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Mounded Bullets LPG Terminal Reference Tender
Mounded Bullets LPG Terminal Reference Tender
Mounded Bullets LPG Terminal Reference Tender
Document No.
SHEET 1 OF 1
1
Rev
PART-II : TECHNICAL
LPG MOUNDED BULLETS
TITLE
PROJECT:
CLIENT
NRL, ASSAM
05.10.2015
05.10.2015
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-MB-PNMV-PD-401
Document No.
Rev
SHEET 1 OF 3
PROJECTDESCRIPTION
05.10.2015
05.10.2015
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-MB-PNMV-PD-401
Document No.
SHEET 2 OF 3
1
Rev
1.0 INTRODUCTION
1.1
1.2
M/s NRL have appointed Projects & Development India Limited (PDIL) for
EPCM services for installation of LPG Mounded Bullets at NRL Assam.
2.0
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
: Kolkata
4.0
: NH-39
4.0.1
4.0.2
Allrightsreserved
EM163-MB-PNMV-PD-401
Document No.
SHEET 3 OF 3
1
Rev
4.0.3
Carrying out route survey up to refinery and inside refinery whatsoever required
for over dimensional consignment (ODC), transportation of all equipment and
material to site including loading and unloading, storage, maintenance,
construction, installation, obtaining all necessary CCOE/PESO/statutory
approvals from concerned Government authorities as applicable. Precommissioning, commissioning including total project management and handing
over of mounded storage bullets and handling facilities on single point
responsibility basis.
4.0.4
Design, drawings, data sheets, specifications & other related documents for
review/approval from PDIL/NRL and issue of As-Built drawings shall be as per
Documentation Schedule.
Allrightsreserved
EM163-MB-PNMV-MI-401
DOCUMENT NO
REV
SHEET 1 OF 8
MASTER INDEX
PROJECT
INSTALLATION OF MOUNDED BULLETS AT NRL,
ASSAM
TENDER DOCUMENT
FOR
INSTALLATION OF MOUNDED BULLETS
ON LSTK BASIS
AT
NUMALIGARH REFINERY, ASSAM
1
REV
05.10.15
REV DATE
05.10.15
VB/PK
NB/AKG
GC
EFF. DATE
PURPOSE
PREPD
REVWD
APPD
EM163-MB-PNMV-MI-401
DOCUMENT NO.
1
REV
SHEET 2 OF 8
MASTER INDEX
Section No.
Description
PART-I : COMMERCIAL
PART-II : TECHNICAL
1
Process
Civil
Pressure Vessel
Instrumentation
Electrical
Piping
Construction
10
Vendor List
EM163-MB-PNMV-MI-401
DOCUMENT NO.
1
REV
SHEET 3 OF 8
Description
Design Basis
No. of
Pages
12
SECTION 2 OF 10 (TECHNICAL)
Civil
Sl. No.
1.
2.
3.
4.
5.
Description
Scope of work
Design Basis
EM163-PNCV-SOW101
EM 163-PNCV-DB-101
Technical specification
EM 163-PNCV-TS-101
EM163-PNCV-TD-001
EM163-PNCV-PL-001
No. of
Pages
19
9
22
1
1
SECTION 3 OF 10 (TECHNICAL)
Pressure Vessel
Sl. No.
Description
No. of
Pages
Cover Page
EM163-TS-401-00
EM163-TS-401
87
EM163-TS-301
72
EM163-MB-PNMV-MI-401
DOCUMENT NO.
1
REV
SHEET 4 OF 8
SECTION 4 OF 10 (TECHNICAL)
Instrumentation
Sl. No.
Document Description
No. of
pages
2.
3.
EM163-PNIN-7901-Part A
Rev. 1
EM163-PNIN-7901-TS
1
14
Rev. 1
EM163-PNIN-0701-00
23
Rev. 1
EM163-PNIN-7901-Part B
Rev. 1
EM163-E-7047
18
EM163-E-7147
40
EM163-E-7052
40
EM163-E-7053
15
EM163-E-7044
17
10.
EM163-E-7022
19
11.
EM163-E-7058
17
12.
EM163-E-7046
16
EM163-E-7148
15
13.
EM163-MB-PNMV-MI-401
DOCUMENT NO.
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SHEET 5 OF 8
1.
2.
ES-7337
3.
ES-7334
4.
ES-7341
5.
ES-7340
6.
ES-7335
7.
ES-7338
8.
ES7332
9.
INSTALLATION STANDARDS
(PRIMARY SKETCHES)
EM163-E-0720
Rev. 1
Rev 1
PART - D : BOQ
10.
11.
EM163-PNIN-7901-Part D
Rev. 1
EM163-PNIN-BOQ-7001
EM163-MB-PNMV-MI-401
DOCUMENT NO.
1
REV
SHEET 6 OF 8
SECTION 5 OF 10 (TECHNICAL)
Electrical
SR NO.
DESCRIPTION
TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION
SYSTEM OF LPG MOUNDED BULLETS
NO. OF
SHEETS
32
LIST OF ATTACHMENTS
1
17
10
11
12
13
14
15
16
17
18
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DOCUMENT NO.
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SECTION 6 OF 10 (TECHNICAL)
Piping
Sl. No.
1
2
Description
Cover Page
No. of Pages
ES 6006
ES 6007
ES 6010
15
ES 6011
10
ES 6101
11
ES 6102
12
ES 6103
13
ES 6104
14
ES 6105
15
ES 6606
16
ES 6018
16
17
PDS-P-001
18
PDS P 011
PDS P 012
PDS P 01-65
47
PDS P123
PDS ST 101
PDS ST 103
10
3
9
3
4
5
19
20
21
22
23
10
3
1
17
EM163-MB-PNMV-MI-401
DOCUMENT NO.
1
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SHEET 8 OF 8
SECTION 7 OF 10 (TECHNICAL)
Construction
Sl. No.
Description
1
Construction/Erection, Pre-commissioning,
Commissioning
No. of Pages
EM163-E-601 Rev 0
51
No. of Pages
EM163-PNPM-003
46
Description
Project execution plan, Planning,
schedule, monitoring, Control & inspection
Description
General Guidelines For HSE
No. of Pages
No. of Pages
30
86
Description
Vendor List
EM163-45-DD-DB 101
Document No.
Sheet 1 of 12
Rev.
DESIGNBASIS
08.06.2015
08.06.2015
First Issue
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 2 of 12
CONTENTS
SN
Item
1.0
PREFACE
2.0
3.0
3.5 Odorization
UTILITIES
b) Service Water
c) Instruments Air
10
10
e) Plant Air
10
10
10
11
11
11
6.1 Piping
11
4.0
5.0
6.0
Page No
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 3 of 12
11
7.0
12
8.0
UNITS OF MEASUREMENTS
12
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 4 of 12
1.0 PREFACE
Numaligarh Refinery Limited, (NRL) presently operates a 3 MMTPA refinery at
Numaligarh, District Golaghat, and Assam. The refinery commenced commercial
production in October, 2000.
This document presents the design basis to be used for the Installation of LPG
Mounded Bullets at Numaligarh Refinery Limited (NRL).
Mounded bullets provide intrinsically passive & safe environment & eradicates the
possibility of Boiling Liquid Expanding Vapor Explosion (BLEVE), through LPG handling
possess many challenges, due to its inherent dangerous properties, modern state of art
safety features has been taken into consideration while designing the facilities using
different OISD codes.
As handling of LPG in above ground vessel has many challenges due to its inherent
dangerous properties, NRL proposed to replace the old aboveground vessels with
mounded bullets of suitable capacity. New statues / guidelines suggest for mounded
bullets which proves to be safer compared to above ground storage vessels. The
project envisages construction of 4 nos. of mounded bullets of capacity 1760.56 m3 (
1000MT) each and upon successful completion / construction of mounded bullets
existing 03 nos. of LPG Spheres and 01 LPG bullet will be dismantled up to ground
level.
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 5 of 12
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
: Kolkata
1.0
Barometric pressure
2.0
3.0
4.0
: NH-39
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %
380C
Relative humidity
85 %
50C (Min)
Temperature
5.0
6.0
Rain fall
Heaviest in a day
160 mm
90 mm
Wind
Wind code
7.0
Seismic Factor
8.0
Elevation
9.0
36 km/hr
10.0
140 km/hr
11.0
Site conditions
12.0
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 6 of 12
LPG Composition
Composition
Mole %
Mole %
C3
30
45
37.5
C4
55
70
62.5
H2S
< 10 ppm
< 10 ppm
< 10 ppm
PROPERTIES OF LPG
Designation
LPG
0
0.558 ( Simulated)
3.35/-/7.51( Simulated)
0.152/-/0.113 ( Simulated)
6 & B1A
13.04
40/65
20.8/31.6
Bullet Details
Operating LPG storage capacity of each Bullet
1760.56m3
Design Temperature
(-) 27 to 55 0C
Material
Internal bottom surface up to 90 degree shall be provided with a coating suitable for
caustic, water, and H2S dissolve in LPG.
Filling Rate
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 7 of 12
3.4
Design Pressure
14.5 kg/cmg
Design Temperature
(-27) 0C to 55 0C
MOC
CS
Capacity
0.5 m3
Corrosion Allowance
Internal Corrosion Allowance: 3 mm (minimum).
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 8 of 12
24
Amb / ( 65 /-27 0C )
0.2-1.7/4.5 Kg/cm2g
- /1.7Kg/cm2g
162029 Kg/Hr
Installation of mounded bullets for the fire case load comes out 62161 Kg/Hr with
molecular weight 52.8.
All PSV/ TSV discharge shall be routed to the new flare header which will be
connected to existing flare header.
Liquid Effluents
Water coming with LPG shall be drained to drain vessel, and any dissolve LPG in
drain water shall be vented to flare in vapour form and water is drained to a Shallow
Sump (RCC) & finally to the storm sewer.
LPG pump drain is to be connected to drain vessel (45-VV-106), so that LPG in
vapour form is vented to Flare Header.
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 9 of 12
In view of above, no effluent is sent to Existing Effluent Treatment Plant & hence Load
of Existing Effluent Treatment Plant is not increased.
Hence Existing Effluent Treatment Plant is Adequate due to Installation of Mounded
Bullets.
In Drain Vessel vent and drain valve normally are to be kept in closed condition. For
draining water from bullets, deadman type valve to be opened closely watching level
gauge in the drain vessel. When LPG comes along with water. There will be two layer
visible in the level gauge (Interface Float Type ) draining to be done slowly very
carefully and initially from time to time water is to be drained to shallow sump, If any
LPG visible in the level gauge . Then same to be vented in the flare before opening
draining valve of the drain vessel.
4.0 UTILITIES
a)
LP Steam :The Minimum, operating and design conditions for low pressure steam shall be as follows
b)
Design temperature
200 0C
Design pressure
7.5 Kg/cm2g
Operating temperature
165 0C
Operating pressure
4.0 Kg/cm2g
Minimum temperature
155 0C
Minimum Pressure
3.5 Kg/cm2g
Service Water :The Minimum, operating and design conditions for service water stream shall be as follows
Design temperature
650C
Design pressure
8 Kg/cm2g
Operating temperature
Amb.
Operating pressure
4.5 Kg/cm2g
Minimum temperature
Amb.
Minimum Pressure
4.0 Kg/cm2g
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 10 of 12
c)
Instruments Air :The Minimum, operating and design conditions for instrument air stream shall be as follows
d)
Design temperature
65 0C
Design pressure
11.5 Kg/cm2g
Operating temperature
Amb
Operating pressure
6.5 Kg/cm2g
Minimum temperature
Amb.
Minimum Pressure
4.5 Kg/cm2g
Dew Point
Inert Gas ( Nitrogen) :The Minimum, operating and design conditions for inert gas (Nitrogen) stream shall be as
follows
e)
Design temperature
65 0C
Design pressure
10 Kg/cm2g
Operating temperature
Amb
Operating pressure
3.5 Kg/cm2g
Minimum temperature
Amb
Minimum Pressure
3.0 Kg/cm2g
Plant air :The Minimum, operating and design conditions for plant air stream shall be as follows
5.0
Design temperature
65 0C
Design pressure
11.5 Kg/cm2g
Operating temperature
Amb
Operating pressure
6.5 Kg/cm2g
Minimum temperature
Amb
Minimum Pressure
4.5 Kg/cm2g
45-VV-101
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 11 of 12
5.2
Piping Numbering
New piping will be numbered using the 3000 series; pipe class will be as per existing
piping material specification.
Philosophy for Line Tag no. :
Line size - Fluid- Line No. Unit no. - Pipe class - Insulation class
Ex.
5.3
6 P 45-3001 -B1A-N
Instruments Numbering
New instrument will be numbered using the 3000 series.
New instruments indicators / controls / interlock / shall be hooked up by NRL in the
New/ Existing DCS / PLC.
Philosophy for Instruments Tag no.:
Area Code- Item Code - Item No.
Ex.
The system will be designed in accordance with the latest addition of the codes and
standard.
List of codes and standards
6.1
ANSI
OISD
API
ASME
IBR
Piping
All process piping shall be in accordance with as per existing PMS.
6.2
Pressure Vessel
All pressure vessels shall be in accordance with ASME section VIII div1/2.
Allrightsreserved
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 12 of 12
8.0
UNITS OF MEASURMENT
The MKS system of units must be used in all engineering documentation and on
drawings with the exception of the following measurements, which must adopt the
stated preferred units.
The following units of measurements should be applied:
Temperature
[C]
Pressure
[kg/cm2g]/ bar
Volume
[m3], [l]
Length/Diameter
[m], [mm]
Mass or Weight
[kg], [ton]
Volume( gases)
[Nm3], [kmol]
[m3/h], [Nm3/h],
Flow Rate(mass)
[kg/h],
Velocity
[m/s]
Energy
[KCal]
Heat Capacity
[kCal/kg C]
Density
[Kg/m3]
Allrightsreserved
EM163-PNCV-TD-101
DOCUMENT NO
SHEET 1 OF 2
0
REV
CLIENT: NRL
CONSULTANT: PDIL
0
P
REV
18.09.2015
11.08.2015
REV DATE
18.09.2015
11.08.2015
EFF DATE
ISSUEDFORIMPLEMENTATION
ISSUEDFORREVIEW
PURPOSE
RRB
RRB
PPD
TP/VP
TP
REVWD
BRIJESH
BRIJESH
APPD
TENDER DOCUMENT
FOR CIVIL & STRUCTURAL WORKS
FOR INSTALLATION OF MOUNDED BULLETS
AT NRL, NUMALIGARH
EM163-PNCV-TD-101
0
DOCUMENT NO
REV
SHEET 2 OF 2
CONTENT
SL. No.
DESCRIPTION
DOCUMENT NO.
1.0
SCOPE OF WORK
EM163-PNCV-SOW-101
2.0
DESIGN BASIS
EM 163-PNCV-DB-101
3.0
TECHNICAL SPECIFICATION
EM 163-PNCV-TS-101
4.0
EM163-PNCV-TD-001
5.0
EM163-PNCV-PL-001
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 1 of 19
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 2 of 19
CONTENTS
S.No.
DESCRIPTION
SHEET No.
1.0
SCOPE OF WORK
2.0
3.0
DESIGN ENGINEERING
SPECIFICATIONS
12
4.0
13
5.0
16
6.0
SITE CLEANING
19
7.0
COMPLETENESS OF WORK/CONTRACT
20
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
1.
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 3 of 19
SCOPE OF WORK:
The scope of complete Civil, Structural and other Allied Works associated with
Installation of Mounded Bullets at Numaligarh refinery limited, Numaligarh shall
be design, detailed engineering, preparation of working drawings and getting
these checked and vetted by Owner/Consultant, supply, erection and construction
of structures & utilities. The scope also includes providing necessary engineering
supervision through qualified and technical personnel, skilled and unskilled
labour, material, tools & tackles etc. The scope of work also includes disposal of
debris/surplus earth & unserviceable materials at designated area outside refinery
premises as per directions of Engineer-in-charge.
1.1 All civil works shall be carried out both below and above ground level strictly in
accordance with the Scope of work, Design basis for civil & structural work,
Technical Specifications for civil, structural & other allied work, relevant IS Codes
& CPWD specifications. The scope of work shall also be read in conjunction with
other attachments of tender documents including tender drawings.
1.1.1 The Order of priority of documents for specifications of materials and
workmanship shall be as follows:
a)
Approved drawings
b)
Scope of work
c)
d)
Bureau of Indian Standard Codes (BIS Codes) with latest amendments &
OISD.
e)
Indian Road Congress (IRC) for road works and Central Public Works
Department (CPWD) for other works with latest amendments
1.1.2
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.
1.2.
Page 4 of 19
The complete civil, structural and allied works associated with the Installation
of Mounded Bullets at Numaligarh refinery limited, Numaligarh shall be, but
not limited, to as below:
i)
Mound for 4 Nos LPG storage vessels (LPG bullets) supported on RCC
Pile Cap along with RCC inspection trench, retaining wall, collection pits,
stair case as shown and detailed in enclosed drawings including
installation of bullets in position.
ii).
iii).
iv).
RCC peripheral water drain shall be provided all around the mounded
bullet foundation after 1.0 m(min.)x 100mm thk. ( min.) plinth protection.
The size of drain shall be 500 x 600 mm depth having precast cover with
pot holes. The drain shall be suitable designed to connect with the existing
drain of the plant. If required collection pit/manhole shall be considered as
per codes. Storm water drains of min. 600mm width running along the
mound and connected to existing storm water drain.
v).
vi).
vii).
viii).
ix).
x).
Stripping & rebuild of existing piles required for pile cap shall be in scope of
Contractor including construction of pile cap.
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 5 of 19
xi).
xii).
xiii).
1.3
Statutory Approvals
The following points must be noted and taken into consideration by the
contractor:
a)
b)
c)
All sources of danger from live electric wire, flooding, caving etc. should
be effectively checked.
d)
The construction shall comply to all fire proofing requirements as per IS:
164. Besides, fire protection and safety requirements as per stipulations
of OISD: 150, OISD: 116, OISD: 144, OISD: 118 shall also be complied
to.
e)
f)
g)
h)
Local fire barriers shall be used as per instruction of Engineer- In- Charge
in line with Operation/ Production requirement.
i)
j)
All steel structures are to be treated with coats of primer and finish paints
as per painting specifications specified or manufacture specifications.
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
k)
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 6 of 19
l)
m)
Suitable chemical anchors & bolts of HILTI make or equivalent shall be used
for facilitating connections & joinery as per requirement.
2.0
2.1
2.1.1
SAND BED:
The sand for the bullet bed, bullet surround and filling between bullets shall
consist of material complying with the following specifications:
i).
ii).
iii).
iv).
2.1.2
b.
Sand filling placed between bullets and line extending out at 45o from the
center of the bullet above the bullet center line shall be hand compacted
and fill placed outside this line shall be machine compacted (both to a
minimum of 95% maximum dry density).
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
c.
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 7 of 19
d.
e.
Sand filling shall be brought up to the levels and slopes as denoted on the
drawings to below the drainage layer.
2.1.3
PEA GRAVEL:
The pea gravel shall be surrounding perforated PVC drain these shall consist
of clean washed, size varying from 6 to 12 mm (average size 8 mm) round
stone free from all organic matter, dust or any other deleterious material.
2.1.4
NON-WOVEN GEOTEXTILE:
a. Non woven geotextile sheet TERRAM 1000 or equivalent shall be used for
separating two different material layer. A layer is to be provided between
stone finish and UPVC layer as shown in drawing. (Drg. No. EM163-PNCVTD-001 Rev. 0).
b. The textile shall be laid carefully to avoid damage/ tearing etc. Minimum 300
mm overlap is to be maintained at the junctions of two rolls.
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
2.1.6
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 8 of 19
mortar. The voids between boulders shall be filled with 1:6 cement mortar. The
top shall be flush pointed neatly with 1:6 cement mortar to give aesthetic view
of the mound. Proper drainage arrangement shall be made to carry
water
RETAINING WALL:
An all round RCC retaining wall shall be provided in around mounds. The height
shall be as per attached drawing. The inside face of wall shall be vertical and
outside face shall be tapered as per design requirement. One all around storm
water channel on top of retaining wall as shown in drawing is to be provided
with sufficient no. of suitable no. of CI pipes ( as per CPWD specifications ) for
disposal of rain water to nearest drainage system. 100 dia GI pipe sleeve weep
holes laid with downward inclination are be provided at a height of 300 mm
above ground at a spacing of 2500 mm (min.)for dissipating rain water during
construction period in all retaining walls. Suitable expansion joints as per
standard engineering practices shall be provided in retaining walls as per
requirements. Insert plates on outer and inner faces of retaining wall as per
requirements shall be provided. The sub surface water shall not be allowed to
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 9 of 19
enter bullet mound and underground collection pits as shown in drawings shall
be provided to prevent entry for the same.
2.1.10 STEPS & STAIRCASES:
All retaining walls are to be provided with RCC staircase as per standard
engineering practices. RCC steps in M-30 grade are to be provided for
negotiating from top of retaining wall to mound top. These steps shall be cast
along with 100 thick RCC base. The desired tread and risers shall be 250 & 150
mm. The width of staircase & steps shall be 1500 mm. M.S. hand rails as per
details shown are to be provided on both sides.
2.1.11 COLUMNS ON TOP OF MOUND;
If some utility and flare lines are to be laid above mound. Columns supporting
these shall be of RCC, to be suitably anchored to sand bed. Some of these
columns may have to be supported directly on retaining wall and necessary
provision in design/ detailing shall be kept for the same.
2.1.12 RCC TRENCH
RCC trenches of height 2.0m( min.) X 1.7m width (min.) are to be provided for
each bullet as shown in tender drawing. Outlet nozzles (pipes) shall be placed
off centre in this trench. The level of raft of the trench shall not be less than
pavement level. Elastometric bearing (Neoprene padding) as per IRC: 83 shall
be placed at contact surface of top slab and bullet shell to protect bullet shell.
The minimum thickness of neoprene padding shall be 150 mm. The height of
trench shall be sufficient, so that a person can move easily. This can be
reduced near bullet shell by making local adjustment. All trenches shall have
provision of double panel steel doors, openable from outside. These shall be
fixed in retaining walls. The steel doors shall be made with fabricated steel
sections with M.S. sheeting on both faces. While fabricating, the shape of door
shall be designed, keeping in mind, that stability of outlet pipe is not disturbed
due to its operation. Locking arrangement from outside shall also be provided in
doors.
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EM163-PNCV-SOW-101
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a. The floor shall be 250 mm thick heavy duty RCC floor with two layer of
reinforcement placed at centre in both directions with 25 thick IPS toppings.
b. Arrangements for operational HOT Crane shall be kept (if required).
2.2
FIRE FIGHTING :
Generally, new pipelines for firefighting as per details mentioned in other parts of
enquiry documents are to be laid. The main pipelines shall be laid on pipe sleepers.
The height of sleepers above FGL shall be as per functional requirements.
Shielding walls for Deluge valve shall be of RCC-200 mm thick. Cross overs &
platforms for valve operation shall be provided as per requirements. These shall be
of structural steel. Hand rails on both sides of stairs and all round for platforms shall
be provided. The foundation system shall be shallow foundation. For fire water lines
laid on top & sides of mound, RCC pedestals with minimum 500 mm deep
anchorage shall be used.
2.3
PIPE SLEEPERS
Pipe sleepers shall be provided for supporting various utilities. The foundation
system shall be shallow foundation. The length, height and width of these shall be
as per functional requirements. Modification in existing pipe sleepers, construction
of new supports, consequent to relocation of some of utilities or otherwise are also
included in scope.
3.0
3.1
GENERAL
3.2
The design considerations given here under indicate the minimum basic
requirements of reinforced cement concrete, brick masonry and structural steel
works. However, all structures shall be designed as per relevant IS code of
practices and according to standard practices for the satisfactory performance of
the functions for which the same are to be constructed.
3.3
Whenever any reference to IS Codes is made, the same shall be taken as the latest
revision with all amendment issued therewith at the time of execution.
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
3.4
EM163-PNCV-SOW-101
DOC. NO.
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Apart from the IS Codes mentioned in particular in the various clauses of this
specification, all other relevant codes related to the specific job under consideration
and / or referred to in the above mentioned codes shall be followed wherever
applicable. Reference to some of the codes in the various clauses of this
specification does not limit or restrict the scope of applicability of other relevant
codes.
3.5
3.6
3.6.1 The foundation of mound, pipe / cable rack trestles etc; shall be supported on RCC
bored min. 450mm dia. vertical piles. Miscellaneous foundations such as trenches,
pipe supports, etc., may rest on cohesive non-swelling soil. For Shallow foundation,
footing shall be designed as per Net Bearing Capacity of soil at a suitable depth
below the Original Ground Level as specified in soil report.
3.6.2 Other related parameters such as soil profile, design depth of water table, type of
foundation and anticorrosive treatment for underground concrete works in view of
the pressure of harmful chemicals in soil and subsoil water, recommendation of soil
investigation report shall be followed. If the soil and subsoil water is corrosive,
necessary precautions shall be taken care of for all concrete work / surfaces in
contact with the soil either as per the recommendations of IS : 456 or by providing
necessary treatment depending upon the nature of corrosiveness of soil at the
proposed site.
3.6.3 Care shall be taken to avoid any fouling of foundation with adjacent existing
foundations of buildings / structures and suitable adjustment in depth, location and
sizes may have to be done depending on the actual condition prevailing at site. No
extra claim for such adjustments will be acceptable by the Owner/Consultant.
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4.0
4.1
Page 12 of 19
required civil and structural Drawings needed for correct and accurate construction.
The design shall comply
All design engineering and preparation of Drawings shall be carried out by the
Contractor in their own design office. If such facilities are not available with the
Contractor, it shall be done by an established agency that has done similar type of
jobs and mounded bullet in particular. The name of such agencies, with their
credentials who may be considered for entrusting with the above design and
preparation of drawing works, shall be submitted along with the offer for approval
of Owner/Consultant. If none of the agencies so named is approved, the
Contractor shall submit a fresh list for approval.
4.3
All Drawings shall be of standard sizes and prepared in ink in metric units showing
dimensions in millimeters and elevations / levels in meters. Drawings shall
indicate quantities of concrete grade wise and or nominal mix wise, reinforcement
bars diameter wise and structural steel section wise and or thickness wise as
detailed therein.
