LPG Blending facilities – List of documents for Tendertenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2655/Tender/COMP... · LPG Blending facilities – List of documents for

LPG Blending facilities – List of documents for Tender 1, Scope of work 8122-03-DA-001 2, Sub vendor list 8122-03-DA-001 VL, 8122-01-DA-001 VL 3, Engg Specifications 25ES205/94-r1 Fabrication and Erection of steel piping 8122-03-ES-001 Spec for GRP piping 8122-12-DA-001 Spec for Cement Mortar lining 8122-12-DA-002 Spec for Pipeline concrete coating 25ES201 Erection of Static equipments 25ES202 Erection of Machinery items 02ES042/97 Spec for Cold Insulation 02ES023/97 Spec for Painting 8122-01-PS-002DV Standard Spec for Deluge Valves 4, Data Sheets of Fire equipments 8122-01-DA-FH100 Hydrant assembly 8122-01-DA-FH101 Water Monitor 8122-01-DA-FH102 Spray nozzles 8122-01-DA-FH103 Hose box 8122-01-DA-FH104 Deluge valve system 5, Layouts 8122-03-OP-00001 Overall plot plan 8122-03-UP-00001 Unit plot plan – Coastal terminal area 8122-03-UP-00002 Unit plot plan – Heat Exchanger area 8122-03-UP-00003 Unit plot plan – Sea Water Pump house 8122-03-KP-00001 Piping Key plan 8122-03-KP-00002 Piping Key plan 8122-03-KP-00003 Piping Key plan 8122-03-KP-00004 Piping Key plan 8122-03-KP-00005 Piping Key plan 8122-03-KP-00006 Piping Key plan 8122-01-ZM-00001 Piping routing of Fire hydrant 6, Isometrics

8122-03-IS-001 to 016 Piping Isometric drawings 16 Nos

7, Schedule of Items of work 8122-03-SW-001

PIPING DEPARTEMNT

8122 – 03 – DA – 001R0 Page 1 of 6

PRPD. BY : GSP CHKD. BY : KPM APPRD. BY: KAK ISSUED ON: 16-10-2009

FACT ENGINEERING AND DESIGN ORGANISATION

Supply, Fabrication, Erection, Testing and Commissioning of Piping and Equipments

Introduction

M/s Hindustan Petroleum Corporation Ltd (HPCL) proposes to install an ‘Online Blending Facility’ at

their Mangalore terminal for blending of Propane and Butane unloaded from the ship. For this purpose

they have requested additional area (appr 3 acres) adjacent to their Coastal terminal which is 1 km away

from the NMPT jetty.

The Online Blending facility shall include one LPG Heater, 3 nos Sea water pumps, one Static Mixer, 2

nos LPG Booster pumps and connected piping and instruments. The LPG Booster pumps will be located

in the new Pump house being constructed at HPCL Terminal whereas all other equipments will be

located in the NMPT jetty area. The Sea water pumps shall be located in the existing fire water pump

house after relocating the existing Jockey pumps.

This tender specification covers the fabrication, erection, testing and commissioning of the LTCS and CS

piping systems and supply, fabrication, erection, testing and commissioning of the GI & GRP piping

systems, supply and erection of Fire fighting equipments and Erection of Equipments

The major piping systems in the plant are

1, LPG system – Carbon steel, Class 300

2, Propane, Butane system – Low Temp Carbon steel, Class 300

3, Sea water system – Glass reinforced plastic (GRP), Class 150

4, Fire water system – Cement lined Carbon steel, Class 150 & Galvanised Iron, Class 150

A, Scope of work - Piping

The scope of the Contractor includes

1, Fabrication and Erection of CS & LTCS piping

2, Supply, fabrication and erection of GI & GRP piping

3, Fabrication and Erection of Cement lined CS piping

4, Testing & commissioning

5, Supply/Application of Painting

6, Supply/Installation of Cold Insulation

7, Dismantling of existing piping

PIPING DEPARTEMNT Fabrication and Erection of Piping

8122-03-DA-002R0

Page 2 of 6


8, Tie in connections with the existing systems

9, Supply/erection of Structural supports etc

10, Supply and Erection of Fire fighting equipments

The details of the above are given below

1 Fabrication and Erection of CS and LTCS piping

The Fabrication and Erection of piping shall be done strictly as per drawings, codes, standards, Engg

specification 25ES205 – 94/R1( Fabrication and Erection of Steel piping) and instructions from the

Engineer in charge in a professional way. All the tools, tackles, consumables, manpower etc, required for

the work, shall be arranged by the Contractor.

The following codes/standards shall apply

a, ASME B31.3 – Process piping

b, OISD 144 – LPG Installations

c, OISD 158 – Recommended Practices on Storage and handling of Bulk LPG

d, OISD 214 – Cross country LPG pipelines

2 Supply, fabrication and erection of GI & GRP piping

GI & GRP materials including pipes, fittings, flanges, gaskets, fasteners, CI/Bronze valves etc are

included in the scope of the Contractor. These items shall be procured from the Sub Vendor list attached

to the tender. If any item is required for which vendor list is not given, the Contractor shall get prior

approval from the Owner/ Consultant before procuring the item.

The general specification of the GRP items ( 8122-ES – 03 – 001) is attached. The Contractor shall

forward their procurement data sheets/specifications to Owner/Consultant for their review

All transportation, loading/unloading, handling, follow up with the supplier etc are included in the scope.

The items shall be despatched from the supplier’s works only after inspection by Owner/ Consultant or

after getting clearance from them.

For all items procured by the Contractor, 6 copies of Manufacturer’s Test Certificates for all mandatory

tests shall be furnished by the Contractor.


8122-03-DA-002R0

Page 3 of 6


The Fabrication and Erection of piping shall be done strictly as per drawings, codes,

specifications/standards and instructions from the Engineer in charge in a professional way. The

installation of GRP piping shall be as per AWWA Manual M45 – Fibreglass pipe Design. All the tools,

tackles, consumables, manpower etc, required for the work, shall be arranged by the Contractor.

The required gaskets and fasteners (galvanized) shall be supplied by the contractor although there are no

separate rates for theses items. Branch connections shall also be made by the Contractor at no extra cost.

For GI piping, all the threaded joints shall be seal welded after hydro static pressure testing.

3 Fabrication and Erection of Cement lined piping

The existing cement lined Fire water headers are to be re routed as per drawing. Also the Jockey

pump discharge lines are to be hooked up with the existing Fire water header in the pump house.

Necessary sleeves for joining, fasteners ( Galvanised)/non metallic gaskets, cement, sand, steel etc for

cement lining are in the scope of the Contractor. Cement lining of new piping as well as repair of cement

lining of the existing piping (if any) as per Specification 8122-12-Da-001attached shall also be carried

out by the contractor at the quoted rate.

4 Testing and Commissioning

Necessary Tests and Inspection of the piping during fabrication/erection and after erection shall be

carried out by the Contractor.

Radiographic/ Ultrasonic Inspection of 100% butt joints and DP testing of 100% fillet joints shall be

arranged by the Contractor.

After completion of the fabrication and erection, the piping shall be subjected to Hydrostatic pressure

Testing at 1.5 times the design pressure.

All the tools, tackles, consumables, manpower etc, required for the work, shall be arranged by the

Contractor

5 Supply and Application of Painting

All Carbon steel and LTCS piping shall be coated with 1coat of primer and Structurals shall be coated

with 2 coats of primer and 2 coats of finish paint as per Engg specification 02ES203/97. All materials,


8122-03-DA-002R0

Page 4 of 6


tools/tackles, manpower, scaffolding etc shall be arranged by the Contractor. Sand/shot Blasting is not

envisaged.

The primer shall be of ‘Two pack poly urethane holding primer’ ( 30 microns DFT) and the finish coats

shall be of ‘High build poly urethane coating’ ( 60 microns total DFT).

6 Supply and Installation of Cold Insulation as per 02ES042/97

Pre formed Poly urethane Cold Insulation over the pipes/valves/flange joints etc shall be applied as per

drawings/specifications /standards and instructions from the Engineer in charge. For all items, 6 copies of

Manufacturer’s Test Certificates shall be furnished to HPCL.

All materials, tools/tackles, manpower, scaffolding etc shall be arranged by the Contractor.

The supply and installation of Permali blocks( treated teak wood blocks)/ High Density Poly Urethane

blocks at the location of supports is also in the scope of Contractor.

Providing 12 mm concrete coating over the insulated piping as per Specification 8122-12-DA-002

attached is also in the scope of the Contractor.

7 Dismantling of existing piping

For the hook up/ installation of new piping, some of the existing pipelines including fittings, valves,

flanges etc are to be dismantled. The dismantled piping is to be transported to the location specified by

the Owner

8 Tie in connections with the existing system

Necessary tie in connections for hooking up the new system with the existing system shall be carried

out by the Contractor. Draining, flushing, blinding, cold cutting, dismantling / boxing up of joints,

temporary connections and any other activity required for obtaining hot work permit are to be carried out

by the Contractor. Hook up at Loading arm area is with flange and no payment shall be made for this tie

in connection. (Payment shall be made for Fabrication and Erection only).


8122-03-DA-002R0

Page 5 of 6


9 Structural supports etc

Necessary pipe supports shall be done by the Contractor. The structurals shall also be painted as per

specification. Supply of structurals and MS plates is also included in the Contractor’s scope. All

miscellaneous works required for the completion of the job are in the scope of the Contractor.

10 Supply and Erection of Fire Fighting Equipments

Supply and erection of Fire fighting equipments such as Deluge valves, Monitors, hydrants, Spray

nozzles, quartzoid bulbs etc are included in the Scope of Contractor including gaskets, fasteners etc.

Supply of these items shall be as per specification 8122-01-PS-002DV and Data sheets ( 8122-01-DA-

FH100, FH101, FH102 , FH103& FH 104) attached.

11 Free issue of Materials

The following materials, limited to the extent of actual usage, shall be issued to the Contractor free of

cost

Metallic pipes, fittings, flanges, gaskets/fasteners( only for CS/LTCS piping)

Valves ( except CI/ Bronze valves), Strainers, Static Mixer

12 Drawings

Construction issue isometric drawings shall be issued except for Fire water piping and for small

bore lines below 50NB.

The quantities indicated are approximate only. Contractor has to supply and erect as per actual

requirement.

B Scope of work – Equipments

1, The following equipments are to be erected as per Engg specifications 25ES201 and 25ES202

1, LPG Booster Pump - Vertical, 2 Nos, 4Te weight, 1.2M x 1.2 Mx 5.5M appr. dimensions

2, Sea water pump – Vertical, 3 Nos, 2.75Te weight, 1.5M x 1.5M x 12 m appr dimensions

3, Jockey pump – Vertical, 2 Nos, 1Te weight, 1.2M x 1.2M x 12 M appr dimesions

4, LPG Heater – Horizontal, 1 No, 10.5 Te weight, 953mm dia x 8300mm overall length


8122-03-DA-002R0

Page 6 of 6


2 All equipment shall be erected as per the instructions specified in the Instruction Manual

supplied by equipment vendor. If suppliers’ engineers are available at site, erection of equipment

shall be as per their instructions.

3 Before taking over the foundation for erection, its dimensions, co-ordinates, orientation and

elevations shall be checked with relevant layout drawings. Location and size of the foundation

pockets shall also be checked. Serious deviations, if any, shall be reported to HPCL engineers at

site.

4, Foundation surface may have to be dressed with a chisel to remove irregularities or to ensure

sufficient roughness. This shall be done by the erection contractor.

5, Before placing the equipment over foundation, the foundation shall be washed clean. 6, The equipment shall be thoroughly cleaned by compressed air or clothes to remove dust/dirt. 7 Foundation bolts are supplied along with the equipment. Erection contractor shall check whether

correct foundation bolts as per equipment drawings are supplied.

8 In case foundation bolts are not available with the equipment, bidder shall supply the same. Unit

rate (Per Kg basis) shall be quoted in the bid for supply of various sizes of foundation bolts.

9 Equipment and drivers shall be aligned at site by erection contractor. If the couplings are

supplied with pilot bores, boring of the couplings to suit shaft diameters and cutting keyways

shall be done by erection contractor. In case any error in holes on base plates are noted, this shall

be got rectified by the erection contractor. Filling lubricants shall be done by erection contractor.

Lubricants will be supplied by HPCL.

10 Shims, wedges, jack bolt pads, routing materials etc. required for erection shall be supplied by

erection contractor. Shims shall be of SS 304 material.

11 Leveling of equipment shall be done by precision tools. 12 All tools, tackles, labour and consumables for erection shall be supplied by the erection

contractor. Bidders shall visit the site and familiarize the site conditions before quoting.

0 15.10.09 FOR TENDER GSP

PREPARED APPROVED

KAK

REV.NO.

PAGE

8122 - 03 - DA - 001 VL

SUB VENDOR LIST - Piping

OF R 02

DATE DESCRIPTION

TECHNICAL

PROCUREMENT

SPECIFICATION

1

00FT024/94


KPM

CHECKED

A) GRP PIPES & FITTI GS

1. M/s Shriram SEPL Composites, Chennai

2. M/s Amiantit, Goa

3. M/s Marketing Services Consortium, Coimbatore

4. M/s Sunrise Polymers & Industries, Vadodara

5. M/s Sangir Plastics P.Ltd., Mumbai.

6. M/s Balaji Fibre Reinforce, Vadodara

B) BRO ZE & CI VALVES

1. M/s Leader valves, Jallunder

2. M/s Brightech Valves, Ahmedabad

3. M/s Steel strong, Mumbai

4. M/s Flowsteer, Ahmedabad

5. M/s Easwar Engg, Chennai

C) METALLIC GASKETS

1. M/s IGP Engineers, Chennai

2. M/s Mechanical Packing Industries, Mumbai

3. M/s Spiraseal Gaskets, Chennai

4. M/s Gaskets India, Mumbai

5. M/s Unique, Mumbai

6. M/s Vicap, Chennai

D) BOLTS & UTS

1. M/s Echjay Industries, Mumbai

2. M/s Fasteners & Allied Products, Hubli

3. M/s Fasteners India Manufacturers, Mumbai

4. M/s Hardwin Fasteners, Mumbai

5. M/s Nagabhushanam Industries, Bangalore

6. M/s Pacific Forgings, Mumbai

7. M/s Vaibhav Industries, Mumbai

8. M/s Fix fit Fasteners, Kolkota

0 15.10.09 FOR TENDER GSP

TECHNICAL

PROCUREMENT

SPECIFICATION

2

00FT024/94


KPM

CHECKEDREV.NO.

PAGE

8122 - 03 - DA - 001 VL

SUB VENDOR LIST

OF R 02

DATE DESCRIPTION PREPARED APPROVED

KAK

E) GI Pipes

1. M/s Ajanta Tubes, New Delhi

2. M/s CSK Tube Enterprise, Chennai

3. M/s Jindal, Mumbai

4. M/s Surya Tubes, New Delhi

5. M/s Sri Laxmi Metal Udyog, Bangalore

6. M/s Ridhi Steel& Tubes, Ahmedabad

F) GI & CS fittings& flanges

1. M/s Madras Engg works, Mumbai

2. M/s Teekay Tubes, Mumbai

3. M/s Metal Forge, Mumbai

4. M/s Super Forge, Mumabi

5. M/s Tube Products, Baroda

6. M/s Evergreen Hardwares, Bangalore

R

7.0 Saha Bhogilal & Jethlal Bros

TECHNICAL

SUB VENDOR LIST - Fire Fighting 8122-01-DA 001 VL

PROCUREMENT

SPECIFICATION PAGE 1

b. HD Fire Protect Company

c. New Age Industries

0

1 Fire Hydrant

a. Zenith Fire Services

OF 1

c. Zenith Fire Services

a. HD Fire Protect Company

b. New Age Industries

2 Medium Velocity Water Spray Nozzles

b. HD Fire Protect Company

d. Saha Bhogilal & Jethlal Bros

3 Stand post type water monitors.

a. Zenith Fire Services

e. Kidde

c. New Age Industries

d. Deepak Safety Systems

Note:

For bought out items from vendors ,other than that indicated in Subvendor list , prior approval

from Purchaser shall be obtained.


REV NO DATE DESCRIPTION PREPARED CHECKED APPROVED

0 JK16.11.09 First issue KK CRP

1.0.0 GENERAL

1.1.0 SCOPE

1.1.1 This specification covers the general require-ments for fabrication and installation of steelpiping (including carbon steels, low-alloy steels,and stainless steels) within petroleum refineriesand chemical plants.

1.1.2 When conflict occurs between this specificationand the piping drawings or the individualspecification, the order of precedence shall bepiping drawings, individual specification, andthis specification.

1.2.0 REFERENCES

1.2.1 The requirements contained in the latest edi-tions of the following standards shall form a partof this specification, in the manner and to theextent indicated herein:

1. Indian Boiler Regulation (IBR)

2. ANSI B2.1, Pipe Threads

3. ANSI / ASME B31.3, Chemical Plant andPetroleum Refinery Piping

4. ASME, Boiler and Pressure Vessel Code:Section V- Non-destructive Examination,Sect ion VI I I - D iv is ion 1, UW-51-Radiographic Examination of Welded Joint,Section IX- Welding and Brazing Qualifica-tions.

1.3.0 DEVIATIONS

1.3.1 When piping cannot be fabricated and installedas shown on the piping drawings, or when it isdeemed to be more appropriate to fabricate andto install the piping in a manner other than asshown on the drawings, the FEDO Engineer /Representative shall be consulted and thepiping shall be fabricated and installed in ac-cordance with his instructions.

2.0.0 FABRICATION

2.1.0 MATERIAL CONTROL

2.1.1 Packages of piping materials delivered to thejobsite shall be opened immediately, and thequantities, specifications, sizes, and identifica-

tion ( color identification and die stamp ) shall bechecked and recorded in the material ledger.The materials shall be stored promptly and neat-ly in the designated warehouse or storage yard.

2.1.2 When the identification is inadequate, thematerial shall be marked according to the colouridentification or an identification mark such asdie stamp shall be applied before storing thematerial.

2.1.3 Piping materials shall be issued only uponpresentation of Material Issue Slips signed bythe FEDO Engineer / Representaive. Pipingmaterials shall be issued only against therelevant isometrics.

2.1.4 Issued materials shall be indicated on the draw-ings or material use charts, etc., to preventduplication of issues.

2.1.5 Any surplus materials found on the job - siteshall be returned promptly to the warehouse orstorage yard.

2.1.6 When more material is needed as a result offaulty fabrication or other similar reasons, theFEDO engineer shall promptly be in formed ofthe matter so that he can give further directionsand advice.

2.1.7 Special precautions shall be taken to keepelectrodes and gaskets dry during storage.

2.2.0 PRECAUTIONS FOR PREPARATION &FABRICATION

2.2.1 When the location of piping connections by fieldwelding is not shown on the piping drawings,consideration shall be given to preparation andfabrication of piping materials so that the fieldwelding position is flat or horizontal as far aspossible.

2.2.2 The minimum clearance between the edges oftwo adjacent welds shall exceed 25mm or 4t imes the pipe nominal wall thickness,whichever is greater.

2.2.3 When both welded pipes and piping com-ponents having a longitudi nal welded joint arejoined at the end, in the girth butt welds thedimension between the longitudinal weldedjoints shall exceed 5 times the nominal pipe wallthickness of the thicker of those being joined. Inunavoidable circumstances when the dimen-sion is less than 5 times, both longitudinalwelded joints in the girth butt welds shall beexamined by radiography over 100mm. In ad-dition, Section 8.1 (14) shall be considered inthe preparation and fabrication.

2.3.0 CUTTING

2.3.1 Pipes shall be marked accurately and then cutaccording to the dimensions shown in the pipingdrawing or the dimensions most suitable for theconditions of field installation.

23.2 When irregular cutting is required for single andmultiple branch connections and for curved andmitred segments of pipe, the cutting shall beperformed by using a template.

2.3.3 In principle, pipes shall be cut mechanically witha pipe cutter or a high speed cutter. Whencutting ss pipe using a high speed cutter, an

25ES205 / 94 - R1ENGINEERING

SPECIFICATIONFABRICATION & ERECTION OF

STEEL PIPING


PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: 19 - 8 - 96

iso2.sty

PAGE 1 OF 28

CONTENTS1.0.0 GENERAL

2.0.0 FABRICATION

3.0.0 WELDING

4.0.0 HEAT TREATMENT

5.0.0 THREADED AND FLANGED JOINTS

6.0.0 PROTECTION & SIZE OF PREFABRICATEDPIPE SPOOLS

7.0.0 INSTALLATION OF PIPE SUPPORTS

8.0.0 PIPING INSTALLATION

9.0.0 TESTING AND INSPECTION

10.0.0 PRESSURE TEST AND OTHERS

11.0.0 APPENDICES

——————————-

abrasive wheel for stainless steel shall be used.

2.3.4 When pipe is of a large diameter, or when a pipecutter or a high speed cutter cannot be used thefollowing methods may be used.

a) Carbon Steel

Carbon steel pipe may be cut with automaticor manual oxygen- acetylene gas ap-paratus. However, base metal with a carboncontent of more than 0.35% shall not be cutwith oxygen-acetylene gas apparatus.

b) Low-alloy steel pipe

Only when unavoidable, low-alloy steel pipemay be cut with oxygen-acetylene gas ap-paratus pursuant to Subitem (a) above.

c) Stainless steel pipe

Only when unavoidable, stainless steel pipemay be cut by plasma arc cutting or arc airgouging. In this case, the pipe shall becoated with spatter deposit prevention paintto avoid adhesion of spatter.

2.4.0 END PREPARATION

2.4.1 Shape of Grooves

1. In principle, grooves for butt welding endsshall be shaped in accordance with ANSIB16.25 However, the grooves shall be inaccordence with the approved ProcedureQalification Records(PQR).

2. Unless otherwise specified, the groovesshall be in accordance with the require-ments shown in Table below which conformto ANSI B16.25.

PIPE WALL THICKNESS (t) GROOVE

3 mm or less (stainlesssteel) and

4mm or less (carbon steeland low alloy steel)

Square grooveor slightlybevelled

Over 4mm (but over 3mmfor stainless steel ) to 22mm

Single v grooveasper figure 1a

Over 22 mm Double v grooveas per figure 1b

2.4.2 Shape of Internal Trimming and Misalignment

1. Radial misalignment at the joining ends ofpiping components shall be such that fullpenetration can be attained.

2. Where component ends have an internalmisalignment over 1.6mm, the thicker com-ponent with the wall extending internallyshall be trimmed internally to an angle lessthan 300C as shown in Figure2. However,such trimming shall not result in a finishedwall thickness less than the required mini-mum design thickness plus corrosion anderosion allowances.

2.4.3 End Preparation method

In principle, the end preparation shall be per-formed by machine. However, when thepreparation is other than by machine, anycracks, flaws, burrs or oxidation scale (rust)shall be removed from the surface with a grinder.

2.4.4 Treatment after End Preparation

When carbon or low-alloy steel pipes and pipingcomponents with the ends prepared are to bestored for an extended period, a groove face rustpreventive that will not damage the welding shallbe applied to the ends (Appendix I). The rustpreventive shall be removed prior to welding, asfar as possible.

2.5.0 BENDING

2.5.1 In principle, ready-made elbows shall be usedfor bends of piping. However, when bends of alarge radius are required due to fluid charac-teristics or plant performance, the pipe may bebent to shape.The procedure for bending shallbe as follows:

1. In principle, pipe shall be cold bent with apipe bender. However, when the pipebender cannot be used because of the largepipe diameter, the pipe may be bent byheating or by high frequency induction.Low-alloy and stainless steel pipes shall not bebent by heating.

2. Pipe bends shall be made of one piece ofpipe with no welds at the bend.

3 The pipe shall be smooth on both the ex-terior and interior, and shall be bent so asnot to form any cuts, cracks, wrinkles, dents,etc.

4 Flattening of a bend shall not exceed therequirements shown in Section 2.8 figure 6.

5 The minimum bending radius shall begreater than 1.5 times the nominal diameterof pipe, unless otherwise specified on thepiping drawings or the individual specifica-tion.

6 Low-alloy and stainless steel pipe shall beheat treated in accordance with the in-dividual specification to relieve residualstress and work hardening of the bend.However, the heat treatment may not beapplied to austenitic stainless pipe or tonickel-alloy steel pipe.

7. For carbon steelpipe of 25 NB and smaller,steam tracing, or discharge-end piping ofvents, drains, etc., the pipe may be bent tothe required angle by heating with anoxygen-acetylene gas torch. However,precautions shall be taken to preventdamage to the pipe by overheating and toensure that the roundness of the steel pipeis maintained.

2.6.0 MITRE BENDS

2.6.1 Unless otherwise specified, mitre bends shall beused for piping 350NB and larger. For piping of300 NB and smaller, ready-made smooth el-bows shall be used.

2.6.2 Mitre bends shall be fabricated as follows unlessotherwise stated in the piping drawings or theindividual drawings.

1 Mitre bends to be used at bends greaterthan 450C shall consist of not less than threesegments. The minimum distance (l) be-tween alternate segments of the mitre bendshall be 4 times the pipe nominal wall thick-ness or 25mm, whichever is greater (Fig-ure3)



STEEL PIPING


PAGE 2 OF 28

FIGURE 1 AWHEN t - 4mm to 22 mm

33 1/2° ± 2 1/2°

1.6 ± 0.8

3.2 ± 0.8 t

FIGURE 1 BWHEN t > 22 mm

3.2 ± 0.8

t

1.6 ± 0.8

R 3.2mm

37° ± 2.5° 10°± 1°

19

FIGURE 2TRIMMING AND PERMITTED MISALIGNMENT

OVER 1.6 mm

30° MAX

THIS PORTION SHALL BE FINISHED

SMOOTHLY SO AS NOT TO HAVE A SHARP EDGE, WHICH MAY HINDER RADIOGRAPHIC EXAMINATION FIGURE 3

SHAPES OF MITRE BENDS

FABRICATION & ERECTION OF STEEL PIPING PAGE 3 OF 28

25 ES205 / 94 - R1

ENGINEERING SPECIFICATION


15°

30°

1.5 D

30°

FIGURE 4 ANGLE OF MITRE BENDS

1.

5 D

2 The radius of the mitre bend shall be greaterthan the nominal diameter of the pipe.

3 The maximum mitre angle (ß of Figure 4) ofeach segment shall be as follows:

When design pressure is8kgf / cm2G or less

: β ≤ 22030’

When design pressure is 28kgf / cm2 G or less

: β ≤ 15000’

When design pressure ex-ceeds 28 kgf / cm2G

: β ≤ 11015’

4 The segments shall be neatly cut so thatthey will closely fit with each other whenassembled. Cutting and end preparation ofpipe shall be in accordance with the require-ments (Sections 2.3 and 2.4)

5 When designing the shape of a groove, themitre angle shall be considered and theshape of the groove shall be suitable for thewelding process used.

6 When assembling the mitre bend, the seg-ments shall be laid out and tack welded ona surface plate or other flat surface to keepthe centers of the segments aligned.

7 After welding is completed, the interior of thepipe shall be inspected and any internalweld protrusions shall be removed.

8 Welding and heat treatment shall be per-formed in accordance with the requirementsspecified in Sections 3.0.0 and 4.0.0 of thisspecification.

2.7.0. BRANCH CONNECTIONS

2.7.1 Branch connections shall be fabricated by as-sembling the fittings that have dimensions andconfigurations shown in the piping drawings.Un-less otherwise specified, branch connectionsshall be made in accordance with Figure 5 andas follows:

2.7.2 Branch connections, which are made by provid-ing a hole in the main run pipe and inserting abranch pipe or a coupling, shall be as follows:

a The hole provided in the main run pipe shallconform to the requirements of Section 6.

b When the main run pipe is welded pipe, thewelds of branch connections shall be madeso as to avoid the welds of the main runpipe.

2.7.3 Branch connections shall be made by means offully penetrated groove welds. The groovewelds shall be made in accordance with thesame welding procedure as for girth butt welds.

2.7.4 In no case shall scraps of metal resulting frommaking the hole be left inside the pipe.

2.7.5 When making branch connections, a jig or ametal fitting shall be attached to the main runpipe to prevent distortion of the main run pipe orbending of the branch pipe due to welding. Thematerial of the metal fitting shall be similar to themain run pipe.

2.7.5 If reinforcement pads are used, unless other-wise specified, a 3.0mm dia vent hole shall beprovided (at the side and not at the crotch) in thereinforcement pad to reveal leakage in the weld

between branch and main run, and to providevent ing during welding and heat treatmentoperations. If the reinforcement pad is made inmore than one piece, each piece shall beprovided with a vent hole.

2.7.7 The material of reinforcement pads shall be thesame as the main run pipe.

2.7.8 An examination of the welds joining reinforce-ment pad to the branch shall be made by FEDOEngineer/ representative before installing thereinforcement pad.

2.8.0 FABRICATION TOLERANCES

2.8.1 To avoid misalignment when joining a pipe orfitting to a pipe, the pipe or fitting shall be turnedto check for any irregularities and shall be joinedcorrectly.

2.8.2 Unless otherwise specified, tolerances forfabrication shall be in accordance with the re-quirements shown in Figure 6.

2.9.0 GALVANISED PIPING

2.9.1 Galvanised carbon steel piping shall be com-pletly cold worked so as not to damage gal-vanised surfaces

3.0.0 WELDING SPECIFICATION

3.1.0 GENERAL

3.1.1 This specification shall be adopted to all weldedpipe joints of carbon steel, alloy steel and stain-less steel piping system.

3.1.2 The welded pipe joints are defined as under:

1. All line joints of the longitudinal and circum-ferential butt welded and socket weldedtype.

2. Attachments of castings, forgings, flangesand other supporting attachments to pipes.

3. Welded manifold headers and other sub -assemblies

4. Welded branch connections with or withoutreinforcement pads.

5. Manufacture of welded / fabricated pipingcomponents.

6. The attachment of smaller connections forvents, drains, drips and other instrumenttappings.

3.1.3 All welding, and heat treatment, shall be inaccordance with the applicable codes andspecifications.

a. codes for petroleumrefinery piping

ANSI B31.3

b. Welding Qualifications. ASME Sec. IX.

c. Code of procedure formetal arc welding of mildsteel (structural work only)

IS : 823

d. The Indian Boiler Regula-tions

IBR

All codes referred shall be the latest editions. Inadition to the codes mentioned above, otherrelevant international codes such relating to thework, shall also be applicable. In case of con-flicts between different codes or between codes



STEEL PIPING


PAGE 4 OF 28


and tender specifications the more stringentshall be applicable.

3.2.0 INSPECTION & TESTING

3.2.1 General

1. The owner’s inspector shall have free ac-cess to all concerned places, where theactual work is being performed. The con-tractor shall also provide the owner’s in-spector all means and facilities necessaryfor carrying out inspection.

2. The owner is entitled to depute his owninspector to the field or shop where pre-fabrication and erection of pipe lines arebeing done with ( but not limited to ) thefollowing functions :

a. To check the quantity, consumables andwelding equipments used on the job

b. To supervise welding procedure & weldersperformance qualification tests.

c. To ensure that only qualified welders areengaged for welding.

d. To check that shop / field welding is in con-formity with the relevant specification andcodes of practice followed in pipe line con-struction.

e. To carry out Non Destructive Examinationof welds.

3. Contractor shall intimate sufficiently in ad-vance the commencement of qualificationtests and welding work to enable theowner’s inspector to be present to supervisethem.

3.2.2 Welding procedure qualification

Welding procedure qualification shall be carriedout in accordence with the job requirements andrelevant requirements laid down in the standardASME Sec. IX and other relevant applicablecodes. The contractor shall submit the weldingprocedures in QW — 482 format given in ASMESec. IX. immediately on receipt of work order.Owner’s inspector will review, check and ap-prove the welding procedure after conductingthe necessary tests. It shall be the responsibilityof the contractor to carry out the tests, at hiscosts. All the necessary arrangements for theprocedure qualification i.e. supply of material forassembly welding consumables, welding equip-ments, preparation of test coupons, welding,heat treatment, machining of test specimen,conducting N.D.T, mechanical & chemical testand maintaining qualification records, shall beby the contractor at his cost. He shall submit thetest results to the Engineer-in-charge in QW-483 format given in ASME Sec. IX. for approval.

3.2.3 Welder’s Qualification

1. Welder’s qualification shall be in accord-ance with the relevent codes specified inscope of work. Owner’s inspector shall wit-ness the test and certify the qualification ofeach welder. Contractor shall submit thewelder qualification report as per Formatbefore the commencement of work. It shallbe the responsibility of the contractor tocarry out the qualification tests of welders.

For piping covered by Indian Boiler Regula-tions, welders with valid IBR certificate,qualified by Boiler Inspectors and accept-able to the local Boiler Authority shall onlybe employed.

2. The welders shall always have in their pos-session the identification card as per Formatand shall produce it whenever demandedby owner’s Inspector. It shall be the respon-sibility of the contractor to issue the identitycards after duly certified by the Inspector.

