housing. In all
such cases, the flow tube housing shall have provision to monitor housing pressure
continuously.
The mass flow meter shall have high vibration immunity.
The meter electronics shall be protected against transients induced by lighting and
power supply surges. Transient protection electronics shall preferably be provided in
the terminal block.
e) Flow meter electronics shall be microprocessor based and shall include pre-amplifier,
converter, transmitter electronics and integral output meter. The indication on the
output meter shall be digital with engineering units.
0 The mass flow meter shall be capable of computing field density and shall incorporate
temperature sensor flow fluid temperature measurement. Whenever required, the flow
meter electronics shall have capabi lity to compute vnliimPtri, flow rates.
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ENGINEERS
'e--1 INSTRUMENTATION OF
$'1g-af f
aWeg INDIA LIMITED 6-52-0052 Rev. 3
>men etro,te =Jot:ow Govt of India Uottertok n og) PACKAGE UNITS Page 34 of 58
The meter electronics shall be protected against transients induced by lightning and
power supply surges. Transient protection electronics shall preferably be provided in
the terminal block. The transient protection shall meet the requirements specified in
IEC-60587.
Unless specified otherwise in the job specification, the performance requirements for
the mass flow meter shall be as follows:
Flow meter accuracy: + 0.2% of mass flow rate for liquid service.
± 0.5% of mass flow rate for gas / vapour
service.
Flow meter repeatability: ± 0.1% of mass flow rate for liquid service.
± 0.25% of mass flow rate for gas / vapour
service.
The performance requirements specified above excludes the effect of zero stability of
the flow meter on these parameters.
Flow accuracy shall be maintained between the minimum and maximum flow. Where
only normal flow is specified, the maximum and minimum flows considered for the
purpose of sizing shall be:
Maximum flow = 1.4 times the normal flow
Minimum flow = 0.4 times the normal flow
When only maximum flow is specified minimum flow shall be considered as 0.2
times the maximum flow for sizing the meter.
The maximum pressure drop at meter maximum shall not exceed the allowable
pressure drop across the meter specified in the data sheet.
The meter shall be selected such that both accuracy and allowable pressure differential
across the meter are complied.
4.9.6 Ultrasonic flowmeter
Ultrasonic flow measurement shall be considered where non-intrusive flow measuring is

required.
The Ultrasonic flow meter shall be based on transit time technology.

The design used shall provide maximum reliability, maximum on-line performance and
minimum maintenance. It shall be immune to other impurities in the fluid stream.
Ultrasonic flow meters and the meter runs/flow conditioners shall be rated for the maximum
design pressure.
Spool piece type Ultrasonic flow meters shall have flanged end connections. Weld joints, if
any, shall be of radiographic quality.
Meter Sizing:
Selected meter size shall ensure that flow meter operates within 85% of their standard range
considering density and viscosity of the fluid. Extended range shall not be referred for the
meter selection.
Vendor to ensure the velocity in the Ultrasonic flow meter and meter run shall not exceed
maximum permissible velocity.
4.9.7 Target meters shall be considered for highly viscous hydrocarbon streams such as asphalt,
tar, polymers etc.

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4.9.8 Vortex meter shall be considered where high rangeability is the prime requirement.
4.9.9 Differential Pressure type flow transmitter shall meet all the requirements specified in clause
2.16.
4.9.10 Wedge flow meter shall be considered in slurry services or where powder deposits may form.
However, Diaphragm seal type DP transmitter shall be provided along with wedge flow
meter duly calibrated with both sensor and the transmitter.
4.10 Control Valves
4.10.1 Control valves shall normally be globe type. Other valve types like butterfly, ball, rotary
plug, angle or 3way etc., shall be selected as per service and process requirements.
4.10.2 Control valve sizing shall be carried out as per ISA S75-01. The valve shall permit upto
150% of normal flow or 110% of maximum flow, whichever is higher. In general, control
valves shall be sized so that the valve opening is as noted below:
At max. flow about 90% open

At normal flow about 75% open
At minimum flow about 20% open.
4.10.3 Flanged control valves shall be used. Body material, body rating and flange rating shall be
as per piping specifications. However body and flange rating shall be minimum 300#.
4.10.4 Minimum control valve body size shall be 1" in general. Reduced trims can also be
considered.
4.10.5 For globe valves trim characteristics shall be equal percentage type unless required
otherwise. Control valve plugs shall be heavy top guided for single seated valves. Cage
guiding may be used in clean applications.
4.10.6 Anti-cavitation trim shall be selected wherever cavitation is expected in the valve. For
flashing services and hardened trim shall be used and anti-cavitation trim shall not be
provided.
4.10.7 Noise from control valve during operation shall be limited to OSHA specified level or
better. The maximum allowable noise is 85 dBA SPL (Sound Pressure Level). Source
treatment for noise may be performed by using special trims like low noise trims, in case
noise exceeds the specified level. Other methods based on merit are also permissible.
4.10.8 Valve seat leakage shall be minimum class IV as per ANSI/FCI 70.2 unless tight shutoff
requirement is required as per the P&ID.
4.10.9 Flanged bolted type gland packing boxes shall be used. Packing shall normally be PTFE on
liquid and gas service up to 200°C (design). Graphite/grafoil shall be used above
200°C(design) temperature. Asbestos based packing material shall not be used.
4.10.10 Bellows seal shall be used where it is required to isolate the packing from the process fluid
or where no leakage to atmosphere can be tolerated like toxic, explosive and precious fluids.
4.10.11 Material used for trim shall be minimum SS 316, with guide bushing of hardened stainless
steel like 440 C, 17-4 PH. For higher pressure drops (more than 10 kg/cm 2) or erosive and
slurry services and in general for all steam services, flashing and cavitating services, plug
and seat shall be stellited.

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INDIA LIMITED
INSTRUMENTATION OF 6-52-0052 Rev. 3
vilrvvt rirove on,tootto IA Govt Of Ind. Undettekvt9) PACKAGE UNITS Page 36 of 58
Special cases may require 17-4 PH seat ring and 440 C solid plugs or other materials like
Hastelloy, Monel etc.
4.10.12 Valve actuator shall be pneumatic spring opposed diaphragm type, in general. Piston type
actuators may be used for very high shut off pressure requirements. Additional equipment
including volume bottle necessary to meet fail safe condition shall also be included in case
double acting piston type actuator is selected. In either case, actuator shall be able to
withstand maximum shut-off pressure (1.5 times of design pressure) with the minimum
instrument air pressure specified.
4.10.13 Whenever limit switches are specified as inductive proximity type, these shall meet
NAMUR (DIN-19234) requirements.
4.10.14 Solenoid valves, wherever used, shall be universal and continuous rated type with class H
coil insulation. These shall be SS body as a minimum.
4.10.15 Self-actuating regulators for flow, pressure and temperature shall be used where loads are
constant and requirements of precision and accurate controls are not stringent.
4.10.16 The actuator shall be painted as below:
Direct action (open on air failure) valves - Green
Reverse acting (close on air failure) valve - Yellow
Actuator for shutdown valves - Red
Items like air volume tanks etc., supplied as an accessory along with the actuators, shall be
painted as per corresponding actuator.
4.11 ON-OFF VALVE

4.11.1 On-off valves shall have flanged end connections integral to the valve body. Top entry valve
design shall not be offered unless specifically indicated. Body rating of valve shall be
minimum 300g.
Whenever flangeless on-off valve body design is specified, following shall apply:
Wafer type or lug type body design for butterfly type on-off valves body size up to
6 inches.
Lug type body design for butterfly type of on-off valve body size more than 6
inches.
4.11.2 For on-off valves with fire safe design, flanged body construction shall only be acceptable.
4.11.3 For all services where full port valves are specified, following shall apply:
Port size shall be equal to line size for rating up to ASME Class 1500.
Port size shall not be less than one size than the line size for rating ASME Class
2500 and above.
4.11.4 For steam jacketed valves, the body and port size shall be one size lower than the on-off
valve end connections.
4.11.5 On-off valve body, bonnet, bottom flange, line flanges and other pressure containing
assemblies shall be of the same material of construction as specified for valve body.
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4.11.6 In case of ball-type of on-off valves;
The valve design shall ensure valve seat and body protection against thermal expansion
of the entrapped fluid when the on-off valve is fully close.
For size up to 4" and rating up to ASME Class 300, the on-off valve shall have floating
ball design. For ratings ASME Class 600 and above, floating ball is acceptable for
sizes less than 2". For higher sizes trunion mounted ball design shall be provided.
4.11.7 Rotary type on-off valves like Ball valves, butterfly valves etc. shall have blow out proof
shaft guiding design.
4.11.8 Guide bushing shall be of a sufficiently hard material to resist side thrust on the plug or
shaft.
4.11.9 Vendor shall be responsible for trim design and selection of the on-off valve. However, it
must meet the following minimum requirements:
The valve characteristics shall be quick-opening (on-off) type.
Vendor shall select proper material pairs, surface finish, hardness and clearances to
avoid galling.
Valves operating under extreme temperature conditions, vendor shall consider

increased clearances at room temperature and seal welding of threaded seat rings
etc whenever required. Hard facing of trim including guide bushing shall be
considered for all valves operating at high temperatures (i.e. temperature more than
200°C). For very low temperature application, material used shall have adequate
cold impact strength.
For all on-off valves including 3-way type of valves, stem and plug shall be
detachable and shall be attached together by suitable threaded design secured with
a pin to avoid plug rotation during operation.
4.11.10 Trim material and actuator colour shall be as specified for the control valve.
4.11.11 Leakage class of on-off valves shall be as specified in data sheet, where no class is
specified it shall be Class IV.
4.11.12 For on-off valves specified with Class VI / bubble tight (as per API) leakage class,
vendor shall select the soft seat (elastomer) material suitable for the process conditions
i.e., shut off pressure, maximum temperature and process fluid. Metal seated on-off
valves meeting the leakage class shall also be acceptable.
4.11.13 For application in vacuum service, vendor to provide inverted packing design suitable for
vacuum service. For pressure-cum-vacuum service, the on-off valve shall have dual
packing design suitable for the application. Dual packing design shall also be provided
for on-off valves in toxic service, with a facility to connect inert fluid between the
packings.
4.11.14 Valve actuator shall be designed to move the valve to the failure position as specified.
For failure position specified as 'fail-locked', vendor shall provide air reservoir with all
required accessories to meet the fail lock position of the valve.
4.11.15 Whenever double acting springless type of actuator is unavoidable, all accessories like
pilot valves, booster relays, non-return valve, pressure gauge, volume tank etc. shall be
provided to ensure desired action on air failure.
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4.11.16 The volume tank shall be of carbon steel construction and sized as per ASME Section
VIII with design pressure of 10kg/cm2g as a minimum. Each volume bottle shall be sized
for a minimum of 3 valve strokes
4.11.17 The actuator casings and diaphragms shall be designed for minimum twice the maximum
pneumatic operating pressure of the on-off valve.
4.11.18 Vendor shall be fully responsible for sizing and selection of correct actuator, while sizing
the actuator vendor shall consider minimum actuator thrust equal to two times (2) the
total force induced by shut off condition and the force required to overcome packing
friction.
4.11.19 Wherever the valves are indicated as fire safe, they shall be tested for fire safe as per BS
6755 (Part-2) when the valves are supplied with metal-to-metal seats and shall be tested
as per API 607 latest edition when the valves are provided with soft seats.
4.11.20 Wherever fire safe actuator and controls have been asked for, actuators and all
accessories such as solenoid valves, air volume bottles etc. shall meet the fire proof
requirement to ensure normal valve operation even during and after exposure to fire.
Vendor shall clearly define the schemes they propose to achieve the above requirements
and ensure that the proposed schemes shall meet the requirement in terms of type of
exposure and exposure time of the testing procedure given in BS 6755/API 607.
4.11.21 Vendor shall furnish type test certificate duly witnessed by third party inspection agency
like M/S LRIS,BV,DNV,TUV etc. for fire safe testing of valve, actuator and controls for
the offered models.
4.12 Smart Type and Field Bus Type Positioners
Digital smart positioners or field bus type of positioners with diagnostic capabilities shall be
provided as per job specific requirement. These shall meet the following minimum
requirements:
The positioner sensor and sensing mechanism shall be rugged and shall not be affected
by the line/valve vibration. The performance of the positioners shall be immune to
above vibration.
The positioner's output and input range shall be field adjustable without any hardware
modification. The output from the positioners shall be available for both single acting
as well as double acting actuator.
Each positioner shall be operable, configurable and accessible through HART

compatible hand held configurator/field bus configurator as applicable. Smart
positioners shall also have dedicated buttons for the above functions.
Control valve's operating signatures in the form of hard copy and soft copy for each
control valve provided with smart positioners shall be supplied. The necessary software
for advanced control valve diagnostics like seat ring condition, gland packing condition,
actuator leakage etc. shall also be included.
Fieldbus positioner shall have the capability to perform functions like PID etc.
All positioners shall have metallic casing and cover.
4.13 Pressure Relief Valves and Rupture Discs

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/511=4TA 4Th\ ENGINEERS INSTRUMENTATION OF
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‘151 Wadi, PACKAGE UNITS Page 39 of 58
4.13.1 Pressure Relief Valves
4.13.1.1 All pressure relieving devices shall be designed in accordance with ASME code for 'Boilers
and Pressure Vessels', API-521 and Indian Boiler Regulations. The pressure relief valve
sizing shall be as per API 520. For mixed phase fluids, sizing shall be as per Leung-Omega
method (or Diers) sizing shall be followed. The orifice sizing, area and designation, valve
size and rating shall be as per API RP 526.
4.13.1.2 Pressure relief valves shall be full nozzle full lift type except for thermal relief valves.
4.13.1.3 Conventional valves shall be specified for constant back pressure while bellows seal type
valves shall be specified for variable back pressure. Pilot operated pressure relief valves
shall be used when Back pressure is greater than 50% of set pressure or when the difference
between operating pressure and set pressure is within 10% of the set pressure.
4.13.1.4 Lifting lever shall be specified for steam, air or water above 65 degree service. Open bonnet
shall be used for steam service.
4.13.1.5 The percentage accumulation in case of pressure relief valves/safety valves shall be as
follows:
Steam Service
- ASME SEC I(steam generation/consumption) 3%
- IBR (Before steam let-down station) 5%
- IBR (Distribution & utilities) and 10%
ASME Section VIII
Gas, Vapour or liquid for process service 10%
Liquid for thermal Relief 25/ 10% (as per Process requirement)
Fire exposure on unfired vessels 21%
4.13.1.6 3/4" x 1" threaded (NPT) modified nozzle type valves with typically 0.38 cm 2 orifice size
shall be specified for thermal relief. However, if discharge is connected to flare or with
variable back pressure more than 10% of set pressure, 1D2 flanged valves as per API-526
as a minimum to be provided.
4.13.1.7 The body material shall, as a minimum, be as per piping specifications. Nozzle and disc
material shall be SS 316 as a minimum with machined stainless steel guide and spindle.
Whenever semi nozzle designs are unavoidable, body material shall be atleast same as
nozzle and disc material.
4.13.1.8 The spring material of pressure relief valves shall be as follows unless otherwise necessary
because of process conditions;
(-)29° C to 230° C Carbon steel with weather protective coating.

above 230°C Tungsten alloy steel.
Below (—)29° C 316 Stainless Steel
4.13.1.9 Flanged connection shall be for standard sizes 1" or larger.
4.13.1.10 Where permissible, screwed connections shall be used on sizes 3/4" and below.

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ligodaalez ENGINEERS
INDIA LIMITED
1.111,1 IA Govt of India Undertaking) PACKAGE UNITS Page 40 of 58
4.13.2 Rupture Disc
4.13.2.1 Rupture discs shall be reverse buckling type, in general and shall be supplied in pre-torqued
holder assembly, which shall fit inside the inner diameter of the bolt circle of standard
flanges. Disc material shall be compatible with the vessel contents and shall be consistent
with the bursting requirements. Inconel discs shall be used above 100°C if compatible with
the process fluid.
4.13.2.2 When rupture disc is used upstream of a pressure relief valve, a pressure gauge shall be
provided on the downstream of the disc to indicate any rupture of the disc in addition to an
excess flow check valve. In addition combination capacity factor of 0.9 shall be used for
sizing unless the combination has been tested and approved for any other combination
capacity factor.
4.13.2.3 The bursting tolerance of the rupture disc shall be 5% of the specified bursting pressure or
less, unless otherwise specified.
4.13.2.4 Vendor shall consider 5 nos. rupture discs (1 for testing + 1 for installation + 3 nos. spare) of
the same specifications.
4.14 Interlock and Shutdown System
4.14.1 Interlock and Shutdown System shall be an independent system with its own dedicated
primary element except for orifice flow measurement. For orifice flow element, separate set
of tapping for each flow transmitter for shut down / interlock shall be considered.
4.14.2 The system shall be designed fail safe and shall meet the following requirements, as a
minimum:
All initiating contacts shall be close (except limit switches for which contact shall close
when the limit reaches) under normal conditions and shall open under abnormal
conditions.
All relays and solenoid valves shall be energised under normal conditions and shall de-
energize under abnormal conditions.
c) If desired, because of operational or maintenance requirements, adequate trip by-pass
facilities are to be provided with warning lights to indicate that the trip has been
bypassed. Trip bypass alarms shall be provided in local as well as in remote location.
All such by-pass switches shall be key-operated type.
4.14.3 Each shutdown circuit and solenoid valve shall be provided with a switch-fuse unit
separately.
4.15 Instrumentation for Rotating Equipments
Rotating Equipment vendor shall be completely responsible for providing adequate

instrumentation for safe and efficient operation of the machine. The commonly used
instruments are being detailed out in the following clauses, however this does not absolve
the vendor of providing additional instrumentation, if required.
4.15.1 Anti surge and performance control system (ASC)
a) Vendor shall be fully responsible for the complete design of Anti surge/performance
control system (ASC) including selection of type of flow element, controller Algorithm,
type of explosion protection, type and operating timings of final control element. Vendor
shall guarantee the performance of machine with the offered ASC system. Wherever
required, ASC system shall be designed in such a way that it is capable of correcting the

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compressor operating point so as to avoid surge in order to protect machine from possible
damage, to minimize process upsets and to minimize recirculation.
ASC system shall typically consist of but not limited to flow element, flow transmitter,
differential pressure transmitter, ASC controller, control valve and other accessories as
felt necessary by the vendor.
Vendor shall supply all the hardware and software related to the operation and safety of
the equipment. This shall include but not limited to the following;
Design and operation of surge control loop scheme based on offered equipment
performance.
Supply of all hardwares in antisurge control loop including dedicated controller,

transmitters, measuring elements, final control element etc.
Fast response transmitter and control valve etc. as required.
Algorithm required for antisurge/ Performance control application.
The ASC shall be a dedicated single loop controller on proprietary Hardware Platform or
single/multi loop controllers of common hardware platform such as PLC. The single loop
controller shall be dedicated controller for each Anti-surge or Performance control
application/Tag. Dedicated panel mounted facia shall be provided. The ASC system
when provided on common hardware platform shall be with redundant configuration as
minimum viz-dual processor, dual input/output, redundant communication & dual power
supply system. The multiloop controller/system shall be dedicated for Anti-
surge/Performance applications/Tags of each machine/each machine tag. Unless specified
otherwise dedicated panel facia for each application shall be provided to mount on
hardwired console in control room
It should be able to accept 4-20 mA signal from field or from HIC at purchaser DCS or
at LCP as a manual override to anti-surge control system with bump less transfer.

0 Auto-manual operation with bump less transfer shall be provided.
The controller response time (total time to read input, processing time and output) shall
be as per the machine dynamics and safety and shall be of the order of max. 40-milisec.
Any faster response required based on machine dynamics shall be considered by
vendor. The input sampling interval shall be as per machine dynamics within the
controller response time as above. The processor cycle time shall be considered to meet
the overall response time.
The ASC shall be field proven, specific to the make of machine and for the similar
application in hydrocarbon industries. Vendor shall provide the proven track record for
the offered ASC meeting the above.
The anti surge/performance control algorithm shall be implemented using standard

firmware in the controller/processor system.
The algorithm developed by vendor shall be specific for given application, surge
control, performance, load sharing etc. and shall be field proven for the compressor
make.
k) The algorithm implemented in the system shall be protected against any

modifications/changes.

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tia-eg INDIA LIMITED 6-52-0052 Rev. 3
rir<Nt ...rwn. IA Govt of InOla Undertakmg) PACKAGE UNITS Page 42 of 58
The configuration shall be stored in non-volatile memory or battery back-up for

configuration shall be provided (minimum 48 hours) in case of volatile memory along
with battery drain indication.
In case of ASC on common hardwired platform separate configurator with necessary

hard ware/ soft ware shall be provided for application programming.
Anti surge controller shall not be used for performing any other machine related inter
locks/logics.
All the instruments (transmitters, Positioner and temperature elements and / or

transmitters) connected with anti-surge control loop shall be flame proof "EExd" type
suitable for the area as specified. The suitability of smart transmitter/ Positioner shall be
confirmed by vendor and to be provided accordingly.
p) The ASC system vendor shall be fully responsible for the sizing and selection of the anti-
surge valve. Vendor to provide the sizing calculations duly vetted by ASC system
manufacturer.
4.15.2 Machine Monitoring System (MMS)
Machine Monitoring system shall be provided for continuous monitoring and indication of
machine parameters like vibration & axial displacement, bearing and winding temperature,
key-phasor etc.
4.15.2.1 Vibration and displacement monitoring system shall be as per API-670. The extent and type
of monitoring shall be as defined elsewhere. However, vendor shall furnish any additional
requirements for monitoring deemed essential by them with reasons. Two probes at 90
degree apart for each location shall be provided and connected to same dual channel monitor
for vibration monitoring.
4.15.2.2 The machine monitoring system shall be provided with preferably built in intrinsically safe
barrier and shall be duly mounted in separate panel. However, separate terminal blocks shall
be provided for terminating the field cables for maintenance purpose. Direct cable
termination on modules shall not be considered.
4.15.2.3 For MMS the display unit shall be provided at local control panel with necessary statutory
certification. Alternatively purged enclosure is also acceptable with necessary certification.
4.15.2.4 The sensing probe shall be accessible for adjustment, repair and replacement without
dismantling the machine.
4.15.2.5 Vendor shall provide hardwired Voted contact output of each parameter for Pre trip and trip
alarms for alarms/ interlock in purchaser's control system. The alarms/trips of the channels
within each monitor/ Module can be grouped together and common pre-trip alarm and
common trip contact for each monitor/ Module shall be provided. 4-20 mA signals from
Vibration & Temperature Monitoring System racks to DCS system are not required
separately, unless specified and vendor to ensure that all the parameters are available
through serial interface. For multi racks, vendor shall provide common serial interface
through multi drop link.
4.15.2.6 In addition to this, it shall be provided with necessary hardware (communication gateway
module) including the cable for serial data communication from monitoring system to
purchaser's DCS for machine monitoring through purchaser's DCS via redundant serial
data interface. This serial link shall be RS 422 / RS 485 with MODBUS RTU protocol.
Vendor shall furnish all details like pin configuration and tag number wise MODBUS
address mapping list etc. for smooth interfacing of this communication link with DCS.

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n-11 ENGINEERS INSTRUMENTATION OF
lig-aria5teg INDIA LIMITED 6-52-0052 Rev. 3
Wren c-lecm,...71iII.1, IA Govt of India Undo,'along) PACKAGE UNITS Page 43 of 58
Vendor shall also provide necessary hardware and software for providing raw data to
conditioning monitoring system for each rack.
4.15.2.7 Vendor shall also supply one common laptop based configuration unit for the package unit
with required configuration software (refer clause 4.17) and hardware for configuration of
MMS system including the serial communication cable required between configuration unit
(laptop) & MMS monitors.
4.15.2.8 Key Phasor
Key phasor system shall be provided by vendor for performing analysis of vibration signals
to determine machine malfunctions. It shall consist of a proximity probe and transmitter,
extension cable etc. and other accessories to make the system complete. Vendor shall
provide necessary reference on the shaft to determine one-per-turn occurrence.
4.15.2.9 Vibration and Axial Displacement Monitoring
Monitors shall be four channel types and shall meet the following specifications as a
minimum:
Continuous channel monitoring with each channel input from one probe. Readout
scale shall read higher of the sensors.
Each channel shall have two independent alarm levels one for pre trip alarm and one
for each trip and that can be set continuously over measurement range. Two relay
contacts for each pre-trip alarm and trip alarm per channel shall be provided.
Broken sensor failure detection without causing shut down.
LED lamps on monitor front for each channel to indicate pre-trip alarm, trip-alarm and
circuit fault conditions.
e) Selector switches on monitor front to read vibration/ displacement pre-trip alarm and
trip set points for each channel shall be provided.
4.15.2.10 Bearing & Winding Temperature Monitoring
a) Sensor shall be three wires RTD element of platinum having 100 ohms resistance at
0°C.
The temperature sensor, cables, terminal heads, junction boxes etc. shall be capable of
withstanding the mechanical vibration and environment of a rotating machinery
atmosphere.
c) Bearing and Winding temperature shall be monitored by means of a temperature

monitor. It shall meet following requirements:
Accept RTD inputs (platinum, I 00ohm at 0°C).
Continuous six channel monitoring with each channel input from each RTD.
Read out scale shall read higher of the six temperatures.
Each channel shall have two independent alarm levels one for pre-trip alarm and
one for trip alarm and that can be set continuously over measurement range.
Broken sensor failure detection without causing shut down.

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k3u ENGINEERS INSTRUMENTATION OF
$earfat51-eg INDIA LIMITED 6-52-0052 Rev. 3
101FR etormt J4317.. ∎ (A Govt n
of n 000 U cWntak.9) PACKAGE UNITS Page 44 of 58
Selector switches on monitor front, to read temperature, pre-trip alarm and trip set
points for each channel shall be provided.
Analog output 4-20 mA DC isolated signals shall be provided for each channel
for remote indication, if specified.
4.15.2.11 Wherever MMS is not specified, vendor shall provide suitable transmitter for all the
vibration and axial displacement, temperature, key phasor to provide 4-20mA signal to
purchaser's control system.
4.15.3 Speed Governor System
4.15.3.1 Digital microprocessor based system mounted in standalone cabinet and located in rack room
shall be provided. Fault tolerant triple modular redundant (TMR) system shall be supplied
unless otherwise specified in Job Specification.
4.15.3.2 HMI for operator interface shall be supplied loose with all mounting accessories for mounting
this HMI in purchaser's hardwired console in general. This shall include all basic features of
governor to enable operator to do all control and monitoring operations from console itself
4.15.3.3 This shall include features like assignable speed range, adjustable speed set point, remote
speed set point input, digital speed indication, adjustable speed ramp, override for testing the
external over speed trip system etc.
4.15.3.4 It should be able to accept 4-20 mA signal from HIC at purchaser's DCS or LCP as a manual
override to governor and pass on the same, after a bump less auto / manual selection and
local / remote selector switches configured in speed governor (shall be possible through
HMI) to governor valve as manual control.
4.15.3.5 Vendor shall provide all hardware & software in the system (including the cable for serial
data communication from system to purchaser's DCS) for serial communication link for all
data transfer from governor to purchaser's DCS. This serial link shall be RS 422 / RS 485
with MODBUS RTU protocol, vendor shall furnish all details like pin configuration and tag
number wise MODBUS address mapping list etc. For smooth interfacing of this
communication link with DCS.
4.15.4 Accumulator of Lube Oil System
4.15.4.1 If accumulators are used with nitrogen for lube oil dampening at the desired pressure to meet
the system requirement the following instrumentation with the accumulator to be provided
by vendor:
Accumulator shall have charge kit with isolation valves and connection hoses.
Standard nitrogen cylinders available in India are at pressure of 140 kg/cm 2g with
standard connection sizes. Vendor shall provide the complete regulator system with
protection for charging nitrogen from nitrogen cylinder to accumulator at the desired
pressure. Regulator shall be suitable for the inlet pressure variation of 140 to 150
kg/cm2g while charging with suitable inlet connection to match the Nitrogen cylinder
connection. Regulator system shall have pressure indicator, regulator, relief valve,
needle valve etc. as a minimum. Material of construction shall be stainless steel.
4.15.5 The compressor loading-unloading scheme for reciprocating compressors shall be provided
as per the minimum requirements specified in the job specifications. Manual as well as
automatic schemes shall be provided.

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k31 ENGINEERS INSTRUMENTATION OF
lig-aria51-eg INDIA LIMITED 6-52-0052 Rev. 3
1.112n 22nTre Tl JWISIC IA Govt O, India tinee11ak.9) PACKAGE UNITS Page 45 of 58
4.15.6 Emergency switch shall be provided in the local panel/local. All such switches shall have a
protective cover to avoid inadvertent shutdown.
4.15.7 Vendor shall provide the following common alarms for purchaser:
Common machine pre-trip alarms.

Common machine trip alarm.
4.16 System Cabinets, Racks and Consoles
4.16.1 All system cabinets, marshalling racks and hardwired consoles shall be free standing and
enclosed cubicles type. All these items shall have bottom cable entry.
4.16.2 Cabinets shall be fabricated from cold rolled steel sheet (CRCA) of minimum 2.0mm
thickness suitably reinforced to prevent warping and buckling. Doors shall be fabricated out
of 1.6 mm thick CRCA sheet. Cabinets having modular construction and with basic frame
structure of heavy duty aluminium shall also be acceptable.
4.16.3 Cabinet/Console finish shall include sand blasting, grinding, chemical cleaning, surface
finishing by suitable filler and two coats of high-grade lacquer with sanding between coats.
Two coats of paint in the cabinet colour and a final coat after assembly at site, shall be given
for non-glossy high satin finish.
4.16.4 In order to remove dissipated heat effectively vent louvers backed by wire fly screen shall be
provided. Further, ventilation fans shall be provided wherever required. High temperature
annunciation shall be provided on operator console.
4.16.5 Illumination shall be provided for all cabinets by fluorescent lamps, which shall be operated
by door switch.
4.16.6 All cabinets/racks/consoles shall be adequately sized to avoid any congestion. Wiring shall
be done as per guidelines provided in clause 4.2.14 of this specification.
4.16.7 The height and colour of the cabinets shall be inline with other equipments being installed in
the control room.
4.17 System software / License

Systems (like PLC, ASC, Speed Governor etc.) software shall include the operating system
and application program. The application program shall include software for performing
functions like interlock and shutdown logic, programming/program modification,
documentation etc. Two copies of application program and two sets of licensed system
software shall be supplied. The program language shall be English.
The licenses and application program shall allow:
Monitoring of system program for troubleshooting purpose.
Carrying out any modifications to the PLC/system program if need arises (engineering
license with proper validity)
Troubleshooting of any system related failures.
Monitoring of the system healthiness
The system shall be supplied with programming tools and related accessories.
Page 490 of 704


$fg-af fafgrdg INDIA LIMITED 6-52-0052 Rev. 3
tsflKa t'leage I A Go, of India UndertaNng) PACKAGE UNITS Page 46 of 58
5.0 LIST OF DOCUMENTS ATTACHED
7-52-0001 Instrument connections on vessels, standpipes and tanks

7-52-0002 Instrument connections on piping.
7-52-0035 Thermowell
7-52-0041 Orifice Plates and Flanges -Dimensional details.
7-52-0254 Duct Fabrication — Bolted Construction Details
Page 491 of 704

oi el ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
51gar015ieg
Wan
INDIA LIMITED
PACKAGE UNITS
IA Govt 01 Ind. Undenakmg)
Page 47 of 58
PART II
SPECIFICATION FOR MATERIAL, INSTALLATION,

TESTING AND COMMISSIONING
Page 492 of 704


ENGINEERS
Oar 1#112,1 eiecnte ,,o++1,
INDIA LIMITED
A Go„ of India Undellaktng) PACKAGE UNITS Page 48 of 58
1.0 INSTALLATION MATERIALS

1.1 Vendor shall ensure and supply all erection hardware required for the installation of
complete instrumentation which form a part of the package unit. This includes items like
cables, cable glands, junction boxes, instrument valves and manifolds, mounting accessories,
impulse piping/tubing, pipe/tube fittings, pneumatic signal tubes, air line pipes and fittings,
filter regulators, steam/electrical tracing, insulation materials, cable duct and trays, conduits,
prefabricated canopies for instruments, identification tags, structural material required for
instrument supports and trays etc.
1.2 Clause 1.1 above broadly covers the items required for any typical plant, however vendor
shall supply all necessary items to make the installation and commissioning work complete
in all respect, irrespective of whether these have been explicitly included in their scope or
not.
1.3 Salient feature and minimum requirement for some of the main installation materials is
being described in the following paragraphs. For items for which no specification has been
provided, vendor may follow their own specifications and prevailing international standards.
1.4 Cables
1.4.1 All cables shall have PVC insulated primary insulation of cable shall be 85°C Polyvinyle
Chloride type as per IS-5831 and inner and outer sheath of cable shall be flame retardant
made of extruded PVC Type ST-2 at 90°C as per IS-5831. Oxygen index of PVC shall be
over 30% at 27 °C+2 °C and temperature index shall be over 250°C. However, Polyethylene
(PE) insulation shall be provided in IIC area classification.
1.4.2 In general cables shall be flame retardant as per standard IEC 60332 Part 3 Cat.A. However,
cables with fire-safe valves shall be fire resistant also as per the following.
1.4.2.1 The insulation grade shall be 650 V/1100 V as a minimum and shall meet insulation
resistance, voltage and spark test requirements as per BS-5308 Part-II.
1.4.2.2 All cables shall be twisted and armoured. Armour over inner jacket shall be of galvanised
steel wire/flat as per IS-1554 part I.
1.4.3 For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall be
light blue for intrinsically safe application and black for others. For thermocouple extension
cables the inner and outer jacket colour shall be as per IEC.
1.4.4 Maximum DC resistance of the conductor of the completed cable shall not exceed the
following:
12.3 ohms/km at 20°C for cables with 1.5 mm2 conductor.

39.7 ohms/km at 20°C for cables with 0.5 mm2 conductor.
1.4.5 The mutual capacitance of the pair or adjacent cores shall not exceed 250 pF/m at a
frequency of 1 kHz whereas the same shall not exceed 100 pF/m for PE insulated cables.
The capacitance between any core and screen shall not exceed 400 pF/ m at a frequency of 1
kHz.
1.4.6 L/R ratio of adjacent cores shall not exceed 40 [tH/Q for cables with 1.5 mm 2 conductor and
25 p,H / Q for cables with 0.5 mm 2 conductor.
1.4.7 The drain wire resistance including shield shall not exceed 30 ohms/km.
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51g-al lagteg INDIA LIMITED 6-52-0052 Rev. 3
.
IMIR712 12ERROA,Sn. IA Govt Of India Undertaking) PACKAGE UNITS Page 49 of 58
1.4.8 A pair of communication wire shall be provided for multipair/multitraid cables. Each wire
shall be 0.5 mm2 of plain annealed single or multi-strand copper conductor with 0.4 mm
thick 85°C PVC insulation. Insulation shall be green and red colour coded.
1.4.9 Each multipair cables shall have 20% pairs as spare.
1.4.10 Running length of the cable shall be printed on the outer sheath at least at every 5 metre
interval.
1.4.11 Signal Cables
Single pair shielded signal/alarm cables shall be used between field instruments and
junction boxes/local control panels.
Multipair individually and overall shielded signal/alarm cables shall be used between
junction boxes/local control panels and control room, in general.
The single pair and triad cables shall be of 1 5 mm 2 conductor size made of electrolytic
copper conductor of 7 strands with each strand of 0.53 mm diameter, multipair cables
with 0.5 mm2 conductor size shall have 16 strands of annealed electrolytic grade copper
conductor with each strand of 0.2 mm diameter, multi triad cable or multi pair cable
with 1 5 mm2 conductor shall have 7 strands with each strand of 0.53 mm diameter, as
per the job specification.
Shield shall be aluminium backed mylar/polyester tape bonded together with the
metallic side down helically applied with either side having 25% overlap and 100%
coverage. The minimum shield thickness shall be 0.05 mm in case of single pair/traid
and 0.075 mm incase of multipair/triad cable.
Drain wire shall be provided for individual pair and overall shield which shall be 0.5
mm2 multi stranded bare tinned annealed copper conductor. The drain wire shall be in
continuous contact with aluminium side of the shield.
All multi pair cables shall have 6 pair/12 pairs only while multitriad cable shall have 6
triads/8 triads only.
1.4.12 Control Cables
Single pair control cables shall be used between field mounted solenoid valves and
junction boxes/local control panels and shall meet the requirements specified in para
1.4.11 above.
Multipair control cables shall be used between junction boxes/local control panel and
control room mounted devices in general. These cables shall have only overall
shielding.
c) These control cables shall have 1.5 sq mm conductor size with 7 stranded conductors of
annealed electrolytic grade copper, with each strand of 0.53 mm diameter.
1.4.13 Fieldbus Cables
Fieldbus cables shall be 16AWG (1.31 mm 2) for trunk and 18 AWG (0.82mm 2 ) for
spur twisted in pair individually and overall shielded with aluminium mylar tape with
drain wire and armoured. Other parameters shall be as per Type A defined in IEC-
61158-2.
Fieldbus cables shall be single pair or two pairs.
Field bus cable shall be field proven for FF applications.
Fieldbus cable shall comply with H1 cable test specification FF 844.
e) Outer jacket color shall be orange with 3 longitudinal blue stripes for spur cables and
black stripes for trunk cables.
Page 494 of 704


,..-e Oa&
OgZrf INDIA LIMITED 6-52-0052 Rev. 3
t-,,05,0,,.,4,, IA Govt of India undertaking) PACKAGE UNITS Page 50 of 58
1.4.14 Thermocouple Extension Cables
Single pair shielded thermocouple extension cables shall be used between

thermocouple head and junction boxes/ transmitters/local control panel mounted
instruments.
Multipair individually and overall shielded thermocouple extension cables shall be used
between junction boxes and control room mounted devices.
The type of thermocouple extension cables shall be compatible with thermocouple
used. In addition the colour coding of the primary insulation shall be as per IS-8784-
1987 (R2004).
The cable shall have 16 AWG and 20AWG solid conductors for single and multipairs
respectively.
All thermocouple extension cable shall be matched and calibrated in accordance with
IEC-60584-2.
Shield shall be aluminium backed by mylar/polyester tape bonded together helically
applied with the metallic side down with either side having 25% overlap and 100%
coverage. Minimum shield thickness shall be 0.05 mm for single pair and 0.075 mm for
multipair cable. Drain wire shall be similar to individual pair and shall be in continuous
contact with the aluminium side of the overall shield.
Inductance shall not exceed 4mH/Km. However for J-type thermocouple inductance
could be 8 mH/km.
Electrostatic noise rejection ratio shall be over 76dB.
i) All multi-pair cables shall have 6 pairs/12 pairs only.
1.4.17 Power Supply and Other Cables
a) All power supply cables shall be as per IS-1554 Part I and shall have copper/aluminium
conductors depending on conductor size. Minimum conductor size shall be 2.5 mm2 of
copper conductor. For higher sizes (above 16 mm2), aluminium conductor can be
considered. All these cables shall be PVC insulated and armoured.
1.4.18 Any other special cable required for instruments shall also be supplied as per the
requirement. Vendor shall ensure that these cables are armoured type and shall meet all other
requirements specified in para 1.4.1 through 1.4.10, as applicable.
1.5 Cable Glands
Vendor shall supply all cable glands required for glanding the above mentioned cables
at field instrument side, local control panel side, junction boxes side and at control room
side.
All cables glands shall be of nickel-plated brass and shall be double compression type
suitable for armoured cables.
Flame proof glands wherever required shall be supplied with Ex (d) certification.
PVC Cable shrouds shall be provided with all the cable glands.
1.6 Junction Boxes (Non-Fieldbus loops)
Vendor shall supply junction boxes as per the cables selected, wherever required. These
shall be of die cast aluminium alloy (min. LM-6) body and shall be weather proof to
IP65 as a minimum.
These boxes shall have terminals suitable for minimum 4.0 mm 2 cable termination
mounted on rails. 20% spare terminals shall be supplied in each junction box.

Page 495 of 704

n31
2151e INDIA UMITED 6-52-0052 Rev. 3

g
I NIR71 2.12M2 JP415.1, IA Govf of lixha Undertaking, PACKAGE UNITS Page 51 of 58
Telephone sockets and plugs shall be provided in junction boxes.
Flame proof junction boxes shall be used in explosion proof/ flame-proof instruments
circuits and supplied with Ex (d) certification. All such boxes shall be weatherproof
also.
e) Each junction box shall have a minimum 12 numbers of entries with 20% or 2 Nos. as
spare entries for branch cable and minimum 2 numbers of entries for multipair cable
with 1 No. spare. All entries shall be provided with suitable plugs.
0 Suitable 3-way power junction box shall be considered for higher size of incomer
power cable, which is not matching with the terminals provided in the control panel.
1.7 Junction Boxes for Fieldbus Loops
1.7.1 For Fieldbus segment, junction box shall be used for mounting the wiring/ terminal blocks to
terminate the trunk and spurs in the fieldbus networks.
Unless otherwise specified, vendor must use the following type of terminal blocks:
For all FISCO signals Weatherproof terminal blocks

For all safe signals Weather proof terminal blocks
For all Explosion proof signals Explosion proof/Flameproof terminal blocks
1.7.2 Junction box for Fieldbus field barrier concept:
Fiedbus junction boxes with field barrier assembly/ assemblies shall be provided. Not more
than 12 spurs shall be considered in one junction box. Each junction shall not have more
than two segments and no. of field barrier assemblies shall be considered accordingly. Field
barrier assemblies in a segment shall be multidropped (shall not be daisy chained in a trunk).
Only one closed loop can be considered per segment. Remaining spur connections in the
segment can be used for open loop. For multi field barrier assembly in a junction box, Field
barrier assemblies shall be DIN rail mounted. Vendor shall terminate the spare pair of trunk
cable in DIN rail mounted terminal in junction box. One field barrier assembly shall contain:
Isolation facilities (EEx de) for isolating the field barrier assembly from fieldbus
trunk.
Not more than 6 spur / barriers connections and Not more than one field device in
each spur connection.
Internal short circuit protection for each spur (short circuit current <= 45 mA)
LED indicator for each spur short circuit.
Each spur shall be galvanically isolated from trunk.
Fieldbus terminator for each segment shall be inside junction box.
1.7.3 Housing of the fieldbus junction boxes shall be electropolished type SS 316.
1.7.4 Surge protectors on the field side shall be provided whenever specifically mentioned in job
specification either within the FFJB or along with the instrument.
1.7.5 Sufficient spacing shall be provided inside the Junction Boxes for mounting of field barrier
assemblies, termination and routing of Trunk/ Spur cables to the barrier/Megablocks,
sufficient space shall be provided for installing terminator etc. inside the Junction Box.
1.7.6 For spur and trunk cables, 20 % addition cable entries must be provided. Unused entries
shall be plugged.

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$2-41- tif5ilegt INDIA LIMITED 6-52-0052 Rev. 3
Riven riecat AA saa dr (A Govt 0 India Undertaking) PACKAGE UNITS Page 52 of 58
1.7.7 Each junction box shall be provided with sufficient entries with weatherproof, flameproof
plugs, as required. Trunk and spur entries shall be from the bottom.
1.8 Instrument Valves and Manifolds
Vendor shall supply instrument valves (miniature type) and valve manifolds wherever
required.
The hydrostatic test pressure for instrument miniature valves shall be 153 Kg/cm2g for
pipe class upto 600 and whereas for Instrument air lines, it shall be 41 Kg/cm2g. All
valves and manifolds shall be forged type only.
c) Valve body and trim material shall be 316 SS unless otherwise specified. Superior trim
material shall be selected as required by process conditions. Packing material in general
shall be of PTFE.
1.9 Impulse Piping/Tubing
Vendor shall supply 1/2" OD x 0.065" thick ASTM A 269 TP 316 L stainless steel
seamless tubes as a minimum for impulse lines.
Where the pressure (operating) exceeds 70kg/cm2g or if piping is specified as impulse
line, seamless pipes of size '/2" NB of required thickness shall be supplied with material
as per piping class.
Seamless tubes shall have a hardness of max 80 RB as typical.
Steam tracing shall be 10 mm OD copper tubes of electrolytic grade copper.
e) Instrument air tubing shall be 6 mm SS316L.
1.10 Pipes and Tube Fittings
Vendor shall supply flareless compression type of tube fitting and of three piece
construction.
The fitting/ferrule hardness shall not be less than RB 90 so as to ensure a minimum
hardness difference of 5 to 10 between tube and fittings. The fitting/ferrule shall be of
SS316 material.
Socket-weld type forged pipe fittings of suitable material and rating shall be supplied
for pipe fittings as per Piping Material Specification. The minimum rating shall be 3000
Lbs. Weld neck fittings shall be used where socket weld type are not allowed by piping
class.
Brass fittings, wherever used as per job specification, shall be suitable for use on
copper tubes conforming to ASTM B68 /B68M hardness not exceeding RB 50. All
fitting parts shall be manufactured from Brass as per IS-319 bar stock or equivalent and
shall be nickel plated.
e) All threaded fittings shall have NPT threads as per ANSI/ASME B 1.20.1 only.
1.11 Pneumatic Signal Tubes
Vendor shall supply 6mm OD x 1mm thick SS316L tube for pneumatic signal tubes.
Vendor shall avoid use of intermediate connections and shall estimate single length for
each instrument location.

