TS- Package SM -47

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STEEL AUTHORITY OF INDIA LIMITED

DURGAPUR STEEL PLANT

RE-BUILDING OF COKE OVEN BATTERY NO. 2

TECHNICAL SPECIFICATIONFOR

INTERPLANT PIPELINE GAS MAIN & COMPENSATOR



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REBUILDING OF COB # 2TECHNICAL SPECIFICATION

FOR

INTERPLANT PIPELINE GAS MAIN &



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FOR INTERPLANT PIPELINE GAS MAIN &

COMPENSATOR

PACKAGE NO. : COB2/EXPN/SM-47



INTERPLANT PIPELINE GAS MAIN & COMPENSATOR

T.S. NO. MEC/TS/11/9172/COB2/EXPN/SM-47

MECON LIMITEDRANCHI-834002



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COMPENSATOR


C O N T E N T S

Chapter Description Page No./No. of Sheets

- Revision Status Amendment -Record Sheet 1 Sheet

01. Technical Specifications Summary 1 Sheets

02. Special Instructions to Tenderer 4 Sheets

03. Technical Specification 8 Sheets

ANNEXURES:

i) ANNEXURE –IFormat for Quotation (Technical)

3 Sheets

ii) ANNEXURE –IIFormat For Inspection Call Letter

1 Sheet

iii) ANNEXURE III 1 Sh t



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COMPENSATOR


REVISION STATUS AMENDMENT - RECORD SHEET

Rev. No.

Date Sheet Amended Description Remarks



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REBUILDING OF COB # 2


INTERPLANT PIPELINE GAS MAIN &COMPENSATOR


01 TECHNICAL SPECIFICATION SUMMARY SHEET

01.1 Technical specification No. : MEC/TS/9172/COB2/EXPN/SM-47

01.2 Package No. : COB2/EXPN/SM-47

01.3 Item No.s : 1. COB2/EXPN/SM-47/01, 2. COB2/EXPN/SM-47/02

3. COB2/EXPN/SM-47/034. COB2/EXPN/SM-47/045. COB2/EXPN/SM-47/056. COB2/EXPN/SM-47/06, 07, 087. COB2/EXPN/SM-47/09

8. COB2/EXPN/SM-47/10, 119. COB2/EXPN/SM-47/1210. COB2/EXPN/SM-47/13

01.4 Item description : 01. BF Gas Pipeline02. Saddle support03. Roller Support04. Single Disc Compensator

05 Condensate Seal Pot



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2.1 General:This chapter shall be read in conjunction with General Conditions of Contract.

2.1.1 The supply items shall meet the requirements stipulated in the technical specificationsand drawings and standard method of manufacture.

2.1.2 Use of inferior materials, which can impair the quality and mechanical properties, is notallowed.

02.01.3 Depending on the performance of manufacture, purchaser reserves the right tocancel the order or increase or decrease the quantity ordered at the same

price/rate without any financial implications on the purchaser’s part or anycompensation to the supplier.

2.1.4 The tenderer shall submit the quotations (technical part) exactly as per theenclosed ‘Format for quotation’ given in Annexure –IA (I) any deviations proposedby the tenderer shall be listed in that format only. NO ADDITIONAL WRITE-UPOR DIFFERENT FORMAT WILL BE ACCEPTED.

2 1 5 Th t d h ll f i h 3 t f d i /d t / t l li bl l



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The following information / documents are to be submitted by the Tenderer along with theoffer:

- Make

- Type & Standards with Grade

- Material of construction

- Nominal sizes with length in metre

- Weight in kg per running metre

- OD and thickness in mm

- Leaflets / catalogues

- Standards being followed for design, dimensions, material, manufacture &testing of offered items

- Quality assurance plan as per Annexure-III



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- All measuring instruments, templates, gauges, jigs & fixtures includingspecial ones to be made by the supplier as per specific requirement of theinspectors.

- All secretarial assistance for preparation of inspection report & related

documents.

2.4.5 Notice period:

Two weeks from the receipt of inspection notice at the purchaser’s office.

02.04.6 Supplier’s obligation:

The inspection of materials at manufacturer’s works and despatch of materials

does not relieve the supplier of his obligation to replace/rectify free of cost FORDSP site basis, those materials which are found defective due to badworkmanship or bad quality of materials at the time of final inspection at plant siteor during agreed warrantee/guarantee period.