3. The identity card shall contain the followingminimum details.

a. Name of Contractorb. Name of welderc. Stamp No.d. Addresse. Recent passport size photographf. Details of qualifications

i Welding process and P numbersii Range of pipe diametersiii Range of thicknessiv Welding positions

g. Date of qualification testh. Period of validityi. Signature of manufacturerj. Signature of Engineer —in—charge

4. No welder shall be permitted to work withoutthe possession of identify card.

5. If a welder is found to perform a type ofwelding or in a position for which he is notqualified, he shall be debarred from doingany further work. All such welds so per-formed shall be cut and redone at the ex-pense of the Contractor.

6. Engineer-in-charge reserves the right to askthe contractors to perform requalificationtest at their cost for welders whoseworkmanship technique etc. are found un-satisfactory during the execution of the job.

3.3.0 SELECTION OF WELDING MATERIALS

3.3.1 Selection of welding electrodes shall be as perAppendix - II

Table - I : Selection of welding electrodes & rodsfor joining similar materials except Aluminium

Table - II : Selection of welding electrodes & rodsfor joining dissimilar materials except Aluminium

3.4.0 STORAGE AND ISSUE OF ELECTRODES

Electrodes shall be stored and issued as fol-lows:

3.4.1 Electrodes shall be stored indoors free frommoisture as far as possible.

3.4.2 Electrodes shall be dried in a heating cabinet inaccordance with the manufacturer’s recommen-dation before welding.

3.4.3 Immediately after drying, electrode shall bestored in a portable dryer, or in a heating cabinetat the following temperature, and shall then beused.

a. Illumenite : 70 - 1000C



STEEL PIPING


PAGE 7 OF 28

b. Others : 100 - 1500C

3.4.4 During welding, electrodes shall be kept in aportable dryer or equivalent. The electrodesshall not be laid down directly on the ground orany other damp places.

3.4.5 Electrodes exposed to the atmosphere for morethan 4 hours shall be redried. However, only tworedryings are permitted.

3.4.6 When the day’s work has been completed, theelectrodes shall be collected and stored in aheating cabinet at the temperature specified in3.3.2 above.

3.4.7 Issue of electrodes shall be controlled by theassigned person.

3.5.0 SURROUNDING CONDITIONS FOR WELD-ING

3.5.1 Welding shall not be performed under the fol-lowing climatic conditions.

1. In the rain

2. In winds of 8 m/s or more

3. In snow

However, welding may be performed if the areais fully protected from the inclement weather.

3.5.2 When the item to be welded is wet with rain orcovered with snow or ice, the snow or ice shallbe removed and the surface dried completelybefore welding.

3.6.0 GENERAL FOR WELDING

3.6.1 Welding shall be performed in accordance withwelding procedure specification (WPS), whichhas been approved by FEDO/Representative.Before welding, the WPS shall be preparedwhich has been qualified by the welding proce-dure qualification test based on the specificationfor welding procedure qualification, according tothis specification and ASME Section IX.

3.6.2 As a general rule, welding for steel pipes shallbe performed as follows.

1. The welding process used shall be SMAW,GTAW, or GMAW (MIG Welding). Any otherwelding process may be used only whenapproved by FEDO / Representative.

2. Preferably, the first layer of butt welded jointshall be made by GTAW. For the first layeron 3Cr. and higher low-alloy steel pipe, orstainless steel, GTAW shall be performedwith back shielding gas such as argon.

3. The surface to be welded shall be cleanedthoroughly and any paint, rust, scale, oil,dust, moisture, or any other foreign matterthat would be detrimental shall be removedat least within the extent of 50mm from thegroove end before welding.

4. The welding position shall be performed inflat position as far as possible.

5. Full consideration shall be given to the weld-ing progression to keep distortion to a min-imum.

6. In multi-layer welding, before welding thefollowing layer, the surface of each layer

shall be removed of any slag or other foreignmatter with a chipping hammer, a grinder, ora wire brush. To prevent spatter adhering tothe base metal, a spatter deposit preventionpaint may be applied around the outside ofthe groove. Wire brushes and abrasivewheels shall be distinguished so that thosefor stainless steel shall not be confused withthose for carbon steel or low-alloy steel.Moreover, any arc starts, craters, or inferiorbeads of each layer shall be removedbefore the welding is continued.

7. Peening on the welds is prohibited.

8. Unless required, the external surfaces ofwelds shall not be finished with a grinder orany other tool. However, when finishing theend of weld beads with a grinder, specialprecautions shall be taken not to reduce thethickness of base metal by over grinding.

9. Arc strike shall not be generated on the pipesurface. Care shall be taken not to lay downthe electrode holder or move it around bythe electrode.

10. To prevent damage from sparks, care shallbe taken to ground the welding equipmentby strict use of ground clips and to groundeach piece of material.

11. When welding galvanized steel, the coatingshall be removed from the surface to bewelded, 50mm on either side.

12. For the joints of P-Number 5 materials,when welding is unavoidably interrupted,postheating shall be applied and the weldsshall be cooled gradually by the use ofinsulation or other suitable materials. ( Para4.3.0 ).

3.7.0 BUTT WELDS

3.7.1 When welding a pipe to a pipe, fitting, valve, etc.,the components shall be placed on a revolv ingstand, aligned accurately within the tolerancesspecified in Section 2.8. of this specification bythe use of tack weld pieces (fit-up pieces), line-up clamps, etc., and shall then be welded.

3.7.2 Backing rings shall not be used unless other-wise specified.

3.7.3 The number of tack welds made shall be theminimum required to secure the pipe, and aminimum of three shall be made for pipes of 50NB and larger.

3.7.4 When tack weld pieces are used for pipematerials of stainless steel,the material of thepieces shall be similar to that of the pipe. Whenthe pipe material is low-alloy steel, carbon steelmay be used for the pieces unless otherwisespecified.The welding for the tack weld piecesshall be performed with electrodes equivalent tothose used for the base metal and shall beperformed by a welder or welding operatorqualified for fillet welds.

3.7.5 Tack welds, which are made directly at the rootof the joint, shall be made by a qualified welderor welding operator specified in Section 3.2.3and shall be made by the same welding proce-dure as the product welding. Tack welds thatare cracked or not fused properly shall beremoved.



STEEL PIPING


PAGE 8 OF 28

3.7.6 Pieces for tack welds shall be removed with agrinder. If a concave surface due to overgrind-ing, etc., is produced on the pipe, the repairwelding shall be performed in accordance withWPS, which has been approved by FEDO En-gineer / Representative. Any convex weld beadsformed on the pipe surface shall be removed.When defects are found while removing tacks /cleats they shall be fully removed, repaired bywelding, and a magnetic particle or liquidpenetration examination shall be performed toconfirm that there are no defects.

3.7.7. Internal weld protrusions of butt welds for orificeflanges shall be finished smoothly to the pipeinside diameters with a grinder.

3.7.8. The root pass of all buttwelds on pipe of sizeless than 50NB shall be made in GTAW groveonly.

3.8.0 FILLET WELDS

3.8.1 Fillet welding shall be performed as follows:

1. Fillet welds shall be multi-layered and ofsufficient strength.

2. Fillet welds shall be as shown in Figures 7Aand 7B.

3. Fillet welds for socket welding flanges shallbe as shown in figure 7C.

4. Fillet welds for socket welding componentsshall be as shown in figure 7D.

3.9.0 SEAL WELDS

3.9.1 Seal welding shall be performed as follows:

1. Threaded joints to be seal welded shall notbe coated with a compound or covered witha seal. After any oil on the threads has beenfully removed, the threads of joint shall bescrewed in securely in accordance withSection 5-1.0, and shall then be welded.

2. If threaded joints are seal welded, all ex-posed threads shall be covered by a sealweld.

3. Seal welding shall be performed by aqualified welder.

4. Electrodes of 3.2 mm dia or less shall beused.

3.10.0 FLANGE ATTACHMENT WELDS

Flange attachment welding shall be performedas fol lows:

3.10.1 Unless otherwise shown on the drawings, inprinciple, flange bolt holes shall straddle theestablished centerlines. The only exception is atequipment flanges required for matching orien-tation.

3.10.2 When installing flanges, flange square or otherjig shall be used, and the center line of the pipeand the perpendicular of the flange face shall bewithin the tolerances specified in Section 2.8.

3.10.3 Joining welding neck flanges to the pipe shall beperformed in accordance with the requirementsof Section 3.7.

3.10.4 Front welding shall be performed on slip-onflange joints except for pipes class less than50NB (Figure 8). Care shall be taken so that theweld reinforcement does not protrude on to the

gasket contact face and that the gasket contactface is not damaged by welding. If the gasketcontact face is damaged,or weld reinforcementprotrudes onto the gasket contact face, suchdefects shall be removed by polishing the gas-ket contact face.

3.10.5 When welding flange joints, care shall be takento handle the flanges carefully so that the gasketcontact face will not be damaged. The gasketcontact face shall not be in direct contact withthe ground, and grounding shall not be takendirectly from the gasket contact face.

3.10.6 In the case slip-on flanges which are to be heattreated, and also require to be front welded,theyshall be provided with a 3mm dia vent hole atthe hub as shown in FIG.8.

4.0.0 HEAT TREATMENT

4.1.0 PREHEATING

4.1.1 Unless otherwise specified, the preheating ap-plies to gas cutting and welding (all welds includ-ing butt welds, fillet welds, socket welds, repairwelds, tack welds, and seal welds of thread edjoints ). Preheating shall be performed as fol-lows:

1. Materials to be pre heated and preheatingtemperature shall be in accordance withrelevant codes as a rule, but for steam linesfallen under the purview of IBR, the sameshall be followed.

2. If the maximum specified carbon content ismore than 0.38, or if the material is under ahigh degree of restraint (weld-all- aroundsuch as pipe shoe), carbon steel shall bepreheated to a minimum of 800C and main-tained at that temperature for surface weld-ing.

3. When welding dissimilar metals, unlessotherwise speci fied, the preheatingtemperature shall be that for the highergrade steel

4. The width of the heated circumferentialband shall be 4 times the pipe nominal wallthickness or 100mm, whichever is greater,extending on both sides of the welds.

5. Heat shall be applied by the use of a gasburner or a heating coil. The use of a gasburner for cutting shall not be permittedsince it tends to heat locally.

4.1.6 Temperature measurements of preheating, in-terpass temperature, and postheating shall beperformed by a temperature crayon ( tempilstick), thermocouple temperature indicator, etc.,and it shall be confirmed that the specifiedtemperature is maintained.

4.2.0 INTERPASS TEMPERATURE

4.2.1 The following items shall be confirmed for inter-pass temperature:

1. Interpass temperature of the materials thatrequire to be preheated shall be the sameas the preheating temperature and shall bemaintained until welding has been com-pleted.

2. Interpass temperature of austenitic stain-less steel pipe shall not exceed 1500C.



STEEL PIPING


PAGE 9 OF 28


4.3.0 POSTHEATING

4.3.1 When postheating is required it shall be carriedout for more than 30 minutes within the tempera-ture range of 300 to 4000C, and the materialshall be cooled gradually by the use of insula-tion, etc. However, when post weld heat treat-ment is performed immediately after welding,post - heating is not necessary.

4.4.0 POST WELD HEAT TREATMENT

4.4.1 Procedure

Unless otherwise specified, post weld heattreatment shall be performed in accordance withthe following procedure. However, post weldheat treatment for dissimilar metals shall be inaccordance with the individual specification.

1. The requirements for heat treatment shallbe in accordance with applicable codes. Butfor steam lines IBR shall be followed. Heattreatment of welded joints between dis-similar ferritic metals shall be within thetemperature ranges for the higher gradesteel.

2. Al l the machined surfaces shall beprotected adequately by the use of paint orcompound to prevent damage from scalingduring heat treatment.

3. In case of furnace heat treatment, all thepipes shall be supported properly duringheat treatment to minimize warps and otherdistortions.

4. In principle, after heat treatment has beencompleted, neither rewelding nor reheatingshall be performed. However, if rewelding isperformed because of repairs, etc., heattreatment shall be performed again.

5. If welding is intrrupted before completion orthe weldment is allowed to cool prior to heattreatment, adequate heat treatment or con-trolled rate of cooling shall be applied toensure that no effects detrimental to thepiping shall result. The pre-heat tempera-ture in the welding must be applied beforewelding is resummed.

6. When heat treatment is performed, the hold-ing temperature, holding time, rate of heat-ing and cooling, and the hardness after heattreatment required shall be recorded andthe records shall be submitted to FEDOEngineer / Representative.

7. The measurement of heat treatmenttemperature shall be performed by measur-ing the metal temperature by the use of athermocouple,or by other suitable methods.However, when the heat t reatmenttemperature is measured by the furnacetemperature, the relation between thetemperature of metal and furnace shall beconsidered.

8. A hardness test shall be performed in ac-cordance with Section 9.4.0 to determine ifthe heat treatment has been performedsatisfactorily.

9. Throughout the cycle of heat treatment, theportion out side the heated band shall besuitably wrapped under insulation so as toavoid any harmful temperature gradient at

the exposed surface of pipe. For this pur-pose temperature at the exposed surface ofpipe should not be allowed to exceed4000C.

10. All online pipe item ( eg. Valves, Instrumentsetc. )within 500mm of the weld which isbeingheat treated, shall be dismantled priorto commencement of heat treatment ofweld.

11. The no. of thermocouples to be used for themonitoring of tempreature shall be as fol-lows.( HAZ - Heat Affected Zone )

DIA OFPIPE NOS. OrientatIO

N ( 0 ) LOCATION

15NB &below 2 0 , 180 One on weld & one

in HAZ

200 to500 NB 3 0 , 120 ,

240one on weld & rest inHAZ on either side

of weld

600 Nb &above 4 0 , 90 ,

180 , 270two on weld & rest inHAZ on either side

of weld

4.4.2 Heating Methods

For heat treatment, application of heat in afurnace is preferable, however, heat may beapplied locally by the following methods:

1. Heating by electrical resistance

This is a method where a programmed mov-able automatic heater applies heat bymeans of nickel-chrome wire appliedaround the welds. Special attention shall begiven to the following items:

a. Protective measures shall be taken toprevent damage to the pipe surface or in-jury to the workers due to a short circuitof the lead wire, and to prevent personsother than the operator entering the workarea.

b. The width to be heated shall extend25mm beyond the edges of the weld oneach side

c. The width to be insulated shall extend atleast 150mm on each side of the weld.

d. The heating and cooling rates above3150C shall be determined by the follow-ing formula, but in no case shall the rateexceed 2200C per hour.

25 x 220wall thickness (mm)

( oC ⁄ h)

2. Heating by gas burner

a. This is a method where heat is appliedby a propane or butane gas burner. Thismethod shall not be used unlessspecified by FEDO Engineer/ Repre-sentative.

5.0.0 THREADED AND FLANGED JOINTS

5.1.0 THREADED JOINTS

Threading of joints shall be as follows.

5.1.1 Taper pipe threads shall be as per ANSI B2.1,



STEEL PIPING


PAGE 11 OF 28

ANSI Standard Taper Pipe Thread (NPT).

5.1.2 Unless otherwise specified, when threading onpipes of NPS 11/2 or smaller, the pipe thicknessshall be Schedule 80.

5.1.3 In principle, all threads shall be cut with a thread-ing machine or lathe. When threading with handdies such as an oster or reed type, a lubricantshall be used to avoid an irregularity of screwthread or scratches due to coarse machining.

5.1.4 All the threads shall be cleaned thoroughly.

5.1.5 In principle, teflon seal tape shall be used forthreaded joints used in services of 1500C andlower. Once the joints are screwed, they shallnot be unscrewed. Fillers such as hemp, jute,lead scraps, and white paint shall not be used.

5.1.6 Seal welding of threaded joints shall be in ac-cordance with Section 3.9

5.1.7 In no case shall threaded joints be made with alength of engagement less than specified.

5.1.8 When pipe is screwed into a threaded flange,the pipe end shall not extend beyond the gasketcontact face. If the pipe end protrudes evenslightly, the pipe end shall be ground off with agrinder or a file so that the gasket contact faceis not scratched.

5.1.9 When screwing a pipe into a threaded bronzevalve, the pipe shall be gripped by a pipe viceand the valve shall be screwed on by clutchingthe end of the valve with a wrench. Threadingand screwing shall be carried out carefully sothat the pipe does not enter the valve too far anddamage the valve due to the threads beingovercut on the pipe.

5.1.10 Scraps of metal due to threading and oil usedfor cutting shall be removed before screwing oninstrument air piping.

5.1.11 Any compound or lubricant used on the threadsshall be suitable for the service conditions, andshall not react unfavourably with either the ser-vice fluid or piping material.

5.2.0 FLANGED JOINTS

Flanged joints shall be made as follows:

5.2.1 In principle, Class 125 and 250 flanges of valvesand other equipment made of gray cast ironshall be of flat face with full contact area gaskets.

5.2.2 Steel to gray cast iron flanged joints shall beassembled with care to prevent damage to thecast iron flange.

5.2.3 Unless otherwise specified, gasket paste shallbe applied uniformly on the gasket contact faceof the flange when a metal jacketed gasket or ametal gasket is used. However, when the flangematerial is austenitic stainless steel, the use ofgasket paste shall be approved by FEDO En-gineer / Representative. As the choice of pasteis limited by the fluid handled, the paste shall besuitable for the service fluid. The gasket pasteshall be kept in a container with a lid and handledwith care to prevent entry of sand, dust or otherforeign matter.

5.2.4 For asbestos-sheet gasket, gasket paste maynot be applied.

5.2.5 For spiral-wound gaskets or ring-joint gaskets,gasket paste shall not be applied.

5.2.6 The thread and bearing surfaces of bolts andnuts to be used on piping at temperatures of2500C or higher shall be coated thinly anduniformly with a lubricant to prevent them be-coming burnt and stuck.

5.2.7 Lubricant shall not be applied to machine boltsunless other wise specified.

5.2.8 Bolts shall be of material and length asspecified. In principle, all the bolts shall extend2 or 3 threads through their nuts.

5.2.9 Flanges shall be tightened with a wrench orspanner of the specified length and with a ham-mer if required, or with a torque wrench. Careshall be taken so that the bolt is not tightenedexcessively or unevenly.

5.2.10 As the tightening force varies according to theflanges, gaskets, and bolts used, the tightnessshall be controlled with care. In particular, flan-ges of piping for low temperature and dangerousservices shall be tightened only with a torquewrench. For large diameter bolts, the use of animpact wrench with torque control or a powermachine ( hydraulic torque wrench ) is preferred.

5.2.11 Bolts of flanged joints shall be successively andevenly tightened in a symmetrical pattern ( Ap-pendix IV ).

5.2.12 Cast iron flanges of equipment such as pumps,turbines, compressors, or other similar equip-ment shall be tightened carefully so that theflange does not break.

5.2.13 The flange clearance with connections ofpumps, compressors, or other similar equip-ment, and ring-joint flanges shall be measuredby the use of a clearance gauge and the paral-lelism shall be checked, and then the bolts shallbe tightened evenly.

5.2.14 Ring-joint gaskets shall be ground with thegroove of the flange for a tight fit prior to instal-lation. The grinding shall be performed by usinga compound (coarse, intermediate, or fine), andred paste shall be applied to confirm the rough-ness of the contact face between the ring andthe groove of the flange. The paste shall beremoved completely before the ring is installed.

5.2.15 If the gasket contact face of the flange isdamaged, the defects shall be removed bypolishing evenly the gasket contact face, or theflange shall be replaced.

6.0.0 PROTECTION OF PREFABRICATED PIPESPOOLS AND SIZE

6.1.0 PROTECTION OF PREFABRICATED PIPESPOOLS

6.1.1 All prefabricated pipe spools that have beeninspected shall be protected as follows until theyare installed in a plant.

1. All dust, rust, weld slags, or other foreignmatter in the pipe shall be removed carefullyby brushing or by flushing with compressedair, or by other suitable means. After clean-ing, all openings of austenitic stainless steelshall be blanked.

2. Pipe spools to be stored temporarily shallbe laid on suitable sleepers and not directlyon the ground.



STEEL PIPING


PAGE 12 OF 28

3. Pipe spools shall be marked with the areanumber (major divisions such as offsite,onsite), line number, and piece number.After cleaning the pipe spool surface andapplying rust preven tive, it shall be markedclearly with paint by the use of a stencil.When specified, in showing the line number,etc., a color code identification or tag plate(die stamped to the sheet metal) for eacharea shall be made, and it shall be attachedwith coated iron wire. However, zinc coatediron wire shall not be used for austeniticstainless steel.

4. If hydrostatic test is performed, the watershall be removed completely.

6.1.2 When prefabricated pipe spools are to be storedfor a long period of time or are to be shipped,the pipe interior shall be checked to see that itis clean, and the openings of pipe ends shall beprotected as follows:

1. When the pipe ends are prepared, the endsshall be coated with rust preventive ( Appen-dix — 1 ) and covered with a plastic cap, etc.

2. When the pipe ends are flanged, the gasketcontact face shall be coated with rustpreventive and be protected with a woodenor plastic cover bolted on to the flange. Incase of a wooden cover, poly ethylene orother suitable film shall be inserted betweenthe flange and the cover.

3. When the pipe ends are threaded, thethreads shall be coated with rust preventiveand threaded end connections shall becovered with wooden or plastic plugs orcaps.

4. When masking tape is intended to be usedinstead of the protection mentioned above,it shall be subject to FEDO Engineer’s/ Rep-resentative’s approval.

6.1.3 However, austenitic stainless steel pipes andprefabricated pipe spools that may be affectedby chlorine ions, shall be protected in accord-ance with the individual specification.

6.2.0 SIZE OF PREFABRICATED PIPE SPOOLS

6.2.1 The size of prefabricated pipe spools shall bedetermined by consideration of the conditions oftransportation, etc. Consideration shall be givento the conditions of inland transportation, size ofthe carrier’s hatch, means of transportation, traf-fic regulations in the country and the economy.

6.2.2 The standard size of a package to transportprefabricated pipe spools is limited to 2.5 meterswidth by 2.5meters height by 13 meters lengthwith a weight of 5 tons per package.

7.0.0 INSTALLATION OF PIPE SUPPORTS

7.1.0 PIPE SUPPORTS

7.1.1 Pipe supports whose materials & dimensionsconform to fabrication drgs, shall be installedaccurately at the positions shown on the draw-ings prior to piping installation. When installingthe pipe supports, pay attention to the following:

1. Each support shall be fabricated and as-sembled so that piping does not becomedisengaged from the support by movementof the piping itself due to operation.

2. Stanchions requiring foundations shall haveanchor bolts of the correct size, position,projection, etc.

3. Before installing the supports, the finishedconditions of the cut ends of all membersand welded conditions shall be checked.

4. Pipe supports shall be made level andplumb to facilitate alignment during pipinginstallation.

5. In principle, when the main run pipe is low-alloy steel or ss, either a pad plate or supportmembers of the same material as the mainrun pipe shall be used, and carbon steelsupports shall not be welded directly tothese. In this case, when welding the pipeto the support, the same electrodes as ap-plied to the pipe shall be used, and thequalified welder specified in Section 3.1.0shall perform the welding in accordancewith WPS. When the main run pipe requiresheat treatment, the welds for attachment ofpipe supports shall be heat treated if re-quired,as per ANSI B31.3.

6. Welds for anchor supports shall be double-layer welds to provide a bond of sufficientstrength.

7. When welding dummy pipe to elbows, tees,etc., the welding shall not melt through totheir interior.

7.2.0 SLIDING SUPPORTS

7.2.1 Sliding supports shall be assembled so that theexpected movement of the supported piping dueto thermal expansion and contraction or otherdesign requirements is possible.

7.3.0 SPRING HANGERS

7.3.1 The lock-pin or preset-piece of spring hangersshall not be taken off until pressure testing andflushing have been completed, except onlywhen a high temperature fluid such as flushingsteam is streamed.

7.3.2 Adjustment of spring hangers shall be per-formed by taking off the lock-pin or preset-pieceprior to ini tial operation. It shall be confirmedthat spring hangers operate on the expectedmovement according to temperature increase inthe initial operation.

7.4.0 ADDITIONAL SUPPORTS

7.4.1 If additional supports are required to preventshaking of piping in the field, they shall beinstalled in accordance with the instructions ofthe FEDO Engineer’s / Representative’s En-gineer in consideration of the effects due tothermal expansion of the piping.

7.5.0 INSULATION SUPPORTS

7.5.1 The configuration, material, and installation pro-cedure of support rings for hot or cold insulationof vertical piping shall be in accordance with theindividual specification.

8.0.0 PIPING INSTALLATION

8.1.0 GENERAL ITEMS FOR PIPING INSTALLA-TION

The general items for attention relating to pipinginstallation shall be as follows:



STEEL PIPING


PAGE 13 OF 28

8.1.1 Pipes shall be stored in accordance with eachcategory of material, and stacked on sleeperswith wedges or stakes provided to prevent thestack from collapsing.

8.1.2 Before installation, pipe spools shall be checkedwith the piping drawings as to dimensions,material, class, etc. In principle, the installationof pipe spools shall start from elevated lines orlarger size lines. The precedence for installationshall be determined after confirming that allequipment has been installed and aligned, andsteel structures and pipe racks are ready forinstallation of the piping. The part which cannotbe painted after piping installation shall bepainted beforehand.

8.1.3 In principle, underground piping shall be in-stalled before above ground piping.

8.1.4 Before installation, the pipe spool shall besuspended at one end by a crane, etc., and hammered to remove the dust inside.

8.1.5 Supports such as stanchions shall be checkedfor the accuracy of position, dimensions, eleva-tion, levelness and plumbness.

8.1.6 When temporary supports are installed un-avoidably to the piping, welding shall not beperformed on the main run pipe.

8.1.7 Temporary work for piping installation shall beplanned in advance, and the necessary equip-ment and materials shall be selected andprepared in time with the schedule. Moreover,the scaffolding required for field connectionsshall be checked, and whether the requirednumber of scaffold pipes and boards shall besufficient.

8.1.8 Scaffolding shall be provided to permit safeoperation, and the use of small size piping,pumps, instruments, etc., in lieu of scaffoldingshall be prohibited. All scaffold boards shall besecurely tied to the scaffold pipes or piping withmetal connectors or iron wire.

8.1.9 The primary cards, cables, and grounding wiresof all welding equipment shall be of sufficientsize, and any conductors with damaged insula-tion shall not be used. They shall be inspectedperiodically.

8.1.10 Piping components such as pipe spools andvalves shall be lifted with the designated wirerope slings, and the use of iron wire shall beprohibited.

8.1.11 Piping components shall be hauled by mechani-cal equipments as far as possible. Even for ashort haul, the components shall be securelytied to prevent them from falling.

8.1.12 Piping requiring cold spring may becomemisaligned during field welding, therefore, thedimensions shall be checked thoroughly in ac-cordance with the piping drawings. After it hasbeen confirmed that guides and anchors havebeen installed at the specified location, thepiping shall be installed. Furthermore, whenthere are flanged joints in the same directionrequiring cold spring, a spacer with the samethickness as the dimension of cold spring shallbe inserted between the flanges, and when theentire piping system has been assembled, thespacer shall be removed and the flange fas-tened.

8.1.13 Alignment tolerances of flange connections in-stalled in piping shall be as per Figure 9 ( Page28 of 28 ). However, alignment tolerances ofpipe flanges for the rotational equipment nozzleshall be as per Section 8.3.0 ( Item 6 ).

8.1.14 In principle, the longitudinal welded joint ofwelded pipe shall be located above the horizon-tal centerline, if the pipe is installed horizontally.

8.2.0 PIPING AROUND COLUMNS, DRUMS ANDHEAT EXCHANGERS

The piping installation around columns, drums,and heat exchangers shall be as follows:

8.2.1 Piping for columns shall be installed in the orderof the overhead line and the risers, and theinstallation of instrument take-off nozzles, sup-ports, spring hangers,etc. The levelness andplumbness of piping shall be complete and true.

8.2.2 For piping installed at high elevations at the topof columns, drums, etc., assembly and non-destructive examination and pressure testingshall be performed on the ground, as far aspossible, to minimize work at high elevations.When piping installation is unavoidably per-formed at high elevations, the area below shallbe fenced in with a safety rope and “MEN ATWORK ABOVE” signs shall be posted.

8.2.3 When piping components are to be lifted intoplace at high elevations by means of largecranes, in advance, the work data such as theweight, position of center of gravity, reach ofcrane, crane boom length, and other vital datashall be ob tained, and they shall be studiedsufficiently.

8.2.4 Temporary supports shall not be taken from theshell (body) of equipment.

8.2.5 After the pipe spool has been installed accurate-ly to the nozzle of the equipment, field weldingshall be performed. In such cases, blinds shallnot be inserted for purposes of pressure testing,etc.

8.3.0 PIPING AROUND PUMPS AND COMPRES-SORS

The piping installation around pumps and com-pressors shall be as follows.

8.3.1 All piping except for the connections to thenozzle of rotating machinery shall be assembledon the ground.

8.3.2 Before installation of piping to rotatingmachinery, the required heat treatment, pres-sure test ing, interior cleaning, etc., shall becompleted. Pressure testing shall not be per-formed by inserting the blinds directly betweenthe nozzle of rotating machinery and the flangeof the connected piping.

8.3.3 The protective cover placed on the nozzle ofrotating machinery shall not be removed untilthe piping is to be connected.

8.3.4 The preset-piece of spring hangers shall betaken off and spring hangers shall be adjusted,so that piping is located accurately.

8.3.5 It shall be confirmed that alignment work ofrotating machinery and measurement prepara-tion for inspecting misalignment has been com-pleted.



STEEL PIPING


PAGE 14 OF 28

8.3.6 Pipe flanges shall be aligned with all the nozzlesof rotating machinery. The alignment shall beperformed by the adjustment of pipe supportsand flange connections. Unless otherwise specified, the misalignment between flanges shall bewithin the following permissible limits:

a. Flange face separation ( space for gasket )

: ± 0.8mm

b. Flange face parallelism : 0.2mm

c. Rotational offset : 0.8mm

d. horizontal and vertical bolthole offset

: 0.8mm

8.3.7 If the piping alignment specified in Item (6)above is not within the permissible limits, it shallbe corrected. The correction of piping alignmentor the adjustment work of supports shall beperformed by dismantling piping from rotatingmachinery. Care shall be taken so that expan-sion or distortion due to welding, etc., does nothave a detrimental influence on the rotatingmachinery.

8.3.8 When connecting piping to a rotating machine,if the machine misalignment is more than thevalues specified, alignment work of the machineand piping shall be performed again by disman-tling the piping from the machine.

8.3.9 After piping is connected to rotating machinery,the rearrangement of pipe supports or retighten-ing of flange bolts shall not be performed withoutpermission.

8.4.0 PIPING AROUND FIRED HEATERS

Piping installation around fired heaters shall beas follows:

8.4.1 Since piping around the burner tends to becomecomplicated, piping for one or two burners shallbe installed first, and after confirming operability,clearance, safety, and other matters, otherpiping shall be installed.

8.4.2 Drain piping around the burner shall not beplaced on the ground or in such a way as toobstruct passage of persons.

8.5.0 PIPING ON PIPE RACK

Piping installation on pipe rack shall be as fol-lows:

8.5.1 Generally, since air cooled heat exchangers areplaced on top of the pipe rack, and pumps areplaced underneath, the precedence for install-ing piping shall be determined in considerationof the time of installing such equipment, thenumber of stages of the pipe rack itself, etc. Inprinciple, piping installation will be performedfrom the bottom to the top level. When installingpiping, a check shall be performed to ensure thatthe pipe rack beams have been painted.

8.5.2 Before connecting piping to other equipment,piping on pipe racks shall be laid down accurate-ly in the places specified beforehand, and thenslide shoes and stoppers shall be installed ac-curately in accordance with the drawings, sothat baseline for dimensional adjustments infield installation may be made. However, el-bows, tees, etc., required for take-off connec-tions to outside the pipe rack may be left in placetemporarily since it may be re quired to perform

adjustments.

8.5.3 After the pipe has been laid on the rack, the pipeshall be tied with wire to prevent it from fallingoff until the weld joints are made.

8.5.4 The pipe fittings and welded lines shall be in-stalled so as not to be positioned on the beams.

8.6.0 OFFSITE PIPING

Installation of offsite piping shall be as follows:

8.6.1 Piping installation inside the dike shall be per-formed after a thorough study of the workschedule has been made, with considerationgiven to other related work such as the confirmation of time of tank water filling and of access forhandling materials.

8.6.2 Pipe sleepers and support footings inside thedike shall be installed after confirming that thelevelness of the ground has not been disturbedby the water filling test of the tank.

8.6.3 Piping to be connected to the tank nozzle shallbe installed after checking that the valve andaccessories installed on the tank are in accord-ance with the specification.

8.6.4 Flexible hoses and expansion joints to the tanknozzle shall be installed accurately in accord-ance with the drawings.

8.6.5 When laying pipe on sleepers, the sleepers shallbe checked to confirm that they are at thespecified elevation, level in line, and painted.

8.6.6 Piping on pipe sleepers shall be laid on sleepersthat have been marked off. Slide shoes andstoppers shall be installed accurately in accord-ance with the drawings. The pipe fittings andwelded lines shall be installed so as not to bepositioned on the sleepers.

8.6.7 For piping penetrating an oil dike, the flanged,threaded, or welded joints shall not be em-bedded in the dyke.

8.7.0 INSTALLATION OF VALVES

The installation of valves shall be as follows:

8.7.1 The valve shall be installed accurately so thatits location and the orientation of the handle isin accordance with the piping drawings. How-ever, when the orientation of the handle isdeemed inappropriate from the viewpoint ofoperation or passage, the FEDO engineer shallbe contacted for directions.