4.4
The Contractor shall submit requisite number of prints (as mentioned elsewhere)
of the supporting design calculations along with explanatory notes / sketches,
computer inputs & outputs and Drawings (complete in all respects) to
Owner/Consultant for review and checking purposes. All the above design
calculations and Drawings submitted by the Contractor shall be completed in all
respects and thoroughly checked, approved, stamped as "Approved for
Construction" and signed by the Contractor's
authorized representative
(irrespective of the fact that whether the same are prepared in the Contractor's
own Design Office or by an Approved Agency to ensure accuracy and
correctness) therefore submission to the Owner/Consultant. Incomplete,
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unchecked and unsigned Drawings and design calculations shall not be accepted
for review / checking and will be returned forthwith.
4.5
The Contractor shall submit a schedule for release of Drawings made in line with
the time schedule given elsewhere.
4.6
The design calculations and drawings prepared for this works shall have to be
checked and approved by the Owner/Consultant as per mutually agreed time
schedule and the Contractor should strictly adhere to these approved drawings
and specifications. Construction work shall be
of
the
fact
whether
the
same
has
been
approved
by
The Contractor shall indicate the names of the computer software to be for drafting
and analysis / design work. The Contractor shall get the approval of the
Owner/Consultant for the computer software's prior to their use. The Contractor
shall forward to Owner/Consultant four prints of design calculations and
Drawings preferably for the whole work at a time along with all the concerned civil
scope Drawings and load data sheets.
review
checking
and
approval. The contractor shall start submitting such first set of design calculations
_____________________________________________________________________________________________________________
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FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
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DOC. NO.
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and Drawing within thirty days from the date of issue of Letter of Intent and
complete the submission of the same for all the items / units to Consultant's Office
within the period mutually agreed upon depending on the volume of job. Any delay
in submission of design calculations and / or Drawings with complete data and
getting the same approved from Consultant shall not absolve the contractor of
their responsibility to complete the work within the completion time.
4.8
If at a late stage, the contractor feels the necessity for any addition or alteration,
prior approval of Consultant must be taken for effecting the changes. The
contractor shall also be bound to incorporate any addition and alteration, which
Owner/Consultant may suggest at a later stage.
4.9
4.10
4.11
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FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
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4.12
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After the completion of erection and construction work, the Contractor shall
submit to the Consultant six prints each of the "As built " Drawings along with two
sets of reproducible and one compact disk(CD) of approved brand containing
drawing prepared in Autocad Latest Version.
5.0
5.1
5.2
The bidders shall be fully responsible for the correct setting out and execution of
the work in accordance with approved drawings. Deviations from approved
drawing shall not be allowed. Any such deviations to be rectified by the
contractor at his own cost without any liabilities to owner. All tools, tackles,
construction equipments etc. shall be responsibility of the bidder.
5.3
For obtaining the preliminary approval prior to drawings at least three copies of
each drawing shall be sent. One copy of this preliminary approved drawing duly
corrected and signed wherever necessary will be returned to the contractor for
preparing and resubmitting drawings in 3 copies for final approval.
5.4
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FOR CIVIL & STRUCTURAL WORK
EM163-PNCV-SOW-101
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fabrication drawing they have to submit the design of all joints for full strength. All
calculations to carried out as per relevant IS codes.
5.5
5.6
The LSTK rates to be quoted are to be fully inclusive of the value of the complete
work described under several items including all costs and expenses which may
be required in and for the construction of the work described together with all
taxes, general risks, liabilities and obligations (e.g. temporary buildings, fencing,
watching, lighting, insurance, labour regulations, indemnity, maintenance and the
like). The prices are to be inclusive of all labour, materials, tools, plants,
equipments, hoists, tackles, scaffoldings, and the sundries etc. as may be
necessary for the full and entire completion of the work in all respects.
5.7
5.8
Materials like sand, gravel, boulders etc. are to be procured from queries
approved from Owner/Consultant. Fulfillment of all necessary statutory rules like
taking permission from mines department and payment of royalty is to be
arranged by contractor.
5.9
5.10
Tests: According to the nature and importance of works owner shall demand the
conduct of tests on concrete materials and steel etc. in which case the contractor
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FOR CIVIL & STRUCTURAL WORK
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EM163-PNCV-SOW-101
DOC. NO.
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shall get the same done at his own cost in a laboratory to be approved by
Owner/Consultant.
5.11
No work shall be undertaken at site until detailed approved drawings have been
approved by Owner/Consultant in writing. Subsequent revisions in the drawings
which become necessary shall be incorporated and to be submitted by the
contractor to Engineer-In-Charge for approval. Revision work at shall not
commence unless the revised drawing is approved by Owner /Consultant.
Nothing extra shall be paid on this account and no claim whatsoever will be
entertained on this account and also no extension in the completion time should
be allowed for these changes. Owner/Consultant reserves to themselves the
right to modify/revise/alter etc. the scope supplied to contractor.
5.15
Any fabrication / construction done before final approval of the drawings shall be
the contractor's responsibility.
5.16
No compensation for any damage done by rain or traffic during the execution of
the work shall be made by Owner/Consultant.
5.17 The portion which is under "HOLD" shown in the approved drawing, the
construction of that the portion would be kept under "HOLD". For clearing the
HOLD the contractor has to submit the drawing with revision for approval of
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SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
EM163-PNCV-SOW-101
DOC. NO.
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Page 18 of 19
Engineer-In-Charge. The contractor can execute only after the said "HOLD" is
withdrawn and Engineer-In-Charge has approved it. The contractor on this
account shall not be entitled to claim for any compensation.
5.18 The work shall have to be so arranged, planned and programmed as to complete
all work within the schedule time. Bidder shall have to strictly adhere to time
schedule.
5.19
The contractor shall prepare and get approved from Owner/Consultant, the bar
bending schedule for all reinforced cement concrete work as per detailed
drawings furnished by them.
5.20
5.21
In order to ensure the proper quality of cement to be used, contractor shall carry out
following tests at site at the rate of half percent for each lot of cement received before
consuming the cement in the work:
a) Initial setting time
b) Final setting time.
c) Compressive test of cement paste for 3 days duration.
Test results shall be properly recorded and maintained at site.
5.22
6.0
SITE CLEANING
During construction and on completion of construction (inclusive of all internal and
external finish), clearing all the debris and waste materials scattered around the site
and disposal of the same as per direction of the Engineer- In- Charge shall be in the
scope of the Contractor.
_____________________________________________________________________________________________________________
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
7.0
7.1
EM163-PNCV-SOW-101
DOC. NO.
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Page 19 of 19
COMPLETENESS OF WORK/CONTRACT
The scope of work mentioned in the contract/NIT is not the comprehensive one, but
gives total idea/outline of the scope of work; however contract shall be responsible for
completeness of the job for the purpose indicated elsewhere to make the system fully
functional and operational.
7.2
The work furnished shall be complete in every respect with all mounding, fittings,
fixtures and standard accessories etc. normally provided for such item/ equipment
and or needed/required for erection, completion and safe operation of the
item/equipment/system as required by applicable codes/OISD-NORMS though they
may not have been specially detailed in the respective specifications, unless
included in the list of exclusions.
7.3
Any additional items and materials which are not specifically mentioned but are
required to complete the system offered in every respect in accordance with the
technical specifications and required for safe operation
and quaranteed
_____________________________________________________________________________________________________________
EM 163-PNCV-DB-101
Document No.
Rev.
Sheet 1 of 9
DESIGN BASIS
FOR CIVIL & STRUCTURAL WORK
Allrightsreserved
EM 163-PNCV-DB-101
Document No.
Rev.
Sheet 2 of 9
CONTENTS
S.No
Item
Page No
1.0
INTRODUCTION
2.0
DESIGN LOADS
3.0
4.0
5.0
6.0
OTHER SPECIFICATIONS
7.0
FABRICATION DRAWING
8.0
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Document No.
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Sheet 3 of 9
1.0 INTRODUCTION
1.1
Scope
This engineering design basis defines the minimum design criteria that shall form the basis for
carrying out detailed design engineering of mound for LPG Bullets and associated facilities.
All structures shall be designed for the satisfactory performance of the functions for which they
are being constructed.
1.2
Units of Measurement
Units of measurement shall be in metric system.
1.3
IS:800
IS:816
Code of practice for use of metal arc welding for general construction
IS:875
IS:1893
IS:2911
IS:13920
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Document No.
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Sheet 4 of 9
Dead Loads
Dead load shall comprise of the weight of all permanent construction including retaining walls,
filling material, floors, stairways and fixed services
Bullets shall be considered as full of water for test case.
2.2
Equipment Loads
The empty / operating / test weight of equipment including all fixtures, platforms, ladders and
attached piping, shall be considered. If piping weight is not indicated separately or not included
in the weight of the equipment, the same shall be taken as 10% of the weight of the equipment.
2.3
Live Loads
Live loads shall, in general, be as per IS:875. However, the following minimum live loads shall
be considered in the design of structures to account for maintenance and erection phases; if
equipment layout / vendor drawings indicate loads of greater magnitude, the same shall be
adopted.
2.4
1. Top of mound -
5.0 kN/m
2. Staircase
5.0 kN/m2
Wind Loads
Wind loads for structural design shall be as per IS-875 (Part-3). The design life span of all
structures, except temporary structures shall be taken as 50 years.
2.5
Seismic Loads
Seismic loads shall be as per IS:1893 (Latest Revision).
2.6
Miscellaneous Loads
Apart from the specified live loads, possible overloading during construction / hydro-test
maintenance / erection shall also be considered in the design Job specifications and shall also
be referred to, for any specific loading.
Hydrostatic pressure shall be adequately accounted for, in the design of structures, below
ground water table.
All the handrails, parapets, parapet walls, balustrades shall be designed for horizontal load
mentioned in Table 3 of IS-875 (Part-2).
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Sheet 5 of 9
2.7
Load Combinations
Structure & its member shall be designed for worst combination of the above loads.
General
Foundation sizing shall be based on working loads without any factor.
3.2
Pile Cap
Pile cap shall be designed to cater the entire load of the mound (including the bullets).This shall
be resting on pile heads, layout of which is attached in the tender.
3.3
Foundation Bolts
General
All retaining walls, access tunnels, trenches, pits etc. shall be of RCC and designed based on
the applicable IS codes (latest revision with all amendments, issued there to) .
Only limit state method as per IS:456 shall be followed for the design unless otherwise specified
elsewhere for special structures.
Where the specified design depth of groundwater table so warrants, all underground pits,
tunnels, basements, etc. shall be leak-proof R.C.C. construction using water proofing
compounds.
4.2
Concrete Grade
43 GRADE OPC should be used.
Minimum M30 Grade Reinforced Cement Concrete shall be used in RCC pile cap, Retaining
wall for the mound, and water retaining structures, if any.
Minimum M25 grade of reinforced cement concrete shall be used for all other structures and
foundations except for grade slabs / paving for which M20 may be used. From durability
consideration the minimum cement content and maximum water-cement ratio shall be as
follows :
Type of Cement
Plain concrete
Reinforced concrete
Remarks
Exposure
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Document No.
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Sheet 6 of 9
Condition
43 Grade-OPC
Minimum
cement
content (kg/m)
Maximum
watercement
ratio
Minimum
cement
content
(kg/m)
Maximum
watercement
ratio
240
0.55
330
0.45
Moderate
100 mm thick lean concrete of grade M10 (nominal mix) shall be provided under all RCC
foundations. The lean concrete shall extend 100 mm beyond the foundation.
4.3
Reinforcement Bars
All reinforcement bars for RCC works should be high yield strength deformed TMT steel bars
of grade Fe500D conforming to IS:1786 of make SAIL,RINL,TISCON,IISCO.
4.4
4.5
Expansion Joints
Expansion joints in concrete structures shall be provided at 30-35 m. Sliding joints shall be
avoided as far as possible.
4.6
Miscellaneous Applications
4.6.1 Admixtures
Generally admixtures should not be used. If required, admixtures shall conform to IS:9103
and to be mixed with concrete strictly as per manufacturers recommendations.
4.6.2
Plinth protection
The peripheral area around bullet foundation & building shall be provided with minimum 1.0
m wide concrete M20, 100 thick laid on 75 mm thick M10 concrete with 8 Tor @ 250 c/c both
ways Reinforcement bars all round as plinth protection. A surface drain to be provided alongwith plinth protection which shall be connected to the drainage system of the plant.
4.6.3
5.1.1
Design, fabrication and erection of structural work shall be carried out in accordance with the
following IS Codes as applicable to the specific structures, viz, IS:800, 816, 875, 1893, etc.
Basic consideration of structural frame work shall primarily be stability, ease of
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Sheet 7 of 9
Steel staircases shall have channels provided as stringers with minimum clear width of 1000
mm. Minimum size of Stringer channel shall be MC200. The vertical height between
successive landings shall not exceed 4.0 meters. Treads shall be minimum 250 m wide
made of grating (with curved chequered plate nosing) spaced equally so as to restrict the
rise to maximum 150 mm. If relevant local by-laws or applicable Factory Act Rules stipulates
more stringent requirements in this regard, the same shall be adhered to.
5.1.3
5.1.4
Bolted connections shall be adopted as far as practicable, except for cases where welded
connections are required. Structural connections shall have minimum two bolts of 20 mm dia,
unless otherwise limited by the size of members.
5.1.5
Lock nuts shall be provided for anchor bolts of structures, process columns, vibrating
equipment, etc.
5.1.6
Minimum two nuts shall used for all anchor bolts except for ladder, stair and hand rail.
5.2
Steel Grade
Structural steel shall be of yield stress of 250 Mpa conforming to grade B of IS:2062. Make of
steel shall be SAIL, RINL, TISCON, IISCO.
Platforms
Platforms shall be provided according to the requirements for regular operating procedure and
normal recurring maintenance.
6.2
Hand Rail
Flexible hand rail system consisting of 1050 mm high vertical posts @ max 1.5 mtr C/C made
up of 32 NB medium duty pipe, top and middle hand rail of size 32 NB and 25 NB MS pipe
respectively and MS Flat 100 mm x 6 mm Toe guard, all jointed, bended and welded with
suitable angle cleat or plates and base plate of size 100 mm x 50 mm x 8 mm thick properly
welded with vertical posts and sand blasting followed by one coat of epoxy primer and two
coats of finished paint as per specifications shall be provided.
Site Grading
The grading of the area shall be done by cutting and filling with the following:
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1. Cutting Area :
2. Filling Area :
8.0
Specific Requirement:
8.1
Fire Proofing: The contractor shall design, supply and apply vermiculite type of fire proofing to
structural steel members, wherever required, as per OISD Standard, TAC rules and other
requirements as applicable. The Fire proofing of 2 Hours rating shall be provided to all
exposed portion on major or minor structures.
8.2
LSTK Contractor shall get the design mix done from reputed and approved laboratory in
consultation with owner/ consultant before start of civil works.
8.3
8.4
All reinforcement bars shall be TMT (Thermo Mechanical Treated) only. All
and reinforcements shall be procured from SAIL / TISCO or RINL.
8.5
8.6
8.7
8.8
Minimum grade of concrete mix for RCC work in Pile cap shall be M:30.
8.9
structural steel
8.10 Cement in foundations shall be Sulphate Resisting Portland Cement conforming to IS:12330 ,if
sulphate content is present in soil.
8.11 Minimum size / section structural members shall be:a.
b.
c.
d.
e.
8.12 Clear Height and width of Man access Tunnel shall be minimum of 2000mm X 1700mm to
provide with closed at rear end. The bottom of man access tunnel shall be minimum 100mm
above FFL .Man access Tunnel shall be designed of RCC with minimum thickness of wall and
slab 250mm with opening for cables and pipes as required. The fixing arrangement shall be
provided on R.C.C surface where ever required.
8.13 The RCC foundation /pile cap shall be designed with minimum thickness of 1500mm .The top
of R.C.C retain wall shall have 300mm with a provision of R.C.C. drain with clear width of
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350mm X depth of 450mm with proper slope having outlet through rain water down take C.I.
pipe of minimum dia. 150mm all fittings and bends to provide for smooth flow of storm water.
8.14 The top of mound shall have Cement concrete. block of minimum size
mmX450mmX200mm Thickness with rounded edge and corners.
300
8.15 The minimum filling above the vessel including top layer shall not be less than 1000mm.
8.16 Soft copies of input files, for analysis & design calculations for all the RCC & Steel structures
shall also be submitted along with hard copies. Other calculations can be submitted in hard
copy.
8.17
8.18
Review of drawing & documents / supervision & inspection done by Owner/Consultant or its
representative will not off-load the LSTK-contractor from any of its responsibility.
8.19
To fulfill all statutory requirement of project and to maintain good quality in work shall be the
responsibility of the LSTK Contractor.
The above shall be read in conjunction with the Scope of work, Technical requirements &
Specifications given elsewhere in this document.
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TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
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TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
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TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
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Page 2 of 22
CONTENTS
SL.NO DESCRIPTION
PAGE NO.
1.
GENERAL
2.
REFERENCE STANDARDS
3.
EARTH WORK
4.
5.
STEEL REINFORCEMENT
11
6.
FORM WORK
12
7.
14
8.
15
9.
18
10.
PLASTERING
19
11.
WHITE
&
COLOUR
WASHING,
CEMENT 20
PAINTING
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1.0 GENERAL
1.1
Wherever reference of BIS Specifications/ or BIS Codes of Practice are made in the
Specifications/ Schedule of Rates or Preambles, reference shall be to the latest
edition of BIS (Bureau of Indian Standards).
IS - 383
IS - 432
IS - 455
IS - 456
IS - 800
IS - 816
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3.0
EARTHWORK
3.1
Excavation
Document No.
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3.1.1 Excavation shall be carried out in soil of any nature and consistency, in the
presence of water or in the dry, met on the site to the lines, levels and contours
shown on the detailed drawings and contractor shall remove all excavated materials
to soil heaps on site or transport for use in filling on the site or stack them for reuse
as directed by the Owner / Consultant.
3.1.2 Surface dressing shall be carried out on the entire area occupied by the buildings
including plinth protection as directed without any extra cost. The depth of
excavation shown on the drawings is the depth after surface dressing.
3.1.3 The site around all buildings and structures to a width of 3 metres beyond the edge
of plinth protection, ramps, steps, etc. shall be dressed and sloped away from the
buildings.
3.1.4 Black cotton soil, and other expansive or unsuitable soils excavated shall not be
used for filling in foundations, and plinths of buildings or in other structures including
man holes, septic tanks etc. and shall be disposed off within the contract area
marked on the drawings, as directed, leveled and neatly dressed.
3.1.5 In case of trenches exceeding 2 metres depth or where soil is soft or slushy, the
sides of trenches shall be protected by timbering and shoring. The Contractor shall
be responsible to take all necessary steps to prevent the sides of trenches from
caving in or collapsing. The extent and type of timbering and shoring shall be as
directed by the Owner / Consultant.
3.1.6 Where the excavation is to be carried out below
structure, the precautions to be taken such as under pinning, shoring and strutting
etc. shall be determined by Owner / Consultant. No excavation shall be done
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unless such precautionary measures are carried out as per directions of Owner /
Consultant.
3.1.7 Specification for Earthwork shall also apply to excavation in rock in general. The
excavation in rock shall be done such that extra excavation beyond the required
width and depth as shown in drawings is not made. If the excavation done in depth
greater than required / ordered. The contractor shall fill the extra excavation with
concrete of mix 1:5:10 as the foundation concrete at his own cost.
3.1.8 Contractor shall make all necessary arrangements for dewatering / defiling as
required to carry out proper excavation work by bailing or pumping out water, which
may accumulate in the excavation pit from any cause/ source whatsoever
3.1.9 Contractor shall provide suitable draining arrangements at his own cost to prevent
surface water entering the foundation pits from any source.
3.1.10 The contractor is forbidden to commence the
out concreting before Owner / Consultant has inspected, accepted and permitted
the excavation bottom.
3.1.11 Excavation in disintegrated rock means rock or Boulders including brickbats which
may be quarried or split with crow bars. This will also include laterite and hard
conglomerate.
3.1.12 Excavations in hard rock - meant excavation made in hard rock to be done
manually, or by blasting using only explosives and / or pneumatic hammers. In case
of blasting, control blasting should be adopted depending on site conditions. For
using explosives contractor shall follow all provisions of Indian Explosives Act /
Rules 1983, corrected / revised upto date.
3.1.13 In case of hard rock excavation to be carried out using explosives the, contractor
shall obtain the written approval in advance.
3.1.14 The measurements for excavations shall be restricted and limited to minimum
excavation line as per drawing for payment purposes.
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
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3.2
FILLING
3.3
Back filling of excavations in trenches, foundations and elsewhere shall consist of one
of the following materials approved by Owner / Con
i) Soil
ii) Sand
iii) Moorum
iv) Hardcore
v) Stone/gravel
All back filling material shall be approved by the Owner / Consultant
3.2.1 Soil / moorum filling - Soil material shall be free from rubbish, roots, hard lumps and
any other foreign organic material. Filling shall be done in regular horizontal layers
each not exceeding 20 Cm. depth.
3.2.2 Back filling around completed foundations, structures, trenches and in plinth shall be
done to the lines and levels shown on the drawings.
3.2.3 Back filling around pipes in the trench shall be done after hydro testing is done.
3.2.4 Back filling around liquid retaining structures shall be done only after leakage testing
is completed and approval of Owner / Consultant is obtained.
3.2.5 Sand used for filling under foundation
etc. shall be fine/ coarse, strong, clean, free from dust, organic and deleterious
matter. The sand filling under foundation shall be rammed with Mechanical
compactor. Sand material shall be approved by Owner / Consultant.
3.2.6 Moorum for filling shall be supplied by NRL as per terms and conditions as
stipulated in other parts of tender documents. Size of moorum shall vary from dust
to 10 mm.
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TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
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4.1
Materials
4.1.1 Water: Water used for mixing and curing concrete and mortar shall conform to the
requirements as laid down in clause 5.4 of IS: 456: 2000. Seawater shall not be used
for concrete work.
4.1.2 Aggregates: Coarse and fine aggregates for cement concrete plain and reinforced
shall conform to the requirements of IS 383 and / or IS 515. Before using, the
aggregates shall be tested as per IS: 2386.
4.1.3 Coarse aggregate: Coarse aggregate for all cement concrete work shall be broken or
crushed hard stone, black trap stone obtained from approved Quarries or gravel.
4.1.4 Sand: Fine aggregate for concrete work shall be coarse sand from approved sources.
Grading of coarse sand shall be within grading zones I, II or III be laid down in IS:
383, table 4. If required the aggregates (both fine and coarse) shall have to be
thoroughly washed and graded as per direction of Owner / Consultant.
4.2
Mixing: All cement concrete plain or reinforced shall be Ready mixed Concrete unless
mentioned otherwise. Mixing by hand may be employed where quantity of concrete
EM 163-PNCV-TS-101
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FOR CIVIL & STRUCTURAL WORK
Document No.
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involved is small, with the specific prior permission of the Owner / Consultant. 10%
extra cement shall be added in case of hand mixing
4.3
Water Cement Ratio: Once a mix, including its water-cement ratio, has been
determined and specified for use by the Owner / Consultant, that water cement ratio
shall be maintained.
4.4
has
inspected and passed the sub-base / base or the centering, shuttering and
reinforcement. Concrete in slab beams, columns, footings etc. shall be laid gently in
layers not exceeding 15 cm and shall be properly consolidated by means of
approved mechanical vibrators.
4.5
Curing
a) After the concrete has begun to harden, it shall be protected with moist Gunny
bags, sand or any other material approved by the Owner / Consultant against
quick drying. After 24 hours of laying concrete, the surface shall be cured by
flooding with water or by covering with wet absorbent materials for 7 days as per
the direction of Owner / Consultant.
b) Approved curing compounds may be used in lieu of moist curing with the
permission of the Owner / Consultant. Such compounds shall be applied to all
exposed surfaces of the concrete as soon as possible after the concrete has set.
No extra payment shall be made for the same.
4.6
Grades of Concrete
i)
M 7.5
7.5
ii)
M 10
10
iii)
M 15
15
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iv)
M 20
20
v)
M 25
25
vi)
M 30
30
4.6.1 A sieve analysis test of aggregates shall be carried out as and when the source of
supply is changed without extra charge not withstanding the mandatory test
required to be carried out as per relevant IS codes.
4.6.2 All tests in support of mix design shall be maintained as a part of records of the
contract. Test cubes for mix design shall be prepared by the contractor under his
own arrangements and at his costs, but under the supervision of the Owner /
Consultant.
4.7
4.7.1
4.7.2
Soon after the contractor gets L.O.I. to commence the work, he shall carry out
preliminary tests for design mix on trial mixes proposed by him in design of mix to
satisfy the Owner / Consultant that the characteristic strength specified in clause
3.6.1 is obtained. Prior to this may ask the contractor has to get design mix done
as per IS: 10262 through govt. approved/reputed institute and contractor shall
arrange the same at his own cost. The concrete mix to be actually used shall be
approved by the Owner / Consultant.
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FOR CIVIL & STRUCTURAL WORK
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4.7.3 The workability of concrete produced shall be adequate, so that the concrete can
be properly placed and compacted. The slump shall be as follows, when vibrators
are used.
i) Mass concrete in RCC
10 to 25 mm
25 to 40 mm
simply reinforced :
iii) Thin RCC sections or
40 to 50 mm
Testing of concrete
4.8.1 Testing of concrete, sampling and acceptance criteria shall be in accordance with
Clauses 15, 16 & 17 of IS-456: 2000.
4.9
4.9.1 The specifications for pre cast concrete will be similar as for the cast in situ concrete.
All pre cast work shall be carried out in a yard made for the purpose. This yard shall
be dry, properly levelled and having a hard and even surface. If the ground is to be
used as a soft former of the units, shall be paved with concrete or masonry and
provided with a layer of plaster (1:2 proportion) with smooth neat cement finish or a
layer of MS sheeting. The casting shall be over suitable vibrating tables or by using
form vibrators as per directions of Owner / Consultant.
4.9.2 The yard, lifting equipment, curing tank, finished material storage space etc. shall be
designed such that the units are not lifted from the mould before 7 (seven) days of
curing and can be removed for erection after 28 (Twenty Eight) days of curing. The
moulds shall preferably be of steel or of timber lined with G.I.sheet metal. The yard
shall preferably be fenced.