02.05 Match Marking

The sub-assemblies / parts shall be properly match marked before dismantling for

ki d d t h M f t f f d i ti t it h ll



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End protectors to be used on bevelled ends shall be securely and tightly attached withbelt or wire.

02.08 Weights:

The tenderer shall study the specification, specification drawings (views, detailsand bill of quantities therein) to appreciate the full scope of supply involved. Incases, where items like, packing material, asbestos rope, wood, etc. are includedin the bill of materials but not included in the total wt. of steel items indicated;tenderer shall include them also in their scope of supply. Additional claims anddisputes on this account would not be entertained after placement of order.All fasteners like nuts, bolts, washers, gaskets, etc., shall be supplied 10% extrain addition to the actual quantity required.

02.09 Documents/Drawings to be furnished by the successful tenderer .

The list of documents/drawings to be furnished by the successful tenderer is givenbelow: -

Sl.No.

Category of Drawing / Documents Status

1 M f t i /G l t d i YES / NA



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03.01 Scope of Work and Supply:

The Tenderer’s scope of work and supply shall include, but not limited to, the following.

03.01.1 The scope of work of the Tenderer shall cover manufacture, shop testing, shoppainting, packing and supply of pipes for interplant Gas mains. This shall includepipes, supports, valves, equipment & fittings as per Annexure-A of TechnicalSpecification.

3.1.2 The items covered under the Tenderer’s scope for Inter-Plant Gas Mainsare as under:

Fabricated Items:• BF Gas Pipeline• Saddle support• Roller Support• Single Disc Compensator • Condensate Seal Pot

Brought Out Items:

• ERW Pi & Fitti



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ii) Bidders confirmation as per Annexure-II (1 sheet)

iii) QAP duly filled in as per Annexure-III (2 sheet).

iv) Implementation schedule in form of bar chart to match thedelivery schedule.

03.01.9 Documents to be furnished by the successful Tenderer:

For approval

i. Detail fabrication drawings in adequate copies as detailedin

Clause 02.02.ii. QAP duly filled in.iii. Test & Warranty certificate for each item offered.iv. Test / Inspection reports, as applicable.

For reference / information

i) Catalogues / sketches of brought out items

ii) C ti l f b ht t it li bl



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contractor and the Purchaser nor shall release the Contractor from any of hisobligations and liabilities under the contract.

03.02.01. 7 Metric system shall be followed and English shall be the language of all

communication.

03.02.01. 8 The Tenderer shall clearly indicate the items, if any, excluded from his scope of work & supply, failing which it will be deemed that the scope of work & supplyshall be in conformity with the requirements of this specification.

03.02.01. 9 Pipes made of steel produced by acidic Bessemer process shall not beacceptable.

03.02.01.10 Test reports shall be supplied for all mandatory tests as per the applicablematerial specifications. Test reports shall also be furnished for any supplementarytests as specified by the Purchaser.

03.02.01.11 Material test certificates (Physical properties, chemical composition & heattreatment reports) shall be furnished for pipes.

03.02.01.12 ERW pipes (as applicable) shall not have any circumferential seam joint in a

d l th



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03.02.02.8 When welding gas pipelines additional welding at the root of joint shall bedone by any suitable method.

03.03 Dimensions of Links and tolerances:

03.03.1 Following tolerances are allowed:

A. For the length of links

i. + 3mm for the length upto 1000 mmii. + 0.5% for the length over 1000 mm but not more than 10 mm for

each complete 10 metre. .

B. For deflection of the cylinder gradient from the straight lines:

i. 0.12% of the link length but not more than 15 mm for links withlengths over 10 m when checking by stretched cord.

C. For difference in diameter of butt-welded ends of links - not more than 2 mm.

Tolerance on diameters of shells shall be within + 5 mm and ellipticity shall be

ithi th t li it



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a) Tests by compressed air with application of soap solution over all joints of links of the gas pipes.

b) Checking by chalk-kerosene test of the joints/ links of the gas pipelines.

03.04.7 Tests by the compressed air are carried out under excess pressure.P test = 0.65 Kgf/Cm2 (gauge).

03.04.8 For kerosene testing all joints are covered firstly with chalk. When chalk is driedup, the inner surfaces of the joints are abundantly covered with kerosene.

Dark greasy spots on the outer surfaces indicate leaks. Examination of joints is

carried out 12 hours after applying kerosene.

03.04.9 All defective sections of joints found during above tests shall be cut out and re-welded. Caulking or welding over the defective weld is not allowed. After repairing, such details are to be subjected to repeated tests.