8.7.2 The valve shall be checked for its class, bodymaterials, and trim materials to prevent anymisuse.

8.7.3 Before installing the valve, the flange faces ofthe valve and the connected piping shall bechecked to see that they are not damaged ordirty, and that they are parallel with each other.

8.7.4 Valves shall be installed in the closed position,except for plug valves and ball valves. Afterbeing installed, valves shall not be opened ex-cept for pressure testing. Especially, welding forinstallation of the butt weld and socket weld typevalves shall be performed in the closed position,to prevent the valve seat being damaged.

8.7.5 For lubricant plug valves, the disc shall be left inthe open position and the lubricant shall bereplenished to prevent loss of the sealant.



STEEL PIPING


PAGE 15 OF 28

8.7.6 Globe valves, check valves, control valves, andother similar valves shall be installed in accordance with the marked direc tion by checking theflow direction.

8.7.7 To prevent the stem threads from rusting,grease shall be applied prior to installation of thevalve.

8.8.0 INSTALLATION OF SAFETY VALVES

The installation of safety valves shall be asfollows:

8.8.1 Until line pressure testing has been completed,in principle, the safety valves shall not be installed with the piping. If safety valves arenecessary to assemble the piping, a spool of thesame face-to face dimension shall be fabricatedand installed. For threaded safety valves, thepiping shall be capped. However, the safetyvalve with test gag may be installed with pipingand subjected to line pressure testing.

8.8.2 All safety valves shall be installed after thespecified set pressure has been tested in thefield.

8.8.3 The seal securing the cap to the safety valvebody shall not be removed without FEDO /Representative’s approval.

8.8.4 The safety valve with a lever shall be installedwith the lever oriented as shown on the drawing.

8.9.0 Installation of expansion joints

The installation of expansion joints shall be asfollows:

8.9.1 Expansion joints shall be installed accuratelyand shall be at the location and of the dimen-sions shown on the piping and detailed draw-ings, and in a manner so as not to be connectedeccen tric with the pipe.

8.9.2 Expansion joints shall be installed after confirm-ing that the line has been completely assembledwith all anchors, guides, and stoppers installedin place as shown on the piping drawings.

8.9.3 Expansion joints shall be installed so that nostress except in the direction intended occurs.

8.9.4 After pressure testing and flushing, all shippingbolts and fixtures shall be removed and thejoints shall be checked to ensure that nothingobstructs the expansion movement.

8.9.5 Prior to installation, expansion joints with innersleeves shall be checked to ensure that thesleeve inlet (fixed) is on the upstream side.

8.9.6 Bellows of expansion joints shall be handledwith utmost care, so that no objects will bedropped upon it.

8.9.7 Each expansion joint shall be blown free of dust/ foreign matter with compressed air or shall becleaned with a piece of cloth.

8.9.8 For handling and installation of expansion joints,great care shall be taken while aligning. Anexpansion joint shall never be slinged with bel-lows corrugations/external shrouds, tie-rods,angles etc.

8.9.9 An expansion joint shall preferably be slingedon the end pipes/flanges or on the middle pipe.

8.9.10 The pipe ends in which the expansion joint is tobe installed shall be perfectlyaligned or shall

have specified lateral deflection as noted on therelevent drawings.

8.9.11 The pipe ends / flanges shall be spaced at adistance specified in the drawings.

8.9.12 The Expansion Joint shall be placed betweenthe mating pipe ends/flanges and shall be tackwelded/bolted. The mating pipes shall again bechecked for correct alignment.

8.9.13 Butt welding shall be carried out at each end ofthe expansion joint. For flanged ExpansionJoint, the mating flange shall be bolted.

8.9.14 After the Expansion Joint is installed the con-tractor shall ensure that the mating pipes andExpansion Joint are in correct alignment andthat the pipes well supported and guided.

8.9.15 The Expansion Joint shall not have any lateraldeflection. The contractor shall maintain paral-lelism of restraining rings or bellows convolu-tions.

8.10.0 INSTALLATION OF INSTRUMENTS

8.10.1 Kinds of instrument handled

1. The following instruments shall be installedin the scope of piping installation work:

a. Flow meters to be installed directly on the line(area type, volume type, magnetic type, etc.).

b. Orifice flanges and orifice platesc. Displacer type or ball float type level metersd. Control / self control valves & safety valvese. Other instruments installed directly on the line

2. In addition, instruments up to the first valveor flange in the nozzle take-off connectionsfor the instrument lead piping are included.

8.10.2 General Procedure : General installation proce-dure for instruments shall be as follows:

a. All instruments shall be checked as to in-strument number and shall be installed trueto level, plumbness, or the specified angle

b. The instruments and the associated piping(excluding instrument piping) shall be sup-ported so that problems will not result dueto distortion or vibration

c. It is preferred to have all the instrumentsinstalled after the interior of piping, columnsand drums have been cleaned. When in-struments are to be installed unavoidablyduring piping construction, measures shallbe taken to prevent the instruments frombeing damaged and to prevent foreign mat-ter from entering the instruments. Orificeplates shall be installed only after testingand flushing of pipes.

d. Flow control valves shall be installed afterchecking the flow direction mark.

8.10.3 Installation of Flow Meters : The installation offlow meters shall be as follows:

a. When installing orifice flanges, the straightlengths of pipe required upstream anddownstream shall be checked to see thatthey comply with the piping drawings. Inprinciple, the upstream straight pipe lengthshall be of one piece. When there is anunavoidable welded line in the length, thedistance between the orifice and the weld



STEEL PIPING


PAGE 16 OF 28

line shall be not less than 14 times the pipediameter. The straight lengths of pipe shallnot be provided with a vent, drain, or othersimilar branch.

b. Jack screws for orifice flanges shall be in-stalled so that they are 180O apart fromeach other.

c. When taps are to be taken off from a pipe,the holes shall be drilled where shown onthe drawings, the burrs removed and theholes made smooth. Sockets shall not beembedded in the pipe.

d. The orientation for pressure differential tapsshall be accurate as shown on the drawings

e. Orifice plates shall not be installed until thepipe interior has been cleaned.

f. When installing orifice plates, the orificeplate number and the flow direction shall bechecked. In general, the handle is pointedupwards and the inlet die stamp mark endis pointed upstream.

g. An orifice plate shall be installed with itscenter coinciding with the center of the pipeand with the gasket not protruding into thepipe.

g. An orifice plate shall be installed with itscenter coinciding with the center of the pipeand with the gasket not protruding into thepipe.

h. Installation of flow meters such as areatype, column type, and magnetic type shallbe in accord ance with the instructions of theFEDO Engineer.

8.10.4 Installation of Control Valves : The installation ofcontrol valves shall be as follows:

a. Control valves shall be installed by checkingthe flow direction and, except for specialcases, with the diaphragm at the top in avertical position.

b. To prevent internal and external damageand entry of foreign matter during construc-tion, control valves shall be installed duringthe last stage after pressure testing andflushing of the line. In this case, a spoolhaving the same face-to-face dimension asthe control valve shall be inserted to keepthe distance during construction. Furthermore, after the piping around the controlvalve has been installed, the dimensionsshall be checked to confirm that the valvecan be fit in place.

c. When installing control valves unavoidablyduring construction, a blind gasket, gal-vanized iron sheet, or other suitablematerial of the same thickness as the maingasket shall be inserted to prevent entry offoreign matter. During construction, controlvalves shall be covered with vinyl sheet orother suitable material, and care shall betaken not to damage the valves. Duringpressure testing and flushing of the line, thevalve shall be removed and the end flangesof the valve shall be covered up.

9.0.0 INSPECTION AND TEST

9.1.0 DOCUMENTS

The Contractor shall submit the following in-spection records for each items of test andinspection:

9.1.1 Non-destructive inspection

a. Record of radiographic inspection

b. Record of magnetic particle inspection

c. Record of liquid penetrant inspection

d. Record of ultrasonic inspection

e. Records of stress relieving

f. Records of hardness test

g. Records of hydrostatic & pneumatic pr. tests

9.1.2 Destructive inspection

Record of welding procedure qualification test9.1.3 Others specifically instructed

Following are to be indicated on the test andinspection record

1. Name of customer

2. Job number and name of work

3. Name of contractor

4. Line number

5. Date of test and inspection

6. Name(s) of attendant (FEDO, Customer, orthird party)

9.2.0 ITEMS OF INSPECTION AND TEST

9.2.1 Prior to, during and after completion of theworks, the following tests and inspections shallbe performed.

ITEMS FOR INSPECTION AND TEST

PRIOR TO COMMENCING WORK

Checkingmaterials Legal qualification certificate

Welding proce-dure test

welder’s techniqe qualifica-tion certificate

Welder’s techni-que qualification

test

Welding rodcheck

PRIOR TO WELDING WORK

Edge preparation Angle, Root opening, Thick-ness of land, Cleanliness

Shape of pipeend

Out of roundness, Thick-ness, Uneven thickness

BendingDegree of flattening at bentpart, Radius of curvature,

Thickness reduction at bentpart

Tack welding Bevelled end misalignment,Root opening

Preheating

Method of preheating,Temperature of preheating,width of heating, Tempera-ture measurement, Heating

temperature, Others



STEEL PIPING


PAGE 17 OF 28

Welding rod Drying temperature, Dryingtime

DURING WELDING WORK

Welding condition

Welding parameters, Flowrate of sealing gas, Protect-

ing measure for welding,Condition of ambient

temperature

Inter-layer temperature

Re-examination of welder

AFTER COMPLETION OF WELDING WORK

Visual ap-pearance inspec-

tion

Inside surface misalignment,Outer surface misalignment,

Inside surface weldprotrusion, Wave irregularity,Uneven leg length, Irregularheight of bead, Undercut,

Overlap, Bead centre shift,Height of reinforcement

welds

Non-destructiveinspection

Radiography, Dye penetrant,Magnetic particle

Stress relieving temperature and method

Hardness test

DURING OR AFTER COMPLETION OFWELDING WORK

Product inspec-tion

Dimension, Condition of con-nection to equipment, Visual

apperance inspection

Treatment of pipe inside

Thread

Seal welding of threaded portion

AFTER COMPLETION OF WORK

Completion of work w.r.t piping drawings

Pneumatic pressure test

Flushing

Removal of temporary supports / scafoldings

AT TRIAL OPERATION

Appearance inspection

9.3.0 VISUAL APPEARANCE EXAMINATION

9.3.1 Following shall be met, checking visually or inusing measuring instrument

1 Inside surfacemisalignment : 1.5mm or less

2 Outer surfacemisalignment due todifference ofdiameter of thick-ness

: 3.0mm or less

3 Inside surface weld protrusionNominal Wall Thk.

Up to 6.4mm : 1.6mm or less

Over 6.4mm to12.7mm : 3.2mm or less

Over 12.7 up to25.4mm : 4.0mm or less

Over 25.4mm : 4.8mm or less

4 Wave irregularity ; 2.5mm or less

5 Irregular height ofbead : 2.0mm or less

6 Under cutNo under cut is al-lowed for piping ofcold or high tempera-ture service.

: Within 0.8mm or12.5% of thicknesswhichever smaller

7 Over lap : 1.5mm or less

8 Height of reinforcement

Nominal Wall Thk.

Up to 6.4mm : 1.6mm or less

Over 6.4mm up to12.7mm ; 3.2mm or less

over 12.7mm up to24.5mm : 4.0mm or less

Over 24.5mm : 4.8mm or less

Throat thickness offillet welds

: 70% of thickness ofthe inner plate or

more

9.4.0 Non-destructive inspection

9.4.1 Non-destructive inspection shall be performedaccording to the grade of inspection stipulatedin the next table. (Pressure classes in accord-ance with ANSI B16.5)

Material

Grade of Inspection

I II III

Pressure classes - ANSI B16.5(psig.)

P - NO: 1

Carbonsteel

Servicetemp.

below 3500C

Lessthan 300

lb400 lb -1500 lb

2500 lband

above

Servicetemp.

3500C ormore

- 150 lb -900 lb

1500 lband

above

Al-killed Steel - 150 lb -900lb

1500 lband

above

P - NO: 3, 4, 5

C- 0.5 Mo Steel Cr- Mo Steel - 150 lb -

900 lb1500 lb

andabove

P - NO: 9

3.5 Ni steel - 150 lb -900 lb

1500 lband

above

P - NO: 8

Aus-tenitic

stainlesssteel

A312 Gr.TP304

Lessthan 150

lb @300 lb -600 lb

900 lband

above

Other thanabove - 150 lb -

300 lb400 lband

above

Note: @ When A312 Gr. TP304 is used for cold orhigh temperature service, the grade II of inspec-tion shall be applied even if it is not above 150lb.

9.4.2 Items of non-destructive inspection and numberof samples for the random inspection shall beas follows:



STEEL PIPING


PAGE 18 OF 28

ITEM OF INSPECTIONR - Radiographic InspectionM - Magnetic particle InspectionL - Liquid PenetrantInspection

Material

Object of inspection

Periphery

Noz-zle (1)

Socket

Nonpres-surepart

GRADE - I

RCarbon

steel

Lessthan 150

lb3 %

- - -Over 150lb to 300

lb10 %

A312 Gr. TP304 10 %

GRADE - II

R All materials 20 % - - -

M(3)

Carbon steel -

10 % 10 % 10 %(4)

C-0.5 Mo steelCr-Mo steel Al-killed steel 3.5-Ni steel 10 %

(2)L

(3)Austenitic

stainless steelNon-ferrous metals

GRADE - III

R All materials 100 % - - -

M(3)

All materials exceptfor austenitic stain-less steel, non-fer-

rous metals &non-magnetic metal 20 % 100 % 100 % 20 %

(4)

L(3)

AusteniticStainless steel

Non-ferrous metal

Notes

(1) In “nozzle welding”, welded parts of reinforcingplate and slip-on flange are included.

(2) This inspection shall be performed for thewelded parts other than those to whichradiographic inspection was applied.

(3) Either magnetic particle inspection or liquidpenetrant inspection shall be performed.

(4) This inspection shall be performed for Cr-Mosteel (A335 Gr. P5 or over grade) and 3.5Nisteel.

Remarks

1. Radiographic inspection for peripheral jointshall be performed for pipes of nominaldiameter of 2" or more having the samecondition.

2. Number of random sampling test shall be atleast one, when less than one is obtained inpercentage of sampling

3. Number of photographs to be taken for oneperipheral joint at radiographic inspectionshall be as follows:

PIPE SIZE NB NO. OFPHOTOGRAPHS

50 to 80 150 x 2 sheets

100 to 150 300 x 3 sheets

200 to 300 300 x 4 sheets

350 to 400 300 x 5 sheets

450 300 x 6 sheets

500 300 x 7 sheets

600 300 x 8 sheets

650 & above

With film overlap of25mm or more, no ofphotographs shall be

equivalent to peripherallength of the pipe

9.4.3 Radiographic examination

Unless otherwise specified, radiographic ex-amination shall be as follows:

1. Radiographic inspection shall be performedin accordance with Article 2, Section V of theASME Boiler and pressure vessel code.

2. The welds to be examined shall be selectedbased on the number of work products ofeach welder and welding operator engagedin all welding operations. A minimum of oneweld per sample shall be examined.

3. All welded joints in a designated lot of pipingshall be radiographed over the completecircumference.

4. When a random type examination reveals adefect, additional examination shall be per-formed in accordance with the requirementsof appendix IV.

5. The radiation source shall, in principle, bex-ray or Gama-ray.

6. Film such as Sakura RR, Fuji #100, KodakAA, or Equivalent shall be used.

7. Identification mark as shown in Figure 10( Page 28 of 28 ) shall be marked on everyradiograph, and radiographs of repair weldshall be marked with repair mark (R).

8. The image quality indicator (IQI) specifiedin B UB-51, ASME Section VIII, Division 1,or equivallent shall be used.

9. Limitations on imperfection shall be in ac-cordance with ANSI B31.3 TABLE 327.4.1(A) for the degree of radiography involved.

9.4.4 Magnetic Particle/Liquid Penetrant Examination

Liquid penetrant or magnatic particle examina-tion shall be as follows:

1. Liquid penetrant inspection shall be per-formed in accordance with Article 6, sectionV of ASME Boiler and pressure vessel code.

2. Limitations on imperfection shall be in ac-cordance with ANSI B31.3 Table 327.4.1 (A)

3. The weld surface, to which liquid penetrantor maganetic particle examination is ap-plied, shall be finished smoothly with agrinder as necessary.

4. If a defect is found in welds, the defect shallbe removed, and liquid penetrant examina-tion or maganitic particle examination shallbe performed again to confirm that no moredefects exist., and then rewelding shall beperformed. After rewelding has been com-pleted, liquid penetrant examination ormaganetic particle examination shall be



STEEL PIPING


PAGE 19 OF 28

performed again to confirm that the reweldsare sound.

a. Magnetic particle inspection shall be per-formed in accordance with Article 7, SectionV of the ASME Boiler & pressure vessel code

b. Limitations on imperfection shall be in ac-cordance with ANSI B31.3 Table 327.4.1 (A)

9.5.0 HARDNESS TEST

9.5.1 After stress relieving (SR) is performed, hard-ness shall be tested as follows:

1. If SR is performed by heat coil, the hardnesstest shall be carried out for all welds.

2. If SR is performed in furnace, hardness testshall be performed for 10% of all welds (atleast one-when 10% of all is less than one)

3. Point to be tested shall be finished flat withfile before the test.

4. The hardness points shall be tested to weldand to heat affected zone. Hardness test ofthe heat affected zone shall be made at apoint as near as practicable to the edge ofthe weld. When dissimilar materials arewelded, both heat affected zones shall betested.

9.5.2 Hardness limit is given in following table ( Hard-ness In Brinell Max. )

P-No. MATERIAL HB(MAX)

P-3 A335 Gr.P1 (STPA12) 225

P-4 A335 Gr.P12 (STPA22)A335 Gr. P11 (STPA23) 225

P-5 A335 Gr. P22 (STPA24)A335 Gr. P5 (STPA25) 241

9.6.0 PRODUCT INSPECTION

Inspection for the finished product shall be per-formed as follows:

9.6.1 Dimension: Right angle, perpendicularity, paral-lelness, dimension, etc. shall be measuredvisually and by measuring tools and checkedagainst the drawings. Dimensional tolerancesare as follows:

1. Length + 0 ; -3.2mm or less

2. Inclination of flange surface: less than 0.5o

against the surface perpendicular to theaxis of pipe. (but, not to exceed 2mm atoutside circumference of flange).

3. Perpendicularity of vertical line: 2/1000 orless.

4. Horizontality: 2/1000 or less

5. Misalignment between flange center andpipe center: 1.6mm or less

6. Shift of bolt hole center: 1.0mm or less.

9.6.2 Inspection of connection to equipment: Forthose pipings which are connected with pump,compressor, turbine, etc., the above dimen-sional tolerance shall be submitted by thetolerances required by each of such machinery.

9.6.3 Appearance inspection:

1. Correction for jig mark.

2. Removal of spatter and slag

3. Any harmful flaw on the flange face, innerand outer surface of pipe.

4. As-erected condition

5. Shape and size of branches and other at-tachment shall comply with drawings.

9.7.0 Inspection for treatment of pipe inside

9.7.1 Inspection shall be performed visually andtouching by hand to confirm that no rust, slag,spatter, sand, or other foreign matters are left.Inspector must confirm whether sufficient flush-ing was performed.

10.0.0 PRESSURE TEST AND OTHERS

10.1.0 GENERAL

10.1.1 Prior to initial operation, the installed piping shallbe pressure tested under witness of FEDO En-gineer/ Representative.

10.1.2 Prior to the pressure test, a line check shall beperformed based on P&I diagrams and thepiping draw ings, in accordance with the instruc-tions of the FEDO Engineer/ Representative.

10.1.3 Types of pressure test are as follows, howeverthe test shall be performed in accordance withthe individual specification:

1. Pressure tests

Hydraulic test (using water or other liquids)

Pneumatic test

2. Leak test

Overall air tightness test

10.1.4 Before filling it with the test fluid, the entire lineto be pressure tested shall be examined in themanner described in Section 9.0.0, and anyfaults shall be repaired. The piping affected byany repairs or additions made after the pressuretest shall be retested.

10.1.5 In principle, piping shall be pressure tested at ametal temperature not less than 20C. However,carbon and alloy-steel piping exceeding 25mmin thickness shall be pressure tested at atemperature not less than 160C.

10.1.6 The following equipment and instruments shallnot be connected to the piping before comple-tion of the pressure test:

1. Rotating machinery such as pumps, tur-bines, and compressors.

2. Pressure relieving devices, such as rupturediscs and pressure relief valves.

3. Equipment that has a castable or liningmaterial .

4. Instruments.

5. Piping which is normally open to the atmos-phere such as drains, vents, and dischargepiping from pressure relieving devices.

6. Any other designated equipment.

10.2.0 TEST FLUID

Test fluid shall be as follows:

10.2.1 In principle, the fluid for hydrostatic testing shallbe fresh water. Unless otherwise specified, the



STEEL PIPING


PAGE 20 OF 28

chlorine ion concentration in the fluid used foraustenitic stainless steel piping shall not exceed30 ppm. After completion of the test, the watershall be drained immediately, and the interior ofthe pipe shall be dried by an air blower, etc.

10.2.2 For piping systems having strong acids and So2where water may become corrosive, or pipingsystems operated at a temperature of 00C orless, kerosene or similar light oils (with a flashpoint not less than 500C) or air is preferred asthe test fluid.

10.2.3 The air to be used for pneumatic testing shall becompressed air from a portable compressor.However, for instrument air lines or wherespecifically specified, oil-free dry compressedair or inert gas shall be used. For high pressurepiping (not less than 100 kgf/cm2G), the use ofinert gas is preferable. When pneumatic testingis performed by the use of an air compressor,precautions against combustion shall be takenby blowing clean the oil separator thoroughly sothat no lubricant enters the air.

10.3.0 TEST PREPARATION

The preparation for pressure test shall be asfollows:

10.3.1 All joints (including welds) are to be left uninsu-lated and exposed for examination during thetest. However, joints previously tested in ac-cordance with this standard may be insulated.

10.3.2 When filling water into piping that is designatedfor vapor, gas, etc., not filled with water duringoperation, temporary supports or other reinfor-cements shall be provided beforehand.

10.3.3 Special fittings in piping components, such asexpansion joints, filters, and flame arrestors,shall be disconnected from the piping.

10.3.4 Equipment which is not to be subjected to thepressure test shall be either disconnected fromthe piping or isolated by blinds or other meansduring the test.

10.3.5 If a pressure test is to be maintained for a certainperiod and the test liquid in the system is subjectto thermal expansion, precautions shall betaken to avoid excessive pressure. In particu lar,for hydrostatic testing, care shall be taken toensure that the water will not be subject tothermal expansion so that the piping is notdamaged during the test.

10.4.0 TEST PRESSURE

10.4.1 Hydraulic Testing of Internally Pressured Piping

1. The test pressure for piping subject to inter-nal pressure shall be as follows:

a. Not less than 1.5 times design pressure

b. For a design temperature above the testtemperature, the minimum test pressureshall be calculated by the following for-mula.

PT = 1.5PST

S

Where

PT= minimum hydrostatic pressure inkgf/cm2 G

P = internal design pressure in kgf/cm2 G

ST= allowable stress in kgf/cm2 at testtemperature

S = allowable stress in kgf/cm2 at designtemperature

3. If the test pressure as defined in Item (2)above produces a stress in excess of theyield strength at the test temperature, thetest pressure may be reduced to the maxi-mum pressure that will not exceed the yieldstrength at test temperature.

10.4.2 Hydrostatic testing piping with vessels as a sys-tem

1. Where the test pressure of piping attachedto a vessel is the same as or less than thetest pressure for the vessel, the piping maybe tested with the vessel at the test pressureof the piping. However, the test pressureshall be controlled carefully so as not toexceed the test pressure of the vessel.

2. Where the test pressure of piping exceedsthe vessel test pressure, the piping shall betested by isolating it from the vessel.

10.4.3 Hydrostatic testing of externally pressuredpiping : The test pressure for piping subjectedto external pressure shall be as follows:

a. Lines in external pressure service shall besubjected to an internal test pressure of 1.5times the external differential design pres-sure, but not less than a pressure of1.0kg/cm2G (15 psig).

b. In jacketed lines, the internal line shall bepressure tested on the basis of the internalor external design pressure, which ever iscritical. The jacket shall be pressure testedon the basis of the jacket design pressureunless otherwise specified.

10.4.4 Pneumatic testing

1. In principle, pressure tests shall be per-formed hydraulically, however, when it isinappropriate to fill piping with water, the testmay be performed with air or inert gas. Thetest pressure shall be 1.1 times the designpressure.

2. Any pneumatic test shall include a prelimi-nary check at not more than 1.75 kgf / cm2G(25 psig) pressure. The pressure shall beincreased gradually in steps providing suffi-cient time to check for leaks.

10.5.0 TESTING METHOD

The method of pressure testing shall be in ac-cordance with the instructions of FEDO. How-ever, the general method by using water shallbe as follows:

10.5.1 In principle, pressure tests shall be performedfor each piping system. However, when designconditions do not permit testing in such a man-ner, the system may be tested in sections.

10.5.2 Test blinds shall have a handle extending outfrom the flange. The handle shall be painted inred, to ensure removal of blind after testing.

10.5.3 Installation and removal of blinds shall be per-formed in accordance with the instructions of



STEEL PIPING


PAGE 21 OF 28

FEDO. The number or all the blinds used andthe location of the insertion shall be recorded atall times.

10.5.4 Test pressure gauges with graduations up to twotimes the prescribed test pressure shall beprovided. All the pressure gauges shall be cer-tified by the national authority, and the calibra-tions shall be checked by periodic inspections.

10.5.5 Two or more pressure gauges shall be installedso that they are easily observed. When thepiping system to be tested extends from a lowto a high level, pressure gauges shall be in-stalled at both the lowest and the highest points.

10.5.6 For each piping system, an outlet for discharg-ing the pressure in case of emergency shall bedesignated and marked to that effect.

10.5.7 During pressure testing of piping, operation ofvalves shall be prohibited and the valves shallbe marked to that effect.

10.5.8 Prior to pressure testing, it shall be confirmedthat a strainer is provided at a designated loca-tion to remove foreign matter.

10.5.9 Vents on piping subjected to hydrostatic testingshall be opened to remove the air when fillingthe piping with water.

10.5.10Prior to hydrostatic testing, the piping shall bechecked to confirm that it is free from air pocketsand if necessary, temporary vents shall beprovided to eliminate the air pockets until testingis completed.

10.5.11 For piping systems with a check valve, the pres-sure shall be applied from upstream of the valve.If this is impractical, the check valve shall eitherbe reversed or shut off with blinds. However,when reversed, the valve shall be reinstalledcorrectly after testing.

10.5.12When the test pressure is not less than 50 kgf /cm2G, pressure shall be increased gradually.

10.5.13The test pressure during a pressure increaseshall be read by the pressure gauge installed atthe lowest point of the piping in consideration ofthe water head pressure.

10.5.14The check for any leaks during the pressure testshall be performed after the prescribed pressureis maintained for a time not less than 10 minutes.All connections and all welded joints shall beinspected thoroughly.

10.5.15After the completion of pressure testing, thewater shall be drained immediately from the lineto prevent the piping system from beingdamaged by freezing or thermal expansion.Also to prevent vacuum forming in the piping,the vents shall be opened when the water isbeing drained.

10.5.16On completion of pressure testing, the line shallbe checked to see that no residual pressure ispresent, and the line shall be drained. All blindsshall be removed.

10.5.17Short pieces of pipe, which must be removed forinstalling blind plates and blind flanges, shall betested separately.

10.5.18All valves, orifice plates, expansion joints, shortpieces of pipe, and other items removed orinstalled for the test, shall be reinstalled with theprescribed gaskets in the correct position.

10.6.0 REPAIR OF DEFECTS

The repair of defects found during test andinspection of piping systems shall be as follows.In principle, the repair shall be performed underwitness of FEDO after the approval of the FEDOEngineer has been given.

10.6.1 Repair of welds

a. Repair welding shall be performed after thepressure and liquid remaining in the pipehave been removed.

b. The defects to be repair welded shallbe removed completley with a grinder, etc.

c. The welding, the heat treatment, and thetest and inspection shall be the same asrequired for the initial welding, and per-formed in accordance with the applicableprovisions of this specification.

d. In principle, repair welding of the same por-tion shall not be performed more than twice.

10.6.2 Repair of Threaded Joints

All defective threaded joints shall be replacedwith complete new ones.

10.6.3 Repair of Flange Joints

All defective flange joints shall be replaced withcomplete new ones, except those which can berepaired in accordance with Section 5.2 (15).

10.7.0 FLUSHING AND CLEANING

10.7.1 Selection of cleaning method

Cleaning method shall be selected in the follow-ing methods considering kind of fluid, pipematerial and condition of internal surface ofpiping to be cleaned. Cleaning method and ex-tend of cleaning shall be as per specific ProjectRequirements.

a. Water Flushingb. Air Blowingc. Steam Blowingd. Acid Cleaninge. Oil Cleaningf. Others

10.7.2 Procedure of cleaning in general

1. Cleaning of fabricated pipings

Inside surface and face of weld of fabricatedpiping shall be made free from slag, cham-fer, scale and other foreign matter, withgrinder, chisel, wire brush, etc., and be air-blown. After completion of air blowing andchecking, ends of the piping shall becovered with vinyl or veneer cap, etc. till theinstallation in the field.

2. Temporary Strainers

Temporary strainers shall be used as fol-lows:

a. After installation of piping, and beforecommencement of flushing/cleaning.

b. The temporary strainers shall be installedat pump suction piping, upstream of con-trol valve and other locations as specified.



STEEL PIPING


PAGE 22 OF 28

c. Mark plate shall be attached to the tem-porary strainers to distinguish from otherstrainers.

d. After a constant period of initial operation,all temporary strainers shall be removed,cleaned and reinstalled.

10.8.0 WATER FLUSHING

10.8.1 Cleaning method by water

1. As a rule, pure water, service water, steamcondensate, industrial water, etc. shall beused. If there is any requirement about thequality of water to be used, it shall be ob-served.

2. After flushing, drying by compressed air ornatural drying shall be carried out. Drying bysuperheated steam shall be carried out withagreement between Customer and FEDO.

3. Flushing shall be performed till the waterbecomes free from foreign matter, scale,etc. This shall be decided by observing tur-bidity of water taken out ( into beaker orcup).

4. Water flushing shall be performed by themethod of running by pressurised water andhammering, or rapid draining with waterfilled. Hammering shall, however, not beperformed for austenitic stainless steelpipe, copper pipe, aluminum pipe.

5. The primary cleaning shall be performed foreach assembled piping system includingthe equipment.

6. Where instruments are included in pipingsystem to be cleaned, the instruments shall,as a rule, be disconnected and spool pipe(distance piece) shall be inserted instead.

7. When cleaning is carried out in the conditionthat control valve is connected, the proce-dure shall be as follows:

a. Disconnect companion flange at upstreamside of the control valve and cover open-ing of the control valve.

b. Clean the piping of upstream side.

c. Connect the control valve and the pipingof upstream side after cleaning.

d. Close the control valve, open by-passvalve, and then clean the piping of downstream side. Where the by-pass valve isnot installed, the temperory strainerhaving austenitic stainless steel screen ofNo. 50 specified in ASTM E-11 shall be in-serted.

10.8.2 Air blowing

1. Air blowing shall be performed by themethod of blowing by pressurized air andhammering. Hammering shall, however, notbe performed for austenitic stainless steelpipe, copper pipe and aluminum pipe.

2. Blowing shall be performed till thereremains no scale in the piping. FEDO per-sonnel in charge shall make judgement ofwhether the result of the cleaning is statis-

factory or not

3. The primary cleaning shall be performed foreach assembled piping. The secondarycleaning shall, as a rule, be performed forpiping from eqpt. to adjacent eqpt. Whetheror not the equipment is included shall bedetermined considering shape, internalconstruction & packing of the eqpt. andaccording to overall cleaning planning.

10.8.3 Steam blowing

1. Execution of steam blowing

Steam blowing shall be executed after com-pletion of pressure test and insulation work.

2. Preparation of steam blowing

a. Temporary piping work, countermeasurefor safety & confirmation of preparationshall be done according to blowing plan.

b. Support shall be attached to exhaustpiping to prevent accident caused by thereaction force during blowing.

3. Procedure of steam blowing

a. Warm up the piping with cooperation byoperator

b. Check expansion joints, spring hangers,etc., for expected thermal expansion.

c. Steam blowing shall be performed at thetemperature near to the operating tempera-ture, considering operating condition ofboiler.

d. To remove the scale effectively by tempera-ture change, it is required to perform flush-ing and cooling cyclically, havingtemperature difference as large as pos-sible between the flushing and cooling.

4. Judgement criteria of steam blowing

a. Judgement on result of steam blowingshall generally be done by checking coloror quantity of foreign material present inthe drain sampled.

b. If necessary, especially for suction line ofsteam turbine etc., result of flushing shallbe judged by observing whether scratchwas produced or not on the test piece in-serted in the line.