Page 497 of 704

=
Ogar Rift
ENGINEERS
INDIA LIMITED
INSTRUMENTATION OF
6-52-0052 Rev. 3
PACKAGE UNITS Page 53 of 58
1.12 Instrument Air Lines Fittings and Valves
Seamless galvanised, inside and outside, carbon steel pipes used for instrument air
distribution shall be as per IS 1239 class Heavy. In view of difficulty in bending such
pipes, elbows shall be used wherever bending is expected or A106 Gr B pipe shall be
supplied.
Galvanised forged screwed carbon steel screwed fittings of 2000 lbs rating fittings shall
be used.
c) Isolation valves on instrument air service shall be packless gland type full bore ball
valves. .
1.13 Air Filter Regulators
Instrument air filter regulator of suitable size, range and capacity shall be supplied for
each pneumatic instrument.
The body of the filter shall be anodised aluminium.
c) The filter shall have 5 micron sintered bronze filter element and shall be provided with
manual drain and 2" nominal size pressure gauge.
1.14 Cable Trays and Cable Ducts
All cables on the main pipe rack shall be laid in cable duct. Cable ducts shall be of
galvanised mild steel with SS bolts and shall be fabricated as per 'Duct Fabrication-
bolted Construction Details' standard No. 7-52-0254.
All branch cables/tubes shall run on cable trays.
These cable trays shall be made out of galvanised mild steel sheets of 2.5 mm
thickness. Ladder trays shall be of galvanised mild steel. 50 mm x 50 mm x 6mm thick
angle shall be used as a minimum.
The width shall be so selected that 50% of tray space is available for future use.
Suitable SS wire cable clamps shall be supplied for binding the cables/tubes at every
500 mm. Nuts/Bolts used for cable trays fixing shall be SS.
FRP cable trays shall be provided when specified.
1.15 Instrument Support/Structural Steel
a) Vendor shall supply instrument stands, stanchions and other structural steel material
required for supporting the cable trays, impulse lines and instruments.
1.16 Heat Tracing and Insulation

Heat tracing and insulation of line mounted instrument impulse lines shall be carried
out as per line specifications. Similar philosophy shall also be followed for equipment
mounted instruments. However, impulse lines for instruments/level instrument in
congealing, viscous services shall also be stream traced even though the
pipe/equipment not traced.
Instruments mounted on jacketed lines and jacketed equipments shall be jacketed only.
In case the jacketing of any particular instrument item is not possible, heat tracing may
be selected after intimation to Owner/ Owner Representative before proceeding ahead.
c) For all steam traced lines and steam jackets, a suitable type of steam trap must be
provided for proper and efficient tracing. Separate dedicated steam trap shall be used
for each instrument. Steam trap shall preferably be located on ground level with its

Page 498 of 704


Ogal" fa5reg INDIA LIMITED 6-52-0052 Rev. 3
lama viva, ,t
451 07-0 1, A Govt of India Undettakogl PACKAGE UNITS Page 54 of 58
outlet connected to drain funnel or as advised elsewhere in the package. Each

instrument to be traced shall be provided with steam isolation valve.
Wherever electric tracing is shown in the approved P&ID and selected for instruments
and instrument lines, this must be suitable for the line temperature rating.
Steam tracing shall be avoided inside any room/ or shelter. The heat tracing required
for analyzers shall be carried out by electrical tracing using prefabricated tube tracers.
0 Insulation of all in-line instruments like control valves, safety valves etc. shall be done
as per the line requirements. Also all direct equipment mounted instruments like level
gauge, displacer/float type instruments etc. shall be properly insulated as per insulation
requirements of the equipment on which these are installed.
The insulation with 25 mm dia. Sodium silicate inhibited ceramic fiber rope (fiber glass
/ SS wire braided) by spiral winding in position, wrapping the rope around piping so as
to cover the piping completely without leaving any gap, application of two layers of
self adhesive aluminum foil tape (min 0.1 mm thick) spirally wound over the rope
surface with the joints in two layers staggered. Ceramic fibre rope shall be of minimum
density 250 kg/m3 shall be made up of ceramic fibre insulation with other properties of
ceramic fibre rope confirming to 3.2.3 (1) of specification "6-44-0002 for hot
insulation" work.
Steam tracing shall be considered for instrument impulse line for cryogenic services
(i.e. operating temperature is less than 0° C).
2.0 INSTALLATION
2.1 Vendor shall be completely responsible for installation of all instruments within their battery
limit, in line with the installation standards (typical) furnished alongwith package
specification.
2.2 Whenever installation is beyond the scope of vendor/contractor, purchaser shall install the
instruments as per the details/documents/drawings provided by the vendor/contractor.
However, in such a case it must be ensured that complete installation materials shall be
supplied.
2.3 All direct mounted instruments like thermocouples, thermowells, temperature gauges,
pressure gauges, pressure switches etc. shall be installed in such a way that they have good
readability and accessibility.
2.4 The capillary of all capillary type instruments shall be supported properly and shall be
protected against mechanical damage.
2.5 All pressure/differential pressure instruments shall be provided with block and bleed/ by-
pass, drain/vent valves etc as per the installation standards, and shall have accessibility.
2.6 All primary piping/tubing (impulse lines) shall have a slope of 1 in 12 on the horizontal run.
2.7 All welding shall be carried out as per the relevant codes with proper electrodes. Any testing
(non destructive) like DP test and radiography on root weld and final weld shall be carried
out as applicable. All consumables shall be part of vendor's scope of supply. Any pre/post
weld treatment as required by the relevant codes shall be carried out.
2.8 All threaded joints shall be joined by PTFE tapes only.
2.9 All impulse lines shall be supported at regular intervals.
2.10 Instrument drain/vent connections shall be piped to safe area like oily water sewer or above
pipe racks to avoid accumulation of hazardous fluid in the plant atmosphere.
Page 499 of 704

Igar la leg INDIA LIMITED 6-52-0052 Rev. 3
g
29-075,2 .770.1) PACKAGE UNITS
IA GoA of Incha Undeffak,N)
Page 55 of 58
2.11 Steam tracing wherever required shall be carried out by 10 mm OD x 1 mm thick coper
tubes and condensate traps shall be provided to collect all the condensate and shall be piped
to the nearest pipe drain funnels.
2.12 All tubes/cables shall be properly laid on cable trays, which shall be supported at regular
intervals.
2.13 Separate routing or physical separation shall be maintained between signal, shut down and
power cables.
2.14 Wherever intrinsically safe system cabling is employed, the minimum separation of 150 mm
shall be adhered between IS (intrinsically safe) and non- IS signal cables.
2.15 The cases of instruments shall be earthed by earthing wire to the nearest earth bus bar for
safety reasons.
2.16 In case the cables are to be buried or laid in concrete trench the same shall be carried out by
vendor. In case civil work is carried out by purchaser, requirement of trenches shall be
provided with prior intimation to client.
2.17 Painting of angle trays, instrument supports and all structural supports shall be painted as
under :-
a) The surface to be painted shall be thoroughly cleaned with brush and sand paper to
remove all scales. After cleaning, one coat of red oxide zinc chromate primer shall be
given conforming to IS-2074 and allowed to dry. One coat of final paint shall be
applied.
Second and final coats of paint of final colour shall be given before handing over the
plant/ commissioning.
2.18 Installation of Systems ( MMS, Analysers etc.)
2.18.1 The system as applicable shall be installed by the system vendor who would be responsible
for installation and termination of interconnecting cables in the system racks/cabinets. All
interconnecting cables shall be identified and the individual cores/wires shall be properly
identified using ferrules. Direct-cross ferruling method shall be used for identification.
2.18.2 All system communication cables shall be laid in covered GI (galvanised iron) trays away
from power cables. Prefabricated cables shall be avoided for interconnection if these are to
be routed out side the cabinets. If unavoidable these should be laid in covered GI trays.
2.18.3 All panels/cabinets shall be properly leveled and secured firmly with the base supporting
structure. However, the consoles and printer stands need not be secured to base structure.
2.18.4 Grounding
Each cabinet, console and other equipment supplied as a part of system shall have
earthling lugs which shall be secured to the 'AC mains earthing bus'.
All circuit grounds, shields and drain wires shall be connected to the 'system ground'
bus which is isolated from 'AC mains earth'. This bus shall typically be 25 mm wide
and 6 mm thick of copper.
The total resistance of system ground shall be less than 5 ohms unless otherwise
recommended by system manufacturer.
c) Safety barriers, if used, shall be secured to 'Safety ground' which shall have typically
ground resistance of less than 1 ohm. The bus shall be designed considering a fault level
of 0.5 A at 250V r.m.s. per barrier.
Page 500 of 704


$tgar Mieg INDIA LIMITED 6-52-0052 Rev. 3
t.A F,t t-tv,,,,A,Afo, 0 IA Govt of India UndeltakIng) PACKAGE UNITS Page 56 of 58
2.18.5 All other installation guidelines as recommended by system manufacturer shall be followed.
3.0 TESTING AND CALIBRATION
3.1 All impulse lines shall be tested hydrostatically at 1.5 times the design pressure / maximum
operating pressure. Ensure that instrument and vessel/piping is isolated during this test.
3.2 In case of special instruments/items where hydrotesting is not permitted due to service
conditions, the impulse lines testing shall be carried out by using air or nitrogen.
3.3 After pressure testing, all these impulse lines shall be drained and dried with dry air for 15
minutes to remove any traces of moisture, oil and dust.
3.4 Instrument air lines shall be duly tested for any leak after pressurising and isolating the main
root valve by soap solution and bubbler unit. After isolation, the rate of fall in pressure shall
be less than 1 kPa for every 4.4 metre (1 psi for each 100 feet) of tubing for a test period of 2
minutes.
3.5 All instrument cables shall be tested for continuity and insulation. While meggering the
cables for insulation testing, ensure that all instruments and barriers are isolated at both ends.
The megger testing at site is not required to be carried out for the field bus cables and
thermocouple extension cables. However, for field bus cables and thermocouple extension
cables, the loop resistance and capacitance shall be checked by the contractor before and
after the completion of cable laying.
3.6 All instruments supplied by the vendor shall be calibrated using proper test equipment.
3.7 All instruments shall be calibrated for 0%, 25%, 50%, 75%, 100% and vice versa.
3.8 All temperature gauges shall be calibrated using temperature baths.
3.9 All thermocouple activated instruments shall be calibrated by generating millivolts by a

potentiometer.
3.10 All transmitters shall be calibrated as per instrument ranges.
3.11 All displacer type level transmitters shall be calibrated with water or suitable fluids and
corrected for specific gravity.
3.12 All alarm and trip switches shall be calibrated over the entire range, finally set and checked
for alarm/trip points and reset points as per the alarm/trip set point schedule. After setting,
these shall be sealed.
3.13 All control valves, prior to stroke checking, shall be externally cleaned thoroughly. The full
stroke of valve shall be checked for opening and closing. Any adjustment required for
obtaining full stroke and reducing hysteresis shall be carried out. The hysteresis shall not be
more than 1% URV (upper range value) with positioners and 5% URV without positioners.
3.14 Solenoid valve shall be checked functionally for its operation and also compatibility with
respect to barrier.
3.15 Safety valves and relief valves shall be set/ tested by using dry air/nitrogen. Leakage if any
shall be removed by proper lapping of seat and disc.
3.16 All electronic/pneumatic receiver instruments shall be calibrated as per the manufacturer's
instructions. Controllers shall be aligned properly.

Page 501 of 704

elf ttai
eg INDIA LIMITED 6-52-0052 Rev. 3
141FR ,I,CP1149,710.0 (A Govt India UnOettak nngt PACKAGE UNITS Page 57 of 58
3.17 All special instruments like analyzer shall be checked and calibrated as per manufacturer's
instructions. Prior to testing, all analyzer sample lines shall be thoroughly cleaned by carbon
tetra chloride or any other cleaning liquid. After cleaning, these lines shall be thoroughly
purged with dry nitrogen.
3.18 No oil should be used in oxygen and chlorine service lines.
3.19 The accuracy of overall loop shall be within 1% for electronic and 1.5% for pneumatic
loops.
3.20 After performing the calibration of all instruments, the entire loop shall be checked for
proper operation.
3.21 The entire shutdown scheme shall be simulated from the process trip switches/ control
system and the scheme shall be tested for its proper operation prior to start up of the unit.
3.22 If no instrument air is available vendor shall provide necessary nitrogen cylinders with
suitable regulators to carry out the above activity.
3.23 Testing Of Systems
3.23.1 All the system functions shall be checked thoroughly for proper functioning. These shall
include but not limited to the following tests:
Visual and mechanical.

Complete system configuration loading.
Demonstration of all system functions.
Checking of all systems displays.
Checking of correct functioning of all keyboards.
Demonstration of all system diagnostics.
Checking of proper functioning of all printers, hardcopy unit, and printing of all reports.
Checking of all disc drives.
Complete checking of logic system, loading of user's program and checkout of results.
Checking of correct changeover of the back-up/redundant units in case of failure of
main units.
Vendor shall also carryout the system checks as per respective items specifications wherever
provided along with package.
3.23.2 The input signals shall be simulated by disconnecting the field wires for all inputs. Wherever
control room mounted Transmitters/Converters/Receiver switches are used, the functioning
of same shall also be checked.
3.24 Loop Checking
3.24.1 Loop checking shall be carried out by vendor, which shall include proper functioning and
interconnection of all items in the loop.
3.24.2 All input signals shall be generated in the field and corresponding reading shall be checked
at all corresponding displays.
All the outputs shall be checked in the field, by physical verification of valve stroke or
operation of solenoid valve/pick-up of electrical contactor.

Page 502 of 704

Ogar faajeg INDIA LIMITED 6-52-0052 Rev. 3
,A Govt of Indo Unclertakow PACKAGE UNITS Page 58 of 58
3.24.3 After loop checking is completed, vendor shall connect back any terminals and connections
removed during loop checking.
3.24.4 For fieldbus loops the segment verification shall be carried out by DCS vendor. Any field
side modifications required shall be carried out by vendor.
4.0 COMMISSIONING
4.1 This activity shall be carried out in a systematic manner so as to avoid any accident to plant
and operating personnel.
4.2 During the plant start up all the instruments calibration, controller alignment, trip point
settings shall be trimmed so as to meet the operation requirements.
4.3 Prior to guarantee run of any package unit, the vital instruments as required by vendor have
to be recalibrated and the results recorded.

Page 503 of 704

ENGINEERS MATERIAL SELECTION CHART Annexure Ito

Ogar faiRegWf INDIA LIMITED STANDARD SPECIFICATION NO.
AMA' WORM) IA Go. of Indus Und.slung)
6-52-0052 Rev. 3
Page 1 of 5
1.0 GENERAL

1.1 Material selection chart defines the base material requirements for major instrument
items. The materials have been specified as per 'piping class' in which these
instruments are installed. Additional requirements like stelliting etc. shall be selected
based on process conditions.
1.2 Although materials as specified in Material Selection Chart shall be acceptable, in

general, this does not absolve vendor of the responsibility of proper selection of
material as per the fluid being handled and process conditions.
1.3 For all instruments in sour service requiring NACE as per Piping class, all materials
of construction shall meet the requirements specified in NACE MR 01-03 latest
edition. In addition, any other requirements if specified in respective piping class,
shall also be complied.
1.4 Impulse pipe material shall be as per the corresponding piping class. However, for
Impulse tubing material shall be 316L SS, as a minimum. Better material shall be
selected wherever required.
1.5 This gives details of selection criteria for most of the common EIL Piping Classes.
However, variations may exist from these in jobs and also new piping classes may
arise. In those circumstances, the material selection shall be based on the relevant job
piping classes and evaluation of actual requirements.
1.6 For testing requirement like Radiography, IBR, NACE, Hydrogen testing, Post weld
heat treatment, etc shall be followed as per piping material specification for the
respective piping class.
Page 504 of 704

fiPzrekgi:—
:h ENGINEERS Annexure I to
iaReg INDIA LIMI1B D MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
14917A 2120,1,61JAMI, una,isonsi
in Govt Of InOta
6 -52 -0052 Rev3
Page 2 of 5
CONTROL VALVE PRESSURE RELIEF VALVE

SL.
PIPING CLASS
NO Body / Nozzle /
Body Trim Bellow
Bonnet disc
1. A1A,A3A,A5A, A6A, A8A, A9A, A216 SS316 A216 SS316 SS316L

AI OA, A14A, A19A, A22A, A28A, Gr. WCB Gr. WCB
B IA, B5A, B6A, B9A, B I3A,
B19A, B28A
2. A16A, A23A, A26A, A68A, B16A, A216 SS 316L* A216 Gr. SS 316L Inconnel
B23A, B24A, B26A, B68A • Gr. WCB * WCB * * *
3. D23A, D26A A216 SS 316L A216 Gr. SS 316L Inconnel
Gr. WCB * Stellited* WCB * * *
4. A2A, B2A, B21A, DI A, D9A, A216 SS 316 A216 SS 316 SS 316L
D19A, D2A, D5A, ElA, E2A, FIA, Gr. WCB Stellited Gr. WCB
F2A, F5A
A4A, B4A, D4A A352 SS 316 A352 SS 316 SS 3I6L
Gr. LCB Gr. LCB
AlB, BIB, D1B, D2B A217 SS316 A217 SS316 SS316L
Gr. WC1 Stellited Gr. WC1 stellited
7. AID, BID, B5D, D1D, D2D, F2D A217 SS316 A217 SS316 SS316L
Gr. WC6 Stellited Gr. WC6 stellited
8. A4F, B3F, B4F A217 SS 321 A217 SS 321 SS321
Gr. C5 Gr. C5
9. A4G, B4G A217 Gr. C12 SS321 A217Gr. SS321 SS321
C12
10. D4G A217 Gr. C12 SS321 A217Gr. SS321 SS321
Stellited C12
A1H, BIH, DIH A352 SS 316 A352 SS 316 SS 316L
Gr. LC3 Stellited Gr. LC3 stellited
AIK, A2K,A3K, A22K, BIK, B2K, A351 SS 316 A351 SS 316 SS 316L
D2K Gr. CF8 Gr. CF8
D2K A351 SS 316 A351 SS 316 SS 3I6L
Gr. CF8 Stellited Gr. CF8
B25K A351 SS 316L A351 SS 316L SS 316L
Gr. CF3 Stellited Gr. CF3 stellited
15. B18K, D18K A351 SS316 A351 SS316 SS 316L
Gr. CF8 Gr.CF8
16, AIM, BIM A351 SS 316 A351 SS 316 SS 316L
Gr. CF8M Gr. CF8M
AIN, BIN, B6N A351 SS 316L A351 SS 316L SS 316L
Gr. CF3M GrCF3M
A26N A351 SS 3I6L* A351 SS 3I6L* Inconnel
Gr. CF3M* GrCF3M* *
D26N A351 SS 316L A351 SS 316L* Inconnel
Gr. CF3M* Stellited* GrCF3M* *
B4K, B5K A351 SS 304H A351 Gr. SS 316 SS 316L
Gr. CF1OM Stellited CFIOM
21. A70M, A74M, B70M, B74M A351Gr. SS 321 A351Gr. SS 321 SS 321
CF8C CF8C
22 D25M A351Gr. SS 347 A351Gr. SS 347 SS 347
CF8C Stellited CF8C Stellited
23. AllK, B11K A351Gr. CF3 SS316L A351Gr SS316L SS 316L
CF3

Page 505 of 704

latitzieift ENGINEERS Annexure Ito
itaieg W INDIA LIMITED MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
MOM evim2fenaae1oo IA Goa of Inclo Undeotalang)
6-52-0052 Rev3
Page 3 of 5
ORIFICE/SENIOR ORIFICE FIELD TRANSMITTER

S.
PIPING CLASS
NO
Flange/Body Plate Body Sensor
AlA, A3A, A6A, A8A, A9A, A10A, A105 SS 316 SS 316 SS 316L
A14A, A19A, A22A, B1A, B21A, B6A,
B9A, B13A, B19A, D1A, D9A, D19A,
E1A, F1A,
A16A, A23A, A26A, A68A, B16A, B23A, A105 * SS 316L* SS 316* SS 316L*
B24A, B26A, B68A, D23A, D26A
A2A, B2A, D2A, E2A, F2A, A105 SS 316 SS 316 SS 316L
A4A, B4A, D4A A350 GrLF2 SS 316 SS 316 SS 316L
AlB, B1B, D1B, D2B A182 SS316 SS316 SS316L

GrF1
AID, BID, B5D, DID, A182 SS316 SS316 SS316L
D2D, F2D GrF11
A4F, B3F, B4F A182 SS 321 SS316 SS321 or
GrF5 Hastelloy-C
A4G, B4G, D4G A182 SS 321 SS316 SS321 or
GrF9 Hastelloy-C
AlH, B1H, D1H A350 SS316 SS316 SS316L
GrLF3
A1K, A2K, A3K, A22K, B1K, B2K, D2K A182 SS 316 SS 316 SS 316L
GrF304
B25K A182 SS 316L SS 316 SS 3I6L
GrF304L
B18K, D18K A182 SS316 SS316 SS316L
GrF304
AIM, BIM A182 SS 316 SS 316 SS321 or
GrF316 Hastelloy-C
AIN, A26N*, B1N, B6N, D26N* A182 SS 316L SS 316 SS 316L
GrF316L
A5A, B5A, D5A, F5A, F25A A105 SS316 SS 316 SS316L with
Note-1 gold plated
B4K, B5K A182 SS 316 SS 316 SS 316L
GrF304H
A70M, A74M, B70M, B74M A182GrF321 SS321 SS316 SS321 or
Hastelloy- C
D25M A 1 82GrF347 SS347 SS316 SS316L with
gold plated
19. AllK, B11K A182GrF304L SS316L SS316 SS316L

Page 506 of 704

101
ifft ENGINEERS Annexure I to
Itgar ial5tegW INDIA LIMITED MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
1.27121OMOOnaOarfl, IA Govl ol Inda Undertalorg)
6-52-0052 Rev3
Page 4 of 5
THERMOWELL LEVEL INSTRUMENT

S.
PIPING CLASS
NO
Flange Well Cage/ Chamber
A1A, A3A, A6A, A8A, Al OA, A14A, A105 SS 316 A106
A19A, A22A, B1A, B21A, B6A, B9A, Gr. B
B13A, B19A, D1A, E1A, F1A, A5A,
B5A, D5A, D9A, D19A, F5A
A16A, A23A, A26A, A68A, B16A, A105 * SS 316L A106 GrB*
B23A, B24A, B26A, B68A, D23A,
D26A
A2A, B2A, D2A, E2A, F2A A105 SS 316 A106 GrB
A4A, B4A, D4A A350 GrLF2 SS 316 A333 Gr6
A1B, B1B, D1B, D2B A182 GrF1 SS 316 A335 GrP1
AID, B1D, B5D, D1D, A182 GrF11 SS 316 A335 GrP11

D2D, F2D
A4F, B3F, B4F, A182 GrF5 SS 321 A335 GrP5
A4G, B4G, D4G A182 GrF9 SS 321 A335 GrP59
A1H, B1H, D1H A350 GrLF3 SS 316 A333, Gr3
A1K, A2K, A22K, A3K, B 1K, B2K, A182 GrF304 SS 316 A312 GrTP304
D2K
B25K A182 GrF304L SS 316L A312 GrTP304L
B18K,D18K A182 GrF304 SS 316 A312 GrTP304
AIM, BIM A182 GrF316 SS 316 A312 GrTP316
AIN, BIN, B6N, A26N*, D26N* A182 GrF316L SS 316L A312 GrTP316L
15. B4K, B5K A182 GrF304H SS 304H A312 GrTP304H
16 A70M, A74M, B70M, B74M A182 GrF321 SS321 A312 GrTP321
D25M A182 GrF347 SS347 A312 GrTP347
AUK, B11K A182 GrF304L SS316L A312 GrTP304L

Page 507 of 704

laffkle/ ift ENGINEERS Annexure Ito
Ogeil Eifilegyr
INDIA LIMITED
Govt ol India U.d.ak.n9)
MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
6-52-0052 Rev3
Page 5 of 5
PRESSURE, DIFFERENTIAL
LEVEL GAUGE PRESSURE AND VACUUM
SL. GAUGE
PIPING CLASS
NO Sensing
Cock Cock Diaphragm
Chamber Element
Body Trim
/ Socket
Al A, A3A , A6A, A8A,A10A, A105 A105 SS 316 SS 316 SS 316
A14A, A19A, A22A, B IA, B6A,
B9A, B13A, B19A, B21A, D1A,
D9A, D19A, E1A, F1A,A5A,
BSA, D5A, F5A
Al 6A, A23A, A26A, A68A, A105* A105* SS SS 316* SS 316L*
B16A, B23A, B24A, B26A, 316L*
B68A, D23A, D26A
A2A, B2A, D2A, E2A, F2A A105 A105 SS 316 SS 316 SS 316
A4A, B4A, D4A A350 A350 SS 316 SS 316 SS 316

GrLF2 GrLF2
AlB, B1B, D1B, D2B A182 A182 SS316 SS316 SS316
GrF1 GrF1
AID, BID, B5D, DID, A182 A182 SS316 SS316 SS316
D2D, F2D GrF11 GrF11
A4F, B3F, B4F A182 A182 SS 321 SS 316 SS 321 or Hastelloy
GrF5 GrF5 or Inconel
A4G, B4G, D4G A182 A182 SS 321 SS 316 SS 321 or Hastelloy
AlH, B1H, DIH A350 A350 SS 316 SS 316 SS 316
GrLF3 GrLF3
A1K,A2K, A22K,A3K, B1K, A182 A182 SS 316 SS 316 SS 316
B2K, D2K GrF304 GrF304
B25K A182 A182 SS 3I6L SS 316 SS 316
GrF304L GrF304L
B18K, D18K A182 A182 SS 316 SS 316 SS 316
GrF304 GrF304
AIM, BIM A182 A182 SS 316 SS 316 SS 321 or Hastelloy
AIN, BIN, B6N, A26N*, D26N* A182 A182 SS 316L SS 316 SS 316L
GrF316L GrF316L
B4K, B5K A182 A182 SS 304H SS 316 SS 316
Gr. F304H GrF304
H
A70M,A74M, B70M, B74M, A182Gr. A182Gr SS321 SS 316 SS 321 or Hastelloy
F321 F321 or Inconel
D25M A182Gr. Al 82Gr SS347 SS 316 SS 347 or Hastelloy
F347 F347 or Inconel
AUK, BlIK A182Gr. A182Gr SS316L SS 316 SS 316L
F304L F304L
Notes:
* Material shall be hardness controlled and shall comply with NACE MR-0103 latest edition.
For Hydrogen service wetted part material for switches, transmitters shall be SS 316L gold
plated, base material Hastelloy shall be avoided
SS 316L, SS 316Ti are also acceptable in place of SS316.

Page 508 of 704

ANNEXURE4I TO STANDARD
15IPZEC(ft
-- ENGINEERS STANDARD SPECIFICATION FOR SPECIFICATION No.
$ fliAegW7- INDIA LIMITED
IA Govt al India UncleMO.9)
PACKAGE UNITS 6-52-0052 Rev. 3
Page 1 of 9
ANNEXURE-Il
Format of Instrumentation Index
Format of Point Data Base
Format for Functional Schematics
Format For cable Schedule (Non-FF)
Format For cable Schedule (FF)
Format for Logic Diagram
Format for Electrical/Instrumentation interface
Format for FF instrument details
Page 509 of 704

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Page 517 of 704

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Page 519 of 704
STANDARD No.
fa.e1 ENGINEERS INSTRUMENT SUPPORT 7-52-0101 Rev. 2
INDIA LIMITED
I4Wñ 9,Thft Onwt of India Undertaking) SINGLE INSTRUMENT
Page 1 of 3
TYPE 11 SINGLE INSTRUMENT SUPPORT - GENERAL ARRANGEMENT

CAP PLATE 6 T
AT END OF PIPE
(TYP.)
2" PIPE
300
WEL HOLES FOR U-BOLTS
ANGLE
50X50X6
REFER
DE AMP"
WELD WEEP HOLE(TYP.)
(TYP.) REFER NOTE-3
6mm THK. 8 SHT. 3 OF 3
6 mm THICK
1751 MS-PLATE
STIFFNER PLATE SIDE VIEW FRONT V EW
DETAIL'?"
TYPE 11-1 TYPE 11-2
Ai iA i 1 iA
2" PIPE 2" PIPE
M12 M12
CLINCH ANCHOR BOLTS BOLTS & NUTS
(QTY. 04 NOS.) (CITY. 04 NOS.)
ISmC 100
II il
F.FLOOR PLTF. GRATING • All WELD TO PLTF. MEMBER
.. ••im., ..I. ......m.m..
•
lialir
MS PLATE MS PLATE
_____Ep. *V 6mm THK. --rp- t / 6mm THK.
a cr•
0 0 in c0 — Tir
in c0 — fiD — tv .—
I
__...4y
14 DIA HOLES 114 DIA HOLES
180 (4 NOS.)
180 (4 NOS.)
250 250
VIEW A-A VIEW A-A

PAVED AREA MOUNTING PLATFORM MOUNTING
TYPE 11-3 TYPE 11-4
II
r PIPE
2" PIPE
STANCHION\\'‘ r M12
SUPPORT a ANCHOR BOLTS a
a a
STRIPS (WELD) .-
(50Lx25Wx6T) (QTY. 04 NOS.)
. ..■
G. LEVEL ., G. LEVEL 1/1111111
4 • - et"
• LI
. • '
300 WELL COMPACTED 3430

EARTH
to (TYP.) (TYP.)
UNPAVED AREA MOUNTING UNPAVED AREA MOUNTING

(WITH INTEGRAL CONC. BLOCK) (WITH SEPARATEW . _1pre.....t
"...
2 14-11-11 Revised 8, Reissued Manoj RG Pi' S DM
1 01-09-06 Reaffirmed and Reissued MN TGM PM VC

Rev. Convenor Chairman
Date Purpose by by
No. Approved by
Format No. 8 - 00 - 0001 - F4 Rev.0 Copyright EL - All rights reserved
Page 520 of 704

STANDARD No.
ENGINEERS INSTRUMENT SUPPORT
oguotaliCE;Men 24e2bre thhfildiA I
INDIA LIMITED
(A Goof of India Undertaking; SINGLE INSTRUMENT
7-52-0101 Rev. 2
Page 2 of 3
TYPE 12 CONCRETE COLUMN MOUNTING
300
6
WEEP HOLE
M12
CINCH ANCHOR BOLTS
QUAINTITY 04 NOS.
MS PLATE
6mm THK. CONCRETE COLUMN
FRONT VIEW SIDE VIEW
TYPE 13 CONCRETE COLUMN (WITH ANGLE INSERT) MOUNTING
ISMC 100 MEMBER

TO BE WELDED
WITH EXISTING
STEEL MEMBER
COLUMN DETAIL
WITH ANGLE INSERT
(BY STRUCTURAL)
CONCRETE COLUMN
6mm THK. (WITH ANGLE INSERT)
TYPE-14 CONCRETE COLUMN (WITH INSERT PLATE) MOUNTING
COLUMN DETAIL
WITH INSERT PLATE
(BY STRUCTURAL)
CONCRETE COLUMN
(WITH INSERT PLATE)
2 14-11-11 Revised & Reissued NYManoj 73e-6— /JMS DM

No. by by
Approved by
Page 521 of 704

STANDARD No.
safaire? ir ENGINEERS INSTRUMENT SUPPORT 7-52-0101 Rev. 2
• INDIA LIMITED
11:47,mifffM.„„ (A 600 of 4100 Undenalong) SINGLE INSTRUMENT Page 3 of 3
TYPE 15 STEEL COLUMN MOUNTING (FLANGE FACE)

300
(REF. NOTE 6)
j2" PIP
WEEP HOLE
111
WELD TYP
WELD(TYP.)
SIDE VIEW FRONT VIEW
TYPE 16 STEEL COLUMN MOUNTING (WEB FACE)

300
(REF. NOTE 6)
2" PIPE
WEEP HOLE
WELD TY WELD TYP
SIDE VIEW FRONT VIEW
TYPE 17 PIPE BRACKET MOUNTING

TYPE 17.1 (VERTICAL PIPE) TYPE 17.2 (HORIZONTAL PIPE)
2" PIPE STANCHION A
MOUNTING MS PLATE BASE PLATE
6mm THICK 300 Lx 150 W x 6T
10
'4"
2" PIPE
0 U-BOLT ASSY.
U-BOLT ASSY. 0 REFER NOTE-4
0 REFER NOTE-4
03
N
WELD TYP
STIFFNER PLATE
(6 THK.) ,;?.
14 DIA HOLES 300
(4 NOS.) 4" MIN. PIPE SIZE 250 WEEP HOLE
NOTE:- WELD TY
DIMENSIONS • & PIPE CLAMPS SIZES SHALL BE
AS PER PIPE DIMENSIONS. 4 . MIN PIPE SIZE
VIEW-AA
(HORIZONTAL PIPE)
NOTES:- 1. ALL DIMENSIONS ARE IN M.M. UNLESS OTHERWISE SPECIFIED.
2 PIPE MATERIAL SHALL BE IS:1239 HEAVY GRADE AS A MINIMUM.
3.6 mm DIA WEEP HOLE SHALL BE PROVIDED AT LOW POINT.
U-BOLT ASSEMBLY SHALL BE OF MINIMUM M12 SIZE WITH NUTS AND SPRING WASHERS.
ALL WELD SHALL BE 3mm FILLET WELD FULL STRENGTH.
ADD 50mm WHERE-EVER FIRE INSULATION IS PROVIDED
BOLT SHALL BE TURNED FROM M.S. ROUNDS CONFIRMING TO IS : 432 GRADE 1
8. NUTS AND WASHERS SHALL CONFIRM TO IS : 1363 AND IS : 3138.
2 14-11-11 Revised & Reissued 4■1^>Manoj oriRG /JMS DM
Rev.
Page 522 of 704

ORIFICE PLATES AND FLANGES STANDARD No.
ENGINEERS
Zitn cf INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
elecole
(NWT 3,72151.1) (A Gov* of India Undenalong)
DETAILS Page 1 of 14
W
SEE DETAIL - Y SEE DETAIL - X
U,
m"
INLET FACE
WELDED AND
SMOOTH
GROUND 45° ± 2° SMOOTHED
WHEN REQD.
SHARP EDGE MUST NOT

REFLECT LIGHT WHEN
V (VENT) VIEWED WITHOUT
IF REQD. MAGNIFICATION
GLOSSED
V (DRAIN)
IF REQD.
A SECTION Z-Z
INLET
d
DETAIL - X
NB
0
ASME CLASS- - - RF
CONCENTRIC SQUARE EDGED ORIFICE PLATE

3 30-05-11 REVISED & REISSUED Manoj R /JMS DM
Page 523 of 704

ENGINEERS
Oa 1856 INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
1.iref eilearre trilJWCWA) (A Govt of India Undertaking)
INLET FACE
WELDED AND
SMOOTH GROUND
45° ± 2° SMOOTHED
WHEN REQD.
ALTERNATE VENT
LOCATION SHARP EDGE MUST NOT
G (VENT)
REFLECT LIGHT WHEN
IF REQD. VIEWED WITHOUT
MAGNIFICATION
SECTION Z-Z
E- (D-) - 0.01 D
INLET
d
NB DETAIL - X
ASME CLASS- - - RF
ECCENTRIC ORIFICE PLATE
3 30-05-11 REVISED & REISSUED Manoj RP/JMS DM

No. by by
Approved by
Page 524 of 704

0 Z1 ENGINEERS
Og-ar Meg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
I 44T7R <wane dRsgr>.■ IA Govt of India Undertaking)
INLET FACE
WELDED AND
SMOOTH GROUND
SMOOTHED
G (VENT)
IF REQD. 45° ± 2°
WHEN REQD. SHARP EDGE MUST NOT
REFLECT LIGHT WHEN
VIEWED WITHOUT
MAGNIFICATION
GLOSSED
SECTION Z-Z
F = 0.98D
DETAIL - X
SEGMENTAL ORIFICE PLATE

,
3 30-05-11 REVISED & REISSUED Manoj W-P411R- RP/JMS DM
Page 525 of 704

WeJeff ENGINEERS
sigur felf5ieg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
WW1 elecnre enlJneralr 1A Govt of India Undertaking)
C
(NOTE-2)
INLET FACE
WELDED AND
SMOOTH GROUND
SMOOTHED
OPTIONAL VENT HOLE
2 mm
SEE DEATIL - A
INSIDE RADIUS
OF PIPE LESS
1 mm (3/64")
0
0
0
A SECTION Z-Z
F = 1.5d BUT NOT GREATER THAN INTERNAL PIPE DIA "D"
INLET RADIUS - r
(TOLERANCE
MATL- - - - 0.01 r)
d DETAIL - Y
DETAIL - X
NB
ASME CLASS- - - RF TAG NO.- - - -
EQUAL TO r
DETAIL - A
QUADRANT EDGE ORIFICE PLATE

NOTES :-
DIMENSIONS A,B,C ARE SAME AS FOR SQUARE EDGE ORIFICE PLATES.
W SHALL NOT BE LESS THAN 2.54 mm AND SHALL NOT EXCEED 0.1D WHERE THE RADIUS 'r' OF THE
UPSTREAM PROFILE EQUALS OR EXCEEDS 0.1D (WHERE IS THE CASE WHEN R? 0.571 OR m ? 0.325),
W SHALL BE REDUCED FROM ? TO 0.1D BY REMOVING METAL FROM THE UP TREAM FACE.
3 30-05-11 REVISED & REISSUED Manoj P/JMS DM

No. by by
Approved by
Page 526 of 704

4oi ei ENGINEERS
f=galia0eg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
(iire?T ?!Oao 057.392F.1) (A Govt of India Undertaking)
I--I(NOTE-3)
WELDED AND
SMOOTH GROUND
OPTIONAL VENT HOLE
2 mm
f
INSIDE RADIUS
OF PIPE LESS
1 mm (3/64")
SECTION Z-Z
INLET
MATL- - - -
d
DETAIL - X DETAIL - Y
NB
TAG NO.- - - -
ASME CLASS- - - RF
0.084d ± 0.003d
0.021d ± 0.003d
0.105d MAX
0.1 D MAX
CONICAL ENTRANCE ORIFICE PLATE
DETAIL - A
NOTES :-
DIMENSIONS A,B,C ARE SAME AS FOR SQUARE EDGE ORIFICE PLATES.
DIMENSION-d SHALL NOT BE LESS THAN 0.25" AND NOT GREATER THAN 0.316D.
3. DIMENSION- W SHALL BE GENERALLY SAME AS FOR SQUARE EDGE ORIFICE PLATES AND
SHALL NECESSARILY CONFORM TO FOLLOWING;
W SHALL NOT EXCEED 0.1D WHERE D IS THE INTERNAL DIAMETER OF STREAM PI LINE. /2i13,4_
3 30-05-11 REVISED & REISSUED Manoj or /JMS DM

Page 527 of 704

ENGINEERS
INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
IA Gov) of India Undertaking)
ALL RATING AS PER ASME CLASS)

RATING 125 TO 2500
A ± 0.40
<315°C > 315° C
NB RATING T T
+0 +0
125 250 900 1500 2500 W TOLER. - 0.25 W TOLER. - 0.25
400 600
mm (") 150 300
25 (1) 66.7 73.0 73.0 73.0 79.4 79.4 85.7 3.18 0.51 6.35
40 (11/2) 85.7 95.3 95.3 95.3 98.4 98.4 117.5 3.18 +0.12 0.76 6.35
50 (2) 104.8 111.1 111.1 111.1 142.9 142.9 146.1 3.18 0.79 6.35
80 (3) 136.5 149.2 149.2 149.2 168.3 174.6 196.9 3.18 -0.25 0.79 6.35
100 (4) 174.6 181.0 177.8 193.7 206.4 209.6 235.0 3.18 1.59 9.52
150 (6) 222.3 250.8 247.7 266.7 288.9 282.6 317.5 3.18 1.59 9.52 ± 0.25
200 (8) 279.4 308.0 304.8 320.7 358.8 352.4 387.4 3.18 3.18 12.7
250 (10) 339.7 362.0 358.8 400.1 435.0 435.0 476.3 6.35 SEE 3.18 12.7 SEE
419.1 457.2 498.5 520.7 549.3 6.35 NO2TE 3.18 12.7 NOTE
300 (12) 409.6 422.3
350 (14) 450.8 485.8 482.6 492.1 520.7 577.9 6.35 ± 0.25 3.18 12.7
400 (16) 514.4 539.8 536.6 565.2 574.7 641.4 6.35 6.35 12.7
450 (18) 549.3 596.9 593.7 612.8 638.2 704.9 6.35 6.35 12.7
500 (20) 606.4 654.1 647.7 682.6 698.5 755.7 6.35 6.35 12.7
550 (22) 660.4 704.9 701.7 733.4 6.35 6.35 12.7
600 (24) 717.6 774.7 768.4 790.6 838.2 901.7 6.35 6.35 12.7
-0 C ±0.4
B + 10
RATING RATING R
NB
125 250 125 10600 TO
400 600 900 1500 2500 400 25 00
mm (") 150 300
25 (1) 100 (D-G)
(D2 G)
40 (1 1/2) 100 R-
88 88 88 30
(2) 100 114
80 (3)
100 (4) 114 127
100
150 (6) 88 100 100
127 158
200 (8) 40
114
250 (10) 140 165
114
300 (12) 177
350 (14) 114 114
127 152
400 (16)
450 (18) 100 50
140 177
500 (20) 127 127 127
550 (22) 144
600 (24) 40 140 140 165 203
d G
LEGEND:-
<d TOLER.
FROM I TO TOLER. D - INTERNAL DIAMETER OF THE PIPE
FROM TO ± 0.05
<6.350 0.007 NB - NOMINAL BORE.
< 25.400 - -
6.350 9.525 0.013 d - ORIFICE BORE DIAMETER.
25.400 88.900 2.38
9.526 12.700 0.015 DIMENSIONS IN mm UNLESS OTHERWISE
88.901 104.775 3.18 SPECIFIED.
12.701 15.875 0.020
104.776 127.000 3.97
15.876 19.050 0.023 NOTE:-
127.001 152.400 4.76
19.051 22.225 0.025 FOR BIDIRECTIONAL FLOW BEVELLING SHALL NOT BE
152.401 171.450 5.56
22.226 25.400 0.030 PROVIDED.
171.451 190.500 6.35
25.401 31.750 0.036 VALUES OF T SHOWN IN THIS STANDARD ARE
190.501 212.725 7.14
31.751 38.100 0.043 VALID FOR THE CORRESPONDING W AND d/D
212.726 234.950 7.94
38,101 44.450 0.051 (6) BETWEEN 0.25 AND 0.70 INCL WHEN THE
234.951 254.000 8.73
44.451 127.000 0.064 VALUES ARE NOT SHOWN AND FOR B < 0.25
254.001 276.225 9.53 AND 6 > 0.70, T SHALL BE CALCULATED EVERY
> 127.000 0.0005
xd 276.226 295.275 10.32 TIME AND SHALL NOT BE HIGHER THAN THE
295.276 317.500 11.11 SMALLER OF THE VALUES RESULTING FROM
317.501 336.550 11.91 THE FOLLOWING RATIOS :-
> 336.550 - 12.70 d D D-d
ORIFICE PLATE DIMENSIONS 8 50 8
3 30-05-11 REVISED & REISSUED Manoj G 4 3/JMS DM
Page 528 of 704
0 el ENGINEERS
ligar lapeg
Wren eleakeandTIM)
INDIA LIMITED
IA Govt of India Undertaking)
DIMENSIONAL 7-52-0041 Rev. 3
ENGAGEMENT OF THREADS OF PLUG

SHALL BE AS PER ASME B 1.20.1
PLUG MATERIAL SHALL BE
SAME AS FLANGE MATERIAL.
SECTION A-A
112" NPT
OR AS SPECIFIED
B 25.4 MINUS
SEAT MACHINED
FOR NUT SUPPORT
Ct -
DETAIL - A SECTION B-B

BEVEL FOR WALL THICKNESS (S) BEVEL FOR WALL THICKNESS (S)
0.19 INCH TO 0.88 INCH INCLUSIVE. GREATER THAN 0.88 INCH.
7° MAX
10±1°
7° MAX
37.5' ± 2.5° 37.5° ± 2.5 °
Cr)
co _t___.
1
—I I-- 0.25" MIN.
0.06"± 0.03 " 0.06" ± 0.03 "
WELD NECK, RAISED FACE ORIFICE FLANGES

,J\ t
3 30-05-11 REVISED & REISSUED Manoj InK G 14/J kre" DM
'
No. Date Purpose by by
Convenor Chairman
Approved by
Page 529 of 704

kilf-aeiel ENGINEERS
Ogaria5teg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
MTN' ereakernhinufail (A Coot of India Undertaking)
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Approved by
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Page 530 of 704

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3 30-05-11 REVISED & REISSUED Manoj 4/JMS DM

No. by by
Approved by
Page 532 of 704

kti-afaelei ENGINEERS
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- (Aireer riecoreashAicnR) (A Govl of India Undertaking)
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3 30-05-11 REVISED & REISSUED Manoj P/JMS fl1"-"----

DM
No. by by
Approved by
Page 533 of 704
ENGINEERS
054eg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
fairer eleotrlaoJVTAI IA Govt of India Undertaking)
TOLERANCES ALLOWED ON FLANGES ACCORDING TO ASME B16.36 / B16.5
DIMENSIONS mm (Inches) TOLERANCES (Inches)
5- 609.6 mm ± 1.59
0 > 609.6 mm ± 3.18 "
NB < 450 + 3.18

(18) - 0
C
NB > 450 + 4.76
(18) - 0
S 609.6 mm ± 1.59 "
X
> 609.6 mm ± 3.18 *
NB <
- 125 + 2.38
- 0.79
A
NB _> 150 + 3.96
- 0.79
NB < 250
_ ± 1.59
(10)
Y
NB > 300 ± 3.18
(12)
K ± 1.59
DRILLING
CENTRES BETWEEN HOLES ± 0.79
FOR G = 1.6 mm ± 0.79
R
FOR G = 6.4 mm ± 0.40
ECCENTRICITY BETWEEN K AND R DIAMETERS ± 0.79
ECCENTRICITY BETWEEN K AND D DIAMETERS ± 0.79
ECCENTRICITY BETWEEN R AND D DIAMETERS ± 0.79 *
150 ± 0.12 *
NB <
- (6)
+ 0.12
0.
200 8250 *
NB - 0.25
(8 &10)
+ 0.12
300 *
D NB - 0.38
(12)
350 8400 + 0.12 *

NB - 0.50
(14 816)
450 + 0.12 *
NB . ?. - 0.76
(18)
* NOT COVERED BY ASME 816.5
WELD NECK RAISED FACE ORIFICE FLANGES

Page 534 of 704
eiel ENGINEERS
f=g-zir PieG. INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
Isirerf riromeem3flrkl) IA Gokt of India Undertaking)
DIMENSIONS AS SHOWN THREAD : ASME B 1.1

FORD" <1 - UNC - 2A
FORD" >1 1/8 - 8 UN - 2A
CONSTRUCTION FORGED, BAR STOCK

V (1.5 x THD. PITCH)
D mm (Inches) THREAD PITCH V 2V *

15.9 (5/8) 2.309 3.46 7
19.0 (3/4) 2.54 3.78 7.5
UNC
22.2 (7/8) 2.822 4.23 8.5
25.4 (1) 3.175 4.76 9.5
> 28.6 (1 1/8) 8 UN 3.175 4.76 9.5
APPROXIMATE VALUE OF THE TWO BEVELS