4.9.1
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FOR CIVIL & STRUCTURAL WORK
4.9.2
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Pre cast concrete units, when ready shall be transported to site by suitable means
approved by Owner / Consultant. Care shall be taken to ensure that no damage
occurs during transportation. All adjustments, leveling and plumbing shall be done
as per the instructions of the Owner / Consultant. The contractor shall render all
help with instruments, materials and staff to the Owner / Consultant for checking
the proper erection of the pre cast units.
4.9.3
After erection and alignment the joints shall be filled with grout or concrete as
directed by Owner / Consultant. If shuttering has to be used for supporting the pre
cast unit they shall not be removed until the joints has attained sufficient strength
and in no case before 14 (fourteen) days. The joint between pre cast roof planks
shall be pointed with 1:2 (1 cement : 2 sand) mortar where called for in the drgs
4.10
4.11
Construction Joints: Construction joints shall be made only where shown on the
drawings or as approved by the Owner / Consultant. The procedure given in
clause 13.4 of IS: 456 shall be followed for general guidance.
4.12
4.13
5.0
STEEL REINFORCEMENT
5.1
All joints in reinforcement shall be lapped adequately to develop the full strength of
the reinforcement, unless reinforcement are as per provision of IS : 456 or as per
instruction of Owner / Consultant.
Following procedure shall be followed for welding of TMTsteel reinforcement bars.
EM 163-PNCV-TS-101
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FOR CIVIL & STRUCTURAL WORK
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6.0
FORM WORK
6.1
The shuttering or formwork shall conform to the shape, lines and dimensions as
shown on the drawings and be so constructed as to remain sufficiently rigid during
placing and compacting of the concrete and shall be sufficiently tight to prevent
loss of liquid from the concrete. The surface that becomes exposed on the
removal of forms shall be examined by Owner / Consultant or his authorised
representative before any defects are made good. Work that has sagged or
bulged out, or contains honey combing, shall be rejected. All shuttering shall be
plywood or steel shuttering.
6.2
The Contractor shall be responsible for sufficiency and adequacy of all formwork.
Centering and formwork shall be approved by the Owner / Consultant, before
placing of reinforcement and concreting.
6.3
Stripping Time : Forms shall not be struck until the concrete has reached
strength at
least
the time of removal of formwork. The strength referred to shall be that of concrete
using the same cement and aggregates, with the same proportions and cured
under conditions of temperature and moisture similar to those existing on the
EM 163-PNCV-TS-101
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FOR CIVIL & STRUCTURAL WORK
Document No.
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work. Where possible, the formwork shall be left longer as it would assist the
curing.
Note 2 - The number of props left under, their sizes and disposition shall be such
as to be able to safely carry the full dead load of the slab, beam or arch as the
case may be together with any live load likely to occur during curing or further
construction.
24 to 48 hours as may be
decided by the Owner /
Consultant
3 days
7 days
7 days
14 days
14 days
2) Spanning over 6m
21 days
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
7.0
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7.1
Fabrication: Fabrication of steel structure shall be carried out in conformity with the
best modern practices and with due regard to speed with economy in fabrication and
erection and shall conform to IS-800. All members shall be so fabricated as to
assemble the members accurately on site and erect them in correct positions. Before
dispatch to site the components shall be assembled at shop and any defect found
rectified. All members shall be free from kink, twist, buckle, bend, open joints etc. and
shall be rectified before erecting in position. Failure in this respect will subject the
defective members to rejection.
7.2
Fabrication Drawings:
the contractor on the basis of approved design. These drawings shall be prepared
by the contractor or by an agency approved by the Owner / Consultant.
7.3
MS Black/High Strength Bolts and Nuts: M.S. Black or high strength bolts, nuts
and washers etc. shall be as per IS-800, IS-1363 and IS-1367. Manufacturer's test
certificate shall be made available to the Owner / Consultant or his representative,
when called for. For bolted joints, shanks and threaded bolts are to be used to
ensure that threaded length do not encroach within the thickness of connected
members of dimension beyond the following limit:
i.
ii.
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
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Every portion work shall have its erection mark or numbers stenciled on the
member for guidance in erection and bear all necessary marks of erections as
directed by the Owner / Consultant.
7.4
7.5
The Owner / Consultant shall have free access at all reasonable time to all places
where the work is being carried out, and shall be provided by the contractor at his
own expenses all necessary facilities for inspection during fabrication and erection.
The Owner / Consultant shall be at liberty to reject the work in whole or in part if
the workmanship or materials do not conform to the terms of the specifications
mentioned herein. The contractor shall remove, replace or, alter any part of the
work as ordered by the Owner / Consultant.
8.0
8.1
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TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
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out Shot blasting/ grit blasting when humidity exceeds 85% (RH).
8.1.1
8.1.2 Equivalent product chart for approved paint manufactures for primer P1 and P2 finish
paint FP1 and FP2 indicated above is enclosed.
8.1.3
All the surfaces must be sand blasted and 2 coats of primer plus 1 coat of finish paint
applied in the shop before the same are shifted to site for erection. All the members
r must be suitably match marked for facilitating proper assembly.
After erection is over all surfaces shall be washed up as follows:
i.Washing with clean water (pressure 7 kg/cm2) using suitable nozzles.
ii.During washing broom corn brushes shall be used to remove foreign matters.
iii. Solvent washing if required to remove traces of oil grease etc.
After washing the surface as indicated above, the surfaces shall be suitably touched up
to the extent required so that all the damages to the premiered surfaces caused during
erection are done up.
The surfaces affected by welding and / or gas cutting during erection shall also be
suitably touched up. Before touch up is taken up surfaces shall be prepared by
mechanical means such as grinding, power brushing etc. to achieve surface finish to
ST-3.
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
Rev.
Page 17 of 22
After touch up work is over as indicated above, all the surface shall be given one coat
of finish paint to the required specification.
8.1.4 The following points must be observed for painting work:
a)
Primer and paint shall be compatible to each other and should be from the
same manufacturer.
8.2
ASIAN
P1
P2
APCODUR -
G&N
SHALIMAR
J&N
BERGER
BOMBAY
EPILAC ZINC
EPILUX-4 ZINC
PENTADUR
Epoxy Zinc
CHROMATE
CHROMATE
CHROMATE
PRIMER 1532
Chrome Primer
PRIMER
PRIMER
PRIMER
CHLOROKOTE
JENSOLAC CR
LINOSOL HB
PRIMER
ASIOCHLOR HB
NEROLAC
ZINC
PHOSPHATE
ZINC
ZINC
ZINC
PHOSPHATE
PRIMER
PHOSPHATE
PHOSPHATE
PHOSPHATE OR
PRIMER
PRIMER
PRIMER
KANGAROO HB
HEMPATEX
PRIMER 1632
FP1
APCODUR CF
NEROLAC TWO
EPIGARD XL
EPILAC 974
EPILUX-4
PENTADUR
692
COMP EPOXY
FINISH
ENAMEL
ENAMEL
ENAMEL 5534
GRAY
FP2
ASIOCHLOR CF
NEROLAC CR
CHLOROKOTE
JENSOLAC
625
PAINT
FINISH
CHLORINATD.
RUBR. PAINT
LINSOL
PENTACHLOR
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
9.0
9.1
Document No.
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Page 18 of 22
9.1.1 The area to be paved shall be divided into suitable panels. Formwork shall be
provided. The boarding / battens shall be fixed in position with their toe at proper
level, giving slope where required. Alternatively base concrete may be deposited in
the whole area at a stretch.
9.1.2
Before placing the base concrete the sub-base shall be properly wetted and rammed.
The concrete of the specified mix shall then be deposited between the forms where
provided, thoroughly tamped and the surface finished level with the top edge of the
forms. The surface of base concrete shall be spreader uniformly. The surface shall be
finished rough to provide adequate bond for the topping. Two or three hours after
concrete has been laid the surface shall be brushed with wire brush to remove any
scum or Laitance and swept clean so that coarse aggregate is exposed.
9.2
9.2.1 The surface of base concrete shall be thoroughly cleaned by scrubbing with coir or
steel wire brush. Before laying the toping, the surface shall be soaked with water at
least for 12 hours and surplus water mopped up immediately before the toping is laid.
9.2.2 The forms shall be fixed over the base concrete dividing into suitable panels. Where
glass dividing strips are provided, thickness of glass dividing strips shall be 4 or as
indicated. Before placing the concrete toping, neat cement slurry at the rate of 2
kg/sq.m shall be then thoroughly brushed into the base concrete just ahead of the
finish. The topping shall then be laid, thoroughly compacted by using screed
board/plate vibrator. The surface floated with a wooden float to a fair and even
surface shall be left for some time till moisture disappears from it. Junctions with
skirting / dado or wall surfaces shall be rounded off using cement mortar 1:2 curing
shall be carried out for a minimum of 7 days.
10.0
10.1
PLASTERING
Sand for plastering: shall be 50% fine sand and 50% coarse sand from approved
sources.
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
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Page 19 of 22
10.2
10.3
Cement mortar shall be of the mix as indicated in the items and shall be mixed as
specified in the specifications.
10.4
Joints in walls etc. shall be raked to a depth of 12 mm, brushed clean with wire
brushes dusted and thoroughly washed before starting the plaster work. The surface
shall be thoroughly washed with water cleaned and kept wet to saturation point before
plastering is commenced.
10.5
Cement mortar as indicated, shall be firmly applied to the masonry walls in a uniform
layer to the thickness specified and will be pressed into the joints. On concrete
surfaces rendering shall be dashed to the roughened surface to ensure adequate
bond. The surface shall be finished even and smooth. Hectoring wherever required
shall be done as per directions of Owner / Consultant. Nothing extra shall be paid on
this account.
10.6
10.7
Integral water proofing compound shall be mixed with cement in the proportion
recommended by the manufacturer. Care shall be taken to ensure that the water
proofing material gets well and integrally mixed with cement. All other operations are
the same as for general plaster work.
10.8 For sand face plaster undercoat of cement plaster 1:4 (1 cement: 4 sand) of thickness
not less than 12 mm shall be applied similar to one coat plaster work. Before the
under coat hardens the surface shall be scared to provide for the top coat. The top
coat also of cement mortar 1:4 shall be applied to a thickness not less than 8 mm and
brought to an even surface with a wooden float. The surface shall then be tapped
gently with a wooden float lined with cork to retain a coarse surface texture, care
being taken that the tapping is even and uniform.
11
11.1
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
11.1.1
Document No.
0
Rev.
Page 20 of 22
White wash shall be prepared from lime slaked at site and mixed and stirred with
5 litres of water for one kg. of unsalted lime to make a thin cream. The cream shall
be screened through a clean, coarse cloth and suitable adhesive such as DDL or
equivalent as per manufacturer specification. About 1.3 kg of sodium chloride in hot
water shall also be added for every 10 kg. of lime for making the coat hard and rule
resistant. Indigo shall also be mixed @ 3 gm/Kg of lime. Each, coat shall be allowed
to dry before next coat is applied. When dry, the wash should show no sign of
cracking. One coat consists of application with brushes in horizontal stroke followed
by vertical stroke.
11.2
Colour Washing
11.2.1 Where colour wash is indicated, one coat of white wash and two coats of colour of
tints approved by the Owner/Consultant shall be applied. Dados and skirting shall not
be white washed, colour washed or distempered or painted.
11.2.2 Only Colour Steiner of approved brand not affected by lime, shall be added to
colour wash. Indigo (Neel) shall, however, not be added in colour wash.
11.2.3 The colour wash shall be applied as described for white wash. After the surface has
been prepared the first primary coat shall be of white wash. Minimum two coats of
colour wash shall then be applied. The entire surface shall present a smooth and
uniform finish of even tint or shade.
11.3
11.3.1
Distempering
Where distempering is indicated, two coats of distemper oil emulsion or dry
distemper over a priming coat as specified in the item shall be applied. Each coat of
distemper shall be approved by the Owner / Consultant before next coat is applied.
11.3.2 Distemper oil emulsion shall be as per IS: 248 of approved brand and manufacture.
The distemper shall be diluted with water or a prescribed thinner in the proportion of
4 parts of paste by weight to one part of cold water or in the proportion specified by
the manufacturer, which shall be invariably followed.
11.3.3 The surface to be distempered shall be cleaned of dust, dirt, chalking and other
foreign matter. All cracks, holes and surface defects shall be repaired with gypsum to
give a smooth surface, and papered and wiped clean. The surface shall then be
rubbed down again with sand paper and made smooth. The surface thus prepared
FORM NO. : 02-0000-0021F2 REV. 1
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
Document No.
0
Rev.
Page 21 of 22
shall be given a coat of alkali resistant, priming paint conforming to IS: 109, or any
other primer as specified by the manufacturer and allowed to dry at least for 48 hours.
11.3.4 Dry distemper shall be of approved make and
Subsequent coats shall be applied in the same way, with time intervals of at least
24 hours between consecutive coats.
11.3.7
A uniform finished surface without patches, brush marks, or distemper drops shall
be obtained.
11.4
11.4.1
Cement Painting
Cement paint shall comply with IS: 5410 specification for cement paint, of colour as
required.
11.4.2
Where shown on drawings for external surfaces of sand faced plaster, or any
other surface, two coats of cement paint shall be applied of tint and shade as
approved by the Owner / Consultant.
11.4.3 The surfaces shall be prepared as specified for white washing. Before applying
cement paint the surface shall be thoroughly wetted to control surface suction. The
surface shall be moist but not dripping wet, when the paint is applied. Not less
than 24 hours shall be allowed between the two coats. In hot weather the first coat
shall be slightly moistened before applying the second coat.
EM 163-PNCV-TS-101
TECHNICAL SPECIFICATION
FOR CIVIL & STRUCTURAL WORK
11.4.4
Document No.
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Page 22 of 22
plain
surfaces, cement paint shall be vigorously scrubbed on to work the paint into the
voids and provide a continuous paint film free from pin holes and other openings.
Curing shall be done between the coats and for at least 2 days following the final
coat.
EM163-TS-401-00
Document No.
Rev.
SHEET 1 of 2
TECHNICAL DESCRIPTION
EQUIPMENT: MOUNDED LPG BULLETS
AND DRAIN VESSEL
29.09.2015
29.09.2015
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-TS-401-00
Document No.
Rev.
SHEET 2 of 2
LIST OF SPECIFICATIONS
Sl.
No.
Description
Doc. No.
Rev
No of
Pages
EM163-TS-401
87
EM163-TS-301
72
29.09.2015
29.09.2015
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 1 of 36
TITLE
1
REV
29.09.15
REV DATE
: NRL, ASSAM
29.09.15
EFF DATE
VB/PK
PREPD
NB/AKG
REVWD
GC
APPD
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 2 of 36
CONTENTS
Sl. No.
Description
INTENT
DESIGN
SCOPE OF SUPPLY
MATERIAL
FABRICATION
10
11
12
13
CALIBRATION
14
PRE-COMMISSIONING / COMMISSIONING
15
GUARANTEE
16
DOCUMENTATION
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 3 of 36
LIST OF ATTACHMENTS
Sl.
No
1
2
3
4
5
6
7
1.0
Rev
No. of
Pages
15
EM163-TS-401-ANNEX I
EM163-TS-401 FORM E
EM163-TS-401-ANNEX II
11
EM163-TS-401-ANNEX III
EM163-45-PNMP-PS 102
Description
EM163-DD45-VV101/102/103/104
EM163-PNMV-DD45-VV101/102/103/104
EM163-TS-401-SR
INTENT
This Attachment / Annexure covers design & detailed engineering, preparation of
fabrication drawings, procurement & supply of all raw materials whatsoever required
to meet complete scope of supply, fabrication, post-weld heat treatment, inspection,
testing,
coating/painting
at
site,
site
fabrication/erection/
installation on compact sand bed, assembly, welding, testing, post-weld heat
treatment of field joints, inspection & NDT, hydro-testing, cleaning, coating/painting
of field joints / internal surfaces / damaged surfaces and installation of Cathodic
protection system ,supply & installation of related piping and instruments including
mound and other civil work for the LPG/ Mounded bullets, and requisite insert plates
in the RCC wall for pipe supports, supply of spares, guarantee, pre-commissioning
and commissioning in strict compliance with the Specifications, applicable code,
relevant drawings and documents enclosed along with tender documents which
forms an integral part of this specification.
Scope also covers obtaining statutory approval on engineering drawings, design
calculations and other related documents.
The requirements for completeness of LPG mounded storage installation with
respect to piping up to companion flange all the valve required for installation of the
in instrument & with piping flanges in the tunnel with its analysis safety security as
per various OISD, GRE Cones for Dome along-with requisite insulation & SS Traps,
Lifting requirements, bolts, fasteners, internal stair, civil, instrumentation, electrical,
cathodic protection system etc. are covered separately (in various Attachments /
Annexure) in the main package.
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 4 of 36
This specification shall be read in conjunction with code, specification sheet and
other tender documents. In case of conflict between code and tender document, the
vendor shall contact PDIL/NRL for clarifications. As a general rule the most
stringent requirement shall govern.
S. No.
1
Item No.
45-VV101/102/103/104
Description
Reqd. Qty.
MOUNDED BULLET
1.1.0
General
1.1.1
1.1.2
Contractor shall adhere to the technical specifications and shall not waive / alter any
part of the specifications or relevant drawings without the written permission of
Owner / PDIL.
1.1.3
1.1.4
The supply shall be in strict compliance with this specification, PDIL drawings, and
other referred codes/standards. Components, for which there are no relevant
codes/standards, shall be designed as per good engineering practice, after getting
approval from PDIL.
Any comments made by PDIL shall be incorporated without any commercial
implication. The Contractor is advised to essentially visit NRL Numaligarh Refinery
site before quoting, to have a clear picture of the interrelated existing facilities
available & specific requirements for the execution of this job. No extra claim shall
be entertained after the award of contract on account of ignorance of site
conditions.
The mounded bullets shall be partially prefabricated including rolling of plates, shot
blasting, edge preparations and application of primer painting etc in bidders shop.
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However the assembly of the bullets shall be carried out in-situ position in mound.
Accordingly contractor has to ascertain the safe transportation of the pre fabricated
parts/sections. Route survey in connections with above shall be carried out by
contractor. Any material consigned by contractor to site which is damaged or lost
shall be to the contractors risk and he shall replace such material at his own cost.
1.1.5
The contractor shall certify that the offer is in complete compliance with all the
technical requirements as specified in the enquiry documents without any deviation.
Contractor shall submit duly filled in, signed & stamped CHECK LIST (TECHNICAL)
document no EM163-TS-401-ANNEX I REV 0 along with offer.
1.1.6
Exceptions & Deviations, if any, from the clauses stipulated here in or code and any
other technical specifications, shall be clearly spelt out in the enclosed Schedule of
Exceptions and Deviations (Technical) Confirm form E (EM163-TS-401 FORM E
REV 0), with proper reference to specific document number, subject, clause number
etc. Absence of any such indication shall mean that the offer complies with all
requirements and such assumptions shall strictly be binding on the contractor,
without any price and/or delivery implications. Any deviation written elsewhere in
the offer but not on the format shall not be recognized and the same shall be
treated as null and void.
1.1.7
Certain items & stipulations, by virtue of their importance may be repeated in one or
the other documents to attract sure attention under any circumstances.
1.1.8
Sub-Contractor, if any, shall have prior approval of NRL / PDIL. Contractor shall
specify the nature of sub-contract. In absence of any such information, it shall be
presumed that complete job shall be executed by the Contractor alone and such
assumption shall be binding on the Contractor.
1.1.9
Contractor shall submit a consolidated sub-vendor list for all the materials and
supplies for PDIL/NRL approval.
1.1.10
The Contractor shall be responsible for compliance with all statutory laws, rules and
regulations (local/state/central) and arranging all necessary permits, approval,
license, certificates etc. that may be obligatory for him to obtain and process for the
execution of his work from appropriate authority.
1.1.11
1.2
1.2.1
Official Language :
1.2.2
English
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1.3
Priority of Order
In case of conflict among the documents, priority of validity shall be in following
order:
a) Statutory requirements ( local / state / central )
b) Equipment Drawings
c) This Specifications
d) Codes
e) Contractors bid
2.0
2.1.1
Other PDIL standards (PDS & ES) and other national/international standards
mentioned on drawing & documents such as relevant ASME for Gasket, Flange
Bolting etc.
2.1.2
2.2
Materials
Materials other than stipulated code of design shall meet all the requirements of
design code. Various testing methods on alternative material shall also comply with
code of design.
Materials for pressure parts shall be designated in accordance with ASME.
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2.3
Coatings / Painting
Surface preparations, primer & internal and external painting/coating shall be grit
blast cleaned & coated as per Doc. No. EM163-TS-401-ANNEX II REV 0 and GA
Drawing Number EM163-PNMV-DD45-VV-101/102/103/104.
2.4
2.5
Piping
All piping shall strictly meet the requirements of specifications/ documents, Piping
Material Specification (Piping Class) etc. Piping shall be in accordance with ASME
B 31.3
The bullets will be subjected to settlement. Also, the ends of the bullets will move in
a longitudinal direction due to change in temperature and internal pressure. These
effects shall be taken into account in the piping design.
Stresses caused by external forces in flanges connected to bullet dome are not
acceptable.
The piping design & works shall be in accordance with relevant specifications
enclosed elsewhere in the Tender. Piping material specification & valve material
specifications are attached with the Tender. The Insert Pates in the RCC wall for
the Pipe support for which location shall be provided during the detailed engineering
phase after the award of the Contract. The Approximate weight of plate insert may
be 4000 kg of weight.
The support details will be provided at the time of execution of the piping on the
mound along with ISOMETRIC DRAWINGS.
The analysis of piping hanger in the tunnel for outlet Nozzle before ROV is in the
scope of contractor.
2.6
Instrumentation
The instrumentation design & works shall be in accordance with relevant
specifications enclosed elsewhere in Tender (Doc No: - EM163-PNIN-7901-00 Rev
0). However valves required for installation of the instruments are under the scope
of contractor. In case of safety valve the scope is till the inlet of the safety valve &
the tapping from outlet of safety valve to flare shall be carried by others.
2.7
Electrical
All cathodic protection electrical supplies erection, testing & commissioning shall be
carried out by the contractor in accordance with relevant specifications enclosed
elsewhere in Tender (Document No.:- EM163 -TS-0801 Rev 1).
2.8
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2.9
Earthquake Factor
According to Design basis and IS: 1893.
2.10
2.11
3.0
DESIGN
3.1
Equipment shall be designed as per the conditions and Codes / Stds. / Specs.
indicated in respective equipment specification sheets / drawings.
3.2
External loadings like mound load (in axial and radial directions), live load, Seismic
loads, thermal loads, bending & frictional force, mound interaction load, load due to
uneven support by foundation etc. shall be considered in the design of unstiffened
Shell, Domes, Manholes & stiffeners.
3.3
Bullet shall be supported, while hydro testing, on the sand bed, which is to be laid
and compacted.
The bullet design shall be based on a theoretical settlement of 1:2500 (Minimum
50mm). The bullet shall be considered as supported on elastic foundations with a
varying modulus. This modulus shall be taken to vary as under;
a) Maximum Modulus = 1.5 x Minimum modulus.
b) No less than One-third of the length of the bullet shall deem to be supported on
a bed with minimum modulus in any analysis.
However bullet foundation shall be designed for following settlement values:
3.4
i)
ii)
Max. Settlement value between centre & end of the bullet (at empty,
operation, test case): 10mm (max.)
3.5
Shell thickness shall be set so that under operation / hydrotest conditions, the
combined stresses in any shell component do not exceed the following;
a). Tensile Stress : 90% Ambient Yield.
b). Compressive Stress : Code Allowable Stress
3.6
Design external pressure (P0) shall be determined by the external load caused by
the mound in combination with negative internal pressure based on worst of
assumed design support distribution pattern & FE Analysis.
Supporting pressure (P0)) by the foundation (sand bed angle 120O) resulting from
dead weight(Q1), weight of liquid/water fill(Q2), mound weight(Q5), live load(Qlive)
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between maximum stiffener spacing (Ls), and shall be added with negative internal
design pressure (F.V.) and the same shall be considered for design.
P0 = [1.33*(Q1 + Q2 + Q5 +Qlive) / (1.2*R*Ls)]
P0 = Maximum shear load (by FEA) * Ls / (1.2*R*Ls)
Where, R is mean radius of shell & Ls is stiffener spacing
3.7
3.8
For parts/components, design of which are not covered in ASME Sec. VIII Div.2,
recommendations of PD5500 or any other international code regarding stability and
buckling / lateral buckling (flange buckling) shall be followed and analytical check
shall be submitted for review & approval of PDIL.
3.9
Stiffener weld (shell to web, flange to web) shall be checked for radial loads in shell.
3.10
The maximum longitudinal compressive stress at mid span of the vessel must be
calculated and compared with code.
3.11
The bullet shall also be analyzed with Finite Element Analysis using latest version
of ANSYS or Equivalent software.
3.12
All equipment shall also be designed for field hydro (without mound cover) and
periodic hydro at latter stage (with mound cover) in new and corroded condition
respectively. Allowable stress during hydraulic testing shall be less than or equal to
90% of yield stress.
3.13
3.14
3.15
Tentative Forces and Moments coming on the nozzles are indicated in the tender,
However the final Forces and Moments shall be furnished after order placements by
PDIL which shall be considered in the design by contractor without any commercial
implications. Alternatively contractor shall indicate maximum forces and moment
caused by bullet contractions and mound settlements for review and confirmations
by PDIL.
3.16
The thickness of stiffener web and flange should not exceed the thickness of shell.
The stiffener webs and flanges shall be of the same material grade and thickness
as of the shell.
3.17
Domes, nozzles and manholes shall be designed to withstand both internal and
external (soil pressure and piping) loads in accordance with ASME section VIII
DIV.2. Due to horizontal movements of vessel, passive soil pressure may generate
large lateral soil pressure/forces and high bending moments on the dome and
manholes. This can be prevented by creating free space around dome and
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manholes using split sleeves. The installation of sleeve structure made of glass
reinforced epoxy or unplasticised polyvinyl chloride (PVC) may be considered.