03.05 Mechanical Testing of welded joints (if applicable)

03 05 1 Th i f h i l t ti i th t l f th t th d



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03.06.1 On the inner surfaces of the link ends of the gas pipelines, the following shall bepainted with white weather proof paint:“Item number and drawing number according to the manufacturing drawings.”

03.06.2 Outer surface of the gas pipeline shall be thoroughly cleaned and painted. Thepainting of all pipelines will be done as per IPSS 1-06 -016 088. Two coats of primer as per IS: 2074 -1992 will be applied on thoroughly cleaned and drysurface. The thickness of dry film coating will not be less than 30µ / each coating.

03.07 Shipment:

Gas pipeline links, supports, valves & all bought out items during transportation

shall be protected from damage.



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SL.NO.

DRAWING

DESCRIPTIONOF PIPE, OD

X THK(mm x mm)

(m)

UNITWEIGHT(Kg/m)

TOTALWEIGHT

(Kg)

1.IS:3589

FabricatedPIPE Ø 1420 x10 Thk.

140 347.86 48700.4COB2/EXPN/SM-47/01

To be fabricated

from platesconforming toIS:2062 Gr A;ERW Black(BEWEL ENDS)

2. IS:1239,Part 1ERW PIPEØ115 x 5.4Thk.

8 14.5 116COB2/EXPN/SM-47/06

Bought Out Item

3. IS:1239,Part 1

ERW PIPE

Ø89.5 x 4.8Thk.

12 8.36 100.32COB2/EXPN/SM-47/07 Bought Out Item

4. IS:1239,Part 1ERW PIPEØ34.2 x 3.2Thk.

100 2.5 250COB2/EXPN/SM-47/08

Bought Out Item

5. IS:1239,Part 2900 ELBOWØ34.2 x 3.2Thk.

10 --- ---COB2/EXPN/SM-47/09

Bought Out Item

6

FUNNEL, DN

260 DN 100 1COB2/EXPN/



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1.DRG.No.MEC/TS/9172/COB2/EXPN

/SM-47/001

DN1400SADDLE

SUPPORT3 100 300 COB2/EXPN/

SM-47/02

FABRICATEDFROM PLATESCONFORMINGTOIS; 2062, Gr A

2DRG.No.MEC/TS/9172/COB2/EXPN

/SM-47/002

DN1400ROLLER

SUPPORT7 100 700 COB2/EXPN/

SM-47/03

FABRICATEDFROM PLATESCONFORMINGTOIS; 2062, Gr A

C. VALVES

SL.NO.

STANDARD/DRAWING/

SPECIFICATIONDESCRIPTION

QUANTITYIn (No)

WEIGHT IN KGITEM No. REMARKSUNIT

WEIGHTTOTAL

WEIGHT

1.IS:14846,

Body CI Gr. FG 200SS Trim

DN 100 - GATEVALVE For BF

Gas Service ,Rising Stem,Flanged End

Connection withcompanion

flanges, nuts, bolts and gaskets

2 50 100COB2/EXPN/SM-47/10

Bought Out Item

DN 25 CS



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Annexure – ISheet 1 of 3

FORMAT FOR QUOTATION

Technical Part Only

1. Enquiry No. : dated

2. Offer No. : dated

1. We agree to supply the items indicated hereinafter in sheet-2 of theannexure as per delivery schedule indicated. We agree to all clausesindicated in the technical specification no. .....………………………………………… and reference drawings listed in thespecification including details of inspection excepting those mentionedunder deviation/exclusions hereunder.

2. We confirm that commercial part of the tender has been submittedseparately.



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Annexure – ISheet 2 of 3

Scope of Supply and delivery schedule

Sl. No

ItemDescription

Qty.quotedfor

UnitWt.

TotalWt.

Drg. Nos.

Offer of sample

Delivery 1st

lot (Qty. to be indicatedin no. of days fromsample

approval)

Monthlyrate of supply

Totaldelivery

period

Remarks

1 2 3 4 5 6 7 8 9 10 11



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Vendor Confirmation

Bid / offer without this confirmation sheet duly signed & with company seal shall be treated asincomplete offer and shall not be considered for technical / commercial evaluation.