10.8.4 Acid cleaning

1. Applicable piping of acid cleaning

Unless otherwise specified in specific jobrequirements, acid cleaning shall apply tooil piping system of rotating machinery.

2. Cleaning method by acid

As a rule, acid cleaning procedure shall beas follows:



STEEL PIPING


PAGE 23 OF 28

a. Ten-percent hydrochloric acid solution orTen-percent sulphuric acid solution withtemperature 30 to 400 C shall be used, andpiping shall be pickled in the acid solutionfor 1 to 6 hours.

b. After pickling, the piping shall be washedsufficiently to remove the acid solution bywater.

c. And the piping shall be rinsed forneutralization of the acid solution bysodium hydroxide solution, followed bywater flushing.

d. The piping shall be well dried by super-haeted steam or dry air and the inside ofpipes given a coat of the oil of the samequality as specified to be used in the oilpiping.

Remarks: Oil piping of stainless steel shall not be acidcleaned.

10.8.5 Oil cleaning

1. Applicable piping of oil cleaning

Oil cleaning shall apply to the oil pipingsystem after the acid cleaning specified inpar. 10.8.4 has been performed.

2. Cleaning method by oil

The procedure shall be as follows:

a. Oil to be used shall have good qualitysuitable for the machinery, and shall becompletly replaced with the specified oilafter cleaning.

b. The cleaning shall be performed by themethod of circulation of the oil and ham-mering. Hammering shall, not be per-formed for copper pipe.

c. After completion of cleaning, it shall bechecked that no foreign matter is presentin temporary strainer screen of No.200specified in ASTM E- 11 for oil pipings ofcentrifugal compressor, and screen ofNo.100 specified in ASTM E-11 for other oilpipings.

10.8.6 Other cleaning method

1. Cleaning method by pig or cushion ball

Cleaning by the use of pig or cushion ballshall confirm to specific job requirements.

2. Cleaning method by sodium hydroxide

Cleaning by sodium hydroxide solution shallconform to specific job requirements.

3. Special cleaning

Special Cleaning, if specified for specialpiping components or systems, shall con-form to specific job requirements.

10.9.0 Overall airtightness test

10.9.1 When specified, an overall airtightness test shallbe performed for the piping of process line bythe use of air or inert gas after completion offlushing.

10.10.0Disposition

10.10.1All construction equipment used for the pipingwork, and all surplus, scrap and debris shall bedisposed of in accordance with the instructionsof the FEDO Engineer.

10.11.0Test record

10.11.1 All inspection and test results shall be made intore cords in accordance with the instructions ofFEDO. The records shall be submitted for ap-proval to FEDO.

11.0.0 APPENDICES

11.1.0 The following Appendices shall form a part ofthis manual:

TITLE REFER TO:

Grove face Rust Preventive APPENDIX I

Selection of welding electrodes APPENDIX II

Procedure for Flange Bolt up APPENDIX III

Additional Random TypeExamination for weld defects APPENDIX IV



STEEL PIPING


PAGE 24 OF 28

APPENDIX — I GROOVE FACE RUST PREVENTIVE

Features of Product

1. As rust preventive applied to the groove face, ingeneral, deoxialuminite is used as it is notdetrimental to the weld. Deoxialuminite is thebrand name of a product of Special ChemicalCo., Ltd.of USA. This was first produced inJapan by Nippon Oil & Fats Co., Ltd. and is soldunder the brand name of Tasteto Silver.

2. The composition of the product is 40% resin,50% solvent, 5% pigment, etc., and the percent-age of resin in the compound is high to reducethe amount of gas produced during welding.

3. This product is recommended for both marineand overland transportation. The thickness ofthe applied product shall not be more than 30microns.

4. The adherent durability is not more than threemonths.

Directions for Use

5. Before applying the rust preventive, it shall beconfirmed that the groove face is clean.

6. After the rust preventive has been applied, weld-ing shall not be performed within two weeks.

7. In principle, the application shall be sprayed bymaintaining a distance not less than 30 cm fromthe spray nozzle to the object. Unless otherwisespecified, the product shall not be applied witha brush.

APPENDIX — IISELECTION OF WELDING ELECTRODES & RODS

Table - I : Selection of welding electrodes & rodsfor joining similar materials except Aluminium

Table - II : Selection of welding electrodes & rodsfor joining disimilar materials except Aluminium

( Tables overleaf )

APPENDIX — IIIPROCEDURE FOR FLANGE BOLT UP

Confirmation Prior to Bolt Up

The following items shall be confirmed prior tobolt up:

1. The gasket has been inserted and centered.

2. Bolts and nuts have been lubricated.

3. Bolts have been inserted and are finger tight.

4. There are at least two threads extending beyondthe nut on either side.

Procedure for Bolt Up

Procedure for flange bolt up shall be as follows

5. Hand tighten bolts with a short wrench by theprocedure shown in Figure 11.

6. Tighten bolts a second time with a spannerwrench and light hammer (about 1 kg), again bythe procedure shown in Figure 11.

7. Continue tightening gradually by the procedureshown in Figure 11, using a heavy hammer(about 2 kg) until bolts are completely drawntight. This may take two or three additionalrounds by the same procedure.

8. For bolts larger than 25mm in diameter, a finalround or two with a heavier hammer (about 3.5kg) is recommended to reach the correct bolttension.

Precautions

Special precautions shall be taken for the follow-ing items for bolt up:

9. Never draw up tight on one or two bolts only.This will cause local gasket crushing or pinch-ing, which will result in leaks.

10. After each round of tightening, the alignmentmay be checked by measuring the distancebetween flange faces.

11. The bolts should be gradually and evenlytightened with a wrench and hammer until thehammer begins to “bounce” with a distinct ring.

APPENDIX — IVADDITIONAL RANDOM TYPE EXAMINATION FORWELD DEFECTS

(Taken from ANSI / ASME B31.3b-1982, 336.5)

When the required examination of a spot orrandom type reveals a defect requiring repair,two additional examinations of the same typeshall be made on the same kind of item (if of aweld, others by the same welder or weldingoperator). If the second group of items ex-amined is acceptable, all items represented bythese additional examinations shall be ac-cepted.

For each of the second group of items whichreveals defects requiring repair, two additionalitems shall be examined. If all of the third groupsof items examined are acceptable, the itemsrequiring repair shall be repaired or replaced tomeet the requirements of the code, and all itemsrepresented by the examined items shall beaccepted.

If any of the third group of items examined revealdefects requiring repair, all comparable itemsmay be replaced or they shall fully examinedand repaired as necessary to meet applicablequality requirements.



STEEL PIPING


PAGE 25 OF 28



STEEL PIPING


PAGE 26 OF 28

TABLE - I : SELECTION OF WELDING ELECTRODES & RODS FOR SIMILAR MATERIALS EXCEPT ALUMINIUM

MATL.

NO.BASE

MATERIALCOVERED ELECTRODES WELDING RODS

AWS SPEC PREFERRED ELECTRODE AWS SPEC. CLASSIFICATION

1carbonsteel

UTS UNDER 60,000psi A 5.1 E6010/E6013 (1) (2) (3) (4) —

2 UTS 60,000psi & above A 5.1 E6010/ E7018 (1) (2) (3) (4) —

2a A333 Gr - 1 A 5.1 E7018 -1(5) (5) --

3 carbon-molybdenum A 5.5 E70XX-A1 (2) (3) (4) —

4 21/4 nickel A 5.5 E80XXC1 (2) —

5 31/2 nickel A 5.5 E80XX-C2 (2) —

6 9 nickel A 5.11 ENi Cr Fe - 3 A5.14 ER Ni Cr -3

7

lowchromium

ferrticsteels

1/2Cr–1/2Mo A 5.5 E8015-B2L (2) 0.05C max.

8 1Cr–1/2Mo A 5.5 E8015-B2L (2) 0.05C max.

9 11/4Cr–1/2Mo A 5.5 E8015-B2L (2) 0.05C max.

10 21/4Cr–1Mo A 5.5 E9015-B3L (0.05C max.) (2) 0.05C max.

11 5Cr–1/2Mo A 5.4 E502-I5 (0.05C max.) A5.9 ER502(0.05C max)

12 7Cr–1/2Mo A 5.4 E7Cr-I5 (0.05C max.) (2) (0.05C max.)

13 9Cr–1Mo A 5.4 E505-I5 (0.05C max.) A5.9 ER505(0.05C max)

14

ferrticstainless

steels

AISI Type405 A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05C max)

15 AISI Type 410S A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05Cmax)

16 AISI Type410 A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05C max)

17 AISI Type430 A 5.4 E430-I5 A5.9 ER430

18

austeniticstainless

steels

AISI Types 304&304H A 5.4 E308-I5 or 16 A5.9 ER308

19 AISI Type 304L A 5.4 E308L-I5 or 16 A5.9 ER308L

20 AISI Types321&321H A 5.4 E347-I5 or 16 A5.9 ER347

21 AISI Types 347 & 347H A 5.4 E347-I5 or 16 A5.9 ER347

22 AISI Types 316 & 316H A 5.4 E316-I5 or E 16 -8 -2 A5.9 ER316

23 AISI Type 316L A 5.4 E316L-I5 or 16 A5.9 ER316L

24 AISI Type309 A 5.4 E309-I5 or 16 A5.9 ER309

25 AISI Type310 A 5.4 E310-I5 or 16 A5.9 ER310

26 Incoloy(32Ni46Fe20Cr) A 5.11 ENi Cr Fe-2 A5.14 ERNiCr -3

27

non–ferrous

metals &alloys

AluminiumBronze A 5.6 ECu Al-A1 A5.7 RCu Al-A2

28 Phosphor Bronze A 5.6 ECuSn-C A5.7 RCuSn-A

29 Copper A 5.6 ECu A5.7 RCu

30 67Ni-30Cu Monel A 5.11 ENiCu-4 A5.14 ERNiCu-7

31 Hastalloy(60Ni-28Mo-5Fe) A 5.11 ENiMo - 1 A5.14 ERNiMo-4

32 Inconel(75Ni 15Cr8Fe) A 5.11 ENiCrFe -1 A5.14 ERNiCrFe-5

33 70Cu-30Ni A 5.6 ECuNi A5.7 RCuNi

34 Nickel A 5.11 ENi-1 A5.14 ERNi-3

35 20Cr-29Ni-21/2Mo-3Cu - Alloy 20 Cb - 3 — Alloy 20Cb3

Notes:

(1) For materials Nos.1 and 2 (Carbon steel) where SMAW is followed, the root run shall be with E 6010 electrodes.

(2) Where no AWS specification exists for base wire, it is acceptable to use wire or rods of the same nominal composition asthe base material with substantially neutral flux or inert gas, provided they have been qualified in the procedure test.

(3) MIG wire shall conform to AWS A5.18 and A5.20

(4) SAW wire and flux shall conform to AWS A5.17

(5) The root run of butt welds for material No. 2a shall be made in GTAW process using ER70S - 2 wires.



STEEL PIPING


PAGE 27 OF 28

TABLE II — SELECTION OF WELDING ELECTRODES & RODS FOR WELDING DISSIMILAR MATERIALS EX-CEPT ALUMINIUM

Lower basemat’lNo.

Higher base material number

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 35

1 A A A A A B B B B B B B B B B B C C C C C C D D E C

2 A A A A B B B B B B B B B B B C C C C C C D D E C

3 @ @ @ B B B B B B B B B B B C C C C C C D D E C

4 A A @ @ @ @ @ @ @ @ @ @ @ C C C C C C D D E @

5 A @ @ @ @ @ @ @ @ @ @ @ C C C C C C D @ E @

6 @ @ @ @ @ @ @ @ @ @ @ E E E E E E E @ E @

7 A A A A A A A A A A C C C C C C D E C @

8 A A A A A A A A A C C C C C C D E C @

9 A A A A A A A A C C C C C C D E C @

10 A A A A A A A C C C C C C D E C @

11 A A A A A A C C C C C C D E C @

12 A A A A A C C C C C C D E @ @

13 A A A A C C C C C C D E @ @

14 A A A C C C C C C D E @ @

15 A A C C C C C C D E @ @

16 A C C C C C C D E @ @

17 C C C C C C D E @ @

18 A A A A A A A A C

19 F F F A F F F C

20 A A A A A A C

21 A A A A A C

22 A A A A C

23 A A A C

24 C E C

25 E C

26 C

DESCRIPTION OF CODE LETTERS IN ABOVE TABLE

A As specified in table I for material corresponding to either the higher or lower base material number

B ASME SFA-5.5, E8015-82L electrode

C ASME SFA-5.4, E309 electrode. Acceptable alternatives shall be as specified in table I for the higher basematerial number

D As specify in table I for the material with the higher base material number

E ASME SFA-5.11, ENiCrFe-2 electrode and ASME SFA-5.4. ERNiCr-3 rods shall be used where designtemperature exceeds 10000F (5380C). ASME SFA-5.4, E310 electrodes are to be used where servicetemperatures are below 10000F (5380C) and expected to be relatively constant after start up. All rods, exclud-ing alternatives shall require written approval from designated authority.

F ASME SFA-5.4, E308 electrode or as specified in table I for the material with the higher base material number

@ Welding of these material combinations are not permitted without written approval from designated authority.

8122-03-ES-001

Page 1 of 4

Specification for Glass Reinforced Plastic (GRP) piping

1 Scope

This specification defines the requirements for glass-fiber-reinforced thermosetting resin pipe (RTRP) as defined in AWWA C950) couplings, fittings, flanges and spools using polyester, vinyl ester or epoxy resin with restrained adhesive-bonded joints, restrained gasketed joints, butt joints with laminated overlay, bell & spigot joints with laminated overlay.

The minimum pressure/temperature rating of the pipe and fittings shall be 10 bar (150 psig) at 65 deg C

2 Materials and Fabrication

The products shall be defined by a cell classification system and shall meet the performance requirements of Section 4 of this specification.

Pipe and couplings shall be filament-wound using polyester, vinylester or epoxy resin and fiberglass reinforcement or centrifugally cast.

Resin System

Resin shall be suitable for the services specified, and shall be noted by the vendor in his proposal. The resin system used for the interior liner, the structural wall, fittings, and adhesives shall be polyester, vinylester or epoxy, with suitable curing agents so that it meets the performance requirements and temperature limits in this Specification.

Glass Reinforcements

The structural wall reinforcement shall be of commercial-grade glass fiber ( E type) treated with a compatible binder and coupling agent

Additives

Resin additives such as pigments, dyes or coloring agents may be used, provided they do not detrimentally affect the performance of the pipe. The pipe exterior must contain a UV inhibitor.

Reinforcing Fiberglass Ribs

Pipe sizes 2600 mm and higher can be manufactured with reinforcing fiberglass external ribs to achieve the required stiffness.

Adhesives and solvent cleaners

Adhesive and solvent cleaner for bonded joints shall be of a material suitable for the services and design conditions specified. It shall be mutually compatible with the resin used to manufacture the pipe. Adhesives and solvent cleaners shall be provided in a self-contained kit with all necessary materials and instructions. Shelf life of adhesive and solvent cleaner kits, at 35 deg C, shall not be less than 9 months from the date of shipment. Adhesive and solvent cleaner kits shall indicate the required storage conditions and date of expiration of shelf life.

Flexible Elastomeric Seals and Joint Tightness

The chemical composition of the flexible elastomeric seals shall be compatible with the type of service and environment to which it will be subjected.

Fittings

Flanges, bends, reducers, tees, wyes and other fittings may be compression-molded, manufactured from mitered section of pipe, or manufactured by the filament wound process, using thermosetting polyester, vinylester or epoxy resin and fiberglass reinforcement such that the resistance to chemical attack, the pressure rating, and the temperature rating, are equal to or better than that of the pipe.

Except for compression-molded fittings, all pipe, fitting, and flange surfaces that are exposed to the fluid shall have a smooth, uniform, resin-rich liner. The interior liner shall be reinforced with either non-woven polyester fibers or epoxy. Liner reinforcement is not required on 100 mm and smaller fittings at the mitered joints, provided all gaps at the joints are completely filled with resin to act as an effective corrosion barrier and to prevent the presence of any exposed glass fibers.

8122-03-ES-001

Page 2 of 4

All machined or cut surfaces shall be post-coated with catalyzed resin, except for bonding surfaces for field points and mechanical RTR (fiberglass) threads. Post-coating shall be performed within four hours of machining or other surface preparation.

Adhesive-bonded joints shall be bell-and-spigot type and shall not require a field-applied overwrap to develop the required strength.

Flanges shall be flat-faced, or flat-faced with a confined O-ring gasket groove.

All pipe, fittings and flanges for a particular installation shall be manufactured or supplied by the same Vendor to avoid incompatibility problems

Fasteners and Gaskets

Machine bolts shall be as per A307 Gr B, galvanised and nuts shall be as per A563 Gr B galvanised. The gaskets shall be full face, non metallic as per B16.21. suitable for the fluid.

3 Dimensions and Tolerances

Dimensions and surface finishes shall be measured in accordance with ASTM D3567 and ASME/ANSI B46.1. The average wall thickness of the pipe shall not be less than the nominal wall thickness published in the manufacturer literature. The minimum wall thickness at any point shall not be less than 87.5% of the nominal wall thickness, when measured in accordance with ASTM D3567.

Flange bolt hole sizes and the number of bolt holes and bolt hole circles for up to 600 mm nominal pipe size shall comply with ASME/ANSI B16.5. For larger than 600 mm nominal pipe size, flange bolt holes sizes and the number of bolt holes and bolt hole circles shall comply with AWWA C207, or MSS SP-44.

Unless otherwise defined in the Purchase Order, specified face-to-face, centerline-to-face, and centerline-to-centerline dimensions of special fabrications (spools) shall have a tolerance of + 6 mm. The lateral offset of flanges from the pipe centerline and rotation of flanges shall be limited to 3 mm. The flange face alignment shall be within 1.5 mm of the required position when measured across the flange face. These tolerances shall be doubled for piping 450 mm nominal size and larger.

4 Performance Requirements

General

The Manufacturer shall perform following Design Type tests and Test reports shall be furnished to Buyer.Testing and test reports shall pertain to items representative of those supplied under the Purchase Order. Design type testing shall be repeated after any change in materials, manufacturing methods, or product design.

Design Type Tests

Hydrostatic Design Stress and Pressure Ratings

The long-term hydrostatic strength of pipe shall be determined in accordance with Procedure A or B of ASTM D2992. The Manufacturer shall select the procedure and one representative size for these tests. Adhesive joints shall be included, using both the factory and field adhesives and their respective joining and curing procedures, if different.

Pressure rating calculations shall be performed in accordance with AWWA-C950.

The calculated pressure ratings shall equal or exceed the pressure rating of the piping specified in section 1 of this specification and in the Purchase Order.

Long-Term Ring Bending Strength

Long-term ring bending strength shall be determined in accordance with AWWA C950, with stress relaxation or creep failure tests instrumented to detect an abrupt, significant reduction in mechanical properties.

Flange Pressure Rating

Flanges shall be pressure-rated and marked in accordance with ASTM D4024. The manufacturer shall test, on a one-time basis, three samples of minimum, median and maximum flange sizes of the manufacturing range at the plant for each pressure rating.

8122-03-ES-001

Page 3 of 4

Joint Integrity Test

Joints shall be of the adhesive-bonded, reinforced overlays or mechanical type joints, as defined in AWWA C950.

The joints shall meet or exceed the hoop tensile and axial tensile strength requirements of the pipe as tested in accordance with AWWA C950. One test for each jointing method shall be performed to establish design stress values.

5 Test Requirements

Pipe Stiffness

The pipe stiffness shall be determined in accordance with AWWA C950.

The pipe shall exhibit, without structural damage, the minimum stiffness at 5 percent deflection of 124 kPa (18 psi)

Axial Tensile Strength

The pipe shall be sampled and tested for axial tensile strength in accordance with AWWA C950. The test results shall meet or exceed the minimum axial tensile strength requirements listed in Table 11 of AWWA C950

Hoop Tensile Strength

The pipe shall be sampled and tested for hoop tensile strength in accordance with AWWA C950. The test results shall meet or exceed the minimum hoop tensile strength requirements listed in Table 10 of AWWA C950

Visual Inspection

Components shall be visually inspected for compliance with the defect limits in Table below

Name Interior Surface Exterior Surface O-Ring Sealing Surface

1. Air Bubble (Void)

Not to penetrate any surface - limits apply to all surfaces, maximum dimension 6 mm diameter, 0.75 mm thickness, 4 per 0.09 sq. m area

Same requirements as for Interior Surface


2. Foreign Inclusion

Not to penetrate any surface - limits apply to all surfaces, maximum dimension 1.5 mm, 1 per 0.09 sq. m area



3. Pit (Pinhole)

Max. depth 0.25 mm, maximum width 1.5 mm, 35 per sq. cm

Not to penetrate reinforced wall

Maximum dimension 0.25 mm

5. Scratch

Max. depth 0.40 mm not to exceed liner thickness

Not to penetrate reinforced wall

Maximum depth 0.25 mm

6. Wrinkle Max. depth 2 mm Not applicable None allowed

Hydrostatic Leak Test

All pipe, fittings and spools shall be hydrostatically leak tested at the factory in accordance with AWWA C950, to a test pressure equal to twice the pressure rating.

If air is used as the pressurizing medium, the component shall be completely submerged in clear water during the pressurization and inspection period.

All pipe, fittings, spools and joints shall be visually examined for leakage. Any item showing evidence of weeping or leakage shall be rejected.

8122-03-ES-001

Page 4 of 4

The standard adhesive-bonded flanges, standard adapters, saddles, nonstandard fittings with plain ends configurations, and prefabricated spools with plain ends that cannot be hydrotested at the manufacturing facility due to size limitations and configurations shall be handled as follows:

a) The Vendor shall mark these items to be field hydrotested.

b) The assembled items and the testing shall be at Vendor's risk.

c) Buyer's Representative shall witness the test. The rejected parts shall be removed from the system or repaired by the. The replaced or repaired part shall be retested.

Rejection

If the results of any QC test do not conform to the requirements of this specification, that test shall be repeated on two additional samples from the same lot of pipe. Each of the two samples shall conform to the requirements specified. If either of the two additional samples fail, the lot shall be rejected.

6 Documentation

Drawings

Product drawings that show product dimensions and tolerances, including couplings, fittings and joints, shall be submitted

Test Reports

The Manufacturer's test reports, both Design Type tests and acceptance tests, shall be furnished to the Buyer.

7 Identification Tagging

All components shall be permanently marked for proper identification. All required marking shall remain legible under normal handling and installation practices. The marking shall include the following:

- Manufacturer's name or trade name, and identification code - Pressure/temperature rating - Nominal diameter

8 Packing

Unless otherwise specified in the Purchase Order, pipe, fittings, O-rings, gaskets, locking rings, and adhesives shall be packed suitably, to withstand rough handling.

End Protectors

End protectors shall be provided and securely attached to both bell and spigot ends of all pipe.

End protectors shall be designed to protect the pipe ends from impact damage, contamination, and weathering of machined bonding surfaces due to ultraviolet exposure. They shall have an open center permitting inspection of the pipe bore.

Flange faces on fabricated piping shall have 12 mm minimum protective plywood covers not smaller than the flange outside diameter

8122- 12– DA - 002 DATA

SHEET SPECIFIC REQUIREME�TS OF WORK

PAGE 1 OF 13 R0

0 19.10.2009 LTA SA SA

REV. DATE PRPD. BY CHKD. BY APPRD. BY

FACT E�GI�EERI�G A�D DESIG� ORGA�ISATIO�

12FT026/94

MANGALORE LPG BLENDING FACILITIES

SPECIFICATION FOR PIPELINE CONCRETE

COATING

PREPARED FOR

HPCL

PROJECT NO. 8122

OCTOBER 2009

8122- 12 - DA - 002 DATA


PAGE 2 OF 13 R0


12FT026A/94

TABLE OF CONTENTS

PAGE �O.

1.0 SCOPE 3 2.0 REFERENCE DOCUMENTS 3 3.0 MATERIALS 4 4.0 COATING REQUIREMENTS 6 5.0 APPLICATION METHOD 6 6.0 EQUIPMENT 7 7.0 COATING OF FIELD WELDS 7 8.0 CURING 8 9.0 MEASUREMENTS & LOGGING 9

10.0 IDENTIFICATION 10 11.0 INSPECTION AND TESTING 10

12.0 TESTING METHODS 11

13.0 PERMISSIBLE REPAIRS TO THE COATING 12 14.0 HANDLING 13

8122- 12 - DA - 002 DATA


PAGE 3 OF 13 R0


12FT026A/94

SPECIFICATION FOR PIPELINE CONCRETE COATING

1.0 SCOPE

1.1 This specification covers the minimum requirements for the materials, application, inspection,

handling and other activities for external concrete coating for pipelines.

1.2 This specification shall be read in conjunction with the conditions of all specifications and

documents included in the contract between company and contractor.

1.3 CONTRACTOR shall execute the work in compliance with all laws, by-laws, ordinances,

regulations, etc. and provide all services and labour, inclusive of supervision thereof, all materials,

equipment, appliances or other things of whatsoever nature required for the execution of the work,

whether of a temporary or permanent nature.

1.4 This document is not intended to be all-inclusive, and the use of the guidelines set forth does not

relieve the contractor of his responsibility to supply a product capable of performing its intended

service.

2.0 RFEFERENCE DOCUMENTS

a) IS 8112 Indian standard specification for 43 grade ordinary Portland cement.

b) IS 383 Indian standard specification for coarse and fine aggregates

from natural sources for concrete.

c) IS 2386 Indian standards methods of test for aggregates for concrete

Part 1 To VIII

d) IS 4826 Specification for hot dipped galvanized coatings on round steel wires

e) IS 1566 Specifications for hard drawn steel wire fabric for concrete reinforcement

f) IS 432 Specification for mild steel and medium tensile steel bars and hard

drawn steel wire for concrete reinforcement.

8122- 12 - DA - 002 DATA


PAGE 4 OF 13 R0


12FT026A/94

g) IS 1199 Method of sampling and analysis of concrete.

h) ASTM C309 Liquid membrane forming components for curing concrete

i) IS 456 Code of practice for plain & reinforced concrete

j) IS 516 Methods of tests for strength of concrete

k) IS 4031 Methods of Physical tests for hydraulic cement

l) IS 4032 Methods of chemical analysis of hydraulic cement

m) IS 1916 Steel Cylinder Pipes with Lining and Coating- Specification

3.0 MATERIALS

The contractor shall supply all the materials necessary for the performance of the work. Materials

for concrete coating shall comply with the following requirements.

3.1 Cement

43-grade ordinary Portland Cement conforming to IS 8112 shall be used. Cement which has

hardened or partially set or which has become lumpy shall not be used. Test certificates from the

cement manufacturer shall be supplied to the company for all cement delivered to site.

3.2 Aggregates

3.2.1 Aggregate shall comply with the requirements of IS-383 and shall be tested in accordance with

IS-2386.

3.2.2 Fine aggregates:

Fine aggregate shall mean any of the following as defined in IS 383.

i) Natural sand

ii) Crushed stone sand

8122- 12 - DA - 002 DATA


PAGE 5 OF 13 R0


12FT026A/94

iii) Crushed gravel sand

Sand shall be well graded from fine to coarse in accordance with Table 4 of IS 383.

3.2.3 Aggregates shall be clean and free from injurious amounts of salt, alkali, deleterious substances

or organic impurities that may affect the strength of concrete.

3.3 Water

The water shall be fresh and clean and shall be free from injurious amount of oils, acids, alkalies,

salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It

shall not contain chlorides, sulphates and magnesium salts. Water from doubtful sources shall be

tested by the CONTRACTOR at his expense and approved by the Engineer-in-charge before use.

3.4 Reinforcement

3.4.1 Reinforcement shall consist of 50 mm x 50 mm x 3 mm diameter galvanized welded wire fabric in

rolls or in sheet to satisfy the application requirement.

3.4.2 Reinforcing mesh shall conform to IS 432 for steel wire, IS 1566 for welded wire mesh and IS

4826 for galvanized steel. Minimum steel in both longitudinal and transverse direction shall be

0.5% of the concrete cross sectional area, or 3 mm dia wire @ 50 mm c/c whichever is more.

For coating thickness of 50mm and above, two layers of mesh shall be provided clear cover being

5 mm from either side.

3.4.3 Alternative reinforcement, having steel cross sectional area per metre of concrete coat, equal to

or more than area of the mesh mentioned above, may be submitted for approval.

Reinforcing steel shall be spooled on with a lap of not less than 25 mm (1 inch) or one mesh

whichever is greater. It shall be embedded approximately midway in the concrete coating

thickness. The reinforcing wire shall not contact the pipe corrosion coating. If the concrete

thickness is equal to or greater than 50 mm, at least two layers of mesh shall be installed.

3.4.4 The reinforcing materials shall not be in physical or electrical contact with the pipes.

Reinforcement shall rest on synthetic resin spacers forming a crown, whose number shall be such

8122- 12 - DA - 002 DATA


PAGE 6 OF 13 R0


12FT026A/94

as to avoid any contact with the pipes’ protective coating. Spacing between the two crown

centers shall be 500 to 1000 mm.

All materials supplied by the contractor, which in the opinion of company, do not comply with the

appropriate specifications shall be rejected and immediately removed from site by contractor at

his expenses.

4.0 COATING REQUIREMENTS

4.1 Pipes shall be concrete coated to a thickness as specified in the drawings and documents. The

concrete unit weight shall be minimum 2300 kg/m3 and the compressive strength shall not be less

than 250 kg/cm2 in 28 days.

4.2 Contractor shall design the mix by suitably proportioning the materials to achieve the specified

requirements of concrete strength, density and weight with a minimum cement content of

600kg/m3.

5.0 APPLICATION METHOD

5.1 Concrete coating shall be applied either using casting or impingement method. Any alteration or

modifications to the methods described in this specification shall be submitted to the Owner/

Engineer-in-charge for approval. The application method shall however ensure the basic

characteristics of concrete coating in compliance with the minimum requirements of this

specification.

5.2 Contractor shall submit to the “Engineer-in-charge”, prior commencement of work, the

procedure/method of application for approval. Wherever practical the total thickness shall be

applied in a single pass. If more than one application is required to produce a coating of the

specified thickness, then the time allowed between successive applications shall not exceed 30

minutes. If the time between coats exceeds 30 minutes, all previous coating shall be removed

and shall be recoated. The cost of removing coating and recoating shall be at contractor’s

expense.

5.3 All pipes shall be kept clean and free from cement, concrete & grout either inside or outside of the

uncoated section.

8122- 12 - DA - 002 DATA


PAGE 7 OF 13 R0


12FT026A/94

5.4 Cutback on concrete coating.

Both ends of each joint for a distance of 305 mm ±25 mm shall be completely free of concrete to

facilitate field joints. The concrete shall be tapered backside at these points at a minimum two to

one slope, until the required thickness of coating is reached. Also it shall terminate approx. 50

mm short of the end of the corrosion coating applied to the pipe surface.

6.0 EQUIPMENT

6.1 The equipment used for performing the concrete coating shall be capable of doing so with a

reasonable degree of uniformity with respect to thickness, density and strength. The

proportioning equipment and procedure shall be of the type to assure consistently proportioned

materials by weight. Concrete shall be mixed in mechanical mixers, which shall ensure thorough

mixing of all materials. Any equipment that tends to separate the ingredients shall not be used.

In all cases concrete shall be placed within 30 minutes after water is first added to the mix.

Before placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and

wetted to obtain a good bond between the fresh material and previously placed materials.

7.0 COATING OF FIELD WELDS

7.1 The contractor shall coat the uncoated pipe surface at field welds in accordance with methods

approved by the company. Contractor shall submit a detailed procedure for joint coating for

company’s approval.

7.2 The reinforcement for the field welds shall be the same as that for line pipe coating with the same

number of layers and the same space between layers as for the existing coating. The edges of

this netting must be carefully secured with galvanized wire to the reinforcement extending from

the existing coating.

7.3 The reinforcement shall not make direct or electrical contact with the pipe.

7.4 Synthetic resin spacer blocks may be used to keep the reinforcement free from the pipe coating.

7.5 The moulds used for applying the concrete coating shall be supplied by the contractor.

8122- 12 - DA - 002 DATA


PAGE 8 OF 13 R0


12FT026A/94

7.6 The composition of the concrete shall be same as that of the concrete coating of the pipe.

7.7 When using moulds, the contractor shall prevent air being trapped by applying mechanical

vibrators or by striking the outside of the mould by sticks.

7.8 If the moulds remain around the pipe, eg: in the case of submerged pipes floated into position,

the contractor shall take appropriate measures to prevent too much water entering the mould.

This can be achieved by clamping strips of burlap between the ends of the mould and the existing

concrete coating. After the mould has been filled with concrete the opening for filling must also be

closed off.

8.0 CURING

8.1 Immediately after concreting, the exposed surfaces of the concrete shall be protected during

hardening from the effects of sunshine, drying winds, rain etc and then after the initial set has

taken place, the concrete coating shall be properly cured. The coated pipe shall be handled

gently by suitable means to prevent undue distortion.