ALL RATING AS PER ASME CLASS
DIAMETER (NB,D) mm (INCHES) & LENGTH - (L) IN mm ( NOTE-1 )
RATING 300 600 900 1500
DIM. NB D L D L D L D L
25 (1) 15.9 (5/8) 127 15.9 (5/8) 127 22.2 (7/8) 152 22.2 (7/8) 152
40 (1 1/2) 19.0 (3/4) 133 19.0 (3/4) 133 25.4 (1) 159 25.4 (1) 159
50 (2) 15.9 (5/8) 127 15.9 (5/8) 127 22.2 (7/8) 152 22.2 (7/8) 152
80 19.0 (3/4) 133 19.0 (3/4) 133 22.2 (7/8) 152 28.6 (11/8) 184
100 19.0 (3/4) 133 22.2 (7/8) 152 28.6 (11/8) 178 31.7 (11/4) 203
150 (6) 19.0 (3/4) 133 25.4 (1) 178 28.6 (11/8) 203 34.9 (1 3/8) 266
200 (8) 22.2 (7/8) 146 28.6 (11/8) 203 34.9 (1 3/8) 229 41.3 (1 5/8) 298
250 (10) 25.4 (1) 165 31.7 (1 1/4) 222 34.9 (1 3/8) 241 47.6 (1 7/8) 343
300 (12) 28.6 (1 1/8) 178 31.7 (1 1/4) 229 34.9 (1 3/8) 260 50.8 (2) 381
350 (14) 28.6 (1 1/8) 191 34.9 (1 3/8) 248 38.1 (1 1/2) 282 57.1 (2 1/4) 418
400 (16) 31.7 (11/4) 203 38.1 (11/2) 266 41.3 (1 5/8) 295 63.5 (2 1/2) 456
450 (18) 31.7 (1 1/4) 209 41.3 (1 6/8) 286 47.6 (1 7/8) 333 69.8 (2 3/4) 503
500 (20) 31.7 (11/4) 216 41.3 (1 5/8) 298 50.8 (2) 355 76.2 (3) 548
600 (24) 38.1 (1 1/2) 241 47.6 (1 7/8) 337 63.5 (2 1/2) 445 88.9 (3 1/2) 623
TOLERANCES ON I'
L-LENGTH mm < 305 310 TO 455 >455
-o -0 -0
TOLERANCE mm + 1.6 + 3.2 + 6.4
STUD BOLT DETAILS FOR RAISED FACE FLANGES

NOTES :-
1. FOR BOLT DIAMETER 1" (25mm) & ABOVE IN EACH RATING, FOLLOWING SHALL BE CONSIDERED TO TAKE CARE OF BOLT TENSIONING.
(i) ONE EXTRA NUT SHALL BE CONSIDERED FOR EACH BOLT/STUD.
Ili) BOLT/STUD LENGTH SHALL BE INCREASED BY ONE DIAMETER.
A I,
3 30-05-11 REVISED & REISSUED Manoj r PIRG P/JMS DM
Page 535 of 704

ENGINEERSORIFICE PLATES AND FLANGES STANDARD No.
401 eltg.
$fgar INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 3
Lice faReg
email
2151070W (A Govt of India Undertaking)
DIMENSIONS :ASME B 18.2.1 THREAD : ASME B 1.1

CONSTRUCTION :FORGED, BAR STOCK FOR D" <1 - UNC - 2A
TOLERANCES : ASME B 18.2.1 ASME B 1.1 FORD" >1 1/8 - 8 UN - 2A
250
G mm H R
D mm (Inches) F
MAX. MIN. mm mm
9.5 (3/8) 14.3 20.2 19.0 6.4 0.8
11.1 (7/16) 15.9 22.5 21.0 7.5 0.8
12.7 (1/2) 19.1 26.9 25.3 8.3 0.8
15.9 (5/8) 23.8 33.7 31.6 10.7 1.6
19.1 (3/4) 28.6 40.4 37.9 12.7 1.6
22.2 (7/8) 33.3 47.1 44.2 15.1 1.6
25.4 (1) 38.1 53.9 50.6 16.7 2.4
28.6 (1 1/8) 42.9 60.6 56.9 19.1 2.4
31.8 (11/4) 47.6 67.4 63.2 21.4 2.4
38.1 (11/2) 57.2 80.8 75.8 25.4 2.4
ALL RATING AS PER ASME CLASS

DIAMETER (NB,D): mm (INCHES) AND LENGTH - (L) IN mm
RATING 300 600 900 1500
DIM. NB D L D L D L D L
25 9.5 (3/8) 75 9.5 (3/8) 75 15.9 (5/8) 90 15.9 (5/8) 90
40 (1 1/2) 9.5 (3/8) 75 9.5 (3/8) 75 15.9 (5/8) 90 15.9 (5/8) 90
50 11.1 (7/16) 85 11.1 (7/16) 85 15.9 (5/8) 100 15.9 (5/8) 100
80 11.1 (7/16) 85 11.1 (7/16) 85 15.9 (5/8) 100 19.1 (3/4) 115
100 11.1 (7/16) 85 19.1 (3/4) 100 19.1 (3/4) 110 19.1 (3/4) 120
150 (6) 11.1 (7/16) 90 22.2 (7/8) 115 22.2 (7/8) 130 22.2 (7/8) 160
200 (8) 12.7 (1/2) 100 22.2 (7/8) 130 25.4 (1) 140 25.4 (1) 170
250 (10) 15.9 (5/8) 110 22.2 (7/8) 135 25.4 (1) 145 25.4 (1) 190
300 (12) 19.1 (3/4) 115 22.2 (7/8) 140 25.4 (1) 155 25.4 (1) 215
350 (14) 19.1 (3/4) 120 22.2 (7/8) 140 25.4 (1) 165 28.6 (1 1/8) 235
400 (16) 22.2 (7/8) 130 25.4 (1) 155 25.4 (1) 170 31.8 (1 1/4) 255
450 (18) 22.2 (7/8) 130 25.4 (1) 160 28.6 (1 1/8) 200 31.8 (1 1/4) 275
500 (20) 22.2 (7/8) 140 25.4 (1) 165 28.6 (11/8) 205 31.8 (11/4) 295
550 (22) 28.6 (1 1/8) 155 25.4 (1) 180 - - - - - -
600 (24) 31.8 (1 1/4) 160 25.4 (1) 185 28.6 (1 1/8) 240 31.8 (1 1/4) 315
SEMI-FINISHED, SQUARE HEAD, FULL THREAD, JACK SCREW
t\'` I l• japc(A4r-
3 30-05-11 REVISED & REISSUED Manoj ir• G /JMS DM
No. by by
Approved by
Page 536 of 704

aarre? ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
21t d INDIALIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev. 4
INSTRUMENTS
ok GoN of inda UndoItaking)
Page 1 of 14
*cv)ercli:ictitil eicuti * firK

Nriv rct kiwi
ELECTRONIC/PNEUMATIC
INSTRUMENTS
4 12.03.12 Revised and Reissued as Standard Specification b§te P /JMS DM
3 15.02.07 Revised and Reissued as Standard Specification AR TGM HCJ VC
2 05.08.05 Revised and Reissued as Standard Specification KI TGM PM VJN
1 20.09.99 Revised and Reissued as Standard Specification PM RK BRS AS
0 30 11 83 Issued as Standard Specification PVS TSN AKV AK

Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose by by Convenor Chairman
No
Approved by
Page 537 of 704

401 ei atENGINEERS
e
groan facitegvi INDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
''''eneww"wu .tea India Undetlaingl INSTRUMENTS Page 2 of 14
Abbreviations:
AARH Arithmetic Average Roughness Height
EDDL Electronics Device Description Language
FISCO Fieldbus Intrinsic Safety Concept
FDT/DTM Field Device Tool/ Device Type Manager
FF Fieldbus Foundation
HART Highway Addressable Remote Transducer
LAS Link Active Scheduler
LCD Liquid Crystal Display
NPS Nominal Pipe Size
NPT National Pipe Thread
RAM Random Access Memory
WC Water Column
Instrumentation Standards Committee
Convener: Ms. R. Priyamvada
Members: Mr.P.K. Sahay

Mr.S. Bhowal
Mr. M. Nandi
Ms. R. Shanti Devi
Mr. M.P Jain (Proj.)
Page 538 of 704

ae'Llealp ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
Wag WINDIA LIMITED FOR ELECTRONIC/PNEUMATIC
t
6-52-0032 Rev.4
(Men .FleTerFM1,19.
i^ INSTRUMENTS
A Gort of India Undedaking)
Page 3 of 14
CONTENTS
1.0 GENERAL 4
2.0 DESIGN AND CONSTRUCTION 6
3.0 NAME PLATE 13
4.0 INSPECTION AND TESTING 13
5.0 SHIPPING 14
6.0 REJECTION 14
ANNEXURES:
ANNEXURE - 1: STUD - BOLTS AND NUTS MATERIAL REQUIREMENT
ANNEXURE - 2: GASKET MATERIAL REQUIREMENT
Page 539 of 704

Oreael a ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
42mm:esINDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
Govt of India undeptakingl INSTRUMENTS Page 4 of 14
1.0 GENERAL
1.1 Scope
1.1.1 This specification, together with the data sheets attached herewith describes the requirements
for the design, materials, nameplate marking, inspection, testing and shipping of
electronic/pneumatic instruments.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest edition
prior to the date of the purchaser's enquiry:-
ASME American Society of Mechanical Engineers
1.20.1 Pipe Threads General Purpose (Inch)
16.5 Pipe Flanges and Flanged Fittings
16.20 Metallic Gaskets for Pipe Flanges,Ring Joint, Spiral wound
and Jacketed.
EN European Standards
10204 Inspection Documents For Metallic Products
IS/IEC Indian Standards/ International Electrotechnical Commission
IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres.
IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code).
IEC 61000-4 Electromagnetic Compatibility (EMC) for Industrial
Process Measurement and Control Equipment
IEC 61158 Fieldbus Standard for use in Industrial Control System
IEC 61158-2 Physical Layer Specification and service definition for
Fieldbus
IEC 61508 Functional Safety of Electrical/Electronic/Programmable
Electronic Safety related Systems.
IEC 61511 Functional safety instrumented system for the process
industry sector
IEC 61804 Function blocks (FB) for process control — Electronic
Device Description
IEC 61518 Mating dimensions between differential pressure (type)
measuring instruments and flanged-onshut-off devices up
to 413 bar (41,3 MPa)
ISA International Society of Automation
S 7.3 Quality Standard for Instrument Air
S 50.1 Compatibility of Analog Signals for Electronic Industrial
Process Instruments.
ITK Interoperability Test Kit (latest version)
1.1.3 In the event of any conflict between this standard specification, job specification/data sheets,
statutory regulations, related standards, codes etc. the following order of priority shall govern:
Statutory Regulations
Job Specifications / Data Sheets

Standard Specification
Codes and Standards
1.1.4 In addition to compliance to purchaser's specifications in totality, vendor's extent of
responsibility shall include the following:
a) Purchaser's data sheets specify the minimum acceptable material of construction of
body, measuring element and accessories. Alternate superior material of
construction shall also be acceptable provided vendor assumes complete
Page 540 of 704

051Przre?da ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
51g7r teltaleuw INDIA UMITED INSTRUMENTS
Go„ of India Undeltak.9)
Page 5 of 14
responsibility for the selected materials for their compatibility with the process
fluid and its operating conditions.
b) Selection of suitable sealant liquid for diaphragm seal instruments compatible with
the process fluid and its operating temperature.
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to the vendor attached
with the material requisition.
1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the
following:
Compliance to the specifications.
Whenever the requirement of a detailed specification sheet for electronic/pneumatic
instruments is specifically indicated, a detailed specification sheet for each item
shall be furnished, which shall provide information regarding type, material of
construction, performance specification, model number etc. of the offered
electronic / pneumatic instruments. The material specification and the units of
measurement for various parts in vendor's specification sheets shall be to the same
standards as those indicated in purchaser's data sheets.
c) Proven references for each offered model number inline with clause 1.2.3 of this
specification.
d) A copy of approval from local statutory authority, as applicable such as Petroleum
& Explosives Safety Organisation (PESO) / Chief Controller of Explosives (CCE),
Nagpur or Director General of Mines Safety (DGMS) in India, for the electronic
instruments installed in electrically hazardous area along with:
Test certificate from recognised test house like Central Institute of Mining
and Fuel Research (CIMFR) / Electronics Regional Testing Laboratory
(ERTL) etc. for flameproof enclosure/intrinsic safety, as specified in the data
sheet, as per relevant standard for all Indian manufactured equipments or for
items requiring Director General of Mines Safety DGMS approval.
Certificate of conformity from agencies like Laboratorie Central Des
Industries Electriques (LCIE), British Approval Service for Electrical
Equipment in Flammable Atmospheres (Baseefa), Factory
Mutual (FM), Physikalisch-Technische Bundesanstalt (PTB) , Canadian
Standards Association (CSA), Underwriters Laboratories (UL) etc. for
compliance to ATEX directives or other equivalent standards for all
equipments manufactured outside India.
e) Deviations on technical requirements shall not be entertained. In case vendor has
any valid technical reason, they must include a list of deviations tag number wise,
summing up all the deviations from the purchaser's data sheets and other technical
specifications along with the technical reasons for each of these deviations.
Catalogues giving detailed technical specifications, model decoding details and
other related information for each type of electronic/pneumatic instruments covered
in the bid. Information shall include, but not limited to product certifications,
dimensional drawings, Transient Protection, range limits, power supply, Current
draw, vibration effect, power supply effect, Electromagnetic compatibility. For
Field bus instruments, Field bus parameters like available standard function
blocks/Advanced function blocks and their execution time for each block, Device
type, number of link objects, virtual communication Relationships, Basic and
advanced diagnostic features, transmitter failure mode, physical profile type etc.
1.2.3 All items, as offered, shall be field proven and should have completed trouble free
satisfactory operation for a period of minimum 4000 hours on the bid due date in the similar
Page 541 of 704

Itilfraeg ENGINEERS
gent laYreu'IS INDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
7412PrefZewenfrol Govl of India undenakm INSTRUMENTS Page 6 of 14
application with the process conditions similar to those as specified in the purchaser's data
sheets. Items with proto-type design or items not meeting provenness criteria specified
above shall not be offered.
1.2.4 Wherever specified vendor must furnish certified values of failure rates, probability of
failure on demand (PFD) and test intervals for offered items for Safety Integrity Level (SIL)
analysis.
1.2.5 All documentation submitted by the vendor including their quotation, catalogues, drawings,
installation, operation and maintenance manuals, etc shall be in English language only.
1.2.6 Vendor shall also quote for the following:
Universal hand held configurator / terminal for the configuration and maintenance
of instruments with HART output.
Field bus configurator with hardware and software for configuration and
maintenance of field bus devices and also to perform diagnostics and trouble
shooting of fieldbus segments wherever specified.
Two-year operational spares for each model of instruments offered in the bid,
which shall include sensor, electronic module, local indicator, o-ring/gasket set etc.
based on vendor's recommendations.
Any special tool other than those covered under 1.2.6 (a) and (b). In case any
special tools are needed for maintenance of offered instruments, vendor must
certify in their offer.
1.3 Drawing and Data
1.3.1 Detailed drawings, data, catalogues and manuals required from the vendor are indicated by
the purchaser in vendor data requirement sheets. The required number of prints and soft
copies should be dispatched to the address mentioned, adhering to the time limits indicated.
1.3.2 Final documentation consisting of design data, installation manual, operation and
maintenance manual, etc submitted by the vendor after placement of purchase order shall
include the following, as a minimum;
Specification sheet for each electronic/pneumatic instrument and their accessories.
Certified drawing for each instrument, which shall provide dimensional detail,
internal construction and part list, material of construction etc.
Calculations for integral orifice
Copy of type test certificates.
Copy of the test certificates of all the tests indicated in clause 4.0 of this specification.
Installation procedure for electronic/pneumatic instrument and its accessories.
Calibration, Configuration and Maintenance procedures including replacement of
its internal parts.
Device Descriptor (DD) Files for configuring the device parameters (Soft Copy)
i) Common File Format (CFF) files for integrating the device into the system (Soft
Copy).
2.0 DESIGN AND CONSTRUCTION

2.1 General Requirements
2.1.1 The type and material of construction of electronic/pneumatic instruments shall be as
specified in the purchaser's data sheet.
Page 542 of 704

a ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ere, EvensvINDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
IA Gort pi Inda Undeflaingl INSTRUMENTS Page 7 of 14
2.1.2 The range of instruments shall be selected by vendor based on the set range indicated in the
purchaser's data sheet. Where no set range is indicated, vendor may select the same as per
the following guidelines;
The set range shall be 1.1 times the maximum process value or 1.4 times the
operating process value whichever is higher rounded to the nearest ten.
The set range shall preferably be in the middle third of the selected instrument
range.
2.1.3 Measuring element in vacuum service shall have under range protection down to full
vacuum, without undergoing a change in calibration or permanent set.
2.1.4 Unless otherwise specified, diaphragm seal instrument shall meet the following requirements;
Instruments shall have its diaphragm seal (flanged type) integral with the
instrument. In case wafer type diaphragm seal is provided, it shall be supplied with
companion flange.
When purchaser data sheets specify wafer seal type of instrument, vendor shall
include supply of studs, nuts and gasket as per the materials specified in the
purchaser's data sheet. Refer Annexure — 1 attached with this specification for stud
— bolts, nuts and gasket material requirement.
c) The sealant shall be an inert liquid, compatible with the process fluid and process
temperature indicated in the purchaser's data sheets. In general, sealant shall be;
DC 704 or equivalent for all diaphragm seal instruments except for oxygen
and chlorine.
Flouro-lube or equivalent for all diaphragm seal instruments in oxygen and
chlorine.
d) The requirement of spacer ring shall be as specified in purchaser's data sheet. The
material of construction of spacer ring shall be 316 Stainless Steel, as a minimum
unless otherwise specified in the purchaser's data sheets.
e) The span of the offered model shall be selected to ensure zero elevation/zero
suppression equal to the head created by the fill fluid for the specified capillary
length in the data sheet.
2.1.5 Wherever purchaser data sheet specifies integral flow transmitter, vendor shall supply
complete assembly consisting of integral orifice, upstream and downstream meter runs with
end flanges, meeting the following requirements:
Three nos. of integral orifice plates shall be supplied i.e. one is installed and two
are spares.
Unless otherwise specified, material of construction shall be 316 Stainless Steel for
integral orifice and meter run with flanges.
2.1.6 The instrument enclosure shall be suitable for the area classification indicated in the
purchaser's data sheets. Unless otherwise specified, the enclosure shall meet the following
standards;
Weatherproof housing IP-65 to IS/IEC-60529.
Flameproof housing Flameproof/ Ex (d) as per IS/IEC-60079
Flameproof housing shall also be made weatherproof.
2.1.7 Unless otherwise mentioned, end connection details shall be as below:-
Threaded end connections shall be to NPT as per ASME B 1.20.1.
Flanged end connections shall be as per ASME B 16.5.
Page 543 of 704

1511=a-ael ENGINEERS
INDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
efalft
. IA GUN oundia undenson) INSTRUMENTS Page 8 of 14
Grooves of ring type joint flanges shall be octagonal as per ASME B16.20.
Flanged face finish shall be as per ANSI B 16.5. The face finish shall be as
follows:
125 AARH : 125 to 250 microinch AARH
63 AARH 32 to 63 microinch AARH
2.1.8 All electronic / pneumatic instruments in oxygen and chlorine service shall be thoroughly
degreased using reagents like trichloro-ethylene or carbon tetrachloride. End connection
shall be blinded / plugged after the degreasing process in order to avoid entrance of grease or
oil particles.
2.1.9 Electronic Instruments
2.1.9.1 All instruments shall be of state-of-the-art technology and shall be in compliance with the
electromagnetic compatibility requirements specified in IEC-61000-4 standard.
2.1.9.2 Plug-in circuit boards shall be designed and manufactured such that reverse insertion or
insertion of the wrong card is prevented.
2.1.9.3 Electronic instruments shall generally operate on nominal voltage of 24 V DC and shall be
protected against short circuit and reverse voltage. Transmission and output signal shall
generally be 4 to 20 mA DC for analog and smart transmitters. The display of integral output
meter shall be in engineering units for pressure, differential pressure, flow & Temperature
and 100% linear for level.
2.1.9.4 Electronic transmitters with two-wire system shall be suitable for delivering rated current to
an external loop resistance of at least 600ohm when powered with 24 V DC.
2.1.9.5 Terminals for electrical connections shall be clearly identified, and polarity shall be
permanently marked.
2.1.9.6 Peak to peak ripple and total noise level in the analog output signal shall not exceed 0.25%
of the maximum signal.
2.1.9.7 Electrical cable entries shall have internal 'A" NPT threads.
2.1.9.8 Zero elevation/zero suppression shall be equal to minimum of 100% of the span of the
offered transmitter.
2.1.10 Pneumatic Instruments.
2.1.10.1 All pneumatic connections shall be 1/4" NPT, unless otherwise specified.
2.1.10.2 All threaded connections shall be internal, unless otherwise specified.
2.1.10.3 The process input connections and pneumatic output and air supply connections etc. shall be
permanently stamped on the body at a suitable place.
2.1.10.4 Unless otherwise specified, pneumatic instruments shall operate on air supply of 1.4 kg/cm2g
and shall have transmission and output signal of 0.2 to 1.0 kg/cm2g.
2.1.10.5 Instrument air quality shall be as per ISA-S7.3 and shall be free from all corrosive,
hazardous, flammable and toxic contaminants.
2.2 Transmitters
2.2.1 Pneumatic Transmitters
2.2.1.1 Pneumatic blind transmitters shall be of the force-balance type and pneumatic indicating
transmitters of the motion balance type.
2.2.1.2 Transmitters shall have an accuracy of 0.5 % of span.
2.2.1.3 Transmitters shall be supplied with external zero and span adjustments.
2.2.2 Electronic Analog Transmitters
Page 544 of 704

lafflzre? ENGINEERS
FOR ELECTRONIC/PNEUMATIC
INDIA LIMITED 6-52-0032 Rev.4
otia IA Govt of India undertism INSTRUMENTS Page 9 of 14
2.2.2.1 Electronic transmitters shall be of the two-wire DC current regulating type. They shall be
provided with integral output indicator. When specified, field mounted external output
meters shall be provided.
2.2.2.2 Electronic analog transmitters shall have an accuracy oft 0.25 % of span.
2.2.2.3 Transmitters shall be supplied with external zero and span adjustments. Flameproof
transmitters shall also have their calibration adjustment from outside, without any need to
remove the cover.
2.2.2.4 Unless otherwise specified, the electronic transmitters shall be certified intrinsically safe.
2.2.3 Smart and Field bus based Transmitters
2.2.3.1 Smart and field bus based transmitters shall be two wire microprocessor based type. These
shall have a non-volatile memory, storing, complete sensor characterisation and
configuration data of the transmitter. All necessary signal conversions and output generation
with the required protocol shall be carried out in the transmitter electronics. Integral output
meter with LCD display shall be provided for all transmitters.
2.2.3.2 Transmitter shall also run complete diagnostic subroutines and shall provide diagnostic
alarm messages for sensor as well as transmitter healthiness. Field bus based transmitter in
addition shall have facility to detect plugged impulse lines, whenever specifically indicated
in purchaser's data sheets. In the event of detection failure, the output shall be driven to a
predefined value, which shall be field configurable.
2.2.3.3 The transmitters with field bus connectivity shall have built in control algorithm like
proportional, proportional-integral and proportional-integral-differential.
2.2.3.4 Whenever specifically indicated in purchaser's data sheets, the meter electronics shall be
provided with in-built lightning and power supply surges. The transient protection shall
meet the requirements specified in IEC-61000-4.
2.2.3.5 The configurational data of the instruments shall be stored in a non-volatile memory such
that this remains unchanged because of power fluctuations or power off condition. In case
vendor standard instrument has battery backed RAM, vendor to ensure that battery drain
alarm is provided as diagnostic maintenance message.
2.2.3.6 Accuracy of transmitters, smart as well as field bus based, shall be as follows:
Type of Transmitter Range of Transmitter Accuracy
Direct 760 mm WC and above Equal to or better than +0.075%
Direct Less than 760 mm WC Equal to or better than ±0.15%
Diaphragm seal 500 mm WC and above Equal to or better than ±0.25%
Diaphragm seal Less than 500 mm WC Equal to or better than ±0.5%
The accuracy is defined as the combined effect of repeatability, linearity and hysteresis.
2.2.3.7 The stability of the transmitters shall be equal to or better than ±0.1% of span for a period of
minimum 6 months, as a minimum.
2.2.3.8 Transmitter shall update the output at least 8 times a second unless otherwise specified.
2.2.3.9 Unless specified otherwise in purchaser's specification, transmitter response time shall be as
follows:
For transmitter range of 760 mm WC and above, the response time shall be equal to
or better than 500 milliseconds.
For transmitter range below 760mm WC, the response shall be equal to or better
than I second.
Page 545 of 704

FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
INSTRUMENTS Page 10 of 14
The response time of the transmitter shall be considered as the sum of dead time and 63.2%
step response time of the transmitter.
2.2.3.10 Unless specified otherwise, the over-range/static pressure protection of the transmitter shall
be as follows:
OVERRANGE / STATIC PRESSURE (*)
Range of Transmitter 0 Pressure Transmitter Differential Pressure Transmitter
Kg/Cm2 Kg/Cm2
0 <®<250 mmWC 20 20
250 < 0 < 1000 mmWC 45 52
1000 < 0 < 5000 45 70
mmWC
5000 < 0 < 10000 45 160
mmWC
1 < ® < 10 Kg/cm2 52 160
10 < 0 < 100 Kg/cm2 160 210
® > 100 Kg/cm2 210 210
(*) However, if the overange/static pressure valve specified above is less than the
maximum/design pressure of service conditions specified in the datasheets, offered
instrument shall be suitable for the maximum/design pressure as per datasheet.
2.2.3.11 In the transmitter, the 'WRITE' option shall be protected through password.
2.2.3.12 Temperature transmitters shall meet the following requirements as a minimum:
Temperature transmitter shall be universal type and shall be able to accept input
from resistance temperature detector (RTD) or thermocouple (T/C) of any type and
range.
Temperature transmitters shall be freely programmable i.e. element type and range
shall be programmable without any change in hardware / software.
Temperature transmitter shall be remote mounted type, in general Head mounted
transmitters shall be supplied when specifically indicated in purchaser's data
sheets.
The accuracy of the temperature transmitter with RTD element shall be as follows:
For temperature range above 350° C, the accuracy shall be equal to or better
than +0.075% of range.
For temperature range with ranges between 350° C to 150° C, the accuracy
shall be equal to or better than 10.15% of range.
For temperature range below 150° C, the accuracy shall be equal to or better
than +0.25% of range.
e) The accuracy of temperature transmitter with cold junction compensation for
Thermocouple element shall be as follows;
For temperature above 350° C, accuracy shall be +0.25% of range.
For temperature between 150°C to 350°C. accuracy shall be ±0.5% of range.
For temperature below 150°C, accuracy shall be +0.75% of range.
Page 546 of 704

satrazre? ENGINEERS
INDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
.211 Govt of India unaertaionci INSTRUMENTS Page 11 of 14
2.2.3.13 When HART protocol is specified, the following features must be ensured;
It shall allow multi masters (two for example, primary and secondary) for
configuration, calibration, diagnostics and maintenance. The primary could be the
control system or host computer and the secondary could be the hand-held
communicator.
It shall be capable of implementing universal commands from either of these
locations.
2.2.3.14 In addition to the requirements specified above, field bus based transmitter shall meet the
following requirements;
All instruments must satisfy the requirements of the field bus registration
laboratory with applicable checkmark like foundation field bus, profibus
NutZerorganisation e.v (PNO), or as specified in the purchaser's data sheets.
All instruments shall be polarity insensitive. Also transmitter shall be LAS capable
and provided with line plugging detection, whenever specified in data sheet.
All instruments shall have one no. of Analog Input (AI) block and One no. of
Proportional, Integration and Differential (PID) control block, as a minimum.
All instruments must be interoperable and shall have valid interoperability test
clearance like ITK latest version for foundation field bus or equivalent for profibus
PA, as applicable.
e) The field bus instruments shall support peer to peer communication.
The field bus instruments in hazardous area shall be certified as per entity concept
or shall be FISCO approved as per the requirements specified in the purchaser's
specification.
All instruments shall support EDDL or FDT/DTM requirements, as specified in
data sheets.
Internal Software shall be configured by the vendor including the following
information.
- Serial Number
Device Tag (Tag No.)
- Process Description
i) All instruments shall be capable of supporting incremental Device Descriptor (DD)
for extra functionality and/or software revisions in Device Memory.
2.3 Receivers
2.3.1 Pneumatic/electrical cables shall be such that they permit the instrument internals to be
drawn from its normal mounting position without affecting operation. Pneumatic connection
points shall seal automatically upon disconnection.
2.3.2 Electronic receivers shall be suitable for standard voltage inputs of 0.25 to 1.25 V, 1 to 5 V,
0 to 10 V dc. Any voltage receiver shall not alter the voltage drop across the conditioning
resistor by more than ±0.1% of input range of maximum input voltage.
2.3.3 Recorder pens shall be easily replaceable.
2.3.4 Each recorder shall be supplied with chart-rolls and ink for six months continuous operation.
2.4 Controllers
2.4.1 Automatic control stations including dedicated cascade control stations shall have switches
to transfer control from automatic to manual mode and vice-versa. The transfer shall be
Page 547 of 704

Iiiif&regeENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
g Lear jalgeg NW INDIA LIMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
- wow mein =AIM) (A GM AI Ma Undcriakingl INSTRUMENTS Page 12 of 14
procedure less and shall not produce any bump in the process under control during such a
transfer, the output signal shall not change by more than I% of span.
2.4.2 Cascade control stations shall have a switch to select local or remote set point.
2.4.3 The control settings of the controller shall be readily adjustable from the front.
2.4.4 Controller action shall be easily reversible.
2.4.5 Pneumatic automatic controller shall be easily removable, without disturbing the manual
control mechanism.
2.4.6 Electronic controller shall be easily removable, with the aid of a service station.
2.4.7 Local mounted pneumatic controllers shall be supplied with gauges for air supply pressure
and control signal. The gauges shall be integral with the instrument.
2.5 Accessories
2.5.1 Field Universal Communicator:
2.5.1.1 It shall be possible to perform routine configuration, calibration, display process variable,
diagnostics etc. from a hand held portable communicator, which can be connected at any
location in the transmitter loop. It shall be possible to perform all the above functions on-line
and the loop function shall remain unaffected.
2.5.1.2 There should be no interruption on the output while communicating with the transmitter.
2.5.1.3 Field communicator shall meet the following requirements:
Hand Held communicator shall be universal type and shall be compatible with all
make and models of HART transmitters and Smart positioners, with all engineering
capability like calibration, diagnostics, configuration, inhibition of HART signal,
etc. Similarly Field bus Hand Held communicator shall also be universal type and
shall be suitable for all make and models of FF transmitters and Positioner.
It shall be possible to connect the communicator at any of the following locations
for purpose of digital communication;
Marshalling cabinet serving the transmitter, in safe area.
Junction box serving the transmitter, in hazardous area.
iii) Directly at the transmitter, in hazardous area.
Plug-in type connections shall be provided with field communicator. Necessary
interconnection accessories shall be supplied by the vendor.
Offered communicator shall be dust-proof, certified intrinsically safe and suitable
for outdoor location. Carrying case shall be supplied with each communicator.
When specified in data sheets, the software shall also be capable of configuring
other makes of transmitters.
e) They shall be battery powered with replaceable and rechargeable batteries, suitable
for recharging with 240 V, 50 Hz . In case vendor's standard design does not make
use of rechargeable batteries, then vendor to provide 2 sets of spare batteries.
2.5.2 Remote output meter
2.5.2.1 Remote output meter shall be electronic with LCD display. The display shall be in actual
engineering units.
2.5.2.2 The indicator electronics shall be able to perform square root extraction for flow
measurement
2.5.2.3 Offered indicators shall be certified Intrinsically safe/FISCO, when used in hazardous area
as specified in Data sheet.
Page 548 of 704

lel MENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA UMITED FOR ELECTRONIC/PNEUMATIC 6-52-0032 Rev.4
Sig:ClItMegay (A Geri oi kwila UndellaMingl INSTRUMENTS Page 13 of 14
2.5.2.4 This Field Bus based field indicator shall be 2 wire segment powered and shall be able to
indicate minimum of 8 signals available in the fieldbus segment, selectively.
2.5.3 Yoke mounted instruments shall be supplied with universal mounting bracket , U-bolt and
nuts suitable for mounting the instruments on a 50 mm (nominal bore) pipe stanchion
(horizontal or vertical)
2.5.4 Air set
Air set, where provided, shall be a combination air filter regulator set with 5-micron filter
cartridge. It shall have a 50 mm diameter pressure gauge to indicate the regulated pressure.
Each air set shall be supplied with mounting bracket and bolts with nuts for surface mounting.
2.5.5 Battery charger
Battery charger shall be supplied with all necessary accessories and shall be suitable for
240V ±10%, 50Hz±3Hz, unless otherwise specified.
3.0 NAMEPLATE
3.1 Each flush panel mounted instrument shall have the following information identified in the
front:-
Tag number as per purchaser's data sheet.
Reading coefficient, if any
c) Pen colour, tag number-wise in the case of recorders.
Each flush panel mounted instrument shall have a back nameplate permanently fixed to it at
a visible place reporting the following information:
Instrument tag number.
Manufacturer's serial number or model number.
c) Manufacturer's name/trade mark.
3.2 Surface mounted instruments shall be provided with only one nameplate.
Local mounted instruments shall have a stainless steel nameplate attached firmly to it at a
visible place, furnishing the following information:
Tag number as per purchaser's data sheets.
Manufacturer's serial number and /or model number
Manufacturer's name/trade mark.
Body material.
Measuring element material.
Range of measurement.
j) Area classification in which the equipment can be used, this shall be to the same
code as per purchaser's data sheets.

Purchaser reserves the right to inspect and witness testing all the items at the vendor's works
in line with the inspection test plan for electronic/pneumatic instruments and approved
quality documents. All these tests shall be completed by the vendor and test reports shall be
submitted to purchaser for scrutiny.
Page 549 of 704

ISiMareq e ENGINEERS
LIMITED FOR ELECTRONIC/PNEUMATIC
51g7ePeg illir INDIA■)0a Undenakingi 6-52-0032 Rev.4
(A Govt INSTRUMENTS Page 14 of 14
5.0 SHIPPING
5.1 All threaded and flanged openings shall be suitably protected to prevent entry of foreign
material.
5.2 Instruments shall be supplied individually, in suitably sealed packing.
5.3 Proper care shall be taken in shipping instruments with diaphragm seals to ensure safety of
the diaphragm seals, extensions, capillaries, where specified.
5.4 All pneumatic / electronic instruments in oxygen and chlorine service shall be separately
packed along with a certificate indicating 'CERTIFIED FOR OXYGEN / CHLORINE
SERVICE', as applicable.
5.5 Proper care shall be taken in shipping instrument accessories clearly indicating the
instrument tag numbers.
6.0 REJECTION
6.1 Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach
only those documents and information, which are specifically indicated in the material
requisition.
6.2 Any offer not conforming to the above requirements, shall be summarily rejected.
Page 550 of 704

OPtade ENGINEERS STUD-BOLTS AND NUTS Annexure 1 10
ElPeg'10, INDIA UMITED MATERIAL REQUIREMENT STANDARD SPECIFICATION NO.
IA Goff of inam undertalonof
6-52-0032 Rev. 4
Page 1 of 1
Sr. No. Piping Classes Nut and Bolt Material
1 AIA, A2A, A5A, A6A, A7A, A8A, A9A, A-193 Gr. B7

AIM, Al IA, A13A, AI4A, AI5A, A-194 Gr. 2H
AI9A, A20A, A32A, A33A, AIK, A6K,
AIM, A1N, BIA, B2A, B5A, B6A, B9A,
BI3A, B18A, B19A, B32A, BIK, B6K,
BI8K, BIM, B3M, B5M, BIN, B6N,
DIA, D2A, WA, D18A, DIK, DISK,
DI8P, EIA, E2A, E5A, E5E, F5A
2 Al6A,B16A A-I93 Gr. B7M

A-194 Gr. 2HM
3 MB, AID, A4F, A4G, BIB, BID, B5D, AI-193 Gr. B16
BIE, B3F, B4F, B4G, DIB, D2B, DID, A-194 GR. 4
D2D, D5D, D5E, F2D
4 A2K, B2K, D2K A-320 Gr. B8 CL.2

A-194 Gr. 8
5 A4A, AIH, B4A, B1H, D4A, DIH A-320 Gr. L7

A-194 Gr. 4
6 A3Y A-307 Gr. B

A-563 Gr. B
7 A3A, A3K, A3Y, A4Y, J3A A-307 Gr. B

A-563 Gr. B
8 AIZ, A4Z, A5Y, J2A, .15A A-307 Gr. B (Gals)

A-563 Gr. B (Gals)
9 B4K, B5K A-193 Gr. B8 MCII

A-194 Gr. 8 MA
10 A32Y A-193 Gr. B (Gaiv)

A-194 Gr. 211 (Galv)
11 B3M, B4K, B5K, B5M A-453 Gr. 660 CL.A

A-453 Gr. 660 CL.A
Format No. 8-00-0001-F1 Rev. 0 Copyrights EIL - All rights reserved
Page 551 of 704

PRZTe? ENGINEERS GASKETS MATERIAL Annexure 2 to
$1g7 efarg
i INDIA LIMITED REQUIREMENT STANDARD SPECIFICATION No.
nda,)
IA Gov' of Ind. Ude 6-52-0032 Rev 4
Page 1 of 1
Sr. Gasket Material

Piping Classes
No.
1 AIA, A6A, A9A, AIOA, Al IA, A13A, AI4A, AI9A, SP WND SS 316 + GRAFIL
AIB, AID, AIH, A1K, AIM, A4A, A4F, A4G, B1A,
BIH, B2A, B4A, B6A, B9A, BI3A, B18A, BOA, B32A,
BI8K, DIA, D2A, DIH, DIK, D4A, D18A, DISK, DISP
2 B5M SP WND SS316H+ GRAFIL + I RING
3 A2K, B2K, D2K SP WND SS 316+GRAFIL+SS 316 I/O
RING
4 BIN SP WND SS 3I6L+GRAFIL + I RING
5 B6N SP WND SS 316L + GRAFIL
6 Al Z, A3Y, A4Y, A4Z, J2A BUTYL RUBBER
7 E IA, E2A, E5A, F5A SOFT IRON
8 ESE, F2D 5% CR, 0.5% MO
9 B4K, B5K SS 316H+GRAFIL+I RING SS 316 0 RING
10 MY, A8A, AI5A, A32Y, A33Y IS 2712 Gr. A/I
II B3M SP WND SS 321+GRAFIL+I RING
12 AIN, A6K, A16A, 1316A SP WND SS 316 L+ GRAFIL
13 A3A, A3K, A33A, J3A, J5A IS 2712 Gr. W/3
14 A2A, A20A, A32A IS 2712 Gr. W/I
15 A5A, B5A, D5A SP WND SS 316 + GRAFIL + I RING
16 A7A, BIB, BID, B1E, B1K, B3F, B4F, B4G,B5D, DIB, SP WND SS 316 + GRAFIL + I RING
D1K, D2B, DID, D2D, D5D, D5E
17 B6K, BIM SS 316 + GRAFIL
Format No. 8-00-0001-F1 Rev. 0 Copyrights EIL -All rights reserved
Page 552 of 704

Pressure Gauges
UNITS: Flow -> Liquid - Kg/hr Gas - Kg/hr Steam - Kg/hr Pressure -> Kg/cm²G Temperature-> °C Level /length -> mm
1. Type- Direct 13. Connection- 1/2" NPT(M)
Connection Location- Bottom
2. Mounting- Local
14. Movement- SS 304
3. Dial Size- *150 mm
15. Diaphragm Seal-* (For congealy, corrosive service and heighly viscous
Color: White with black engravings service.)
Type-
4. Case Material- Die Cast Aluminium Wetted Parts Material-
Others Material-
Process Connections : Size & Rating:
5. Bezel Ring- Screwed Facing & Finish-
Capillary Material-
6. Window Material- Shatterproof glass Armour-Flexible-Material
Capillary Length-
Flushing/ Filling Connection with
7. Enclosure- Weatherproof to IP-65
8. Pressure Element- Bourdon Tube 16. Over Range Protection- 130% of the range or maximum
pressure whichever is higher
9. Element Material- * SS 316 17. Blow Out Protection- Required
10. Socket material- * SS 316 18. Options

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

ENGINEERS INDIA LIMITED
NEW DELHI PLANT: Unit - DATA SHEET NO. REV
09000200828c2256_A4.xls,sheet1 VENDOR: A842-000-16-51-DS-1001 A

This drawing and the design it covers are the properties of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will
not be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower
ENGINEERS INDIA
Page 553 of 704

Pressure Instruments
UNITS: Flow->Liq- Gas- Steam- Pressure-> Temperature->°C Level / Length-> mm
GENERAL MEASURING UNIT
1. Function:- TRANSMITTER (INDICATING) 23. Service:- PRESSURE
2. Type:- WIRELESS / FIELDBUS ** 24. Element:- DIAPHRAGM
3. Case:- MANUFATURER STANDARD 25. Body Material:- SS 316
4. Mounting:- YOKE 26. Element Material:- SS 316L
5. Electrical Area Classification 27. Process Connection. 1/2" NPTF
6. Enclosure:- 28. Process Connection Location MANUFATURER STANDARD
Enclosure Class:- WP to IP 65 in flameproof enclosure.
29. Diaphragm Seal: * (For congealy, corrosive service and heighly
7. Intrinsically Safe:- viscous service.)
8. Air Supply:- Wetted Parts Material
9. Power Supply:- Other Material:-
10. Cable Entry:- 1/2" NPT ( See note 2 ) Process Conn.:
11. Accuracy:- ± 0.075% OF RANGE Size & Rating:-
12. Repeatability:- ± 0.1% Facing & Finish:-
TRANSMITTER Capillary Material:-
13. Output WIRELESS / FIELDBUS ** Armour Flexible:-
14. Trans.Power Supply:- BATTERY / BUS POWERED ** Armour Flexible Material:-
CONTROLLER Capillary Length:-
15. Output:- Flush./Fill. Conn. With Plug:-
16. A/M Switch:- MISCELLANEOUS
No. of Positions:- 30. Over Range Protection:- Note-1
17. Set Point Adjusment:-
18. Manual Regulator:- 31. Options:-
19. Mode:- a) IS Output meter:- Required
RECORDER b) Test jack
20. Chart & Chart Drive:- (for calibration)
21. Moving Parts Material 32. Load driving capability:-
22. Chart Speed:-
Operating Maximum Maximum Range Control
Tag Number Service Options
Pressure Pressure Temp. Span Set Action
TO BE ADVISED LATER * * * * * * * *
* BY VENDOR
** AS PER INSTUMENTATION JOB SPECIFICATION
1. 130% OF RANGE OR MAXIMUM PRESSURE WHICHEVER IS HIGHER.

2. VENDOR TO PROVIDE CERTIFIED EX. PROOF DOUBLE COMPRESSION TYPE CABLE GLAND. FLYING LEAD TERINATION IS NOT ACCEPTABLE
3. CCOE CERTIFICATION SHALL BE FURNISHED.
4. MAKE AND MODEL NO. SHALL BE INDICATED.

09000200828c2259_A4.xls
VENDOR : A842-000-16-51-DS-1101 A
Page 554 of 704

Gage Glasses & Cocks
1. Vendor's Scope of Supply.:- Gauge Glasses & Cocks 6. Illuminator:
assembled with nipples Power Supply :-
Area Class :-
GAUGE GLASSES Enclosure :-
2. Type:- Reflex Cable Entry :-
3. Chamber Connection:- 7. Heating Jacket:

Size & Type :- 3/4" NPT(F) Medium :-
Location :- * Max. Temp / Press. :-
Vent & Drain :- 1/2" NPT (F) with plug Connections :-
Inlet :-
4. Material : Outlet :-
Chamber :- *
Cover Plate :- * COCKS
Studs :- ASTM A193 Gr. B7 8. Type:- Offset
Nuts :- ASTM A194 Gr. 2H
Gaskets :- * 9. Type of Connection:
Vessel:- 3/4" NPT (F)
5. Options: Gauge:- 3/4" NPT(M) through 3/4" spherical (F) union
a ) Mica Shield Vent:- 1/2" NPT (F) with plug
Drain:- 1/2" NPT (F) with isolation valve and plug
b ) Illuminator 10. Material:
c ) Heating Jacket Body :- *
d ) Calibrated Scale Trim :- * SS 316
e ) No-Frost Extn. 11. Closing :- Quick
f ) I.B.R. certificate 12. Bonnet Type :- Bolted
g) 13. Ball Checks :- Required
h) 14. Renewable Seats :- Required
VISIBLE C TO C MAX. OPERATING
TAG NUBER FLUID LOCATION VESSEL CONNECTION OPTIONS NOTES
LENGTH LENGTH TEMP. PRESS.
* (To be Advised * * * * * * * * *
later)

1. Vendor shall furnish hydrotest certificates for each level gauge.
2. Indicate the make and model number offered.
3. Visible length for level gauges shall be as follows. C-C length shall be 250 mm more than the visiblelength. Vendor to select one or more level gauges
accordingly for the tag.
220 mm, 470 mm, 720 mm, 980 mm.

09000200828c2676_A4.xls VENDOR: A842-000-16-51-DS-2601 A

ENGINEERS INDIA
Page 555 of 704

Restriction Orifice Plates
1 Tag Number * (To be advised later)
2 Line Number *
General 3 Line Size & Schedule *
4 Service *
5 Plate Only ¦ Assembly ¦ Assembly
6 Required Pressure Drop *
7 Type Concentric Square Edge
8 Single Stage pressure reduction Yes
9 Multi Stage pressure reduction -
10
11 Material * SS 316
Plate 12 Thickness 'W' (mm) *
13 Beta = d/D *
14 Bore Diameter 'd' (mm) *
15 Vent / Drain ¦ Diameter (mm) *
16 Centre Distance 'R' (mm)
17
18
19
20 Type *
21 Material *
22 Size & Rating *
23 Facing & Finish *
Suitable 24 Line I.D. ¦ O.D. (mm) *
for 25 Gasket Thickness (mm) *
Flanges 26 Gasket Material *
27 Plate Holder
28 Plate Holder Material
29 Stud Bold Material *
30 Nut Material *
31 Welded Construction *
32 Spool Piece Length
Options 33 Connection
34 Material
35 Fluid ¦ State *
36 Flow - Minimum ¦ Maximum *
37 Flow - Normal *
Service 38 Inlet Pressure *
Cond- 39 Temp. °C - Operating ¦ Maximum *
itions 40 Sp. Gr. at operating temp.¦ at 15°C *
41 Steam specific volume m3/kg
42 Molecular Weight ¦ Cp / Cv *
43 Operating Viscosity m Pa.s (cP) *
44 Compressibility Factor
45 Pipe Reynolds Number
46 Make
47 IBR Certification -
* - Vendor to specify / confirm.