3.18
At least two manholes, one at each end of the vessel, shall be installed. Each
manhole shall be provided with internal permanent ladder
3.19
Each vessel shall be electrically isolated from all other vessels, pipelines, plant, and
buried metal structures and electrical and instrument earthlings systems.
4.0
SCOPE OF SUPPLY
The extent of supply shall also include but not be limited to the following:
4.1
Unless otherwise specified, the complete main equipment and their various
components as specified in GA drawings and various specifications/documents
spelt out in the tender shall be included in contractors scope of supply.
4.2
4.3
Obtaining all statutory approvals from PESO/CCOE for bullets, and from CPWD /
Weight & Measure for Calibration.
4.4
Procurement and supply in sequence and at appropriate schedule, all metallic and
nonmetallic consumables required for complete construction, fabrication,
installation, inspection, testing and Post Weld Heat Treatment shall be contractors
responsibility.
4.4.1
All plates, Forged Flanges, SR Nozzle necks & Dome and Fittings
4.4.2
All materials for internal piping, domes, nozzle necks and ladder at each manhole
complete with supports and fasteners.
4.4.3
Companion / mating flanges, Cover flanges for manholes and all instrument
connections.
4.4.4
Fasteners & Gaskets for Companion/mating flanges, Cover flanges for manholes
and all instrument connections.
4.4.5
Blind flanges, bolting and gasket for Hydro-testing / Commissioning for all nozzles
connection without cover/blind flanges with companion flanges.
4.4.6
Minimum two number Manholes each with Davit and permanent fixed internal
ladder up to the bottom of bullet
4.4.7
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4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
Selection, engineering & supply of fireproof coating materials required for fire
proofing (material certified by Underwriters Laboratory as per their test method
UL1709 for Hydrocarbon fire test 2 hours fire rating).
4.4.13
All materials for external piping and instruments including all mounted permanent
instruments as specified in relevant specification enclosed with ITB.
4.4.14
All materials and equipment required for mounding like earth, sand, clay, gravel,
PVC sheet, terram-1000 sheet, PVC pipe, stone, inspection tunnel/trench, resilient
material at tunnel opening, fire barricading in the fabrication yard, fences etc as
specified in relevant specification enclosed with Tender.
4.4.15
Supply of all materials for Fire Barricading Screen with water spray system and
hydrocarbon detector with local hooter for detection of any fire leakage as
applicable.
4.4.16
Supply of Template of the size and shape of LPG Bullet for mound shaping.
4.4.17
All materials for viz. cables, electric wire, tubing, junction boxes, etc. required for
Instruments, as specified in relevant specification enclosed with ITB.
4.4.18
All instruments, controls, valves etc. as per relevant specification enclosed with ITB.
4.4.19
All materials, electrical cables, instruments, all accessories required for Cathodic
Protection system including Monolithic Insulating joints for all liquid and vapor lines
including utility pipe lines and insulating flange joint kit for all Instrument
connections (Manhole excluded) as specified in relevant specification enclosed with
Tender.
4.4.20
The Contractor shall arrange at his own expenses all consumables materials such
as, but not limited to, Welding consumables, welding gases, filler wires, fluxes,
electrodes, grinding wheels, cotton waste, bolts and nuts and all other temporary
fastenings, clips, cleats, packing materials, gaskets, etc. that might be required by
him to execute the entire erection & commissioning (as applicable) job in a
satisfactory manner.
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Providing all tools, tackles, jigs, fixtures, lifting / handling cranes, wire rope slings,
DShackles, hoist, chain pulley blocks, hydra, other machines, safety equipment, A
Frame, welding/cutting / grinding machines, air compressors, blower, pump for
filling/dewatering/hydro-testing, valves, pressure gauges, spray guns for painting,
PWHT equipment / recorder etc., and any other items required to carry out the
entire job properly and in schedule time.
4.4.22
4.4.23
5.2
5.1.0
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
Installation of Monolithic Insulating joints for all liquid and vapor lines including utility
pipe lines and insulating flange joint kit for all Instrument connections (Manhole
excluded).
5.1.8
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5.1.9
5.1.10
5.1.11
Cleaning of inside of bullet with vacuum cleaner and blowing of equipment as per
instruction of site in-charge after Hydro test.
5.1.12
Civil foundation i.e. preparation of mound as per civil scope of work and
specifications.
5.1.13
Installation of all instrumentation (for Mounded Bullets, other equipment & piping
mounted Instruments) and valves as marked in drawings & as specified in relevant
specification enclosed with Tender.
5.1.14
5.1.15
4 thick HDPE bolted sleeve (in two halves) with flexible cover fixed with SS Strap
around dome-1, dome-2 and nozzles mark M1 & M2 for absorbing bending
moment due to earth pressure / vessel expansion.
5.1.16
5.1.17
5.1.18
cleaning of site and final handing over of the complete package to the purchaser.
5.1.19
5.1.20
5.2
Mandatory spares:
Contractor shall indicate item-wise prices for following:All spares recommended for requisite piping, cathodic protection system, as
specified in respective specifications.
Mounded Bullet & other Spares
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Gaskets: 200% for each nozzle with companion flanges, blind flanges including
manholes & instrument nozzles.
Fasteners: 10 % (min in each size) of installed fasteners
Contractor / Vendor shall supply Mandatory spares as per the list furnished in
Tender. Contractor shall provide all mandatory spares and same shall be handed
over to Maintenance after commissioning of the unit. Quoted price by contractor
shall include the cost towards the mandatory spares and the same shall be
considered for bid evaluation. Cost of Mandatory Spares shall be included by
contractor in the lump sum cost of basic equipment as well as unit rate also.
b)
Commissioning spares:
Bidder shall provide spares required for commissioning. Any spares required during
commissioning shall be supplied by Bidder without any time and price implication.
Price of commissioning spares shall be included in the lump sum price of the
package.
Replacement of commissioning spares, if any, required during commissioning stage
shall be done by contractor/ Vendor on free of cost. Generally this will not be
quantified and also not be considered for bid evaluation.
c)
Contractor shall indicate Spares for two years normal operation along with the bid
and item wise prices shall also be submitted for such recommended spares.
Price lists of these Two years normal operation spares are intended for information
purpose only and shall not be included in quoted Lump-sum price. These prices
shall remain valid for 12 (twelve) months from the date of mechanical Completion.
Gaskets for Two years Normal Operation
200% for each nozzle with companion flanges, blind flanges including manholes &
instrument nozzles.
Fasteners for Two years Normal Operation
2 sets of studs & nuts for each nozzle with companion flanges, blind flanges
including manhole & instrument nozzles
6.0
MATERIAL
6.1
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Unless otherwise specified material used for pressure parts / stress bearing
components shall be fully killed
6.3
6.4
UTS of material for Bullet shell, head & stiffener shall be limited to 80,000 psi.
Maximum.
6.5
6.6
Production test coupon for plate shall undergo heat treatment twice at temperature
610 + 100C for SR (SR of each section at shop and Local SR of field weld joints) &
910 + 100C for normalizing of dished head during forming and SR of bullet section.
Details of the mechanical test as simulated shall also be indicated in mill test
certificate.
6.7
6.8
Material including Weld and Heat Affected Zone shall be impact tested (Charpy-V)
at the lowest of minimum ambient temperature, design temperature and minimum
design metal temperature (MDMT) as per design code & relevant ASME
Specification.
6.9
C.S. and low alloy steel plates exceeding thickness of 50 mm shall be vacuum
degassed except for plate ring flanges.
6.10
6.11
6.12
All forgings shall be ultrasonically tested as per ASTM A 388 for thickness greater
than 100 mm with criteria shown in ASME Sec.VIII Div.2 Para AM-203-2. In case
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any defect is found, no repair by welding shall be allowed. ANSI flanges for
equipment designed as per ASME Sec.VIII Div.1 need not be ultrasonically tested.
6.13
All forgings (including nozzle flanges) shall be examined for surface defects by
MP/DP after machining.
6.14
All pipe fittings including those elbows shall be forged / wrought. All fittings shall
conform to ASME B 16.9 and ASME B 16.11.
6.15
For bullets, Flanges of sizes 24NPS shall be welding neck, according to ASME B
16.5, Size of Flanges >24 NPS shall be as per ASME B 16.47, series A.
Bolt holes of Flanges & Counter flanges of all instrument nozzles, bearing insulating
joint gasket kit, shall be suitable to accommodate stud bolts insulating sleeve and of
length suitable to accommodate washers.
6.16
Flange raised face for gasket seating face shall have smooth finish 125 AARH (63
to 125 in AARH) finish except nozzle mark N2. Flange for nozzle mark N2 shall
have RTJ face with smooth finish 63 AARH (32 to 63 in AARH) finish
6.17
Brinnel hardness for RTJ groove shall be at least 20BHN more than that of
corresponding gasket as specified.
6.18
Nonmetallic gaskets shall conform to ANSI B16.21 up to 24, and B16.47 series A
beyond 24, unless otherwise specified.
6.19
Spiral wound gaskets and ring joint gaskets shall conform to ANSI B16.20 with
inner & outs ring of SS.
6.20
All gaskets shall be SS304 spiral wound with graphite filler with SS ring. Gaskets
shall be lapped with insulating gasket kit, excluding gasket for RTJ.
6.21
All bare electrodes and fluxes shall be selected as per ASME IIC. All weld metal
shall have equal or better mechanical properties than the parent metal. Only dry flux
shall be used.
7.0
7.1
Before starting any welding at site fire barricading (temporary) screen with water
spray system shall be erected as per the guidelines of clients safety department
and requirements of concerned statutory authority.
The barricading structure should be open able type to allow movement for
construction, men, material and machinery for pump house.
Hydrocarbon detector with local hooters shall be provided by contractor. Fresh
water shall be used for sprinkler. Water for barricading shall be once through with
closed circuit system (recycling) which shall be arranged by contractor.
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8.0
FABRICATION
8.1
The manufacturer of the equipment shall comply, in all respects, with the provisions
of the applicable code/standards and specifications including such jobs as welding,
fabrication, forming of heads etc. radiography, heat treatment, inspection, testing
and quality control etc. unless otherwise specified.
8.2
During execution of job within NRLs site premises, NRLs safety rules/ regulations
shall be strictly followed.
8.3
Fabrication work, planning and scheduling shall be done in such way that minimum
fabrication works will be done at site i.e. (a) Rolling of plates (b) Edge preparation
(c) Blasting & primer application etc. will be done at fabricator shop only.
8.3.1
Forming of shell sections and heads shall be done by machines, either hot or cold,
in such a way so as to preserve the specified material properties and to produce a
regular finish.
8.3.2
Transverse rolling while forming of shell sections is not allowed. Plate shall be bent
/ rolled along the direction of the mill rolling of plate during shell forming. The
hemispherical head shall be fabricated in 2 pieces (4 petals each) & 1 crown
separately. Caps of dome shall be formed in single piece. Latest applicable code
requirement shall be satisfied.
8.3.3
8.4
All welding jobs shall be carried out by qualified welders using qualified welding
procedure to requirement of Design Code and specification etc. and approved by
the inspecting authority. All new welding procedures must be got approved from
authorized inspecting authority before starting any fabrication job
8.5
Contractor is suggested to visit NRL site to have clear picture of the inter related
existing facilities and specific requirements for the executions of the job. No extra
claim shall be done after award of contract on account of ignorance of site
conditions. Contractor shall note that the Mounded Bullets shall be fabricated in 6
sections or as applicability for erection of equipments, ND Tested & inspected
before installation on foundation/mound including external anti corrosive coating.
Inter-section circumferential (field) weld seams shall be welded in-situ position in
mound. All exposed uncoated surfaces & internal bottom 900 shall be coated after
hydro and MPI examined.
8.6
Sections/ Finished rolled plates of bullet will be transported to NRL site, from
contractors fabrication shop/yard. Route survey up to refinery and inside refinery
shall be carried out by the contractor to assess the transportation constraints.
Accordingly nos. of shell sections / joints shall be firmed up on the basis as well as
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the area demarcated within refinery premises for carrying out the mounded bullet
fabrication.
It shall be the responsibility of contractor to arrange and provide all loading /
unloading facilities, transportation of bullet sections from refinery gate to site inside
the Refinery premises (where bullets are to be erected / installed), including all roll
on, roll off facilities, crane(s), labor etc. contractor shall conduct complete survey
and shall strengthen all weak areas. Contractor shall remove all route hindrances
to facilitate transportation of bullet sections. Quoted price shall include all charges
towards all activities not specifically mentioned but required to transport the bullet
sections from refinery gate to erection site inside the refinery. Contractor shall
submit transportation scheme along with the offer.
8.7
8.8
All materials whatsoever required for welders qualification, welding procedure tests
and production control coupons shall be arranged by the contractor. All instruments
required during performance testing to establish guaranteed figures shall also be
arranged by the contractor.
8.9
8.10
Welding parameters of any approved weld procedure shall not be changed without
prior approval of the Owner / PDIL.
8.11
8.12
Suitable trench (with proper arrangement to safe guard the compactness of mound)
shall be made to carry out the in-situ welding of closing circ. seams. Width of trench
shall be suitable for carrying out heat treatment and there after coating of the
closing seams.
8.13
Plates of different thickness shall be made flush at the inner surfaces of equipment
unless otherwise stated.
8.14
8.15
C.S. dished head, if cold formed or hot formed below normalising temperature, shall
be subsequently normalised. Formed ends of vessels with diameter less than
1600mm shall preferably be made in one piece. Larger heads which can not be
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formed in one piece shall be fabricated in minimum number of pieces, with prior
approval with following guide lines;
a) If in two pieces, the welding seam shall be included in the middle third and
preferably on the center line.
b) If in petal construction it shall be with meridional seams and a central cap of
diameter not larger than 0.75 times the vessel OD.
c) For Bullets, the number of pieces / petals shall be indicated in offer.
8.16
Production test coupons shall be applicable for all the mounded bullets irrespective
of thickness.
The production test plate shall be from material of the same heat and thickness as
of shell/head. During and after welding, the test plates shall be subjected to same
heat treatment as and together with the course they represent. Test plate coupons
shall be subjected to all tests like Micro, Macro, Hardness, Charpy-V Impact test
etc. in addition to mechanical tests (Tensile, Transverse tensile, Bend (root and
face) test as required.
Minimum numbers of production test plate coupons shall be as under,
a). Two production test plate coupons representative of one longitudinal and
another circumferential seam shall be provided for each welder ,procedure,
position, thickness & heat in each bullet shell.
b). One production test plate coupons representative of weld seams shall be
provided for each welder, procedure, position, thickness and heat for welded
dished heads/cones.
c). Extra coupons shall be preserved to take care of eventuality of retests.
8.17
Equipment having diameter greater than 2 meters shall have only two longitudinal
welds. Orientation of longitudinal weld seams between adjacent courses shall be
staggered. Location of weld seams shall be kept so as to avoid coverage with initial
mound i.e. 1200 to bullet center line to permit visual inspection. Orientation of
longitudinal seams and position of circumferential seams shall be clearly marked in
the fabrication drawing.
8.18
All sharp corners shall be rounded off with smooth radius. Inside edge of manhole
and hand holes at the internal surface shall be rounded to min. radius 5 mm.
8.19
8.20
Internal Stiffener Rings (T-type) shall be fabricated and fitted to the shell belts and
welded in position immediately after shell forming to avoid distortion.
8.21
All parts involving welding construction including stiffeners shall have continuous
welds unless otherwise stated.
8.22
All manways, pads, nozzles, lugs for lifting, CP lugs etc., shall be fabricated and
welded on bullet section in contractors shop/fabrication yard before transporting to
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site. Contractor shall ensure the overall dimension of the bullet pieces / sections
with nozzle welded can be transported as an ODC by the transporter
8.23
Suitable mouse hole/Notch shall be provided in stiffener to clear long seam weld.
8.24
Stiffeners shall be provided with drain holes of radius between 50 and 100mm in the
bottom part to allow the vessel to be completely drained and to allow sufficient flow
towards either the bottom discharge. Drain opening shall be suitably reinforced.
Stiffeners, protruding nozzles shall be provided with mouse holes of 25mm radius in
the top of the vessel to release the air during hydrotest.
8.25
Due provisions must be kept for venting out entrapped gases during welding of
pads, flanges etc.
8.26
Inner edges of all mouse holes, notches in stiffeners shall be seal welded.
8.27
All nozzles shall be self-reinforced nozzle type including those on dome unless
otherwise specified.
8.28
All nozles shall be set-in type welded. If manhole & dome with pad construction is
specified, all nozzle reinforcing pads shall be tested pneumatically at 0.5 Kg/cm2g
pressure with soap solution on attachment welds. Tell-tale holes shall be plugged or
filled with non-hardening mastic to prevent ingress of water.
8.29
All internals fabricated in pieces shall be shop / fabrication yard assembled and
properly match marked for easy assembly at site.
8.30
8.31
Equipment / sections shall be provided with suitable bracing / stiffeners to avoid any
damage during transportation and erection at site. Welded temporary attachments
shall be kept to a minimum, and may only be used for alignment or of lifting of
vessel segments during construction. The same shall be removed after erection.
8.32
8.33
All butt-welds shall be double-V full penetration welds with back chipping and
rewelding from the second side. Single V welding with backing strips shall not be
permitted.
For those joints which are inaccessible for back chipping, the root run shall be
carried out with TIG process.
Cable with CP lugs shall be thermit welded.
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 21 of 36
All welding shall be done preferably by submerged arc welding SAW. SMAW / SAW
shall be adopted for field weld closing circumferential seams of bullet section and
areas where SAW is not possible
8.34
8.35
8.36
Preheat treatment requirement shall be specified for each type of weld including
those for all attachments (including temporary attachments) and tack welds, taking
into account climatological effects.
8.37
Stress relieving is mandatory for bullet. Welding of all parts (including temporary
attachments) must be completed before heat treatment of individual section. Inter
section circ. seams shall be local stress relieved electrically.
After PWHT of vessel/sections, no welding / cutting of temporary attachment shall
be permitted.
8.38
8.39
4 mm thick HDPE bolted sleeve (in two halves) with flexible cover fixed with SS
Strap shall be provided around dome-1, dome-2 and nozzles mark M1 & M2 to
avoid any damage caused by bullet expansion / contraction due to pressure /
temperature and movement due to seismic effect. Suitable sealing arrangement
shall also be provided to disallow any ingress of rainwater to mound. One 3 thk.
Aluminium canopy shall also be provided over the dome and nozzles to further
safeguard against rain water ingress.
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 22 of 36
8.40
Bullet shall rest on a minimum 150mm resilient pad (Neoprene rubber) placed
below the bullet shell at tunnel cut out, made for outlet nozzle. Suitable metallic
enclosures shall be provided to safeguard the pad from fire and weathering effect.
8.41
All internal pipes / stilling well shall be perfectly vertical and the same shall be
checked & recorded.
8.42
Inside diameter / surfaces of stilling well pipes shall be free from welding / drilling
burrs
8.43
Permanent reference points shall be located longitudinally on the top of the vessel
to monitor the bullet settlements. The maximum spacing of these reference points
shall be approximately twice the vessel diameter. A minimum three reference points
shall be installed to identify possible vessel bending (i.e. two near the tan line and
one on middle)
8.44
Name plate: NRL contractor shall provide name plate on each equipment. In
addition to providing name plate, the following details are to be punched on the
manhole flange ring: design code, design temperature, test pressure, date of first
test, inspected by, certificate number, drawing number.
9.0
9.1
9.2
The construction methodology for mound shall be as stated in civil scope of work.
9.3
The Contractor shall provide a detailed methodology and this must be submitted
formally to the Owner / PDIL for their review / acceptance.
9.4
9.5
LPG Bullets shall be fabricated in 6 sections or as the length shell piece shall be
decided to suit transportation & erection and each duly tested, inspected, trial
assembled only for connecting ends, match marked and stress relieved at
shop/fabricated yard & transported to site.
9.6
It is presumed that the Contractor shall use steel plates having minimum 2.5 meters
width. The plates should be ordered in such lengths so as to ensure that there are
Maximum 2(two) longitudinal weld joints in one shell belt of the bullets of equal shell
length.
9.7
To reduce stress concentration at shell to dome weld joint & to make dome bottom
piece forging economical, insert plate has been proposed.
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 23 of 36
9.8
The Contractor shall roll and weld together the 2.5 meter wide plates into 2.5 meter
wide shell belts and re-roll after welding to the exact internal diameter as per
approved drawing.
9.9
A number of the shell belts will be welded together to form a shell section. The
number of shell belts forming a shell section depends upon the transportation of
each section from the shop / fabrication yard to its final location on the mound sand.
9.10
To reduce the number of inter section circ. seams, size of shell section shall be
suitable for moving by minimum two (2) Nos. mobile cranes of suitable capacity.
9.11
9.12
It is proposed that hemispherical ends will be used for these bullets. However the
Contractor may wish to import pre-fabricated hemispherical ends or Petal sections
thereof.
9.13
External Coating of bullet sections will be done prior to installing the same on the
sand bed. Contractor shall follow recommendations of the applicator on handling
and transportation of coated sections / bullets with a view to eliminate / minimise
damage of coating in transit. Suitable resilient / nonmetallic sheet shall be wrapped
on shell during transportation
9.14
9.15
The sections for each bullet shall then be lifted and transported to the sand bed in
accordance with the overall approved Construction Methodology.
9.16
The first bullet section to be laid on the prepared, templated and leveled sand bed
will be the section adjacent to the R.C.C. Wall.
9.17
The other section will be installed in sequence and each section aligned with
adjacent section within tolerance limits and tack-welded in place.
9.18
The Contractor shall ensure that prior to commencement of final circ. welding, bullet
sections that are tack-welded together are dimensionally inspected to ensure the
alignment and other dimensional requirements have been met.
9.19
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 24 of 36
supported upto 600 from the center line on either side of the bullet (total 1200). This
is the minimum sand bed level for Hydrotesting.
At the time of hydrotest, the adjacent bullets on either side of the bullet under test
pressure shall be kept water filled, i.e., minimum three adjacent bullets including the
one under test in the middle shall remain completely filled with water anytime during
hydrotest.
9.20
After completion of the final circ. welds and acceptance / approval of radiography,
the whole LPG bullet will be finally hydrotested. The whole bullet shall be air dried
to remove all moisture after hydrotesting. In case of bullet having in-tank pump
system, Removal of water from bullet shall be done by employing a water draining
pump and manually removing the balance water till the bullet is completely emptied.
Contractor shall arrange suitable draining pump and air compressor.
9.21
After successful completion of the hydrotest, weld areas resting on the mound
which could not be visually inspected during hydrotest, shall be checked by
ultrasonic testing & MPT from inside the bullet for leakage. Wet fluorescent MP
Examination of all welds shall be done after hydrotest (100% on inside & excepting
lower 1200 of C seam welds from outside).
9.22
After ND Examination, testing & inspection, the surface around the final circ. Welds
shall be coated in accordance with coating specifications enclosed.
9.23
Trench provided for field weld shall be properly filled and compacted. It is extremely
important during the filling of the mound that the fill is raised uniformly on each side
of bullets so as to avoid any pressure imbalance whatsoever on any of the bullets.
9.24
During the whole fabrication process the Contractor shall have to work strictly in
compliance with the QA/QC procedures and requirements as set out in ASME SEC
VIII Div 2 (latest) and this specification.
9.25
After award of job, within 3 weeks, the contractor shall submit the following for
PDILs approval
a) Erection schemes indicating type of cranes used, their capacity & sketches
showing the location of crane for unloading, shifting & erection etc. The
erection schemes must be safe & workable. Decision of PDIL/Owner in this
regard shall be final & binding.
b) Manpower deployment at site.
10.0
10.1
Quality Assurance (QA) shall mean the organizational set up, procedures as well as
test methods and facilities developed by contractor in order to ensure that all
equipment leaving Contractors shop are of the highest possible standard quality i.e.
equal to or exceeding the requirements specified.
EM163-TS-401
TECHNICAL SPECIFICATION
10.2
REV
DOCUMENT NO
SHEET 25 of 36
Quality Control (QC) shall mean all the test, measurements, checks and calibrations
to be carried out in Contractors shop in order to compare the actual characteristics
of the equipment with the specified ones, as well as the documentation
(certificates/records) containing the data or results of these activities.
10.3
Contractor shall submit a description (manual) of his QA/QC with a view to this
specification along with offer.
10.4
10.5
QA/QC systems shall cover all products and services of the contract including
subcontracted jobs, if any, e.g. documentation and site works etc..
10.6
Minimum quality control requirements as specified in Doc. No. EM163-401ANNEXIII shall be considered as indicative only and they shall need expanding to
incorporate items such as (a) Characteristic to be verified (b) Procedure Reference.
(c) Acceptance Criteria, (d) Verifying Document etc.
10.7
10.8
11.0
11.1
All raw materials shall be covered with proper identifiable material mill test
certificate endorsed by third party: Lloyds / BV / TUV for imported materials & PDIL
for indigenous materials. All charges towards such inspection shall be included in
price.
11.2
All equipment shall be inspected during various stages of manufacture starting from
identification of raw materials to completion by PDIL/Owner or its authorized
inspecting authority. The equipment shall be considered acceptable and for
dispatch only after final certification for acceptance & dispatch clearance are issued
by the inspector
11.3
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 26 of 36
nuts, ordinary gaskets etc. may be exempted from the stage inspection with specific
approval from PDIL.
11.4
11.5
11.6
Inspection order on third party shall also include specific instructions for making
copies of all correspondence from inspecting authorities to PDIL and reporting
monthly progress and status with indication of status (delayed/on time) of delivery of
the order to owner / PDIL. Complete responsibility of getting approval of drawings,
calculations and documents from inspecting authority shall be that of the contractor.
11.7
11.8
A)
Radiography
i) Technique for radiography and acceptance criteria shall be as per code of
design and construction.
ii) Radiography when called for shall be applicable to all pressure welds i.e.
longitudinal and circumferential butt-welds including butt-welds in stiffener.
iii) When formed heads are made of welded plates/petal construction all weld
seams prior to forming and after forming shall be fully radiographed.
iv) All the T-joints shall be radiographed.
B)
Ultrasonic Examinations
i. Butt weld plate thickness > 50 mm as supplement to radiography.
ii. All butt-weld (after Heat Treatment)
iii. Full penetration welds of nozzle attachments on equipment shell/head as
substitute for radiography.
iv. 4 inch around the nozzle opening (before cutting / opening hole)
v. Any repair welds (before and after hydrotest)
vi. All circumferential welds located in the lower 1200 of sand bed (after hydrotest).
vii. 100% T-joints (after hydrotest).