8.2 During curing the concrete coated pipe shall be racked on sand ridges or on flat earth surface

free of obstruction. If the joints are placed on sand ridges they should be so placed as to

eliminate any injurious deflection in the pipe. The concrete shall be cured by application of curing

membrane approved by the Engineer-in- charge.

8.3 Curing shall be performed by application of an approved curing membrane using sealing

compounds and shall meet the requirements as mentioned in the manufacturer’s specifications.

The material shall be stored, prepared and applied in strict conformity with the instructions of the

manufacturer. The ingredients of any such compound shall be non-toxic and non-inflammable

and shall not react with any ingredient of concrete, the reinforcement, the protective coating or

pipe. The application of this curing compound shall take place immediately after the coating is

completed and preferably before the pipe is removed from the concrete coating apparatus.

8.4 The surface of the concrete shall be lightly sprayed with water before applying the curing

compound or as specified in the manufacturers specifications. The pipe surface shall be kept wet

during day light hours for (7) seven days after application of the concrete coating. The concrete

shall not be allowed to dehydrate.

8122- 12 - DA - 002 DATA


PAGE 9 OF 13 R0


12FT026A/94

8.5 All concrete coated pipes shall be cured continuously for a period of seven days. Pipe shall not

be handled or loaded out from the yard until so cured. No deviation from this requirement shall be

permitted. Transportation/handling of concrete coated pipe shall be done after 28 days of

concreting.

9.0 MEASUREMENTS & LOGGING

9.1 All measurements as mentioned below shall be taken during the work stages and clearly logged

in a proper log-book. A separate log-book shall be used for recording tests and trial results.

9.2 Pipes having same nominal diameter, steel wall thickness and protection coating shall be

recorded in a single register.

9.3 The following shall be entered in the log book for each pipe length.

a) Line pipe

i. Field identification number (F)

ii. Mill serial number (M)

iii. Length (L)

iv. Weight (BW)

v. Average outside diameter (OD)

(Shall be obtained by measuring the girth at least at five places, two of which 400 mm from the

ends of pipe and the other equispaced between them)

b) Concrete coating

i. Batch identification number (B)

ii. Date of concrete coating (TD)

iii. Average concrete coating thickness (CT)

iv. Dry weight of concrete coated pipe and date of weighing, after 28 days (DW) of

application of concrete.

9.4 No concrete coating shall be allowed unless all the details pertaining to the pipe before coating

are entered in the log-book. In addition each batch/shift shall be identified and registered against

8122- 12 - DA - 002 DATA


PAGE 10 OF 13 R0


12FT026A/94

cube samples/core samples taken for crushing strength tests, and the same shall be logged.

10.0 IDENTIFICATION

10.1 A certified permanent records shall be supplied to Engineer-in-charge showing the serial number,

average outside diameter, length and weights. Pipe identification shall be maintained by the

contractor for each joint of pipe and restencilling pipe mill coding shall be done on the internal

surface of the pipe.

10.2 For each concrete coated pipe length, at one of the two ends, the field identification number and

the date of concrete placing shall be marked.

11.0 INSPECTION AND TESTING

11.1 Contractor shall provide the method and means of obtaining the weight, length, and average

outside dia of each joint of pipe immediately after being coated. A permanent record certifying

such data shall be compiled daily and copies of such records shall be promptly be made available

to Engineer-in-charge.

11.2 Contractor shall furnish all materials to be tested and required testing apparatus. Contractor shall

obtain test samples in accordance with the applicable standard specification for the concrete

being applied and shall provide company with the results of tests made on these samples.

Samples shall be taken and tests performed at least once per shift during continuous operation or

once for every twenty five joints for non continuous operations.

11.3 The Engineer-in-charge or his representative shall have full and free access to the office and/or

plant, every part of the coating yard, and the ON/OFF loading facilities of the contractor.

Contractor shall assist the Engineer-in-charge or his representative for inspecting the works at

every stage. Pipe coating not meeting requirements, as outlined herein, shall be rejected.

11.4 Causes for rejection of the concrete coating shall include, but not be limited to, the following:

a) Coatings that weighs less than or more than five (5) percent of the weight specified.

b) Improper placement of reinforcing steel

8122- 12 - DA - 002 DATA


PAGE 11 OF 13 R0


12FT026A/94

c) Coating damaged in handling or storage that is considered by Engineer-in-charge to be

excessive and beyond repair.

d) Coating that are allowed to remain unfinished for a period of time exceeding 30 minutes,

as in the case of breakdown, or otherwise.

e) Any failure to meet the requirements of this specification.

In general substandard concrete coating causing lesser weight, improper placement of steel,

coating damage and unfinished concrete etc. shall lead to rejection of the concrete coating and

decision of the Engineer-in-charge in this respect shall be final.

12.0 TESTING METHODS

12.1 Samples of the concrete mix, as applied during the coating operation, shall be taken to determine

the compressive strength and density of the concrete coating.

12.2 All testing shall be at the contractor’s expense and as directed by the Engineer-in-charge or his

representative. The testing methods to be used are outlined below.

a) Compressive strength test

i. Concrete shall be so proportioned so as to produce a compressive strength of not

less than 250 kg/cm2 at 28 days and not less than 167 kg/cm2 in 7 days. Test

shall be carried out as per the relevant Indian standards.

ii. Minimum of six (6) cubes, three (3) each for 7 days strength and 28 days strength

shall be taken. Copies of all test reports shall be made for 7 days and 28 days

strength as decided by the Engineer-in-charge and the contractor.

b) Coated pipe tolerance and weight tests

i. Contractor shall maintain a surface tolerance of +/- 6 mm maximum for 30 mm thick

and +8mm/-6mm for thickness above 30 mm over outside diameter of the coated

pipe, between high and low elevations of pipe.

8122- 12 - DA - 002 DATA


PAGE 12 OF 13 R0


12FT026A/94

ii. The acceptable weight tolerance for any pipe shall be limited to +5/-2 % of the

calculated theoretical weight. The theoretical weight shall be calculated using total

weight of the pipe with concrete and corrosion coating.

13.0 PERMISSIBLE REPAIRS TO THE COATING

13.1 The following are repairs that will be permitted to coating due to unavoidable damage in handling

and storage. This is applied only to concrete that has hardened.

13.2 Spalling is defined as damage, which cause a loss in concrete of more than 25% of the total

thickness of the coating at the point of damage. Damage due to spalling of an area of less than

0.1m2 (1 ft2) where remaining concrete is sound will be accepted without repairs. Damage due to

spalling of an area more than 0.1 m2 and less than 0.3 m2 shall have the concrete removed as

necessary to expose the reinforcing steel throughout the damaged area. Edges of the spalled

area shall be undercut so as to provide a key lock for the repair material. A stiff mixture of cement

and aggregate of 1:3 ratio shall be trowelled into and through the reinforcement and built up until

the surface is level with the coating around the repair. The pipe shall then be carefully laid with

the repaired area at the top and shall be moist cured for a minimum of thirty six ((36) hours

before further handling. If the damaged area is more than 0.3 m2, the coating shall be removed

around the entire damaged area. The repairs shall be made by satisfactorily restoring the

reinforcement, forming the area with a metal form and pouring a complete replacement of

materials similar to that from which the coating was made. The mixture shall be one (1) part of

cement, three (3) parts of aggregate and necessary water to produce a slump not to exceed 100

mm. The resulting coating shall be equal in weight, density, uniformity, thickness, strength and

other characteristics to the originally applied coating. The pipe shall then be carefully laid in a

position where it shall be allowed to remain for a minimum of thirty six (36) hours before further

handling.

14.0 HANDLING

14.1 Pipes shall be handled in a manner to prevent damage to coating, pipe walls and beveled ends.

Adequate strapping and padding shall be provided when loading for transfer to any location.

14.2 Pipes shall be raised or lowered to or from the stockpile, ground barge, truck by using brass lined

end hooks inserted in the ends of the pipe, and carried by a canvas sling with a spreader bar

8122- 12 - DA - 002 DATA


PAGE 13 OF 13 R0


12FT026A/94

between the lines. All pipe handling shall be with equipment approved by Engineer-in-charge or

his representative. Contractor shall submit written handling, stacking and storage procedure for

approval of the Engineer-in-charge.

14.3 If the Engineer-in-charge or his representative observed coating or pipe damage due to handling,

the contractor shall take immediate corrective action. Finally, pipe shall not be loaded or stacked

until such handling will not damage the concrete coating.

8122- 12– DA - 001 DATA SHEET

SPECIFIC REQUIREMENTS OF WORK PAGE 1 OF 14

0 19.10.2009 LTA SA SA

REV. DATE PRPD. BY CHKD. BY APPRD. BY


12FT026/94

MANGALORE LPG BLENDING FACILITIES

SPECIFICATION FOR CEMENT MORTAR LINING INSIDE PIPELINES

PREPARED FOR

HPCL

PROJECT NO. 8122

OCTOBER 2009

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

TABLE OF CONTENTS

1.0 Scope Of Work 3

2.0 Reference Documents 3

3.0 Materials 4

4.0 Application 5

5.0 Curing 7

6.0 Procedure Qualification 7

7.0. Inspection 8

8.0 Repair Of Lining 9

9.0 Pipe Jointing 9

10.0 Fittings And Flanges 10

11.0 Branch Connection 10

12.0 Cutting Methods For Cement Lined Pipes 10

13.0 Damage Protection 11

14.0 Installation 11

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

SPECIFICATION FOR PIPELINE CEMENT MORTAR LINING

1.0 SCOPE

1.1 This specification covers the minimum requirements for the materials, mixing,

application of cement lining, curing, inspection, repair, handling, transportation

and other activities for internal cement mortar lining for pipelines.

1.2 This specification shall be read in conjunction with the conditions of all

specifications and documents included in the contract between company and

contractor.

1.3 CONTRACTOR shall execute the work in compliance with all laws, by-laws,

ordinances, regulations, etc. and provide all services and labour, inclusive of

supervision thereof, all materials, equipment, appliances or other things of

whatsoever nature required for the execution of the work, whether of a temporary

or permanent nature.

1.4 This document is not intended to be all-inclusive, and the use of the guidelines

set forth does not relieve the contractor of his responsibility to supply a product

capable of performing its intended service.

2.0 RFEFERENCE DOCUMENTS

a) ANSI/ AWWA

C 205 – 00 Cement mortar Protective Lining and Coating for Steel water

pipe- shop Applied

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

pipe- shop Applied

b) IS 8112 Indian standard specification for

43 grade ordinary Portland cement.

c) IS 383 Indian standard specification for

coarse and fine aggregates from natural sources for

concrete.

d) IS 2386 Indian standards methods of test

Part1 To VIII for aggregates for concrete

e) IS 1199 Method of sampling and analysis of concrete

f) IS 456 Code of practice for plain & reinforced concrete

g) IS 4031 Part 6 – Determination of compressive strength of hydraulic

cement.

h) IS 1916 Steel Cylinder Pipes with Concrete Lining and Coating -

Specification

i) IS 4032 Methods of chemical analysis of hydraulic cement

3.0 MATERIALS

The contractor shall supply all the materials necessary for the performance of the

work. Materials for cement mortar lining shall comply with the following

requirements.

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

3.1 Cement

43 grade ordinary Portland Cement conforming to IS 8112 shall be used.

Cement which has hardened or partially set or which has become lumpy shall not

be used. Test certificates from the cement manufacturer shall be supplied to the

company for all cement delivered to site.

3.2 Fine aggregates:

Fine aggregate shall mean any of the following as defined in IS 383.

i) Natural sand

ii) Crushed stone sand

iii) Crushed gravel sand

Sand shall consist of inert granular material and the grains shall be strong,

durable and uncoated. Sand shall be clean and free from injurious amounts of

dust, clay, flaky particles, oil, alkali, mica and other deleterious substances. Sand

shall conform to IS:383 Grading Zone III.

3.3 Water

The water used for cement mortar mixing and curing shall be fresh and clean and

shall be free from injurious amount of oils, acids, alkalies, salts, sugar, organic

materials or other substances that may be deleterious to concrete or steel. It

shall not contain chlorides, sulphates and magnesium salts. Water from doubtful

sources shall be tested by the Contractor at his expense and shall be approved

by the Engineer-in-charge before use.

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

4.0 APPLICATION

4.1 Cement Mortar mixing

Cement lining shall be done in the field shop, which may be outside the project

site boundary. Suitable mechanical equipment capable of mixing mortar and

doing the lining work to a reasonable degree of uniformity with respect to

thickness, density and strength shall be employed. Mortar shall be mixed in

batches.

Mortar shall compose of cement, sand and water and mixed well in proper

consistency to obtain a dense, homogeneous lining that shall adhere firmly to the

pipe surface. Cement mortar for lining shall consist of one part cement to not

more than three parts sand by weight and shall have a minimum cement content

of 600kg/m3. Water to cement ratio shall be between 0.3 to 0.4 by volume.

Trial mixes shall be made to arrive at mix to achieve the requirements specified in

procedure qualification clause 6.0 below:

4.2 Surface Preparation & Primer Application

Pipes shall be welded in suitable length and immediately prior to lining, the

surface shall to be thoroughly cleaned removing all grease, scale, dust, etc. by

power tool to St. 3 as per IS 9954. Surface cleaning shall be followed by spray

application of welding grade of inorganic Zinc silicate prefabrication primer from

approved paint manufacturers with a dry film thickness of 25 microns at both the

pipe ends upto 100 mm pipe length. The cement lining shall be done at least

after 10 hours of drying of the prefabrication primer to avoid damage of the

primer. Suitable products are such as Inter plate – 11 from M/s AKZO NOBEL

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

Coatings (India) Ltd., Bangalore, Carboweld – 11 from M/s Carboline products

Chennai.

4.3 Application Method

The lining shall be applied in one course for the pipe section. No unfinished

surface shall remain exposed for more than 20 minutes. Mortar shall be handled

so as to avoid any kind of segregation and excessive moisture loss. During

mortar application pipe should be at ambient temperature. If pipe is hot due to

such reasons as lying in the hot sun, then the pipe must be cooled with the help

of wet gunny bags prior to application of mortar. Lining shall be free of any sharp

corners and edges and must be suitably contoured/rounded prior to curing.

Straight sections of pipe shall be lined by using spinning method or a method

known to provide equivalent results such as by a machine traveling through the

pipe and distributing the freshly mixed mortar uniformly along the full section and

long radius bends of the pipe. The lining machine shall be provided with

attachments for mechanically trowelling the mortar. Both the application and

trowelling of the mortar shall take place at the rear of the machine so that the

freshly placed and trowelled mortar will not be damaged. The trowel attachment,

the rate of travel of machine and the rate of discharge of mortar shall be such that

the pressure applied to the lining will be uniform and produce a lining of uniform

thickness with a smooth, finished surface.

Hand patching at the end of the pipe, for length not more than 100 mm length,

shall be permitted to rectify the thinning of linings.

Fittings and specials shall be centrifugally spray lined to the same standard as

straight pipes or, if this is precluded by their shape, be hand patched so as to

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

achieve comparable results.

The thickness of lining shall be as per Drg No. 8122-12-DG-00001, however to

accommodate the disc movement of Butterfly valves the cement lining of the

mating flanged spools shall be suitably tapered keeping minimum 3 mm lining

thickness.

5.0 CURING

After lining, the pipes shall be marked with the date of lining and shall be covered

with plastic caps and shall be moved carefully to a curing yard. The curing area

shall be sheltered so that lined pipes and fittings are protected from harmful

climatic conditions.

Moist curing shall start after 24 hours of completion of cement lining and shall be

done by continuous wetting or ponding. Under no circumstances the lining shall

be allowed to dry during curing period. Curing shall be carried out for a minimum

period of 7 days.

6.0 PROCEDURE QUALIFICATION

Prior to the application of the shop cement lining the manufacturer shall perform

procedure tests and qualify a working procedure to demonstrate that he is able to

produce a lining system in accordance with design requirement. The

constituents, mortar & finished pipes shall be tested. To establish the correct

combination of sand & water, minimum of five samples shall be prepared. For

each mix following shall be accurately checked and recorded.

For individual constituents

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

- Cement

- Sand

- Water

- Proportions & weights of respective materials

For Cement Mortar Test Specimen

- Density

- Compressive Strength

- Water absorption

Test blocks of this material when subjected to testing as per IS 4031 shall exhibit

compressive strength of not less than 250 Kg/Sq.cm. after 28 days of curing and

the density of cured lining shall not be less than 2300 kg/cu.m. Water absorption

as per ASTM C642 shall not exceed 10% for the test specimen.

Based on the test results a procedure shall be standardised for mixing of the

materials.

Inspection personnel shall witness the mixing of materials and sample

preparations for procedure qualification. Test results shall be correlated with

sample no. and a standard procedure shall be evolved. 7.0 INSPECTION DURING PRODUCTION

The entire procedure of applying cement-mortar lining shall be subjected to

continuous inspection by Owner or their authorised representative. However,

such inspection shall not relieve the contractor of the responsibility of meeting the

specifications. The job shall be subjected to inspection at the following stages:

i) After surface preparation and prior to application of lining

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

ii) After application and curing

Any lining not applied in accordance with this standard or not as per required

thickness shall be subjected to rejection and replaced/repaired at the expense of

the contractor.

The inspector shall have free access to all areas and facilities concerned, and the

contractor shall furnish all reasonable assistance.

The inspection of lining in pipe upto 600NB shall be made from both ends of the

lined pipe segment by using strong lights and/or mirrors. The inspection shall be

done before the lining has attained its initial set. For pipes 650NB & above, a

manual, visual inspection of the lined pipe interior shall be made.

Defects in cement mortar lining include, but are not limited to sand pockets, voids,

over sanded areas, honey comb, excessively cracked, drummy areas, areas of

lining thinner than specified and areas of unsatisfactory surface finish.

The surface of lining shall be smooth and free from irregularities, cracks upto 0.8

mm wide and not over 300 mm in length are acceptable. Trough to crest height

shall not exceed 1.0 mm.

8.0 REPAIR OF LINING

8.1 For pipes up to 600NB, the defective lining shall be removed in total from the

pipe segment before the initial setting. The pipe segment shall then be relined in

full compliance with specifications.

8.2 For pipes above 600NB, small defective areas shall be repaired by manual

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

removal of the defective lining and by hand reapplication of mortar lining.

Defective areas encompassing the full diameter of the pipe shall be replaced by

machine wherever practical.

8.3 A pipe that has been exposed by spilling or cracking of the lining shall be cleaned

thoroughly free from debris.

8.4 When an epoxy pipe-joining compound is to be used for the repair, the surface

shall be dry and dust free and a coating of the compound shall be applied with a

small trowel or spatula. When the cement mortar mix is to be used, the surface

shall be dust free and moistened with clean fresh water. Immediately after

moistening the cement mortar mix shall be applied using a small trowel. If

necessary a brush can be used for “feathering in” the surface edges of the repair.

8.5 Where cement mortar is used for the repair, the adjacent lining shall be coated

far enough back to cover any visible cracks and shall be maintained in a moist

condition for three days using a wet hessian sack or similar means. Alternatively,

if the line can be filled, it shall be put into use after the initial set has taken place.

9.0 PIPE JOINTING

Pipe joints both for above ground and underground upto 600NB shall be done by

collars in general and by flanged fittings in specific cases wherever requirement

arises for ease of fabrication, inspection and maintenance. Typical joint details

shall be as shown in Drg. No.8122-12-DG-00001.

9.1 Jointing Methods 9.1.1 Pipes which have been cement-mortar lined cannot be butt welded together in

the normal way as the mortar adjacent to the weld will be damaged by heat.

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

9.1.2 For pipe size upto 600NB, Pipe OD and sleeve ID & both end faces of the cement

lining shall be provided with epoxy coating. The sleeve welds should be located at

90 deg. clear of any longitudinal pipe weld.

9.1.3 The terminal ends shall be cut at right angles to the pipe axis and after completion

of all welding out of roundness shall be within the limits specified by API Spec.

5L.

10.0 FITTINGS & FLANGES

All fittings upto 600NB size shall be generally collar joined with pipe. However

flanged joints can be provided at critical locations for ease of fabrication,

inspection and maintenance. Flanges may be welded in field/shop prior to lining.

Flange faces shall be free of cement lining. For detail refer Drg. No.8122-12-DG-

00001.

11.0 BRANCH CONNECTION 11.1 Branches in cement lined pipes shall be of minimum of 150 NB size. Stub in

branch connections of size 150 NB onward shall be collar joined as per Drg.

No.8122-12-DG-00003. However to meet specific requirement at critical

locations for ease of fabrication, inspection and maintenance flanged joints may

also be used as per Drg. No.8122-12-DG-00003.

11.2 Instruments branches for Pressure instruments shall be as per Drg. No.8122-

12-DG-00002. The 150NB blind flange shall be drilled to suit

instrument/vent/drain size.

11.3 Vents and drains on cement-lined piping shall be by 150NB flanged stub with

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

blind flange, which is internally epoxy (FRE) lined. The blind flange shall be

provided ¾” tapped hole and ¾” vent/drain with valve & blind. 12.0 CUTTING METHODS OF CEMENT LINED PIPES 12.1 For cutting lined pipe, a slitter saw supported as necessary and containing a

nylon bonded carborundum disc shall be used. Alternatively, a rigid pipe cutting

machine using tungsten carbine tipped tools ground to the cutting angles shall be

used.

12.2 On fusion welded steel pipes, the external weld shall be removed flush with, but

not below, the face of the pipe for the width of the cutters, and if necessary for the

complete width of the cutting machine.

12.3 The section to be removed and the adjacent pipe ends shall be suitably supported

to avoid imposing any weight on the concrete lining when breaking through. 13.0 DAMAGE PROTECTION 13.1 Handling

Handling of lined pipe lengths shall be by means of nylon belts such that the

pipes are supported 1/5 of their length from each end. Pipe shall not be lifted

using hooks inserted in the pipe ends.

13.2 Transportation

13.2.1 Lined pipes being transported shall be adequately supported in a level

horizontal position in order to minimize flexing and prevent induced bending and

damage to the lining.

8122- 12 - DA - 001 DATA SHEET



12FT026A/94

13.2.2 Pipes shall be protected from direct and indirect impact by means of suitable

cushioning material.

13.2.3 Pipes shall not be transported using tractor units with trailing bogies or other

method offering no central support. 13.2.4 During transportation and storage pipe lengths shall have end caps or other

suitable means of protection, with sufficient holes to permit air circulation,

provided this does not cause drying out and cracking of the lining. Means shall

be taken to ensure that the end protection remains securely fastened, especially

during transportation.

13.2.5 Branch connections shall be suitably plugged or capped as described above.

14.0 INSTALLATION

14.1 Care shall be taken when handling jointed lengths of pipes to ensure that the

induced bending and the possibility of damage to the lining is minimized.

14.2 During pipeline installation, when handling, lifting and laying pipe, the spacing

of lifting points and supports shall be adequate to avoid induced bending.

X

4

5

8

9

10

11

12

13

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

50

51

52

53

54

55


49

19.0 Certification ISI marking

20.0 Test pressure Kg/cm2G 23

17.0 Accessories

18.0 Monitor weight Kg

Locks for swivel joints Gun mettal

16.0 Lubrication Grease lubrication for joints

Water barrel IS 1239 Seamless

Nozzle Aluminium alloy

Base flange CS

Swivel joints Gun mettal

+80, (-)45

15.0 Material of construction

- Vertical plane

- Horizontal plane 360

Rotation Angle Deg.

53

- Vertical 20

- Horizontal

Pressure Kg/cm2G

Jet length M

Perfomance

7

1750Flow rate lpm

14.0

16

13.0 Water barrel pipe thickness mm

12.0 Back pressure at base flange Kg/cm2G IS 1239, Heavy

14

11.0 Design pressure Kg/cm2G 7 operating / 15 design 15

10.0 Type of joint Swivel joints

8.0 Nozzle diameter mm 32

9.0 Base flange details 100 NB, ANSI B16.5, Class 150, SORF

6.0 Monitor size mm 75 with 100 NB base flange

7.0 Connection size mm

4.0 No. off 2

5.0 Codes / Standards IS 8442

6

3.0 Type Stand post type with swivel joints, Type 1 of IS 8442 7

2.0 Model

Item No. :

1.0 Make

3

WATER MONITOR

1

Site : MANGALORE Job No : 8122Unit : LPG BLENDING FACILITY

1

Applicable to : Proposal Purchase As built TPS No. :

FIRE HYDRANT SYSTEM8122-01-DA- FH101

DATA SHEET

PAGE 1 OF

02ES023/97 ENGINEERING SPECIFICATION

PAINTING

PAGE 1 OF 13

PRPD.BY:- RS CHKD.BY:- GPN APPRD. BY:- KV ISSUED ON:- 23.07.97


CONTENTS: 1.0.0. SCOPE 2.0.0. MATERIALS 3.0.0. SURFACE PREPARATION

4.0.0. STORAGE OF PAINTING MATERIALS

5.0.0. MIXING AND THINNING

6.0.0. PAINTING

7.0.0. SAFETY

8.0.0. INSPECTION

9.0.0. GUARANTEE

10.0.0. CODIFICATION OF PAINTING MATERIALS

11.0.0. SCHEME OF PAINTING

12.0.0. COLOUR CODING & MATERIAL FOR PIPING TABLES

02ES023/97 ENGINEERING

SPECIFICATION PAINTING PAGE 2 OF 13


1.0.0. SCOPE 1.1.0. This specification covers the

requirements for surface preparation, painting and painting materials for equipment, structures and piping (including those painted/primed at shop and those painted at Field/Site.

1.2.0. Requirement of painting for any item

shall be as specified in any of the following documents.

a) Equipment Data Sheet b) Piping line schedule c) Design Basis for package

items d) Painting schedule

1.3.0. The purpose of painting described in

this specification is generally for protection against corrosion.

1.4.0. Painting for other reasons shall be as

indicated in the respective equipment data sheets or painting schedule.

1.5.0. The following surfaces exposed to

atmosphere are covered by this specification, which are not provided by any other form of covering/coating.

a) Pressure vessels, Tanks, Heat

Exchangers and other process equipment with Carbon steel and low alloy steel as material of construction.

b) Machinery items including motors.

c) Steel structures d) Carbon and low alloy steel

piping 1.6.0. The following items shall not be

painted unless otherwise specifically required by respective equipment Data Sheets/Painting schedule

a) Non ferrous surfaces, stainless steel and High Alloy steel surfaces.

b) Glass, tile or ceramic surfaces c) Name plates and identification

tags d) Valve stems e) Machined contact surfaces f) Galvanised surfaces g) Insulation covers h) Plastics i) Underground / buried piping

and equipments which are provided with special type of protective coatings.

j) Surfaces / Items which are excluded from painting due to specific reasons.

1.7.0. This specification also covers painting

of “Markings” and color-coding of carbon steel, low/high alloy steel, stainless steel, galvanized iron and insulated pipes.

2.0.0. MATERIALS 2.1.0. All painting materials shall be of good

quality as covered by respective IS or other international specifications

2.2.0. Special paints and painting materials

shall have proven quality and shall meet the requirements laid down in the respective data sheets for equipment and piping.

2.3.0. All painting materials shall not have

passed the date of expiry or shelf life as recommended by manufacturer.

3.0.0 SURFACE PREPARATION 3.1.0 All surfaces to be painted shall be free

from rust, oil, grease, dust, stain, moisture or any other foreign material/contamination, as per IS 1477 Part I.




3.2.0 Surfaces to be painted shall be

completely dry. 3.3.0 Oil, grease, stains and other similar

contaminants shall be completely removed by using proper solvents and removers, After cleaning, the surfaces shall be free from even traces of contaminants and solvents/removers.

3.4.0 Dust shall be removed by air blowing

or vacuum cleaning. 3.5.0 Hard and caked dust, mud, mill scale

and rust shall be removed by mechanical means like wire brushing, sand blasting , shot blasting or grit blasting.

3.6.0 Wet surfaces shall be dried by blowing

warm air. 3.7.0 All surfaces cleaned by different

methods shall be painted immediately with out allowing the clean surfaces to gather dust, rust and other external substances.

3.8.0 During the course of painting if it is

found that the surfaces are contaminated due to any reason, the same shall be cleaned by any of the methods described earlier, before further proceeding with painting.

3.9.0 All surfaces to be painted after sand,

grit or shot blasting shall exhibit almost clean white metal and shall have surface finish of SA 2 ½ as per IS 9954.

3.9.1 Blast cleaned surfaces shall be primed

within 2 hrs, after blasting, before re-rusting starts and before contamination.

3.9.2. Blast cleaning shall not be carried out

when temperatures are less than 20

deg.C or when the relative humidity of air exceeds 90%.

3.9.3. Blasting operations shall not be carried

out during rain, snow, or strong winds. 3.9.4. Blasting medium viz. Slag, grit, or shot

shall be completely dry and shall be free from any sort of contaminants like dust, oil, grease etc.

3.9.5. Blasting air shall be completely dry

and shall have minimum pressure of 3.5 kg/cm2.

3.10.0 Surfaces which are not suitable for

blast-cleaning or could not be blast-cleaned due to practical reasons shall be thoroughly wire brushed to exhibit a pronounced metallic sheen, equivalent to St 3 as per IS 9954.

3.10.1 Absence of compressed air,

slag/shot/grit and/or blasting equipment and accessories shall not be a reason for not carrying out blast cleaning.

4.0.0. STORAGE OF PAINTING

MATERAILS 4.1.0. Paints, varnishes, thinner, additives and

other volatile substances shall be stored in a flame proof enclosure, away from heat.

4.2.0. Fire extinguishers or sand and water

for emergency fire fighting operations shall be provided near storage area at easily accessible place for use, in case of fire.

4.3.0. Warning Boards and signs shall be

exhibited around the storage area.




5.0.0. MIXING AND THINNING 5.1.0 Mixing and thinning of paints shall be

carried out as per manufacturer’s recommendations.

5.2.0 Mixing and thinning operations shall

be carried out in well ventilated rooms. 5.3.0 Only that quantity of paint which is

sufficient to cover the required area within the specified painting time, shall be mixed at a time.

5.4.0 Mixed paints shall be used with in the

time span as recommended by manufacturer. Mixed paints, for which standing time specified has elapsed, shall not be used.

5.5.0 Ready-mixed paints containers shall

be opened only at the time of painting. Containers shall be closed air tight after drawing paint from it.

5.6.0 Ready-mixed paints shall be stirred

well before drawing from the storage container as well as during painting operations.

5.7.0 Ready-mixed paints shall be thinned

only if absolutely necessary by using thinners commended by manufacturer.

5.8.0 Balance of ready-mixed paints shall not

be poured back into the main container after use, but shall be kept in a separate air tight container.

6.0.0 PAINTING 6.1.0 General Requirements. 6.1.1 Painting of equipment, piping and

structurals shall be carried out at shop or site as prescribed in the respective eqpt. data sheets, piping line schedule or structural detail drawing.

. 6.1.2 Painting shall not be carried out on

surfaces not prepared and not meeting the requirements of clause 3.0.0.

6.1.3 Painting shall be carried out only under

favourable conditions. Painting shall not be carried out in dusty and draught conditions in damp areas and during rainy seasons or cold atmosphere.

6.1.4 During painting, adjacent equipments

or surfaces shall be protected from paint sprays, splashes or drips.

6.1.5 Painting shall be carried out only by

using brushes, rollers, air/airless spray. 6.1.6 Caution boards indicating ‘wet paint’

shall be posted after painting is over and kept till the curing time is completed.

6.1.7 For painting of multiple coating, each

coat shall be applied only after sufficient curing time has elapsed after the previous coat, as recommended by manufacturer.

6.1.8 All painted surfaces shall have a

uniform and smooth regular finish. The surfaces shall be free from foreign particles, brush marks, bristles, ridges, waves, laps wrinkles etc. If such surface defects occur, the same shall be removed by using abrasive paper/cloth and re-painted.

6.1.9 Surfaces inaccessible after assembly

shall be painted to requirement before assembly.

6.1.10 Any imperfect or damaged layer/coat

shall be repaired before subsequent coating.

6.1.11 At places where welding is to be

carried out at field after assembly, a space of 100 to 200 mm width shall be left unpainted on both sides of the welding joint.




6.1.12 Field welded areas shall be thoroughly

cleaned as required in clause 3.0.0 and painted in the same manner as the remaining area.

6.2.0 Shop Painting/Priming. 6.2.1 Shop painting/priming shall be carried

out as specified in the respective data sheets/line schedule etc. and shall meet all the requirements of this specification.

6.3.0 Painting at Field /Site. 6.3.1 Field/site painting shall be carried out

as specified in the data sheets/painting schedule and shall meet all the requirements of this specification for painting.

6.3.2 Where equipments/piping/structures

have already received shop painting/priming, the painted/primed surfaces shall be thoroughly cleaned and inspected for any damage or defects. Such damages or defects shall be repaired before starting the filed/site painting.

7.0.0. SAFETY 7.1.0. Sufficient safety precautions shall be

taken to ensure protection of Personnel, equipments, piping structures and buildings in the vicinity, where painting materials are stored and painting and blasting operations are carried out.

7.2.0. Open flames and exposed elements or

sources of ignition of any kind shall be prohibited in the area where painting materials are stored and painting operations are carried out.

7.3.0. ‘Warning’ or ‘Caution’ boards

indicating chances of fire shall be displaced around the paint storage and painting areas.