1. - Vendor to indicate the manufacturer's name
DEVIATION NO DEVIATION VENDORS' SIGNATURES WITH SEAL

VENDOR DRAWING NO- ORDER NO:-
FILE- REQUISITION NO :

ENGINEERS INDIA LIMITED DATA SHEET NO. REV
PLANT: Unit -
NEW DELHI
09000200828c2677_A4.xls VENDOR- A842-000-16-51-DS-3201 A
ENGINEERS INDIA
Page 556 of 704

Temperature Gauges
1. Type- Bi-metallic FILLED SYSTEM
2. Well- Required 15. SAMA Class-
Compensation-
3. Mounting- Local
16. Bulb Type-
4. Dial Size- *150 mm Bulb Material-
5. Color- White with black engravings 17. Bulb Union Threaded to-
6. Case Material- Die Cast Aluminium 18. Extension Type-
7. Window Material- Shatterproof glass 19. Bulb Dia.-
8. Connection Location- Bottom 20. Capillaery Material-
Armour Flexible-
9. Accuracy- ± 1% of URV (Upper Range Value) Armour Material-
Capillary Length-
10. Enclosure Weatherproof to IP-65
Enclosure Class- 21. Over Range Protection-
11. Zero Adjustment Screw- Required (External) THERMOWELL

22. Material- SS 316
BIMETAL- 23. Construction- Drilled Bar Stock
24. Process Connection- 1 1/2" Flanged
12. Stem- 25. Guage Connection- 1/2" NPT (F)
Type- Adjustable Union 26. Thermowell as per drawing- 7-52-0035
Material- SS-316
Size- 1/2" NPT (M) 27. Options:
a) Liquid Filled
13. Stem Diameter- To suit well b)
14. Make and Model No. c)
RANGE Temperature Well Dim. Flange

TAG NO. Service Options
Nor. Max. U T Material Rating, Face, Finish
* (To be advised * * * * * * * * *
later)
1. Ù' length shall be 280 mm for 4" to 6" line, 320 mm for 8" & above size lines and 400 mm for Vessels. Lines less than 4" size shall be blown to 4".

09000200828c55ea_A4.xls,sheet1 VENDOR : A842-000-16-51-DS-4001 A

ENGINEERS INDIA
Page 557 of 704

Thermal Relief Valve
1 Tag Number * (To be advised later)
2 Line Number *
General 3 Vessel Protected *
4 Safety / Relief Thermal Relief
5 Type :
6 Full Nozzle Full Lift ¦ Mod. Nozzle Modified Nozzle
7 Bonnet Type Closed, Bolted
8 Conv. / Bellows / Pilot Operated Conventional
9 Inlet Connection: Size & Rating 3/4" NPT (M)
10 : Facing & Finish *
Valve 11 Outlet Connection: Size &Rating 1" NPT (F)
12 : Facing & Finish *
13 Cap Over Adjusting Bolt: Required
14 Screwed ¦ Bolted Screwed
15 Lifting Gear- Type Required
16 Test Gag Required
17
18 Body and Bonnet * CS
19 Nozzle and Disc * SS316
Material 20 Spring * Cd / Ni / Zn / Al plated CS
21 Bellows -
22
23
24 Resilient Seat Seal *
Options 25 Radiography *
26
27 Code API
Basis 28 Basis of Selection Thermal Liquid Relief
29
30 Fluid and State *
31 Corrosive Costituent *
32 Required Flow Capacity *
33 Mol. Wt.¦Sp.Gr. at Relieving Temp. *
34 Operating Pressure *
35 Operating Temp.¦Relieving Temp. *
Service 36 Valve discharges to *
Cond- 37 Back Press. ¦ Constant / Variable *
itions 38 Set Pressure *
39 Cold Bench Test Pressure *
40 % Over Pressure ¦ % Blowdown 25% ¦*
41 Cp/Cv ¦ Compressibility Factor *
42 Viscosity at Rel. Temp. mPas(cP)
43 Vessel:Wall temp°C¦Surf.Area-m2
44
45 Calculated Area - cm2 *
46 Sel. Area - cm2 ¦ Orifice Design * ¦ *
Orifice 47 No. of valve required for capacity *
48 Total area - cm2 *
49 Actual Flow Capacity *
50
51 Make and Model No. *
Model 52
Nos. 53 IBR Certification -
NOTES:- This data sheet is indicative only indicating minimum requirement, vendor to develop the detail data sheet during detail engg
*. Vendor to specify / confirm.
1. Indicate the make and model number of the offered instrument.

CLIENT : M/s BPCL-KR DATE BY CHKD

ENGINEERS INDIA LIMITED DATA SHEET NO.
PLANT: Unit -
NEW DELHI
09000200828c4e2e_A4.xls,Sheet1 VENDOR- A842-000-16-51-DS-3701
ENGINEERS INDIA
Page 558 of 704

gth -> mm
l engg
APPD
REV
09000200828c4e2e_A4.xls,Sheet1
A
agreement that they will
Page 559 of 704

This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower’s express
agreement that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the
Radar Level Instruments (Guided Wave Radar)
1 Wave Guide Type UNITS **
2 Response Time <1 Sec Max. response to step change
3 Linearity <0.1% of Probe length
4 Repeatability mm ±1
5 Operating Temp. effect ±0.01% of probe length/°C
Ref. Continuation
Sensor 6 Connection Orientation Side-Side
sheets
7 Accuracy mm 3
8 Chamber material ASTM A105 with weld neck head and
process flanges, unless otherwise
specified against tag no. in
continuation sheets.
10 Function – Indicating/ Trans. Indicate & Transmit
11 Output
12 Electrical Cable Entry -Signal Power ½” NPTF
13 Power Supply | ¾” NPTF
Transmitter 14 Enclosure IP-66
15 Electrical Area Classification IEC Zone-2 Gr.IIA/B
16 Intrinsic Safety
17 Gauge Head Material Manufacturer’s standard
18
19 Type Digital
Local 20 Location Integral
Indicator 21 Graduations
22 Enclosure
23
¾” NPTF connection on the side near
24 Vent Connections
the top of the chamber.
¾” NPTF connection at the bottom of
25 Drain Connections
the chamber.
26 Interface Devices: -
27 - Temperature Element Not Required
28 - Water Cut Probe Not Required
29 Type -
30 Element Type | No. of Elements -
Temperature
31 Connection Size & Rating -
Element
32 Element Anchoring -
33 Sheath Material -
34 Type Not Required
Water cut 35
5 Dedicated | With Temp. Probe -
Probe 36
37 Calibration Pin
38 Still Well
39 Power Switch
40 Mounting Brackets
41 Built-in Alarm contacts
Options
42 Inter connecting cables between
43 - Tank side Indicator & Gauge head
44 - Gauge and temperature element
45 - Tank Gauge & Water Probe
46 - Power cable between gauge head & Indicator
47 Fluid
48 Pressure –Oper. Max Kg/cm2g
Service
Conditions
49 Temp. –Oper. Max C
50 Operating Specific Gravity
51 Viscosity | Corrosive Constituent Cst |-
52 Statutory -
CCOE
intended use.EIL-1641-507. A4-210 x 297.
Certification 53 Others
54 Manufacturer
Others 55 Model Number
Note: This data sheet is indicative only indicating the minimum requirement, package vendor to develop detail data sheet for
the required instrument.
98 [ ] Deviation [ ] No Deviation Vendor’s Signature

Requisition No.
Legend:
0 29.06.12 PP HMX AR Order No.
* By Vendor
Rev Date By Chkd Appd Vendor
ENGINEERS INDIA SPECIFICATION REV
PLANT : PDO
LIMITED
NEW DELHI CLIENT : M/s BPCL-KR A842-PDO-16-51-DS-2501 0
Page 560 of 704

Self Actuated Pressure Control Valves
UNITS: Flow -> Liquid- Gas- Steam- Kg/hr Pressure -> Temperature-> °C Level /length -> mm
1 Tag No. *
2 Line No. *
General 3 Line Size & Sch. *
4 Service *
5
6 Type : Standard ¦ Pilot-operated *
7 Size : Body ¦ Port
8 End Conn.: - Size & Rating
9 - Facing & Finish
10 Body Material * CS
11 Trim Material * SS 316
12 Set Point *
13 Impulse Conn.: Int. ¦ Ext. *
14 Conn. Size & Type if External *
Valve 15 Material of Diaphragm * SS 316
16 Bonnet type *
17 Cv : Min. ¦ Max. *
18 Cv : Normal *
19 Selected Valve Cv *
20 Pridicted sound Level dBA *
21 Inlet Velocity *
22 Packing or seals *
23 Lubricator ¦ Iso-Valve *
24 Guiding ¦ No. of Ports *
25 Regulation Upsteream¦Downstream *
26 Pressure Indicator
Accessories 27 Relief Valve
28 Line Stainer
29 Fluid ¦ State *
30 Flow - Min. ¦ Max. *
31 Flow - Normal *
32 Inlet Pressure - Max. ¦ Min. *
33 Inlet Pressure - Normal *
34 Del. Pr. Max. ¦ Nor. ¦ Min. *
35 Del. Pr. Shut Off *
36 Temp. °C - Oper. ¦ Max *
37 Oper. S.G ¦ Mol. Wt. *
Service 38 Cp / Cv ¦ Compress. Factor *
Cond- 39 Flash% ¦ Oper. Visc. mPa.s(cP) *
itions 40 Deg. Of Superheat ¦ % Solids *
41 Vapour Pr. ¦ Critical Pr. *
42 Model No. Valve ¦ Actuator *
43 Make and Model No.
44 IBR Certification
45 Specification Remarks
* - Vendor to Specify / Confirm.

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


PLANT: Unit -
NEW DELHI
VENDOR- A842-000-16-51-DS-3401 A
ENGINEERS INDIA
09000200828c2679_A4.xls
Page 561 of 704

Rotameters
1 Tag No. *
2 Line No. *
3 Service *
4
General 5 Type METAL TUBE
6 Function LOCAL & DCS INDICATION
7 Conn.:-Size:Size & Rating *
8 -Facing & Finish *
9 Direction : Inlet ¦ Outlet BOTTOM ¦ TOP
10
11 Tube Size ¦ Float Guide *
12 Tube Matl. ¦ Float Matl. SS 316 ³SS 316
13 Scale length & Type *
14 Scale Gratuation * & LINEAR
15 Range *DIRECT READING
Meter 16 Meter Factor *
17 End Fitting Matl. (Flg) *
18 Packing or O-ring Matl. NOTE-1
19 Accuracy 2% FSD
20
21
Extension 22 Extension Well Matl.
23 Gasket Matl. *
24 Type (2 wire) 2 WIRE
25 Power supply or Air supply
26 Output *
Transmitter 27 Electrical Area Classification
28 Scale Range *
29 Enclosure Weatherproof to IP65 & IS
30 Cable Entry 1/2" NPTF
31 Prot. Shiels with Safety Glass
32 Jacketting - Medium ¦ Conn.
33 - Temp. °C ¦ Pressure
34 Constant - Diff. Relay
Options 35 Needle Valve
36 Filter Regulator With Gauge
37
38
39
40 Fluid & State *
41 Maximum Flow *
42 Minimum Flow *
43 Normal Flow *
Service 44 Pressure - Oper. ¦ Max. *
Cond- 45 Temp. °C - Min ¦ Oper. ¦ Max *
itions 46 Oper. S.G. ¦ Mol. Wt. *
47 Max. Oper. Viscosity mPa.s(cP) *
48 Max. Allowable Pr.Drop *
49
50
51 Make and Model No. *
52 Tube No. ¦ Float No.
53 IBR Certification
54 Specification Remarks
NOTES:This data sheet is indicative only indicating minimum requirement, vendor to develop the detail data sheet during detail engg
`*' VENDOR TO FURNISH/CONFIRM.
1. PACKING SHALL BE PTFE IF TEMPERATURE IS 230° C OR BELOW. FOR TEMPERATURES HIGHER THAN 230°C
PACKING SHALL BE GRAFOIL.
2. OFFERED TRANSMITTER SHALL BE CERTIFIED INTRINSICALLY SAFE WITH WEATHER PROOF ENCLOSURE FOR ABOVE
ELEC. AREA CLASS.

PLANT: Unit -
NEW DELHI
09000200828c2254_A4.xls VENDOR- A842-000-16-51-DS-0201 A
ENGINEERS INDIA
Page 562 of 704

Approved Sub-Vendor List
Projects A842-PDE-85-41-VL-14(6041) Rev 0
PDPP-BPCL-KR Page 1 of 7
VENDOR LIST
PROJECTS
(MR-6041)
PROJECT : Propylene Derivative Petrochemical Project-Acrylate

Unit
OWNER : BHARAT PETROLEUM CORPORATION LTD. (BPCL-KR)
PMC : ENGINEERS INDIA LTD.
JOB NO. : A842
0 25.07.2016 ISSUED FOR PURCHASE SSK GS KSR

Date Purpose Approved by
No by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 563 of 704

A842-PDE-85-41-VL-14(6041) Rev 0
Projects Page 2 of 7
PDPP-BPCL-MR
PRESSURE RELIEF VALVE-15EC
1 A710 ANDERSON GREENWOOD CROSBY
2 A761 AST APPARECCHI DI SICUREZZA E TENUTA SPA
3 B015 BHEL (TRICHY)
4 B110 BLISS ANAND PVT LTD
5 C700 CURTISSWRIGHT FLOW CONTROL CORPORATION
6 D523 DRESSER INC.
7 I172 INSTRUMENTATIONLTD. (PALGHAT)
8 L569 LESER GMBH & CO. KG
9 N541 NAKAKITA SEISAKUSHO CO LTD
10 T181 TYCO SANMAR LTD
11 W092 WEIR BDK VALVES – A UNIT OF WEIR INDIA PVT. LTD.
12 F103 FAINGER LESER VALVES (P) LTD.
SELF ACTUATED PR. CONTROL VALVE – 15EG
1. 1 D127 DRESSER VALVE INDIA PVT LTD
2. 2 D649 DRESSER PRODUITS INDUSTRIELS
3. 4 E534 ESME VALVES LTD.
4. 5 E6231 EMERSON PROCES MGMT ASIA PACIFIC PTE LTD
5. 6 E626 ELSTER-INSTROMET NV-FORMER. I563
6. 7 G603 GORTER CONTROLS B.V.
7. 8 N088 NIRMAL INDUSTRIAL CONTROL PVT. LTD.
8. 9 M055 MIL CONTROLS LIMITED
9. 1 P538 PIETRO FIORENTINI SPA

0
10. 1 R539 RMGREGEL+MESSTECHNIKGMBH
1
11. 1 R610 RICHARDS INDUSTRIES (FORMERLY TRELOAR)
2
12. 1 S442 SAMSON CONTROLS PVT LTD
3
13. 1 S510 SAMSON AG MESS-UND REGELTECHNIK
4
ORIFICE PLATES AND FLANGES – 15GA

BALIGA LIGHTING EQUIPMENTS (P) LIMITED
1 B024
COMFIT & VALVES PVT. LTD.
2 C220
CAMERON LTD.
3 C720
DANIEL MEASURMNT & CONTROL ASIA PACIFIC
4 D509
EUREKA INDUSTRIAL EQUIPMENTS (P) LTD.
5 E022
GURU NANAK ENGGWORKS
6 G016
INSTRUMENTATIONLTD. (PALGHAT)
7 I172
MICRO PRECISION PRODUCTS PVT LTD
8 M010
MINCO (INDIA) PVT LTD (GEN. INST.)
9 M045
PETROL VALVES SRL
10 P514
PIETRO FIORENTINI SPA
11 P538
4
Page 564 of 704

A842-PDE-85-41-VL-14(6041) Rev 0
PDPP-BPCL-MR
STAR-MECH CONTROLS (INDIA) PVT LTD
12 S286
TMTECNOMATIC SPA
13 T516
THERMOWELLS – 15HD
1. 1 A206 ALTOP INDUSTRIES LTD.
2. 2 A682 ABB AUTOMATION LTD
3. 3 D004 DETRIV INSTRUMENTATION & ELECTRONICS LTD
4. 4 D677 DAILY THERMETRICS CORPORATION
5. G192 GOA INSTRUMENTS INDUSTRIES PVT. LTD.
6. 5 G622 GAYESCO LLC
7. 6 P190 PYRO-ELECTRIC INSTRUMENTS GOA PVT LTD
8. 7 T232 TECHNOINSTRUMENTS
9. 8 T095 TEMP-TECH
10. 9 T146 TEMPSENS INSTRUMENTS INDIA PVT LTD
11. 1 T241 THERMAL INSTRUMENT (I) P LTD (GEN.INST.)

0
12. 1 T514 THERMO ELECTRIC CO. INC.
1
13. 1 T705 THERMO-COUPLE PRODUCTS CO
2
14. 1 T734 THERMO-ELECTRAB.V
3
15. 1 T516 TMTECNOMATIC SPA
4
16. 1 W589 WIKA ALEXANDERWIEGAND & CO GMBH
5
PRESSURE GAUGES -15KA

AN INSTRUMENTS PVT LTD
1. 1 A053
ASHCROFT INDIA PVT LTD
2. 2 A362
BADOTHERMPROCESS INSTRUMENTS B.V.
3. 3 B696
BAUMER BOURDON HAENNI SAS
4. 4 B561
BAUMER TECHNOLOGIES INDIA PVT.LTD(W058)
5. 5 B213
BUDENBERG GAUGE CO. LTD
6. 6 B618
GAUGES BOURDON (I) PVT. LTD. (GEN.INST)
7. 7 G115
GOA INSTRUMENTS INDUSTRIES PVT. LTD
8. G192
H GURU INSTRUMENTS(SOUTH INDIA)PVT. LTD
9. 8 H081
H.GURUINDUSTRIES
10. 9 H099
MANOMETER (INDIA) PVT. LTD.
11. 1 M029
0 WIKA INSTRUMENTS INDIA PVT LTD
12. 1 W061
1 WALCHANDNAGAR INDUSTRIES LTD(TIWAC DIVN)
13. 1 W064
2 WIKA ALEXANDERWIEGAND & CO GMBH
14. 1 W589
3
TEMPERATURE GAUGES – 15LA

1 A053
2 A362
4
Page 565 of 704

A842-PDE-85-41-VL-14(6041) Rev 0
PDPP-BPCL-MR
3 B213
4 B561
5 B696
6 G115
GOA INSTRUMENTS INDUSTRIES PVT. LTD.
7 G192
8 H081
H.GURUINDUSTRIES
9 H099
WIKA INSTRUMENTS INDIA PVT LTD
10 W061
WALCHANDNAGAR INDUSTRIES LTD(TIWAC DIVN)
11 W064
WIKA ALEXANDERWIEGAND & CO GMBH
12 W589
VARIABLE AREA FLOW METERS – 15MB

ALFLOW GLASS EQUIPMENTS
1 A172
ASA SPA
2 A623
ABB AUTOMATION PRODUCTS GMBH
3 A682A
BROOKSINSTRUMENT
4 B510
5 E022
HEINRICHSMESSTECHNIK GMBH
6 H626
INSTRUMENTATION ENGINEERS PVT. LTD.
7 I030
KROHNE MARSHALL PVT. LTD
8 K105
KROHNE MESSTECHNIK GMBH & CO KG
9 K582
PLACKA INSTRUMENTS INDIA P LTD
10 P293
ROTA YOKOGAWA GMBH & CO. KG
11 R515
TOKYO KEISO CO LTD
12 T530
YOKOGAWA INDIA LIMITED
13 Y006
GAUGE GLASSES AND COCKS – 15OA

B110 BLISS ANAND PVT LTD
1. 1
C201 CHEMTROLS SAMIL (INDIA) PVT LTD
2. 2
C716 CESARE BONNETTI S.P.A.
3. 3
J543 JERGUSON GAUGE & VALVE
4. 4
K637 KLINGER SPA
5. 5
L009 LEVCON INSTRUMENTS PVT LTD
6. 6
N141 NISAN SCIENTIFIC PROCESS EQUIP. P LTD
7.
N520 NIHON KLINGAGE CO LTD
8. 7
P017 PRATOLINA INSTRUMENTS PVT LTD
9. 8
P239 PUNE TECHTROL PVT LTD
10. 9
S036 SIGMA INSTRUMENTS CO
11. 1
0
SPECIAL LEVEL INSTRUMENTS – GUIDED WAVE RADAR -15OG

A759 ABB INC (FORMLY K622)
1
4
Page 566 of 704

A842-PDE-85-41-VL-14(6041) Rev 0
PDPP-BPCL-MR
E179 EMERSON PROCESS MANAGEMENT INDIA PVT LTD
2
E232 ENDRESS+HAUSER (I) AUTO. INSTRL. PVT. LTD.
3
E657 ENDRESS+HAUSER GMBH+CO. KG
4
K582 KROHNE MESSTECHNIK GMBH & CO KG
5
L562 L & J TECHNOLOGIES
6
M508 MAGNETROL INTERNATIONAL N.V
7
V518 VEGA GRIESHABER KG
8
FIELD INSTRUMENTS – 15RD

A200 ABB INDIA LTD (BANGALORE)
1
A682A ABB AUTOMATION PRODUCTS GMBH
2
3
E623 EMERSON PROCES MGMT ASIA PACIFIC PTE LTD
4
E641 ENDRESS+HAUSERWETZER GMBH+ CO.KG
5
6
F644 FUJI ELECTRIC SYSTEMS CO. LTD
7
H150 HONEYWELL AUTOMATION INDIA LTD.
8
H621 HONEYWELL INC.
9
I177 INVENSYS INDIA PRIVATE LIMITED
10
Y006 YOKOGAWA INDIA LIMITED
11
Y501 YOKOGAWA ELECTRIC CORPORATION
12
MOTOR-INDUCTION-M.V (FLAME PROOF) – 13JF

1 B048 BHARAT BIJLEE LIMITED
2 C010 CROMPTON GREAVES LTD.
3 K005 KIRLOSKAR ELECTRIC CO LTD
4 L065 LAXMI HYDRAULICS PVT LTD
5 M282 MARATHON ELECTRIC MOTOR I LTD-FORM A350
MOTORS - IMPORTED -13JK

1 A661 ASEA BROWN BOVERY LTD (ABB LTD)
2 C736 CEMP SRL
3 C730 GE ENERGY POWER CONVERSION FRANCE SAS
4 G632 GENERAL ELECTRIC CANADA
5 H510 HITACHI LTD
6 H641 HYUNDAI HEAVY INDUSTRIES CO. LTD
7 J511 JEUMONT SA/ FRAMATONE ANP
8 L603 LLOYD DYNAMOWERKE GMBH & CO. KG
9 L575 LOHER GMBH
10 A717 NIDEC ASI SPA

4
Page 567 of 704

A842-PDE-85-41-VL-14(6041) Rev 0
PDPP-BPCL-MR
11 S524 SIEMENSAG
12 T597 TOSHIBA CORPORATION
13 W598 WEG EQUIPAMENTOS ELECTRICOS S.A.
14 W598A WEGEURO-INDUSTRIA ELECTRICA S.A.
CABLE GLANDS ( HAZARDOUS AREA)– 14CA

1 B024 BALIGA LIGHTING EQUIPMENTS (P) LIMITED
2 C195 COMET BRASS PRODUCTS
3 C205 COMET INDUSTRIES
4 F024 FLEXPRO ELECTRICALS PVT LTD
5 F036 FLAMEPROOF EQUIPMENTS PVT.LTD
6 F141 FCG POWER INDUSTRIES PVT LTD
7 F165 FCG FLAMPROOF CONTROL GEARS P. LTD(C-157
8 K173 KAYSONS TECHNO EQUIPMENT P LTD.
9 S158 SUDHIR SWITCHGEARS PVT LTD
10 S375 STANDARD METAL INDUSTRIES
GENERAL NOTES
1.0 CONTRACTOR shall necessarily procure all the material / equipment forming permanent part of the
unit / plant from OWNER / PMC approved vendors only. This shall include sub-ordered items /
components also. The “Approved Vendors” shall be item specific.
2.0 OWNER / PMC approved vendor list for the various items is enclosed in this section.
3.0 CONTRACTOR may procure material from any of OWNER / PMC approved vendors. However,
current validity, holiday status and range of approval as per EIL enlistment letter, workload,
stability and solvency need to be verified by the CONTRACTOR with vendor before placement of
order. CONTRACTOR is also required to ensure that equipment qualification criteria, specified
elsewhere in the bid document, are also simultaneously met.
4.0 Vendors on OWNER / PMC holiday list shall not be considered for ordering. CONTRACTOR shall
comply with this requirement without any time or cost implication to the OWNER. If a vendor is put
on OWNER / PMC’s holiday list subsequent to CONTRACTOR placing an order, it shall be
CONTRACTOR’s responsibility to ensure quality work and timely supply from the vendor.
5.0 For items not covered in the above list, the CONTRACTOR shall approach OWNER/PMC for that
list or the vendors list shall be approved by OWNER / PMC prior to placement of order by
CONTRACTOR. CONTRACTOR shall list down the proposed suppliers / vendors for such items
and submit the same for OWNER / PMC’s review / approval along with necessary documents /
credentials. “Approval status” documents / credentials to be furnished by the vendors in such
cases shall solely be the responsibility of the CONTRACTOR. OWNER / PMC’s decision on
above shall be final and non negotiable. Non –acceptance of a particular proposed vendor due to
any reasons whatsoever shall not be a cause of schedule and cost implication.
6.0 CONTRACTOR shall make an independent assessment of capability of all the vendors for timely
deliveries of material/ equipment. Any delays in deliveries by vendor(s) shall not be a cause of
schedule and cost implication.

4
Page 568 of 704

A842-PDE-85-41-VL-14(6041) Rev 0
PDPP-BPCL-MR
7.0 At any stage of the project, if it comes to the notice of OWNER / PMC that CONTRACTOR has
procured material / equipment, intentionally or unintentionally whatsoever, from an unapproved
vendor and/or items not falling in approved range of vendor(s), the same shall be rejected fortwith
and CONTRACTOR shall be liable to replace such material / plant / machinery without any
schedule and cost implication to the OWNER.
8.0 List of vendors appearing anywhere else in the contract document in case of duplication of the
items at two or more places shall not be considered by CONTRACTOR and shall be superseded
by the vendor list enclosed herewith.
9.0 It is understood that should the name of vendor be changed due to change in their company or
corporate share holding. OWNER may accept such vendors under its new name with prior
approval.
Any such approval shall however, not absolve the CONTRACTOR from any of his obligations
under the contract; neither shall any such approval signify nominations or instruction to use such a
vendor. All approved vendors are deemed to have been freely chosen by the CONTRACTOR at
his own risk.
10.0 The approved vendors list for fabricated equipment (Vessels, Column, Heat Exchangers, Ejectors
etc.) is for fabrication alone. Where mechanical design of the equipment is included in
CONTRACTORS’S scope, CONTRACTOR shall either himself or through his Detailed
Engineering sub-contractor be responsible for designing and obtaining approval/ review of
Mechanical design calculations as per codes/specifications specified elsewhere in the Bid/
Contractor document from OWNER / PMC.

4
Page 569 of 704

THERMOCOUPLE / RTD STANDARD No.
onfaelei ENGINEERS
I vt
2151-eg
2422152 a513917.1)
INDIA LIMITED
I A Govt of India Undertaking)
ASSEMBLY 7-52-0036 Rev. 4
WITH THERMOWELL Page 1 of 1
1/2" NPT
(NOTE-1)
CHAIN
UNION 1/2" NPT
NIPPLE 1/2" NPT
(NOTE-2)
THERMOWELL
NOTE - 1. IN THE CASE OF DUPLEX THERMOCOUPLE/RTD, TWO INDEPENDENT

CABLE ENTRIES SHALL BE PROVIDED.
2. FLANGE TYPE, SIZE AND RATING SHALL BE AS PER DATA SHEET.
11 'RN
3--
4 24.10.16 Reaffirmed & Reissued Manoj RG
3 19-07-11 Revised & Reissued Manoj RG RP/JMS DM
No. by by
Approved by
Format No R-O0-0001-F4 Rev () Convrinht Fit - All rinhts rastarvarl
Page 570 of 704

STANDARD No.
k3g-ifaelegy fit ENGINEERS LEVEL GAUGE
geff 251-eg vv: INDIA LIMITED 7-52-0481 Rev. 5
(71E7f 21E4151? an34ir.1) (A Govt of India Undertaking)
ON VESSEL Page 1 of 1
P - BY PIPING
I- BY INSTRUMENTATION
V - BY INSTRUMENT VENDOR
LIST OF ITEMS
7 NIPPLE 1/2" THXPL 4 Ne
48 FLANGE 2" X 3/4" FL X TH (Red) 2 Ne

51 CAP 1/2" TH 2 Ne
210 GATE VALVE 1/2" SW 2 Ne
-// ..
24.10.16 Reaffirmed Reissued Manoj MN RN

4 12-10-11 Revised and Reissued Manoj RG RP/JMS DM
No. by by
Approved by
Format No R-00-0001-F4 RPV ennvrinht Fli - All rinhts rpsprwm1
Page 571 of 704

Page 572 of 704
Page 573 of 704
JOB SPECIFICATION & SCOPE OF WORK DOCUMENT No.
(ELECTRICAL)
AGITATORS FOR PRESSURE VESSEL A842-PDE-16-50-SP-6042 Rev. 0
PROPYLENE DERIVATIVE PETROCHEMICAL
PROJECT, BPCL-KR Page 1 of 3
JOB SPECIFICATION & SCOPE OF WORK

(ELECTRICAL)
FOR
AGITATORS FOR PRESSURE VESSEL
(PR NO. A842-PDE-VV-PR-6041-0041)
PROJECT : PROPYLENE DERIVATIVE PETROCHEMICAL PROJECT
CLIENT : M/s BPCL-KR
LOCATION : AMBALAMUGAL, KOCHI
CONSULTANT : ENGINEERS INDIA LIMITED
JOB NO. : A842
ISSUED WITH PR (M/s SHREE

0 10.04.17 SNM HK HK
SATYANARAYANA IND SUPP PVT LTD)
A 14.07.16 ISSUED WITH MR SNM NV HK
Rev. No Date Purpose Prepared Checked Approved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 574 of 704

(ELECTRICAL)
1.0 GENERAL
1.1 The specification defines the basic requirements of the electrical works/supply in vendor’s scope for the
Agitators of pressure vessel for Acrylates Unit of Propylene Derivative Petrochemical Project, Kochi of
M/s BPCL-KR. This job specification shall be read in conjunction with EIL standard specifications, data
sheets and documents attached with the Purchase Requisition. In case of any conflict amongst various
documents enclosed with PR, the most stringent requirement shall govern and Owner/EIL decision in
this regards shall be final.
1.2 The equipment shall conform to this specification, enclosed data sheets and standard specifications.
2.0 SCOPE
Vendor's scope of supply shall include but not be limited to the following for Agitators of pressure
vessels. Anything required over and above that is specified, for safe and satisfactory operation of the
package shall be included by the vendor in his scope without any cost /time implications to purchaser:
Sr. Description Specified by Remarks
No. Purchaser
(Yes/No)
1 Electric Motor for Agitators Yes
2 Double compression flame proof & weather proof cable Yes
glands and tinned copper lugs for equipments supplied by
vendor.
3 Spares & Tools/Tackles
3.1 Commissioning spares as recommended by the equipment Yes
manufacturer.
3.2 For two years operation and maintenance spares for electrical Yes
items refer elsewhere in PR/PO.
3.3 Special tools and tackles required, if any, for erection, site Yes
assembly and maintenance of motors as recommended by
the equipment manufacturer.
4. Inspection & testing as per the applicable standard Yes
specification & inspection test plan attached with the PR for
electrical items.
5. All data & drawings as per Vendor data requirements, data Yes
sheets, specifications and referenced codes and standards.
3.0 EXCLUSIONS
The following works / item are excluded from the scope of the Vendor:
3.1 Supply of 415V feeders for DOL starters for Agitator motors.
3.2 Supply, laying and termination of power, control & space heater cables from Substation to field.
3.3 All cable trays / trenches for owner’s cables.
3.4 Earthing outside package battery limit.
4.0 UTILIZATION VOLTAGE
Utilization voltage for motors, anti-condensation heaters based on their ratings shall be as listed below:
a.) Motors rated upto 160kW : 415V ± 10%, 50Hz ± 3%
b.) Anti-condensation heaters : 240V ± 10%, 50Hz ± 3%
5.0 SPECIAL REQUIREMENTS
5.1 MV motors (<1100V) shall conform to EIL Specification 6-51-0064 and MV Motor data sheet attached
elsewhere with the PR.
5.2 The enclosure type / area classification requirement for motors and their auxiliaries shall be as listed
below:
S. No. Tag No. Item Description Enclosure Type Area Classification
1. PDE-AM-405 V-405 Agitator Ex-d/ Ex-de Zone-2, IIA/IIB, T3
2. PDE- AM-505 V-505 Agitator Ex-d/ Ex-de Zone-2, IIA/IIB, T3
Page 575 of 704

(ELECTRICAL)
5.3 Motors having enclosure protection Ex-d/Ex-de shall meet the requirements of IS/IEC 60079-1.
5.4 All motors shall be provided with fabricated GI canopy.
5.5 Exact cable sizes of power and control cables shall be finalised during detailed engineering. Provisions,
as required in Vendor’s equipment for termination of the same, shall be made accordingly without any
cost & time implications to Owner. Cable sizes indicated under clause 6.2.5 of specification 6-51-0064
is only for guidance/estimation.
5.6 Vendor to note that the MV motors (415V and upto 160kW) supplied shall be of Energy efficient (IE2)
type as per IS 12615 (2011) or equivalent IEC codes.
5.7 Type test certificate from the authorized agency of country of origin for all hazardous area electrical
equipment/items shall be provided by vendor.
5.8 All electrical equipment for use in hazardous areas shall be certified by CIMFR, PTB, Baseefa, UL, FM
or equivalent independent testing Agency for the service and the area in which it can be used. All the
equipment indigenous and imported shall have a valid statutory approval of CCOE/PESO and copies of
the same (CCOE/PESO) shall be furnished during detailed engineering stage which is mandatory as
per local rules/regulations.
5.9 Cable glands to be supplied with the motor shall meet all the requirement of IS/IEC-60079-0. For motors
and outdoor equipment, double compression type Nickel plated brass FLP/weatherproof cable glands
shall be supplied.
5.10 All lugs to be supplied shall be heavy duty, crimping type and made of copper.
6.0 MAKES OF EQUIPMENT AND COMPONENTS
6.1 List of approved vendors for Electrical equipment/components is as mentioned elsewhere in the Master
Vendor List, attached in the PR.
6.2 In case of imported equipment, the contractor shall furnish the reference list of customers and shall
ensure that type test certificates for similar type of equipment are available, which is essential for
technical acceptability. Additional makes of imported items shall be subject to Owner/EIL’s approval
during detailed engineering.
6.3 Vendor may procure material from any of the listed vendors. However current validity and range of
approval as per EIL enlistment letter, workload, stability and solvency need to be verified by the vendor
before placement of order.
7.0 Variation /Clarification against the standard specification for MV motor 6-51-0064, shall be as per the
MOU agreed with EIL by respective motor manufacturer. No further deviations to PR requirements shall
be entertained.
8.0 LIST OF ATTACHMENTS
S. No. Title Document No. Rev.
1. Data Sheet – MV Motors (415V) A842-PDE-16-50-DS-0501 A
2. Vendor Data Requirement (Electrical) A842-PDE-16-50-VR-6041 0
3. Specification for Energy efficient MV
6-51-0064 1
Induction Motors
4. Inspection & Test Plan for MV Motors 6-81-1032 5
Page 576 of 704

Document No.
VENDOR DATA REQUIREMENTS A842-PDE-16-50-VR-6041
FOR Rev. 0
AGITATORS FOR PRESSURE VESSEL Page 1 of 3
VENDOR DATA REQUIREMENTS

FOR
AGITATORS FOR PRESSURE VESSEL
0 10-APR-2017 ISSUED WITH PR SNM HK HK

A 14-JUL-2016 ISSUED WITH MR SNM NV HK
Rev. Date Purpose Prepared by Checked by Approved by
No.
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved
Page 577 of 704

Document No.
FOR Rev. 0
The following drawings/documents marked " " shall be furnished by the bidder.
MV MOTOR
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Data Sheets (Duly filled-in)
3. Dimensional/Assembly Drawings : GA Drawing To be furnished along
with motor data sheet
For motors < 75kW as single document in
vendor portal
4. Dimensional/Assembly Drawings : Installation To be furnished along
Plan/Mounting Details as single document in
vendor portal
5. Dimensional/Assembly Drawings : Terminal To be furnished along
Box Arrangement as single document in
vendor portal
6. Dimensional/Assembly Drawings : Name Plate To be furnished along
Drawing as single document in
vendor portal
7. Performance Curves : Speed Torque Curves To be furnished along
as single document in
vendor portal
8. Performance Curves : Speed-Current/Time To be furnished along
Curves as single document in
vendor portal
9. Performance Curves : Thermal Withstand To be furnished along
Curves (Hot & Cold) as single document in
vendor portal
10. Performance Curves : P.f. & Efficiency Curves To be furnished along
as single document in
vendor portal
11. Inspection & Test Plan (ITP) -For review by Refer Note-'*'
Inspection Dept.
12. Test Records
13. Type Test Certificates for similar equipment
14. List of Commissioning Spares
15. List of Maintenance Spares
16. List of Special Tools & Tackles
17. Data Books/ Manuals : Installation Manual
18. Data Books/ Manuals : Operating/ Maintenance
Manual
19. Data Books/ Manuals : Catalogues/ Brochures
20. Equipment storage procedure at site
Page 578 of 704

Document No.
FOR Rev. 0
POST ORDER
S. WITH WITH
BID
(FINAL)
21. Statutory approval certificate of CCOE/PESO
Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
8. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
9. Bill of Material shall form part of the respective drawing.
10. '*' indicates the following:
a. Equipments whose ITP is attached with Contract -ITP for respective equipment shall be followed. Therefore,
no ITP is to be furnished for review for those equipments.
b. Equipments whose ITP is not attached with Contract-Manufacturer's ITP shall be submitted by Packager/
Vendor/Contractor to respective Regional Procurement Office (RPO) near to manufacturer's works for approval
by EIL Inspection.
11. All technical details and documents furnished with bids shall be treated as data for engineering. These shall
however be subject to Purchasers review after order placement and bidder shall comply to MR/Tender
requirements without any cost & time implication to EIL/Owner.
12. "*" indicates submission of documents to Inspection Agency.
Page 579 of 704

DOCUMENT NO.
MANDATORY SPARES
INSTRUMENTATION A842-PDE-80-42-SL-6041/0041
REV 0
Page 1 of 2
MANDATORY SPARES
INSTRUMENTATION
The vendor shall note the following and furnish the quotation for Mandatory Spares accordingly:
1. Mandatory spares shall consist of the Spares as listed below.
2. The word ‘Set’ means the quantity required for full replacement of that part in one machine.
3. The Vendor shall supply all the mandatory spares as defined below & as applicable to the proposed
design of the equipment. In case, any spare which is listed in the checklist but not applicable due to
specific construction/design of the equipment, the same shall be highlighted as ‘Not Applicable’
against that spare supported with proper technical explanation.’
4. Spare part shall be identical in all respects to the parts fitted on the main equipment, including
dimensions, material of construction, testing and heat treatment.
5. Vendor shall note that, only the mandatory spares (Rotating, Instrumentation, Electrical, and Static
Equipment & Piping) as specified below shall be included in the base price. No other spares of any
type shall be included in this list of mandatory spares.
6. If any additional spare is included, the same will not be taken cognizance of.
If vendor wishes to quote for any spare over and above those specified below, the same shall be
quoted as part of the Two years normal operation spares.
7. Vendor shall furnish the following checklist of mandatory spares, duly filled in, separately for each
equipment Item included in the inquiry, in his proposal.
Mandatory Spare Parts for Instrumentation Items –
Quoted
S. No. Part Description Quantity Required
Yes/No
1 FIELD INSTRUMENTS (as applicable)
10% (Subject to min. of 2 Nos) of each model,
1.1 Pressure Gauges range, material of construction and rating,
whichever is higher.
10% (Subject to min. of 2 No) of each model,
1.2 Draft Gauges range, material of construction and rating,
5% (Subject to min. of 1 No) of each model,
Temperature Gauges
1.3 range, material of construction and rating,
A) For transparent gauges, 10% of illuminators
1.4 Level Gauges
with holder and reflector and 50% of bulbs
B) In case of magnetic type level gauges, 10% of
bi-color rollers for each gauge to be provided in
addition to above.
C) 10% subject to minimum one number of glass

of each type, size along with pair of Gaskets (
Cushion & Wet Gaskets), whichever is higher.
D) 10% subject to minimum one number of

Gaskets for Gauge Cocks/Valves Bonnet /
Packing.
SMART & FF
Transmitters for 10% (subject to minimum of 1 No) of each model,
1.5 Pressure, Flow (DP), range, make and material of construction,
Level(DP) and whichever is higher.
temperature etc
RTDs 5% (subject to minimum of 1 No) of each length
1.6
of RTD with Thermowell, whichever is higher.
5% (subject to minimum of 1 no) for each type of
1.7 Thermowell
Special MOC.
Page 580 of 704

DOCUMENT NO.
MANDATORY SPARES
INSTRUMENTATION A842-PDE-80-42-SL-6041/0041
REV 0
Page 2 of 2
Variable Area 5% or minimum one no. float & set of Packing for
1.8 Flowmeter each type, size, rating and material, whichever is
(Rotameters) higher. Spare glass of enclosure/indicating box
A) Repair kit consisting of (orifice, plug, spring,
Pressure control Valve
1.9 gasket, diaphragm, O-ring for each type, size &
(Self actuating valve)
rating of the valve.
B) Minimum 1 no of each type/ size, rating etc. of
Trim set consisting of seat, seat ring / seal ring,
plug with stem, cage (wherever applicable),
packing material for each valve to be provided as
spare.
NOTES:
1. The word ‘TYPE’ means the Make, Model no., Type, Range, Size/ Length, Rating, Material as
applicable.
2. Wherever % age is identified, Vendor shall supply next rounded figure.
3. The terminology used under ‘Part Description’ is the commonly used name of the part and may
vary from manufacturer to manufacturer.
4. The above list indicates Predefined Mandatory spares excluding the Commissioning spares,
Consumables and installed engineering spares for system-oriented items. The Commissioning
spares and Consumables shall also be part of Vendor scope of supply. The installed engineering
spares for system oriented items like Sub-package PLC, Dedicated control systems, Local Control
Panels etc.(As applicable) shall be as per specification given elsewhere.
5. Mandatory spares shall also be applicable for instrumentation items of sub-packages as per
mandatory spares philosophy.
Page 581 of 704

JOB SPECIFICATION AND SCOPE OF WORK Document No.
(INSTRUMENTATION) A842-PDE-16-51-SP-6041/0041
AGITATORS REV-0
OF ACRYLATE UNIT, PDPP, BPCL-KOCHI Page 1 of 10
JOB SPECIFICATION AND SCOPE OF WORK
(INSTRUMENTATION)
FOR
AGITATORS
ACRYLATE UNIT
PDPP, BPCL-KOCHI
A842-PDE-VV-PR-6041/0041
0 10.04.17 ISSUED FOR PR AS KB AA

Rev. Prepared Checked Approved
Date Purpose
No by by by
Page 582 of 704

AGITATORS REV-0
1.0 GENERAL
1.1 The purpose of this specification is to define general requirements and philosophy of
instrumentation for Agitators package..
1.2 This specification along with standards and relevant part of this requisition covers the
design, engineering, supply and testing of Instrumentation system with all accessories and
materials, required for Agitators package.
1.3 If there is any conflict between this specification, data sheets, related standard, code etc.
Vendor shall refer the matter to owner/consultant for clarification and only after obtaining
the same should proceed further.
2.0 SCOPE OF SUPPLY AND WORK
2.1 Vendor's scope of instrumentation supply and work shall include the followings as a
minimum:
a) Supply and installation of all instruments (as applicable) as required for smooth and
satisfactory operation of Package.
b) Design and detailed engineering including residual engineering of instrumentation
and controls of the package based on P&IDs (to be developed by Vendor) and other
technical requirements described in various documents attached with the PR. This
shall include detailed engineering including preparation of engineering drawings/
documents, specification data sheets, sizing, selection of materials.
c) Piping and all other erection material including all fittings, mounting accessories,
instruments supports (2" yoke type) required for erection of instruments, under
Vendor's scope of supply, as per list of applicable installation standards (shall be
given to successful Vendor after order).
d) Supply and installation of all cables between instruments and Local Control Panel (if
applicable) supplied by Vendor.
e) Cable glands/plug shall be duly installed with the instruments.
f) Submission of documents shall be as per VDR.
g) One number potential free contact for stop & one number for running indication shall
be made available by the vendor for further use by purchaser. The isolated potential
free contact shall be suitable for 2A rating @ 24V DC for further interrogation/ usage
by the Purchaser.
3.0 DESIGN PHILOSOPHY AND TECHNICAL REQUIREMENTS
3.1 All electronic field transmitters shall be suitable for intrinsic safe circuit and shall be
certified suitable for Zone-2 Gr IIA/B T3 hazardous area classification by statutory body.
All the instruments shall also be dust proof. Additionally instruments shall be certified by
CCE/ PESO India, irrespective of the origin of the instrument..
3.2 All instruments shall be weatherproof to IP-65 as per IS/IEC-60529.
3.3 In place of process switches Foundation Field bus transmitters shall be provided for seal
plan for Agitators. Vendor shall provide the alarm set values during detail engineering. FF
Transmitter shall be bus powered type and shall have interoperability test clearance
complying ITK (latest revision). FF transmitter shall also have capability to become device
link master whenever required. It shall be compatible with EDDL (Electronic Device
Description Language) as per IEC 61804, latest revision or FDT/DTM requirements.
Foundation Fieldbus type transmitters shall be used in high powered trunk concept with
Page 583 of 704

AGITATORS REV-0
intrinsically safe Field barrier. Hence the intrinsically safe (entity concept) parameters of
the transmitters shall match with the entity parameters of field barriers.
3.4 All field instruments/transmitters shall be provided with dual cable entries. Unused entry
shall be plugged using suitable metallic plug. All cable entries shall be 1/2" NPT (F) size
and shall be fitted with double compression type nickel-plated brass cable glands with
Slipper type PVC sleeves (cable shrouds) and suitable for hazardous area classification as
indicated elsewhere in the bid package.
3.5 All the instruments shall be supplied from EIL / purchaser's approved vendors only. Vendor
shall furnish proposed sub-vendor list for EIL / purchaser's approval. It shall be approved
by EIL / purchaser during detail engineering after order. Vendor shall take prior approval of
make and specification of all instrument items before placement of order on sub-vendor.
3.6 Pressure rating of thermowell for temperature element/ temperature gauge, self-actuated
pressure control valve body and flanges shall be minimum 300# rating or as per respective
piping specification whichever is higher.
3.7 Instrument connection on vessel, standpipes and tanks shall be as per Doc no. 7-52-0001
and instrument connection on pipes shall be as per Doc no. 7-52-0002. The minimum
rating of all instrument nozzles on the vessels shall be 300#
3.7 All instruments shall have internal terminal block, anti-vibration type for cable termination.
Flying leads are not acceptable.
3.8 S.S. tag plates shall be provided for all the instruments.
3.9 Prefabricated FRP canopy shall be used for field electronic instruments,. Canopy for
transmitters shall cover TOP and all 4 SIDES with transparent door on the front.
FRP canopy shall have Acrylic window & mounting bracket plate material shall be SS304.
Color of the canopy shall be Light grey
Typical characteristics of FRP canopy shall be following:
i) High mechanical strength

ii) Weather resistant (Resistant to most of the acids, alkalies, vapours & fumes).
iii) UV resistant
iv) Anti Static
v) Special rubber grommets for Cable/ Tube entry
3.10 Typical (skeleton / blank) instrument data sheets for each type of instruments are enclosed
with the requisition. The ‘.isf’ files for the same shall be furnished by Purchaser during
detailed engineering. Vendor shall furnish filled in data sheet for each tag after sizing,
range selection, material selection etc. These data sheets shall be reviewed and approved
by EIL / purchaser after placement of order. Proper selection of instruments, materials etc.
shall be Vendor's responsibility. Any necessary change required later for meeting the
specification shall be done by the Vendor. While filling the instruments data sheets, the
following shall be taken care:
a) All the relevant data shall be filled in. If any point is not applicable then N/A shall be
indicated.
b) Make and model number of the supplied instruments shall be indicated with model
decoding details for supplied instrument, without model no, data sheet shall not be
reviewed.
c) Vendor seal with signature shall be provided and pump vendor shall ensure the
correctness of the process data.
Page 584 of 704