C).
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 27 of 36
iii.
iv.
v.
vi.
E).
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 28 of 36
ix. For equipment meant for caustic service, H2S service, Amine service etc., one
hardness test reading shall be taken on inside of each shell section, head,
longitudinal weld, circumferential weld and nozzle longitudinal weld after
PWHT.
F) Four points on each shell course at position 0, 90, 180, & 270 degree shall be
marked by preparation of proper dimensional sketch for future checking record of
initial NDT list of these reference points shall be maintained for periodic/
subsequent inspection per OISD- 150. Base UT reading of shell, dome & nozzles is
required for future comparison purpose & trending/ corrosion rate analysis.
12.0
a).
Hydrotesting
All completed equipment shall be tested hydrostatically as per the requirements of
specifications/codes & approved hydrotest procedure in presence of the inspecting
authority. Prior to hydrotest, all weld splatter, weld studs, scale, dirt, etc. shall be
removed from the vessel. The vessel is to be supported while hydrotesting on sand
bed which is to be laid & completed upto a level of 120 degree taken from the
center of vessel to the edge of vessel. Entrapped air near dome shall be completely
removed by suitable means during hydrotest. Contractor shall submit a detail
procedure for Hydrostatic testing for approval by Owner/PDIL prior to
commencement of testing time. Pressure-Time graph shall also be submitted.
All necessary precautions shall be taken to safe guard against the risk of brittle
fracture during hydrostatic test at site. It is suggested that the temperature of the
testing medium shall not be less than 15C. PH of water used for hydrotest shall be
between 6.0 7.0. After hydro testing water shall be drained in NRL drains.
At the time of hydro test the adjacent bullets on either side of the bullet under test
pressure shall be kept water filled, i.e., minimum three adjacent bullets shall remain
completely filled with water anytime during hydro test.
A method of measuring the water height in the bullet is also to be established.
Water shall be filled / emptied in stages 25%, 50%, 75% and full with 2 hours
holding period at stages. Loading rate shall be monitored such that the loading rate
does not exceed 2.0M/day subject to a pumping rate of not more than 20cm/hour.
Minimum 2 nos. Dial gauges, dial graduated over the range of not less than 1.5
times and not more than about 2 times the test pressure and an accuracy of +/- 0.6
percent or finer, shall be used.
All pressure gauges / pressure recorders (the same accuracy or finer) used in
testing shall have a calibration record showing values of standard indicated
pressure and validity period. Inspector shall verify that calibration tag is displayed
on the pressure gauge/recorder.
Pressure pumps, pipe / hose pipe, fittings and other accessories shall be capable of
developing and withstanding the test pressure.
Hydro Test pressurization shall be developed in stages i.e. 0 Working Pressure,
Design Pressure, Hydro test Pressure with holding period of two hours minimum at
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 29 of 36
stages. Depressurization shall also be done in stages i.e. Hydro test Pressure,
Design Pressure, Working Pressure with holding period of two hours minimum at
stages. All visible weld joints / connections shall be visually inspected for any
leakage/sweating at various stages.
After successful hydrotesting, test water shall be transferred to the other Bullet
ready for hydro testing.
Unless otherwise stated, gaskets used during testing shall be same as specified for
operating conditions.
Sweet potable water shall be used for hydrotesting. Minimum duration to hold
hydraulic pressure shall be 4 hours
b) Settlement
Their initial levels of equidistant points (bench marks) placed on top of the bullet
shall be taken with respect to minimum 3 numbers permanent bench marks for
settlements readings which shall be provided as near to bullet as possible but not
more than twice the vessel diameter from the periphery of the mound. Further
bench marks shall be painted as per vessel specifications. Standard reference level
for comparison of future readings with current measurements shall be provided.
Mound settlement shall be recorded / checked after allowing 24 hours time at
different filling/emptying stages of hydrotesting of each bullet and after 48 hours
with the bullet completely filled. Also after completion of hydro-testing, settlement
recording shall be continued by the contractor during construction of mound, and till
successful commissioning of bullet once in a week. Settlement recording shall be
done preferably when atmospheric temperature is not more than 30 Celsius..
IMPORTANT
The settlement rate during this testing period needs to diminish with time as
otherwise there would be a danger of instability. If the rate does not diminish
adequately, the client/inspecting authority shall be informed immediately. The bullet
shall be (partly) emptied, and a geotechnical / specialist should be consulted.
13.0
CALIBRATION
13.1
Contractor shall prepare & submit a LPG Mounded Bullet calibration procedure
including Calibration Chart in accordance with IS:2009 & IS:2166. Contractor shall
obtain necessary approval for calibration from statutory authority CPWD / Weight &
Measurement Deptt. or competent authority.
14.0
PRE-COMMISSIONING/ COMMISSIONING
14.1
EM163-TS-401
TECHNICAL SPECIFICATION
15.0
REV
DOCUMENT NO
SHEET 30 of 36
GUARANTEE
15.1
The contractor shall guarantee all the bullets and their components against faulty
design with regard to mechanical adequacy, improper material of construction and
poor workmanship after successful testing at site for a period as specified in
commercial terms and conditions.
15.2
Approval by PDIL of design calculation and detailed shop drawings will not in any
way absolve the contractor from his responsibilities to supply equipment in
accordance with order specifications
15.3
16.0
DOCUMENTATION
16.1
Before starting any fabrication, drawings / design calculation must be get approved
from PDIL and inspection authorities. Detailed design, fabrication drawings & FE
Analysis shall be prepared by contractor based on contract documents and shall
bear reference document number & revision of the corresponding PDIL reference
drawings including item name & code, clients name, project name, fabricators
name, P.O. No. clearly indicating all design data, nozzle data, details of all parts
with tolerances, all welding joint details and detailed bill of materials etc. Location of
weld seams, construction notes, welding processes, detailed specification of
electrodes including NDT tests etc. as applicable shall be clearly indicated in the
drawing.
16.2
16.3
Drawing submitted for approval must be complete in all respects and thoroughly
checked and approved by contractors competent authority before submitting to
PDIL. Drawings without complete information are likely to be rejected and any delay
on this account shall be attributable to the contractor.
16.4
All drawing shall be drawn in AUTOCAD 2000 R-14 to the scale. Subsequent
revisions, incorporation of comments shall also be made in AUTOCAD R-14.
Manually drawn new and/or revised drawings shall not be accepted.
EM163-TS-401
TECHNICAL SPECIFICATION
16.5
REV
DOCUMENT NO
SHEET 31 of 36
16.6
Documents and letters shall be furnished in electronic format. The software used
shall be as follows.
a). MS OFFICE 2003 or above.
b). ADOBE ACROBAT 6.0 & above
16.7
Before starting any fabrication, drawings / design calculation must be get approved
from PDIL and inspection authorities. Any comments marked on fabrication
drawings shall have to be incorporated and decision of PDIL in this regard shall be
considered as final. In case of third party inspection COPY OF
CORRESPONDENCES WITH THIRD PARTY shall also be endorsed to PDIL.
16.8
16.9
After approval, one set of drawings/documents shall be given to the inspector by the
contractor.
16.10
Contractor shall submit 1(one) soft copy (CD-ROM) along with 8(eight) prints of
documents to PDIL and 4(Four) prints of documents to NRL followed by visit of their
personnel on an agreed schedule for getting spot approval. Contractor shall depute
their concerned engineer along with draughtsman for deciding and incorporating the
various agreed comments during their stay. Same procedure shall also be followed
for the approval of subsequent revisions, if any. All soft copy documents/drawings
shall be in an editable format compatible with Auto CAD 2000.
16.11
Revision for AS-BUILT shall also be entered in CAD files. The nos. of copies for
ASBUILT Drawings, Documents, Design calculations, Data Folders comprising
Material Test Certificates, Inspection /measurements records, NDT reports, WPS,
PQR, WPQ, QAP, PWHT records, Hydro & Pneumatic test reports, rub-off Name
Plate, catalogues, Literatures etc. shall be 8 (eight) sets of hard copies, properly
bound in folders and indexed. Two sets of CDs of all drawings & two sets of
Reproducibles shall also be submitted. Documents shall be with certification for
ASBUILT by the inspecting authority (Uncertified drawing / documents shall not be
accepted as AS-BUILT).
16.12
For the documents submitted for approval or comments, the delivery is fulfilled only
when documents are received in a state suitable for the action required.
EM163-TS-401
TECHNICAL SPECIFICATION
16.13
REV
DOCUMENT NO
SHEET 32 of 36
16.14
Approval of design calculation and detail fabrication drawing by PDIL will not in any
way absolve the contractor his responsibilities to supply the equipment in
accordance with the order.
16.15
16.16
Equipment shall fall under the purview of PESO/CCOE and shall require statutory
approval from inspector of Explosives. It will be the responsibility of the contractor to
get the fabrication drawings / design calculation of the equipment approved at his
cost.
Contractor shall obtain approval from CCOE for drawings and design calculations
before start of bullet fabrication
Bullet shall be requiring statutory approval from CPWD/Weight and Measure deptt.,
it will be the responsibility of the contractor to get the calibration procedure /
calibration chart of the bullet approved at his cost.
16.17
16.18
Documents marked with (*) are to be approved by the PDIL Design Office.
Documents marked with (**) shall be approved endorsed by the inspecting authority
during detail engineering stage.
16.19
16.20
16.21
All documents, their number of copies and schedule for approval and submission
shall be as specified below.
16.22
The delivery time in weeks from the data of Telex of Intent/Order for each document
is given below and defines the documents for approval. Documents are to be
received in a state suitable for action required.
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 33 of 36
Description
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Copies Reqd
with Bid
8
8
8
8
8
8
8
8
8
8
21
21
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 34 of 36
17
18
19
20
21
22
23
24
25
26
10
21
10
21
21
8
8
30
30
30
8
8
30
30
30
30
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 35 of 36
27
28
29
30
30
30
30
After handling
over
equipment
After handling
over
equipment
After handling
over
equipment
-do-
-do-
-do-
8
8
8
-do-do-do-
8
8
-do-do-
8
8
8
8+2R+
2E
8
-do-do-do-do-
8+2R+
2E
-do-
31
32
Records
of
NDT
tests
e.g.
Radiography, UT, DP, MPI, hardness,
impact etc. ( ** )
(Radiographed films shall also be
supplied)
Records
of
shot
blasting,
coating/painting. (** )
Materials
test
certificates
duly
stamped by inspecting authority ( ** )
PWHT Charts ( ** )
Test on production test coupons ( ** )
Hydraulic & pneumatic test report of
bullet and R.F. Pad respectively (**)
Bullet Settlement check record. ( ** )
Inspector
final
certificate
of
compliance
Inspector Release Note
Suppliers Guarantee Certificate
Rub-off Name Plate (**)
All final as built drgs. including
detailed fabrication/shop drgs ( ** )
Mechanical design calculation and
FEAnalysis
Operating manual wherever required
including C.P. System
All Drgs./Doc. of bought out items
PESO/CCOE approved drawings and
calculations
Statutory Agency approved calibration
charts
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
(*)
Welding procedure & performance
record approved by inspecting
authority (as per ASME SEC. VIII
DIV. 2) ( ** )
NDE personnel qualification/record
(**)
Sketch showing weld seams no. &
welder identification number. ( ** )
Specification of welding consumables
(meeting ASME SEC. IX (**)
-do-
-do-do-
-do-
EM163-TS-401
TECHNICAL SPECIFICATION
REV
DOCUMENT NO
SHEET 36 of 36
Description
Technical offers
GA
Drawings,
Fabrication
Shop
drawings & documents
for approval
Mechanical
design
calculation, FE analysis
for review / approval
QAP
for
review /
approval
Find / As built drawings,
design and calculation,
FEA, QAP, WPS, PQR,
WPQ, Material Test
Certificate
ND
test
reports documents Data
folder(Bound & duly
Indexed.
Hard
copy
6
8
No. of Copies
PDIL
Soft files
Reproducible Hard
CD ROM
polyester film copy
--4
1
-4
NRL
Soft files Reproducible
CD ROM polyester film
--1
--
--
--
--
--
--
--
--
--
--
1
(Editable
Soft files)
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 1 of 6
2
1
0
REV
02.09.2015
18.06.2015
29.05.2015
REV DATE
02.09.2015
18.06.2015
29.05.2015
EFF DATE
SKK/ VKS
SKK/ VKS
SKK/ VKS
PREPD
SCA
SCA
SCA
REVWD
SCA
SCA
SCA
APPD
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 2 of 6
Project:InstallationofLPGMoundedBulletsat
NRLRefineryLimited
Equipment:LPGMoundedBullets
TagNo.: 45VV101/102/103/104
No.ofunits:Four(4)
Service:LPGSTORAGE
Size:mm(ID)7000x52000(TLTL)
Position:HorizontalCylindricalwithdishedends
DESIGNDATA
MATERIALOFCONSTRUCTION
Fluid:LPG
Shell:CS(Refer.Clauseno5.1,ii(a))ofOISD150
(NOTE2&NOTE14.)
CapacityTypem3:2071.3(waterCapacity)
Liningifany:NOTE2
Capacity(Max.LPGStored)m3:1760.56(85%
Capacity)
Head:
Flow(INLET)T/hr:13.04
NozzleNeck
PumpOutm3/hr:291(Max.)
NozzleFlanges
Workingpressurekg/cm2g:2.3378.6
StudsandBolts
DesignPr.Kg/cm2g(Internal):14.5+Statichead
DesignPr.kg/cm2g(External):FullVacuum+Wtof Nuts
Mound
WorkingtempOC10/40/55
Gaskets
DesigntempOC:()27TO55
Distributors
SpecificGravity:0.500.57
Grates
Outlet(Vapour)/(Liquid)Kg/m3:
AdditionalAttachmentsInternals:
CorrosionAllowance(mm):3
InternalAttachments:
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 3 of 6
NOZZLES
MARK
SIZE
RATING REMARK
LiquidLPGInlet
N1
300#
WithDippipe
LiquidLPGOutlet
N2
12
300#
Note16B
LPGVapourReturn/Balance
N3
300#
RadarTypeLevelIndicator
N4
8
Hold
300#
ServoTypeLevelIndicatorNote18
RadarTypeLevelIndicator Note18
N5
6
Hold
300#
N6
8
Hold
300#
300#
8
Hold
300#
300#
Temp.IndicatorNote18 N7A/B
Sizeshallbe
confirmedby
instrumentvendor
SafetyValve(NOTE3)
N8A/B
PressureTransmitter
N9 A/B
RecirculationLine
N10
300#
WithDippipe
SpareNozzle
N11
300#
ManualVent
N12
300#
Manhole1
M1
32
300#
Manhole2
M2
24
300#
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 4 of 6
Despatch
CompleteSegments
SpecialInstruction
NOTES.
1.
AllprocessdataareindicatedinBold&italic.
2.
AsperOISD150InternalBottomportionoftheVessel(90oCAngle)shallbecoatedwith
anticorrosivecoatingsuitableforCAUSTIC.
3.
Twonos.ofPSVwillbeprovidedonN8A/BforeachBullet.Onewillbeinlineandothershallbe
spare.
4.
Vesselwillbeslopedtowardsthebottomoutlet@1:200.
5.
Thetopandsidesoilcovertobeofneutralmaterialwhichiswellcompactedtopreventwaterand
airerosion.
Themoundshouldhavegooddrainagetopreventanywateraccumulationonthemound.Material
shouldbefreefromabrasivematerialorparticleslikelytodamagetheequipment.
6.
Theentirenozzletobeoutsidetheearthlevel/mound,suitablecoatingforexternalsurfacetobe
provided.
7.
Vesseltobedesignedfortheexternalloading.
8.
Thefireproofingtotheexposedvessel,bottomoutletlineinsidetunnel,nozzles&pipeshallbe
doneuptothefirstROV.
9.
Alldrawings,documents,designcalculation,stageinspection&certificationshallbegotapproved
bychiefcontrollerofexplosives.
10. Inspectiontunnelshallbeprovidedforbottomoutletnozzle(N2)asperOISD150.
11
HydrocarbonLeakdetectorintheLiquidOutletLineTunnel&nearROVstobeprovided.
12. VortexbreakershallbeprovidedinthebulletOutlet.
13. Firefightingfacilitiesshallbeconsideredasperrelevantcode.
14. Mercaptandosing:20ppmApprox
15. AllnozzlesexceptN2shallbelocatedonthedome.
16A. ManholeswithstaircaseshallbeprovidedontheBullettop.Accessplatformshallbeprovidedat
theTopforaccessingofInstrument/maintenancealongwithhandrail.
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 5 of 6
16B. MatchingflangewithROVs(BottomOutletnozzleN2)onbulletandpipingsideshallbeRTJtype.
17. Remoteoperatedvalves(ROV)shallbeprovidedoninletandoutletLPGnozzlefromBullet,Recycle
liquidLPG&vapourreturnline.Thesevalvesshallbefiresafedesign.
18. Radar&ServoGauge,Temperaturemeasurementshallbewithstillingwell.Perforations/slotsshall
beasperInstrumentationrequirement.
19. Safetyvalvesetpressureshallbe14.5kg/cm2g;itshallbedesignedfor21%overpressure(fire
sizing).Thefullflowcapacityofeachsafetyvalveshallbeminimum30%ofthecapacityrequired
foranequivalentsizeofabovegroundvessel.
20. DuringLPGfillinginbullet,thebulletshellshallexpandduetopressure.TheRCCwalldesignshall
beabletotakecareofthethrust.
21. Bullet&moundingshallbedesignedasper latest OISD 150.
22. Suitablecathodicprotectionshallbeprovidedforeachbullettoguardagainstcorrosion.Monolithic
insulationjointshallbeprovidedoninlet/outletpipelines&PSVdischargepipeline.
23. AreaClassification:ZoneI,IIA/IIB,T3.
24
Bottomdrawofflineshallhaveslopeangle1.50 minimumdistanceof3mfromvesseltangentline
toROVatnozzleN2shallbemaintainedasperOISD150
EM163-TS-401-SR
DOC
CUMENT NO
O
REV
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
S
SHEET
1 OF
F 15
SUPPLEME
ENTARY REQUIR
REMENTS
S FOR
MOUNDE
M
ED BULL
LET
0
P
RE
EV
15.09
9.15
24.07
7.15
REV DATE
D
15.09.15
24.07.15
EFF DATE
D
ISSUED F
FOR ENQUIR
RY
ISS
SUED FOR CLIENTS COM
MMENTS
PU
URPOSE
VB/PK
VB/PK
PREPD
NB/AKG
NB/AKG
REVWD
GC
GC
APPD
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
CON
NTENTS
CLAUS
SE NO.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10
0.0
DESCRIPTION
D
G
GENERAL
R
RESPONSIB
BILITY OF SUPPLIER
S
M
MECHANICA
AL DESIGN
N
M
MATERIALS
S
S
SCOPE
OF SUPPLY
F
FABRICATIO
ON
I
INSPECTIO
N AND TES
STING
C
CLEANING,
PAINTING AND DESPATCH
G
GUARANTE
EE
D
DOCUMENT
TATION
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
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REV
Page2of1
15
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page3of1
15
1.0
GENERAL
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2.0
RESPONSIBILITY OF THE
T
SUPPL
LIER
2.1
s
include
e but not be
e limited to the following
g.
The responsibility of the supplier shall
w
is nott listed here but is requiired for com
mpletion of th
he
Any other ittem/activity which
supply as pe
er the enquiry documentt shall also be
b the respo
onsibility of th
he supplier.
a) Comple
ete design of
o the equipm
ment includin
ng civil/strucctural, piping
g, electrical &
instrumentation dessign as per code indica
ated in relevvant drawing
gs, equipment
specific
cation sheets, standardss and any other enquiry documen
nts; supply of
o
civil load data for fo
oundation de
esign.
b) To obtain approva
al of PDIL on design
n calculation
ns, drawing
gs and othe
er
docume
ents as spec
cified in Para
a 10.0.
c) To obttain statutorry approval of design calculation
ns, drawing
gs and othe
er
docume
ents whereve
er applicable
e.
d) Procure
ement of alll the materiials whatsoe
ever require
ed to meet the scope of
o
supply.
e) Shop Fabrication,
F
inspection, testing, painting, matcch marking, packing an
nd
dispatch
h of the shop fabricated//assembled items/equip
pment.
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page4of1
15
f)
g)
h)
i)
j
j)
Site fab
brication, inspection, te
esting, paintting, refracto
ory lining, site
s
handling
g,
erection
n, assemblyy, welding, te
esting etc. in-situ
i
condition of the prefabricate
ed
and site
e assembled
d items/equip
pment, if app
plicable.
Site hyd
dro-testing, ifi applicable.
Pre-com
mmissioning & assistancce during commissioning
g, if applicab
ble.
Submis
ssion of the periodic
p
prog
gress report showing the
e status of th
he job.
Supply of the final documents
d
a
as specified in para 10.0
0.
3.0
CAL DESIGN
N
MECHANIC
3.1
Complete mechanical
m
d
design
of eq
quipment as per latest ccode of cons
struction sha
all
be the respo
onsibility of the
t supplier.. Strict comp
pliance with the requirem
ments of cod
de
/ equipmentt specificatio
on and any o
other referred
d document shall be fullyy ensured.
Detailed des
sign calculations for ade
equacy of sttrength of alll individual parts
p
shall be
b
made and submitted
s
to PDIL for co
omments an
nd approval. After receip
pt of approval
from PDIL the desig
gn of equ
uipment sha
all be con
nsidered ass final. An
ny
change/com
mment, mad
de on desig
gn calculatio
ons to satissfy the req
quirements of
o
code/enquirry documents shall havve to be incorporated without anyy commercial
implicationss. For high alloy
a
steel pa
arts/components designe
ed as per ASME Sec.VIII
DIV.1/2 low
wer allowable
e stresses sshall be ado
opted, for fla
anges of ga
asketed joints
unless othe
erwise speciified. After tthe approva
al of variouss documentss subsequent
deviations shall
s
be disco
ouraged (no
ot considered
d).
Any modification in desiign parameters as may be required by PDIL at any
a time sha
all
have to be suitably in
ncorporated. Commercia
al implicatio
ons, if any, due to succh
changes shall be mutua
ally discusse
ed and settle
ed. Any subssequent cha
anges desire
ed
by supplier owing to changes in m
material of construction
c
n/fabrication details, sha
all
have prior approval
a
of PDIL
P
design office.
All equipme
ents shall also be desig
gned for hyd
drostatic tesst in operatin
ng position in
corroded co
ondition considering 25%
% of design
n wind load.. Allowable stress durin
ng
hydraulic tes
sting shall be 90% of yie
eld stress.
Unless othe
er wise speccified elsewh
here in enquiry/order doccument, Win
nd loads sha
all
be calculate
ed in accorda
ance with IS
S: 875 (Part 3)
3 with follow
wing conside
eration:
Equipment shall
s
be con
nsidered as IImportant Bu
uilding Classs of Structurre accordingly
risk coefficie
ent (K1 Facttor) shall be taken from Table
T
1 IS: 8
875.
Terrain cate
egory (K2 Fa
actor) shall b
be taken con
nservatively as 2; Terrain Class sha
all
depend upo
on the size of equipmentt.
Topography
y (K3 Factor)) shall be takken to be eq
qual to 1.0.
Force coeffiicient (Cf) fo
or the equipm
ment (non-ssmooth) shall be taken from
f
table 23
2
accordingly wind force calculated.
c
Wind forcess shall be in
ncreased byy 20% to ca
ater for the effect of piping system
m,
platforms an
nd ladders etc.
e
Vertical ves
ssels with height/diame
h
eter ratio eq
qual to or greater than 6 shall be
b
analyzed fo
or vibration due
d
to vorte
ex shedding
g when criticcal wind spe
eed does no
ot
exceed 30 m/s.
m
Unless othe
erwise site spectra furnisshed by clie
ent, Seismic loads shall be calculate
ed
in accordan
nce with IS: 1893(Latesst Edition). For the dessign values of horizontal
3.2
3.3
3.4
3.5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page5of1
15
3.6
3.7
3.11
3.12
3.13
3.14
seismic co-e
efficient h Response S
Spectrum Me
ethod shall be compute
ed as given in
section 2 sta
ack line structures IS:18
893, ( Part 4)):2005.
Design of supports
s
and
d anchor/fou
undation bo
olts shall be the respon
nsibility of th
he
supplier. Th
he type, num
mbers, locatiion and any
y other inform
mation if furrnished in th
he
specification
n sheets shall be strictlly adhered to.
t Howeverr, adequacyy of the sam
me
must be che
ecked by the
e supplier. In no case diameter
d
of a
anchor bolts shall be lesss
than M24 fo
or skirt suppo
ort and M16 for others.
All items wh
hether intern
nal or extern
nal which arre welded directly to a shell or hea
ad
shall be of the
t same ma
aterial categ
gory as that of the shell or head. Th
his shall app
ply
to all nozzle
es, brackets, pads and upper portion
n of the skirt for vertical vessels.
v
Forces & moments com
ming on the nozzles sha
all be furnish
hed after ord
der placement
by PDIL wh
hich shall be
b considere
ed in the design
d
by th
he supplier,, without an
ny
commercial implication.. Alternative
ely supplier shall indicate maximum
m permissible
forces & mo
oments for re
eview and co
onfirmation by
b PDIL.
Lifting lug sh
hall be desig
gned with a sshock factorr of 2.
Unless othe
erwise speciffied minimum
m corrosion allowance fo
or C.S and low alloy steel
material sha
all be 1.5 mm
m.
In case of vessels minimum
m
thicckness of shell
s
and h
head includiing corrosio
on
allowance shall
s
be as under unless otherwise specified
s
Shell Dia
D in mm
ID 500
500 < ID 1200
1200 < ID 2000
1200 < ID 2000
ID > 2600
3.15
Minimum no
ozzle diametter shall be 1 nomina
al.