7.4.0 Electrical fittings and appliances shall

be spark proof and shall not cause a fire in the painting storage and painting areas.

7.5.0 Cleaning agents with flash point less

than 400C shall be used. 7.6.0 Adequate ventilation shall be ensured

during painting and storage of paints. 7.7.0 Painting workmen shall wear face

masks, gloves and protective clothing during painting and mixing operations. In addition, workmen engaged in blasting operations shall be earmuffs also.

7.8.0 Area where painting is carried out, as

well as materials are stored shall be clean, After work, the areas shall be cleared of all scaffoldings, balance materials etc. in order to prevent fire hazards and hinder fire fighting operations.

7.9.0 Painting materials shall be stored and

painting and blasting operations shall be carried out only in areas where fire fighting equipments/vehicles and personnel evacuation vehicles can have easy access. In areas where such easy access is not available suitable precautions are to be ensured.

8.0.0 INSPECTION 8.1.0. All painting materials and related items

shall be inspected to check the suitability of the same for the specified purposes.

8.2.0. Painting surfaces are to be inspected

after cleaning operation, to ensure that the surfaces are fit for painting.

8.3.0. Finished surfaces shall be checked for

uniformity in colour, finish and appearance as well as for defects.




8.4.0. Thickness of each coat of paint shall be checked after curing time. The total thickness of multiple coats shall be as specified in the data sheets/piping line schedules/painting schedules.

8.5.0. Paint thickness gauge shall be either

mechanical or electronic. The gauges shall be calibrated regularly. Defective gauges shall not be used.

8.6.0. Absence of paint thickness gauge shall

not be made for each eqpt/line/structure separately.

8.7.0. A detailed quality / inspection report

shall be made for each eqpt / line / structure separately

9.0.0. GUARANTEE

Guarantee shall cover materials and workmanship.

10.0.0. CODIFICATION OF PAINTING

MATERIALS 10.1.0. Primers

A.01 Synthetic Zinc Phosphate Primer

A.02 Epoxy based Zinc Phosphate Primer

A.03 Epoxy based Zinc Rich Primer A.04 Alkyd High Build Zinc

Phosphate Primer A.05 Inorganic Zinc Silicate Primer A.06 Chlorinated Rubber based High

Build Zinc Phosphate Primer 10.2.0. Finish Paints

B.01 Epoxy Resin based Enamel B.02 Epoxy Resin based Micaceous

Iron Oxide Paint B.03 Epoxy Resin based High Build

Paint B.04 Coal Tar Epoxy Resin based

Paint B.05 Chlorinated Rubber Paint

10.3.0. Bituminous Coating

C.01 Nontoxic Inert Coating for drinking water tanks

C.02 Acid Alkali and Heat Resisting Coating

10.4.0. Heat Resistant Paints

D.01 Dual Pack Aluminium Paint (upto 250oC)

D.02 Single Pack High Temperature Silicon Aluminium Paint (upto 600oC)

10.5.0. Polyurethane Coating. (For low temp.

application)

E.01 Two-Pack Polyurethane Holding Primer

E.02 High Build Polyurethane Coating 10.6.0. General Purpose Paints F.01 Synthetic Resin based Enamel F.02 Chemical Resistant Enamel

F.03 Alkyd, Antiskid Abrasion Resistant Synthetic Floor Paint

10.7.0. Special Applications

G.01 Bituminous Mastic Coating G.02 Asphalt doping as per IS 10987

App-B G.03 Thermocolour Paint

10.8.0 As an alternative, in place of one coat

of E.01 – Two pack Polyurethane Holding Primer, one coat of Epoxy Zinc Phosphate Primer A02 (20 microns) followed by one coat of High Build Epoxy containing Micaceous Iron oxide-Bo2 (20 microns) shall be applied before applying finish paint E-02-High build Polyurethane coating.

11.0.0 SCHEME OF PAINTING 11.1.0. Scheme of painting of equipment,

piping, structures and other items shall conform to class 1, class II or class III as specified in the equipment data sheet/ piping line schedule/ painting schedule/ structural drawings.

11.2.0 Representation of painting




Requirement of painting of an item shall be indicated in respective drawings/ data sheets/ line schedule/ painting schedule as follows. Indicate primer or finish or both as requiredfollowed by subclass indicated in Table 1, Table 2 or table 3 as the case may be.

Eg Primer Class I (1)L F i n i s h Class I (1)L

Primer & Finish Class I (2 )M

Primer Class II (2)O

Primer & finish Class II (3)O/P

Primer Class III (1 )

Finish Class III (1 )

Primer & Finish Class III (3 )

12.0.0 COLOUR CODING AND MARKING

FOR PIPING 12.1.0 In addition to the requirements of

painting as per 11.0 the finish painting of the piping shall have the specified colors as per Table 4 – Color coding for pipes, for purposes of identification of service.

12.2.0 All pipes and pipe lines covered under

1.7 shall be provided with “Markings” such as color bands, hazard markings, line identification markings, flow arrow markings etc. at specified locations/intervals and dimensions as indicated in Table 5 – Marking of pipes.

*******************




TABLE 1 – CLASS I – Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping

PRIMER FINISH Sl.No.

SERVICE CONDITIONS

OPERATING TEMP.

PAINT SUB- CLASS

Type No.of coats

*DFT Type No.of coats

*DFT

=/< 15 (1) L E.01 1 30 E.02 2 30 =/< 65 (1) N A.01 2 20 F.01 2 20 =/< 125 (1) M D.01 2 20 D.01 2 20

1 UN INSULATED NON CORROSSIVE ATMOSPHERE

=/< 400 (1) H D.02 2 20 D.02 2 20

=/< 15 (2) L E.1 1 30 E.02 2 20 =/< 65 (2) N A.06 2 20 B.05 2 20 =/< 125 (2) M A.02 2 20 B.02 2 20

2 UN INSULATED CORROSSIVE ATMOSPHERE =/< 400 (2) H D.02 2 20 D.02 2 20

=/< 15 (3) L E.01 1 30 - - - =/< 65 (3) N A.04 2 25 - - - =/< 125 (3) M D.01 2 20 - - -

3 INSULATED CORROSSIVE ATMOSPHERE

=/< 400 (3) H D.02 2 20 - - - =/< 15 (4) L E.01 1 30 - - - =/< 65 (4) N A.06 1 30 - - - =/< 125 (4) M D.01 1 30 - - -

4 INSULATED CORROSSIVE ATMOSPHERE

=/< 400 (4) H D.02 1 30 - - - =/< 15 (5) L E.01 1 30 E.02 2 30 =/< 65 (5) N A.01 2 20 F.01 2 20 =/< 125 (5) M D.01 2 20 D.01 2 20

5 SUPPORTS FOR ALL EQPTS.(INSULATED/UN INSULATED)

=/< 400 (5) H D.02 2 20 D.02 2 20

=/< 15 (6) L E.01 1 30 E.02 2 30 =/< 65 (6) N A.06 2 20 B.05 2 30 =/< 125 (6) M A.02 2 20 B.01 2 30

6 EQPT. AND STRUCTRURES SUBJECTED TO SALINE ATMOSPHERE UN INSULATED

=/< 400 (6) H D.02 2 20 D.02 2 20

* DFT – Dry film Thickness per coat microns Notation: L – Low Temperature N – Normal Temperature M – Moderate Temperature H – High Temperature :




TABLE 2 – CLASS II – OTHER EQUIPMENTS PRIMER FINISH

Sl. No. TYPE OF ITEM

PAINT SUB

CLASS Type No.of coats *DFT Type No.of

coats *DFT

1

Chimneys,Stacks,Furnaces,heaters (fired and unfired)operatingTemp upto450oC

Outside (1) A.05 2 25 D.02 2 20

Outside (2)O A.01 2 20 F.01 2 25 2 D.M.Water Storage Tanks Inside (2)P A.03 2 35 B.03 2 35

Outside (3)O A.01 2 20 F.01 2 25 3

Fresh Water/fire Water Storage Tanks Inside (3)P A.03 2 35 B.04 2 75

Outside (4)O A.01 2 20 F.01 2 25 4 Drinking Water Storage Tanks Outside (4)P A.01 2 20 C.01 3 20

5 Acid/alkali Storage Tanks Outside (5) A.04 2 30 C.02 3 25

Outside (6)O A.04 2 50 D.01 2 25 6

Storage Tanks/Vessels for Petroleum Products Inside (6)P A.02 2 30 B.03 2 75

Outside (7)O A.04 2 50 D.01 2 25

(7)P A.02 2 30 B.03 2 75 7

Floating Roof Tanks:Inside of shell, top of bottom plate,topside and underside of deck, inside of pontoon (7)Q A.01 2 25

8 Underside of Bottom Plate of Tanks

(8) A.01 1 20 G.01 1 80

9 Underground Tanks (buried) Outside (9) A.01 1 20 G.02

10 Below Ground (submersible) Tanks

Outside (10) A.06 2 35 B.05 3 35

11

Secondary Reformer&Similar Eqpt.(Thermo colour paint)

(11) G.03 2 ** G.03 1 **

*DFT : Dry Film Thickness per coat microns ** : As per Manufacturer’s recommendations Notation: O- Outside P-Product Side Q-Specified Side




TABLE 3 – CLASS III – MISCELLANEOUS

PRIMER FINISH Sl. No.

TYPE OF ITEM PAINTING

SUB CLASS Type

No. of

coats *DFT Type No.of

coats *DFT

1 Steel structures, Platform Supports

(1) A.04 2 20 B.01 2 25

2 Chequered Plate,Floorplanks&Gangways

(2) A.04 2 20 F.03 2 25

3 Handrails Posts,Railings,Ladders and Stairways

(3) A.04 2 20 B.01 2 25

* DFT – Dry Film Thickness per coat microns




TABLE 4 – COLOUR CODING FOR PIPES

Sl.No. Service Identification

Ground / Finish Colour Colour Band - 1 Colour Band - 2

1 Instrument Air0 Sky Blue White - 2 Service Air Sky Blue Light Brown - 3 Plant Air Sky Blue French Blue - 4 Cooling Water Sea Green French Blue - 5 Service Water Sea Green French Blue Signal Red 6 Demineralised Water Sea Green Light Orange French Blue 7 Boiler Feed Water Sea Green - - 8 Steam Condensate Sea Green Light Brown - 9 Boiler Blow Down Sea Green White Signal red 10 Turbine condensate Sea Green White - 11 Process Condensate Sea Green Black - 12 Low Pressure Steam Silver Grey Light Orange - 13 Medium Pressure Steam Silver Grey Light Brown - 14 High Pressure Steam Silver Grey Signal Red - 15 Very High Pressure

Steam Silver Grey Signal Red French Blue

16 Naphta Liquid Light Brown French Blue - 17 Naphta Vapour Light Brown French Blue White 18 Fuel Oil Light Brown White - 19 Antifoam Solution Black Sea Green - 20 Phosphate Black Signal Red - 21 Hydrazinc Black Signal Red Sea Green 22 Waste Water Black Sea Green Signal Red 23 Oily Water Black White - 24 Ammonia Liquid Dark Violet French Blue - 25 Ammonia Water Dark Violet French Blue Sea Green 26 Ammonia gas Dark Violet French Blue Canary Yellow 27 MDEA Solution Dark Violet Black White 28 Process Vent Canary Yellow Light Grey Signal Red 29 Carbondioxide Canary Yellow Light Grey - 30 Hydrogen Canary Yellow Signal Red - 31 Nitrogen Canary Yellow Black - 32 LPG Canary Yellow French Blue - 33 Fuel gas Canary Yellow Light Brown - 34 Process Gas Canary Yellow Sea green - 35 Synthesis Gas Canary Yellow White - 36 Effluent Black Sea Green Signal Red 37 Drinking Water Sea Green Light Orange -




TABLE 5 – MARKING FOR PIPES 1.0. GROUND COLOUR UNIT OF MEASUREMENT Insulated Line – all (excludes buried line) 1.1. Un-insulated Lines–Stainless : Ground colour for a length Per Marking as per para 6.0

Steel,GI ,Alloy steels & of 2 meters below including pipe supports Other non-ferrous pipelines (excludes buried line) ___________________________________________________________________________

1.2. Un-insulated carbon steel : Ground colour applied Run length in Meters along Lines (excluded buried throughout entire length centreline including Markings Lines) as per Para 6.0 below & pipe supports ___________________________________________________________________________ 2.0. COLOUR BANDS MARKINGS

Colour band(s)and its width,Band 2 downstream of Band 1(ie.after band 1 along the direction of flow)

Pipe size NB (D-pipe size in inches)

Band 1 mm

B and 2 mm

80 NB and below 75 Above 80 NB(3”) up to 100 NB(4””) D x 25 Above 100 NB(4”) up to 300 NB(12”) D X 20 Above 300 NB(12”) D x 15

¼ of Band 1 (Rounded to the nearest mm)

HAZARD Diagonal strips of Black and golden Yellow as per IS2379 superimposed on

MARKINGS the ground color. If color bands exists,the hazard marking shall be painted Downstream of the bands (ie. after bands in the direction of flow) 3.0. LINE IDENTIFICATION Color shall be Black or White to contrast with the color on

MARKINGS which they are painted. It shall consist of Line No., Line size, Fluid code & Pipeline Spec. No. The lettering dimensions Shall be as per IS2379. 4.0. FLOW ARROW Color shall be Black or White to contrast with the color on

MARKINGS which they are painted. The dimension of the arrow shall be as follows and is based on the size of the pipeline.

150NB & below

200NB & above

a 65 90 b 30 50 c 95 125

d a c b

d 20 30




5.0. LOCATION OF MARKINGS

Marking includes 2M long ground color, color band(s), hazardous marking, Line No. & flow direction arrow which shall be located at the following points with proper visibility as per IS2379.

a. Battery Limit Points b. Either side of walls & dyke

walls c. For long yard piping – at 30M

interval d. Inter-section on pipe bridge e. Any other location indicated by

the Engineer-in-charge at site

6.0. PIPE SUPPORTS 6.1. This includes base springs, hanger

springs, shoes and trunnions etc. and excludes pipe bridge structures, platform, equipment support structures and such structures which do not actually support the pipeline.

6.2. The painting of pipe supports forms part of the pipelines and a separate rate will not operate.

6.3. The painting specification for pipe

supports shall be same as that for pipe ground colour.

****************

02ES042/97 ENGINEERING SPECIFICATION

COLD INSULATION

PAGE 1 OF 26

PRPD.BY:- CK CHKD.BY:- GPN APPRD. BY:- KV ISSUED ON:- 24-7-97


CONTENTS

1.0.0 SCOPE 2.0.0 INSULATION MATERIALS

3.0.0 ANCILLARY MATERIALS

4.0.0 INSULATION THICKNESS

5.0.0 APPLICATIOIN

6.0.0 PIPING INSULATION

7.0.0 MACHINERY ITEMS

8.0.0 INSTRUMENTS & MISC. ITEMS

9.0.0 INSULATION CAST - IN - SITU 10.0.0 SAFETY

11.0.0 GUARANTEE

12.0.0 APPLICATION DETAILS


SPECIFICATION COLD INSULATION

PAGE 2 OF 26


1.1.0 SCOPE

This specification covers the requirements for the supply and application of external, self extinguishing type thermal insulation of equipment and piping for cold service conditions.

1.1.0 REQUIREMENT OF COLD INSULATION

1.1.1 Requirement of cold insulation of any equipment or piping shall be as specified in any of the following documents.

a. Equipment data sheets / drawings b. Piping line schedule c. Design basis for package items d Insulation schedule

1.1.2 Cold insulation is required to be provided on Pressure vessels, Heat Exchangers, Columns, Tanks other process equipment and Piping to meet the following requirements. a.. To maintain process / operating

temperature. b. To prevent ingress of heat from

external source/atmosphere. c. To avoid surface condensation.

1.1.3 Insulation requirement to maintain process/operating temperature shall be as indicated in documents referred to in 1.1.1.

1.1.4 Insulation for preventing ingress of heat from external source/atmosphere and to avoid surface condensation shall be provided on all equipment and piping operating below 20o C.

1.2.0 Limits of Application. 1.2.1 The following items shall not be

insulated unless otherwise specified. a. Bonnets of valves above packing glands b. Nameplates and data plates of equipment.

1.2.2 All attachments and projections such as

supports, structures attached to equipment pipe hanger supports, Instrument lead lines, branch lines like vents and drains and instrument connections connected directly to cold insulated equipment and piping shall be cold insulated up to a distance of 5 times the adjoining insulation thickness.

2.0.0 INSULATION MATERIALS 2.1.0 The material of insulation shall be as

specified in the documents indicated in 1.1.1 and shall be one of the following. a. Polyurethane foam b. Expanded Polystyrene

2.2.0 Material of insulation shall be non-absorbent with a closed cell structure to ensure non-permeability of moisture / water vapour.

2.3.0 Material of insulation shall be fungus and vermin proof.

2.4.0 Insulation material shall not contain chemicals, which may be harmful to the equipment or piping or to the protective coating at ambient or service temperatures in wet or dry condition.

2.5.0 Insulation material used for austenitic steel equipment and piping shall be free from water-soluble chlorides and other harmful chemicals.

2.6.0 POLYURETHANE FOAM (PUF)

2.6.1 Polyurethane foam (PUF) may be used for insulation of equipment and piping either as preformed sections or cast-in-situ.

2.6.2 Polyurethane foam shall be of rigid preformed cellular urethane foam and self-extinguishable type in accordance with ASTM-C 591, Type II, Gr.2.



PAGE 3 OF 26


2.6.3 The foam shall be formulated in such a way that it shall be of self-extinguishing quality which shall not cause fire to spread under any circumstances.

2.6.4 The finished foam, in the form of sections, slabs or cast-in-situ, shall be of uniform closed cell structure, free from unreacted material, shrinkage and distortion.

2.6.5 Density of finished foam shall be approximately 45 Kg/m3.

2.6.6 Thermal conductivity of the finished polyurethane foam shall not exceed 15 Kcl/hr deg C at 10 deg C mean temperature after ageing.

2.6.7 Closed cell content of finished PUF shall be at least 95% by volume.

2.6.8 Maximum permeance of finished PUF shall be 4.0 gms/m. 24h.mm Hg.

2.6.9 Resistance of 10% compression of finished PUF at ambient temperature shall be 1.5 Kg/cm

2.7.0 EXPANDED PLYSTYRENE (EPS)

2.7.1 Expanded polystyrene (EPS) may be used for insulation of equipment and piping in the form of preformed sections or slabs.

2.7.2 Expanded polystyrene shall be of self-extinguishing type with closed cell structure in accordance with IS-4671 type 2.

2.7.3 Finished EPS shall be free from shrinkage distortion and unreacted materials.

2.7.4 Density of finished EPS shall be given below: Preformed sections 20 to 22 Kg/m3

Slabs 18 o 20 Kg/m3

2.7.5 Thermal conductivity of finished EPS shall be as given below: ---------------------------------------------- Density Thermal conductivity Kcal/m.hr. oC 0oC 10oC ---------------------------------------------- 18 0.028 0.031 20 0.027 0.030 22 0.026 0.029

2.7.6 Maximum permeance of finished EPS shall not be more than 4.0 gms/m. 24 hr.mm.Hg.

2.7.7 Finished EPS shall be free from leachable chlorides.

3.0.0 ANCILLARY MATERIALS

3.1.0 Wire netting; Lacing & Stitching Wire netting of preformed sections and slabs shall be of 24 swg x 20 mm GI. Lacing and stitching wires shall be of 20 swg and 22 swg GI respectively.

3.2.0 BANDS Aluminium bands of size 20mm width x 24 swg shall be used for securing insulation sections and slabs in place.

3.3.0 METAL CLADDING Commercial quality aluminium jacketing conforming to IS 737 shall be used for all equipment and piping. Thickness of cladding sheets shall be as indicated in table. 1.

3.4.0 SELF TAPING SCREWS

Self tapping screws to be used for securing the metal cladding shall be 6mm dia cadmium plated or galvanised, and best quality.

3.5.0 SEALING COMPOUND



PAGE 4 OF 26


3.5.1 To ensure perfect water proofing, cladding joints shall be packed with sealing materials, which may either be in the form of bituminous mastic sealing compound or fibre based bituminous felt strips.

3.5.2 Sealing compound shall be suitable to withstand the temperature of insulation to seal the joints.

3.6.0 MASTIC BEDDING Insulating sections and slabs shall be

bedded in non-setting mastic to eliminate air pockets. The same mastic shall be used for ensuring vapour tight joints between adjacent sections/slabs.

3.7.0 HARD SETTING PLASTER Hard setting plaster (mixture of sand & cement or asbestos & cement shall be applied over wire netting on piping subjected to foot traffic.

3.8.0 BITUMINISED SELF-FINISHING ROOFING FELT. Bituminised self-finishing roofing felt shall conform to IS 1322 Type 3 Gr. 1. [

3.9.0 VAPOR BARRIER 3.9.1 Sealing mastic for the vapour barrier

shall be fire retardant mastic, bituminous emulsion mastic or elastomeric polymer mastic.

3.9.2 Instead of sealing mastic, aluminium foil of about 0.025mm (25 microns) thick glued to craft paper using polyethylene glue or aluminium foil (.025mm thick) coated with polyester may also be applied as vapour barrier.

4.0.0 INSULATION THICKNESS 4.1.0 Insulation thickness shall be as

specified in the equipment data sheet/piping line schedule/insulation schedule.

4.2.0 For package items, the insulation thickness as per table 2 may be used as

a guidance for selecting the minimum thickness of insulation required. The vendor shall check the same for process adequacy.

5.0.0 APPLICATION 5.1.0 GENERAL 5.1.1 The surfaces to be insulated shall be

thoroughly cleaned by wire brushing to remove dirt and loose scale. Equipment and piping which have received primer / painting shall be cleaned well, without disturbing the surface treatment already received.

5.1.2 Unprimed carbon and low alloy steel surfaces shall be thoroughly cleaned by wire brush and one coat (30 microns) of epoxy based zinc phosphate primer shall be applied before starting cold insulation. Sufficient curing time shall be allowed for surface treatment.

5.1.3 Stainless steel and other non-ferrous surfaces shall not be primed.

5.1.4 The equipment drawings indicate the extend of insulation and location of insulation supports. However, the insulation contractor shall recommend, furnish and install any additional supports and anchorage that may be required to adequately support the insulation. Field welding of clips and supports shall be carried out only with the prior approval of the Engineer-in-charge.

5.1.5 All insulating and ancillary materials shall be new and unused and shall be free from contaminating materials, dust and dirt.

5.1.6 All insulation materials shall be stored in covered areas protected from moisture and dust. Insulation materials shall not be stacked directly on ground. Insulation materials showing any evidence of absorption of moisture shall not be used.



PAGE 5 OF 26


5.1.7 Insulation work shall be carried out only after hydrostatic testing of equipment / piping have been completed.

5.1.8 Insulation of flange joints shall be come only after they have been proved to be leak tight.

5.2.0 MULTILAYER INSULATION 5.2.1 When thickness of insulation exceeds

60mm, the insulation may be applied with multi layers, with all joints staggered. Each layer of insulation shall be secured by metallic banding.

5.2.2 All cracks and voids in the insulation shall be completely sealed by using the mastic bedding indicated in 3.6.0.

5.2.3 No. of layers to be employed shall determined as given below: Insulation thickness No. of layers Up to 60 mm 1 Up to 120 mm 2 Above 120mm 3

5.3.0 VAPOR BARRIER 5.3.1 Vapour barrier shall be applied on

insulation of all equipments at the outermost layer before metal cladding is applied.

5.3.2 Polyurethane foam and expanded polystyrene insulation shall be completely covered with a continuous vapour tight layer to prevent permeation of vapour into the insulating material.

5.3.3 A layer of sealing mastic shall be applied over the entire surface of the insulation, to obtain a thickness of 2 to 2.5 mm when completely dry. Over this coat while it is still wet a layer of open weave glass fibre cloth of 10 mesh size and 0.125 mm thick stretched with out any wrinkles or air pockets shall be laced with glass fibre threads. A final coat of sealing mastic shall be applied

over the glass fibre mesh to obtain a thickness of 2.5 mm when dry.

5.3.4 Alternative type of vapour barrier as described in 3.9.2 may be applied instead of that given in 5.3.3, in which case all joints shall be completely sealed and shall leave an overlap of at least 100 mm. Sealing of joints shall be done by using airtight and waterproof adhesive tape.

5.4.0 WIRE NETTING & BANDING 5.4.1 Aluminium bands as specified in 3.2.0

shall be fixed over insulation blocks at an interval of 300 mm.

5.4.2 Before application of vapour barrier, the insulation sections and slabs shall be completely covered by wire netting, laced and stitched by using wire nets, lacing and stitching wire specified in 3.1.0. The bands shall be sufficiently tightened to keep the insulation sections/slabs firmly in place without deforming the insulation.

5.4.3 Protruding ends of the bands shall be cut off or turned down so as not to damage vapour barrier.

5.5.0 FILLING OF VOIDS 5.5.1 Polyurethane dust mixed with specified

adhesive shall be packed tightly so as to fill voids and contractions on PUF insulation.

5.5.2 Blown bitumen mixed with polystyrene beads shall be used to fill voids and contractions in EPS insulation.

5.6.0 ALUMINIUM CLADDING 5.6.1 Vapour barrier of PUF or EPS

insulation shall be protected by aluminium cladding specified in 3.3.0.

5.6.2 Aluminium cladding shall be bent to shape grooved & properly riveted by using pop rivets.

5.6.3 All joints of the cladding shall overlap aluminium of 50 mm and shall be arranged in such a way as to shed



PAGE 6 OF 26


water. Joints shall be offset between pieces.

5.6.4 Cladding shall be secured to aluminium bands of size 20 x 3 mm. Which are provided at a gap or 450 mm along the circumference.

5.6.5 All joints in the cladding shall sealed water tight by using seating compound or tapes as described in 3.5.0.

5.6.6 Jacketing for dished heads shall be fabricated radial segments with an overlap of 50mm. The sheeting shall be secured in position by radial tensioned metallic bands stretched over the heads. One end of each band is anchored to the circumferential band with shell, while the other is fastened to a floating ring fabricated in the form of a ring. The sheet metal bands may be held in place by using pop rivets.

5.7.0 FLASHING 5.7.1 Openings in metal jackets for nozzles,

manholes, brackets shall be cut as close as possible for a smug fit.

5.7.2 All openings through insulation finish shall be flashed weather tight by an approved sealant particularly where connections are not insulated.

5.7.3 Skirt supported vessels shall have the skirt insulated inside and outside for at least 600 mm below the tan gent line.

5.7.4 Unless otherwise specified no insulation shall be applied to the inside of the skirt, which are externally, fire proofed.

5.7.5 For leg-supported vessels, insulation shall be provided to a length of at least 5 times the insulation thickness minimum.

5.8.0 VERTICAL VESSELS 5.8.1 Cylindrical Shell 1. Slabs/sections in handy sizes shall be

applied resting on to the supports with joints tightly butted, staggered and

adhering to each other with specified adhesives.

2. The slabs/sections are to be secured in position by circumferential metallic bands at an interval of 300mm. When multi layer insulation is applied each layer shall be banded separately.

5.8.2 Top Heads 1. Insulating material shall be properly

shaped and tightly pressed on the top head.

2. The insulation shall be held in position by using metallic bands one end of which shall be fastened to the floating ring and the other end shall be anchored to the circumferential band laced on shell near the head.

3. Radial bands shall be spaced at 300 mm gap measured along the circumference of the vessel.

4. The final layer of insulation shall be held in position by metallic wire net laced at the top vortex nozzle by about two to three loop of 10 swg galvanised iron wire and the wire net over the insulation of he shell close to the head.

5. When there are no top vertex nozzles, the insulation shall be held in position by wire netting and metallic bands stretched over the head and anchored on the cylindrical section close to the head by circumferential metallic band on the shell near the head.

5.8.3 Bottom Heads 1. Preformed and shaped insulation

sections shall be used for insulating the bottom head.

2. Preformed and shaped insulation sections shall be held in place in the same manner as for top heads.

3. While one end of the metallic bands shall be fastened to floating ring if a bottom vortex nozzle is present, the other end shall be anchored to the



PAGE 7 OF 26


insulation support ring provided inside the skirt support.

4. Radial bands shall be spaced at 300mm pitch measured along the circumference.

5. In case of absence of a bottom vortex nozzle, the metallic bands shall be stretched across the bottom head and anchored at the ring inside the skirt.

5.9.0 HORIZONTAL VESSELS 5.9.1 Insulation of horizontal vessels shall be

carried out by using preformed and shaped insulation blocks/sections.

5.9.2 Insulation material shall be held in place by using metallic bands a spacing of 300 mm.

5.9.3 Final layer of insulation shall be provided with netting, laced and stitched.

5.9.4 Each layer of insulation shall be banded separately and bands of successive layers shall be staggered.

5.9.5 Insulation blocks/sections shall be held in position by metallic bands at radial pitch of 300mm on the heads and anchored to the circumferential metallic bands on shell near the head.

5.10.0 HEAT EXCHANGERS 5.10.1 Insulation of vertical heat exchangers

shall be carried out in the same manner as in 6.0.0.

5.10.2 Insulation of horizontal heat exchangers shall be carried in the same manner as in 7.0.0.

5.10.3 Exchanger channels and channel covers including bolting flanges shall be insulated with removable aluminium covers lined with insulation sections/blocks of specified thickness.

5.11.0 SPHERICAL VESSEL 5.11.1 Shaped insulation block shall be used for

spherical vessels. 5.11.2 All joints shall be sealed well by

approved joint sealant.

5.11.3 Inner layers of insulation shall be held separately in place by metallic bands at 300 mm pitch at equator.

5.11.4 The bands shall be tied up with floating rings of 20mm O/D made of 15 SS rod at the poles of the sphere.

5.11.5 The bands on the successive layers shall be staggered and the clip ends are to be bent and recessed in to the insulation.

5.11.6 Outer layer of insulation shall be secured in place by wire netting, laced and stitched together.

5.12.0 STORAGE TANKS 5.12.1 Insulation of storage tank shell shall be

carried out in the same manner as described in 6.0

5.12.2 Where tank fabricator has provided support rings and vertical flats on the tank shell, the insulation contractor shall provide additional rings at a pitch of 900 mm. These additional rings shall be tack welded only to the support rings and vertical flats. No welding shall be permitted on the tank surface.

5.12.3 Metal cladding of tank shell shall be with 22 swg corrugated aluminium sheet. All points shall be staggered by 300mm and shall be sealed water proof with approved sealing material.

5.12.4 Tank Roof 1.Tank roof shall be thoroughly cleaned of

all dirt and rust and other contaminants. 2.Preformed insulation sections/slabs shall

be laid over one coat of adhesive mastic and pressed well. All joints shall be sealed with adhesive mastic to make it airtight.

3. When multi layer insulation is applied of successive layers shall be staggered and sealed with adhesive mastic.

4. Each lay of insulation shall be secured with bands and wire netting laced and stitched as detailed in 5.8.2.



PAGE 8 OF 26


5. Vapour barrier shall be applied as specified in 5.3.0.

6. Fix a shed water shroud constructed from 20 swg GI plain sheets at the periphery of the tank.

7. Apply a 20mm thk hard setting non-conductive plaster made from asbestos fluff and Portland cement troweled to a smooth and even finish.

8. When hard setting plaster is completely dry apply a standard 4 course bitumen felt as per IS 1346. Aluminium cladding shall be applied over this.

6.0.0 PIPING INSULATION 6.1.0 GENERAL 6.1.1 External surfaces of pipes shall be

cleaned well with wire brush (CS brush for CS pipes and SS brush for SS pipes) to remove all dirt rust and contaminating material and wiped well.

6.1.2 If painting is provided for specific reasons the insulation contractor shall not carry out any harsh cleaning and shall ensure that painting is undisturbed.

6.1.3 All pipes and supports shall be permanently set before commencement of insulation. Disturbed pipes and supports shall be restored to their original location and alignment when insulation is complete.

6.1.4 All insulation shall be applied when piping is at ambient temperature.

6.1.5 Spacer rings for supporting metal cladding shall be installed by the contractor.

6.1.6 Insulation in the form of preformed pipe sections shall be applied over the pipe without spacer rings. On top of each layer wire netting shall be applied and tightly butted against each other so that the wires interlock both longitudinally and circumferentially. The wire net joints shall be stitched with 20 swg soft galvanised iron wire.

6.1.7 At un-insulated flanges, insulation shall be terminated at suitable distance from the flange so that the flange bolts can be withdrawn without disturbing the insulation.

6.1.8 In case of vertical piping, insulation supports shall be installed by the insulation contractor. These shall consist of spacer rings at 4 metres intervals clamped to the pipes.

6.1.9 Insulation of piping shall be complete with mastic bedding, sealing compound, vapour barrier, filling of voids and metal cladding as described earlier in the specification.

6.1.10 Insulation of flanges and valves shall be provided only when specifically mentioned in the line schedule/work order. When specified, removable covers shall be provided over all flanges and valves. The insulation shall be preformed, filled in aluminium sheet boxes, and fitted with quick release clips.

6.2.0 INSULATION OF PIPING FOR FOOT TRAFFIC

6.2.1 After application of insulation including vapour barrier the insulation sections are to be held together with GI wire netting and joints laced with GI wire.