AGITATORS REV-0
d) Instruments tag numbers /data sheet numbers shall be indicated.
3.11 Level Transmitter
a) For liquid measurement , Guided Wave Radar is not acceptable if process fluid is
Acrylate since there is chance of polymerization in presence of acrylate.
3.12 Level Gauge
a) Level Gauges shall be steel armoured Magnetic type or Transparent type with body
material of SS 316 as a minimum or better corresponding to seal pot material and
tempered borosilicate glass. In case Transparent type gauge is being provided ,
illuminator to be provided for the same.
b) Level Gauge shall be supplied with off-set type quick closing ball check valve (Gauge
Glass and cock type) with carbon steel body and SS 316 trim as a minimum.
c) Level gauge shall be hydrostatically tested up to 72 Kg/cm2 (as a minimum) or up to
hydrostatic test pressure of seal pot, whichever is higher. Hydro test certificates shall
be furnished.
d) Vessel (Seal Pot) connection for level gauge shall be 3/4" NPT (F) with primary
isolation valve and 3/4" spherical union.
e) Studs and bolt material shall be ASTM A193 Gr. B7 and ASTM A194 Gr. 2H
respectively.
3.13 Pressure Gauge
a) Pressure gauge dial shall be 6” white of non-rusting material with black figures.
Pressure gauge shall have solid front for operating pressure exceeding 60 Kg/cm2g.
b) Pressure gauge shall have 1/2" NPT (M) bottom connection.
c) Pressure gauge shall be provided with features like screwed bezel, externally
adjustable zero, over range protection and blow out disc.
d) Sensing element (bourdon tube) shall be of SS 316 and movement of SS 304, as a
minimum. Case material for pressure gauges shall be SS 304
e) Pressure gauge shall have an accuracy of ± 1% of URV (Upper Range Value) and
range shall be so selected that gauge normally operates in middle third of the range.
f) Pressure gauge shall be suitable for maximum pressure or 130% of the range
whichever is higher, without any calibration drift.
3.14 Transmitter
a) All open & closed loops shall be Foundation Fieldbus type while all interlock analog
signals shall be conventional SMART type. In case some special instruments not
available as FF Type, SMART instruments is also acceptable with Purchaser
approval. For SMART instruments details ,refer 6-52-0032 & 6-52-0052 attached
with this PR.
b) FF type Transmitters used in the seal plan shall be as per clause 3.3 above and shall
be suitable for the specified area class.
b) Integral LED/LCD output meter shall be provided for all transmitters.
c) Transmitters calibrated accuracy shall be of ± 0.075% of span. Calibrated accuracy

for diaphragm seal transmitters shall be ± 0.25% of span.
d) Transmitters shall have minimum static pressure/overpressure rating of 160 kg/cm2g
except for very low-range for which the static pressure will be considered suitably
based on the availability.
Page 585 of 704

AGITATORS REV-0
e) Threaded end connections shall be to NPT as per ANSI B 1.20.1. Flanged end
connections shall be as per ANSI B 16.5
3.15 Pressure Relief Valve / Thermal Relief Valve
a) Pressure Relief Valve shall meet the limiting relief valve requirements as defined in
API RP-520 (Part-I & II) and in API-526.
b) Pressure Relief Valve shall be full nozzle full lift type and Thermal Relief Valve shall
be modified nozzle type.
c) Percentage Accumulation shall be 10% for Pressure Relief Valve and 25% for
Thermal Relief Valve.
d) Body material shall be Carbon Steel as a minimum. Nozzle and disc material shall be
SS 316 as a minimum with machined SS guide and spindle.
e) Spring material shall be selected as per operating conditions. Normally it shall be
Cadmium/Nickel/Zinc/Aluminium plated Carbon Steel.
f) Pressure Relief Valve shall have flanged connections for sizes 1" and above and
shall have screwed connection for sizes 3/4" and below. Thermal Relief Valve shall
have screwed connection with 0.38 cm2 orifice size and inlet outlet shall be of 3/4"
NPT(M) X 1" NPT(F) sizes.
g) Pressure relief valve type shall be vendor’s responsibility suitable for the system.
3.16 Self Actuated Control Valve
a) Body material shall be Carbon Steel as a minimum. Trim material shall be Stainless
Steel as a minimum. Actuator shall be diaphragm type and diaphragm material shall
be Stainless Steel as a minimum.
b) All pressure parts shall be designed to withstand maximum shut off pressure.
c) Hardening of trim (includes plug and seat joint, orifice and plug contour) like stelliting
etc. shall be considered for pressure drops greater than 10 Kg/cm2g.
d) Valve shall have flanged connections for sizes 1" and above and shall have screwed
connection for sizes 3/4" and below.
3.18 Orifice Plate and Flanges:
Orifice plate shall be concentric square edged type of minimum of SS316 material and
flanges shall be min. carbon steel of minimum 300# rating. The sizing of Orifice shall be as
per ISO 5167. Dimensional detail shall be as per 7-52-0041.
3.20 Restriction Orifice Plate
a) Restriction Orifice Plate shall be concentric square edged type.

b) Each Restriction Orifice Plate shall have an integral handle, which shall, upon assembly
with flanges, extend to a distance of 50 mm, with following information punched on it:
 Tag Number.
 Nominal pipe size in inches and rating in psi.
 Material of plate.
c) Restriction Orifice Plate material shall be SS 316 as a minimum or better.
3.21 Temperature Instrument
Page 586 of 704

AGITATORS REV-0
a) The temperature gauges shall be bimetallic type and shall be provided with 1½"
flanged (min. 300# rating) thermo well with ½" NPT (F) connection for temperature
gauges on process lines.
b) All temperature elements shall be RTD (Pt-100) for temp range (-200) to 650 DegC
and Duplex type. All temperature signals shall be provided with field remote mounted
(not head mounted) type temperature transmitter. Thermo wells shall be fabricated
out of bar stock.
c) Temperature gauges shall have accuracy of ± 1 % of URV (Upper Range Value).
d) Thermo well and flanges of Thermo well shall be minimum of SS-316 or better to suit
the service conditions. Minimum 300# rating shall be considered for thermowell.
e) Case material for temperature gauges shall be SS 304.
f) Temperature transmitter shall be provided for all temperature elements for both open
and closed loops except where signals are connected to vibration and temperature
machine monitoring system and shall be remote field mounted.
g) Temperature transmitters shall be provided with dual compartment.
3.22 Rota-transmitter (Rotameter with Flow Transmitter if applicable)
a) Rotameter shall be of metal tube type. Transmitter shall be FF type as per clause 3.3
above. In case FF type transmitters are not available from any manufacturer, 4-20 mA
SMART output transmitters with HART protocol are acceptable.
b) The material for tube & float shall be SS 316 as a minimum.
c) The packing material shall be PTFE if the liquid temperature is below 230° C. For
temperatures above 230° C, packing shall be of GRAFOIL.
d) Rotameter shall have an accuracy of minimum ± 2% FSD.
3.25 Installation Standards/ Material:
(a) For Non-congealing Hydrocarbon services as well as utility services (except steam
which shall be closed coupled with 5 valve manifold), standard bought out Pre-
fabricated (with 5 valve manifold for flow and 2 valve manifold for PT) & pretested hook-
up for all flow (dP) transmitters, Pressure transmitters shall be used. These hook-ups
shall be basically close coupled instrument hookup integral type complete with
instrument root valve, equalizing valves, oval flange adaptors, vent, drain pre-tested and
pre-engineered ready for installation. All drain connections of pre-fabricated & pre-
tested hook-up for pressure transmitters shall be provided with connector, tube and
tubing cap for remote draining.
(b) 2 valve integral manifold along piping standard shall be considered for Local Pressure
gauges.
(c) Separate Vent/Drain valves are not required when 5 valve manifolds / pre-fabricated
and pre-tested hook ups are used for DP type flow transmitters
(d) Remote Instrument Installation shall be used for Level and Differential Pressure
Transmitters (DPTs) with hybrid standard (i.e. complete piping with tubing at the end).
Vent / drain valves shall be gate valve and isolation valve shall be globe valve.
(e) For pre-fabricated and pre-tested hook-up, first isolation valves shall be part of hook-up
and it shall be miniature type quarter turn ball valve with minimum 1500 # rating with
metal seated/ soft seated as per process pressure/ temperature condition. For all other
installation, the first isolation valves of piping shall also be quarter turn ball valves.
(f) The material of construction for the complete assembly of pre-fabricated hook-up shall
be SS 316 as a minimum unless more stringent materials are required as per process
conditions and PMS.
(g) Field transmitter supports should be properly clamped to the pipe for pre-fabricated
hook-up, wherever required. No air gap shall be kept between support clamp and pipe.
Page 587 of 704

AGITATORS REV-0
(h) Vendor shall follow EIL installation standard for instrument hook-ups. The same shall be
provided to the successful vendor during detailed engineering.
(i) For seal oil, lube oil services tubing installation for instrument is also acceptable.
All instruments mounted on steam traced lines shall also have their installation steam traced.
3.26 Local Panel (if applicable)
Local panels shall be used only for startup and normal critical operations. Unless
otherwise indicated in the package, following points shall be kept in mind while engineering
the local panels:
Weatherproof local panel shall be provided by Vendor for classified area, wherein
the Alarm Annunciator shall be intrinsically safe and push button, lamps; selector switches
shall be flame-proof “Exd” type mounted on LCP. Barriers for IS alarm annunciator shall be
supplied by Vendor along with IS annunciator and Purchaser will provide potential free
contact for the same. The IS power supply module for alarm annunciator shall be installed
in a flameproof box in local panel. For Lamps, Purchaser will provide wet contact. The
Power supply distribution box inside the Local Panel shall also be flame-proof “Exd’. IS
PCs for display of loop powered indicators shall be used in weather-proof local panels in
case no. of tag local display more than 5 tags. The same IS PC can also be used for local
display of Vibration and Temperature monitoring system parameters at field instead of
separate display unit at field. Separate Local Panel shall be required for each Pump. Local
panel shall be located in field near the Pump.
Electronic Components / system located at local panel shall be suitable for combined
effect of outdoor ambient/climatic conditions and current carrying for installation in LCP.
Vendor shall confirm with catalogue / document mentioning ambient temperature rating of
Vendors supplied Electronic Components / system suitable for installation in local panel or
else Vendor shall supply necessary cooling arrangement.
.
Power supply (110 V AC (UPS ± 10%, 50Hz ± 3%) and / 240V AC 50Hz. 50Hz ±3%)
shall be given at one place near each panel in the field by Purchaser. Further
distribution shall be by Vendor. Vendor shall indicate the power consumption for 110
VAC (UPS) and 240 VAC for package, along with the bid proposal
3.27 Miscellaneous requirement:
a. Softcopy of all instrumentation documentation shall be submitted in editable format for

loading into purchaser’s Documentation Node. Vendor to ensure that all’ final as-built
instrumentation documentation are submitted as separate volume / section.
b. Any Instrument loose supplied items are to be packed separately instead of packing the
same with other mechanical items while shipping to site. Markings shall be provided for
such packing as “Instrument Items – Loose Supply”
c. The package vendor shall generate and submit all instrument specifications, datasheets
using Intergraph Smart Plant Instrumentation (SPI) 2009.Purchaser shall provide blank
".isf files" (SPI) during detailed engineering for each instrument tag to vendor for filling
the same using “external editor”. Vendor shall prepare instrument datasheets using the
same only and submit pdf outputs for review/records and after finalisation, the final ".isf
file" shall be submitted for migrating the data into purchaser’s main SPI database.
Page 588 of 704

AGITATORS REV-0
d. Small nut/bolts, used for fixing of instrument items in addition to cable trays, shall also be
stainless steel.
e. All drain connections of pre-fabricated & pre-tested hook-up for pressure transmitters
shall be provided with connector, tube and tubing cap for remote draining.
f. The Fieldbus devices configuration shall be provided by Vendor in the form of soft file
(CD) as part of VDR during detailed engineering. For all the Fieldbus instruments
supplied under the package, vendor to provide all the necessary data of field instruments
required for FF DCS engineering like Device Tag, Device type, Device revision, Device
address, DD file revision, CFF revision etc as actually configured in the supplied
instruments in the format given in the PR.
4.0 TAG NUMBERING
4.1 Instrumentation symbol shall follow latest edition of ISA standard S 5.1.
4.2 All vendor-supplied instruments shall have Tag No. as per the format indicated below.
Numerical no. for all the instruments shall be unique i.e. without any repetition of tag no.
for same type of instrument.
Unit No. Instrument Type Numerical No.

AAA BBBB ........ CCDD
AAA = Unit Number (PDE FOR THIS CASE)
BBBB = Refer ISA S 5.1
CC = Last two digit of P&ID no.
DD = Instrument serial number (51 - 99)
5.0 INSPECTION:
All instruments shall be inspected by owner / consultant for calibration and proper
operation prior to dispatch.
6.0 Mandatory Spares :
10% subject to minimum 1 no. of each type of applicable supplied Instruments. The word
‘TYPE’ means the make, Model No., Type, range, Size / length, rating, material as
applicable.
The installed engineering spares for system oriented items like Local Control Panels
etc.(As applicable) shall be as per specification given elsewhere
7.0 COMMISSIONING SPARES
7.1 Vendor shall supply Instrumentation commissioning Spares required as per vendors
recommendation for successful commissioning of the supplied Package.
7.2 Deleted.
Page 589 of 704

AGITATORS REV-0
7.3 Vendor shall note that in case any additional spare is required during erection and
commissioning over and above the recommended spares, the same shall be supplied by
vendor without any implications. Also, if any spares are consumed during commissioning
from mandatory spares, the same shall be replenished by vendor.
8.0 Deleted.
Page 590 of 704

AGITATORS REV-0
ATTACHMENTS:
A. LIST OF INSTALLATION STANDARDS:
Serial no. Description Document no.
1. Instrument connection on vessels, stand pipes and tanks 7-52-0001
2. Instrument connection on piping 7-52-0002
3. Thermo well 7-52-0035
4. Thermocouple / RTD assembly with Thermowell 7-52-0036
5. Pressure Gauge liquid/gas service A842-000-16-51-IS45
5. Pressure instrument general service A842-000-16-51-IS59
6. Level gauge on vessel 7-52-0481
7. Standard Specification for Package Units 6-52-0052
8. Instrument Support Single Instrument 7-52-0101
9. Orifice plates and flanges dimensional details 7-52-0041
10. Standard specifications for Electronic/Pneumatic instruments 6-52-0032
B. LIST OF BLANK DATA SHEETS:
Serial no. Description Document no.
1. Pressure Gauge A842-000-16-51-DS-1001

2. Pressure Instruments A842-000-16-51-DS-1101
3. Gage Glasses and Cocks A842-000-16-51-DS-2601
4. Restriction Orifice Plates A842-000-16-51-DS-3201
5. Temperature Gauge A842-000-16-51-DS-4001
6. Thermal relief Valves A842-000-16-51-DS-3701
7. Radar Level Instruments A842-000-16-51-DS-2501
8. Self Actuated Control Valve A842-000-16-51-DS-3401
9. Rotameters A842-000-16-51-DS-0201
Page 591 of 704

Document No.
FOR Rev. 0
AGITATORS Page 1 of 3

FOR
AGITATORS
0 10-APR-2017 ISSUED FOR PURCHASE AS KB AA

A 25-JUL-2016 Issued with MR -AS- -SA- -AA-
No.
Page 592 of 704

Document No.
FOR Rev. 0
POST ORDER
S. WITH WITH
BID
(FINAL)
1. Drawing and Document Schedule
2. Utility & Power Requirements
3. Spare part list for 2 years operation
4. Spare part list for Mandatory Spares
5. Instrument Index Note-19
6. Sub-Vendor List for Instruments and (only for items not

appearing in
accessories purchasers vendor list)
7. Instrument Sizing calculations Note-2
8. Purchase Requisitions along with Technical

catalogue for all vendor supplied instruments
and systems, etc.
9. Technical catalogs for selected system models
10. Logic Diagrams
11. Bill of material for installation items Note-18
12. Inspection and test procedures

13. Installation, Operation and Maintenance
Manuals
Notes :
2. Review Only for Critical items like Control valves, On-off valves, Pressure Safety Valve, self actuated control
valves . Others are for Records only.
3. Any other document/drawing not listed above but required to carryout the engineering and for integration of
other equipment packages sub-ordered by contractor shall also be prepared and furnished to Client / EIL.
4. Vendor to note that the system engineering documents are required for further engineering and site work.
These documents shall be, positively, provided as per mutually agreed schedule after order.
6. Vendor shall prepare & submit the as built drawings / documents after commissioning. All the
drawings/documents listed shall be converted into âAs Builtâ after commissioning of Project. âAs Builtâ shall
include documents generated by Contractor & documents generated/ submitted by various Sub-vendors.
7. All instrument document/drawing shall be submitted after issue of P&IDs. The submission of document /
drawing is sequenced in such a way that submitted document /drawing is neither dependent nor changed due
to drawing / document yet to be submitted. Document/ drawing submission schedule shall be made accordingly.
8. Vendor shall furnish Hazardous area certificates for all instruments & equipments located in hazardous area.
Statutory certificates shall be obtained from authorities like PESO (Petroleum Explosive Safety Organizer) /
Page 593 of 704

Document No.
FOR Rev. 0
Chief controller of Explosive (CCE) Nagpur etc. as applicable

9. Also refer other department's VDR :-
10. Electrical
11. Static Equipment
12. Rotating Equipment
13. Piping
15. Approval, Review and Records as marked have to be strictly followed.
18. Bill of material shall be prepared based on the EIL installation standards being used with contractor¿s item
codes for installation material items.
19. The package contractor shall generate and submit all instrument datasheets, Cable Schedule, instrument
index and loop wiring diagram using Intergraph Smart Plant Instrumentation (SPI) 2009
20. Bidder shall generate these documents in the formats which shall be provided by purchaser during detailed
engineering.
21. Documents other than those identified for review by Client/ EIL shall be submitted for record.
22. Bidder shall furnish filled in data sheet for each tag after sizing, range selection, material selection etc. with
make and model nos. These data sheets shall be reviewed / retained for records by purchaser after placement
of order. Proper selection of instruments, materials etc. shall be bidder's responsibility. Any necessary change
required later for meeting the specification shall be done by the bidder without any price or delivery implications.
While filling the instruments data sheets, the following shall be taken care:
i) All the relevant data shall be filled in. If any point is not applicable then N/A shall be indicated.
ii) Make and model number of the offered instruments shall be indicated with model decoding details for offered
instrument, without model no, data sheet shall not be reviewed
iii) Vendor seal with signature shall be provided and bidder shall ensure the correctness of the process data.
iv) Instruments tag numbers /data sheet numbers shall be indicated
Page 594 of 704

Projects A842-PDE-85-41-VL-6041-41 Rev-0
PDPP-BPCL-KR Page 1 of 7
VENDOR LIST
PROJECTS
(MR-6041)
PROJECT : Propylene Derivative Petrochemical Project-Acrylate

Unit
OWNER : BHARAT PETROLEUM CORPORATION LTD. (BPCL-KR)
PMC : ENGINEERS INDIA LTD.
JOB NO. : A842
0 10.04.17 Issued for PR SSK HV PKB

Prepared Checked
Rev Date Purpose Approved by
by by
Page 595 of 704

A842-PDE-85-41-VL-16041-41 Rev 0
PDPP-BPCL-MR
PRESSURE RELIEF VALVE-15EC

1 A710 ANDERSON GREENWOOD CROSBY
2 A761 AST APPARECCHI DI SICUREZZA E TENUTA SPA
3 B015 BHEL (TRICHY)
4 B110 BLISS ANAND PVT LTD
5 C700 CURTISSWRIGHT FLOW CONTROL CORPORATION
6 D523 DRESSER INC.
7 I172 INSTRUMENTATIONLTD. (PALGHAT)
8 L569 LESER GMBH & CO. KG
9 N541 NAKAKITA SEISAKUSHO CO LTD
10 T181 TYCO SANMAR LTD
11 W092 WEIR BDK VALVES – A UNIT OF WEIR INDIA PVT. LTD.
12 F103 FAINGER LESER VALVES (P) LTD.

SELF ACTUATED PR. CONTROL VALVE – 15EG
1. 3631 EMERSONPROCESSMANAGEMENT CHENNAI PVT LTD
2. D127 DRESSER VALVE INDIA PVT LTD
3. D649 DRESSER PRODUITS INDUSTRIELS
4. E179A EMERSON PROCESS MANAGEMENT CHENNAI LTD.
5. E534 ESME VALVES LTD.
6. E6231 EMERSON PROCES MGMT ASIA PACIFIC PTE LTD
7. E626 ELSTER-INSTROMET NV-FORMER. I563
8. G603 GORTER CONTROLS B.V.
9. N088 NIRMAL INDUSTRIAL CONTROL PVT. LTD.
10. M055 MIL CONTROLS LIMITED
11. P538 PIETRO FIORENTINI SPA
12. R539 RMGREGEL+MESSTECHNIKGMBH
13. R610 RICHARDS INDUSTRIES (FORMERLY TRELOAR)
14. S442 SAMSON CONTROLS PVT LTD
15. S510 SAMSON AG MESS-UND REGELTECHNIK
ORIFICE PLATES AND FLANGES – 15GA

CAMERON CANADA CORPORATION
1. 27415
BALIGA LIGHTING EQUIPMENTS (P) LIMITED
2. B024
COMFIT & VALVES PVT. LTD.
3. C220
CAMERON LTD.
4. C720
DANIEL MEASURMNT & CONTROL ASIA PACIFIC
5. D509
6. E022
GURU NANAK ENGGWORKS
7. G016
INSTRUMENTATIONLTD. (PALGHAT)
8. I172
MICRO PRECISION PRODUCTS PVT LTD
9. M010
4
Page 596 of 704

A842-PDE-85-41-VL-16041-41 Rev 0
PDPP-BPCL-MR
MINCO (INDIA) PVT LTD (GEN. INST.)
10. M045
PETROL VALVES SRL
11. P514
PIETRO FIORENTINI SPA
12. P538
STAR-MECH CONTROLS (INDIA) PVT LTD
13. S286
TMTECNOMATIC SPA
14. T516
THERMOWELLS – 15HD
1. 1 A206 ALTOP INDUSTRIES LTD.
2. 2 A682 ABB AUTOMATION LTD
3. 3 D004 DETRIV INSTRUMENTATION & ELECTRONICS LTD
4. 4 D677 DAILY THERMETRICS CORPORATION
5. G192 GOA INSTRUMENTS INDUSTRIES PVT. LTD.
6. 5 G622 GAYESCO LLC
7. 6 P190 PYRO-ELECTRIC INSTRUMENTS GOA PVT LTD
8. 7 T232 TECHNOINSTRUMENTS
9. 8 T095 TEMP-TECH
10. 9 T146 TEMPSENS INSTRUMENTS INDIA PVT LTD
11. 1 T241 THERMAL INSTRUMENT (I) P LTD (GEN.INST.)

0
12. 1 T514 THERMO ELECTRIC CO. INC.
1
13. 1 T705 THERMO-COUPLE PRODUCTS CO
2
14. 1 T734 THERMO-ELECTRAB.V
3
15. 1 T516 TMTECNOMATIC SPA
4
16. 1 W589 WIKA ALEXANDERWIEGAND & CO GMBH
5
PRESSURE GAUGES -15KA

1 A053
2 A362
3 B696
4 B561
5 B213
BUDENBERG GAUGE CO. LTD
6 B618
7 G115
8 H081
H.GURUINDUSTRIES
9 H099
MANOMETER (INDIA) PVT. LTD.
10 M029
11 W061
12 W064
13 W589

4
Page 597 of 704

A842-PDE-85-41-VL-16041-41 Rev 0
PDPP-BPCL-MR
TEMPERATURE GAUGES – 15LA
1 A053
2 A362
3 B213
4 B561
5 B696
6 G115
GOA INSTRUMENTS INDUSTRIES PVT. LTD.
7 G192
8 H081
H.GURUINDUSTRIES
9 H099
10 W061
11 W064
12 W589
VARIABLE AREA FLOW METERS – 15MB

CHEMTROLS INDUSTRIES LTD
1. 3625
ALFLOW GLASS EQUIPMENTS
2. A172
ASA SPA
3. A623
ABB AUTOMATION PRODUCTS GMBH
4. A682A
BROOKSINSTRUMENT
5. B510
6. E022
HEINRICHSMESSTECHNIK GMBH
7. H626
INSTRUMENTATION ENGINEERS PVT. LTD.
8. I030
KROHNE MARSHALL PVT. LTD
9. K105
KROHNE MESSTECHNIK GMBH & CO KG
10. K582
PLACKA INSTRUMENTS INDIA P LTD
11. P293
ROTA YOKOGAWA GMBH & CO. KG
12. R515
TOKYO KEISO CO LTD
13. T530
YOKOGAWA INDIA LIMITED
14. Y006
GAUGE GLASSES AND COCKS – 15OA

3638 GAUGES BOURDON (I) PVT LTD (GEN. INST)
1. 1
B110 BLISS ANAND PVT LTD
2.
C201 CHEMTROLS SAMIL (INDIA) PVT LTD
3. 2
C716 CESARE BONNETTI S.P.A.
4. 3
J543 JERGUSON GAUGE & VALVE
5. 4
K637 KLINGER SPA
6. 5
L009 LEVCON INSTRUMENTS PVT LTD
7. 6
N141 NISAN SCIENTIFIC PROCESS EQUIP. P LTD
8.
N520 NIHON KLINGAGE CO LTD
9. 7
P017 PRATOLINA INSTRUMENTS PVT LTD
10. 8
4
Page 598 of 704

A842-PDE-85-41-VL-16041-41 Rev 0
PDPP-BPCL-MR
P239 PUNE TECHTROL PVT LTD
11. 9
S036 SIGMA INSTRUMENTS CO
12. 1
0
SPECIAL LEVEL INSTRUMENTS – GUIDED WAVE RADAR -15OG

A759 ABB INC (FORMLY K622)
1
2
E232 ENDRESS+HAUSER (I) AUTO. INSTRL. PVT. LTD.
3
4
K582 KROHNE MESSTECHNIK GMBH & CO KG
5
L562 L & J TECHNOLOGIES
6
M508 MAGNETROL INTERNATIONAL N.V
7
V518 VEGA GRIESHABER KG
8
FIELD INSTRUMENTS – 15RD

3615 ENDRESS + HAUSER WETZER INDIA PVT LTD
1.
A200 ABB INDIA LTD (BANGALORE)
2.
A682A ABB AUTOMATION PRODUCTS GMBH
3.
4.
E623 EMERSON PROCES MGMT ASIA PACIFIC PTE LTD
5.
E641 ENDRESS+HAUSERWETZER GMBH+ CO.KG
6.
7.
F644 FUJI ELECTRIC SYSTEMS CO. LTD
8.
H150 HONEYWELL AUTOMATION INDIA LTD.
9.
H621 HONEYWELL INC.
10.
I177 INVENSYS INDIA PRIVATE LIMITED
11.
Y006 YOKOGAWA INDIA LIMITED
12.
Y501 YOKOGAWA ELECTRIC CORPORATION
13.
MOTOR-INDUCTION-M.V (FLAME PROOF) – 13JF

1 B048 BHARAT BIJLEE LIMITED
2 C010 CROMPTON GREAVES LTD.
3 K005 KIRLOSKAR ELECTRIC CO LTD
4 L065 LAXMI HYDRAULICS PVT LTD
5 M282 MARATHON ELECTRIC MOTOR I LTD-FORM A350
MOTORS - IMPORTED -13JK
1. 1 27420 TOSHIBA MITSUBISHI ELEC. IND. SYS. CORP.
2. A661 ASEA BROWN BOVERY LTD (ABB LTD)
3. 2 A717 NIDEC ASI SPA
4. 3 C736 CEMP SRL

4
Page 599 of 704

A842-PDE-85-41-VL-16041-41 Rev 0
PDPP-BPCL-MR
5. 4 C730 GE ENERGY POWER CONVERSION FRANCE SAS
6. 4 G632 GENERAL ELECTRIC CANADA
7. 5 H510 HITACHI LTD
8. 6 H641 HYUNDAI HEAVY INDUSTRIES CO. LTD
9. 7 J511 JEUMONT SA/ FRAMATONE ANP
10. 8 L603 LLOYD DYNAMOWERKE GMBH & CO. KG
11. 9 L575 LOHER GMBH
12. 1 S524 SIEMENSAG

1
13. 1 T597 TOSHIBA CORPORATION
2
14. 1 W598 WEG EQUIPAMENTOS ELECTRICOS S.A.
3
15. 1 W598A WEGEURO-INDUSTRIA ELECTRICA S.A.
4
CABLE GLANDS ( HAZARDOUS AREA)– 14CA
1. 27421 CMP PRODUCTS LIMITED
2. B024 BALIGA LIGHTING EQUIPMENTS (P) LIMITED
3. C195 COMET BRASS PRODUCTS
4. C205 COMET INDUSTRIES
5. F024 FLEXPRO ELECTRICALS PVT LTD
6. F036 FLAMEPROOF EQUIPMENTS PVT.LTD
7. F141 FCG POWER INDUSTRIES PVT LTD
8. F165 FCG FLAMPROOF CONTROL GEARS P. LTD(C-157
9. K173 KAYSONS TECHNO EQUIPMENT P LTD.
10. S158 SUDHIR SWITCHGEARS PVT LTD
11. S375 STANDARD METAL INDUSTRIES
GENERAL NOTES
1.0 CONTRACTOR shall necessarily procure all the material / equipment forming permanent part of the
unit / plant from OWNER / PMC approved vendors only. This shall include sub-ordered items /
components also. The “Approved Vendors” shall be item specific.
2.0 OWNER / PMC approved vendor list for the various items is enclosed in this section.
3.0 CONTRACTOR may procure material from any of OWNER / PMC approved vendors. However,
current validity, holiday status and range of approval as per EIL enlistment letter, workload,
stability and solvency need to be verified by the CONTRACTOR with vendor before placement of
order. CONTRACTOR is also required to ensure that equipment qualification criteria, specified
elsewhere in the bid document, are also simultaneously met.
4.0 Vendors on OWNER / PMC holiday list shall not be considered for ordering. CONTRACTOR shall
comply with this requirement without any time or cost implication to the OWNER. If a vendor is put
on OWNER / PMC’s holiday list subsequent to CONTRACTOR placing an order, it shall be
CONTRACTOR’s responsibility to ensure quality work and timely supply from the vendor.
5.0 For items not covered in the above list, the CONTRACTOR shall approach OWNER/PMC for that
list or the vendors list shall be approved by OWNER / PMC prior to placement of order by
4
Page 600 of 704

A842-PDE-85-41-VL-16041-41 Rev 0
PDPP-BPCL-MR
CONTRACTOR. CONTRACTOR shall list down the proposed suppliers / vendors for such items
and submit the same for OWNER / PMC’s review / approval along with necessary documents /
credentials. “Approval status” documents / credentials to be furnished by the vendors in such
cases shall solely be the responsibility of the CONTRACTOR. OWNER / PMC’s decision on
above shall be final and non negotiable. Non –acceptance of a particular proposed vendor due to
any reasons whatsoever shall not be a cause of schedule and cost implication.
6.0 CONTRACTOR shall make an independent assessment of capability of all the vendors for timely
deliveries of material/ equipment. Any delays in deliveries by vendor(s) shall not be a cause of
schedule and cost implication.
7.0 At any stage of the project, if it comes to the notice of OWNER / PMC that CONTRACTOR has
procured material / equipment, intentionally or unintentionally whatsoever, from an unapproved
vendor and/or items not falling in approved range of vendor(s), the same shall be rejected fortwith
and CONTRACTOR shall be liable to replace such material / plant / machinery without any
schedule and cost implication to the OWNER.
8.0 List of vendors appearing anywhere else in the contract document in case of duplication of the
items at two or more places shall not be considered by CONTRACTOR and shall be superseded
by the vendor list enclosed herewith.
9.0 It is understood that should the name of vendor be changed due to change in their company or
corporate share holding. OWNER may accept such vendors under its new name with prior
approval.
Any such approval shall however, not absolve the CONTRACTOR from any of his obligations
under the contract; neither shall any such approval signify nominations or instruction to use such a
vendor. All approved vendors are deemed to have been freely chosen by the CONTRACTOR at
his own risk.
10.0 The approved vendors list for fabricated equipment (Vessels, Column, Heat Exchangers, Ejectors
etc.) is for fabrication alone. Where mechanical design of the equipment is included in
CONTRACTORS’S scope, CONTRACTOR shall either himself or through his Detailed
Engineering sub-contractor be responsible for designing and obtaining approval/ review of
Mechanical design calculations as per codes/specifications specified elsewhere in the Bid/
Contractor document from OWNER / PMC.

4
Page 601 of 704

7 Code -
16 Material for Mixing BUOH / PTSA Item No. V-405
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 650
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
Page 602 of 704

7 Code -
16 Material for Mixing 2EHOH / PTSA Item No. V-505
23 Mfr. -
26 No. of Stage 1
27 Diameter mm 450
28 No. of Blade 3
29 Speed rpm @
32 Dimension mm -
35 Diameter mm -
39 Sealing Fluid -
41 Cooling Water
46 MATERIAL
51 ACCESSORIES
56 PAINTING Type @
70
Page 603 of 704

11 Fluid Name P - -
14 o
16 o
Temp. C 65 - -
36 Leg,Saddle - - -
37
38 REMARKS
39
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
64
65
66
67
68
69
70
Page 604 of 704

2
3 Job No. E029636001
5
6
7
8
CONFIDENTIAL
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54 NOZZLE LIST
61 N6(*3) 2" 1 #150 SO-RF LN Inlet
63 N8~9 2" 2 #150 SO-RF MXA Inlet
67 V1 4" 1 #150 SO-RF VENT
68 V2(*3) 2" 1 #150 SO-RF VENT
69 D1~2 2" 2 #150 SO-RF DRAIN
70
Page 605 of 704

2
3 Job No. E029636001
5
6
7
8
CONFIDENTIAL
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
Page 606 of 704

11 Fluid Name P - -
16 Temp. °C 65 - -
26 ( ) Agitator
37
38 REMARKS
39
43
44
45
46
47
48
49
50
51
52
53
54
55
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11 Fluid Name P - -
16 Temp. °C 65 - -
26 ( ) Agitator
36 Leg,Saddle - - -
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42 V1 : sum of volume for pipes under 10m from grade connected from LZ-441, LZ-451 and E-443
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59 N4 2" 1 #150 SO-RF Liquid from V-471 D2 2" 1 #150 SO-RF DRAIN
61 N6 2" 1 #150 SO-RF Liquid from LZ-416 L1a,b 2" 2 #150 SO-RF LT
62 N7 2" 1 #150 SO-RF Liquid from E-443 L2 3" 1 #150 SO-RF LT
66 N11 (*2) 1 #150 SO-RF Min. Flow (From P-424A/B) MH1 24" 1 #150 SO-RF Manhole(w/Cover)
67 N12 (*2) 1 #150 SO-RF Min. Flow (From P-425A/B)
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11 Fluid Name P - -
14 o
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Temp. C 65 - -
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60 N5 (*2) 1 #150 SO-RF Min. Flow
61 N6 3" 1 #150 SO-RF Equalization MH1 24" 1 #150 SO-RF Manhole (w/Cover)
63 N8 3" 1 #150 SO-RF Gas from V-420
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65 V1 4" 1 #150 SO-RF VENT
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11 Fluid Name P - -
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57 N2 2" 1 #150 SO-RF Liquid to V-433
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62 D1 2" 1 #150 SO-RF DRAIN
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11 Fluid Name P - -
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Temp. C 65 - -
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61 N6~7 2" 2 #150 SO-RF MXA Inlet
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11 Fluid Name P - -
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42 Case BA HA
44 Operating Temp. °C 31 37
46 V1 : sum of volume for pipes under 10m grade connected from LZ-541, LZ-551 and E-543.
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60 N5 2" 1 #150 SO-RF Liquid from V-571 L1a,b 2" 2 #150 SO-RF LT
62 N7 2" 1 #150 SO-RF Liquid from LZ-516 L3 3" 1 #150 SO-RF LT
64 N9 2" 1 #150 SO-RF Liquid from V-541 G2a,b 2" 2 #150 SO-RF LG
65 N10 2" 1 #150 SO-RF Liquid to P-524
66 N11 2" 1 #150 SO-RF Liquid to P-525A/B MH1 24" 1 #150 SO-RF Manhole(w/Cover)
67 N12 (*2) 1 #150 SO-RF Min. Flow
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Page 629 of 704
Page 630 of 704
CHAPTER-5
CONFIDENTIAL
CLIENT: Bharat Petroleum Corporation Limited

PROJECT NAME: PDP Project
JOB No. E029636001 PREPARED BY H.Kawasaki
DATE: 17 Jan. 2016 CHECKED BY M.Matsuyama
SCALE: NONE APPROVED BY J.Takahashi
1 11 Mar. 2016 Revised H.K. M.M. J.T. DOC. No. PDPP-SDR-0001 REV. 1
No. DATE DESCRIPTION PRED CHKD APVD
REVISION
Page 631 of 704

REVISION 1
11 Mar. 2016
CONTENTS
5.1 COMMON NOTICE………………………………………………………………… 4
5.1.1 General ……………………………………………………………………… 4
5.1.2 Distinctive Features of AA/AE Process …………………………………… 4

5.1.2.2 Odor
5.1.3 Analysis ……………………………………………………………………… 4
5.2 DESIGN REQUIREMENT FROM PROCESS FEATURES…………………….. 5
5.2.1 General ……………………………………………………………………… 5
5.2.2 Equipment ……………………………………………………………………… 5

5.2.2.1 General
5.2.2.2 Reactor
5.2.2.3 Column
5.2.2.5 Drum
5.2.2.6 Tank
5.2.2.7 Pump
5.2.3 Piping …………………………………………………………………………… 11
5.2.4 Insulation and Tracing ……………………………………………………… 13

5.2.4.1 General
5.2.5 Civil …………………………………………………………………………… 16
5.2.6 Vendor List ……………………………………………………………………… 18

5.3 CONSIDERATIONS FOR DETAILED ENGINEERING………………………… 19
5.3.1 General ……………………………………………………………………… 19
5.3.2 Project Design Basis ……………………………………………………… 19
5.3.3 Battery Limit Conditions ……………………………………………………… 19
5.3.4 Piping & Instrument Diagram (P&ID) ………………………………………… 19
Page 2 of 25
Page 632 of 704

REVISION 1
11 Mar. 2016
5.3.4.1 Line Size

5.3.4.2 Insulation
5.3.5 General Plot Plan and Equipment Plot Plan ……………………………… 21
5.3.6 Hazardous Area Classification ……………………………………………… 21
5.3.7 Equipment ……………………………………………………………………… 21

5.3.7.1 General
5.3.7.2 Column
5.3.7.4 Tank
5.3.7.5 Pump
5.3.7.6 Vacuum System
5.3.7.8 Hoist
5.3.8 Piping …………………………………………………………………………… 23
5.3.9 Instrument ……………………………………………………………………… 24
5.3.10 Electrical ……………………………………………………………………… 24
5.3.11 Civil …………………………………………………………………………… 24
5.3.12 Others …………………………………………………………………………… 24
Page 3 of 25
Page 633 of 704

REVISION 1
11 Mar. 2016
5.1 COMMON NOTICE
5.1.1 General
This document provides the information to achieve safe and stable operation of
Acrylate plant and shall be referred / accommodated in detailed engineering.
5.1.2 Distinctive Features of AE Process

AE process has following two distinctive features which are caused by the
handling material’s properties especially for Acrylic Acid and Acrylate.
- Polymerization
- Odor
Hence, AE PLANT shall be designed strictly to avoid occurrence of these
phenomena.
The polymerization of Acrylic Acid and Acrylate causes blockage in the equipment
and piping. To avoid the polymerization, countermeasures shown as below shall
be taken into account for the process equipment and piping which have possibility
to make polymerization.
- Stagnation of liquid shall be minimized
- Condensation shall be avoided
- Inhibitors and air shall be provided adequately to process liquid
- Contamination of foreign objects causing polymerization shall be avoided
5.1.2.2 Odor
Since Acrylic Acid and Acrylate have foul odor, countermeasures against leakage
shall be incorporated in the plant design.
5.1.3 Analysis
Acrylic Acid and Acrylate are easy to polymerize. Analysis itself is a point of vital
importance for stable operation with good product and polymerization prevention,
as the analysis result leads to the correct operation conditions. Analytical
requirements and information, such as “Chemicals to analyze”, “Sampling point”,
“Frequency of sampling”, “Analytical method for raw materials or stream products”
and so on, are referred to “Chapter 22 ANALYSIS EQUIPMENT INFORMATION”.
Page 4 of 25
Page 634 of 704

REVISION 1
11 Mar. 2016
5.2 DESIGN REQUIREMENT FROM PROCESS FEATURES
5.2.1 General
This paragraph describes design requirement from process features which shall
be accommodated in detailed engineering stage.
5.2.2 Equipment
5.2.2.1 General
(1) For welding on internals and inner surfaces of equipment, double fillet welding or
full penetration and continuous butt welding shall be used without gaps. Socket
welds are not allowed for any of the equipment. After welding, be sure to
thoroughly finish and clean the welding lines to ensure that there are no adverse
affects on the product quality. All welding lines on the inner surfaces of equipment
must be smoothly finished by a grinder. Moreover, all welding lines that contact
the process fluid should be finished by acid-pickling and rinsed with fresh water
(e.g., boiler feed water) to remove particles and dust on the surfaces.
(2) All butt joints in the shell and head shall be welded by full penetration welding
without backing strip for process equipment. This requirement shall also apply to
the welded joints between the bodies and nozzles. Even a small gap may lead to
the accumulation of stagnant fluid and which may cause polymerization.
(3) Gap, crevice and/or groove on any joint of equipment shall not be provided to
prevent the stagnation of fluid has possibility of polymerization. For this purpose,
such as Bell-and-Spigot type joint or Tang-and-Groove flange shall not be applied.
Unless otherwise specified in PDP documents, Modified Male and Female type
flange (refer to Fig.-1 below) is preferable for equipment girth flanges or heat
exchanger channel head flanges with PTFE solid sheet gasket under the vacuum
condition.
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Page 635 of 704

REVISION 1
11 Mar. 2016
Fig.-1: Modified Male and Female Flange (Typical)
Gasket
Gasket
Equipment Girth Flange Heat Exchanger Channel Head Flange
(4) Dead space (the part which has possibility of fluid stagnation) in equipment shall
not be allowed to prevent the polymerization. Any design changes in detailed
engineering stage leading to make dead space shall not be allowed without
permission of LICENSOR. This change includes, for instance, the addition of
nozzles or the change of instrument type, etc.
(5) Weep holes for internals and devices on equipment shall be provided for complete
drainage.
5.2.2.2 Reactor
Esterification Reactor
To prevent polymerization in the reactor, spray of process liquid with inhibitors
shall be provided for all inner surfaces in gas phase zone of the reactor including
agitator installation nozzles. Actual arrangement of spray nozzle location shall be
designed and finalized in detailed engineering stage according to process
requirements specified on the reactor data sheet.
5.2.2.3 Column
(1) Column and internals shall be designed so as to remove polymers easily which
might be formed and accumulated inside. Following structures are applied to the
design in detailed engineering stage;
Minimum dead space
Welding with smooth finished structure for not removable internal parts
Bolt and nut tighten structure for removable internal parts
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Page 636 of 704

REVISION 1
11 Mar. 2016
(2) The levelness of trays and trough-type distributors shall be as shown below.
Inside Tower Diameter (mm) Max Levelness (mm),(Note 1)
1500 and under 2
from 1501 up to 2500 3
from 2501 up to 4000 4
from 4001 up to 5000 5
Note 1: “Levelness” refers to the difference between the highest point and the
lowest point out of at least 5 equivalently spread points.