4.0
MATERIALS
4.1
4.2
4.3
4.4
4.5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
4.6
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page6of1
15
4.20
5.0
SCOPE OF SUPPLY
5.1
Unless oth
herwise spe
ecified the complete main equipment and its variou
us
components
s as specifie
ed in speciffication shee
ets and enq
quiry documents shall be
b
included in suppliers scope
s
of supply. Scope
e of supply shall includ
de but not be
b
limited to the
e following:
4.7
4.8
4.9
4.10
4.13
4.14
4.15
4.16
4.17
4.18
4.19
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
5.1.1
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page7of1
15
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
5.1.11
5.1.12
5.2
6.0
FABRICATIION
6.1
The manufa
acturer of the
e equipment shall comp
ply in all resspects with the
t provision
ns
of the app
plicable cod
de/standardss and spec
cifications with
w
respectt to welding
g,
fabrication, forming of heads,
h
radio
ography, heat treatment, inspection
n, testing an
nd
quality contrrol etc.
All welding shall be carried out byy qualified welders
w
using
g approved procedure in
compliance with the req
quirements o
of code & sp
pecificationss and duly ce
ertified by th
he
inspecting authority.
a
Alll welding prrocedure mu
ust be got a
approved fro
om authorize
ed
inspecting authority
a
beffore starting any fabricattion job. We
elding of all parts
p
must be
b
completed before
b
heat treatment.
t
Plates of different
d
thiccknesses sh
hall be mad
de flush witth the innerr surfaces of
o
equipment unless
u
otherrwise stated..
Minimum skkirt height off dished hea
ad shall be 50
5 mm unlesss otherwise stated.
CS / Alloy steel dished
d end/toricon
nical head including
i
co
one if cold formed
f
or ho
ot
formed belo
ow normalisin
ng temperatture shall be
e subsequently normalise
ed. In case of
o
austenitic SS
S materials
s solution a
annealing shall
s
be carried out if hot worked
d.
Formed end
ds of vesse
els with diam
meters less than 1600 mm shall preferably
p
b
be
made in one piece. Larger heads which can not
n be formed in one piece
p
shall be
b
fabricated as follows witth prior apprroval from PDIL:
a) In two pieces,
p
with the welding seam includ
ded in the middle
m
third and
a preferab
bly
on the centre
c
line.
b) In petall constructio
on, with meridianal seam
ms and a ce
entral cap off diameter no
ot
larger th
han 0.75 tim
mes the vessel outside diameter.
5.1.2
5.1.3
6.2
6.3
6.4
6.5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page8of1
15
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
Formed hea
ads when fab
bricated in p
pieces shall be normalized and weld
d seams radio
graphed afte
er forming.
Impact test when requ
uired as perr code & sp
pecifications shall be ca
arried out on
o
parent meta
al, weld and HAZ.
Production control coup
pons, when required ass per code & specificattions shall be
b
subjected to
o impact te
est, corrosio
on test etc. in addition to mechan
nical tests as
a
required. In case of hea
at tested equ
uipment testt coupons shall be given
n similar hea
at
treatment ass for the equ
uipment.
Each shell section havving diameter equal fo
or less than 2 meters to
t the extent
possible, sh
hall be rolled out of a single plate witth one longittudinal seam
m.
Orientation of longitudinal seams and position of circumferential sea
ams shall be
b
clearly mark
ked in the fa
abrication drawings. Noz
zzles, suppo
ort and otherr attachments
shall be loca
ated clear off weld joints..
The centerss of the weld
ded longitudinal joints of adjacent co
ourses shall be staggere
ed
or separated
d by a distan
nce of five times the thic
ckness of the
e thicker pla
ate or 100 mm
whichever iss greater.
All parts invvolving weld
ding constru
uction includ
ding internalss and stiffen
ner ring sha
all
have continu
uous welds unless otherrwise stated.
All welds sh
hall be full penetration w
welds with back chipping
g and rewelding from th
he
second side
e. For those joints which
h are inacce
essible for ba
ack chipping
g the root ru
un
shall be carrried out with
h TIG proce
ess. Single side
s
welding
g with backin
ng strip is no
ot
permitted.
Due provisions must be
b kept for venting
v
out entrapped gases durin
ng welding of
o
pads, flange
es and liner plates etc.
All nozzle reinforcing pads
p
shall be
e tested pne
eumatically at 0.5 Kg/cm2g pressurre
with soap solution
s
on attachment welds. Ven
nt holes shall be plugg
ged with no
on
hardening mastic
m
to pre
event ingresss of water.
Pads for sup
pports and external
e
clea
ats etc. shall be of same material as that of shelll.
All sharp co
orners shall be rounded off with sm
mooth radius. Inside edg
ge of nozzles,
manhole and handhole at the intern
nal surface shall
s
be roun
nded to min. radius 5 mm
m.
Unless othe
erwise state
ed all nozzle
e flanges shall be weld
d neck type
e. For nozzle
flange size 24 dimen
nsions shall cconform to ASME
A
ANSI B16.5 and nozzle flang
ge
size > 24 NPS
N
dimensions shall co
onform to AS
SME ANSI B
B16.47 (Serie
es-B).
All welding neck flangess shall be bo
ored to suit nozzle I.D. F
Flange facin
ngs shall havve
suitable serrrations for gasket seatin
ng in case off plain, male//female and raised.
Unless othe
erwise stated
d all girth flange joins sh
hall be confin
ned type. Minimum deptth
of gasket fa
acing for girth
h flanges sh
hall be 5 mm
m for compre
essed fiber gaskets
g
and 6
mm for spira
al wound / metal
m
jackete
ed gaskets
In case of equipment
e
to
o be assemb
bled at site trrial assembly in shop sh
hall be carrie
ed
out and mattch marked for
f proper asssembly at site.
s
Equipment shall
s
be pro
ovided with suitable
s
braccings/stiffene
ers to avoid any damag
ge
during transsportation an
nd erection a
at site.
In case of equipment involving site assembly/fa
abrication, th
he entire site
e job includin
ng
fabrication, radiographyy, heat treatment, inspe
ection, testing and tran
nsportation to
t
site shall be
e in supplierss scope of w
works at his cost.
c
All flange bo
olts & skirt-b
bolts shall strraddle centre
e line unlesss otherwise stated.
s
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
6.22
6.23
6.24
6.25
6.26
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
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Page9of1
15
7.0
INSPECTIO
ON AND TESTING
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page10of15
a)
7.13
7.14
Ultraso
onic Examina
ations
i) Butt weld in thick
kness > 50 m
mm as supplement to ra
adiography.
ii) Full penetration welds of n
nozzle attachments on equipment shell/head of
o
thickkness > 50 mm
m as substtitute for radiiography.
iii) All fo
orgings
b) Magnettic particle / Liquid penettrant examin
nation
i) All edges
e
of plattes and openings in she
ell of C.S. ha
aving thickness > 40 mm
and low alloy stteel / S.S. h
having thickn
ness > 25 m
mm and allo
oy steel of all
a
thickkness.
ii) Roott-run and final layer of all butt welds.
iii) All welds
w
having
g thk. > 50 m
mm, all weldss of low allo
oy steels and
d all materia
als
with UTS > 52 Kg/mm2.
K
iv) Knu
uckle surface of dished
d ends / to
oriconical se
ections, pipe
e bends an
nd
expa
ansion bellow
w.
v) All welds
w
of SS and
a non ferrrous materia
als and weld
ds for vessells with desig
gn
temp
p. (-) 45C and below aftter hydro tessting.
vi) All weld
w
surface
es after PWH
HT.
vii) All forgings
f
after machining.
c) Radiogrraphy
i. Radiiography wh
hen called fo
or shell be applicable tto all pressu
ure welds i.e
e.
longitud
dinal & circumferential.
ii. In ca
ase heads are
a formed of
o welded pla
ates / petal construction
n, all the weld
seams prior to form
ming and afte
er forming.
iii. Circu
umferential joint of shell to dished he
ead.
iv. All T-weld
T
joints..
d) Hardness
Hardness va
alue shall no
ot exceed 215
2 HB for steel
s
having Cr < 2% an
nd 240 HB fo
or
steel having
g Cr > 2%.
All complete
ed equipme
ent shall be tested hydrraulically as per the req
quirements of
o
specification
n/codes in presence of
o the inspe
ecting autho
ority. Pneum
matic test of
o
completed equipment
e
s
shall
be carrried out on
nly when sp
pecially men
ntioned in th
he
specification
n sheets. Ch
hloride conte
ent in water used for tessting shall not
n exceed 30
3
ppm for SS equipment and 40 ppm
m for CS and
d low alloy steel
s
equipm
ment. Duratio
on
of test shall be 1 hour minimum
m
When requiired as per specification / code, strain gauge measurements shall be
b
carried out on
o outside circumferenc
c
ce during hydrostatic tessting. The re
esults shall be
b
plotted both
h during pre
essurizing an
nd depressu
urizing and procedure to such strain
measureme
ents shall hav
ve prior app
proval of PDIL.
8.0
CLEANING, PAINTING
G AND DESP
PATCH
8.1
After hydrau
ulic testing, the
t equipme
ent shall be dried,
d
thorou
ughly cleane
ed from insid
de
and outside and shall be
e free from a
all shop dirt, loose scale
e, grease etcc.
All external surfaces of CS includin
ng internal surface
s
of skkirt to be painted shall be
b
degreased and
a all rust and
a mill scalle removed.
i) Austeniitic stainlesss steels and non-ferrous materials sh
hall not be painted.
p
8.2
8.3
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page11of15
ii)
8.4
8.5
8.6
8.7
The equ
uipment sha
all be shot/grit blasted (m
min SA 2.5
5 ISO 8501--1) before th
he
primer coat is app
plied on extternal surfaces. Primerr shall be compatible
c
t
to
succeed
ding painting
g.
iii) In gene
eral, uninsula
ated equipm
ment working
g below 94C
C, alkyd high
h build prime
er
of thickn
ness 50 miccrons DFT sh
hall be applie
ed.
iv) For Un
ninsulated equipment
e
above 94C
C to 204C
C working temperature
e,
aluminu
um paint of 30
3 microns D
DFT shall be
e applied.
v) For uninsulated eq
quipment upto 420C wo
orking temp.. inorganic zinc
z
silicate of
o
50 micrrons zinc silic
cate shall be
e applied.
vi) For insu
ulated equip
pment up to 94C, prime
er painting sh
hall be of alkkyd high build
epoxy primer
p
of 50 microns DFT shall be applied.
vii) For ins
sulated equ
uipment tem
mperature exceeding 94C, prim
mer shall be
b
aluminu
um paint of 30
3 microns D
DFT.
viii) Thermo
o-indicative paint (three
e colour pha
ases) shall be applied on refractory
lined equipment
e
to give w
warning of insulation/rrefractory failure.
f
Paint
manufa
acturers reco
ommendatio
on shall be fo
ollowed.
ix) All flang
ge faces, bo
olting and otther machine
ed surfaces shall be pa
ainted with an
a
easily re
emovable ru
ust-preventivve coating.
All machine
ed surfaces, boltings an
nd flange facces shall be
e properly protected from
rust and me
echanical inju
ury during transit and sto
orage.
Nozzles sha
all be sealed
d suitably. Th
hreaded con
nnections an
nd beveled openings
o
sha
all
be suitably protected.
p
Name and code numb
ber of equip
pment shall be painted on each eq
quipment at a
conspicuouss place in lettters 150 mm
m high.
After hydrau
ulic testing, all
a SS parts of equipmen
nt shall be p
pickled and passivated
p
a
as
per the following proced
dure:
a)
Cleanin
ng
Clean surface
s
and remove all extraneous matter with a hard fiberr brush or S
SS
wire bru
ush. M.S. wire
w
brush shall not be used. All organic mate
erials shall be
b
remove
ed with any paint remo
over like lig
ght solvent naphtha orr benzene o
or
equivale
ent. Motor petrol
p
shall not be used.
b)
Pickling
g
Aqueou
us pickling so
olution shall be as follow
ws :
Nitric accid (Tech. grade)
g
10 to 25% plus Hydrofluoric
H
acid 1 to 8%
% (to be use
ed
only forr stabilized SS
S grades). Temperaturre 50 to 60C
C for 10% Nitric
N
acid an
nd
20C fo
or 25% Nittric acid. W
When size and
a
shape of product permit, tottal
immersion in the piickling solutiion is preferrred. Where immersion is
i impractica
al,
pickling
g may be accomplishe
a
ed by wettin
ng the surfface by 1) swabbing or
o
spraying
g 2) by pa
artial filling tthe item with pickling solution and rotating or
o
rocking so that all th
he surface receive the re
equired chemical treatm
ment.
The ma
aximum perio
od for which
h the pickling
g solution sh
hall be allow
wed to remain
on the surface
s
is 30
0 minute. Du
uring pickling
g removal off oxides may
y be hastene
ed
by brushing with a hard
h
fiber orr SS wire bru
ush. Over pickling shall be avoided.
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page12of15
8.8
8.9
8.10
8.11
9.0
GUARANTE
EE
9.1
9.2
9.3
9.4
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page13of15
10.0
DOCUMENTATION
10.1
Detailed fab
brication dra
awings shall be preparred by supp
plier clearly indicating all
a
design data, nozzle data
a, details of all parts with
h tolerancess, all welding
g joints details
and detailed bill of ma
aterials etc.. Location of
o weld sea
ams, constrruction notes,
welding processes, detailed specifiication of ele
ectrodes inccluding NDT
T tests etc. a
as
applicable shall
s
be clea
arly indicated
d in the draw
wing. Drawin
ng submitted
d for approval
must be co
omplete in all respectts and thorroughly che
ecked and approved b
by
suppliers competent
c
authority befo
ore submittiing to PDIL
L. Drawings without succh
information are likely to be rejeccted and an
ny delay on
n this acco
ount shall be
b
attributable to the supplier.
Before startting any fab
brication, drrawings mus
st be got ap
pproved from PDIL. An
ny
comments marked on fabrication drawings shall
s
have to be incorporated an
nd
decision of PDIL
P
in this regard shalll be considered as final.
In case of vessels und
der the purrview of IBR
R, complete responsibillity of gettin
ng
approval of drawings an
nd design ca
alculations etc.
e from con
ncerned IBR authorities of
o
state of man
nufacture an
nd state of in
nstallation sh
hall be with the supplier at
a his cost.
For equipment requiring
g statutory a
approval fro
om Inspector of Explosivves, it will be
b
the respons
sibility of th
he supplier to get the fabrication drawings of
o equipment
approved att his cost, wh
herever requ
uired.
All drawings
s shall be drrawn in CAD
D to scale. Subsequent
S
revisions/inccorporation of
o
comments shall
s
also be
e made in CA
AD. Manual drawing sha
all not be acccepted.
It will be preferable; the
e soft copy along with 6 prints is b
brought to PDILs
P
desig
gn
office for getting
g
apprroval. Supp
plier shall depute
d
the concerned engineers &
draftsmen with
w prior inttimation and
d agreed datte for decidiing and inco
orporating th
he
various agre
eed commen
nts during th
heir visit/stay
y. Same pro
ocedure sha
all be followe
ed
for the apprroval of subssequent revisions, if any
y. Revisionss shall also be entered in
CAD file. Ma
anual revisio
on in drawing
g shall not be
b accepted..
After approv
val one set of drawingss / documents shall be g
given to the
e inspector b
by
the supplier.
Approval / comments
c
on various do
ocuments sh
hall be given
n by PDIL within
w
3 weekks
of the receip
pt of the sam
me, mailing time exclude
ed
Turn around
d time for su
ubmission off revised dra
awings / doccuments bassed on PDIL
Ls
comments shall be tw
wo weeks. Any
A
delay in approval on account of delay in
submission of revised drawings / do
ocuments sh
hall be attribu
utable to the
e supplier.
Payment ag
gainst submission/appro
oval of draw
wing if appliccable shall be
b made afte
er
approval of drawing und
der Code 1 or
o as per com
mmercial terrms & condittions of ITB.
All documen
nts / drawing
gs shall be in
n English lan
nguage and in Metric sysstem.
All final doccuments ind
dicated agaiinst Sl.No.08
8 to 30 sha
all be prope
erly arranged
d,
indexed and
d bound in one folder.
The docume
ent as marke
ed (**) are to
o be approve
ed by authorrized inspecting agency.
The number of copies of
o documentts and required deliveryy time in wee
eks from datte
of letter of intent / orrder for eacch documen
nt is given below unle
ess otherwisse
indicated in the technica
al specification
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.11
10.12
10.13
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page14of15
Sl.No.
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Descriptio
on
2
Outline sketch
s
show
wing thickne
ess
of main parts,
p
weight & anchora
age
details (R
Refer Clause
e 10)
List of items likely to be
subcontra
acted
witth
probable
vendors
Based on
o delivery stipulationss a
time bar chart in
ndicating time
required for materiall procureme
ent,
fabrication, testing, transportation
a
as
s required.
and site assembly
Billing Sc
chedule
Reference list of simiilar equipme
ent,
indicatin
ng
vario
ous
supplied
of
ers
&
material
paramete
construction
Descriptio
on of prese
ent shop lo
oad
and spare
e load availa
able for this jjob
and annu
ual turnover.
List of dra
awings
Final civvil load data
d
including
details of foundation/anchor boltss
Design ca
alculation & FE analysiss
Detail fab
brication draw
wing
Spare parts list
Procedurre for hydra
aulic test a
and
heat treattment ( ** )
Procedurre for sitte jobs like
assembly
y, heat trea
atment, testing
etc
Detailed manufacturing schedule
RT & progre
ess report to be
CPM/PER
submitted
d every month ( ** )
Welding
proced
dure
a
and
performance recordss approved by
inspecting
g authority ( ** )
Transporttation draw
wing showing
overall dimension,
d
ght
C.G., weig
and han
ndling insttructions duly
approved
d by appropriate authoritty
Operating
g/maintenan
nce
manual
whereverr required
Records of NDT
T tests e
e.g.
phy, UT, MP
P/PT, hardne
ess
radiograp
etc. ( ** )
Materials test cerrtificates duly
stamped by inspectin
ng authority ( **
)
Reqd
d.
with bid
b
Copie
es
3
Days
D
from L//I
5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
20
21
22
23
24
25
26
27
28
PWHT Ch
harts ( ** )
Test on production test coupo
ons
( ** )
Corrosion
n test reportts including C,
Cr, Ni, Mo and fe
errite contents
als, weldmen
nts,
report of raw materia
HAZ etc. ( ** )
Hydraulicc / pneumattic test repo
orts
( ** )
Strain gauge measurrement ( ** )
Inspectorrs final certifficate ( ** )
Suppliers
s guarantee certificate
Procedurre
for
removal
&
reassemb
bly of weld seal
s
gasket
All final as
a built sho
op drawingss &
calculatio
ons duly certified by
inspecting
g authority( ** )
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page15of15
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 1 of 4
REV
Enquiry No.
N
: EM163-TS-401
Items: LPG Mounde
ed storage fa
acilities
Bidder ____
__________
___________
__________
Bid No.____
__________
__________
__________
A
1
5
6
Description
Confirm that
t
following details / informa
ation are
furnished / attached alo
ong with offe
er
Past expe
erience reccord of co
ontractor along with
references / other ne
ecessary documents forr meeting
the qualifyiing requirem
ments as per Tender doccument
Furnish de
etailed reference list o
of Mounded
d storage
Bullets sup
pplied earlierr and in servvice for atlea
ast 1 year.
Details sha
all include i.e. size, dessign conditio
ons, shell
thickness, weight, ma
aterial of con
nstruction, inspection
agency, client, year of supply, orde
er value.
Contractor shall submiit along with the bid, a te
echnically
asible and satisfacto
ory methodology of
suitable/fea
fabrication//erection, post-weld
p
h
heat treatm
ment and
hydro-test for LPG Mounded
M
Bullets with complete
details, forr technical evaluation
e
o
of the bid. This
T
shall
specificallyy keep in view transporta
ation limitatio
ons of the
bullet partss/items as well as site co
onstraints
Route survvey upto refinery and in
nside refineryy shall be
carried out
o
by the
e contracto
or to asssess the
transportattion constraints (Route ssurvey reporrt shall be
submitted to
t PDIL/Own
ner for review
w)
Contractor shall get him
mself familia
ar with site conditions,
c
d storage a
area constraints etc.
approach to mounded
oting
before quo
Site facilities to the extent
e
as sp
pecified in document
d
SITE FAC
CILITY Do
oc. No. EM
M163-E-601 shall be
provided
Contractor to indica
ate the extent of su
ubcontract
proposed, if any.
at any workk or part of it can be
Contractor to note tha
oved by
subcontraccted, only to agencies appro
PDIL/Clien
nt. Approval from PDIL//Client shall be taken
prior to sub
bcontracting any work
Time Bar chart.
c
Duly Fille
ed in, stam
mped & ssigned Sch
hedule of
Exceptions
s & Deviations (FORM E) is enclosed.
d
taken by the
e contracto
or to the
1) Any deviation
stipulattions of th
he Tender document shall be
brough
ht out as pe
er this forma
at only and enclosed
Vendors co
onfirmation
(Tick mark which
w
ever iss
applicable)
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 2 of 4
REV
along with
w the offer.
10
B
1
2) Any de
eviation writtten elsewhere in the offfer but not
on the
e format, sh
hall not be recognized
d and the
same shall
s
be trea
ated as null and
a void
Itemwise price
p
of Sparres for 2 Years normal operation
and recom
mmended sp
pares submittted (Unpriced List of
spares encclosed)
Bid compliies with all items / works as per Technical
tender spe
ecifications, Codes / sta
andards & drawings
d
/
documentss
Confirm th
hat the sco
ope of work is exactly
y as per
requiremen
nts of bid do
ocuments.
Yess / No
Yess / No
Confirm tha
at:
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 3 of 4
REV
authoriity by the co
ontractor
All site
e work includ
ding compacction of grou
und, bullet
section
ns assembly
y, welding, ra
adiography, post weld
heat trreatment, tes
sting etc. sh
hall be in co
ontractors
scope and shall be execu
uted by co
ontractors
person
nnel. Cranes
s, tools, ta
ackles, cons
sumables,
devices for inspecttion and testing etc. sha
all also be
in conttractors scope.
Confirm the
t
inclusio
on and fa
abrication (wherever
(
necessary)) of followin
ng, as per the scope of supply
defined in bid
b documen
nt:
i) Manho
ole davit, Liftting lugs & ssettling markker
ii) Lugs/ccleats for CP
P.
iii) Piping works
M
& Strructural workks
iv) Civil, Mound
v) Electrical works
mentation wo
orks
vi) Instrum
vii) Cathod
dic protection system
viii) Manda
atory spares
s.
ix) Coatin
ng & Painting
g
x)
Any other accesssories as sspecified in technical
Enquiry Specificattions
II.
Yess / No
Yess / No
9
10
a) The qu
uoted price includes
i
for the Holds details of
which are
a indicated
d on the drawing
b) The weights
w
of each
e
mound
ded bullets shall be
indicated by contra
actor.
Confirm gu
uarantee off LPG Moun
nded Bulletss, and all
other allie
ed work ind
dicated in the Tender for the
following:
n
a) Design
b) Materia
als and supp
plies
c) Workm
manship fo
or construcction/ fabriication /
installa
ation
system
d) Satisfa
actory
p
performance
and
comple
eteness
a) Contra
actor to note
e that CCO
OE/PESO ap
pproval is
require
ed for all LPG Bullets and the sa
ame is in
contrac
ctor scope.
b) Confirm
m that quoted price includes obtaining
statuto
ory approval of dra
awings, do
ocuments,
inspecttion and fina
al certificatio
on of equipm
ment from
CCOE//PESO
Confirm tha
at quoted prrice includess calibration of bullets
including preparation
n, submisssion and obtaining
o calibration
n chart from
m competentt statutory
approval of
authorities like CPWD / weights an
nd measures
s.
Equipmentt shall be offfered for sta
age wise insp
pection to
TPIA / Clie
ents authorissed agency.
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 4 of 4
REV
11
12
13
Vendor shall
s
tick (
) whichever agreed
Yess / No
Yess / No
Yess / No
SCHEDULE OF EXC
CEPTIONS
S AND
ATIONS (T
TECHNICAL
L)
DEVIA
EM163-TS
S-401 FORM
ME
DOCU
UMENT NO
REV
SH
HEET 1 OF 1
(FORM E)
SCHEDULE OF EXC
CEPTIONS
S AND DEV
VIATIONS (TECHNICA
(
AL)
In line with Tende
er Documen
nt, Vendor may stipulate exceptions / devia
ations to th
he
t
tender
cond
ditions if co
onsidered unavoidable.
Sl.
No.
Tender
T
Doc
cument No.,
Page
P
No.
Clause No. of
er Documen
nt
Tende
Subject
Deviation
NOTE:
1).
A deviation
Any
n taken by th
he vendor to
o the stipulattions of the tender
t
document shall be
b
brrought out as
a per this format only an
nd enclosed along with tthe offer.
2).
A deviation
Any
n not brough
ht out in this form and written
w
elsewhere in the offer
o
shall no
ot
be
e recognized
d and the sa
ame is treate
ed as null an
nd void.
3).
THIS FORM IS EXCLUS
SIVELY FOR
R TECHNICA
AL DEVIATIO
ON. FOR CO
OMMERCIA
AL
D
DEVIATIONS
S REFER CO
OMMERCIAL PART OF THE ENQU
UIRY.
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 1 of 11
0
REV
TITLE
E:
MO
OUNDED BUL
LLET
SP
PECIFIC
CATION
COATING
C
G
PAINTING
G
NSTALLA
ATION O
OF MOUNDED BULLETS
B
S AT
PROJECT: IN
NR
RL
NT:
CLIEN
NR
RL, ASS
SAM
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
CON
NTENTS
Sl. No.
1
2
3
4
5
6
7
8
9
10
11
Descriptio
on
SCOPE
REFEREN
NCE DOCUMENTS
GENERAL
L REQUIRE
EMENTS
SAFE PRA
ACTICES
MATERIAL SPECIFIC
CATION
SURFACE
E PREPARA
ATION
PRIMING
COATING
G
INSPECTIION
QUALITY ASSURANC
CE
RECOMMENDED PA
AINT MANUFACTURER
R
DOCUMENT NO
SH
HEET 2 of 11
0
REV
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 3 of 11
0
REV
1.0
1.1
1.2
1.3
1.4
1.5
2.0
SCOPE
This specifiication gove
erns the minimum requ
uirements fo
or materials
s, equipmen
nt,
application, inspection, repair, han
ndling and other
o
aspeccts of extern
nal Corrosio
on
Protection Coating
C
of Mounded
M
LPG (Liquefied
d Petroleum
m Gas) using
g 100% solid
ds
(Solventless
s) two com
mponent, Hig
gh liquid, fast
f
cure Elastomeric
E
Polyurethan
ne
Coating.