Sl.No(A)

Description(B)

Confirmation(C)

Alternative proposal byVendor

(D)

1. Dimensions as per certifiedmanufacturing/ approved vendor drawings

2. Material composition as per Annexure- A

3. Inspection as per Cl. No. 02.04

4. Delivery period as per Cl. No. 01.8

5. QAP (Quality Assurance Plan) Annexure-III

6. Part order acceptance as per Cl. No.02.01.8

7 T i i f d h i d d



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Annexure - IISheet 1 of 1

FORMAT FOR INSPECTION CALL LETTER

PROJECT: REBUILDING OF C.O. BATTERY NO. 2, DURGAPUR STEEL PLANT

SL.NO.

DESCRIPTION DETAILS

1 A/T or Purchase Order No.

2 Description of the item/ items with

identification mark/ Sl. No.3 Specification no. of the item/items

4 Drawing No. of the item/ items

5 Type of the inspection:- Stage/Sample/ Final

6 Quantity ordered/offered/balance (Nos. &Weight)

7 Proposed date of Inspection

8 l f i ( i h ll dd d

Annexure - III



Annexure III

FORM NO. 11.20(DQM) F-9 Rev. 0

PURCHASER --

QUALITY ASSURANCE PLANFOR

MECHANICAL EQUIPMENT

PROJECTREBUILDING OF COKE OVEN BATTERY NO. 2DURGAPUR STEEL PLANT

ORDER No. & DT. -- PACKAGE No. COB2/EXPN/SM-47

MANUFACTURER

PACKAGE NAMEREPLACEMENT OF LEAN GAS HEADER DN1400 ON COKE SIDE OF COB NO. 2

ORDER No. & DATE TS No. MEC/TS/11/9172/COB2/EXPN/SM-47

INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :

1. QAP shall be submitted for each of the equipment separately with break-up of assembly /

sub-assembly & part / component or for group of equipment having the same specification.

2. Use numerical codes as indicated for extent of inspection & tests and submission of test

certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant & equipment.

3. Separate identification number with quantity for equipment shall be indicated wherever

equipment having same specifications belonging to different facilities is grouped together.

4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may

be indicated wherever actual weights are not available.

CODE DESCRIPTION

1. Visual (Welding, etc.)

2 . Dime nsiona l3. Assembly ,Fitment &

Alignment4. Physical Test (sample)5. Chemical Test (sample)6. Ult rasonic Test7. Magnetic Particle Test8. Radiography Test9. Dye Penetration Test10. Metallographic Exam.11. Welder’s Qualification &

weld procedure Test12. Approval of Test and Repair

procedure13. Heat Treatment14. Pressure Test15. Leakage Test16. Balancing

CODE DESCRIPTION

17. Vibration Test18. Amplitude Test19. Sponge Test20. Dust / Water Ingress Test21. Friction Factor Test22. Adhesion Test23. Performance Test /

Characteristic curve24. No Load / Free Running Test25. Load / Overload Test26. Measurement of speeds27. Acoustical Test28. Geometrical Accuracy29. Repeatability & Positioning

Accuracy30. Proving Test31. Surface preparation32. Hardness Test33. Spark Test for Lining

CODE DESCRIPTION

34. Calibration35. Safety Device Test36. Ease of Maintenance37. Pouring witness38. Load/Deflection test of springs39. Sample

DOCUMENTSD1. Approved GA drawingsD2. Information and other

reference drg. / stampeddrgs. released for mfg.

D3. Relevant cataloguesD4. Bill of matl. / Item NoD5. Identification Relevant

catalogues ,Match mark details

D6. Line / Layout diagram

D7.

D8.

D9.

D10.D11.D12.

D13.

D14.

D15.

Approved Erection proceduresUn priced sub P. O. with

specification andamendments, if any.Calibration Certificates of all measuring Instrumentsand gaugesGuarantee CertificateHeat CurvePhysical & chemical testcertificateIBR / Other Statutoryagencies CompliancecertificateManufacturer’s TestCertificates for boughtout itemsInternal Inspection Report

by Contractor

ABBREVIATIONS USED :

MECON : MECON LIMITEDMFR : MANUFACTURER

E Q U I P M E N T D E T A I L S I N S P E C T I O N AND T E S T S

Test Certificates &documents to be

submitted toMecon /DSP

Acceptance CriteriaStandards/IS/ BS/

ASME/ Norms andDocuments

Remarks/sampling planSl.

No.

Description (withequipmentheading,place of use & brief specifications)

Item No.

QuantityManufactur er’s Name& address

ExpectedScheduleof FinalInspn.