(1) Shell & Tube Heat Exchanger
For all vertical heat exchangers, at least five (5) numbers’ tubes including those
weldment on upper side shall have no projection from tube sheet surface which is
shown in the right side [Type-B] of Fig.-2 below so as to perform good drainage
and minimize remaining liquid on the tube sheet. Tube arrangement with this
requirement is referred to EQUIPMENT DATA SHEET.
Fig.-2 Upper Tube End of Vertical Heat Exchanger
[ Type-A ] [ Type-B ]
Standard Type For 5 tubes
(2) Tank Cooler

In PDP, heat duties of tank coolers are estimated values as LICENSOR’s own
practice. These values shall be verified / modified according to radiation heat from
sun light, corresponding line length, final selected insulation thickness, heat input
from selected pump and etc. in detailed engineering stage. In case verified heat
duties are different from the values of PDP, heat duties of tank coolers shall be
modified in detailed engineering stage with notification to LICENSOR for the
review.
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Page 637 of 704

REVISION 1
11 Mar. 2016
5.2.2.5 Drum
Feed nozzles of liquid from overhead condenser and vent condenser to reflux
drum shall be connected to side of shell and lower than LLL (Low Liquid Level) as
shown in Fig.-3. Unless otherwise specified in P&ID or EQUIPMENT DATA
SHEET, inner pipe shall not be provided to prevent polymerization.
Fig.-3: Liquid Inlet Nozzle of Reflux Drum
From Condenser
Reflux Drum
5.2.2.6 Tank
(1) Tank roofs with butt welding or double fillet welding as shown in Fig.-4 below shall
be applied.
Fig.-4: Fillet Welding of Tank Roof
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Page 638 of 704

REVISION 1
11 Mar. 2016
(2) In order to eliminate dead space from tank inner surface, following construction
shown in Fig.-5 shall be applied.
Roof rafters shall be installed above roof (outside of tank)
Roof plate and shell plate shall be welded and smoothed
Fig.-5: Structure of Tank Roof
(3) Liquid circulation lines for the tank shall be installed to achieve good mixing for
minimizing temperature difference and inhibitors maldistribution at any part of tank
inside.
5.2.2.7 Pump
(1) Mechanical seal system
(a) Mechanical seal system for the process pumps might have leakage trouble by
polymerization of process liquid and crystallization of inhibitors in process liquid.
Hence, the most suitable mechanical seal system shall be selected for such fluid
properties. TANKEN SEAL SEIKO Co., Ltd. or John Crane are required as
mechanical seal Vendor because LICENSOR has many experiences applying
their mechanical seals for Acrylate process pumps.
(b) Following table gives reference specifications about mechanical seals for
process pumps in the existing and/or the past licensed plant.
Fluid BA / HA HE
Single Single
Type
Stationary Stationary
Seal face WC/WC WC/WC
Back metal Titan Hastelloy-C
Secondary seal O ring (Chemraz) Metal bellows
Page 9 of 25
Page 639 of 704

REVISION 1
11 Mar. 2016
(c) Mechanism of mechanical seal trouble on Acrylate process pumps is

presumed as follows.
Generated heat in-between mechanical seal faces of process pump induces
polymer film. This polymer film grows up and expands gap of seal faces. As the
result, leakage of process fluid from mechanical seal occurs.
To prevent this trouble, LICENSEE is recommended to request manufacturers
that following considerations to be taken into account to pump and mechanical
seal design.
For pump manufacturers:
To reduce the rotating speed of shaft (for reboiler pump and HE
decomposer bottom pump)
For mechanical seal manufacturers:
To reduce the seal balance ratio
To reduce the spring pressure
It is also good idea for realizing low-heat-generating mechanical seal system that
the limitation of seal balance and spring pressure is applied as minimum values as
possible in the heat generation calculation.
(2) Motor shall be connected directly with pump. Any kind of reducer, especially belt
reducer, shall not be installed to prevent belt trouble.
(3) Double fillet welding or full penetration welding shall be applied to nozzles'
connections of pump contacts with process fluid. Threaded connection with seal
welding and / or socket welding shall not be applied.
Page 10 of 25
Page 640 of 704

REVISION 1
11 Mar. 2016
5.2.3 Piping
(1) For welding of process piping, full penetration and continuous butt welding shall
be used. Socket welds are not allowed. Projection of weld metal into pipe bore
shall be minimized. Welding by GTAW (Gas Tungsten Arc Welding) for first layer
of all process piping is required except for the double welding. After welding, be
sure to thoroughly finish and clean the lines to ensure that there are no adverse
affects on the product quality.
Moreover, all piping welding lines of more than 20” diameter that contact the
process fluid shall be finished smoothly by a grinder and acid-pickling, and rinsed
with fresh water to remove particles and dust on the surface.
(2) Flange quantities in piping system shall be minimized for process line except for
flanges necessary for facilitate cleaning, maintenance and inspection.
(3) For process liquid lines, piping slopes shall be designed to ensure the complete
drainage of the process liquid from the drain nozzles. For gas and/or vapor lines,
“no pocket” piping layout shall be designed to ensure the complete drainage of
process liquid condensate from gas and/or vapor.
(4) “Min.” in the P&ID represents the constructive minimum distance requirement for
piping. The minimum distance construction of piping prevents polymerization by
reducing the stagnation in piping which might become a dead end. EPC
Contractor shall carefully comply with the minimum distance construction
specified on the P&ID in detailed engineering stage. As a best way, the fittings
such as flange (WN Flange or Stub-end for Lap joint) and tees should be welded
directly to construct minimum distance. When the adjustment of the distance
between them is necessary, the short pipe piece can be inserted under the above
mentioned purpose. In this case, the enough consideration for the practical
fabrication procedure shall be done. A target value of the “Min.” distance from
COP (Center of Pipe) to flange face is shown as follows.
Main Pipe Min. Distance
Size [mm]
1”or less Not more than 100
1_1/2”-4” Not more than 200
6” or above Not more than 300
(5) Liquid circulation lines shall be installed to pipe line between process area and
tank yard area for BA, HA and HE services to prevent blockage caused by
stagnation of liquid. Required specifications for these lines are as follows.
Page 11 of 25
Page 641 of 704

REVISION 1
11 Mar. 2016
Circulation Required Specifications

lines for
Fluid Velocity [m/s] Pipe Size
BA More than 0.02 ---
HA More than 0.06
HE More than 1.0 2” or above
(6) For polymerization service lines, length of bypass lines for FI and CV shall be
minimum distance to minimize stagnation of liquid. These lines will be shown as
Fig.-6-I in P&ID. But these lines shall be designed as Fig.-6-II and Fig.-6-III in
In addition to the above, for the services which has possibilities to include solid
particles, lines to / from FI and CV shall be branched / connected horizontally to
the main lines as similar arrangement as Fig.-6-II and Fig-6-III.
Fig.-6-I: Piping around Flow Meter and Control Valve in P&ID
Min. Min.
Min. Min. Min.
FI
Fig.-6-II: Piping around Area Flow Meter and Control Valve
Page 12 of 25
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REVISION 1
11 Mar. 2016
Fig.-6-III: Piping around Flow Meter (excluded area) and Control Valve
(7) All drain nozzles shall be straight line until drain valve.
(8) Length of forced circulation reboiler loop line and film evaporator bottom line shall
be shortened to reduce retention time because it affects process performance.
(9) Air Distributer for reboiler circulation line shown in P&ID shall be finalized in
detailed engineering stage referring to schematic drawing shown in “Chapter 16.8
PIPING PARTS INFORMATION”. Requirement (hole size and numbers) for each
nozzle is shown on P&ID.
(10) Strainer washing box for washing of strainer element shall be provided near
process pump strainer on Grade. Schematic drawing of strainer washing box are
referred to “Chapter 16.8 PIPING PARTS INFORMATION”. Actual location of
strainer washing box shall be decided in detailed engineering stage referring to
“Chapter 12. GENERAL PLOT PLAN” and “Chapter 13. EQUIPMENT PLOT
PLAN”.
5.2.4 Insulation and Tracing
5.2.4.1 General
This paragraph describes insulation and tracing requirements to prevent the
condensation of process fluids in equipment, piping, and instrument piping.
Installation required portion of tracing and/or insulation are shown in P&ID and/or
EQUIPMENT DATA SHEET individually in process requirement point of view.

Steam tracing shall be provided on process lines and equipment to prevent
polymer formation due to condensation of process vapor and to prevent increasing
of heavy end liquid viscosity. LLS or MS tracing systems shall be applied to the
process lines and equipment as they are specified in P&ID and EQUIPMENT
Page 13 of 25
Page 643 of 704

REVISION 1
11 Mar. 2016
DATA SHEET.
(a) Selection of LLS or MS tracing system
These systems are to prevent condensing of process vapor (e.g. in distillation
column shell or inside of overhead lines) and/or increasing HE viscosity. Selection
either LLS tracing system or MS tracing system are specified in P&ID and
EQUIPMENT DATA SHEET in accordance with operating temperature of process
fluid.
(b) Thermal insulation slip
Thermal insulation slip (referring to Fig.-7 bellow) shall be installed between tracer
and process line to avoid local heating of process line.
Fig.-7 Thermal insulation slip (For Reference)
Page 14 of 25
Page 644 of 704

REVISION 1
11 Mar. 2016

Followings are recommended specifications and information referring to
LICENSOR’s existing plant and/or past licensed plants. Detailed configuration of
tracing system shall be decided by EPC Contractor in detailed engineering stage.
(1) Tracing Line Specifications
Pipe Carbon steel NPS 1/2
Tube Copper or Stainless steel OD 10mm / ID 8mm
(2) Arrangement on process pipe
Pipe Parallel along with process pipe
Tube Spiral along with process pipe (refer to Fig.-8 below)
Fig.-8 Spiral Installation (For Reference)
(3) In general, NPS 1/2 carbon steel tracing pipe is applied for all tracing systems,
however only in case carbon steel pipe is not possible to install relatively tangled
portion such as around instruments equipment, OD 10mm / ID 8mm tube can be
used as alternative.
(4) Tracing line specifications (tracer size and quantities) with respect to each
process line size and length are shown in following tables as LICENSOR’s past
experiences. Required tracing line quantities shall be verified and determined
according to site conditions considering with actual selected insulation
specifications in detailed engineering stage.
(a) Steam Tracing
Steam Tracing
Process Line (NPS)
(LLS,MS)
Tracer size Quantity

Less than 2" NPS 1/2 2
3" to 8" NPS 1/2 4
10" to 16" NPS 1/2 6
18" to 28" NPS 1/2 8
30" or 36” NPS 1/2 10
38” to 44” NPS 1/2 12
44” to 50” NPS 1/2 14
More than 50” NPS 1/2 Pitch=200mm
Note: Length of steam tracer pipe should be less than 30m/loop.
Page 15 of 25
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REVISION 1
11 Mar. 2016
(5) Typical installation arrangement

Basically flow direction in tracer should be as follows.
Steam: Down flow
Typical installations for Steam tracing is referred to following diagrams (Fig.-9).
Fig.-9 Typical installation diagram for

Steam tracing (For Reference)
Steam Tracing
(6) Flanges and connections for tracers should be installed at the same place of
process lines’ flanges so as to facilitate piping / equipment maintenance. Also joint
of tracer is recommended to be placed outside of process line insulation.
5.2.5 Civil
Liquid Acrylic Acid (AA) and Solid or Solution of Para Toluene Sulfonic Acid
(PTSA) have corrosive property. Anticorrosive countermeasures for civil structure
are required to consider for the following places having chance of exposing to AA
or PTSA. (For example, Acid resistant concrete)
(a) Mandatory Place
Inside of WW Pit and Oil Pit
(b) Recommended Place
On the surfaces of concrete or civil structure around AA or PTSA handling
equipment (especially for pump base).
Inside of trench around AA or PTSA handling equipment
Corrosivities of AA and PTSA against structural materials are referred to following
table.
Page 16 of 25
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REVISION 1
11 Mar. 2016
Corrosivities of AA and PTSA (For Reference)

corrosivity
Water not
Solubility in Relative reinforced
Phase Name Formula pH absorptivity reinforce brick wood steel aluminum
Water humidity concrete
concrete
(%)
liquid acrylic acid CH2CHCOOH yes 1 to 2 - Yes strong medium medium weak strong weak
Pala toluene
liquid sulｆonic acid CH3C6H4SO3H yes 1 to 2 - yes strong strong medium medium strong strong
solution
Pala toluene
solid CH3C6H4SO3H yes 1 to 2 - yes strong strong medium medium strong strong
sulｆonic acid
Page 17 of 25
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REVISION 1
11 Mar. 2016
5.3 CONSIDERATIONS FOR DETAILED ENGINEERING
5.3.1 General
This paragraph describes considerations and/or study items shall be performed in
detailed engineering stage referring to PDP. In general, descriptions in this
paragraph are not strongly related to process requirements, therefore this
paragraph does not contain the descriptions listed in the Paragraph 5.2 above.
Any design changes related to process requirements specified in PDP shall be
informed to LICENSOR for the review and the approval in case the design
changes are executed in detailed engineering stage.
5.3.2 Project Design Basis

PROJECT DESIGN BASIS (“Chapter 1. PROJECT DESIGN BASIS”) is prepared
based on the latest information of this project. Some items might be updated, if
required.
5.3.3 Battery Limit Conditions

BATTERY LIMIT CONDITONS (shown in “Chapter 1. PROJECT DESIGN BASIS”)
is prepared based on the latest (and/or estimated) design results by LICENSOR.
Some items shall be reviewed / updated according to the information during
5.3.4 Piping & Instrument Diagram (P&ID)
5.3.4.1 Line Size

(1) All line sizes are specified on P&ID as estimated line sizes based on the estimated
piping route, it shall be verified and finalized based on the piping routing plan
during detailed engineering stage. However circulation lines between process
area and tank yard for HE services have limitations as process requirements
referring to “Section 5.2.3 (4)” hereinabove. These limitations shall be considered
in finalization of line size in detailed engineering stage.
(2) Size of pump minimum flow lines in P&ID are described as “XX”. They shall be
finalized based on pump vendor information.
5.3.4.2 Insulation
Insulation thickness is specified in Line List based on “Chapter 2. DESIGN
CRITERIA”, it shall be verified and finalized in detailed engineering stage
according to selected insulation material and/or LICENSEE’s standards.
Page 19 of 25
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REVISION 1
11 Mar. 2016

(1) Safety valve design is executed based on API STD 520 & 521 in PDP referring to
“Chapter.3 DESIGN CRITERIA”. It shall be verified / finalized in accordance with
the local regulations and/or LICENSEE’s standards.
(2) Number of safety valve is specified on P&ID based on minute of meeting of Kick
off meeting. It should be modified based on local regulations (necessity of spare
safety valve, upstream/downstream block valve, bypass valve, mechanical
interlock etc.), if required.

Breather valve design for atmospheric tank is executed based on API STD 2000
referring to “Chapter.3 DESIGN CRITERIA”. It shall be verified / finalized in
accordance with applicable laws, codes, local regulations, and/or LICENSEE’s
standards in the detailed engineering stage.

Spectacle blinds’ position described in P&ID is based on the view point of
operability and maintainability. It should be reviewed / modified in detailed
engineering stage according to the requests by laws, codes and regulations, if
necessary. However, some of spectacle blinds are for prevention of fluids
contamination. In case spectacle blind needs to be removed from original position
described in P&ID of PDP, LICENSEE shall notify this intention to LICENSOR for
the review.

In detailed engineering stage, spill back line for vacuum system shall be designed
carefully because available pressure drop of this line is restricted. Followings are
design guidelines.
Size of spill back line is to be reviewed and finalized according to actual piping
routing plan so that maximum flow rate can be passed through this line within
available pressure drop. Maximum flow rate and available pressure drop are
referred to the corresponding vacuum system DATA SHEET in PDP. And
available pressure drop is considered as “Delivery pressure – Suction pressure”
referring to the each data specified in the DATA SHEET.

Restriction orifice differential pressure is based on the estimated value. It shall be
verified / finalized in detailed engineering stage.
Page 20 of 25
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REVISION 1
11 Mar. 2016
5.3.5 General Plot Plan and Equipment Plot Plan

(1) Plot plan and elevation is prepared as conceptual layout and process requirement
is shown in Chapter 12. GENERAL PLOT PLAN” and “Chapter 13. EQUIPMENT
PLOT PLAN”. It shall be modified, updated and finalized based on the actual
allowable plot area and the final equipment sizes. In case plot plan and elevation
is to be modified, LICENSEE shall inform this intention to LICENSOR for the
review.
(2) Tie-in point location in PDP is recommended and estimated location by
LICENSOR. Location shall be reviewed and finalized in detailed engineering
stage according to LICENSEE’s actual needs.
(3) Catwalks, operation deck, platform and spiral stairs for tanks are provided in
consideration of operability and maintainability. However these can be modified in
accordance with LICENSEE’s standards and/or experience.
5.3.6 Hazardous Area Classification

This drawing is prepared based on API RP 505. Any requirements other than the
above such as laws, codes and regulations shall be verified / modified in detailed
engineering stage.
5.3.7 Equipment
5.3.7.1 General
In general, process requirements are specified in EQUIPMENT DATA SHEET of
PDP. However, specifications (such as dimension of parts, nozzle position, nozzle
orientation, etc.) other than specified in EQUIPMENT DATA SHEET shall be
decided in detailed engineering stage considering with its purpose or operability,
maintainability and etc. In case these specifications are to be decided by
LICENSEE or EPC Contractor, its relative position shall be kept as process
requirements described in the EQUIPMENT DATA SHEET of PDP.
5.3.7.2 Column
(1) Column diameter is specified as preliminary sizes, it shall be verified based on the
process requirements described in data sheet and shall be modified accordingly, if
necessary.
(2) Feed inlet nozzles and reboiler return nozzles shall be verified based on the
process requirements which is described in data sheet and shall be modified
based on vendor’s information in detailed engineering stage, if necessary.
(3) Tray plate shall be designed that tray plate is tighten with bolt, nut and washers so
as to set and remove easily.
Page 21 of 25
Page 650 of 704

REVISION 1
11 Mar. 2016

(1) Thermal rating design of all shell & tube type heat exchangers are carried out by
LICENSOR, no more additional thermal design is required.
(2) Any modification in accordance with LICENSEE’s standards shall be executed in
detailed engineering stage, if necessary. However, in case modifications will be
carried out, it shall be done keeping the process requirements described in the
data sheet in PDP.
5.3.7.4 Tank
Design of “Air Foam Chambers” for all required tanks shall be executed in detailed
engineering stage.
5.3.7.5 Pump
(1) Pump head specified on data sheet is calculated based on the estimated piping
length and number of fittings etc., it shall be verified and finalized based on the
piping routing plan in detailed engineering stage. Design pressure for equipment
and instrument shall be modified according as final shut off pressure in detailed
engineering stage.
(2) Motor rated output specified on data sheet is preliminary figure, it shall be verified
and finalized based on the vendor’s information.
(3) Pump capacities (Minimum, Normal and Design) specified on data sheet do not
include any minimum flow rate, it shall be requested pump vendor to specify the
required minimum flow rate.
(4) Estimated system and size of cooling water lines and flushing lines for pump were
specified on P&ID. It shall be verified / finalized in detailed engineering stage.
5.3.7.6 Package Unit

In general, any description in PDP documents (such as data sheet, PFD, P&ID
and so on) are prepared in the view point of process requirements by LICENSOR.
Modifications for mechanical configurations and pipings etc. according to vendor’s
information, LICENSEE’s standards and/or good engineering practice by any
parties shall be accommodated in detailed engineering stage. However, in case
modifications will be carried out, it shall be done keeping the process
requirements described in the data sheet in PDP.
Minimum flow rates for desuperheater are based on PDE-400 operation assuming
Page 22 of 25
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REVISION 1
11 Mar. 2016
5.3.7.8 Hoist
Hoist is recommended to install in operability point of view. EPC Contractor shall
finalize specifications of hoist considering with shape of inhibitor paper bag,
Vendor’s information and final plot plan in detailed engineering stage.
Recommended location to install hoist is;
Above Inhibitor / PTSA drum (for lifting up of inhibitor paper bag)

Any spare parts for equipment are not specified in data sheet. LICENSOR’s
recommended spare parts for continuous operation are shown below.
Construction spare parts and operation spare parts other than shown below shall
be decided by LICENSEE in accordance with LICENSEE’s standards or the
selected vendor’s information.
(a) Film Evaporator Wipers
Full set spare of film evaporator wipers for PDE-E-554 should be prepared for
replacement.
(b) Mechanical Seal Units
100% complete set of spare parts for mechanical seal units for all process
pumps with mechanical seal shall be prepared for replacement.
(c) Strainer Elements
Strainer elements for special bucket type should be prepared for replacement.
Recommended amount is one for each size.
5.3.8 Piping
(1) In general, mechanical design of piping shall be performed in accordance with
ASME B31.3.
(2) In detailed engineering stage, thermal stress analysis of piping should be
conducted which operating temperature shown in line list exceeds 100 deg.C. For
piping which the results of the analysis show excess in allowable stress or
moment and considered to have detrimental distortion, the piping systems shall
be designed so that they have adequate flexibility by installing expansion joints or
reinforcing equipment nozzles, etc.
(3) If low point drain nozzles other than specified in P&ID of PDP are found necessary
to install according to actual piping routing plan in detailed engineering stage, it
shall be added in consideration of complete drainage from the pipelines after the
shutdown operation.
(4) Equipotential bonding shall be provided considering the requirement of local
regulations, laws or LICENSEE’s standards in detailed engineering stage.
Page 23 of 25
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REVISION 1
11 Mar. 2016
(5) Details of Air Regulator for process vent gas line shown in P&ID shall be finalized
in detailed engineering stage referring to schematic drawing shown in “Chapter
16.8 PIPING PARTS INFORMATION”.
5.3.9 Instrument
(1) All pressure data on pump discharge line are specified based on estimated pump
head calculation, it shall be reviewed and finalized accordingly based on the
piping routing plan in detailed engineering stage.
(2) Elevation (static head) is not considered for the pressure data in the Instrument
List. The pressure data shall be finalized in detailed engineering stage considering
with its installed elevation.
(3) Minimum flow rates for PDE-700 are based on PDE-400 operation assuming
5.3.10 Electrical
Motor List
All motor outputs mentioned on motor list is estimated figures, it shall be reviewed
and finalized based on vendor’s information in detailed engineering stage.
5.3.11 Civil
(1) Base Level is assumed as EL +/- 0m and set as floor level of Process Area, Pipe
Rack and Intermediate Tank Yard Area in PDP. Actual altitude of each level shall
be decided in detailed engineering stage.
(2) Anti-vibration design for structure and for foundation of rotating equipment shall be
provided in accordance with the selected vendor’s information (dynamic load etc.).
5.3.12 Others
(1) Firefighting system
Firefighting system (including air foam chamber for tanks) shall be designed by
EPC Contractor in detailed engineering stage in accordance with applicable laws,
codes, local regulations, and/or LICENSEE’s standards.
Page 24 of 25
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REVISION 1
11 Mar. 2016
(2) Hose Station, Eye Washer and Safety Shower

(a) Numbers and locations of hose station, eye washer and safety shower shall be
designed in detailed engineering stage considering with personnel safety,
operability, LICENSEE’s standards and so on. LICENSOR’s recommended
numbers and locations are shown below as each type described in P&ID.
(I) Type A (For Process Yard and Intermediate Tank Yard)

(i) Grade (Process Yard)
Hose length should be 10m and Hose Station should be put in every 15 ~ 20
m.
(ii) Above 1st Floor
(iii) Intermediate Tank Yard
(II) Type B (For Column)

Hose Station should be put in every plat form installed man hole.
(b) Eye washer and safety shower should be installed nearby sample box and
strainer washing box for operator’s safety as recommendation of LICENSOR.
Refer to Attachment 1.
Page 25 of 25
Page 654 of 704

LIST OF APPLICABLE DOCUMENT No.
SPECIFICATIONS & A842-80-43-LL-6041/0041
STANDARDS Rev. 0
Page 1 of 4
LIST OF APPLICABLE
SPECIFICATIONS & STANDARDS
0 12.04.17 ISSUED FOR PURCHASE SA PVSS PVSS

Date Purpose Approved by
No by by
Page 655 of 704

STANDARDS Rev. 0
Page 2 of 4
LIST OF APPLICABLE SPECIFICATIONS

[X] indicates applicability
Title Doc No.
[X] General specification for pressure 6-12-0001
Vessels
[X] Supplementary specification for carbon 6-12-0002
steel vessels
[] Supplementary specification for low 6-12-0003

alloy steel vessels
[X] Supplementary specification for 6-12-0006
austenitic stainless steel vessels
[] Supplementary specification for clad 6-12-0007
vessels
[] Supplementary specification for 6-12-0008
3½ % Ni steel vessels
[X] Standard specification for boiler quality 6-12-0011
carbon steel plates
[X] Standard specification for weldable 6-12-0014
structural quality steel plates for
storage tanks and vessels
[] Standard specification for clad plates 6-12-0015
[] Standard specification for
3½%Ni steel plates for pressure 6-12-0016
vessels
[] Standard specification for 1%Cr-½%Mo 6-12-0017
& 11/4%Cr-½%Mo steel plates
[] Standard specification for 2.25-Cr-1 6-12-0018
Mo steel plates
[X] Standard specification for stainless 6-12-0020
steel plates
[X] Installation procedure for trays and 6-14-0003

tower internals
[] Standard specification for review of site

installation of column internals 6-14-0016
[X] General specification for wire mesh 6-14-0017

demister
[] Packing, marking and shipping 6-14-0009
specifications for tray and tower
internals
[X] Standard Specification for Positive 6-81-0001

Material Identification (PMI) at Vendor’s
works
[X] Inspection & Test Plan for Pressure 6-81-0011
Vessels/Columns carbon steel
Page 656 of 704

STANDARDS Rev. 0
Page 3 of 4
Title Doc No.

[X] Inspection & Test Plan for Stainless 6-81-0014
Steel Pressure Vessels/Columns
Reactors
[X] Inspection & test plan for wire mesh 6-81-0060
demisters
[] Inspection & test plan for weld overlay 6-81-0130
[X] Standard Specification For Health, 6-82-0001

Safety & Environment (HSE)
Management At Construction Sites
[X] Specification for quality management 6-78-0001
system requirements from bidders
[X] Specification for documentation 6-78-0003
requirements from suppliers
[X] Job specification for surface A842-000-79-41-PLS-01
preparation and protective coating
[X] Standard specification for mechanical 6-26-0001

agitators
[X] Detail of Vacuum Stiffener for insulated

A842-PDE-80-43-SK-0003
equipments
LIST OF APPLICABLE STANDARDS

[X] indicates applicability
Title Doc No.
[X] Vessel tolerances 7-12-0001
[X] Support for horizontal vessel 7-12-0002
[] Wooden pillows for saddle support 7-12-0003
[X] Skirt base details 7-12-0004
[X] Skirt opening details 7-12-0005
[X] Angle leg support 7-12-0006
[X] Pipe leg support 7-12-0007
[X] Bracket support for vertical vessel 7-12-0008
[X] Manhole with hinged cover 7-12-0009
[X] Manhole with davit 7-12-0010
[X] Ladder rungs for manhole/ demister 7-12-0011
[] Retaining plate 7-12-0012
[X] Nozzle reinforcement and projection 7-12-0013
[] Pad nozzles for vessels 7-12-0014
[X] Standard bolt hole orientation 7-12-0015
[] Alloy liner details 7-12-0016
Page 657 of 704

STANDARDS Rev. 0
Page 4 of 4
Title Doc No.

[X] Sight glasses for pressure vessels 7-12-0017
[X] Internal flanges 7-12-0018
[X] Vortex breakers 7-12-0019
[] Inlet deflector baffle 7-12-0020
[] Support ring and bolting bar 7-12-0021
[] Support ring sizes for packed towers 7-12-0022
internals
[X] Pipe davit 7-12-0023
[X] Lifting lug top head type 7-12-0024
[X] Fire proofing and insulation supports 7-12-0025
[X] Earthing lug 7-12-0026
[X] Name plate 7-12-0027
[X] Manufacturer name plate 7-12-0028
[X] Bracket for name plate 7-12-0029
[X] Name plate for small equipment 7-12-0030
[] Details of forged nozzles 7-12-0031
[X] Supports for internal feed pipe 7-12-0032
[X] Hot insulation supports for horizontal 7-12-0033
vessel
[] Pipe davit support detail for cold 7-12-0034
insulated vessels
[X] Typical details of wire mesh demister 7-12-0036
and its supports
[] SR nozzle neck 7-12-0037
[X] Allowable nozzle loads 7-12-0038
Page 658 of 704

DOCUMENT No.
SCOPE OF SUPPLY A842-80-43-SS-6041/0041
Rev. 0
Page 1 of 6
SCOPE OF SUPPLY

Date Purpose
No by by by
Page 659 of 704

DOCUMENT No.
Rev. 0
Page 2 of 6
SCOPE OF SUPPLY
[X] Indicates applicability
The following materials will be supplied by
1. Owner
1.1 Boiler quality/low-alloy/stainless/clad steel plate conforming to specification

NIL for
[ ] Shell
[ ] Dished head/intermediate head/cone
[ ] Sump and sump head
[ ] Skirt
[ ] Manhole neck, nozzle neck 300 NB and above in carbon steel and 125 NB and
above in stainless steel
[ ] Renforcement pad
[ ] Wrapper plate
[ ] Plate type flange
[ ] Internal piping
[ ] Tray support ring/bolting bar/seal pan welded to the vessel
[ ] Pad for external attachment (directly welded to shell)
[ ] Insulation support
[ ] Lifting lugs
[ ] Baffle
[ ] Demister support
1.2 [ ] Forged flange/matching blind flange
[ ] Pipe for nozzle neck
[ ] Pipe fitting
[ ] Gasket
1.3 [X] Foundation/anchor bolts
Page 660 of 704

DOCUMENT No.
Rev. 0
Page 3 of 6
[X] Platform and ladder
[X] Permanent instruments
[ ] Demister with grid & bolting
[X] Fire proofing and insulation
[X] Pump assembly with bolting
[ ] Agitator assembly with bolting
[ ] Tray/down comer/seal pan/chimney tray not welded to the equipment
[ ] Brick lining
[ ] Refractory lining
[ ] Spray nozzle/ Distributor Nozzles
[ ] Tower packing & associated internals including distributor, feed pipes, support grid /
plates, retaining grid / bed limiters, etc. associated with packing
[ ] Light and sight glass assembly
[ ] Thermowells
[ ] Refractory lining
[X] Temperature Element
2. VENDOR
2.1 Boiler quality carbon/low alloy/Stainless/Clad/monel steel plate conforming to specification

As indicated in engineering datasheet
[X] Shell
[X] Dished head /intermediate head/cone / toricone/Flat head
[X] Sump and sump head
[X] Skirt (Partly)
[X] Manhole neck, nozzle neck 300 NB and above in carbon steel and 125 NB and
above in stainless steel & 200 NB and above in clad steel
[X] Reinforcement pad/ Insert Plate
[X] Wrapper plate
Page 661 of 704

DOCUMENT No.
Rev. 0
Page 4 of 6
[X] Plate type flange
[X] Internal piping/distributor and its supports
[ ] Tray Support Ring/ Chimney tray support/ Packing support ring/ Bolting Bar/ Seal
Pan/ Tray Downcomer welded to the equipment
[X] Pad for external attachments
[X] Fire proofing and insulation supports
[X] Saddle support/bracket/leg support
[X] Lifting Lugs
[X] Internal baffles, vortex breaker, ladder rungs
[X] Demister support ring and beam
[X] Structural & Piping Clips
[X] Vacuum stiffening rings
[X] All welded internal and their support as required
[] Anchor for refractory lining
2.2 Structural steel section and plate conforming to IS: 226/IS: 2062 Gr.B / SA-283 Gr.C for
[ ] Shell
[ ] Internals
[X] Insulation support / fire proofing support on skirt (IS-2062 portion)
[ ] Flat cover
[ ] Manway flange/cover
[ ] Section for stiffeners
[X] Leg supports and base plate
[ ] Structural sections for platform, ladders, hand railing, grating etc as per SOR
attached with requisition
[X] Skirt (Partly) /anchor chair assembly/base plate/Saddle/Bracket support
[ ] Tailing lug and Stiffening Block/Beam in skirt portion
[X] Structural and piping clips welded on BQCS/SS pad
Page 662 of 704

DOCUMENT No.
Rev. 0
Page 5 of 6
2.3 [X] Forged flanges / matching blind flange wherever shown.
[X] Studs/bolts and nuts for manway / handholes / internal flanges / nozzles with blind
flange/shell flange, including jack bolts for manways, and shell flanges
[X] Gasket for manway/internal flange /shell flange/ nozzles shown with blind
flanges/companion flanges
[X] Welding consumables and gases
[X] Demisters with grid and bolting
[X] Wire Mesh
[X] Agitator assembly with ancillaries including assembly & disassembly tools for
mechanical seal and any special tools & tackles for agitator assembly
[X] Associated piping works, instrumentations works and electrical works for Agitators.
(Refer P&ID No. A842-79-41-PDE-11044, A842-79-41-PDE-11045, A842-79-41-
PDE-11046, A842-79-41-PDE-11084, A842-79-41-PDE-11085 & A842-79-41-PDE-
11086 for scope)
[ ] Pump assembly with bolting
[X] Internal piping and supports, Plate type flanges, pipe fittings
[X] Internal baffles, vortex breaker, ladder rungs
[X] All welded internal and their support as required
[X] Seamless nozzle necks 250 NB & below in Carbon Steel, 100NB & below in
Stainless Steel & 150 NB & below for weld overlayed nozzle
[ ] Spray nozzle
[ ] Internal packing
[X] Ladder rung for all items
[X] Light and sight glass assembly
[X] Davit/hinge assembly for manway / Shell Flange
[X] Pipe davit assembly for equipment
[X] Items covered in applicable EIL standards
[X] All other metallic and non-metallic parts, consumables and gases not covered under
1 and 2 but required to complete fabricated equipments including inspection, testing
and supply of equipments as per this requisition
Page 663 of 704

DOCUMENT No.
Rev. 0
Page 6 of 6
[X] Mandatory spares –10% of fasteners (min 2 nos. in each size) and two sets of
gaskets for each nozzle shown with blind/companion flange
[X] Commissioning spares –10% of fasteners (min 2 nos. in each size) and two sets of
gaskets for each nozzle shown with blind/companion flange
[] Mandatory spares (for demister) – refer Standard specification 6-14-0017
[] Commissioning spares (for demister) – refer Standard specification 6-14-0017
[X] Spares (for Agitator) –

a) 10% fasteners (minimum two numbers) and two sets of gaskets for each
flanged/ bolted connections for Agitator/motor assembly
b) 1 set of Wear parts for mechanical seal for each Item
c) 1 set of mechanical seal for each item
d) 1 set of Bearing for Gear reducer for each item
e) 1 set of Bearing for Agitator for each item
[X] Spares for Instruments as per A842-PDE-16-51-SP-6041
[X] Spares for Electrical as per A842-PDE-16-50-SP-6041
[X] Supply of Electrical items as per Job Spec Doc. No. A842-PDE-16-50-SP-6041
[X] Supply of all items related to instrumentation items Doc. No. A842-PDE-16-51-SP-
6041) for agitator assembly
[X] Instrument/ accessories required for sealing system
[X] Accessories for Agitators. (Refer PDS No. PDPP-DS-A405, PDPP-DS-A415, PDPP-
DS-A455, PDPP-DS-A505, PDPP-DS-A515 & PDPP-DS-A555 for scope)
[] LWN Nozzles
[] Design and supply of tailing lug
[] Supply of self reinforced nozzles
[] Templates for foundation for skirt supported vessels
[ ] Supply of all materials, fabrication of all platforms, ladders, cage ladders and other
structural works, supply, fabrication of hot dipped electro forged galvanized grating
and its installation as per Schedule of rates
[X] Supply & application of all primer (pre-erection) & finish painting of all equipments at
vendor’s works/shop as per Job specification A842-000-79-41-PLS-01
[ ] Match marking of structural members
[X] Hopper for item nos. PDPP-DS-V405, PDPP-DS-V415, PDPP-DS-V455, PDPP-DS-

V505, PDPP-DS-V515 & PDPP-DS-V555
Page 664 of 704

DOCUMENT No.
INSTRUCTIONS TO VENDOR A842-80-43-TR-6041/0041
Rev. 0
Page 1 of 13
INSTRUCTIONS TO VENDOR

Date Purpose
No by by by
Page 665 of 704

DOCUMENT No.
INSTRUCTIONS TO BIDDERS A842-80-43-TR-6041/0041
Rev. 0
Page 2 of 13
INSTRUCTIONS TO BIDDERS
(A) Bidding Instructions (Category-I MR)
1. Bidder to note that no correspondence shall be entered into or entertained after the bid
submission. Bids shall be evaluated based on the details submitted by the bidder. In
view of the same bidder in his own interest is advised not to submit any deviation.
2. Bidder shall furnish quotations only for those items/parts:

a. for which bidder is approved by EIL and
b. for which bidder can supply strictly as per Technical specifications
3. No technical details of any nature shall be included in the offer. If the offer contains any
technical deviations or clarifications or stipulates any unsolicited technical specifications
(even if in line with the MR requirements), the offer is liable for rejection.
4. The submission of prices by the bidder shall be construed to mean that he has
confirmed compliance with all technical specifications of the corresponding item(s).
(B) Bidders to note that a prebid meeting shall be held in which bidders can seek any
clarifications/confirmation if required. Bidder to ensure that this conference is attended
by both technical and commercial personnel of the Bidder who should have thoroughly
scrutinized the MR before hand so that all issues are finally resolved in this meeting.
Technical Instructions
1. The shape of dished end/toricone, profile of conical reducer, knuckle radius, cone angle
and overall height shall be as per engineering drawing. Minimum thickness of shell, cone
and dished end shall be achieved taking into account thinning and scaling etc.
2. Dished ends and hot formed pressure parts shall have 10% or 2mm (whichever is
higher) allowance for scaling and thinning, in order to achieve minimum thickness
specified on the drawing.
3. a. Wherever hot forming and subsequent heat treatment is involved, adopted

procedure shall not impair the mechanical properties of the material beyond the
limits specified in respective material specification.
b. For low temperature equipment and hot formed parts, number of production
coupons and the tests thereon shall be as per requisition.
4. Post weld heat treatment and all non destructive testing like radiography, ultrasonic
testing, magnetic particle/dye penetrant examination etc. shall be conducted as per
requisition.
5. Transportation of Vessels to site shall be in single piece.
Bidder’s scope also includes transportation of Agitator and Hopper to site.
Installation of Agitator and Hopper at site shall be done by Mechanical contractor

(not in bidder’s scope) under supervision of bidder and agitator sub-vendor.
6. Workmanship and materials, in Bidder's scope of supply, shall be guaranteed.
Page 666 of 704

DOCUMENT No.
Rev. 0
Page 3 of 13
7. Pickling and passivation of internal / external surfaces of stainless steel and internal /
external surface of SS internals shall be carried out as per ASTM A-380.
8. For IBR vessels complete design of equipment as per IBR, approval of drawings,
documents, stagewise inspection and final certification of the equipment by Inspectorate
of Boilers shall be included in Bidder’s scope.
9. For items which are to approved by PESO,Nagpur ,approval of drawings, documents,

stagewise inspection and final certification of the equipment by PESO shall be included
in Bidder’s scope and getting approval from PESO shall be sole responsibility of bidder.
10. The main equipment shall not be subcontracted, however the bought out items/
components can be sub-ordered or sub-contracted to EIL approved vendors/sub-
contractors only.
11. Demister shall be procured from EIL approved vendors only listed in annexure - I to this
specification.
12. Agitators shall be procured from EIL approved vendors only (listed in Annexure-II to this
document) based on their capability of enlistment with EIL.
13. Hoppers for Hastelloy metallurgy (item no. PDE-V-405 & PDE-V-505) shall be procured
from EIL approved vendors only (listed in Annexure-III to this document) based on their
capability of enlistment with EIL
14. Wherever vacuum stiffening rings are provided, same shall be used as insulation
supports also (refer sketch no. A842-PDE-80-43-SK-0003). Additional insulation
supports shall be EIL standard.
15. Vacuum stiffening rings shall not be welded to shell until all fouling with respect to piping
and structural cleats are resolved.
16. Fabricator to supply template for checking the orientation of anchor bolts on foundation
and to ensure matching of base plate that is drilled in advance. The schedule of supply
of template at site shall be 8 weeks from LOI.
17. Gaskets used for hydrotesting of equipment shall be of the same specification as service
gaskets and the fabricator shall supply new gaskets for manholes and nozzles with blind
/companion flanges apart from spares. Gaskets used for hydrotest shall not be used for
actual hook up.
18. Gaskets shall be as per data sheet, in case a equivalent gasket are being used; Gasket
catalogue indicating make / type / m & y value shall be furnished for approval by
Licensor. Vendor to furnish gasket drawing in separate A4 sheet (AUTOCAD Format).
19. While transporting completed equipment, fabricator shall provide suitable type and no. of
supports so that no deformation of any part of the equipment takes place.
20. Fabricator shall exercise utmost care during loading/unloading of equipment so that no
damage to any part of the equipment occurs. Suitable type and no. of supports shall be
provided for supporting the equipment.
Page 667 of 704

DOCUMENT No.
Rev. 0
Page 4 of 13
21. Transportation of equipment shall be governed by commercial conditions.
i) The equipment having length more than 20 m and / or forming ‘Gross vehicle
weight (Weight of equipment and the weight of vehicle clubbed together) more
than 32 MT shall be transported by Hydraulic axles only with compliance to all
statutory norms of authorities concerned.
Fabricator/transporter to check the requirements as per latest guidelines issued

by Ministry of surface Transport before shipping the equipment.
ii) Prime mover of the Vehicle to have GPS tracking system to monitor the
movement of consignment.
iii) The required operational password shall be provided to EIL/Owner, to enable all
concerned to monitor movement en-route
22. Erection weight given in equipment data sheet is approximate. Vendor shall calculate the
actual equipment weight and furnish calculation. Erection weight furnished in vendor
drawing shall be based on fabricator’s calculation. Calculation of Centre of Gravity (C.G.)
of the equipment shall also be done by vendor and marked on the equipment & in the
fabrication GA drawing.
23. When spot radiography is specified the extent of radiography defined in Clause
5.4.2 of EIL specification 6-12-0001 Rev. 5 shall be replaced as follows:
Each category A or B pressure containing weld shall be spot radiographed in

accordance with ASME Section-VIII Division-I, paragraph UW-52 as a minimum
requirement. Each Spot radiograph shall be a minimum of six inches (150mm) in
length and minimum one spot shall be selected in each circumferential &
longitudinal seam. Additionally at least one T-joint in each circumferential seam
shall also be selected. Welds from each welding procedure, welded/welding
operator shall be examined.
24. Refer Spec 6-26-0001 Rev 3 attached with MR. Following modifications to this
specification shall be noted. However, final guarantee of agitator as per Cl. 7 of 6-26-
0001 lies with Bidder :
Clause Modification
2.1.5 The intent of this clause is to remove agitator without dismantling Vessel.
2.4.1(ii) Rigid type coupling without spacer is also acceptable subject to using slotted
coupling to obtain proper assembly.
2.4.3 Snug fit Rigid coupling is acceptable and Material shall be selected based on
vendor’s standard which shall be suitable for process conditions.
2.6.2(b) As an alternative to the requirements mentioned; Agitators can be designed for
full cold jamming condition
2.6.2(d) Maximum dynamic shaft deflection shall be limited to 0.15mm in place of 0.07mm.
Mechanical seals shall be designed for a maximum deflection of 0.5mm in normal
operating conditions and 1mm in extreme conditions.
2.6.2(e) Shaft runout of “1.0mm per meter” indicated in this clause may be read as
“1.0mm per meter on each side”
2.7.4 Dynamic balancing of agitators are required for units having rpm of 300 and
Page 668 of 704

DOCUMENT No.
Rev. 0
Page 5 of 13
above.
2.8.3 For Mechanical seal, Agitator manufacturer may recommend the seal
manufacturer based on their experience. However final responsibility of
performance guarantee lies with Agitator supplier.
25. The thickness indicating in Mechanical Datasheets are minimum to be provided.