It is envisag
ged that the Polyurethan
ne Coating on external surface of bullets
b
should
provide a ve
ery hard, tou
ugh surface with
w outstan
nding adhesion and impa
act resistancce
to protect against da
amage during the pro
ocess of burying
b
for undergroun
nd
(mounded) service con
ndition and tthereafter. Variation
V
of temperature
e between (
(
)50C (Low)) and + 55C (ambient)) may be en
ncountered a
and are to be
b considere
ed
for design conditions.
The work to
o include fu
urnishing all labour (skilled and un
nskilled), ma
aterials, tools,
equipment and
a the perfformance off all operatio
ons and incid
dentals nece
essary for th
he
coating, han
ndling, storin
ng and transporting of co
oated LPG Bullets
B
- or part thereof.
The steel su
urface prepa
aration, priorr to actual co
ommenceme
ent of coatin
ng, to conform
to SSPC SP 10-63T
T (STEEL S
STRUCTUR
RE PAINTING COUNCIIL SURFAC
CE
PREPARAT
TION SPECIFICATIONS
S) near - white
w
blast ccleaning, inccluded in th
he
scope of wo
ork.
Also include
ed in the sco
ope of work iis removal of
o all equipm
ment and exccess materia
als
from site, following completion of co
oating appliccation.
Applicator to
t obtain prior written approval from
f
the Ow
wner/Consu
ultant for an
ny
deviations from
f
the req
quirements o
of this specification and/or the stan
ndard referre
ed
herein.
REFERENC
CE DOCUME
ENTS
The following docume
ents (latest revision or as specifie
ed) are refferred in this
specification
n. In case of
o conflict be
etween referrence standa
ards or speccifications th
he
most stringe
ent shall ap
pply. In case
e of conflictt between th
his specifica
ation and th
he
reference do
ocument, thiis specificatiion shall app
ply.
a. NACE 6H
6 284
: Urethan
ne Top coatss for (1984) Atmospheric
c application
ns
(Technica
al Committee Report)
b. AWWA C-203
: Coal Ta
ar Protective Coatings fo
or pipelines - Enamel an
nd
Linings fo
or Steel wate
er pipelines.
: Structurral Steel Pain
nting Counccil: Solvent Cleaning
C
c. SSPC - SP1
d. SSPC - SP10
: Structu
ural Steel Painting
P
Co
ouncil: Nearr white Blast
Cleaning.
: Recomm
e. API RP 5L1
mended practice for "Ra
ail Road tran
nsportation of
o
Line Pipe
e"
: Recommended pra
actice for "M
Marine Tran
nsportation of
o
f. API RP 5L5
Line Pipe
e".
5900
: Pictorial surface preparation sttandard for painting steel
g. SIS 055
structuress.
h. NACE TM-01
T
-7
: "Visual Standard for
f surfaces and new steel
s
Air-blast
cleaned w
with sand ab
brasives".
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 4 of 11
0
REV
i.
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
NACE TM-01-75
T
: "Visual S
Standard forr surfaces and new stee
el centrifugally
last clean
ned with stee
el Grit and Shot.
S
GENERAL REQUIREM
MENTS
The Applica
ator shall perrform all worrk in accorda
ance with th
his specificattion and othe
er
requirementts noted. Applicator shalll submit a detailed writte
en descriptio
on in the form
of an annua
al covering coating equip
pment proce
edure, materials, inspecttion, tests an
nd
repair etc. fo
or Owner /Consultant's a
approval.
The Applica
ator shall prrovide the skilled
s
perso
onnel requirred for execcution of this
work. The equipment required sh
hall be in good operatiing conditio
on improvise
ed
equipment shall
s
not be acceptable.
a
The Applica
ator shall supply all coatting materia
als required by this spec
cification, an
nd
shall carry out
o tests on one sample
e per batch of
o supply, ass described subsequenttly
in this specification in se
ection.
The tests sh
hall be carried out by th
he Applicator at his yard
d and the re
esults shall be
b
reported to the
t Owner/C
Consultant fo
or approval and
a accepta
ance.
If the Appliccator does not have ad
dequate facilities at the
e yard to ca
arry out thesse
tests, the same shall be
b got done
e at a Owne
er/Consultan
nt approved independent
laboratory.
The Applica
ator shall un
nload the bu
ullets, or parrts thereof a
at the coatin
ng plant, tally,
store and provide
p
security for the
e bullets an
nd parts the
ereof during coating an
nd
storage. The Applicatorr shall be re
esponsible fo
or placemen
nt of the barre and coate
ed
bullets, or part thereof in
n storage in accordance
e with the refference speccifications.
All coating operations shall
s
be perrformed under the superrvision of, and performe
ed
by, personn
nel skilled in
n the appliccation of the
e coating syystem. Insp
pection of th
he
coating sha
all be perfo
ormed by qualified in
nspectors. T
The qualificcation of th
he
inspectors shall be verified and appro
oved by the Owne
er/Consultants
Representative.
The Applic
cator shall provide access,
a
durring all phases of work,
w
to th
he
Owner/Conssultant and their
t
represe
entatives/insspectors. Any expense caused
c
by th
he
Owner/Conssultants insp
pector stopp
ping the worrk because iit is not bein
ng carried out
as per this specification
s
shall be borrne by Applicator.
All tools and
d equipmentt furnished b
by Applicatorr shall be off good quality, maintaine
ed
in good operating cond
dition and suitable
s
for use to app
ply materials
s as per this
specification
n. All equipm
ment shall be
b subject to
o approval by
b the Owne
er/Consultants
representatiive.
All cleaning, priming and coating machines sha
all be prefera
ably equippe
ed with rubbe
er
or wheels ovverlaid with hard fiber to
o prevent ma
arking or den
nting the steel surface.
The Owner shall be re
esponsible fo
or the strucctural integrity of the steel and sha
all
advise the Applicator
A
re
egarding ava
ailable Sche
edules and shall
s
provide
e Engineerin
ng
information to the con
ntractor as required., including
i
drrawings when available
e,
showing all dimensions
s, obstructio
ons and acccess for the area to be
e coated, an
nd
giving sufficcient informa
ation for calculation of arrea to be sprrayed.
Before bid submission, the Appliccator to accclimatize hiimself with Site workin
ng
conditions and
a owner will
w permit applicator to viisit site.
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 5 of 11
0
REV
3.11 Th
he applicator shall im
mmediately bring to Owner/Con
nsultants attention
a
an
ny
unacceptable metal deffects detecte
ed at the time of surface preparation
n and hold th
he
steel piece till
t such time
e as cleared for further action
a
3.12
4.0.
4.1
4.2
4.3
5.0
5.1
The coating
g to be app
plied using plural
p
compo
onent Airlesss Spray syystem, as pe
er
recommend
dation of Prim
mer, Polyure
ethane manu
ufacturer.
SAFE PRAC
CT ICES
Urethane coatings
c
beiing inflamm
mable and potentially
p
T
Toxic,
requiire all safety
regulations (local, state, central) to be observed
d during the
e coating ope
erations. Alsso
safe storag
ge practices
s should be
e followed for
f
storage of Primer and Coatin
ng
materials att site. Prope
er safety pre
ecautions must be obse
erved againsst recognize
ed
safety hazarrdous.
Ingredients in Urethane coatings wh
hich may pose a hazard include ISO
OCYANATES
S,
HYDROCAR
RBON SOLVENTS, PIGMENTS & ADDITIVES etcc. Applicable
regulation (sstatutory, sta
ate local etc.) shall applyy governing safe handlin
ng practices.
Isocyanates
s in Urethane Coatings have been associated with skin an
nd respiratory
irritations and sensitiza
ation of individuals (do
oing coating operations, as well as,
those prese
ent in close
e vicinity and inhale vapour
v
mistt or over spray
s
beyon
nd
threshold lim
mit value (TL
LV) during spray applica
ation) overexxposed to this. Therefore
e,
proper prev
ventive mea
asures shall be adopted
d to preven
nt such ove
erexposure. A
careful evaluation of the controls, p
protective equipment an
nd work pra
actices should
be made to reduce unw
wanted (haza
ardous expossure).
If an individ
dual is sensiitized to ISO
OCYNATES, completelyy removing the
t
Individual
from area's potential exposure is ma
andatory.
MATERIAL SPECIFICA
ATION
ELASTOME
ERIC URETH
HANE COA
ATING (Bulle
et External s
surfaces):
Spray applied, Imperm
meable Elasstomeric Arromatic Ure
ethane Coa
ating, As pe
er
ASTM-D16, Type V (100% solids, tw
wo compone
ent, chemica
al cure) having:
TENSILE
E STRENGT
TH
ADHESIO
ON (ELECTOMETER PULL OFF)
[TO STEEL BLAST CLEANED
C
TO
T SSPCSP10, SU
UITABLY PR
RIMED] (AST
TM D 897)
RECOVE
ERABLE ELONGATION
N ASTM D
638)
SURFAC
CE HARDNE
ESS (CURED
D FILM)
(SHORE D)
WATER VAPOUR. PERMEABIL
P
LITY (ASTM
E-96)
OPERAT
TING TEMPE
ERATURES
S
SALT SP
PRAY (ASTM
M B117-73) (6000
HOURS))
NOMINA
AL THICKNE
ESS (FILM BUILD)
B
IMPACT RESISTANCE (ASTM G-14
G
ON
STEEL PIPE)
P
TEAR ST
TRENGTH (ASTM D624
4)
ABRASIO
ON RESISTA
ANCE (TAB
BER
ABRASE
ER H-10 WH
HEEL 1000 GMS
G
15 N/mm
m2 (Min.)
8 N/mm2
2 (Min.)
50% Min
n. AT 25 C
50 Min.
0.5gms/2
24hour/m2M
Max
(-)50C TO
T +60C
NO EFFECT
1000 MICRONS (un
nless otherwise notified)
1.1 X 10
0gm cm (100
00 inch-lbs)
200 PLI
WEIGHT
T LOSS 0.05
5 gms (Max.)
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
1000CYC
CLES) (AST
TM D 4060)
RESISTA
ANCE TO CATHODIC
DISBONDMENT (30
0 DAYS, 70O
O-75O F)
(ASTM G8)
G
FLEXIBIL
LITY (ASTM
M D 1737)
ACCELE
ERATED WE
EATHERING
G (ASTM
G23)
DOCUMENT NO
SH
HEET 6 of 11
REV
NO LOS
SS OF ADHE
ESION NO EFFECT
E
ON
N
COATIN
NG
TO PASS 180 BEN
ND OVER 1 inch
i
el
MANDre
EXCELL
LENT, SOME
E CHALKING
G
5.2
PRIMER
The type of primer used
d shall be ass per coating specificatio
on viz.
For areas
s not to be
Purethane
P
(P
Polyvinyl, Bu
utryl wash) tyype.
Cathodicc protected
For areas
s to be Cath
hodic
Primer
P
P-111 (Aluminium
m filled Moissture cured) Urethane.
protected
d
or
o
R-Primer
R
(tw
wo component chemical cure) Uretha
ane.
Single packkage moisturre-cured Ure
ethane prime
ers containin
ng non-leafin
ng Aluminium
pigmented, are fast cu
uring, chem
mical & corrrosion resisttant, and eliminates
e
th
he
mixing and pot
p life~ limitations of tw
wo-package materials.
m
The followin
ng characteristics for the
e Primer:
FLASH POINT
P
COVERA
AGE
SHELF LIFE
L
DRYING TIME
CLEAN UP
U
5.3
28C TCC
@ 1 Mil DF
FT Square fe
eet per gallo
on
810 Theo
oretical
648 Pracctical (Based
d on possible
e 20% loss fa
actor due to
o over
spray, wind
d etc.)
Six(6) mon
nths
At 25C
To touch 30 minutes.
To handle 45 minutes
To recant 4 Hrs.
Toluene (im
mmediately a
after use.)
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 7 of 11
0
REV
One coat of
o Two com
mponent high
h build solv
vent-less ph
henolic interrmediate coa
at
cured with polyamine
p
ha
ardener @ 7
75-100 micro
ons D.F.T./coat +
Finish Paintt
One coat off Two compo
onent high build
b
solvent-less pheno
olic finish co
oat cured witth
polyamine hardener
h
@ 75-100 micrrons D.F.T./c
coat
(Total dry film
f
thicknesss inclusive primer = 200
2
micronss minimum, 275 micron
ns
maximum)
6.0
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
TION (Extern
nal surfaces)
SURFACE PREPARAT
c
material has exceptionall corrosion and Erosion resistant
Urethane coating
properties but
b must be
e considered
d part of an
n engineered
d system which
w
include
es
adequate surface preparation. It iss axiomatic in protectivve coating work
w
that th
he
performance
e of most appropriately chosen coa
ating work w
will be no be
etter than th
he
surface prep
paration.
The externa
al surface off bullets, or part thereoff, shall be blast cleaned to SSPC-S
SP
10- 63T No.10 specifica
ation. Near white Blast cleaning witth 2-3 Mil Anchor
A
profile
e.
Or else confform to (SIS
S) Gra. SA 2--1/2 specification.
nish is defin
Near white blast cleane
ed surface fin
ned as one ffrom which all
a oil, grease
e,
dirt, Mill sca
ale, rust, corrrosion products, oxidess, paints or o
other foreign
n matter havve
been completely removed.
The overall blast cleaning effect exxpanded (no
ozzle time) shall
s
be not less than tw
wo
thirds (2/3) of
o that which
h would be required
r
to produce
p
aw
white metal surfaces
s
finissh
as per SSPG
G - SP5 on the same su
urface: nor should
s
more
e than ninetyy five per cent
(95%) of suc
ch effort be required. Ho
owever, this limitation sh
hall not be co
onstrued as a
waiver of an
ny of the abo
ove requirem
ments.
REPARATIO
PROCEDUR
RES FOR SURFACE PR
ON
Near White Blast Cleaning shall con
nsist of the following
f
seq
quence of op
perations:
(Dry sand blasting
b
/ We
et sand blastting shall no
ot be employyed)
Heavy depo
osits of oil orr grease sha
all be removved by the methods
m
outlined to spec.
SSPC-SPl-6
63,"Solvent Cleaning". S
Small quantities of oil orr grease mayy be remove
ed
by the blast cleaning op
peration. If o
oil and greasse are removved by blast cleaning, th
he
abrasive sha
all not be reused if such
h reuse is de
etrimental to the surface..
Excessive rust
r
scale may be remo
oved by impa
act tools, ass outlined in Spec.SSPC
CSP2- Hand
d Tool Clean
ning" or SS
SPC-SP-3, P
Power Tool Cleaning" or by special
blast cleanin
ng equipmen
nt.
The surface
e shall be blast cleaned to a Ne
ear-White Finish
F
by an
nyone of th
he
following me
ethods.
Dry sandbla
asting using compressed air blast nozzles
n
and dry sand of
o a maximum
particle size
e no larger than that p
passing thro
ough a 16 m
mesh screen
n, U.S. sievve
series.
Wet or water vapor sa
andblasting using comp
pressed air b
blast nozzle
es, water an
nd
sand of a maximum
m
pa
article size no larger th
han that passses through a 16 messh
screen, U.S. sieve serie
es.
Grit blasting
g using comp
pressed air b
blast nozzles and crushed grit made
e of cast iron,
malleable iron, steel, orr synthetic g
grits other than sand, of a maximum
m particle sizze
no larger th
han that pa
assing through a 16 mesh screen,, U.S. sieve
e series. Th
he
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 8 of 11
0
REV
6.4.7
6.4.8
6.4.9
6.4.10
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 9 of 11
0
REV
6.13
6.14
6.15
6.16
6.17
7.0
7.1
7.2
7.3
with a base
e having a bearing
b
leng
gth of two in
nches and a measuring
g rod of 3/32
2"
diameter.
The blast clleaned surfa
ace should be further trreated or prrimed, as sp
pecified in th
he
agreement covering the
e work, prefe
erably within
n 24 hours after
a
blast cleaning whe
en
practicable, but in any event
e
before any visible or detrimenttal rusting occcurs
Where chemical conta
amination off the surfac
ce may occcur, the steel should be
b
painted as soon
s
as posssible after bllast cleaning
g.
All above op
perations to be witnesse
ed by & certiffied by Owner/Consultants inspecto
or.
As stated in the SSP
PC Steel Sttructures Pa
ainting Man
nual (P114. Vol.1), it is
axiomatic in
n protective coating wo
ork that the
e performancce of the most
m
carefully
selected coating will be
e no better than the su
urface prepa
aration. A co
oating system
well suited to
t a particula
ar exposure system will perform poo
orly if surfacce preparatio
on
is not carrie
ed out in a manner
m
com
mpatible with
h the expose
ed PURETH
HANE coatin
ng
material has exceptional corrosion
n and erosio
on resistantt properties but must be
b
considered part of an
a enginee
ered system
m which in
ncludes pro
oper surfacce
preparation,, priming an
nd applicatio
on for these propertiess to be fullyy effective in
protecting th
he coated su
urface.
The abrasivve shall not be reused a
as this could
d be detrime
ental to the surface.
s
Mark
150 mm width around the bullet ssection conn
necting seam
ms where circumferential
welding (in-s
situ on sand
d bed) is to be
b done.
PRIMING
Prior to prim
ming the blasted surface, all dustt, abrasive residue
r
and
d loose metal
particles shall be remo
oved from th
he steel surfface. If amb
bient conditio
ons are succh
that condensate or dustts form on th
he surface of
o the steel, p
priming shalll not be don
ne
until these conditions
c
arre satisfactorily modified
d.
Before beg
ginning prim
ming and ccoating me
easure the humidity using a slin
ng
psychrometer and calcu
ulate the dew
w point. Dela
ay spraying if the air dew
w point is lesss
than 3C be
elow the ambient tempe
erature. Under controlled
d conditionss it is possible
to heat the steel
s
surface
e to eliminate
e condensattion problem
ms.
The type of primer used
d shall be ass described in the coatin
ng specificattion. Normally
for areas not subject to
t cathodic Protection Voltages
V
Pu
urethane P--24 (Polyvinyl
Butryl Wash
h) Primer sh
hall be used
d and for ca
athodically p
protected ste
eel. primer PP
111 (Alumin
nium Moisture cured Urrethane) or R-primer (Tw
wo component Chemical
Cure Uretha
ane) shall be used. The
e clean blassted steel sh
hall be grimed preferab
bly
within 2 ho
ours after blast cleanin
ng but not more
m
than 24 hours and
a
under no
n
circumstanc
ces shall th
he Primer b
be applied to a surfacce where corrosion
c
ha
as
occurred. Primer shall be
b sprayed onto the cle
eaned surfacce in a fog coat as thinly
as possible (approx 1 Mil)
M so as to tint but not mask
m
the colour of the substrate.
s
Th
he
primer on application sh
hall be free from runs or
o drips. The
e primed surrface shall be
b
protected so
o that it will not come in
n contact with rain, for mist spray, dust or othe
er
foreign subs
stances unttil completelly hardened
d and the U
URETHANE top coat ha
as
been applied. The URE
ETHANE top coat shall be
b applied. b
before the prrime coat ha
as
completely cured, not le
ess than two hours norr more than 18 hours affter the prim
me
coat has been applied but
b in any ca
ase prime co
oat shall be h
hard and nott tacky.
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
8.0
8.1.1
8.2
8.3
8.4
8.5
8.6
9.0
9.1
9.2
9.3
9.4
9.5
9.6
DOCUMENT NO
SH
HEET 10 of 11
1
0
REV
COATING
Equipment for spray ap
pplication sh
hall be Plura
al Compone
ent Airless Spray
S
System
ego Pressu
ure produce
ed at tip 2
2200-3000 PSI, Tip S
Size 0.66 to
t 0.76 mm
m,
Temperature (Resin 50--60C, activa
ator 10- 30C). Follow sstandard insttructions from
supplier from
m spray, ma
aterial handling and stora
age as per g
general speccification.
Always kee
ep a blanket of dry nitrog
gen over materials.
Nominal thickness of Polyurethan
ne 386/9000
0 shall be 40 Mils (1000 Micron
ns
minimum) or
o as otherw
wise specified
d for the ap
pplication. In case no prrimer is used
d,
DFT shall be
e 1050 Micro
ons minimum
m.
Before application on th
he substrate
e apply a tesst patch and
d inspect for runs or drip
ps
and gel time
e as well as tack free tim
me. Test for adhesion
a
if in doubt.
Calculate th
he 'unit repe
eat area', ma
aterial volum
me in counters numbers (counters arre
attached on the Unit tha
at measure tthe volume of
o materials dispensed),, approximatte
speed and number of passes.
p
Spra
ay applies required
r
thicckness in mu
ultiple passe
es
in a single application
a
k
keeping
gun
n perpendicu
ular to the su
ubstrate. If the
t surface is
large enoug
gh to require
e more than one day for the coating, the edges of the coate
ed
area shall be
b feathered
d and roughened with a grinding to
ool for over spraying an
nd
primed. Are
eas /equipm
ment not to be coated should be
e masked by
b disposable
cardboard/p
plastic sheets
s.
Any holidayys or skips should
s
be re
epaired with Urethane 3
385/9000 ha
and mix kit or
o
equivalent after
a
roughen
ning the edg
ges. .
INSPECTIO
ON
All work under
u
this specificatio
on shall be
b subject to inspecction by th
he
owner/consu
ultant or his
s representa
ative. All parts of the wo
ork shall be accessible to
t
the inspecto
or. The Appliicator shall ccorrect such work as is found
f
defecttive under th
he
specification
ns. If the Applicator
A
do
oes not agre
ee with insp
pector, the arbitration or
o
settlement procedure
p
es
stablished th
he contract, if any, shall be followed.
During Coa
ating application the wet film thickne
ess shall be measured using Nordso
on
or equivalen
nt Wet Film Gauge
G
as per ASTM D 4414. The dry
d film thick
kness shall be
b
checked with a Magne
etic Mil Gau
uge (posites
st by DeFelsko or equ
uivalent). Th
he
coating shall be checked for holidayys using Tinker Rasor or equivalent High Voltag
ge
Holiday Dettector. Due care shoulld be taken
n not to use
e voltage exceeding
e
th
he
dielectric strrength of the
e coating (40
00 Volts/Mil) to avoid damage.
Pull Off adh
hesion to ste
eel measured
d using elcometer Adhesion Tester as per ASTM
D- 4541 using an Alumiinium dolly a
attached to the
t coating and
a a perpendicular forcce
applied to th
he dolly. Ave
erage readin
ng from three
e randomly sselected spo
ots shall be at
a
least 1200 Psi.
P Test are
ea to be flat without
w
curvature.
All above tests to be wittnessed and
d certified by Owner/Con
nsultants inspector.
All the batch
hes of coating material, primer to be
b tested at Applicator's laboratory o
or
at any otherr recognized
d laboratory and
a test results duly cerrtified by the
e laboratory to
t
be handed over
o
to Owner/Contracto
or by Applica
ator as QC records.
r
All painting materials including
i
prrimers, thinn
ners & final for applica
ation shall be
b
procured directly
d
from
m manufaccturers as per speciffications an
nd shall be
b
accompanie
ed by manuffacturers test certificate
es for all the
e parameterrs specified in
their printe
ed datasheet for the
e supplied batch of paint mate
erials beforre
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 11 of 11
1
0
REV
10.0
11.0
commencem
ment of paiinting job. Paint formu
ulations with
hout certific
cates are no
ot
acceptable. All paint ma
aterials shall be fresh/ne
ew.
Stage-wise inspection for
f the total painting job
b shall be ca
arried out byy the qualifie
ed
engineer of the contracttor as underr and Record
d shall be ma
aintained
Checkin
ng of surface
e preparation, cleanlinesss & surface
e profile
Checkin
ng of airless spray equip
pment.
Wet film
m thickness of
o first coat and
a intermed
diate coats
Dry film
m thickness of
o total paint system afte
er curing of fiinal coat.
Low volltage holidayy/pin hole de
etection test
Adhesio
on test by crross cut method
Visual inspection fo
or surface fin
nish & covera
age.
Cathodic disbondm
ment test datta at ambien
nt condition as per BS 4164
4
shall be
b
submitted
QUALITY ASSURANC
A
E
The contractor shall guarantee
g
tthat the ch
hemical and
d physical properties of
o
coating/pain
nt materials used are in
n accordanc
ce with the specificatio
ons containe
ed
herein/to be
e provided du
uring executtion of work.
RECOMMENDED PAIN
NT MANUFA
ACTURERS
A). Interna
al surfaces Coating
C
i). Asian Paints
P
ii). J&N
iii). Berger Paint
B). Polyure
ethane Coating
i. M/s. Am
mchem Products Pvt. Ltd
d., Noida
ii. M/s. Go
oldschmidt TIB
T GmbH, G
Germany
iii. M/s. Me
etrotech Ltd.., England
iv. M/s. Fu
utura Coating
gs Inc., St. Louis,
L
USA
v. M/s. Ca
arboline Com
mpany, St. Louis, USA
vi. M/s. Mo
odison Chem
mical Industrries Inc., Can
nada
(1) Apart fro
om these ve
endors LST
TK contracto
or shall prop
pose their approved sub
bvendors for PDIL / NRL approval
EM163-TS-401-ANNEX III
DOCUMENT NO
SHEET 1 of 10
REV
Characteristics
checked
Type of
check
Approval of
fabrication
drawing & design
calculation, FE
Analysis
Approval of
Engg
Drgs./docs
Review/
verification/
check
QAP
Approval of
QAP
4
5
Item Description
NDT Procedure
(PT, RT, MT, UT),
Weld Repair
Procedure
Hydro-test &
Pneumatic Test
Procedure
FABRICATION
Raw Materials,
Bought out items
identification
(Plate, Pipe,
Flanges, SR
Nozzles/Dome),
Pipe fittings, etc.,
correlation of mill
TC & witness of
stamp & stamp
transfer
Non pressure
Parts
Extent
Reference
Document
Acceptance
Document
Inspection By
Contractor
PDIL
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Review
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Approval of
Procedure
Review
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Approval of
Procedure
Review
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Material Spec.,
Chem./Physical,
Dimension,
Punch Mark, etc
Visual &
verification,
correlation
100%
PO /
Applicable
Code / Stds.