6.2.2 Wire netting shall be held together with 20mm wired hoop iron bands at 300mm spacing.

6.2.3 Apply hard setting plaster as per 3.7.0 of 20mm thick-troweled smooth.

6.2.4 After the hard setting plaster has dried wrap bituminised self-finishing roofing felt over the plaster with an overlap of 50mm both longitudinally and circumferentially.

6.2.5 The roofing felt shall be secured with 24 swg x 20mm GI wire netting and all joints are to be laced with 20 swg GI wire.



PAGE 9 OF 26


6.2.6 Apply 3mm thick bituminous emulsion mastic compound for water and weather proofing.

6.2.7 When bitumen emulsion has completely dried the surfaces shall be painted with bitumen based aluminium paint.

6.3.0 PIPING INSPECTION WINDOWS 6.3.1 Plug type inspection windows shall be

provided on all insulated pipelines having size 50 mm and above.

6.3.2 The size of the inspection windows shall be as indicated below: Pipe dia (mm) Window dia (mm)

50 35 80 45 100 75 150 and above 100 6.3.3 Inspection windows shall be provided at

the bottom of the pipelines. 6.3.4 There must be at least one inspection

window within a span of 10m. 6.3.5 At least 50% of the bends shall be

provided with inspection windows. 6.3.6 In case of critical pipelines, more number

of inspection windows may be provided at the discretion of the Engineer-in-charge.

6.3.7 Sheet metal covering of inspection windows shall be of the same gauge as that of insulation cladding. These covers are to be fixed on with 6 mm self-tapping screws.

6.3.8 The plug shall be of perfect fit into the inspection window and shall ensure leak tightness.

7.0.0 MACHINERY ITEMS in general PUF/EPS filled removable prefabricated sheet metal boxes shall be adopted for insulation of machinery items. The contractor shall submit insulation details of individual items of equipment depending on the nature of

item to be insulated for the approval of Engineer-in-charge.

8.0.0 INSTRUMENTATION & MISCELLANEOUS ITEMS

8.1.0 Drain and vent piping up to the first valve on insulated equipment shall be insulated with similar type of insulation and finish as the equipment to which it is attached.

8.2.0 Headers, branch lines sample connections and pipelines to instruments shall be insulated with similar type of insulation and finish as the connected piping.

8.3.0 The thickness and type of insulation for all lines mentioned before shall be determined from piping like schedule for corresponding temperature and pipe sizes. Thickness of insulation for the parts not mentioned shall be as specified by Engineer-in-charge.

9.0.0 INSULATION CAST-IN-SITU 9.1.0 Large vessels and equipment may be

insulated using polyurethane foam, foamed in situ.

9.2.0 Before commencement of foaming-in-situ, the contractor shall demonstrate the foaming procedure to the approval of Engineer-in-charge to check for the presence of voids after formation.

9.3.0 3 samples of PUF per shift shall be foamed in transparent polyethylene bags in presence Engineer-in-charge. Insulation work shall commence only after the approval of samples by the Engineer-in-charge.

9.4.0 Both the surface of equipment to be insulated and the cladding shall be free of rust, dirt and other contaminating matters.

9.5.0 The sheet metal cladding shall be adequately strapped and braced to withstand pressures developed during foaming, without distortion or failure. All joints of cladding shall be made leak



PAGE 10 OF 26


proof by using impermeable mastic sealing compound.

9.6.0 Air escape holes provided in the cladding shall be sealed well after foaming.

9.7.0 The annular space between the equipment and the cladding shall not be less than the thickness of insulation specified and shall be maintained uniform throughout by use of performed Polyurethane spacers, which will remain embedded in foam.

10.0.0 SAFETY The insulation contractor shall provide adequate protective appliances, like gloves, masks, glasses and clothing to workmen carrying out the insulation work for protection against any hazardous / toxic chemicals and gases. Sufficient for protection methods / gadgets shall also be deployed at the place of insulation.

11.0.0 GUARANTEE 11.1.0 The insulation contractor shall furnish

authentic test certificates to confirm that all materials offered conform to the requirements of this specification and standards mentioned therein.

11.2.0 All insulation works shall be guaranteed against defective materials and bad workmanship for the period specified in enquiry / order.

12.0.0 APPLICATION DETAILS Refer the following details attached to this specification for application of insulation of various parts.

Table 1 Thickness of Aluminium cladding sheets

Table 2 Thickness for Cold Insulation Fig.1 Insulation of Vertical Vessels Fig.2 Insulation of Exchanger Shell &

Head Fig.3 Expansion joint for Rigid

Insulation Fig.4 Support for Vertical Insulated

Piping Fig.5 Welded Elbow Insulation Fig 6 Tee Insulation Fig.7 Bottom Head Insulation for

Vertical Vessels Fig.8 Flange Insulation Fig.9 Valve Insulation Fig.10 Flashing at Nozzles & Other

Projections. Fig.11 Uninsulated Flange Fig.12 Tank shell insulation-Details Fig.13 Support detail for metal covering

of insulation. Fig.14 Man hole Insulation

Fig.15 Details of Corrugated sheet overlapping

Fig.16 Details of Tank Roof Insulation supports.

Fig.17 Details of Tank Top setting Plaster Finish

Fig.18 Single layer Insulation for Piping Fig.19 Multiple layer Insulation for

Piping.

*******************



PAGE 11 OF 26


TABLE 1 – THICKNESS OF ALUMINIUM CLADDING SHEETS

TABLE 2 – THICKNESS OF COLD INSULATION

Type of aluminium sheeting Item Size (mm) Or Dia Vertical Other portions

< / = 350 NB 24 SWG plain

24 SWG plain

>350 NB 22 SWG Corrugated 24SWG plain Equipment

Tanks 22 SWG Corrugated 22 SWG plain for roof and 24SWG

plain for other parts

< / = 350 NB 24 SWG plain 22 SWG plain

> 350 NB 24 SWG plain 24 SWG plain Piping Valves, flanges

etc. 24 SWG plain 22 SWG plain

Insulation Thickness (mm) for Temperature Deg.C Nom: Dia < / = -40 -30 -20 -10 0 10 20

20 60 60 60 50 50 40 40 65 70 70 70 60 60 50 50 80 80 80 80 70 70 50 50 150 90 90 90 80 80 50 50

400 100 100 100 80 80 50 50

500 110 110 110 80 80 50 50

900 120 120 120 80 80 50 50

Above 900

130 130 130 80 80 50 50

1.0.0 SCOPE

This specification covers the requirement for theinstalla tion, alignment and grouting work ofstatic equipments like towers, vessels and heatexchangers.

2.0.0 REFERENCES

The requirements contained in the latest edi-tions of the following standards shall form anintegral part of the requirements of thisspecification in the manner and to the extentspecified herein.

ANSI B 30.5 Safety Code for Crawler,Locomotive & Track Cranes

ANSI B 30.6 Safety Code for Derricks.

ANSI B 30.9 Safety Standard for Slings.

ANSI S 310 Specification for Design ,Fabrication & Erection ofStructural Steel for Build-ings

3.0.0 GENERAL

The installation work shall further comply withthe requirements of the applicable codes orregulations in force at the locality of the job site.

4.0.0 PLANNING

After investigating the job site but prior to com-mencing of the work, installation plans shall bemade by considering the following items:

a. Shape, dimension, weight, and material ofequipment.

b. Installation sequance of equipment.

c. Transportation route of equipment.

d. Strength and condition of unloading jetty.

e. Installation procedure, including utilisationplan of gin pole, boom derrick, crane, con-struction equipment, and special vehicles.

f. Work space around the installation area.

g. Schedule of installation of each equipment.

h. Strength calculation sheet including stressdiagram of gin pole/ boom derrick, guyropes and anchor points.

i. Orientation and position and strength oflifting lugs or lifting beam.

j. List of temporary equipment and tools to beprepared.

k. List of principle components of g inpole/boom derrick.

l. Transportation plans of gin pole/ boom der-rick construction equipment and specialvehicles.

m. Installation plan and progress schedule ofgin pole/boom derrick.

n. Electric power to be consumed during in-stallation.

5.0.0 CONSTRUCTION EQUIPMENT

5.1.0 HOISTING EQUIPMENT

5.1.1 Gin pole / Boom derrick

Select the gin pole/boom derrick according tothe shape, weight, and dimension of the equip-ment to be installed, and the surrounding con-dition. The gin pole/Boom derrick shall haveample height to lift the tallest equipment to beinstalled.

The mast base of the gin pole/boom derrick shallbe anchored securely. The erection plan of thegin pole/boom derrick shall be made by con-sidering the following:

1. Site of Gin Pole/Boom derrick.

Prior to starting the gin pole/boom derrick erec-tion, the soil condition shall be investigated anda temporary concrete foundation shall beprovided, if necessary.

2. Strength

The gin pole/boom derrick shall be of a designto withstand all loads of equipment weight,dynamic forces such as wind load, orearthquake load, etc.

The design of the gin pole/boom derrick shall bein accordance with the AISC specifications. Theloads shall not exceed the manufacturer’s ratingwith the recommended reeving.

3. Guy Rope

All guy ropes of the gin pole shall conform to thefollowing requirements:

a. The gin pole of the double mast type shallhave atleast eight guy ropes. For the singlepole type, six guy ropes shall be provided.If the gin pole of the double mast type is tobe used at an inclined position, at least twowire ropes shall be provided to limit the ginpole inclination. Preferably, the guy ropesshall be equally spaced around the mast.

b. All guy ropes shall be stretched to have auniform and ample slack. Guy ropes shallbe installed so as not to interfere with otherwork or traffic.

c. All guy ropes shall be fitted with a minimum

25ES201 / 94


ENGINEERINGSPECIFICATION ERECTION OF STATIC EQUIPMENT

PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: MAR ’94

PAGE 1 OF 5

iso2.sty

CONTENTS1.0.0 SCOPE

2.0.0 REFERENCES

3.0.0 GENERAL

4.0.0 PLANNING

5.0.0 CONSTRUCTION EQUIPMENT

6.0.0 INSTALLATION

7.0.0 ALIGNMENT

8.0.0 GROUTING

9.0.0 LOOSENING SLIDE END ANCHOR BOLT

10.0.0 INSPECTION RECORD

——————————————

of three cable clamps or equivalent at eachconnection to prevent slippage. Thediameter of the usable guy ropes shall notbe less than that specified in the installationplan. The safety factor of guy ropes shallcomply with ANSI B 30.6.

4. Anchor

Anchoring of winch, guy ropes etc. shall beaccomplished by installing deadmen unlessotherwise specified. Deadmen shall beplaced so as not to interfere with eqpt foun-dations, underground facilities & struc-tures.

5.1.2 Winch

1. The winch shall be located so that it doesnot obstruct passage of equipment norprevent the operator from observing thesignalman.

2. Anchors to the winch shall be provided towithstand the maximum force working onthe winch. Brakes and clutches shall beprotected from the weather so that a suddenrain fall, during lifting, shall not cause theload to slip or drop.

5.1.3 Mobile crane

1. All mobile crane operators shall be qualifiedby governmental or other equivalentauthorities.

A set of the manufacturer’s lift tables shallbe placed conspicuously in the mobilecrane operator’s cab at the job- site. Thecapacities given shall be adhered to strictly.Additional boom sections installed on theequipment shall be compensated by addi-tional counterweights in accordance withthe instruction manual. Timber mats and/orsteel mats shall be provided for treads ortires considering the soil bear ing. Basically,outriggers and jacks shall be provided onthe mobile crane to guard it against suddentire failures and overturning while liftingheavy equipment.

2. All cranes shall be inspected in accordancewith ANSI B 30.5 . When a risky condition isfound, appropriate measures shall be takenimmediately.

Major items of inspection shall be as follows:

a. All control mechanisms as to maladjust-ment.

b. All control mechanisms as to excessivewear of components and contamination bylubricants or other foreign matter.

c. All control mechanisms as to malfunction.

d. Deterioration or leakage in air or hydraulicsystems.

e. Electrical apparatus as to malfunctions andsignals.

f. Crane hooks with deformations or cracks.

g. Deformed, cracked, or corroded membersin the crane structure and boom..

h. Rope reeving as to noncompliance.

i. Ropes.

5.2.0 WIRE ROPE, SLINGS, CHAINS AND FIT-TINGS

1. Wire Rope

Wire ropes shall be of suitable size, grade andconstruction to withstand the maximum loadimposed.

Wire ropes in the main hoisting system shall beof ample length for the entire range of movementspecified with at least two full wraps of the ropeon the hoist drum at all times.

Wire ropes shall be inspected in accordancewith ANSI B 30.6.

When any of the risky conditions listed below isfound, the wire rope shall be removed from thesling service and appropriate measures shall betaken to improve the condition.

a. In running ropes, six randomly distributedbroken wires in one rope lay, or three brokenwires in one strand in one rope lay.

b. Wear of one-third of the original diameter ofthe outside individual wires.

c. Linking, crushing, bird caging or any otherdamage resulting in distortion of the ropestructure.

d. Evidence of any heat damage from anycause.

e. Reductions from nominal diameter of ropeexceeding:

3/64 inch for diameters upto 3/4 inch in-clusive.

1/16 inch for diameters 7/8 inch to 1-1/8inches inclusive.

3/32 inch for diameters 1-1/4 inches to 1-1/2inches inclusive.

f. In standing ropes, more than two brokenwires in one lay in sections beyond the endconnection or more than one broke wire atan end connection.

2. Wire Rope and Sling

Wire rope slings shall comply with ANSI B30.9.

The safety factor for wire rope slings of allgrades shall be not less than five.

3. Chain

All chains shall be forged or electric weldedsteel link type of the proper size for the loadsto be lifted.

Overloaded chains shall be discarded im-mediately.

4. Drum, Pulley and Sheave

The diameter of the drum or pulley shall benot less than 20 times the rope diameter.The diameter of sheaves shall be not lessthan 10 times the rope diameter.

5. Fitting

All hooks, swivel hooks, anchor shackles,swivel sockets, safety hooks, cable clamps,turnbuckles, and other attach ments shallbe made of drop forged steel.

6. Safety Factor

25ES201 / 94



PAGE 2 OF 5

TABLE - 1

ITEMMIN.

SAFETYFACTOR

Hoist Rope3.5Hoist Rope for Raising and

Falling Boom

Wire Rope for SupportingBoom

3Wire Rope for Turning

Wire Rope or Guy Ropefor Tension

Wire Rope for Sling 5

6.0.0 INSTALLATION

6.1.0 ERECTION OF GIN POLE/BOOM DERRICK

6.1.1 Inspection of gin pole components

Prior to erecting the gin pole/boom derrick allwinches, hooks, shackles, thimbles, wires,chains, etc., shall be inspected thoroughly as tomaterial, capacity, wear and tear.

6.1.2 Grounding

The gin pole/boom derrick shall be equippedwith grounding. Resistance of grounding shallbe under 10 ohms.

6.1.3 Assembly and disassembly

The following precautions shall be taken in theassembly and disassembly of the gin pole.

1. During the assembly and disassemblyoperation of the gin pole/boom derrick onlypersons to be engaged directly in the workshall be admitted into the work area.

2. Only qualified operators for hoisting andslinging shall be assigned and a list of suchoperators shall be prepared and filled.

6.1.4 Inspection after assembling

Immediately after assembly and prior to startingthe lifting of any equipment, the following partsof the gin pole/boom derrick shall be inspectedcarefully:

1. Gin pole/boom derrick members and con-nections thereof.

2. Anchor of winch.

3. Guy ropes as to number, tension and con-dition.

4. Wire ropes as to condition of wear anddamage.

5. Hook, shackle, thimble and other hangingimplements as to conditions of wear anddamage.

6. All control mechanisms and other safetydevices.

7. Electrical apparatus and controls of winch.

6.1.5 Preventing accidents by guy rope

For preventing accidents, all guy ropes shall beattached with red flags so that they will berecognizable from a distance.

6.2.0 PREPARATION OF SHIMS AND WEDGE

6.2.1 Shims & wedges shall be made of carbon steel.

6.2.2 In general shims & wedges shall be prepared bymachining or grinding as indicated in Table 2.

TABLE - 2

ITEM LENGTHmm

WIDTHmm

THICK mm SLOPE

Shim 100-450 50-200 3.2,4.5,9,12,19,25 —

Wedge 100-450 50-200 6,9,12,16,19,25 (max.) 4o-5o

6.3.0 INSTALLATION OF EQUIPMENT

6.3.1 Inspection before installation

1. Prior to commencing the installation work,any damage during the transportation, theorientation of the equipment, the center ofgravity, base level from the datum line of thefoundation, the condition of the slings andlifting lugs, and the condition of the anchorbolts etc., shall be inspected thoroughly.

2. The function of brakes, clutches, othersafety devices and controls of the winchshall be inspected.

3. To prevent overloading, any test water orother temporary materials remaining or leftin the equipment shall be drained orremoved.

4. The bottom face of the equipment baseplate shall be cleaned.

5. The concrete surface of the foundation shallbe thoroughly chipped and then be cleanedcompletely with compressed air, etc.

6. The required number of shims and wedgeswith the necessary tools shall be preparedto ready use.

6.3.2 Precautions against storm

1. When the wind velocity exceeds 15m/sec.all installa tion work shall be stopped.

2. No equipment shall be installed under stor-my winds, heavy rain or heavy snow.

6.3.3 Special crew

1. During heavy equipment installation, espe-cially installation by the gin pole/boom der-rick a special crew shall be organized.

2. The crew shall comprises a general super-visor, signal/flag man, hoist operator, craneoperator, rigger, safety supervisor, etc.

3. The function of each individual of the crewshall be clearly defined.

6.3.4 Installation

1. Heavy equipment shall tentatively be lifted,slightly, to examine all parts of the ginpole/boom derrick, crane, wire ropes, tools,etc. If any defect is found, the equipment tobe installed, shall be lowered on the ground.After the defect is corrected, the equipmentshall be lifted slowly.

2. Crane work shall not be suspended atdangerous and incomplete positions duringthe lifting operation.

25ES201 / 94



PAGE 3 OF 5

3. The protective cover on equipment for noz-zles and flanges shall not be removedwithout the approval of the Engineer-in-charge.

4. During installation work, special care shallbe taken so as not to damage the anchorbolts or their threads.

5. While seating and leveling, use shims andpairs of wedges.

6. As a rule, shims and wedges shall be placedon liner plates fixed on the concrete founda-tion at both sides of the anchor bolts, andleveling shall be done temporarily. Wherethe distance between anchor bolts is largerthan 800mm, extra shims and wedges shallbe located between the anchor bolts toprevent the base plate from bending.Wedges or shims shall not be substitutedwith wooden strips, bricks concrete blocks,etc.

7. After leveling is finished and all anchor boltsare firmly tightened, all shims and wedgesto remain in place shall be tack-welded toprevent them from becoming loose.

8. As a rule, welded lifting lugs used in theinstallation shall be left in place.

7.0.0 ALIGNMENT

7.1.0 GENERAL

7.1.1 All installed equipment shall be aligned plumb-ness or level.

7.1.2 Towers/vertical vessels shall be aligned plumb-ness and satisfy the requirements of Par. 7.2.0

7.1.3 Horizontal vessels & heat exchangers shall bealigned level and satisfy the requirements ofPar.7.3.0

7.2.0 PLUMBNESS

1. Plumbness shall be checked by viewingfrom two directions 90o apart with a transit.Check of plumbness of very tall equipmentshall be done early in the morning.

2. Out-of-plumb of the equipment installedshall not exceed 1.0mm per lm of height ora total of 25mm for the entire height,whichever is smaller, unless otherwisespecified in the job Specification.

3. After alignment is finished and the lock nutsof the anchor bolts are tightened firmly, theshims and wedges shall be tack-welded toeach other and any excess in the shims andwedges shall be cut off with gas cutter.

7.3.0 LEVELING

1. The alignment level shall be made using aspirit level instrument or a transit at fourpoints based on the center line marked onthe equipment in the shop. The level shallbe aligned in the direction of AB or CD andAC or BD at the center line on the equip-ment. ( Refer to Fig. on Page 5 of 5 )

2. The maximum tolerance shall be as shownin Table 3, unless otherwise specified.

TABLE - 3

POINT TOLERANCE

A and B or C and D l mm per Meter of Length

A and C or B and D 2 mm Max.

3. Considering the drain-out during main-tenance, the channel end of the heat ex-changer shall be lowered 1 to 2mm/m thanthe shell cover end.

4. After leveling is finished and the lock nuts ofthe anchor bolts are tightened firmly, theshims and wedges shall be tack-welded toeach other and any excess in the shims andwedges shall be cut off with a gas cutter.

8.0.0 GROUTING

Grouting shall be accomplished in accordancewith the fol lowing requirements, unless other-wise specified.

8.1.0 PREPARATION FOR GROUTING

1. The foundation surface shall be cleanedthoroughly and be removed of any dirt or oilyspots.

2. The top surface of the foundation shall bewetted thoroughly with fresh water prior togrouting.

8.2.0 MATERIAL

1. Portland cement mortar may be used ingrouting under the base plates, unlessotherwise specified.

2. The mixing ratio of portland cement andclean fine sand shall be approx. 1:2 involume, and the ratio of water to cementshall be less than 40 percent in volumeunless other wise specified.

8.3.0 GROUTING PROCEDURE

1. The base plate shall be grouted as follows:

a. The space under the base plate shall bepacked full with grout.

b. The grout shall cover all shims and wedges.

2. After the grouting mortar has been pouredfully, the excess grout shall be trimmedaway. The surface of the mortar outside ofthe base plate shall be finished smoothly.

3. The shims and wedges shall not beremoved, unless otherwise specified.

9.0.0 LOOSENING SLIDE END ANCHOR BOLT

1. After grouting has set and hardened, thenuts of the sliding end anchor bolts shall beloosened to allow for thermal expansion.

2. The above requirement shall be applied tohorizontal vessels, shell and tube heat ex-changers, and when requested by the En-gineer- in - charge

10.0.0 INSPECTION RECORD

The results of the following inspections shall berecorded and submitted.

1. Alignment

a. Plumbness

b. Leveling

25ES201 / 94



PAGE 4 OF 5

25ES201 / 94 ENGINEERING SPECIFICATION ERECTION OF STATIC EQUIPMENT

PAGE 5 OF 5


00FT001

LEVELLING POINTS FOR HORIZONTAL EQUIPMENT

X

A B

C D X

PLAN SCALE A C B D VIEW X – X LEVEL INSTRUMENT

1.0.0 SCOPE

1.1.0 This specification covers the general require-ments for the erection, alignment and groutingof machinery.

1.2.0 For specific machineries, the requirements ofthe manufacturers installation manuals shallapply in addition to all non-conflicting require-ments of this specification.

2.0.0 INSPECTION AND STORAGE

2.1.0 On receipt of machinery at site, it should bechecked for completeness against the packinglist and the purchase order specifications. Spe-cial care must be taken to see that the looselypacked items such as foundation bolts, cou-plings with bolts and nuts, belts, auxillary piping,all spares items including spares requiredduring erection, special tools, coupling guard,hold down bolts, eye bolts, etc. have been sup-plied with the unit.

2.2.0 The Engineer in charge shall also determinewhether any damage has occured to the equip-ment during transit.

2.3.0 The equipment with all the loosely packed itemsand spare parts shall be tagged and storedunder covered storage place, to protect theequipment from weather and other forms ofabuse.

2.4.0 The tags on equipment shall indicate the follow-ing details:

a. Equipment No. & Description.

b. Plant and Location of Erection.

c. P.O. Ref.

d. Date of receipt & inspection at site.

2.5.0 The equipments are to be stored separatelyplant wise to facilitate easy location and iden-tification during erection.

2.6.0 Should the equipment be not installed immedi-ately after delivery, the closest adherence to thefollowing in structions is strongly recommended.

2.6.1 The base plate to rest fully on a flat surface andnot just partially.

2.6.2 The components not to be stacked one upon theother.

2.6.3 All components and the equipment to be storedin a dry clean place.

2.6.4 All machined parts, likely to corrode, either in-side or outside, to be protected by suitableinhibitors (grease or rust preventive compound).

2.6.5 All lids and covers to be closed to prevent dustor foreign matters from entering the equipment.

2.6.6 Bearings and motors shall be kept in indoorinstallations.

2.7.1 In rotating machinery, rotate the shaft weekly tocoat the bearings and shaft surfaces withlubricant and to retard oxidation and corrosion.

2.7.2 Some vendors may provide lock nuts to preventthe rotating parts from revolving during transitand handling. In such cases ensure appropriatecoating method is done as per 2.6.4 above.

3.0.0 HANDLING

3.1.0 When handling the equipment, care must betaken to avoid supporting or lifting in a mannerthat would place excessive stress on parts orshaft extensions that are not designed to sup-port the weight of the unit. Lifting hooks, Eye-bolts, etc. if provided, should be used for lifting.Strings/wire ropes are to put through the por-tions of the equipment marked/recommendedby the manufacturer of the equipment.

3.2.0 All equipments are normally balanced at shopand sent to site. If the rotator shaft and rotatoris damaged in anyway during handling it maycause an out of balance condition, which wouldrequire rebalancing or replacement of shaft.

4.0.0 ERECTION

4.1.0 Well before preparing for erection of the equip-ment ensure that the details of the equipmentnozzle dimensions and locations, couplings,base plate, anchor bolts dimension and loca-tions, direction of rotation of drive and drivenunits, details of key and key way as per therelevant drawings.

4.2.0 Prepare an outline sketch of the equipment,which shall be used as ready reference sheet,marking the design requirements such as co-or-dinates of the equipment centre lines, P.O.S.elevations, critical nozzle elevation, distancebetween shaft ends, minimum projection re-quired for the anchor bolts from P.O.S. eleva-tion, location and dimensions of anchor bolts,grouting clearance, etc.

4.3.0 With the above details check the equipment andthe respective foundation to take remedial ac-tions for any discrepancy noted if it is beyondacceptable limits.

4.4.0 The foundation block shall be made ready inadvance, with regard to the date of erection ofthe equipment so as to permit the same suitablyset.

4.5.0 Before shifting the equipment to position thelocation of foundations, bolt holes, etc. shall beinspected the cross checked with the equipmentto be erected. Any mistake noticed is to berectified before erection.

4.6.0 Before placing the equipment on the foundationroughen and clean the top of the foundation toremove oil, grease, dirt and any loose particles.Clean out care fully by compressed air hose thefoundation bolt-holes.

4.7.0 The top of the foundation shall be placed 25 to

25ES202 / 94


ENGINEERINGSPECIFICATION ERECTION-ALIGNMENT AND GROUTING OF

MACHINERY ITEMS

PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: MAR ’94

PAGE 1 OF 3

iso2.sty

CONTENTS1.0.0 SCOPE

2.0.0 INSPECTION AND STORAGE

3.0.0 HANDLING

4.0.0 ERECTION

5.0.0 GROUTING

6.0.0 ALIGNMENT

—————————————-

50 mm below the final level of the equipment.

4.8.0 Mark the centre-line of the equipment both onthe foundation and on the equipment.

4.9.0 Lift the equipment and place it on the foundationwith the foundation bolts in position.

4.10.0 Proper equipment and tools for lifting, levelingand alignment should be made ready beforeputting the machine over the foundation.

4.11.0 The equipment shall rest on steel packingplates.Packing plates shall be placed very closeto the foundation bolts and on either sides of allthe foundation bolts. If the distance betweenanchor bolts are more than 800mm, additionalpacking plates shall be provided in between.

4.12.0 Level and align the equipment base frame withutmost care using spirit levels or master level,depending on the precision required. Highspeed and high torque machinery shall bealigned with special care. The tolerances onalignment shall be maintained as per the instal-lation manual furnished by the equipment supplier.

Note: Small equipments like centrifugal pumpsetc. are aligned and assembled on the baseframe at the shop. In these cases the equip-ments are directly erected on the foundation inthe assembled form.

4.13.0 The foundation surface will support the equip-ment with the packing plates under the baseframe. The foundation should be smooth andlevel at these points to distribute the load evenlyon the foundation through packing plates. A thinmetal plate leveled in a puddle of grout is theeasiest way to achieve this level and smoothsurface.

4.14.0 Always use thick shims wherever possible toavoid spongy shim base.

4.15.0 Adjust shims under base plate until the baseframe/equipment is level. The space betweenthe base frame and foundation shall be 25 mmto 50 mm (or as per the instructions given in themanufacturer’s manual).

4.16.0 For leveling the equipment use machined truesurface viz. pump flange, coupling face, shaftsurface, etc.

4.17.0 After checking the level, the equipment is to beimme diately grouted - grouting shall be done asper 5.0.0

5.0.0 GROUTING

5.1.0 Grout compensates for unevenness in the foun-dation and base frame and distributes theweight of the unit uniformly over the foundation.It is preferable that the unit be expertly groutedwith a non shrinking grout.

5.2.0 Saturate with water the top surface of the foun-dation and the foundation bolt holes. Wettingwith water should be done at least six hours priorto grouting.

Remove excess water with air hose or ragebefore pouring grout.

5.3.0 The grout mixture must be sufficiently fluid at thesame time shrinkage must be minimum. Use agrout with lower water content and which can

be operated easily on the narrow space underthe base frame. The grout prepared must floweasily.

5.4.0 Normal grouting mixture comprises of one partof port land cement and one part of clean finesharp sand mixed in adequate quantity of water.

5.5.0 To avoid shrinkage of grout during setting anynon shrinking compound can be added to groutmixture as additive.

5.6.0 During grouting of large base frames there is apossi bility of air trapping, which can be avoidedby temporarily introducing thick walled rubbertubes to provide venting. Remove the tubesafter the grout has filled all the cavities beforepouring the remainder.

5.7.0 The grout should be poured quickly and con-tinuously to prevent unequal setting of grout.

5.8.0 It is preferable to shut down other machinesnear the equipment which is being erected, asthe vibration of running machineries will havedamaging effect on the grouting and alignmentof the new machine.

5.9.0 The frame work for grout should be built to sucha height that on setting the top of the grout isapproximately 15mm above the bottom of thebase plate.

6.0.0 ALIGNMENT

6.1.0 When the grouting is set, the holding down boltshould be gently but firmly tightened. Greatcare must be taken not to spring the bed plateby excessive tightening. Check the level again.

6.2.0 Eventhough it is normal that small equipmentswill be aligned in the factory itself, it is mandatorythat the unit be field aligned since any base platecan be warped in and when installed on founda-tion.

6.3.0 The driven unit viz. pump, blower, compressoretc. is assembled and levelled on the baseframe already grouted.

6.4.0 Then the drive unit is bolted on the base frame,the clearance between couplings shall be set asper the manufacturers’ directive using feelergauge and the unit be aligned.

6.5.0 Preliminary coupling alignment may be doneusing straight edge and feeler gauge. Theparallelism (angular alignment) and intersectionof axes (shafts in line at the coupling ends) canbe checked accurately using dial gauge. Forusing dial gauges it is essential that both drivingand driven shafts rotate together. This cangenerally be accomplished by linking the cou-plings of the driving and driven units by at leastone coupling pin. Alternatively where free move-ment between two half couplings are difficult theabove alignment can be checked by rotating thehalf-drive coupling keeping the magnetic baseof the dial gauge on the drive coupling, but therim of the machine coupling should be markedat intervals of 90o and readings taken only whenthe mark are in line.

6.6.0 Alignment is to be done using minimum dial-gauges or with any suitable instruments avail-able. Radial and axil alignment shall be checkedsimultaneously using two dial gauges.

25ES202 / 94



MACHINERY ITEMS PAGE 2 OF 3

6.7.0 TOLERANCES

It is difficult to lay down limits of accuracy withinwhich adjustments should be made because ofthe differences in the size and speed of units,but as a rough guidance, the following variationsin the dial gauge readings can be tolerated.

For angular alignment

Couplings upto 12" dia : 0.002"

Couplings over 12" dia : 0.003"

For radial alignment readings more than 0.004"(i.e. 0.002" eccentricity) call for adjustment.

The above figure are suggested for speeds upto1500 rpm. For speeds of 3000 rpm or over agreater degree of accuracy should be observed.

6.8.0 ALIGNMENT OF BELT DRIVE

6.8.1 For belt driven equipment, the drive motors aregenerally mounted on independent slide rails.After final levelling and grouting of the drivenequipment the slide rails are placed on steelshims over the motor foundation.

6.8.2 The motor belts sheave is assembled on themotor shaft by using tapered bushing and capscrews. Do not lubricate the cap screws.

6.8.3 The motor is placed on the slide rails nearer tothe equipment side. The alignment of the drivenunit sheave with the motor shaft sheave ischecked by placing a straight edge or stringacross both sheave faces. Adjustments if any,may be done by moving the motor rails.

6.8.4 The foundation bolts of the slide rails aregrouted.

6.8.5 The slides are also grouted after checking thelevelling.

6.8.6 After setting of foundation bolts grouting as wellas side rails grouting, move the motor towardsthe driven unit as far as the slide base will permit.

6.8.7 Install the belts in sheave grooves without forc-ing them. Do not pry the belts over the sheaverims with a screw driver or similar tool as this willdamage the belts and greatly reduce belt ser-vice life.