Vendor to check/verify the whole design of the vessel and nozzle size “X1” based on
process datasheet and actual details/parameters of the agitator. Only upward increase in
the thickness is permissible.
Bidder to quote accordingly keeping this aspect in consideration. No price implication at

later stage shall be allowed on this account.
General Instructions
1. Inspection requirements are as mentioned hereunder. All materials including those used
for internals shall be procured with stage-wise inspection. Stage wise and final
inspection of equipments and its components shall be carried out by following:
a) For Foreign Vendors:
Stagewise & final inspection of the equipment including all components and internals shall
be carried out by third party inspection agency. Quoted price shall include for the same.
b) For indigenous Vendors:
EIL shall be inspection agency for equipments and its indigenous components. Incase
internals/forging/plates etc. are procured from abroad, the inspection shall be carried out by
third party inspection agency. Quoted price shall include for the same. Charges for EIL
inspection to be borne by the OWNER.
c) For acceptable third party inspection agencies, refer commercial documents.
2. Raw material procurement may proceed prior to approval of vendor drawings on the
basis of Purchase Requisition. However for plates & nozzles where there is no Hold in
size, thickness, etc, material procurement shall be initiated by successful vendor based
on MR drawings immediately after placement of order.
3. Shell rolling/welding and dished - head fabrication shall commence without awaiting
fabrication drawing approval.
Inspection shall be carried out in accordance with Purchase Requisition documents till
approved fabrication drawings are available.
4. Material for shell, dished ends and skirt shall be considered as major raw material
wherever identification of major raw material is one of the payment milestones.
5. Purchase requisition shall be issued within two weeks of Fax of intent (FOI). Final nozzle
sizes (without any holds) shall be issued alongwith purchase requisition or latest within
two months of Fax of intent (FOI).
Page 669 of 704

DOCUMENT No.
Rev. 0
Page 6 of 13
6. Nozzle orientation of the equipment shall be issued latest by mid of contractual delivery
period reckoned from date of issue of Fax of Intent (FOI).
7. Pipe support/structural clip details shall be issued latest by three months before
contractual delivery date.
8. Minimum course width shall be 1 metre. Maximum no. of longitudinal seams shall be as
follows:
( a) vessels upto 2 metre diameter : 1 seam
( b) vessels from 2 metre upto 4 metre dia. : 2 seam
( c) vessels from 4 metre upto 6 metre dia. : 3 seam
In any case, distance between two longitudinal seams shall not be less than 3 meter.
9. If any discrepancy is found during design and fabrication stages, the fabricator shall
inform EIL immediately and shall obtain necessary clarification/approval before
proceeding with that portion of the job any further.
EIL's review of fabricator's drawings and documents must not be considered as a check
and shall not relieve the fabricator of his responsibilities to supply equipment as per
requisition. Fabricator shall remain responsible for conflicts between his
drawings/documents and EIL drawings/documents.
10. English language and metric units shall be used in all documents. Drawings shall be
prepared in prescribed sizes as standardized by bureau of Indian standards (BIS) and
shall be preferably in the sizes such as 210 x 297, 297 x 420, 420 x 597, 597 x 841, 841
x 1189 mm.
11. All fabricator's drawings submitted to EIL shall be based on purchase requisition and
shall bear reference number and revision of the corresponding EIL drawings. In addition,
it shall indicate item number, client's name, project name, fabricator's name, purchase
order number, purchase requisition number, drawing number, revision number etc. all in
the lower right hand corner. All revisions shall be clearly marked by encircling with
revision marks.
12. Submission of required drawings/documents shall be the responsibility of fabricator. In

the event of fabricator's failure to meet this requirement, the supply of equipment shall
be considered as incomplete.
13. Vendor shall submit a list of those drawings, which are to be submitted for review
to EIL along with the submission dates for each drawing within 15 days of
placement of FOI. A soft copy of this index shall also be provided in the format
provided. Vendor shall strictly adhere to this drawing submission schedule.
Updated vendor drawing / document submission schedule shall be forwarded
along with each submission. This shall be submitted in soft copy also.
14. All drawings shall be thoroughly checked and duly signed by fabricator. Unchecked
drawings and drawings without revisions clearly marked shall be returned without
review. Successive review of the same fabricator's drawing shall apply only to EIL's
latest data sheet/comments on the previous revision. Drawings and documents returned
to fabricator for revision shall be resubmitted preferably within ten days of receipt. In
case of items like demisters & agitators, sub-vendor’s drawing shall be reviewed and
duly signed by vessel fabricator before submission to EIL
Page 670 of 704

DOCUMENT No.
Rev. 0
Page 7 of 13
15. Dimensions of all flanges shall be as per ANSI B16.5 for nozzle sizes 24"NB and below
and as per ANSI B16.47 Series B for sizes greater than 24"NB unless otherwise stated.
16. Fabrication drawings shall be submitted in following stages:
Stage-I
- General arrangement drawing indicating design data, fabricated equipment's
weight, general notes, nozzle schedule, detail of shell, heads, skirt/supporting
arrangement, main weld seams, nozzle orientation plan, cutting layout (in case of
free issue material) etc.
- Detail of all nozzles, manholes, accessories etc.
- Bill of material for each item showing part size, quantity, material specification,
scope of supply and weight etc.
Stage-II
- Detail of internals such as tray, tray support ring, support beam, inlet weir and
bolting bar.
- Detail of internal distributor, demister support and packing support, etc.
- Detail of external clips for ladder, platform, pipe support, insulation, fire proofing,
pipe davit, lifting trunnion, tailing lugs, lifting lugs etc.
- Shell development drawing incorporating all attachments and weld seams,

highlighting all the fouling along with suggestions for resolution.
- Bill of material for each item showing part size, quantity, material specification,
scope of supply and weight etc.
- In case of owner's free issue plate material, fabricator shall submit plate cutting
diagram for EIL's approval.
17. After receipt of order, fabricator shall submit to EIL, the planning of fabrication which
shall indicate the details and scheduled date of:
- Sub orders.
- Purchase of materials such as plates, pipes, forged flanges, bolting, gaskets, etc.
- Start of fabrication of dished ends and shell, welding of shell and heads.
- Welding of nozzles and external attachments such as cleats etc.
- Phased program of shop/site fabrication of equipment section, shop

assembly, testing and dispatch to site.
This planning shall be established to extend from purchasing of equipment components

to the end of fabrication and delivery of equipment.
Page 671 of 704

DOCUMENT No.
Rev. 0
Page 8 of 13
18. All drawings shall be drawn in AUTOCAD R-14 or above.No hand drawn drawings shall
be accepted. All residual calculations shall be computerized.
19. Documents and letters shall be furnished in electronic format. The software used shall
be as follows.
a) MS OFFICE 2000 or above

b) ADOBE ACROBAT 5.0 & ABOVE
20. In case of owner's free issue plate material, fabricator shall tabulate each plate detail as
per following table:
Plate No./ Material Size of Plate Equipment Ref. Dwg. Part

Plate mark Specification Thk x Width x Length Number No. number and
(mm) x (M) x (M) qty.
Size of Plate Heat/ Plate Weight Used plate Burnout

Thk x Width x Length sample (Kgs.) weight (Kgs.) losses
(mm) x (M) x (M) number (Kgs.)
Returnable offcut Returnable offcut Non returnable scrap Remarks

size with sketch weight (Kgs.) weight (Kgs.)
Fabricator shall be allowed 2% burnout losses against the material consumed in case of
pressure vessels and 1% in case of storage tanks and spheres unless otherwise specified. In
general purchase conditions.all offcuts of width 800mm and perimeter 2400mm in carbon
steel materials and 150mm width and perimeter 1500mm in stainless steel materials shall be
returned to owner, unless otherwise specified. Returnable offcuts shall have original plate
markings transferred and duly stamped by inspector. All other non returnable scrap shall be
sold by fabricator on the basis of owner's instructions and approval.
21. Words “fabricator”, “vendor”, “contractor” appearing any where in the MR/Specifications/
Standards etc. shall be read as “bidder”.
22. Bidder to note that interference of nozzles with circumferential seams is not acceptable.
Vendor to take suitable care to avoid fouling of external/internal attachments with shell
seams.
23. Vendor shall note that the vendor drawing for the following standard components (as
applicable) shall not be reviewed by EIL. It shall be solely vendor's responsibility to
ensure the correctness of these drawings as per EIL Standards and Drawings. If any
discrepancy / mistake is found at a later date the vendor shall rectify the same at his
time and cost.
- Manhole davit/ hinge arrangement & Ladder rungs

- Pipe Davit
- EIL Name plate, Manufacturer's Nameplate, Nameplate bracket
- Skirt (Pipe) opening details, Access Opening Details, Skirt vent.
- Lifting lugs (Standard Type)
- Fireproofing and Insulation Support
- Earthing lug
Page 672 of 704

DOCUMENT No.
Rev. 0
Page 9 of 13
- Pipe support cleats and ladder and platform cleats (Fouling of external support
cleats (if any), shall be highlighted to EIL along with shell development drawing
and suggestion for resolution)
However all these above listed drawing shall be submitted in a separate drawing for
information to EIL ensuring adherence to all the respective EIL Standards and Drawings.
Clarifications (if any) shall be obtained by Vendor from EIL before fabrication.
24. Standard Inspection and test plans are attached with requisition for guidance. Vendor
shall submit inspection test plans for the approval of visiting inspection engineer.
Inspection shall take care of all the requirements of specifications. Inspection engineer
has the authority to modify the plan depending on the criticality of the item.
25. In the event of conflict, most stringent requirement in following order of

precedence shall govern:
a) EIL Mechanical Data Sheet

b) Data Sheets for demister, etc. wherever applicable
c) EIL specifications and standards
d) Codes
However in event of conflict it shall be the duty of the Vendor to bring it to EIL’s
attention for resolution and resolve it before proceeding with the manufacture.
EIL’s comments shall be final and binding on vendor without any cost and
delivery implications.
26. Finish painting of all equipments shall be in vendor’s scope.
27. Equipment tag number shall be engraved/welded on all components (if equipment is
being sent in parts) and on all spares. If spares are small enough or if welding/engraving
will damage the spares, metallic tag shall be provided with equipment tag number. If
welding/engraving on equipment can result in damages, equipment tag number shall be
painted on the equipment or its part (minimum three locations). Color coding of spares
as per PFI (Pipe Fabrication Institute) Standard ES-22 shall be done.
28. All drawings / documents of Agitator and vessels with agitator submitted shall be
reviewed by Licensor also. Consolidated comments (including Licensor comments) shall
be furnished within 06-08 weeks after receipt of documents / drawings. Vendor shall
incorporate all these comments without any time and cost implications.
Page 673 of 704

DOCUMENT No.
Rev. 0
Page 10 of 13
Annexure-II
Vendor list for Agitators:
Page 674 of 704

DOCUMENT No.
Rev. 0
Page 11 of 13
Page 675 of 704

DOCUMENT No.
Rev. 0
Page 12 of 13
Page 676 of 704

DOCUMENT No.
Rev. 0
Page 13 of 13
Annexure-III
Vendor list for Hoppers (Hastelloy):
Page 677 of 704

VENDOR DATA REQUIREMENTS Document No.
A842-PDE-80-43-VDR-6041
FOR Rev. 0
PRESSURE VESSELS CARBON STEEL
AND STAINLESS STEEL Page 1 of 4

FOR
PRESSURE VESSELS CARBON STEEL AND
STAINLESS STEEL
0 06-APR-2017 ISSUED FOR PURCHASE SA PVSS PVSS

A 28-JUL-2016 ISSUED FOR BIDS SG VIVEK IK
No.
Page 678 of 704

A842-PDE-80-43-VDR-6041
FOR Rev. 0
VESSELS WITHOUT AGITATOR
POST ORDER
S. WITH WITH
BID
(FINAL)
1. GENERAL ARRANGEMENT DRAWING
INDICATING DESIGN DATA FABRICATED
EQUIPMENT WEIGHT, GENERAL NOTES,
NOZZLE SCHEDULE, DETAIL OF SHELL,
HEADS, SUPPORTING ARRANGEMENT,
MAIN WELD SEAMS, NOZZLE ORIENTATION
PLAN, CUTTING LAYOUT ETC.
2. DETAIL OF NOZZLES, MANHOLES,
ACCESSORIES, AGITATOR ASSEMBLY &
MOUNTING ETC
3. DETAILS OF DEMISTER.
4. DETAILS OF PACKING SUPPORT,
DEMISTER SUPPORTS, GRATINGS, AND
GRATING SUPPORTS.
5. DETAIL OF INTERNAL DISTRIBUTOR.
6. DETAIL OF EXTERNAL CLIPS SUCH AS
LADDER, PLATFORM, PIPE SUPPORT.
7. DETAIL OF INSULATION, FIRE PROOFING
8. DETAIL OF PIPE DAVIT
9. DETAIL OF LIFTING LUG,TRUNION AND
TAILING LUG ETC.
10. CERTIFIED 'AS BUILT' DRAWINGS
INCORPORATING ACTUAL DIMENSIONS
AND MATERIAL USED, DULY CERTIFIED BY
THE INSPECTOR
11. DATA FOLDER AS PER SPECIFICATION
12. INSPECTION AND TESTING PLAN @
13. WELDING PROCEDURES AND
QUALIFICATION TEST REPORTS @
14. DESTRUCTIVE AND NON-DESTRUCTIVE
TEST REPORTS @
15. MATERIAL TEST CERTIFICATES @
16. RADIOGRAPHIC EXAMINATION REPORTS
WITH FILMS @
17. HEAT TREATMENT PROCEDURE AND TIME
TEMPERATURE CHARTS @
18. CODE CERTIFICATES (INCLUDING
INSPECTION CERTIFICATE, HYDROSTATIC
TEST CERTIFICATE, LOCAL CODE
REQUIREMENTS, RUBBING OF CODE
STAMP AND NAME PLATE ETC.) @
Page 679 of 704

A842-PDE-80-43-VDR-6041
FOR Rev. 0
POST ORDER
S. WITH WITH
BID
(FINAL)
19. PACKING AND FORWARDING
INSTRUCTIONS @
20. ASSEMBLY AND INSTALLATION DETAIL
VESSELS WITH AGITATOR
POST ORDER
S. WITH WITH
BID
(FINAL)
1. GENERAL ARRANGEMENT DRAWING
INDICATING DESIGN DATA FABRICATED
EQUIPMENT WEIGHT, GENERAL NOTES,
NOZZLE SCHEDULE, DETAIL OF SHELL,
HEADS, SUPPORTING ARRANGEMENT,
MAIN WELD SEAMS, NOZZLE ORIENTATION
PLAN, CUTTING LAYOUT ETC.
2. DETAIL OF NOZZLES, MANHOLES,
ACCESSORIES, AGITATOR ASSEMBLY &
MOUNTING ETC
3. MECHANICAL DESIGN CALCULATIONS OF
AGITATOR
4. AGITATOR GA DWG, DETAIL DRGS
CATALOGUE ETC.
5. DETAIL OF INTERNALS SUCH AS BASKET
6. DETAIL OF INTERNAL DISTRIBUTOR.
7. DETAIL OF INSULATION, FIRE PROOFING
8. DETAIL OF PIPE DAVIT
9. DETAIL OF LIFTING LUG,TRUNION AND
TAILING LUG ETC.
10. CERTIFIED 'AS BUILT' DRAWINGS
INCORPORATING ACTUAL DIMENSIONS
AND MATERIAL USED, DULY CERTIFIED BY
THE INSPECTOR
11. DATA FOLDER AS PER SPECIFICATION
12. INSPECTION AND TESTING PLAN @
13. WELDING PROCEDURES AND
QUALIFICATION TEST REPORTS @
14. MATERIAL TEST CERTIFICATES @
15. RADIOGRAPHIC EXAMINATION REPORTS
WITH FILMS @
16. HEAT TREATMENT PROCEDURE AND TIME
TEMPERATURE CHARTS @
17. CODE CERTIFICATES (INCLUDING
INSPECTION CERTIFICATE, HYDROSTATIC
TEST CERTIFICATE, LOCAL CODE
REQUIREMENTS, RUBBING OF CODE
STAMP AND NAME PLATE ETC.) @
Page 680 of 704

A842-PDE-80-43-VDR-6041
FOR Rev. 0
POST ORDER
S. WITH WITH
BID
(FINAL)
18. PACKING AND FORWARDING
INSTRUCTIONS @
19. ASSEMBLY AND INSTALLATION DETAIL
20. FILLED IN MIXER/AGITATOR DATASHEET
Notes :
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
9. Bill of Material shall form part of the respective drawing.
10. Also refer other department's VDR :-
11. Electrical
12. Instrumentation
13. "@"- These document shall be reviewed by EILs regional procurement office (RPO) pertaining to vendors
region. Vendor shall submit this document in hard copy to RPO-EIL for review.
Page 681 of 704

NOZZLES AND CONNECTIONS ¼uksty o duSD'ku½ GENERAL NOTES (tujy uksV~l½ SPECIFICATIONS ¼LisflfQds'lUl½ DESIGN DATA ¼fMtkbu MkVk½
The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the limited way permitted by written consent given by the lender to the
MARK QTY
NOM. DIA SCH./THK. FLANGES PROJECTI
ON NOTE-
PAD W
SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SECTION VIII DIV.-1 LATEST EDITION,PRACTICE
ukfeuy 'kMwy o CLASS TYPE FACING 4
xT 1 ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (kg/cm2g) ATM
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. X SUPP. SPEC. FOR AUSTENTIC SS VESSELS 6-12-0006 DESIGN PRESSURE (NOTE-27) (mmWCg) INT. F.W. +150 EXT. (-) 50
N1 1 50 80S 150 SO RF 400 - LIQUID FROM OSBL

3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. X STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE
0
( C) 35
4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM VESSEL CENTER LINE TO X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE
0
( C) 65
N2 1 80 80S 150 SO RF 1610 40xT OVER FLOW

FLANGE CONTACT FACE.
X STD. SPEC. FOR SS PLATE 6-12-0020 MDMT (0C) 15
4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO FLANGE JOB SPEC. FOR SURFACE PREPARATION & PROTECTIVE CORROSION ALLLOWANCE (MM) NIL
CONTACT FACE. X COATING A842-000-79-41-PLS-01
TYPE OF HEAD TOP/BOTTOM - FLAT , INTERMEDIATE - HEMISPHERICAL
N3 1 50 80S 150 SO RF 1560 - LIQUID FROM UPPER PART
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER CONSTRUCTION. X STD. SPEC. FOR MECHANICAL AGITATOR 6-26-0001 JOINT EFFICIENCY SHELL 0.85 FLAT/INTERMEDIATE HEAD 1
6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. RADIOGRAPHY SHELL SPOT FLAT/INTERMEDIATE HEAD FULL
N4 1 50 80S 150 SO RF 1560 - LIQUID TO LOWER PART
7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER ASME B16.5
STANDARDS ¼LVS.MMZl½ POST WELD HEAT TREATMENT AS PER SPEC./CODE
N5 1 50 80S 150 SO RF 1560 - LIQUID TO P-405

AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 UNLESS SPECIFIED
OTHERWISE.
X VESSEL TOLERANCES 7-12-0001 HEAT TREATMENT HEAD AS PER SPEC./CODE
SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM PROCESS FLUID
REFER 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF NOZZLE WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY 0.897
N6 1 50 80S 150 SO RF - LN INLET
DRG. PIPE/SHELL. X SKIRT BASE DETAILS 7-12-0004 WIND SPECIFICATION IS 875
REFER 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK FLATS 900 SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
N7 1 50 80S 150 SO RF - LN INLET
DRG. APART. ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M ) 3
31.4
10 VENDOR TO ENSURE THAT ALL REMOVABLE INTERNALS SHALL PASS THROUGH MANHOLE. PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
N8~9 2 50 80S 150 SO RF 1560 - MXA INLET
11 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED. X BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 INSULATION THICKNESS (mm) NIL HOT COLD
12 SURFACE CLEANING/ PRIMER SHALL BE AS PER JOB SPECIFICATION. MANHOLE WITH HINGED COVER 7-12-0009 FIRE PROOFING YES X NO
N10~11 2 50 80S 150 SO RF 1560 - SPARE + B.F.
13 MOC OF INTERNAL GASKET SHALL BE SUITABLE FOR THE DESIGN TEMPERATURE. X MANHOLE WITH DAVIT 7-12-0010 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL VERTICAL (AT TOP)
N12 1 REFER DRG. PTSA INLET

14 AFTER COMPLETION OF FABRICATION & TESTING, ALL SS CLAD SURFACES & SS X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) FULL OF WATER
INTERNALS(BOTH SIDES) SHALL BE PICKLED & PASSIVATED IN ACCORDANCE WITH RETAINING PLATE 7-12-0012 INSPECTION BY X EIL/TPIA CIB LLOYDS
ASTM A-380.
V1 1 100 40S 150 SO RF 400 60xT VENT X NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013
15 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A262 PRACTICE-E. PAD NOZZLES FOR VESSELS 7-12-0014 S
V2 1 50 80S 150 SO RF
REFER
- VENT
16 AFTER HYDROTEST ALL WELDS IN PRESSURE PARTS SHALL BE CHECKED BY DP X STANDARD BOLT HOLE ORIENTATION 7-12-0015
DRG. EXAMINATION. ALLOY LINER DETAILS 7-12-0016 SHELL / FLAT HEAD /INTERMEDIATE HEAD SA 240 GR.316
REFER 17 ALL WELDING LINES ON THE INNER SURFACE SHALL BE SMOOTHLY FINISHED BY A SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 REINFORCEMENT PAD / INSERT PLATE SA 240 GR.316
D1~2 2 50 80S 150 SO RF - DRAIN
DRG. GRINDER
X INTERNAL FLANGES (GUIDANCE ONLY) 7-12-0018 BOTTOM PLATE / TOP PLATE SA 240 GR.316
18 SUPPORT FOR VENT PIPES SHALL BE PROVIDED AS PER EIL STD. 7-12-0032. VORTEX BREAKERS 7-12-0019 SHELL FLANGES SA 240 GR.316
T1 1 50 80S 150 SO RF 1560 - TG
19 SUPPORT LUGS PROVIDED ON HOPPER IS FOR GUIDING PURPOSE ONLY. INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE FLANGES SA 182 F316
20 BASED ON FINAL AGITATOR NOZZLE OPENING OTHER NOZZLES IN THE HEAD AND SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK UPTO 100 NB SA 312 TP316
L1 1 80 80S 150 SO RF 1610 40xT LEVEL TRANSMITTER (DP DIASEAL) LOADING ON TOP HEAD, VENDOR TO CHECK FOR REINFORCEMENT OF OPENING AND
0 SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 NOZZLE NECK ABOVE 100 NB SA 240 GR.316
INCREASE THE THICKNESS OF HEAD (IF REQUIRED) CONSIDERING LIGAMENT
PIPE DAVIT 7-12-0023 PIPE FITTINGS SA 403 GR.316 (SEAMLESS)
L2 1 80 80S 150 SO RF 1610 40xT LEVEL TRANSMITTER (DP DIASEAL) 0 EFFICIENCY DUE TO LARGE NO. OF OPENINGS IN THE HEAD.
LIFTING LUG TOP HEAD TYPE 7-12-0024 GASKET EXTERNAL V#7010 OR EQUIVALENT
G1a,b 2 50 80S 150 SO RF 1560 - LEVEL GAUGE (MAGNETIC)

21 FULL AGITATOR ASSEMBLY INCLUDING MOTOR, GEARBOX, ALL SUPPORTS, DRIVES X FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 GASKET INTERNAL(NOTE-13) V#7010 OR EQUIVALENT
0 INCLUDING ALL ACCESSORIES AND SPARES ETC. ARE TO BE DESIGNED AND SUPPLIED
BY VENDOR.
X EARTHING LUG 7-12-0026 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7 / SA 194 GR.4
G2a,b 2 50 80S 150 SO RF 1560 - LEVEL GAUGE (MAGNETIC) 0

X NAME PLATE 7-12-0027 INTERNAL STUDS/BOLTS/NUTS SS 316
22 HOPPER INCLUDING GRID, BASKETS & THEIR SUPPOTS, LUG SUPPORT ARE TO BE X MANUFACTURER NAME PLATE 7-12-0028 SKIRT / SUPPORT -
X1 1
200
12 THK. 150 SO RF 400 -
AGITATOR MOUNT+ AGITATIOR SUPPLIED BY VENDOR.
X BRACKET FOR NAME PLATE 7-12-0029 SUPPORT BASE SA 240 GR.316
(HOLD) ASSEMBLY + GASKET+BOLT 23 THE THICKNESS INDICATING IN THE ENGG. DATA SHEETS ARE THE MINIMUM TO BE NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 INTERNAL PARTS (WELDED) SA 312 TP316 / SA 240 GR.316
MANHOLE + B.F. + DAVIT PROVIDED. VENDOR TO CHECK/VERIFY THE WHOLE DESIGN OF THE VESSEL AND DETAILS OF FORGED NOZZLES 7-12-0031 INTERNAL PARTS (BOLTED) SA 312 TP316 / SA 240 GR.316
MH1 1 600 6 THK. 150 SO RF 1660 255xT NOZZLE SIZE "X1" BASED ON PROCESS DATA SHEETS AND ACTUAL
+ GASKET + BOLT
DETAILS/PARAMETERS OF THE AGITATOR. ONLY UPWARD INCREASE IN THE X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 CLIPS & ATTACHMENTS DIRECTLY WELDED
SA 240 GR.316
MANHOLE + B.F. + DAVIT HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 (EXTERNAL)
MH2 1 600 6 THK. 150 SO RF 1660 255xT THICKNESS IS PERMISSIBLE.
+ GASKET + BOLT BIDDER TO QUOTE ACCORDINGLY KEEPING THIS ASPECT IN CONSIDERATION. NO PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 CLIPS & ATTACHMENTS WELDED OVER PAD
IS 2062 GR.E 250 QUALITY B
HANDHOLE + B.F. + DAVIT PRICE IMPLICATION AT LATER SHALL BE ALLOWED ON THIS ACCOUNT. TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 (EXTERNAL)
HH1 1 150 6 THK. 150 SO RF 400 -
+ GASKET + BOLT (NOTE-26) 24 FINAL LOAD AND FOUNDATION LOADING DATA TO BE CONFIRMED BY THE VENDOR. S.R NOZZLE NECK 7-12-0037 WRAPPER PLATE -
25 PIPE FITTINGS SHALL BE THE SAME SIZE AND THICKNESS AS THE ATTACHED PIPE. X ALLOWABLE NOZZLE LOADS 7-12-0038 DEMISTER/GRID -
26 HANDHOLE NOZZLE SHALL BE LOCATED JUST ABOVE VENT PIPE. PAD FOR EXTERNAL ATTACHMENT SA 240 GR.316
27 DESIGN PRESSURE OF HOPPER IS FW+150MM WC(g). LIFTING LUG SA 240 GR.316
28 VENDOR TO DESIGN LIFTING LUG FOR ERECTION OF COMPLETE EQUIPMENT WITH CURB ANGLE SA 240 GR.316
AGITATOR CONSIDERING AN IMPACT FACTOR OF 2.0. WIRE MESH SS 316
'T' DENOTES CORRESPONDING SHELL/DISH END/SKIRT NOMINAL THICKNESS.
29 LOCATION OF NIPPLE SHALL BE SUCH THAT OPERATOR CAN STAB BOTTOM OF HOPPER
WITH BAR THROUGH SAFETY BAR. HOPPER
30 MINIMUM THICKNESSES OF INTERNAL SHALL BE 6THK. IF NOT SPECIFIED. TOP PLATE SA 240 GR.316
31 DESIGN LOAD FOR BASKET IS 4.0 KN WHICH IS WEIGHT OF HQ. SHELL / CONE SB 575 HASTELLOY C-276
MESH OF BASKET SHALL BE PROPERLY SECURED WITH ROD & END PLATE. NOZZLE FLANGES SB 462 HASTELLOY C-276
ALL FILLED WELD SHALL BE MINIMUM 6MM. REFERENCE DRAWINGS¼jsQjsUl MkbZx½ NOZZLE NECK UPTO 100 NB SB 622 HASTELLOY C-276
32 ALL REQUIREMENTS OF PDS SHALL BE COMPLIED. NOZZLE ORIENTATIONS NOZZLE NECK ABOVE 100 NB SB 575 HASTELLOY C-276
NECESSARY FREE SPACE ON TOP OF THE VESSEL IS REQUIRED FOR LIFTING AND REMOVING OF THE LADDERS/PLATFORM CLEATS PIPE FITTINGS SB 366 HASTELLOY C-276
AGITATOR ASSEMBLY. PIPE SUPPORT CLEATS GASKET INTERNAL V#7010 OR EQUIVALENT
TRAY SUPPORT AND BOLTING BARS EXTERNAL STUDS/BOLTS/NUTS SB 574
DEMISTER DATA SHEET INTERNAL STUDS/BOLTS/NUTS SB 574
X PROCESS DATA SHEET PDPP-DS-V405 SUPPORT SA 516 GR.70 WITH SB 575 PAD
X AGITATOR DATA SHEET PDPP-DS-A405 INTERNAL PARTS SB 575 / SB 622 / SB 366
CLIPS & ATTACHMENTS DIRECTLY WELDED SB 575 HASTELLOY C-276

FILE NAME : A842-PDE-80-43-DS-3405-0-1
STATUTORY REGULATIONS ¼LVSpqvjh jsxqys'kUl½

LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION) INDIAN BOILER REGULATIOS (IBR)
ykbZlsUlj LisflfQds'lUl 0 QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku)(NOTE-24) 0 HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)
TYPE MAX MOMENT AT BASE (M) (kgm)

MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES - X1
APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼,ijkSfDlesaV otu½(NOTE-24)
(kg) NOZZLE ELEVATIONS X PIPE SUPPORT CLEATS
borrower for the intended use.
SEISMIC
36000 11000
SUPPORT HEIGHT X LADDER/PLATFORM CLEATS
ERECTION 12500 OPERATING 41000
LICENSOR'S STANDARD (DB) DETAILS OF INTERNALS TRAY SUPPORT/BOLTING BARS
ykbZlsUlj LVS.MlZ SEISMIC PIPE DAVIT
(MC) - - PACKING SUPPORT
HYDROTEST(SHOP) 43900 HYDROTEST ( FIELD ) 46000
WIND 3500 1200 NUMBER OF ITEMS : ONE
JOB NO: UNIT NO: DESIGN DATA fMtkbu MkVk DRAWING NUMBER
ENGINEERS INDIA LIMITED dk;Z l[;k A842
;÷fuV l[;k PDE MkbZx uEcj REV
NEW DELHI CLIENT :
M/s BPCL, KOCHI CATALYST MIXING DRUM dSVyhLV fefDlax Mªe A842-PDE-80-43-DS-3405 0
DykbZV 0 12.04.2017 REVISED AS MARKED & ISSUED FOR PURCHASE. AKP SA PVS
bathfu;lZ bafM;k fyfeVsM PLANT : A 26.07.2016 ISSUED FOR BIDS/ENGG. SV SK/VIVEK IK
¼Hkkjr ljdkj dk midze½ IykaV PDPP
REVISION APPROVED
ITEM NO. PDE-V-405 vAbVe uEcj ihMhbZ&oh&405 SHEET 1 OF 3
REV DATE BY CHECKED
FORMAT NO.3-1646-0122 REV.2 (06.12.2011) A3-420 X 297
Page 682 of 704

vkbZVe uEcj & ihMhb oh&405
Page 683 of 704

Page 684 of 704

MARK QTY
ON NOTE-
PAD W
SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SECTION VIII DIV.-1 LATEST EDITION
xT 1 ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (kg/cm g)
2
ATM
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. X SUPP. SPEC. FOR AUSTENTIC SS VESSELS 6-12-0006 DESIGN PRESSURE (mmWCg) INT. F.W. +150 EXT. NIL
N1 1 50 80S 150 SO RF
SEE
- LIQUID FROM LZ 441
3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. X STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE (0C) 32
DWG. 4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM VESSEL CENTER LINE TO STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE (0C) 65
N2 1 50 80S 150 SO RF
SEE
- LIQUID FROM LZ 451
X STD. SPEC. FOR SS PLATE 6-12-0020 MDMT ( 0C) 15
DWG. 4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO FLANGE JOB SPEC. FOR SURFACE PREPARATION & PROTECTIVE CORROSION ALLLOWANCE (MM) 0 FOR SS
SEE CONTACT FACE. X COATING A842-000-79-41-PLS-01
TYPE OF HEAD FLAT
N3 1 50 80S 150 SO RF - LIQUID FROM LZ 451
DWG. 5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER CONSTRUCTION. JOINT EFFICIENCY SHELL 0.85 HEAD 1
6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. RADIOGRAPHY SHELL SPOT HEAD FULL
N4 1 50 80S 150 SO RF 1510 - LIQUID FROM V-471
STANDARDS ¼LVS.MMZl½ POST WELD HEAT TREATMENT -

OTHERWISE.
SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM P
SEE 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF NOZZLE WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY 0.863/0.977
N6 1 50 80S 150 SO RF - LIQUID FROM LZ 416
DWG. PIPE/SHELL. X SKIRT BASE DETAILS 7-12-0004 WIND SPECIFICATION IS 875
SEE 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK FLATS 90 0
SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
N7 1 50 80S 150 SO RF - LIQUID FROM E-443
DWG. APART. ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M ) 3
15.5
SEE 10 VENDOR TO ENSURE THAT ALL REMOVABLE INTERNALS SHALL PASS THROUGH MANHOLE. PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
N8 1 50 80S 150 SO RF - LIQUID FROM P-412A/B
DWG. 11 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED. BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 INSULATION THICKNESS (mm) NIL HOT COLD
12 SURFACE CLEANING/ PRIMER SHALL BE AS PER JOB SPECIFICATION. MANHOLE WITH HINGED COVER 7-12-0009 FIRE PROOFING NIL YES NO
N9 1 50 80S 150 SO RF 1510 - LIQUID TO P-424A/B

14 AFTER COPMPLETION OF FABRICATION & TESTING, ALL SS CLAD SURFACES & SS X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) FULL OF WATER
INTERNALS(BOTH SIDES) SHALL BE PICKLED & PASSIVATED IN ACCORDANCE WITH RETAINING PLATE 7-12-0012 INSPECTION BY EIL/TPIA CIB LLOYDS
ASTM A-380.
N11 1
50
80S 150 SO RF
SEE
- MIN. FLOW (FROM P-424A/B)
X NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013 MATERIAL OF CONSTRUCTION ¼eSfVfj;y vk¡Q dUlVªD'ku)
(HOLD) DWG. 15 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A262 PRACTICE-E. PAD NOZZLES FOR VESSELS 7-12-0014 (AS PER ASME / IS OR EQUIVALENT)
N12 1
50
80S 150 SO RF
SEE
- MIN. FLOW (FROM P-524A/B)
(HOLD) DWG. EXAMINATION. 7-12-0016 SHELL/BOOT SA 240 GR.304
ALLOY LINER DETAILS
17 ALL WELD LINES ON THE INNER SURFACE SHALL BE SMOOTHLY FINISHED BY A SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 REINFORCEMENT PAD/INSERT PLATE SA 240 GR.304
N13 1 80 80S 150 SO RF 1560 45xT OVER FLOW GRINDER.
X INTERNAL FLANGES 7-12-0018 BOTTOM PLATE/TOP PLATE SA 240 GR.304
SEE VORTEX BREAKERS 7-12-0019 SHELL FLANGES -
N14 1 50 80S 150 SO RF - FCS INLET
DWG. INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE FLANGES SA 182 F304
SEE SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK UPTO 150 NB SA 312 TP304
V1 1 80 80S 150 SO RF 45xT VENT
DWG. SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 NOZZLE NECK ABOVE 150 NB SA 240 GR.304
D1 1 50 80S 150 SO RF 1510 - DRAIN
FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 GASKET INTERNAL(NOTE-13) V#7010 OR RQUIVALENT
D2 1 50 80S 150 SO RF 1510 - DRAIN
X EARTHING LUG 7-12-0026 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7 / SA 194 GR.2H
L1A/B 2 50 80S 150 SO RF 1510 - LEVEL TRANSMITTER (DISPLACER)

0
X MANUFACTURER NAME PLATE 7-12-0028 SKIRT / SUPPORT -
L2 1 80 80S 150 SO RF 1560 - LEVEL TRANSMITTER (DIASEAL)

X BRACKET FOR NAME PLATE 7-12-0029 SKIRT / SUPPORT BASE SA 240 TP304
0 7-12-0030 INTERNAL PARTS (WELDED) SA 312 TP304 / SA 240 GR.304
NAME PLATE FOR SMALL EQUIPMENT
DETAILS OF FORGED NOZZLES 7-12-0031 INTERNAL PARTS (BOLTED) SA 312 TP304 / SA 240 GR.304
G1A/B 2 50 80S 150 SO RF 1510 - LEVEL GAUGE TRANSPARENT (SS) 0
X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 CLIPS & ATTACHMENTS DIRECTLY WELDED
SA 240 GR.304
HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 (EXTERNAL)
G2A/B 2 50 80S 150 SO RF 1510 - LEVEL GAUGE (MAGNETIC) 0
PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 CLIPS & ATTACHMENTS WELDED OVER PAD
SA 516 GR.70
TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 (EXTERNAL)
MH1 1 600 150 SO RF 1660 300xT MAHOLE + DAVIT+ B.F.
S.R NOZZLE NECK 7-12-0037 WRAPPER PLATE -
HH1 1 150 150 SO RF 1560 85xT HANDHOLE + B.F. X ALLOWABLE NOZZLE LOADS 7-12-0038 DEMISTER/GRID -
PAD FOR EXTERNAL ATTACHMENT SA 240 GR.304
LIFTING LUG SA 516 GR.70
CURB ANGLE SA 240 GR.304
REFERENCE DRAWINGS¼jsQjsUl MkbZx½

NOZZLE ORIENTATIONS
LADDERS/PLATFORM CLEATS
PIPE SUPPORT CLEATS
TRAY SUPPORT AND BOLTING BARS
DEMISTER DATA SHEET
X PROCESS DATA SHEET PDPP-DS-V425
THERMOWELL DETAIL
FILE NAME : A842-PDE-80-43-DS-3425-0-1
TAILING LUG DETAIL A842-PDE-80-43-SK-0002

MONKEY LADDER A842-PDE-80-43-SK-0001 STATUTORY REGULATIONS ¼LVSpqvjh jsxqys'kUl½
ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) 0 HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)

MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES N11,N12
APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼,ijkSfDlesaV otu½
(kg)
X NOZZLE ELEVATIONS X PIPE SUPPORT CLEATS
SEISMIC SUPPORT HEIGHT X LADDER/PLATFORM CLEATS

(MC) PACKING SUPPORT
WIND NUMBER OF ITEMS : ONE
NEW DELHI CLIENT :
M/s BPCL, KOCHI WATER SURGE DRUM okVj ltZ Mªe A842-PDE-80-43-DS-3425 0
bathfu;lZ bafM;k fyfeVsM PLANT : A 28.06.2016 ISSUED FOR BIDS/ENGG. TAA DG/MKP -
REVISION APPROVED
ITEM NO. PDE-V-425 vkbVe uEcj ihMhbZ&oh&425 SHEET 1 OF 2
REV DATE BY CHECKED
FORMAT NO.3-1646-0122 REV.2 (06.12.2011) A3-420 X 297
Page 685 of 704

14 AFTER COPMPLETION OF FABRICATION &
TESTING, ALL SS CLAD SURFACES & SS
INTERNALS(BOTH SIDES) SHALL BE PICKLED &
15 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A26
16 AFTER HYDROTEST ALL WELDS IN PRESSURE
PARTS SHALL BE CHECKED BY DP EXAMINATION.
17 ALL WELDING LINES ON THE INNER SURFACE

SHALL BE SMOOTHLY FINISHED BY A GRINDER
Page 686 of 704

vkbZVe uEcj & ihMhb&oh&425
Page 687 of 704

The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the
MARK QTY
NOM. DIA SCH./THK. FLANGES PROJECTION PAD
SERVICE
UNLESS STATED OTHER WISE
X DENOTES APPLICABLITY CODE ASME SEC VIII DIV. 1 EDITION 2015
ukfeuy 'kMwy o CLASS TYPE FACING NOTE-4 WxT
1 ALL DIMENSIONS ARE IN MM. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (kg/cm 2g) ATM
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl SUPP. SPEC. FOR CS VESSELS 6-12-0002 DESIGN PRESSURE (mmWCg) INT FW+150 EXT -50
N1 1 50 80S 150 SO RF 460 - LIQUID FROM V-432 2

ALL ANCHOR BOLT HOLES TO STRADDLE N/S X STD. SPEC. FOR AUSTENTIC SS VESSEL 6-12-0006 WORKING TEMPERATURE (0C) 35
CENTRELINE. STD. SPEC. FOR BQCS PLATE 6-12-0011 DESIGN TEMPERATURE (0C) 65
N2 1 50 80S 150 SO RF 460 - LIQUID TO P-433 3

NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 MDMT ( 0C) 15
TO PLAN VIEW. X STD. SPEC. FOR STAINLESS STEEL PLATES 6-12-0020 CORROSION ALLLOWANCE (MM) NIL
N3 1 50 80S 150 SO RF 460 - LIQUID TO V-407 4 (A)

FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM X STD. SPEC. FOR SHOP & FIELD PAINTING A842-000-79-41-PLS-01 TYPE OF HEAD TOP-FLANGE BOTTOM-2:1 ELLIPSOIDAL
VESSEL CENTER LINE TO FLANGE CONTACT FACE. JOINT EFFICIENCY SHELL 0.85 HEAD 1
RADIOGRAPHY (REFER NOTE-10) FULL
N4 1 50 80S 150 SO RF 460 - OVER FLOW 4(B)
FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD
T.L TO FLANGE CONTACT FACE. STANDARDS ¼LVS.MlZ½ POST WELD HEAT TREATMENT
SHELL SPOT
AS PER CODE
HEAD
N5 1 50 80S 150 SO RF 460 - FCS INLET 5

THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER X VESSEL TOLERANCES 7-12-0001 HEAT TREATMENT HEAD AS PER SPEC./CODE
CONSTRUCTION. SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM PROCESS FLUID
SEE 6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY 0.884
V1 1 80 80S 150 SO RF - VENT
DWG 7 SKIRT BASE DETAILS 7-12-0004 WIND SPECIFICATION IS 875
DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS
SEE PER ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
D1 1 50 80S 150 SO RF - DRAIN ASME B16.47 SERIES `B' UNLESS SPECIFIED OTHERWISE.
DWG ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M3) 0.9
LEVEL TRANSMITTER (DP 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER SPEC
L1/L2 2 80 80S 150 SO RF 460 40x4 ID OF NOZZLE PIPE.
DIASEAL) 0 X BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 INSULATION THICKNESS (mm) NIL HOT COLD
SIGHT GLASS CONNECTION 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2NOS. 40 MANHOLE WITH HINGED COVER 7-12-0009 FIRE PROOFING (mm) (BY OTHERS) NIL YES NO
SG1-8 8 AS PER EIL STD 7-12-0017 X 6 THK. FLATS 90° APART.
(REFER NOTE-15) X MANHOLE WITH DAVIT (FOR GUIDANCE) 7-12-0010 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL VERTICAL (AT TOP)
SIGHT GLASS CONNECTION FOR 10 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) FULL OF WATER
G1-8 8 50 80S 150 SO RF 460 - RADIOGRAPHED.
LIGHTING (REFER NOTE-15) RETAINING PLATE 7-12-0012 INSPECTION BY X EIL/TPIA CIB LLOYDS
11 AFTER COMPLETION OF FABRICATION & TESTING, ALL SS CLAD
SURFACES & SS INTERNALS(BOTH SIDES) SHALL BE PICKLED &
PAD NOZZLES FOR VESSELS 7-12-0014 (AS PER ASME / IS OR EQUIVALENT)
PASSIVATED IN ACCORDANCE WITH ASTM A-380
12 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS X STANDARD BOLT HOLE ORIENTATION 7-12-0015 SHELL SA 240 GR.304
PER ASTM A262 PRACTICE-E. ALLOY LINER DETAILS 7-12-0016 REINFORCEMENT PAD SA 240 GR.304
13 AFTER HYDROTEST ALL WELDS IN PRESSURE PARTS X SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 HEADS SA 240 GR.304
SHALL BE CHECKED BY DP EXAMINATION. INTERNAL FLANGES 7-12-0018 SHELL FLANGES SA 240 GR.304
14 ALL WELDING LINES ON THE INNER SURFACE SHALL BE VORTEX BREAKERS 7-12-0019 NOZZLE FLANGES SA 182 F304
SMOOTHLY FINISHED BY A GRINDER INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE NECK UPTO 100 NB SA 312 TP 304
15 FOR SIGHT GLASS CONNECTION DETAILS, REFER SHT. 2 SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK ABOVE 100 NB -
OF 2 OF EIL STD. 7-12-0017 AND FOR SIGHT GLASS SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 PIPE FITTINGS SA 403 WP 304 (SEAMLESS)
CONNECTION FOR LIGHTING DETAILS, REFER SHT. 1 OF 2 PIPE DAVIT V#7010 OR EQ.
7-12-0023 GASKET EXTERNAL
OF EIL STD. 7-12-0017.
LIFTING LUG TOP HEAD TYPE 7-12-0024 GASKET INTERNAL SS 304
X FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7/ SA 194 GR.2H
NO PLATFORM/PIPE CLIP SHALL BE SUPPORTED FROM THIS X EARTHING LUG 7-12-0026 INTERNAL STUDS/BOLTS/NUTS SS 304
NAME PLATE 7-12-0027 SKIRT / SUPPORT IS 2062 GR. E250 QUALITY B
EQUIPMENT. MANUFACTURER NAME PLATE 7-12-0028 SKIRT / SUPPORT BASE IS 2062 GR. E250 QUALITY B
BRACKET FOR NAME PLATE 7-12-0029 INTERNAL PARTS (WELDED) SA 240 TP 304
X NAME PLATE FOR SMALL EQUIPMENT

limited way permitted by written consent given by the lender to the borrower for the intended use.
7-12-0030 INTERNAL PARTS (BOLTED) -

DETAILS OF FORGED NOZZLES 7-12-0031 CLIPS & ATTACHMENTS DIRECTLY WELDED (EXTERNAL) SA 240 TP 304
SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 CLIPS & ATTACHMENTS WELDED OVER PAD (EXTERNAL) IS 2062 GR. E250 QUALITY B
HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 PAD FOR EXTERNAL ATTACHMENT SA 240 TP 304
PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 PIPE DAVIT SA 106 GR.B/SA 53
TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036
S.R NOZZLE NECK (FOR GUIDANCE) 7-12-0037
REFERENCE DRAWINGS ¼jsQjsUl MkVk½

NOZZLE ORIENTATIONS
FILE NAME : A842-PDE-80-43-DS-3433-0-1
LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION)

ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) HOLD UPS ¼gksYM vIl½ INDIAN BOILER REGULATIONS (IBR)
TYPE
MAX MOMENT AT BASE (M) MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS SIZE OF NOZZLES PETROLEUM & EXPLOSIVES SAFETY ORGANISATION, (PESO)
(kgm) (kg) NOZZLE ELEVATIONS PIPE SUPPORT CLEATS
SEISMIC SUPPORT HEIGHT LADDER CLEATS

APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼ ,ijkSfDlesaV otu½
- -
LICENSOR'S STANDARD (DBE) DETAILS OF INTERNALS TRAY SUPPORT/BOLTING BARS
ykbZlsUlj LVS.MlZ PIPE DAVIT
SEISMIC
- -
(MCE)
HYDROTEST ( SHOP ) 1900 HYDROTEST ( FIELD ) 1900
WIND - -
NUMBER OF ITEMS : ONE
JOB NO: VESSEL DESIGN DATA oSly fMtkbu MkVk DRAWING NUMBER
ENGINEERS INDIA LIMITED dk;Z l[;k A842 PDE MkbZx uEcj REV
(A Govt. OF India Undertaking) CLIENT :
BPCL,KOCHI
0 12.04.2017REVISED AS MARKED & ISSUED FOR PURCHASE. AKP SA PVS SCUM SEPERATOR स्कम सेपेरटोर A842-PDE-80-43-DS-3433 0
DykbZV REVISED SHEET-2 SG/VIVEK
bathfu;lZ bafM;k fyfeVsM PLANT : PROPYLENE DERIVATIVES
B
A
03.10.2016
28.06.16 ISSUED FOR BIDS/ENGG.
TAA
TAA AS/SG
IK
VIVEK
¼Hkkjr ljdkj dk midze½ IykaV PETROCHEMICAL PROJECT (PDPP) REV DATE REVISION BY CHECKED APPROVED
ITEM NO. PDE-V-433 पीडीई&वी&433 SHEET 1 OF 3
FORMAT NO.3-1646-0113 REV.0 A3-420 X 297
Page 688 of 704

A842 PDE
BPCL,KOCHI
Lde lsijsVj
Page 689 of 704

A842 PDE
BPCL,KOCHI
Lde lsijsVj
Page 690 of 704

The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the
MARK QTY
NOM. DIA SCH./THK. FLANGES PROJECTION PAD
SERVICE X DENOTES APPLICABLITY CODE ASME SEC VIII DIV. 1 EDITION 2015
ukfeuy 'kMwy o CLASS TYPE FACING NOTE-4 WxT
1 ALL DIMENSIONS ARE IN MM. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (kg/cm 2g) ATM
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl SUPP. SPEC. FOR CS VESSELS 6-12-0002 DESIGN PRESSURE (mmWCg) INT FW+150 EXT -50
N1 1 50 80S 150 SO RF 460 -

LIQUID FROM V-420, V-430, V-
2
ALL ANCHOR BOLT HOLES TO STRADDLE N/S X STD. SPEC. FOR AUSTENTIC SS VESSEL 6-12-0006 WORKING TEMPERATURE (0C) 35
431 CENTRELINE. STD. SPEC. FOR BQCS PLATE 6-12-0011 DESIGN TEMPERATURE (0C) 65
N2 1 50 80S 150 SO RF 460 - LIQUID TO V-433 3

NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 MDMT ( 0C) 15
TO PLAN VIEW. X STD. SPEC. FOR STAINLESS STEEL PLATES 6-12-0020 CORROSION ALLLOWANCE (MM) NIL
N3 1 50 80S 150 SO RF 460 - LIQUID TO LZ-611 4 (A)

FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM X STD. SPEC. FOR SHOP & FIELD PAINTING A842-000-79-41-PLS-01 TYPE OF HEAD TOP-FLANGE BOTTOM-2:1 ELLIPSOIDAL
VESSEL CENTER LINE TO FLANGE CONTACT FACE. JOINT EFFICIENCY SHELL 0.85 HEAD 1
RADIOGRAPHY (REFER NOTE-10) FULL
N4 1 50 80S 150 SO RF 460 - FCS INLET 4(B)
FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD
T.L TO FLANGE CONTACT FACE. STANDARDS ¼LVS.MlZ½ POST WELD HEAT TREATMENT
SHELL SPOT
AS PER CODE
HEAD
V1 1 80 80S 150 SO RF
SEE
- VENT 5
THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER X VESSEL TOLERANCES 7-12-0001 HEAT TREATMENT HEAD AS PER SPEC./CODE
DWG CONSTRUCTION. SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM PROCESS FLUID
SEE 6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY 0.884
D1 1 50 80S 150 SO RF - DRAIN
DWG 7 SKIRT BASE DETAILS 7-12-0004 WIND SPECIFICATION IS 875
DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS
SIGHT GLASS CONNECTION PER ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
SG1-17 17 AS PER EIL STD 7-12-0017 ASME B16.47 SERIES `B' UNLESS SPECIFIED OTHERWISE.
(REFER NOTE-15) ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M3) 1.5
SIGHT GLASS CONNECTION FOR 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER SPEC.
G1-17 17 50 80S 150 SO RF 460 - ID OF NOZZLE PIPE.
LIGHTING (REFER NOTE-15)
X BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 INSULATION THICKNESS (mm) NIL HOT COLD
9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2NOS. 40 MANHOLE WITH HINGED COVER 7-12-0009 FIRE PROOFING (mm) (BY OTHERS) NIL YES NO
X 6 THK. FLATS 90° APART.
X MANHOLE WITH DAVIT (FOR GUIDANCE) 7-12-0010 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL VERTICAL (AT TOP)
10 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) FULL OF WATER
RADIOGRAPHED.
RETAINING PLATE 7-12-0012 INSPECTION BY X EIL/TPIA CIB LLOYDS
11 AFTER COMPLETION OF FABRICATION & TESTING, ALL SS CLAD
PAD NOZZLES FOR VESSELS 7-12-0014 (AS PER ASME / IS OR EQUIVALENT)
PASSIVATED IN ACCORDANCE WITH ASTM A-380
12 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS X STANDARD BOLT HOLE ORIENTATION 7-12-0015 SHELL SA 240 GR.304
PER ASTM A262 PRACTICE-E. ALLOY LINER DETAILS 7-12-0016 REINFORCEMENT PAD SA 240 GR.304
13 AFTER HYDROTEST ALL WELDS IN PRESSURE PARTS X SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 HEADS SA 240 GR.304
SHALL BE CHECKED BY DP EXAMINATION. INTERNAL FLANGES 7-12-0018 SHELL FLANGES SA 240 GR.304
14 ALL WELDING LINES ON THE INNER SURFACE SHALL BE VORTEX BREAKERS 7-12-0019 NOZZLE FLANGES SA 182 F 304
SMOOTHLY FINISHED BY A GRINDER INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE NECK UPTO 100 NB SA 312 TP 304
15 FOR SIGHT GLASS CONNECTION DETAILS, REFER SHT. 2 SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK ABOVE 100 NB -
OF 2 OF EIL STD. 7-12-0017 AND FOR SIGHT GLASS SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 PIPE FITTINGS SA 403 WP 304 (SEAMLESS)
CONNECTION FOR LIGHTING DETAILS, REFER SHT. 1 OF 2 PIPE DAVIT V#7010 OR EQ.
7-12-0023 GASKET EXTERNAL
OF EIL STD. 7-12-0017.
LIFTING LUG TOP HEAD TYPE 7-12-0024 GASKET INTERNAL SS 304
X FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7/ SA 194 GR.2H
NO PLATFORM/PIPE CLIP SHALL BE SUPPORTED FROM THIS X EARTHING LUG 7-12-0026 INTERNAL STUDS/BOLTS/NUTS SS 304
NAME PLATE 7-12-0027 SKIRT / SUPPORT IS 2062 GR. E250 QUALITY B
EQUIPMENT. MANUFACTURER NAME PLATE 7-12-0028 SKIRT / SUPPORT BASE IS 2062 GR. E250 QUALITY B
BRACKET FOR NAME PLATE 7-12-0029 INTERNAL PARTS (WELDED) SA 240 TP 304
X NAME PLATE FOR SMALL EQUIPMENT

limited way permitted by written consent given by the lender to the borrower for the intended use.
7-12-0030 INTERNAL PARTS (BOLTED) -

DETAILS OF FORGED NOZZLES 7-12-0031 CLIPS & ATTACHMENTS DIRECTLY WELDED (EXTERNAL) SA 240 TP 304
X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 CLIPS & ATTACHMENTS WELDED OVER PAD (EXTERNAL) IS 2062 GR. E250 QUALITY B
HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 PAD FOR EXTERNAL ATTACHMENT SA 240 TP 304
PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 PIPE DAVIT SA 106 GR.B/SA 53
S.R NOZZLE NECK (FOR GUIDANCE) 7-12-0037
REFERENCE DRAWINGS ¼jsQjsUl MkVk½

NOZZLE ORIENTATIONS
X PROCESS DATASHEET PDPP-DS-V432

FILE NAME : A842-PDE-80-43-DS-3432-0-1
LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION)

ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) HOLD UPS ¼gksYM vIl½ INDIAN BOILER REGULATIONS (IBR)
TYPE
MAX MOMENT AT BASE (M) MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS SIZE OF NOZZLES PETROLEUM & EXPLOSIVES SAFETY ORGANISATION, (PESO)
(kgm) (kg) NOZZLE ELEVATIONS PIPE SUPPORT CLEATS
SEISMIC SUPPORT HEIGHT LADDER CLEATS

- -
LICENSOR'S STANDARD (DBE) DETAILS OF INTERNALS TRAY SUPPORT/BOLTING BARS
ykbZlsUlj LVS.MlZ PIPE DAVIT
SEISMIC
- -
(MCE)
WIND - -
NUMBER OF ITEMS : ONE
JOB NO: VESSEL DESIGN DATA oSly fMtkbu MkVk DRAWING NUMBER
ENGINEERS INDIA LIMITED dk;Z l[;k A842 PDE MkbZx uEcj REV
(A Govt. OF India Undertaking) CLIENT :
BPCL,KOCHI
0 12.04.2017REVISED AS MARKED & ISSUED FOR PURCHASE. AKP SA PVS OIL SEPERATOR ऑइल सेपेरटोर A842-PDE-80-43-DS-3432 0
DykbZV REVISED SHEET-2 SG/VIVEK
bathfu;lZ bafM;k fyfeVsM PLANT : PROPYLENE DERIVATIVES
B
A
03.10.2016
28.06.16 ISSUED FOR BIDS/ENGG.
TAA
TAA AS/SG
IK
VIVEK
¼Hkkjr ljdkj dk midze½ IykaV PETROCHEMICAL PROJECT (PDPP) REV DATE REVISION BY CHECKED APPROVED
ITEM NO. PDE-V-432 पीडीई&वी&432 SHEET 1 OF 3
FORMAT NO.3-1646-0113 REV.0 A3-420 X 297
Page 691 of 704

A842 PDE
BPCL,KOCHI
vkW;y lsijsVj
Page 692 of 704

A842 PDE
BPCL,KOCHI
vkW;y lsijsVj
Page 693 of 704

NOZZLES AND CONNECTIONS ¼uksty o duSD'ku½ 0 GENERAL NOTES (tujy uksV~l½ SPECIFICATIONS ¼LisflfQds'lUl½ DESIGN DATA ¼fMtkbu MkVk½
MARK QTY
ON NOTE-
PAD W
SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SECTION VIII DIV.-1 EDITION-LATEST
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. X SUPP. SPEC. FOR AUSTENTIC SS VESSELS 6-12-0006 DESIGN PRESSURE (kg/cm2g) INT. 3.5 EXT. -
0
3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE ( C) 35
N1 1 80 80S 150 SO RF 1710 40 X T LIQUID FROM V-430
4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM HORIZONTAL X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE 0
( C) 65
N2 1 100 80S 150 SO RF 1710 50 X T LIQUID TO P-431A/B

PLANE/VERTICAL PLANE TO FLANGE CONTACT FACE.
4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO JOB SPEC. FOR SURFACE PREPARATION & SHOP/FIELD CORROSION ALLLOWANCE (MM) 0
SEE FLANGE CONTACT FACE. X PAINTING A842-000-79-41-PLS-01
TYPE OF HEAD 2:1 ELLIPSOIDAL
N3 1 50 80S 150 SO RF - LIQUID TO V-432
DRG. 5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER JOINT EFFICIENCY SHELL 0.85 HEAD 1
CONSTRUCTION. RADIOGRAPHY SHELL SPOT HEAD FULL
N4 1 50 80S 150 SO RF 460 - LIQUID TO V-432
6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH.
N5 1
100
40S 150 SO RF 2075 50 X T MIN. FLOW
7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER ASME X VESSEL TOLERANCES 7-12-0001 HEAT TREATMENT HEAD AS PER SPEC./CODE
(HOLD) B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47
UNLESS SPECIFIED OTHERWISE.
X SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM PROCESS FLUID
WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY 0.884
N6 1 80 80S 150 SO RF 2000 40 X T EQUALIZATION
WIND SPECIFICATION IS 875
8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF SKIRT BASE DETAILS 7-12-0004
SEE NOZZLE PIPE/SHELL. SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
N7 1 100 80S 150 SO RF 50 X T OVER FLOW
DRG. 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M ) 3 49.7
FLATS 900 APART. PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
N8 1 80 80S 150 SO RF 2000 40 X T GAS FROM V-420
10 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED. INSULATION THICKNESS (mm) NIL HOT
BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 COLD
V1 1 100 80S 150 SO RF 2000 50 X T VENT
12 MOC OF INTERNAL GASKET SHALL BE SUITABLE FOR THE DESIGN TEMPERATURE. X MANHOLE WITH DAVIT 7-12-0010 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL (AT TOP)
L1A 1 80 80S 150 SO RF 1710 40 X T LEVEL TRANSMITTER (DIASEAL)

13 AFTER COMPLETION OF FABRICATION & TESTING, ALL SS CLAD SURFACES & X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) 4.55
SS INTERNALS(BOTH SIDES) SHALL BE PICKLED & PASSIVATED IN RETAINING PLATE 7-12-0012 INSPECTION BY X EIL/TPIA CIB LLOYDS
ACCORDANCE WITH ASTM A-380.
L2a,b 2 50 80S 150 SO RF 460 - LEVEL TRANSMITTER (DISPLACER)
X NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013
MATERIAL OF CONSTRUCTION ¼eSfVfj;y vk¡Q dUlVªD'ku)
14 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A262 PAD NOZZLES FOR VESSELS 7-12-0014
(AS PER ASME / IS OR EQUIVALENT)
G1a,b 2 50 80S 150 SO RF 1710 - LEVEL GAUGE (MAGNETIC)
PRACTICE-E. X STANDARD BOLT HOLE ORIENTATION 7-12-0015
15 AFTER HYDROTEST ALL WELDS IN PRESSURE PARTS SHALL BE CHECKED BY ALLOY LINER DETAILS 7-12-0016 SHELL/BOOT SA 240 GR.304
DP EXAMINATION. SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 REINFORCEMENT PAD/INSERT PLATE SA 240 GR.304
G2a,b 2 50 80S 150 SO RF 460 - LEVEL GAUGE TRANSPARENT (SS)
16 ALL WELDING LINES ON THE INNER SURFACE SHALL BE SMOOTHLY HEADS SA 240 GR.304
INTERNAL FLANGES 7-12-0018
MH1 1 600 XX THK 150 SO RF

SEE
255 X T
MANHOLE + B.F. + DAVIT + FINISHED BY A GRINDER.
X VORTEX BREAKERS 7-12-0019 SHELL FLANGES -
DRG. GASKET + BOLTING 17 ALL INTERNALS SHALL BE ATLEAST 6mm THK. INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE FLANGES SA 182 F304
SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK UPTO 100 NB SA 312 TP 304
SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 NOZZLE NECK ABOVE 100 NB SA 240 GR.304
PIPE DAVIT 7-12-0023 PIPE FITTINGS SA 403 GR. 304 (SEAMLESS)
LIFTING LUG TOP HEAD TYPE 7-12-0024 GASKET EXTERNAL V#7010 OR EQ.
FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 GASKET INTERNAL V#7010 OR EQ.
'T' DENOTES CORRESPONDING SHELL/DISH END NOMINAL THICKNESS.

X MANUFACTURER NAME PLATE 7-12-0028 SUPPORT (SADDLE) IS 2062 GR. E250 QUALITY B
X BRACKET FOR NAME PLATE 7-12-0029 SUPPORT BASE IS 2062 GR. E250 QUALITY B
NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 INTERNAL PARTS (WELDED) SA 312 TP 304 / SA240 GR. 304
DETAILS OF FORGED NOZZLES 7-12-0031 INTERNAL PARTS (BOLTED) SA 312 TP 304 / SA240 GR. 304
X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 CLIPS & ATTACHMENTS DIRECTLY WELDED (EXTERNAL) SA 240 GR. 304
HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 CLIPS & ATTACHMENTS WELDED OVER PAD (EXTERNAL) IS 2062 GR. E250 QUALITY B
PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 WRAPPER PLATE SA 240 GR.304
TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 PAD FOR EXTERNAL ATTACHMENT SA 240 GR. 304
S.R NOZZLE NECK 7-12-0037
X ALLOWABLE NOZZLE LOADS 7-12-0038

NOZZLE ORIENTATIONS
PIPE SUPPORT CLEATS
FILE NAME : A842-PDE-80-43-DS-3431-0-1

ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)

MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES - N5
(kg)
X NOZZLE ELEVATIONS - AS MARKED X PIPE SUPPORT CLEATS
SEISMIC
_ _
(MC) _ _ PACKING SUPPORT
WIND _ _ NUMBER OF ITEMS : ONE
NEW DELHI CLIENT : V-440 FEED DRUM वी&400 फीड ड्रम
DykbZV M/s BPCL, KOCHI
0 12.04.2017 REVISED AS MARKED & ISSUED FOR PURCHASE. AKP SA
A842-PDE-80-43-DS-3431 0
bathfu;lZ bafM;k fyfeVsM PLANT : A 06.07.2016 ISSUED FOR BIDS/ENGG. JSN SA/VIVEK
PVS
IK
PDPP ITEM NO. PDE-V-431 vkbVe uEcj & ihMhई&oh&431 SHEET 1 OF 2
¼Hkkjr ljdkj dk midze½ IykaV REV DATE REVISION BY CHECKED APPROVED
FORMAT NO.3-1646-0122 REV.2 (06.12.2011) A3-420 X 297
Page 694 of 704

A842 PDE DRAWING NO. REV.
M/s BPCL, KOCHI
0 12.04.2017 REVISED AS MARKED & ISSUED FOR PURCHASE. AKP SA PVS
PDPP A 06.07.2016 ISSUED FOR BIDS/ENGG. JSN SA / VIVEK IK
Page 695 of 704

MARK QTY
ON NOTE-
PAD W
SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SECTION VIII DIV.-1 LATEST EDITION,PRACTICE
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. X SUPP. SPEC. FOR AUSTENTIC SS VESSELS 6-12-0006 DESIGN PRESSURE (NOTE-27) (mmWCg) INT. F.W. +100 EXT. (-) 50
N1 1 50 80S 150 SO RF 400 - LIQUID FROM OSBL

3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. X STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE
0
( C) 35
4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM VESSEL CENTER LINE TO X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE
0
( C) 65
N2 1 80 80S 150 SO RF 960 40xT OVER FLOW

4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO FLANGE JOB SPEC. FOR SURFACE PREPARATION & PROTECTIVE CORROSION ALLLOWANCE (MM) NIL
CONTACT FACE. X COATING A842-000-79-41-PLS-01
TYPE OF HEAD TOP/BOTTOM - FLAT , INTERMEDIATE - HEMISPHERICAL
N3 1 50 80S 150 SO RF 910 - LIQUID FROM UPPER PART
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER CONSTRUCTION. X STD. SPEC. FOR MECHANICAL AGITATOR 6-26-0001 JOINT EFFICIENCY SHELL 0.85 FLAT/INTERMEDIATE HEAD 1
6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. RADIOGRAPHY SHELL SPOT FLAT/INTERMEDIATE HEAD FULL
N4 1 50 80S 150 SO RF 910 - LIQUID TO LOWER PART

OTHERWISE.
SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM PROCESS FLUID
8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF NOZZLE WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY 0.937
N6~7 2 50 80S 150 SO RF 910 - MXA INLET
PIPE/SHELL. X SKIRT BASE DETAILS 7-12-0004 WIND SPECIFICATION IS 875
9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK FLATS 900 SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
N8~9 2 50 80S 150 SO RF 910 - SPARE + B.F.
APART. ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M ) 3
9
10 VENDOR TO ENSURE THAT ALL REMOVABLE INTERNALS SHALL PASS THROUGH MANHOLE. PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
N10 1 REFER DRG. PTSA INLET
11 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED. X BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 INSULATION THICKNESS (mm) NIL HOT COLD
V1 1 100 40S 150 SO RF 400 60xT VENT
V2 1 50 80S 150 SO RF
REFER
- VENT
14 AFTER COMPLETION OF FABRICATION & TESTING, ALL SS CLAD SURFACES & SS X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) FULL OF WATER
DRG. INTERNALS(BOTH SIDES) SHALL BE PICKLED & PASSIVATED IN ACCORDANCE WITH RETAINING PLATE 7-12-0012 INSPECTION BY X EIL/TPIA CIB LLOYDS
REFER
ASTM A-380.
D1~2 2 50 80S 150 SO RF - DRAIN
DRG. 15 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A262 PRACTICE-E. PAD NOZZLES FOR VESSELS 7-12-0014 (AS PER ASME / IS OR EQUIVALENT)
T1 1 50 80S 150 SO RF 910 - TG

EXAMINATION. ALLOY LINER DETAILS 7-12-0016 SHELL / FLAT HEAD /INTERMEDIATE HEAD SA 240 GR.316
17 ALL WELDING LINES ON THE INNER SURFACE SHALL BE SMOOTHLY FINISHED BY A SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 REINFORCEMENT PAD / INSERT PLATE SA 240 GR.316
L1 1 80 80S 150 SO RF 960 40xT LEVEL TRANSMITTER (DIASEAL) 0 GRINDER
X INTERNAL FLANGES (GUIDANCE ONLY) 7-12-0018 BOTTOM PLATE / TOP PLATE SA 240 GR.316
18 SUPPORT FOR VENT PIPES SHALL BE PROVIDED AS PER EIL STD. 7-12-0032. VORTEX BREAKERS 7-12-0019 SHELL FLANGES SA 240 GR.316
L2 1 80 80S 150 SO RF 960 40xT LEVEL TRANSMITTER (DIASEAL) 0 19 SUPPORT LUGS PROVIDED ON HOPPER IS FOR GUIDING PURPOSE ONLY. INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE FLANGES SA 182 F316
20 BASED ON FINAL AGITATOR NOZZLE OPENING OTHER NOZZLES IN THE HEAD AND SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK UPTO 100 NB SA 312 TP316
G1a,b 2 50 80S 150 SO RF 910 - LEVEL GAUGE (MAGNETIC) 0 LOADING ON TOP HEAD, VENDOR TO CHECK FOR REINFORCEMENT OF OPENING AND SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 NOZZLE NECK ABOVE 100 NB SA 240 GR.316
INCREASE THE THICKNESS OF HEAD (IF REQUIRED) CONSIDERING LIGAMENT
G2a,b 2 50 80S 150 SO RF 910 - LEVEL GAUGE (MAGNETIC) EFFICIENCY DUE TO LARGE NO. OF OPENINGS IN THE HEAD.
0
X LIFTING LUG TOP HEAD TYPE 7-12-0024 GASKET EXTERNAL V#7010 OR EQUIVALENT
X1 1
200
12 THK. 150 SO RF 400 -
AGITATOR MOUNT+ AGITATIOR 21 FULL AGITATOR ASSEMBLY INCLUDING MOTOR, GEARBOX, ALL SUPPORTS, DRIVES X FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 GASKET INTERNAL(NOTE-13) V#7010 OR EQUIVALENT
(HOLD) ASSEMBLY + GASKET+BOLT INCLUDING ALL ACCESSORIES AND SPARES ETC. ARE TO BE DESIGNED AND SUPPLIED
BY VENDOR.
X EARTHING LUG 7-12-0026 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7 / SA 194 GR.4
MH1 1 600 6 THK. 150 SO RF 1010 255xT

MANHOLE + B.F. + DAVIT X NAME PLATE 7-12-0027 INTERNAL STUDS/BOLTS/NUTS SS 316
+ GASKET + BOLT 22 HOPPER INCLUDING GRID, BASKETS & THEIR SUPPOTS, LUG SUPPORT ARE TO BE X MANUFACTURER NAME PLATE 7-12-0028 SKIRT / SUPPORT -
MH2 1 600 6 THK. 150 SO RF 1010 255xT

MANHOLE + B.F. + DAVIT SUPPLIED BY VENDOR.
X BRACKET FOR NAME PLATE 7-12-0029 SUPPORT BASE SA 240 GR.316
+ GASKET + BOLT 23 THE THICKNESS INDICATING IN THE ENGG. DATA SHEETS ARE THE MINIMUM TO BE NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 INTERNAL PARTS (WELDED) SA 312 TP316 / SA 240 GR.316
HANDHOLE + B.F. + DAVIT PROVIDED. VENDOR TO CHECK/VERIFY THE WHOLE DESIGN OF THE VESSEL AND DETAILS OF FORGED NOZZLES 7-12-0031 INTERNAL PARTS (BOLTED) SA 312 TP316 / SA 240 GR.316
HH1 1 150 6 THK. 150 SO RF 400 - NOZZLE SIZE "X1" BASED ON PROCESS DATA SHEETS AND ACTUAL
+ GASKET + BOLT (NOTE-26)
DETAILS/PARAMETERS OF THE AGITATOR. ONLY UPWARD INCREASE IN THE X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 CLIPS & ATTACHMENTS DIRECTLY WELDED
SA 240 GR.316
THICKNESS IS PERMISSIBLE.
BIDDER TO QUOTE ACCORDINGLY KEEPING THIS ASPECT IN CONSIDERATION. NO PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 CLIPS & ATTACHMENTS WELDED OVER
IS 2062 GR.E 250 QUALITY B
PRICE IMPLICATION AT LATER SHALL BE ALLOWED ON THIS ACCOUNT. TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 PAD (EXTERNAL)
24 FINAL LOAD AND FOUNDATION LOADING DATA TO BE CONFIRMED BY THE VENDOR. S.R NOZZLE NECK 7-12-0037 WRAPPER PLATE -
25 PIPE FITTINGS SHALL BE THE SAME SIZE AND THICKNESS AS THE ATTACHED PIPE. X ALLOWABLE NOZZLE LOADS 7-12-0038 DEMISTER/GRID -
26 HANDHOLE NOZZLE SHALL BE LOCATED JUST ABOVE VENT PIPE. PAD FOR EXTERNAL ATTACHMENT SA 240 GR.316
27 DESIGN PRESSURE OF HOPPER IS FW+100MM WC(g)/FV. LIFTING LUG SA 240 GR.316
28 VENDOR TO DESIG LIFTING LUG FOR ERECTION OF COMPLETE EQUIPMENT WITH CURB ANGLE SA 240 GR.316
AGITATOR CONSIDERING AN IMPACT FACTOR OF 2.0. WIRE MESH SS 316
29 LOCATION OF NIPPLE SHALL BE SUCH THAT OPERATOR CAN STAB BOTTOM OF HOPPER
WITH BAR THROUGH SAFETY BAR. HOPPER
30 MINIMUM THICKNESSES OF INTERNAL SHALL BE 6THK. IF NOT SPECIFIED. TOP PLATE SA 240 GR.316
31 DESIGN LOAD FOR BASKET IS 2KN WHICH IS WEIGHT OF PTSA. SHELL / CONE SB 575 HASTELLOY C-276
MESH OF BASKET SHALL BE PROPERLY SECURED WITH ROD & END PLATE. NOZZLE FLANGES SB 462 HASTELLOY C-276
ALL FILLED WELD SHALL BE MINIMUM 9MM. REFERENCE DRAWINGS¼jsQjsUl MkbZx½ NOZZLE NECK UPTO 100 NB SB 622 HASTELLOY C-276
32 ALL REQUIREMENTS OF PDS SHALL BE COMPLIED. NOZZLE ORIENTATIONS NOZZLE NECK ABOVE 100 NB SB 575 HASTELLOY C-276
NECESSARY FREE SPACE ON TOP OF THE VESSEL IS REQUIRED FOR LIFTING AND REMOVING OF THE LADDERS/PLATFORM CLEATS PIPE FITTINGS SB 366 HASTELLOY C-276
AGITATOR ASSEMBLY. PIPE SUPPORT CLEATS GASKET INTERNAL V#7010 OR EQUIVALENT
TRAY SUPPORT AND BOLTING BARS EXTERNAL STUDS/BOLTS/NUTS SB 574
DEMISTER DATA SHEET INTERNAL STUDS/BOLTS/NUTS SB 574
X PROCESS DATA SHEET PDPP-DS-V505 SUPPORT SA 516 GR.70 WITH SB 575 PAD
X AGITATOR DATA SHEET PDPP-DS-A505 INTERNAL PARTS SB 575 / SB 622 / SB 366
CLIPS & ATTACHMENTS DIRECTLY WELDED SB 575 HASTELLOY C-276

FILE NAME : A842-PDE-80-43-DS-3505-0-1

ykbZlsUlj LisflfQds'lUl 0 QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku)(NOTE-24) HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)

MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES - X1
APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼,ijkSfDlesaV otu½(NOTE-24)
(kg)
X NOZZLE ELEVATIONS - N6, N7 X PIPE SUPPORT CLEATS
SEISMIC
15000 4000
(MC) - - PACKING SUPPORT
WIND 2000 900 NUMBER OF ITEMS : ONE
NEW DELHI CLIENT :
M/s BPCL, KOCHI CATALYST MIXING DRUM dSVyhLV fefDlax Mªe A842-PDE-80-43-DS-3505 0
bathfu;lZ bafM;k fyfeVsM PLANT : A 26.07.2016 ISSUED FOR BIDS/ENGG. SV SK/VIVEK IK
REVISION APPROVED
ITEM NO. PDE-V-505 vAbVe uEcj ihMhbZ&oh&505 SHEET 1 OF 3
REV DATE BY CHECKED
FORMAT NO.3-1646-0122 REV.2 (06.12.2011) A3-420 X 297
Page 696 of 704

Page 697 of 704

Page 698 of 704

MARK QTY
ON NOTE-
PAD W
SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SECTION VIII DIV.-1 LATEST EDITION
xT 1 ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (kg/cm g)
2
ATM
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. X SUPP. SPEC. FOR AUSTENTIC SS VESSELS 6-12-0006 DESIGN PRESSURE (mmWCg) INT. F.W. +150 EXT. NIL
N1 1 50 80S 150 SO RF
SEE
- LIQUID FROM LZ-541
3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. X STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE (0C) 37
DWG. 4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM VESSEL CENTER LINE TO STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE (0C) 65
N2 1 50 80S 150 SO RF
SEE
X STD. SPEC. FOR SS PLATE 6-12-0020 MDMT ( 0C) 15
DWG. 4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO FLANGE JOB SPEC. FOR SURFACE PREPARATION & PROTECTIVE CORROSION ALLLOWANCE (MM) 0 FOR SS
SEE CONTACT FACE. X COATING A842-000-79-41-PLS-01
TYPE OF HEAD FLAT
N3 1 50 80S 150 SO RF - LIQUID FROM LZ -551
DWG. 5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER CONSTRUCTION. JOINT EFFICIENCY SHELL 0.85 HEAD 1
6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. RADIOGRAPHY SHELL SPOT HEAD FULL
N4 1 50 80S 150 SO RF
SEE
DWG.
STANDARDS ¼LVS.MMZl½ POST WELD HEAT TREATMENT -

OTHERWISE.
SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 OPERATING MEDIUM P
SEE 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF NOZZLE WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 SP. GRAVITY REFER TABLE-I
N6 1 50 80S 150 SO RF - LIQUID FROM E-543
DWG. PIPE/SHELL. X SKIRT BASE DETAILS 7-12-0004 WIND SPECIFICATION IS 875
SEE 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK FLATS 90 0
SKIRT OPENING DETAILS 7-12-0005 SEISMIC IS 1893 + SITE SPECTRA
N7 1 50 80S 150 SO RF - LIQUID FROM LZ-516
DWG. APART. ANGLE LEG SUPPORT 7-12-0006 CAPACITY (M ) 3
10.9
SEE 10 VENDOR TO ENSURE THAT ALL REMOVABLE INTERNALS SHALL PASS THROUGH MANHOLE. PIPE LEG SUPPORT 7-12-0007 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
N8 1 50 80S 150 SO RF - LIQUID FROM P-512A/B
DWG. 11 ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED. BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 INSULATION THICKNESS (mm) NIL HOT COLD
12 SURFACE CLEANING/ PRIMER SHALL BE AS PER JOB SPECIFICATION. MANHOLE WITH HINGED COVER 7-12-0009 FIRE PROOFING NIL YES NO

14 AFTER COPMPLETION OF FABRICATION & TESTING, ALL SS CLAD SURFACES & SS X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 PRESSURE (NEW & COLD) FULL OF WATER
INTERNALS(BOTH SIDES) SHALL BE PICKLED & PASSIVATED IN ACCORDANCE WITH RETAINING PLATE 7-12-0012 INSPECTION BY EIL/TPIA CIB LLOYDS
ASTM A-380.
15 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A262 PRACTICE-E. PAD NOZZLES FOR VESSELS 7-12-0014 (AS PER ASME / IS OR EQUIVALENT)
N12 1
50
- 150 SO RF - - MIN. FLOW
(HOLD) EXAMINATION. 7-12-0016 SHELL/BOOT SA 240 GR.304
ALLOY LINER DETAILS
17 ALL WELD LINES ON THE INNER SURFACE SHALL BE SMOOTHLY FINISHED BY A SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 REINFORCEMENT PAD/INSERT PLATE SA 240 GR.304
N13 1 50 80S 150 SO RF 1360 - OVER FLOW GRINDER.
X INTERNAL FLANGES 7-12-0018 BOTTOM PLATE/TOP PLATE SA 240 GR.304
SEE VORTEX BREAKERS 7-12-0019 SHELL FLANGES -
N14 1 50 80S 150 SO RF - FCS INLET
DWG. INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE FLANGES SA 182 F304
SEE SUPPORT RING AND BOLTING BAR 7-12-0021 NOZZLE NECK UPTO 150 NB SA 312 TP304
V1 1 80 80S 150 SO RF 45xT VENT
DWG. SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 NOZZLE NECK ABOVE 150 NB SA 240 GR.304
D1 1 50 80S 150 SO RF 1360 - DRAIN
FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 GASKET INTERNAL(NOTE-13) V#7010 OR RQUIVALENT
D2 1 50 80S 150 SO RF 1360 - DRAIN

X MANUFACTURER NAME PLATE 7-12-0028 SKIRT / SUPPORT -

X BRACKET FOR NAME PLATE 7-12-0029 SKIRT / SUPPORT BASE SA 240 TP304
NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 INTERNAL PARTS (WELDED) SA 312 TP304 / SA 240 GR.304
DETAILS OF FORGED NOZZLES 7-12-0031 INTERNAL PARTS (BOLTED) SA 312 TP304 / SA 240 GR.304
L3 1 80 80S 150 SO RF 1410 45xT LEVEL TRANSMITTER (DP DIA SEAL)
X SUPPORTS FOR INTERNAL FEED PIPE (HOLD) 7-12-0032 CLIPS & ATTACHMENTS DIRECTLY WELDED
SA 240 GR.304
G1A/B 2 50 80S 150 SO RF 1360 - LEVEL GAUGE (TRANSPARENT-SS)
PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 CLIPS & ATTACHMENTS WELDED OVER PAD
SA 516 GR.70
TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 (EXTERNAL)
G2A/B 2 50 80S 150 SO RF 1360 - LG
S.R NOZZLE NECK 7-12-0037 WRAPPER PLATE -
MH1 1 600 150 SO RF 1460 300xT MAHOLE + DAVIT+ B.F. X ALLOWABLE NOZZLE LOADS 7-12-0038 DEMISTER/GRID -
PAD FOR EXTERNAL ATTACHMENT SA 240 GR.304
LIFTING LUG SA 516 GR.70
HH1 1 150 150 SO RF 1460 85xT HANDHOLE + B.F.
CURB ANGLE SA 240 GR.304

NOZZLE ORIENTATIONS
PIPE SUPPORT CLEATS
TRAY SUPPORT AND BOLTING BARS
DEMISTER DATA SHEET
THERMOWELL DETAIL
FILE NAME : A842-PDE-80-43-DS-3525-A-1
TAILING LUG DETAIL A842-PDE-80-43-SK-0002

MONKEY LADDER A842-PDE-80-43-SK-0001 STATUTORY REGULATIONS ¼LVSpqvjh jsxqys'kUl½
ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)

MAX. SHEAR FORCE AT BASE (H) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES N12
(kg)
X NOZZLE ELEVATIONS X PIPE SUPPORT CLEATS
SEISMIC SUPPORT HEIGHT X LADDER/PLATFORM CLEATS

(MC) PACKING SUPPORT
WIND NUMBER OF ITEMS : ONE
NEW DELHI CLIENT :
M/s BPCL, KOCHI WATER SURGE DRUM okVj ltZ Mªe A842-PDE-80-43-DS-3525 0
DykbZV 0 12.04.2017REVISED AS MARKED AND ISSUED FOR PURCHASE TAA SA PVS
bathfu;lZ bafM;k fyfeVsM PLANT : A 28.06.2016 ISSUED FOR BIDS/ENGG. TAA DG/MKP -
REVISION APPROVED
ITEM NO. PDE-V-525 vkbVe uEcj ihMhbZ&oh&525 SHEET 1 OF 2
REV DATE BY CHECKED
FORMAT NO.3-1646-0122 REV.2 (06.12.2011) A3-420 X 297
Page 699 of 704

L2 1 80 80S 150 SO RF -
G1a,b 2 50 80S 150 SO RF -
G2a,b 2 50 80S 150 SO RF -
MH1 1 600 150 SO RF 300xT
HH1 1 150 150 SO RF 85xT
'T' DENOTES CORRESPONDING SHELL/DISH END/SKIRT NOMINAL THICKN
Page 700 of 704

LT
LG
LG
MAHOLE + DAVIT+
B.F.
HANDHOLE + B.F.
RT NOMINAL THICKNESS.
Page 701 of 704

vkbZVe uEcj & ihMhb&oh&525
Page 702 of 704

NOZZLES AND CONNECTIONS ¼uksty o duSD'ku½ GENERAL NOTES (tujy uksV~l½ SPECIFICATIONS ¼LisflfQds'kUl½ DESIGN DATA ¼fMtkbu MkVk½
The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the limited
MARK QTY
NOM. DIA SCH./THK. FLANGES PROJECTION
PAD WxT SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SEC VIII DIV. 1 LATEST EDITION
ukfeuy 'kMwy o CLASS TYPE FACING NOTE-4 1 ALL DIMENSIONS ARE IN MM, UNLESS OTHERWISE STATED. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (mm Hg) 200
ekdZ DokfUVVh Mka;k fFkduSl Dykl VkbZi Qsflx izkstsD'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRELINE. X SUPP. SPEC. FOR AUSTENTICS SS VESSELS 6-12-0006 DESIGN PRESSURE (kg/cm2a) INT 3.5 EXT F.V.
3 NORTH DIRECTION, WHEREVER SHOWN, IS WITH RESPECT TO PLAN SUPP. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE (0C) 31
N1 1 150 40S 150 SO RF 2020 70x12 LIQUID FROM E-412 VIEW.
X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE 0
( C) 65
N2 1 50 80S 150 SO RF 980 - LIQUID FROM E-413 4 (A)

FOR NOZZLES ON SHELL, PROJECTIONS ARE REFERRED FROM VESSEL X STANDARD SPEC. FOR SS PLATES 6-12-0020 MDMT (0C) 15
CENTER LINE TO FLANGE CONTACT FACE.
X JOB SPEC. FOR SHOP & FIELD PAINTING A842-000-79-41-PLS-01 CORROSION ALLLOWANCE (MM) NIL
FOR NOZZLES ON HEAD, PROJECTIONS ARE REFERRED FROM HEAD T.L TYPE OF HEAD 2:1 ELLIPTICAL
N3 1 100 80S 150 SO RF 1810 50x12 LIQUID TO P-411A/B 4(B)
TO FLANGE CONTACT FACE. JOINT EFFICIENCY SHELL 0.85 HEAD 1
5 THE INDICATED THICKNESS ARE THE MINIMUM ACCEPTABLE AFTER RADIOGRAPHY SHELL SPOT HEAD FULL
N4 1 100 80S 150 SO RF 1810 50x12 LIQUID TO P-412A/B CONSTRUCTION. POST WELD HEAT TREATMENT AS PER CODE/SPEC.
100 6 FLANGE GASKET FACE SHALL HAVE 125 AARM FINISH. HEAT TREATMENT HEAD AS PER SPEC.
N5 1 80S 150 SO RF 2020 50x12 MIN. FLOW (FROM P-411A/B) DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER
(HOLD) OPERATING MEDIUM PROCESS FLUID
100
7
ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME
B16.47 SERIES `B' UNLESS SPECIFIED OTHERWISE.
STANDARDS ¼LVS.MMZl½ SP. GRAVITY (LIQUID/GAS) 0.857/0.977
N6 1 80S 150 SO RF 2020 50x12 MIN. FLOW (FROM P-412A/B)
(HOLD) 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF X VESSEL TOLERANCES 7-12-0001 WIND SPECIFICATION IS 875
N7 1 50 80S 150 SO RF 2020 - EQUALIZATION

NOZZLE PIPE.
X SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 SEISMIC IS 1893 + SITE SPECTRA
9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2NOS. 40 X 6 WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 CAPACITY (M3) 62.5
THK. FLATS 90° APART.
SKIRT BASE DETAILS 7-12-0004 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
N8 1 50 80S 150 SO RF 2020 - LN INLET
ALL NOZZLES FABRICATED FROM PLATE SHALL BE 100% SKIRT OPENING DETAILS 7-12-0005 INSULATION THICKNESS (mm) NIL HOT COLD
10
RADIOGRAPHED. 7-12-0006 FIRE PROOFING (mm) ( BY OTHERS) - X YES NO
ANGLE LEG SUPPORT
N9 1 50 80S 150 SO RF 1450 - FCS INLET AFTER COMPLETION OF FABRICATION & TESTING, ALL SS CLAD
11 PIPE LEG SUPPORT 7-12-0007 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL (AT TOP)
PASSIVATED IN ACCORDANCE WITH ASTM A-380. BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 PRESSURE (NEW & COLD) 4.55
T1 1 50 80S 150 SO RF 1450 - TE
12 ALL PLATES, WELDS AND HAZ SHALL BE IGC TESTED AS PER ASTM A262 MANHOLE WITH HINGED COVER 7-12-0009 INSPECTION BY X EIL /TPIA CIB LLOYDS
LEVEL TRANSMITTER PRACTICE-E.
X MANHOLE WITH DAVIT 7-12-0010 MATERIAL OF CONSTRUCTION ¼eSfVfj;y vk¡Q dUlVªD'ku)
L1a 1 50 80S 150 SO RF 2020 -
(DISPLACER) 13 AFTER HYDROTEST ALL WELDS IN PRESSURE PARTS SHALL BE CHECKED X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 (AS PER ASME / IS OR EQUIVALENT)
LEVEL TRANSMITTER BY DP EXAMINATION. SHELL SA 240 Gr.304
RETAINING PLATE 7-12-0012
L1b 1 50 80S 150 SO RF 1450 -
(DISPLACER) X NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013 REINFORCEMENT PAD SA 240 Gr.304
LEVEL TRANSMITTER (DP PAD NOZZLES FOR VESSELS 7-12-0014 HEADS SA 240 Gr.304
L2a 1 80 80S 150 SO RF 2020 40x12
DIASEAL) X STANDARD BOLT HOLE ORIENTATION 7-12-0015 SHELL FLANGES -
LEVEL TRANSMITTER (DP ALLOY LINER DETAILS 7-12-0016 NOZZLE FLANGES / LWN SA 182 F304
L2b 1 80 80S 150 SO RF 1450 40x12
DIASEAL) SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 NOZZLE NECK UPTO 100 NB SA 312 TP.304
G1a 1 50 80S 150 SO RF 1810 -

LEVEL GAUGE TRANSPARENT X INTERNAL FLANGES
7-12-0018
NOZZLE NECK ABOVE 100 NB SA 240 Gr.304
(SS)
X VORTEX BREAKERS 7-12-0019 PIPE FITTINGS SA 403 WP 304
LEVEL GAUGE TRANSPARENT INLET DEFLECTOR BAFFLE 7-12-0020 GASKET EXTERNAL V#7010 OR EQ.
G1b 1 50 80S 150 SO RF 1300 -
(SS) SUPPORT RING AND BOLTING BAR 7-12-0021 GASKET INTERNAL V#7010 OR EQ.
SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7/ SA 194 GR.2H
G2a,b 2 50 80S 150 SO RF 1300 - MAGNETIC LEVEL GAUGE
PIPE DAVIT 7-12-0023 INTERNAL STUDS/BOLTS/NUTS SS 304
LIFTING LUG TOP HEAD TYPE 7-12-0024 SUPPORT(SADDLE) IS 2062 GR.250 QUALITY B
P1 1 50 80S 150 SO RF 2020 - PT
FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 SUPPORT BASE IS 2062 GR.250 QUALITY B
P2 1 50 80S 150 SO RF 2020 - PG X EARTHING LUG 7-12-0026 INTERNAL PARTS (WELDED) SA 240 Gr.304/SA 312 TP.304
X NAME PLATE 7-12-0027 INTERNAL PARTS (BOLTED) SA 240 Gr.304/SA 312 TP.304
MH1-2 2 600 6 THK. 150 SO RF 1060 300x12

MANHOLE WITH DAVIT & BLIND X MANUFACTURER NAME PLATE 7-12-0028 CLIPS & ATTACHMENTS DIRECTLY WELDED (EXTERNAL) SA 240 Gr.304
FLANGE X BRACKET FOR NAME PLATE 7-12-0029 CLIPS & ATTACHMENTS WELDED OVER PAD (EXTERNAL) IS 2062 GR.250 QUALITY B
way permitted by written consent given by the lender to the borrower for the intended use.
NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 PAD FOR EXTERNAL ATTACHMENT SA 240 Gr.304
DETAILS OF FORGED NOZZLES 7-12-0031 WRAPPER PLATE SA240 Gr.304
X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032

HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033
PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034
S.R NOZZLE NECK 7-12-0037
X ALLOWABLE NOZZLE LOADS 7-12-0038
REFERENCE DRAWINGS ¼jsQjsUl MªkabZx½

NOZZLE ORIENTATIONS -
FILE NAME : A842-PDE-80-43-DS-3411-0-1
LADDERS/PLATFORM CLEATS -
PIPE SUPPORT CLEATS -
LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION) DEMISTER DATA SHEET -
ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) X PROCESS DATASHEET PDPP-DS-V411 INDIAN BOILER REGULATIONS (IBR)
PETROLEUM & EXPLOSIVES SAFETY ORGANISATION, (PESO)
MAX. SHEAR FORCE AT BASE (H)
(kg) HOLD UPS ¼gksYM vIl½
SEISMIC X NOZZLE ORIENTATIONS X SIZE OF NOZZLES-N5, N6
- -
(DBE)
LICENSOR'S STANDARD X FIXED/SLIDING SUPPORT X PIPE SUPPORT CLEATS ERECTION 16000 OPERATING 73000
ykbZlsUlj LVS.MlZ SEISMIC X LADDER/PLATFORM CLEATS
- -
(MCE)
WIND - -
0 NUMBER OF ITEM : 01 (ONE)
JOB NO: DESIGN DATA fMtkbu MkVk DRAWING NUMBER

ENGINEERS INDIA LIMITED dk;Z l[;k A842 UNIT - PDE MkbZx uEcj REV
(A Govt. OF India Undertaking)
bathfu;lZ bafM;k fyfeVsM
CLIENT :
DykbZV M/S BPCL- KOCHI REFINERY
0 12.04.2017 REVISED AS MARKED AND ISSUED FOR PUR. AKP SA PVS
V-410 RECEIVER oh&410 fjlhoj A842-PDE-80-43-DS-3411 0
PLANT : ISSUED FOR BIDS/ENGG. SG/VIVEK
¼Hkkjr ljdkj dk midze½ IykaV ACRYLATE
A
REV
11.07.2016
DATE REVISION
SV
BY CHECKED
IK
APPROVED
ITEM NO. PDE-V-411 ihMhÃ&oh&411 SHEET 1 OF 2
FORMAT NO.3-1646-0118 REV.2(6.12.2011) A3-420 X 297
Page 703 of 704

Page 704 of 704

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Engineering, Procurement and Construction Management

Consultancy Services - Stage-2 (EPCM-2) for Propylene Derivative

GROUP ITEM CODE: 01AA,01AE DESTINATION: As per Commercial Documents

A842 PDE VV PR 6041 / 0041 0 12/04/2017 80 43

S133 Shree Satyanarayan Ind. Supp. Pvt. Ltd

VENDOR CODE VENDOR NAME

REV. DATE BY CHK. APPD. DETAILS

Project: PMC-2 FOR PROPYLENE DERIVATIVE

including design of Agitators, procurement

of following equipment, supply of agitator

08.01 {08}PDE-V-405 For Sr. No. 01.01 1 /diem rate

Project: PMC-2 FOR PROPYLENE DERIVATIVE

SL. REV. REV. REV. REV.

In case of any subsequent revision of MR or PR, only revised sheets of the

1. FOR LIST OF ATTACHMENTS REFER "TABLE OF CONTENTS".

Project: PMC-2 FOR PROPYLENE DERIVATIVE

SPECIAL DESIGN REQUIREMENT

CLIENT: Bharat Petroleum Corporation Limited

5.1 COMMON NOTICE………………………………………………………………… 4

5.1.1 General ……………………………………………………………………… 4

5.1.2 Distinctive Features of AA/AE Process …………………………………… 4

5.1.3 Analysis ……………………………………………………………………… 4

5.2 DESIGN REQUIREMENT FROM PROCESS FEATURES…………………….. 5

5.2.1 General ……………………………………………………………………… 5

5.2.2 Equipment ……………………………………………………………………… 5

5.2.3 Piping …………………………………………………………………………… 11

5.2.4 Insulation and Tracing ……………………………………………………… 13

5.2.5 Civil …………………………………………………………………………… 16

5.2.6 Vendor List ……………………………………………………………………… 18

5.3 CONSIDERATIONS FOR DETAILED ENGINEERING………………………… 19

5.3.1 General ……………………………………………………………………… 19

5.3.2 Project Design Basis ……………………………………………………… 19

5.3.3 Battery Limit Conditions ……………………………………………………… 19

5.3.4 Piping & Instrument Diagram (P&ID) ………………………………………… 19

5.3.4.1 Line Size

5.3.5 General Plot Plan and Equipment Plot Plan ……………………………… 21

5.3.6 Hazardous Area Classification ……………………………………………… 21

5.3.7 Equipment ……………………………………………………………………… 21

5.3.8 Piping …………………………………………………………………………… 23

5.3.9 Instrument ……………………………………………………………………… 24

5.3.10 Electrical ……………………………………………………………………… 24

5.3.11 Civil …………………………………………………………………………… 24

5.3.12 Others …………………………………………………………………………… 24

5.1 COMMON NOTICE

5.1.2 Distinctive Features of AE Process

5.2 DESIGN REQUIREMENT FROM PROCESS FEATURES

Fig.-1: Modified Male and Female Flange (Typical)

Equipment Girth Flange Heat Exchanger Channel Head Flange

5.2.2.4 Heat Exchanger

(2) Tank Cooler

Page 100 of 704

(c) Mechanism of mechanical seal trouble on Acrylate process pumps is

Page 101 of 704

Page 102 of 704

Circulation Required Specifications

Fig.-6-I: Piping around Flow Meter and Control Valve in P&ID

Min. Min. Min.

Fig.-6-II: Piping around Area Flow Meter and Control Valve

Page 103 of 704

5.2.4 Insulation and Tracing

5.2.4.2 Requirement for Insulation and Tracing

Page 104 of 704

Fig.-7 Thermal insulation slip (For Reference)

Page 105 of 704