Raw Material and in processstage inspection

Final Inspection / Test by

No./M T MFR DSP MECON MFR DSP MECON

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1.1 Fabricated

Pipe

COB2/EXPN/

SM-47/01

140m

As per TS

1, 2, 3, 4, 5,11

- -1, 2, 9,14, 15,28, 31

1, 2,3, 9,14 ,15

1, 2, 9,14,15,28, 31

D1,D2,D4,D5,D9, D10, 4, 5

D1,D2 &As per RelevantStandardCodes

1. D.P Test 10%2. Control Assemblywith Match Mark 100%

2.2

Saddlesupport

COB2/EXPN/

SM-47/02

3 No.sAs

per TS

1, 2, 3 ,4,5,11 - -1, 2, 3,

9,28,31

1, 2,3, 9

1, 2, 3,9 D1, D2, D4,D5, D9, D10,D12, D15

D1,D2 &As per RelevantStandardCodes

100%

For MANUFACTURE (Stamp & Signature) For MECON (Stamp & Signature)

QAP No. MEC/ 9172/ COB2/EXPN/SM-47/01SHEET 1 OF 2

REV. - O

1 2 3 4 5 1 2 3 D1 D2 D4 As per TS &



3.Roller

Support

COB2/EXPN/

SM-47/03

7 No.sAs

per TS

1, 2, 3, 4, 5,11

- -1, 2, 3,

9,28,31

1, 2,3, 9

1, 2, 3,9

D1,D2, D4,D5, D9, D10,D12, D15

As per TS &Certified Mfg.Drg. 100%

4.Single Disc

Compensator

COB2/EXPN/

SM-47/04

2 No.sAs

per TS

1, 2, 3, 4, 5,11

- -

1, 2,3,9, 14,15, 28,

31

1, 2,3, 9,14 ,

15,28

1, 2, 9,14,15,28, 31

D1,D4,D5,D9, D10, D10,D12, D15

As per TS Drg.& RelevantStandard Codes 100%

5.Condensate

Seal Pot

COB2/EXPN/

SM-47/05

1 No.s

As

per TS

1, 2, 3,11 - -

1, 2, 3,9, 14 ,

15,28,31

1, 2,3, 9,

14 ,15,28

1, 2, 3,9, 14 ,

15,28,31

D1,D2, D4,D5, D9, D10,

D12, D14,D15

As per TS &Certified Mfg.

Drg. 100%

6.

FLEXIBLEMETALLIC

HOSE

COB2/EXPN/

SM-47/13

1 No.sAs

per TS

1, 2, 3 - -1, 2, 3,9, 14 &

15

1, 2,3,9,14, 15

1, 2, 3,9, 14 &15

D2, D4, D5,D8,D9, D10,D12, D14,D15

As per RelevantStandardCodes /D8/D14/D15

100%

7. ERW Pipes(Bought Out)

COB2/EXPN/

SM-47/06,07,08

-8m- 12m

-100m

As per TS

1, 2, 4, 5, 11

- -1, 2,14,

15

1, 2,14,15,31

1, 2, 9,14,15,31

D2, D4, D5,D8,D9, D10,D12, D14,D15


100%

8. 90o ElbowCOB2/EXPN/

SM-47/09

10 No.sAs

per TS

1, 2, 4, 5, 11

- -1, 2,14,

15

1, 2,14,15,31

1, 2, 9,14,15,31

D2, D4, D5,D8,D9, D10,D12, D14,D15


100%

9. Valves

COB2/EXPN/

SM-47/10,

11

6 No.sAs

per TS

1, 2, 3 - -

1, 2, 3,9, 14 ,15,28,

31

1, 2,3, 9,14,

15,28,31

1, 2, 3,9, 14 ,15,28,

31

D2, D3,D4,D5,D8, D9,D10, D12,D14,D15


100%

10.

Funnel

COB2/EXPN/

SM-47/12

1 No.s

As

per TS

1, 2, 3,11 - -1, 2, 3,9, 14 &

15

1, 2,3, 9,

14 &15

1, 2, 3,9, 14 &

15

D1,D2,D4,D5,D9, D10, 4, 5

As per TS &Certified Mfg.

Drg.100%

For MANUFACTURE (Stamp & Signature) For MECON (Stamp & Signature)

QAP No. MEC/ 9172/ COB2/EXPN/SM-47/01SHEET 2 OF 2

REV. - O