6.8.8 With the belts in the grooves, reposition themotor to take up the slack until the belts are fairlytight.

6.9.0 BELT TENSION

6.9.1 Start the drive motor, and continue to adjust thebelt tension until the belts have only a slight’bow’ in the slack side of the drive while operat-ing underload.

6.9.2 After a few days of operation, the belts will seatthemselves in the sheave grooves and it maybecome necessary to readjust them so that thedrive once again shows a slight “bow” in theslack side.

6.9.3 The drive is now properly tensioned and shouldoperate satisfactorily with only an occasionalreadjustment to compensate for normal belt andsheave groove wear.

25ES202 / 94



MACHINERY ITEMS PAGE 3 OF 3

—————————————————————-

X

4

5

8

9

10

11

12

13

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


Rev DATE PRPD. CHKD. APPRD.

0 16.11.09 KK CRP JKVENDOR

HPCL

1 P.O No.

2

PROJECT

3

4

CLIENT

LPG BLENDING FACILITY

PLANT AT MANGALORE

End connection of landing valve shall be 80 NB flange drilled to suit ANSI B 16.5

Note:

Blind cap with chain required (brass)

14.0 Certification ISI marking

13.0 Accessories

Coupling Instantaneous female

Landing valve body

Landing valve disc Gun mettal

Material of construction

Gun mettal

CSStand pipe

11.0

16

10.0 Pressure Kg/cm2G 7 operating / 15 design

9.0 Flow rate lpm 900

14

8.0 Landing valve size mm 63 female instantaneous 15

Dimensions ANSI B16.5 150#

Flanged

Size 80 NB

Type

6.0 Hydrant size mm 63

7.0 Connection

4.0 No. off 1

5.0 Codes / Standards IS 5290 : 1993 Type A

7

1.0 Make

2.0 Model 6

3

FIRE HYDRANT ASSEMBLY

1

Site : MANGALORE Job No : 8122 2

LPG BLENDING FACILITY Item No. :

1


FIRE HYDRANT SYSTEM8122-01-DA FH100

DATA SHEET

PAGE 1 OF

Unit :

3.0 Type Single Hydrant

X

4

5

8

9

10

11

12

13

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

50

51

52

53

54

55


49

Capacity

No. off

required

10.0 Hose station N/A

Stand with foundation bolts

Keys required

Couplings

Hose reels 16

14

9.0 Accessories 15

8.0 Material of construction MS galvanised and painted

Thickness mm 20 guage

Capacity To hold 1 no 15 M long hoses with branch pipes,

nozzles & couplings

5.0 Codes / Standards

6.0 Dimensions mm 30" x 10" x 24" (Height 24")

7

4.0 No. off 1

3.0 Type Stand mounted type, glass fronted

6

3

HOSE BOX

1

Site : MANGALORE Job No : 8122 2


Purchase As built TPS No. :

Item No. :

8122-01-DA FH103DATA SHEET

PAGE 1 OF 1

Applicable to : Proposal

7.0

FIRE HYDRANT SYSTEM

Unit :

1.0 Make

2.0 Model

X

4

5

8

9

10

11

12

13

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

50

51

52

53

54

55


49

Dimensional check and performance test shall be

done on 10 % of nozzles selected at random

Spanner required

Half coupling required

10.0 Cone angle deg.

11.0 Acessories

14

8.0 Orifice size mm 15

9.0 Connection size Threaded Suitable for 15 mm, IS 554 16

7.0 Flow rate lpm

K factor

Spray nozzle Marine Bronze

Half coupling A 105 galvanized

5.0 Codes / Standards FM / UL / NFPA

6.0 Material of construction

6

3.0 Type Medium velocity spray nozzles - pendant type 7

4.0 No. off 11

1.0 Make

2.0 Model

FIRE HYDRANT SYSTEM8122-01-DA FH102

MANGALORE Job No : 8122

Unit : LPG BLENDING FACILITY Item No. :

DATA SHEET

PAGE 1 OF

3

SPRAY NOZZLE

1

Site : 2

1


X

4

5

8

9

10

11

12

13

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

Size

Dimensions

Accessories

Valve body

Valve internals

Valve disc

Codes / Standards

Valve size

Connection

Type

Make

Model

Type

Flanged

mm

No. off

As per B16.5, Class 150. FF

50

12

50NB

A105, galvanised, threaded

01F

T074C

/94

LPG BLENDING FACILITYPROJECT

HPCL

kk

APPRD.VENDOR

P.O No.

crp jk20.11.090

1


CHKD.PRPD.DATERev

CLIENT

3

2

4

TPS No. :Applicable to : As builtProposal Purchase

DATA SHEET FIRE HYDRANT SYSTEM8122-01-DA-FH 104

1 OF 1PAGE

2

1

8122

3


HPCL, MANGALORE

7

6

14

Site :

Unit :

Job No :

Item No. :

DELUGE VALVE SYSTEM

2

ALUMINIUM BRONZE

Bronze

Bronze

ALUMINIUM BRONZE

ALUMINIUM BRONZE

10.0 Pressure

Material of construction11.0

Kg/cm2G

1.0

2.0

3.0

4.0

5.0

6.0

7.0

13.0

Pressure gauges

Actuation piping

Isolation valves

Bypass valve

Mating flages & pipe fittings

Solinoid valve

Pressure switch

Page 1 of 6

0 23.11.09 First issue KK CRP JK

REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

Page 1 of 7 R0

8122-01-PS-002 DV ENGINEERING

SPECIFICATION


00

FT

02

1A

/94

STANDARD SPECIFICATION FOR

DELUGE VALVE

2 of 7 R0

8112-01-PS-002 DV TECHNICAL

PROCUREMENT

SPECIFICATION

SPECIAL REQUIREMENT OF THE PROJECT


00

FT

02

1B

/94

CONTENTS

1. SCOPE

2. CODES AND STANDARD

3. DESIGN REQUIREMENTS

4. MATERIAL OF CONSTRUCTION

5. CONSTRUCTION AND PERFORMANCE

6. INSPECTION AND MARKING

7. INFORMATION REQUIRED FROM VENDOR

ANNEXURE - 1

P&ID OF DELUGE VALVE (HYDRAULIC DETECTION SYSTEM)

3 of 7 R0


PROCUREMENT

SPECIFICATION



00

FT

02

1B

/94

1. SCOPE

This specified describes design requirements, material of construction and performance of automatic deluge valve for fire water distribution.

2.0 CODES AND STANDARDS

1. NEPA Codes 2. Rules for Water Spray System (BY TAC) 3. Indian Standard Specifications

3.0 DESIGN REQUIREMENTS 3.1 An automatic deluge valve shall consist of following:

1. Deluge valve unit 2. Diaphragm unit 3. Integral test and drain valve manifold 4. Alarm system 5. Priming equipment 6. Installation stop valve with pressure gauge and outlet valve 7. By pass ball valve 8. Detector pipe work manifold

3.2 Size and capacity of deluge valve shall be as under: Size (Inch(mm) Rated Flow(lpm) Working Pressure(kg/cm2g) 2(50) 7.0 to 10.5

3(80) 1150 7.0 to 10.5 4(100) 5000 7.0 to 10.5 6(150) 13500 7.0 to 10.5 8(200) 18500 7.0 to 10.5 3.3 The deluge valve shall be provided with solenoid operated water release valve for remote

operation in addition to automatic operation of deluge valve. 3.0 MATERIAL OF CONSTRUCTION 4.1 For non saline water service

Body Cast iron to IS 210 Gr. FG 200 Seat Bronze Clack Graphite iron Diaphragm spindle and hinged pin SS 304 Test and drain valve, )

4 of 7 R0


PROCUREMENT

SPECIFICATION



00

FT

02

1B

/94

Installation stop valve , ) Outlet valve and ) Cast steel (A53A spec) Check valve )

4.2 For saline water service aluminum bronze in place of cast iron and cast steel shall be used. 5.0 CONSTRUCTION AND PERFORMANCE 5.1 The deluge valve unit shall be provided with a clack to keep the valve close through a

diaphragm unit. 5.2 The deluge valve shall also be fitted with an integral test and drain manifold. It shall

consist of 50mm test and drain valve, body drain valve and a drip plug. 5.3 The test valve shall allow water to flow through the deluge valve to drain during testing of

deluge valve and to drain water from distribution pipe after fire. At open position the valve clack shall be held against its seating by an internal compression spring of sufficient strength to keep it in closed position till the pressure acting on underside of it does not exceed approx. 0.3 kg/cm2. The clack will open at pressure exceeding 0.3 kg/cm2.

5.4 The drain valve shall drain all the water from the deluge valve body and the outlet

connection during maintenance of the deluge valve. The drain pipe work is to be designed to periodically check the rate of flow available in the system to satisfy the requirements appropriate to the hazard class for which the deluge valve is provided. Flow measurement shall be checked with differential pressure.

Water operated alarm motor gang shall be connected to the test and drain valve so that it gives an alarm as the deluge valve opens.

5.5 On detector pipe work manifold, test valve shall be provided at one end while on supply pipe pressure control regulator with by pass, isolation valve, check valve, strainer and restricted orifice shall be provided. Both detector pipe work and supply line shall be terminated with flanged ends. Piping shall be GI conforming to specification BIS. In case of hydraulic detector network, tapping from existing fire water network on U/S of deluge shall be taken by the vendor.

5.6 In addition to above an electric pressure switch shall be provided to give alarm at “Low

pressure”. Low pressure alarm shall be set at 1.7kg/cm2.

Provision of changing the set pressure of both the alarms shall also be provided. The alarm switch(s) shall thus activate at low pressure of 1.7 kg/cm2 and with alarm to initiate warning of fire. Vendor shall confirm the set pressure based on inlet water supply pressure. For remote operation of the deluge valve, solenoid operated valve shall be provided.

5 of 7 R0


PROCUREMENT

SPECIFICATION



00

FT

02

1B

/94

When deluge valve is located in an hazardous area, SOV and alarm switches shall be explosion proof/intrinsically safe and suitably for hazardous area.

5.7 Installation stop valve and outlet valve above deluge valve shall be as per piping

specifications described above. In addition following provisions shall be made.

Valve must be strapped (not chained) end padlocked in open position a all normal times. 5.8 The deluge valve shall be tested for operation/opening at set pressure and operation of the

alarms at set pressure. 5.9 For testing and setting of deluge valve a priming valve and a vent valve shall be provided

with deluge valve assembly. At all normal times, and when testing the deluge valve according to various tests required, the body of the deluge valve shall remain full of water.

5.10 Pressure gauge shall be fitted immediately above the deluge valve on water supply line.

Another pressure gauge shall be provided on detector pipe work manifold.

Pressure gauges shall be bourden type and shall be weather proof to NEMA-4. Vendor shall specify the range of pressure gauge and also submit detailed specification / data sheet of the instrument.

5.11 The complete valve assembly shall be of good workmanship and finish and free from burrs

and sharp edges. All waterways shall have smooth finish. 5.12 The deluge valve shall be tested for a test pressure of 18kg/cm2g. 6.0 INSPECTION AND MARKING

6.1 HPCL or its authorised representatives shall have access at all reasonable times to the

manufacturer’s work where the deluge valve assembly are being manufactured or being tested.

6.2 Deluge valve assembly shall be clearly and permanently marked with the purchaser’s name,

design and test pressure. 7.0 INFORMATION REQUIRED FROM VENDOR 7.1 The vendor shall furnish the following information along with the offer and for approval

prior to fabrication.

- P&ID of deluge valve - General arrangement of deluge valve assembly and elevation - Constructional features of deluge valve assembly - Initial setting procedure of deluge valve - Automatic and manual operational procedures

6 of 7 R0


PROCUREMENT

SPECIFICATION



00

FT

02

1B

/94

- Periodic testing and safety procedures 7.2 Following information shall be furnished by the vendor along with the supply of the deluge

valve. 7.2.1 Instruction book(s) for the guidance of the user including both the operating and normal

maintenance procedures. The book(s) shall include an itemized and illustrated part list / spare parts list giving reference no. of all the wearing parts.

7.2.2 Duly approved final drawings listed in Clause 7.1.

FOR TENDER PURPOSE ONLY










REF DRAWINGS

FLOW SHEET REF.

INSULATION

FACT ENGINEERING & DESIGN ORGANISATIONNOTES


REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



REF DRAWINGS

FLOW SHEET REF.

INSULATION



R 0 Sl. No. Unit Quantity

(1) (3) (4) Fig.

03FT

067B

/ 96

Project - LPG Blending facilities

FACT ENGINEERING AND DESIGN ORGANISATIONPrepAred - GSP Checked - KAK Approved - KAK 15.10.09

The pay quantity shall be the actual centreline length in metres of straight or fabricated pipeincluding valves, etc. actually installed as required. Payment for the work done will be made onlywhen the piping is properly located and permanently supported in its final position in the field afterhydrotesting.This rate does not cover radiography/UT/MP/DP tests,which shall be paid as per item D

All the CS pipes, fittings etc shall be painted with 1 coat of 'Two pack poly urethane holding primer’ as per 02ES023/97 after surface cleaning by mechanical means

The scope of work under this item includes transportation of all piping items from storage point,handling, cleaning, welding, fabrication, erection, painting, testing and commissioning of aboveground piping as per the drawings and specifications.All activities associated with making weld joints such as cleaning, marking out, cutting , profiling,bevelling, grinding, aligning, fitting up, tack welding, chipping, preheating, placing of windshields/weather protection and final welding together with any special wlelding requirement areincluded in the scope.

All the works required for the proper installation, at all elevations, of piping with attached fittingsand valves, handling, rigging, scaffolding, placing and alignment of pipes and fittings to theirrespective positions and on to their respective supports, fabrication and erection of trunnionsupports, pad at supports are also included in this item. Hydraulic testing of the pipingsystems, flushing, draining and drying up also included in this.

Installation of all types of valves, control valves, safety valves, Y strainers, static mixure, orifice plates and assembling of flanged joints are also included in the rate. The contractor shall ensure the initial satisfactory operation of the valves. Cleaning of flange faces, insertion of gaskets, bolts etc, aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also included

A FABRICATION AND INSTALLATION OF PIPING

Description of item Amount Rs. (2) Words (6)

Rate Rs. (5)

PIPING SCHEDULE OF ITEMS OF WORK 8122 - 03 - SW - 001DEPARTMENT PAGE 1 OF 10

R 0Sl. No. Unit Quantity

(1) (3) (4) Fig.A.1

1 20NB SCH160 M 2

2 25 NB SCH 80 6

3 40NB SCH 80 2

4 50 NB SCH 40 6

5 100 NB SCH 40 6

6 250 NB SCH 40 6

7 300 NB SCH 40 235

A.2

1 20NB SCH160 M 2

2 40NB SCH 80 2

3 150NB SCH 40 12

4 200 NB SCH 40 200

5 250 NB SCH 40 200

6 300 NB SCH 40 24

A.3

1 25 NB PN 10 M 1

2 40 NB PN 10 1

3 50 NB PN 10 2

4 100 NB PN 10 1

5 150 NB PN 10 18

6 200 NB PN 10 3

7 250NB PN 10 3

PIPING SCHEDULE OF ITEMS OF WORK 8122-03-SW-001DEPARTMENT PAGE 2 OF 10

(6)Rate Rs. (5)Description of item Amount Rs.

(2) WordsCARBON STEEL, ASTM A 106 GR B

Total / Sub-total


LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6

GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION


(1) (3) (4) Fig.A.3 C/O8 300 NB PN 10 M 3

9 400NB PN 10 194

10 450 NB PN 10 1

11 500 NB PN 10 1

A.4

1 100 NB M 5

2 300NB 5

3 450NB 35

B

1 20NB 60 MM THICK M 4

2 25NB 60 MM THICK 9




GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION(6)

Rate Rs. (5)Description of item Amount Rs. (2) Words


CEMENT LINED PIPING

Supply and application of Pre formed PUF cold Insulation, over pipes, valves, flanges, specials as per specifications/standards/drawings and instruction from the site in charge. 12 mm concrete coating shall be provided over the insulation. All the materials, tools/tackles, scaffolding, transportation/handling, manpower etc. shall be arranged by the contractor. Measurements for the release of payment shall be as per IS 14164.

SUPPLY AND APPLICATION OF COLD INSULATION

Total / Sub-total


The rate shall also include making Tie in connections, galvanised fasteners, non metallic gaskets, sleeves, sand, cement, reinforcement etc


(1) (3) (4) Fig.B C/O6 150NB 60 MM THICK M 12


8 200NB 90 MM THICK 195

9 250NB 60 MM THICK 195

10 300NB 60 MM THICK 250

C

LS 1

D RADIOGRAPHY / DYE PENETRANT TESTS.

1 CMS 27000

2 CMS 700DP InspectionTotal / Sub-total


Radiographic, UT/ DP / MP inspection of the weld joints shall be conducted as per thecode, specs., drgs. and instructions of the Engineer-in-charge. The rate quoted shall beinclusive of all operations necessary to fulfill the work of radiography ( X ray / Gammaray ), DP / MP tests including all tools / tackles, films, chemicals etc. complete. Aftertesting, if any joint is found defective, the same shall be rectified and re-tested free ofcost. The pay quantity shall be linear centimeters of weld successfully passed. Penaltyshots shall not be counted for payment.Radiographic/ UltrasonicInspection

TIE IN CONNECTIONS

All activities required for taking two tappings from the existing header at Terminal and shall include all safety precautions such as draining/ flushing/ blinding etc, cutting the header, providing flanged MOV in the line , welding two equal tees in the pipeline oneither side of the MOV etc


Description of item Amount Rs. (2) Words (6)

Rate Rs. (5)



(1) (3) (4) Fig.E C/O

1 100NB M 5

2 300NB 5

3 450NB 35

4 150NB 6

5 250NB 6

6 300NB 6

F

1 Fabrication, erection and Painting of structural supports

MT 2.5

2 Cu M 5

3 Chipping of RCC for fixing insert plates, clamps, making cut outs etc Cu M 2

4

Nos 2


Total / Sub-total

DISMANTLING OF PIPINGCutting and dismantling of pipelines including attached fittings, flanges, valves, instruments, insulation etc, transporting to owner's store or other designated areas without damage to nearby equipments, pipelines, structures etc in a safe and sound manner. Cement lined piping

Carbon Steel piping

MISCELLANEOUS JOBS

Supply, transportation, handling, rigging, cutting, edge preparation, drilling, threading, welding and fixing of structural supports at all elevations and chipping and grouting and clamping/ bolting/ fixing of pipelines (including cost of sand & cement for grouting). MS Plates & structurals shall be included in the rate

PCC/ RCC pedestals for pipe supports including cost of materials


Amount Rs. (2) Words (6)

Rate Rs. (5)

The structural supports shall be painted with 1 coat of ‘Two pack poly urethane holding primer’ ( 30 microns DFT) and final painting shall be 2 coats of ‘High build poly urethane coating’ ( 60 microns total DFT).

Erection of Basket FiltersErection of flanged basket filter, 400NB, 150#, on the foundation, levelling, grouting , anchoring, fixing of accessories such as vent/drain valves, davit assembly, pressure guages etc, initial servicing .

Description of item


(1) (3) (4) Fig.G

G.1 C/O1 25NB M 1

2 40NB 1

3 50NB 2

4 100NB 1

5 150NB 18

6 200NB 3

7 250NB 3

8 300NB 3

9 400NB 194

10 450NB 1

11 500NB 1

G.2

1 25NB NOS 16

2 40NB 23 50NB 14 100NB 4

5 150NB 8

6 200NB 2

7 250NB 3

SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION

SCHEDULE OF ITEMS OF WORK

GRP PIPES, PN 10

8122-03-SW-001DEPARTMENT PAGE 6 OF 10


(2) Words

PIPING

Total / Sub-total


GRP FLANGES, 150#, FF, DRILLING AS PER B16.5


(1) (3) (4) Fig.G.3 C/O1 300NB NOS 18

2 400NB 22

3 450NB 1

4 500NB 1

5

G.4

1 40 NB NOS 2

2 400 NB 1

G.5

1 50NB NOS 1

2 100NB 3

3 150NB 14

4 200NB 3

5 250NB 3

6 400NB 15

G.6

1 400NB NOS 3

G.7

1 150NB NOS 1

2 400NB 2

45 DEG ELBOW, GRP, PN 10


EQUAL TEE, GRP, PN 10

Total / Sub-total


(2) WordsGRP FLANGES, 150#, FF, DRILLING AS PER B16.5

GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5



PIPING SCHEDULE OF ITEMS OF WORK


(1) (3) (4) Fig.

C/O

G.8

1 NOS 1

G.9

1 NOS 1

2 3

G.10

1 NOS 11

G.11 NOS 3

300NB X 250NB

25NB

GATE VALVES - LEADED TIN BRONZE BODY AS PER IS 318 LTB2 AND TRIM AS PER IS 320 ALLOY HT2. ENDS SHALL BE FLANGED AS PER CLASS 150, B 16.5, FF. DESIGN PR - 10 BAR, TEMP - 50 DEG C.

CONCENTRIC REDUCER , GRP, PN 10

ECCENTRIC REDUCER , GRP, PN 10

500NB X 400NB

450NB X 400NB


(2) Words


RUBBER EXPANSION BELLOWS SUITABLE FOR SEA WATER PUMP DISCHARGE LINE . OPERATING PRESSURE - 10 BAR. FLANGED AS PER B16.5, FF, CLASS 150. SIZE - 300NB. OVERALL LENGTH 400MM.

Total / Sub-total



(1) (3) (4) Fig.H

H.1 C/O1 25NB M 40

2 40NB 43

3 50NB 50

4 80NB 1

5 100NB 30

H.2 NOS 1

H.3

1 25 NB NOS 4

2 40 NB 7

3 50 NB 4

4 EQUAL TEE 25 NB 3

5 EQUAL TEE 40 NB 1

6 EQUAL TEE 50 NB 1

7 UNEQUAL TEE 1

8 UNEQUAL TEE 8

9 UNEQUAL TEE 14

10 3

11 2

12 25 NB 7

13 40 NB 10

CON. REDUCER

COUPLING

COUPLING

40 NB x 25 NB

40 NB x 25 NB

50 NB x 40 NB

40 NB x 15 NB

25 NB x 15 NB

90 ELBOW

90 ELBOW

90 ELBOW

CON. REDUCER

GI FLANGES, A105, 150#, FF, DRILLING AS PER B16.5, THREADED - 100NBGI FITTINGS, A105, CLASS 3000, THREADED

PIPING

Total / Sub-total


Description of item Amount Rs. (2) Words


SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS


GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS

(6)Rate Rs. (5)


(1) (3) (4) Fig.I

I.1 NOS 1 C/O

I.2 NOS 1

I.3 NOS 11

I.4 NOS 11

I.5 NOS 1

I.6 NOS 2

I.7 NOS 1J

J.1 NOS 2

J.2 3

J.3 2

J.4 TE 10.5

K

K.1 NOS 2

K.2 NOS 1


SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST TYPE 1, SIZE 63MM

SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS INCLUDING GASKETS AND FASTENERS


(6)Rate Rs. (5) Amount Rs.

Words

JOCKEY PUMP- VERTICAL- 1 TE APPR

Total / Sub-total


QUARTZOID BULB, 15 MM, MALE THREADED

DELUGE VALVE ASSEMBLY CONSISTING OF DELUGE VALVE, 2 NOS ISOLATION VALVES, BYPASS VALVE, CONNECTED PIPING, GASKETS, FASTENERS AND MATING FLANGES AS PER DATA SHEET& ENGG SPEC. SIZE 50NB

WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR

PIPING

SPRAY NOZZLES AS PER IS 319 TYPE II & DATA SHEET, SIZE K40

WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM

Description of item (2)

INSTALLATION OF EQUIPMENTSP301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR

CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS. FLANGED AS PER B16.5 , 150# , FF, 100NB

HOSE BOX AS PER DATA SHEET

DISMANTLING OF PUMPS

P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR

JOCKEY PUMP- VERTICAL- 1TE APPR

E301- LPG HEATER- HORIZONTAL

Sl. No. Unit Quantity (1) (3) (4)

The scope of work under this item includes transportation of all piping items from storage point,handling, cleaning, welding, fabrication, erection, painting, testing and commissioning of aboveground piping as per the drawings and specifications.

All activities associated with making weld joints such as cleaning, marking out, cutting , profiling,bevelling, grinding, aligning, fitting up, tack welding, chipping, preheating, placing of windshields/weather protection and final welding together with any special wlelding requirement areincluded in the scope.

Installation of all types of valves, control valves, safety valves, Y strainers, static mixure, orifice plates and assembling of flanged joints are also included in the rate. The contractor shall ensure the initial satisfactory operation of the valves. Cleaning of flange faces, insertion of gaskets, bolts etc, aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also

PIPING SCHEDULE OF ITEMS OF WORKDEPARTMENT

A FABRICATION AND INSTALLATION OF PIPING


03FT

067B

/ 96

Project - LPG Blending facilities


PrepAred - GSP Checked - KAK Approved - KAK

The pay quantity shall be the actual centreline length in metres of straight or fabricated pipeincluding valves, etc. actually installed as required. Payment for the work done will be made onlywhen the piping is properly located and permanently supported in its final position in the field afterhydrotesting.

This rate does not cover radiography/UT/MP/DP tests,which shall be paid as per item D

All the CS pipes, fittings etc shall be painted with 1 coat of 'Two pack poly urethane holding primer’ as per 02ES023/97 after surface cleaning by mechanical means

All the works required for the proper installation, at all elevations, of piping with attached fittings andvalves, handling, rigging, scaffolding, placing and alignment of pipes and fittings to their respectivepositions and on to their respective supports, fabrication and erection of trunnion supports, pad atsupports are also included in this item. Hydraulic testing of the piping systems, flushing,draining and drying up also included in this.

aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also included


2 20NB SCH160 M 2

3 25 NB SCH 80 6

4 40NB SCH 80 2

5 50 NB SCH 40 6

6 100 NB SCH 40 6

7 250 NB SCH 40 6

8 300 NB SCH 40 235

9 20NB SCH160 M 2



CARBON STEEL, ASTM A 106 GR B

LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6

9 20NB SCH160 M 2

10 40NB SCH 80 2

11 150NB SCH 40 12

12 200 NB SCH 40 200

13 250 NB SCH 40 200

14 300 NB SCH 40 24

15 25 NB PN 10 M 1

16 40 NB PN 10 1

17 50 NB PN 10 2

18 100 NB PN 10 1

19 150 NB PN 10 18

20 200 NB PN 10 3

21 250NB PN 10 3




22 300 NB PN 10 M 3

23 400NB PN 10 194

24 450 NB PN 10 1

25 500 NB PN 10 1

26 100 NB M 5

27 300NB 5


The rate shall also include making Tie in connections, galvanised fasteners, non metallic gaskets, sleeves, sand, cement, reinforcement etc

CEMENT LINED PIPING



27 300NB 5

28 450NB 35






Supply and application of Pre formed PUF cold Insulation, over pipes, valves, flanges, specials as per specifications/standards/drawings and instruction from the site in charge. 12 mm concrete coating shall be provided over the insulation. All the materials, tools/tackles, scaffolding, transportation/handling, manpower etc. shall be arranged by the contractor. Measurements for the release of payment shall be as per IS 14164.






36 200NB 90 MM THICK 195

37 250NB 60 MM THICK 195

38 300NB 60 MM THICK 250

39

LS 1


TIE IN CONNECTIONS

All activities required for taking two tappings from the existing header at Terminal and shall include all safety precautions such as draining/ flushing/ blinding etc, cutting the header, providing flanged MOV in the line , welding two equal tees in the pipeline oneither side of the MOV etc



RADIOGRAPHY / DYE PENETRANT TESTS.

40 CM 27000

41 CM 700

Radiographic, UT/ DP / MP inspection of the weld joints shall be conducted as per thecode, specs., drgs. and instructions of the Engineer-in-charge. The rate quoted shall beinclusive of all operations necessary to fulfill the work of radiography ( X ray / Gammaray ), DP / MP tests including all tools / tackles, films, chemicals etc. complete. Aftertesting, if any joint is found defective, the same shall be rectified and re-tested free ofcost. The pay quantity shall be linear centimeters of weld successfully passed. Penaltyshots shall not be counted for payment.

Radiographic/ UltrasonicInspection

DP Inspection


oneither side of the MOV etc


42 100NB M 5

43 300NB 5

44 450NB 35

45 150NB 6

46 250NB 6

47 300NB 6

DISMANTLING OF PIPING

Cutting and dismantling of pipelines including attached fittings, flanges, valves, instruments, insulation etc, transporting to owner's store or other designated areas without damage to nearby equipments, pipelines, structures etc in a safe and sound manner. Cement lined piping

Carbon Steel piping

MISCELLANEOUS JOBS

PIPING SCHEDULE OF ITEMS OF WORKDEPARTMENTDescription of item

(2)

48 Fabrication, erection and Painting of structural supports

TM 2.5

49 Cu M 5

50 Chipping of RCC for fixing insert plates, clamps, making cut outs etc Cu M 2

51

Nos 2


MISCELLANEOUS JOBS

Supply, transportation, handling, rigging, cutting, edge preparation, drilling, threading, welding and fixing of structural supports at all elevations and chipping and grouting and clamping/ bolting/ fixing of pipelines (including cost of sand & cement for grouting). MS Plates & structurals shall be included in the rate

PCC/ RCC pedestals for pipe supports including cost of materials

The structural supports shall be painted with 1 coat of ‘Two pack poly urethane holding primer’ ( 30 microns DFT) and final painting shall be 2 coats of ‘High build poly urethane coating’ ( 60 microns total DFT).

Erection of Basket Filters

Erection of flanged basket filter, 400NB, 150#, on the foundation, levelling, grouting , anchoring, fixing of accessories such as vent/drain valves, davit assembly, pressure guages etc, initial servicing .


(1) (3) (4)

52 25NB M 1

53 40NB 1

54 50NB 2

55 100NB 1

56 150NB 18

57 200NB 3

58 250NB 3

DEPARTMENTDescription of item


(2)

SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION

GRP PIPES, PN 10

58 250NB 3

59 300NB 3

60 400NB 194

61 450NB 1

62 500NB 1

63 25NB NOS 16

64 40NB 2

65 50NB 1

66 100NB 4

67 150NB 8

68 200NB 2

69 250NB 3




70 300NB NOS 18

71 400NB 22

72 450NB 1

73 500NB 1

74 40 NB NOS 2

75 400 NB 1

GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5



(2)


75 400 NB 1

76 50NB NOS 1

77 100NB 3

78 150NB 14

79 200NB 3

80 250NB 3

81 400NB 15

82 400NB NOS 3

83 150NB NOS 1

84 400NB 2




EQUAL TEE, GRP, PN 10



85 NOS 1

86 NOS 1

87 3


300NB X 250NB

GATE VALVES - LEADED TIN BRONZE BODY AS PER IS 318 LTB2 AND TRIM AS PER IS 320 ALLOY HT2. ENDS SHALL BE FLANGED AS PER CLASS 150, B 16.5, FF. DESIGN PR - 10 BAR, TEMP - 50 DEG C.


(2)

ECCENTRIC REDUCER , GRP, PN 10

500NB X 400NB

450NB X 400NB

CONCENTRIC REDUCER , GRP, PN 10

88 NOS 11

89 NOS 3

25NB

BAR, TEMP - 50 DEG C.


RUBBER EXPANSION BELLOWS 300NB


(1) (3) (4)

90 25NB M 40

91 40NB 43

92 50NB 50

93 80NB 1

94 100NB 30

95 100NB NOS 1

Description of item

GI FLANGES, 150#, FF, DRILLING AS PER B16.5, THREADED

GI FITTINGS, A105, CLASS 3000, THREADED

(2)

GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS

DEPARTMENT

SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS

SCHEDULE OF ITEMS OF WORKPIPING

96 25 NB NOS 4

97 40 NB 7

98 50 NB 4

99 EQUAL TEE 25 NB 3



102 UNEQUAL TEE 1

103 UNEQUAL TEE 8

104 UNEQUAL TEE 14

105 3

106 2

107 25 NB 7

108 40 NB 10

90 ELBOW

25 NB x 15 NB


COUPLING

40 NB x 25 NB

40 NB x 25 NB

50 NB x 40 NB

40 NB x 15 NB

COUPLING

CON. REDUCER

CON. REDUCER

90 ELBOW

90 ELBOW


(1) (3) (4)

109

NOS 1

110

NOS 1

111

NOS 11

112 NOS 11

113 NOS 1

Description of itemDEPARTMENT

SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST TYPE 1, SIZE 63MM

SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS


QUARTZOID BULB, 15 MM, MALE THREADED

PIPING

SPRAY NOZZLES AS IS 319 TYPE II & DATA SHEET, SIZE K40

WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM

(2)

CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS. 113 NOS 1

114 NOS 2

115 NOS 1

116 NOS 2

117 3

118 2

119 TM 10.5

120 NOS 2

121 NOS 1

E301- LPG HEATER- HORIZONTAL

DISMANTLING OF PUMPS

JOCKEY PUMP- VERTICAL- 1 TE APPR

WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR

HOSE BOX AS PER DATA SHEET


DELUGE VALVE ASSEMBLY

P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR

JOCKEY PUMP- VERTICAL- 1TE APPR

INSTALLATION OF EQUIPMENTS

P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR

CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS. FLANGED AS PER B16.5 , 150# , FF 100NB