Hold
Witness/ Review
Material Spec.,
Chem./Physical,
Dimension,
Punch Mark,
etc.
Visual &
verification
100%
PO /
Applicable
Code / Stds.
Hold
Review
Remarks
* Fabrication
shall start
after recpt.
Of Appd.
Drawing
EM163-TS-401-ANNEX III
REV
DOCUMENT NO
SHEET 2 of 10
Welding
Consumable
Spec., Brand
Approval of
WPS/PQR & WPQ
Compatibility,
Appd. Brand,
T.C.
Welding
parameters,
Approved
procedure
Review
100%
PO /
Applicable
Code / Stds.
Manufacturers
Batch TC
Review
100%
WPS
Applicable
Code / Stds.
Witness/
Review
Witness/
Review/Approval
Review
Certificate
Level
100%
LEVEL II
Certificates
Review
Hold / Review
Hold
Hold
Approved
Drawing
Perform
Review
Approved
Drawing, Code
Hold
Witness
Approved
Drawing, WPS
Hold
Witness
Approved
Drawing
Hold
Witness
10.1
NDE Personnel
Level, minimum
Qualification
10.2
Welders
Identification
Number
Welders stamp
location sketch
11
Shell plate,
marking, cutting,
edge preparation,
pre-pinching &
rolling
Dimension,
surface,
rectangularity,
rolling direction
Visual /
dimension /
profile
100%
12
Dished end,
Crown, Petal
plates marking,
cutting, edge
preparation &
Pressing
Dimension,
surface check,
profile check
with template
Visual /
dimension /
profile, edge
DPT
100%
13
Cleanliness of
Plate/ Edge,
Root gap, Bevel
Angle,
Alignment,
Ovality
Visual /
dimension /
profile, edge
DPT
100%
14
Weld defects,
soundness
Visual, MPI
100%
PO /
Applicable
Code /
Stds./
Approved
Drawing
PO /
Applicable
Code /
Stds./
Approved
Drawing
PO /
Applicable
Code / Stds.
PO /
Applicable
Code / Stds.
WPS
Witness/
Review/Approval
EM163-TS-401-ANNEX III
DOCUMENT NO
SHEET 3 of 10
REV
15
16
Radiography of
LS joint before SR
Weld
soundness
RT
Stiffener
Fabrication & Fitup to shell
Cleanliness of
Plate/
Edge, Root gap,
Bevel Angle,
dimension,
Alignment,
Ovality
Visual,
Dimension
Meas. &
template
checking
17
Visual, MPI
Post weld of
stiffener ring weld
Weld
soundness
Visual, RT &
MPI
19
Cleanliness of
Plate/
Edge, Root gap,
Bevel Angle,
Alignment,
Ovality
Visual, Meas.
dimension &
profile, DP on
edges
20
21
18
Weld Finish /
Weld
Reinforcements
Visible defects
Weld finish /
weld
Reinforcement
Visual / MPI
Visual / MPI
PO /
Applicable
Code / Stds.
Approved
Drawing
Hold
Witness/ Review
* 100% for
outside final
pass/ 25%
inside final
pass
100%
PO /
Applicable
Code /
Stds.
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
100%
PO/
Applicable
Code /
Stds.
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
Butt-weld of
Stiffener
joint RT,
Fillet weld
MPI
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness /
Review
EM163-TS-401-ANNEX III
REV
DOCUMENT NO
SHEET 4 of 10
22
Radiography of
CS joints before
SR
Weld
soundness
RT
23
All Nozzles
(Comp. Plate,
Pads etc. Fit-up)
MPI of shell
edges
to be welded &
alignment
Visual, Meas.
dimension &
MPI
24
25
Post weld
inspection of
above completed
weld
26
26.1
26.2
26.3
26.4
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
Weld defects
Visual / MPI
Weld
Soundness
Visual, RT,
UT,
Pneumatic
test
RF Pads
Dimension &
profile
Visual, Meas.
dimension &
MPI on
knuckle
100%
Applicable
Code / Stds.
Profile &
workmanship
100%
Applicable
Code / Stds.
Normalising of
petals
Normalising of
petals
Review of
normalising
chart
100%
Applicable
Code / Stds.
Fitup of dished
head joints
Cleanliness of
Plate/
Edge, Root gap,
Bevel Angle,
Alignment,
Ovality
Dished head
Profile,
dimensions &
thickness after
pressing
Crown / petals
after pressing /
gauging & edge
preparation
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
Hold
Witness
Perform
Witness &
Review
Hold
Witness &
Review
Hold
Witness
Hold
Hold
Hold
Review
Visual &
Meas.
dimension
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
EM163-TS-401-ANNEX III
REV
DOCUMENT NO
SHEET 5 of 10
26.5
Weld defects
26.6
Post weld
inspection of
above joints
Weld finish,
weld
reinforcement
26.7
Radiography of
above joints
Weld
soundness
27
Fitup of lifting
lugs & welding
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
RT
100%
Applicable
Code / Stds.
Location,
Orient., Weld
soundness
Visual,
Meas., MPI
100%
Applicable
Code / Stds.
28
Temporary
attachment weld
areas after
grinding
Surface
soundness
100%
Applicable
Code / Stds.
29
Individual section
before PWHT
Completeness
Visual
100%
Applicable
Code / Stds.
30
PWHT of
individual section
(SR)
Visual
100%
Applicable
Code / Stds.
31
Production test
coupons
Visual &
Mechanical
property
100%
Applicable
Code / Stds.
32
Hardness test
(spot), weld &
HAZ
100%
Applicable
Code / Stds.
Verification of
thermocouple
location,
PWHT Cycles
Impact,
Mechanical
property incl.
Hardness
Hardness
Visual, MPI
Brinell
Hardness
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
Hold
Witness /
Review
Perform
Review
Hold
Witness /
Review
Hold
Witness /
Review
Hold
Hold
Hold
Hold
Hold
Hold
Hold
Witness
Portable
hardness
tester
EM163-TS-401-ANNEX III
REV
DOCUMENT NO
SHEET 6 of 10
33
Weld
soundness
34
Weld
soundness
35
Painting / Coating
material
identification
Matl.
Identification,
Appd. Coating /
Paint
Spec, Quality,
Brand,
36
Painting / Coating
Procedure
Approved
procedure
37
38
Final Assembly of
bullet section field
joint fit up,
welding
RT/TOFD
MPI
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
Hold
Witness
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Review
Review &
Approval
Review
Applicable
Code / Stds.
/
Specification
-do-
Perform
Review &
Approval
Visual, blast
surface
profile,
primer
thick.(DFT),
finish thick
(DFT)
measurement
100%
Applicable
Code / Stds.
/
Specification
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness /
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Hold
Visual,
Manuf. TC
Visual,
dimension
& Weld
reinforcement
100%
EM163-TS-401-ANNEX III
REV
DOCUMENT NO
SHEET 7 of 10
RT of CS field
joints before
Local SR
Weld defects
40
PWHT of field
weld joints (local
SR)
Verification of
thermocouple
its
location,
Recorder
calibration,
PWHT
cycles
41
NDE UT of field
weld joints after
PWHT
Weld
soundness
42
Final visual /
dimensional
check /
completeness
check before
Hydro test
Final
Dimension,
Orientation,
Slope,
Level etc.
Visual, Meas.
Hydrotest
Procedure
Approval of
Hydrotest
procedure,
Pump,
Pressure
gauges
Visual /
Meas.,
Verification of
Pressure
Gauge
Calibration
certificate
39
43
44
Hydrotest of bullets
and settlement
measurement &
Recordw.r.t
permanent
reference bench
mark.
Leakage /
seepage,
settlement
Visual / RT
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
Visual,
Meas.,
Calibration
Certificate
TOFD
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
100%
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Perform
Review &
Approval
100%
Applicable
Code / Stds.
Applicable
Code/Stds.
& Approved
Drawing
Hold
Hold
Visual, Meas
100%
Hold
Hold
EM163-TS-401-ANNEX III
DOCUMENT NO
SHEET 8 of 10
REV
45
46
47
48
49
Draining out of
water & drying
MP of Stiffener
web to shell fillet
weld seam & Web
to flange fillet
weld (both sides)
after Hydro
UT (TOFD) of
Shell circ. buttwelds seams
(bottom 1200 ) &
MPI of all Internal
& accessible Ext.
butt-weld circ &
long. seams after
PWHT.
Wire brush,
cleaning, painting
of field joint area /
components,
Repair of Paint
Damage s, DFT
survey (Stages &
Final)
Wire brush
cleaning, painting
of 90O bottom
internal bullet
area including
stiffening ring,
DFT survey
(Stages & Final)
Complete
draining &
Cleanliness
Weld
soundness
due to mound
settlement
Weld
soundness
due to mound
settlement
Surface
cleanliness,
Paint surfaces,
Paint
thickness,
Spark test
Surface
cleanliness,
Paint surfaces,
Paint
thickness,
Spark test
Visual
MPI
TOFD/MPI
Visual, Meas.
Visual, Meas.
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Hold
Review
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Hold
Witness
100%
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Hold
Witness
100%
PO,
Approved
Coating
Procedure,
& Approved
Drg.
PO, Approved
Coating
Procedure,
& Approved
Drg.
Hold
Witness/ Review
100%
PO,
Approved
Coating
Procedure,
& Approved
Drg.
PO, Approved
Coating
Procedure,
& Approved
Drg.
Hold
Witness/ Review
100%
100%
EM163-TS-401-ANNEX III
DOCUMENT NO
SHEET 9 of 10
REV
50
Calibration of
bullets under
State Government
Statutory
Authority
Calibration
procedure,
chart
Visual, Batch
/
Matl.
Correlation
100%
Applicable
Code/ Stds.
IS:2009 &
IS:2166
Hold
Review
Statutory
Authority
100%
PO,
Approved
Fire
proofing
Procedure
& Apprd
Drg.
PO, Approved
Fire
proofing
Procedure
& Apprd Drg.
Review
Review
Perform /
Hold
Witness/ Review
Hold
Witness/ Review
51
Fire Proofing
Material
Matl.
Identification,
TC
52
Fire Proofing
Application /
Procedure
Surface
cleanliness,
Fire proofing
thickness
Visual, Meas.
100%
Applicable
Code /Stds.
53
Final acceptance
As-Built,
Documents,
Dossier
Verify
100%
Applicable
Code /Stds.
54
Cp System
55
DOCUMENTATION
Design/Drawing/
Procedure
Verify
PO,
Applicable
Code / Stds.
Verify
100%
Final
Certification
by
inspecting
authority /
site incharge
100%
Applicable
Code /
Stds. &
Approved
Drawing
Applicable
Code /
Stds. &
Approved
Drawing
Applicable
Codes/stand
ards /Spec.
As per tender
Document
Perform
Witness/ Review
AsPerP.O.
AsPerP.O.
Hold
Review/
Approval
EM163-TS-401-ANNEX III
DOCUMENT NO
SHEET 10 of 10
1
REV
EM163-45-PNMP-PS 102
Document No.
Sheet 1 of 3
Rev.
MINIMUMALLOWABLENOZZLELOADINGS
FORMOUNDEDBULLET
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ALLOWABLENOZZLELOADINGS
EM163-45-PNMP-PS 102
Document No.
Rev.
Sheet 2 of 3
Allrightsreserved
ALLOWABLENOZZLELOADINGS
EM163-45-PNMP-PS 102
Document No.
Rev.
Sheet 3 of 3
Allrightsreserved
EM163-TS-301
DOCUMENT NO
REV
SHEET 1 OF 14
TECHNICAL SPECIFICATION
FOR
DRAIN VESSEL (45-VV-106)
(DOC: EM163-TS-301)
ISSUED BY
21.09.15
17.07.15
21.09.15
17.07.15
REV DATE
EFF DATE
VB
VKV
PREPD
PK/NB
NB/PK
REVWD
GC
GC
APPD
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 2 OF 14
CONTENTS
SL. NO.
DESCRIPTION
1.
Scope
2.
Mechanical Design
3.
Special Requirements
4.
Scope of Supply
5.
Material of Construction
6.
Fabrication
7.
8.
9.
10.
11.
Documentation
12.
13.
Completion period
14.
15.
List of Deviation
16.
17.
Reference List
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 3 OF 14
LIST OF ATTACHMENTS
SL.
NO.
DESCRIPTION
1.
EM163DD45VV106,Rev1
2.
EM163-PNMV-DD-45-VV-106
3.
List of Spares
EM163-PNMV-TS301-SP01
4.
EM163-PNMV-TS301-F1
5.
Documentation Schedule
EM163-PNMV-TS301-DOC
6.
EM163-PNMV-TS301-CL01
7.
List Of Deviation
EM163-PNMV-TS301-D1
8.
Waiver/Deviation/Concession
EM163-PNMV-TS301-W1
9.
Vessel Tolerances
PDS : PV 001
PDS : PV 002
PDS : PV 003
PDS: SR 300
PDS: PV 302
PDS: PV 225
PDS : SR 104
EM163-0000-0202 Rev 0
EM163-9511-0905 Rev P
ES 2001
DOCUMENT NO.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 4 OF 14
1.0 Scope
Detailed mechanical design of equipment along with supporting arrangements, preparation of fabrication
drawings, complete procurement of all materials and other bought-out items whatsoever deemed
necessary, fabrication at shop, transportation up to the respective projects sites, inspection & testing,
complete painting and supply of following equipments including all internals(if applicable) with their
supporting arrangement, mechanical guarantees, supply of spare parts both for main equipment and
internals(if applicable) in accordance with the applicable equipment specification and other documents
enclosed with enquiry.
S. No.
Item Code
Description
Quantity
DRAIN VESSEL
1.
45-VV-106
1 No.
2.0
Mechanical Design
2.1
Design & fabrication Code for all vessels shall be ASME Section VIII Div 1 Latest or as
mentioned in attached specification sheet of relevant vessel.
2.2
Complete mechanical design of Equipment as per latest codes / standards of construction shall
be the responsibility of the bidder. Strict compliance with the requirement of codes/equipment
Specification & any other referred document shall be ensured.
2.3
Detailed design calculations for adequacy of strength of all individual parts shall be made by
bidder and submitted to Owner/PDIL for comments & approval. After receipt of approval from
Owner/PDIL the design of equipment shall be considered as final. Any change/comment made
on design calculations and drawing to satisfy the requirement of code/enquiry documents to
make the equipment perfectly fit for smooth operation shall have to be incorporated by Bidders
without any commercial implications.
2.4
Design conditions for the equipment shall be as per equipment specification sheet & Technical
Specification enclosed with the enquiry. Minimum required thicknesses of various components
shall be calculated based on design parameters considering different types of loadings
conditions including effect of static head of liquid column, wind pressure, force of moment owing
to connected piping & other attachments as platform etc. Equipment shall also be designed for
hydrostatic condition. Final thickness shall be decided giving due consideration for corrosion
allowance & thinning allowance.
2.5
Design pressure indicated in datasheets shall be considered at the top of the Vessel. The design
Pressure at any lower point shall be determined by adding the maximum operating liquid head
and any pressure gradient within the column.
2.6
Wind analysis shall be performed as per IS-875 (Latest Edition). Wind forces shall be increased
by 30% (over & above design code requirement) to cater the effect of piping system, platforms
and ladders etc. Wind Speed shall be 55 m/s and Wind Zone VI is to be considered.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
2.7
2.8
EM163-TS-301
DOCUMENT NO
REV
SHEET 5 OF 14
Seismic analysis shall be performed by Response spectrum method (RSM) as per IS 1893-2005
part 4 considering seismic Zone-III.
Local stresses in column wall resulting from nozzle load shall be determined by WRC 107/537,
WRC 297 code requirements. Forces and moments acting on nozzles shall be considered in the
design of vessel and resultant stresses shall not exceed allowable stresses as per applicable
codes /standards/specifications. The Forces and moments on nozzles shall be furnished during
detailed engineering after award of contract. Bidder shall take care of the same during
mechanical design of equipment without any delivery/commercial implications to owner.
2.9
All carbon steel (CS) pressure parts shall have minimum of 3.0 mm corrosion allowance unless
specified otherwise. All internal CS parts including low temperature materials shall have at least
1mm corrosion allowance on either side unless otherwise specified.
2.10
Unless otherwise specified, all internal parts / components shall be removal type unless
otherwise specified.
2.11
2.12
Bolts of size M52 and above shall be designed and spaced so as to permit tightening with a
hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of
approximately 1 bolt diameter and shall be provided with threaded protection caps. Hex nuts
shall have suitable holes for manual tightening. Equipment having bolt size above M52 shall be
supplied with hydraulic bolt tensioning device along with recommended spares and operating
manual indicating tightening torque. For bolts size above M52 the following information are
required to be furnished along with offer:
i)
ii)
iii)
iv)
v)
2.13
2.14
All items whether internal or external which are welded directly to a shell or head shall be of the
same material category as that of the shell or head. This shall apply to all nozzles, brackets,
pads and upper portion of the skirt for vertical vessels.
2.15
Design & Supply of Anchor Bolts shall in scope of Bidder. The permissible tensile stress for
Anchor Bolts shall be 120 N/mm2 and Shear Stress shall be 80 N/mm2.
2.16
When design pressure is more than 400# class and/or shell thickness is 50 mm and above, self
reinforced forged nozzle shall be provided. Nozzle size 3 NPS Shell to SR nozzle welding shall
be set-in type welding.
2.17
As it is a drain vessel, under deposit corrosion of bottom dished end will be more than other
components, hence suitable lining on bottom dished end may be considered
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 6 OF 14
3.0
Special requirements
3.1
3.2
For equipment to be designed as per IBR all requirements specified therein shall be taken care.
3.3
The design of equipment supports and anchor bolts shall be the responsibility of the Bidder. The
type, number and location etc. indicated in the equipment specification sheets are minimum and
indicative, adequacy of the same must be checked by the Bidder & design calculation shall be
submitted for Owner/PDIL approval.
3.4
Design of the support shall be based on seismic / wind / thermal considerations and fireproofing /
insulation requirements. Saddles to equipment support shall also be analysed for all loading
conditions.
3.5
ASME Section VIII, Div. 1, Appendix S shall be shall be considered mandatory for bolted flange
connections. However flange shall be designed as per Appendix2 for different loading
conditions.
3.6
Local stress calculations for external structural attachments, such as platform clips, pipe support
clips and lifting lugs shall be performed & submitted to PDIL/owner for approval.
3.7
International System of Units (SI) System and English language shall be used for all drawing and
documents.
3.8
Deviations from ITB, if any, shall be clearly spelt out in the offer with proper reference to clause
numbers. In absence of any such indication it shall be assumed that the offer complies with all
the requirements and such assumptions shall be strictly binding on bidder.
4.0
Scope of Supply
4.1
Bidder shall include the following items in scope of supply besides supply of equipment including
spares etc. referred under 1.0 Scope.
i)
ii)
All external cleats/pads required for ladders, platforms, pipe support pads including
cleats for earthing connections etc. Details of pads & cleats for ladders, platforms &
pipe supports shall be defined during approval of design & drawing stage. Such details
shall have to be incorporated by Bidder without any commercial/delivery implication.
However Bidder shall include cost of such attachments in the Bid based on his
experience.
iii)
iv)
v)
vi)
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 7 OF 14
vii)
viii)
Cleats for Insulation. However supply and application of insulation is excluded from
bidders scope.
ix)
5.0
Material of Construction
5.1
Material of construction for equipments shall be as per Datasheets & Technical specification.
5.2
The following additional material requirements as indicated below shall be considered by Bidder.
5.2.1
All raw materials including bought-out items, whatsoever required, to complete the supplies shall
be procured and supplied with due identifiable mill material test certificates & inspection reports
duly certified by third party inspection agency.
5.2.2
For coarse grained and high tensile materials in carbon steel (UTS > 52 Kg/mm2) guaranteed
impact strength shall be ensured at a temperature 150C below envisaged hydraulic test
temperature as a precaution against brittle fracture during hydraulic test.
5.2.3
a)
b)
c)
d)
e)
f)
Carbon steel plates shall be procured in fully killed condition. CS plates shall be
normalized / annealed.
Dish ends of the equipment shall be stress relieved.
All plates above 50mm thickness shall be vacuum-degassed and examined by Ultrasonic
Testing (UT) at surfaces & edges as per SA-578 Level B and other equivalent applicable
material specification code/standard.
Pressure parts having thickness between 16 mm to 50 mm shall be ultrasonically tested
as per SA - 435.
Bend test as per supplementary requirement S-14 of SA -20.
Material used for pressure parts and attachment to pressure parts shall be necessarily
impact tested (Charpy-V) as per design code & specifications. Impact test temperature
shall be minimum of MDMT, impact test temp. Specified in applicable material code or
given in job
specification which ever is lower. Impact energy values shall be as per
Para UG-84 of ASME code or specified in material specification, which ever is higher.
Orientation of test bar shall be transverse to rolling directions.
5.2.4
All forgings except for flanges as per ANSI shall be UT tested as per applicable material
specification & shall be examined according to ASTM A388 with criteria shown in ASME Section
VIII. Div. 2 (AM 203.2).
5.2.5
All forgings including self reinforced nozzles & flanges shall be examined for surface defects by
MP/PT testing after machining as per applicable material specification code & standard.
5.2.6
All external / internal attachments, pads/cleats directly welded to the equipment shall be of same
materials as that of equipment, unless specified otherwise.
5.2.7
For sizes above DN 12 Nozzle connection shall be rolled from plates with full radiography.
5.2.8
Unless otherwise specified copper or copper alloys shall not be used. Copper content up to
0.40% are acceptable in carbon steel and 0.6% in stainless steel.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
5.2.9
EM163-TS-301
DOCUMENT NO
REV
SHEET 8 OF 14
Unless more restrictive prescription given by material specification the maximum carbon content
of carbon steel used for fabrication as shown by ladle analysis shall be 0.23% for plates, pipes &
tubes, 0.25% for forgings.
5.2.10 C.S. exceeding thickness of 50 mm shall be vacuum degassed except for plate ring flanges.
6.0
Fabrication
6.1
The Bidder shall comply in all respects with the provision of the applicable codes, standards and
specification during fabrication with respect to tolerances, welding, fabrication, forming of heads,
radiography, heat treatment, inspection, testing and quality control etc. unless & otherwise
specified.
6.2
Plates of different thicknesses shall be made flush with the inner surfaces of equipment unless
otherwise stated.
6.3
All dish heads shall preferably of single piece construction. Larger heads which can not be
formed in one piece shall be fabricated as follows with prior approval from Owner.
a)
In two pieces, with the welding seam included in the middle third and preferably on the
centre line.
b)
In petal construction, with meridian seams and a central cap of diameter not larger than
0.75 times the column outside diameter.
6.4
Due provisions must be kept for venting out entrapped gases during welding of pads, flanges
and liner plates etc.
6.5
All welds shall be full penetration welds with back chipping and re-welding from the second side.
For those joints which are inaccessible for back chipping the root run shall be carried out with
TIG process. Single side welding with backing strips shall are not permitted.
6.6
All sharp corners shall be rounded off with smooth radius. Inside edge of manhole and hand hole
at the internal surface shall be rounded to minimum radius 5 mm.
6.7
All flange bolts shall straddle center line unless otherwise stated.
6.8
In case of nozzle with butt-end construction, extra length shall be provided to facilitate hydraulic
testing and subsequently cutting and edge preparation to suit piping welding at site.
6.9
All nozzles less than or equal to NB 65 mm shall be stiffened with three equi-spaced plate ribs of
the same material as that of shell.
6.10
Orientation of longitudinal seams and position of circumferential seams shall be clearly marked in
the fabrication drawing. Nozzles, support and other attachments shall be located clear of welded
joints.
6.11
The centres of the welded longitudinal joints of adjacent courses shall be staggered or separated
by a distance of five times the thickness of the thicker plate or 100mm whichever is greater.
6.12
All parts involving welding construction including internals and stiffener ring shall have
continuous weld unless otherwise stated.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 9 OF 14
6.13
All welds shall be full penetration welds with back chipping and rewelding from the second side.
For those joints which are inaccessible for back chipping the root run shall be carried out with
TIG process. Single side welding with backing strip is not permitted.
7.0
7.1
After hydraulic testing, the equipment shall be dried, thoroughly cleaned from inside and outside
and shall be free from all shop dirt, loose scale, grease etc.
7.2
All CS equipment shall be shot/grit blasted (min SA 2.5 ISO 8501-1) before the primer coat is
applied on external surfaces. Primer shall be compatible to succeeding painting as per ES-2001.
7.3
All machined surfaces, bolting and flange faces shall be properly protected from rust and
mechanical injury during transit and storage.
7.4
Name and code number of equipment shall be painted on each equipment at a conspicuous
place in letters 150 mm high.
7.5
After hydraulic testing, all SS parts of equipment shall be Pickled & Passivated as per following
procedures; if applicable:
a) Cleaning:
Clean surface and remove all extraneous matter with a hard fibre brush or SS wire brush. M.S.
wire brush shall not be used. All organic materials shall be removed with any paint remover like
light solvent naphtha or benzene or equivalent. Motor petrol shall not be used.
b) Pickling:
Aqueous pickling solution shall be as follows:
Nitric acid (Tech. grade) 10 to 25% plus Hydrofluoric acid 1 to 8% (to be used only for stabilized
SS grades). Temperature 50 to 60 C for 10% Nitric acid and 20 C for 25% Nitric acid. When
size and shape of product permit, total immersion in the pickling solution is preferred. Where
immersion is impractical, pickling may be accomplished by wetting the surface by
i)
ii)
Swabbing or spraying
Partial filling the item with pickling solution and rotating or rocking so that the entire surface
receives the required chemical treatment.
The maximum period for which the pickling solution shall be allowed to remain on the surface is
30 minute. During pickling removal of oxides may be hastened by brushing with a hard fibre or
SS wire brush. Over pickling shall be avoided.
The pickling agent shall be washed off with plenty of water so as to leave no trace behind.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 10 OF 14
c) Passivation
After pickling and water rinsing, an aqueous caustic permanganate solution containing NaOH 10
weight % and KMnO4 4 weight % shall be used for neutralizing pickling solution. This shall be
followed by thorough water rinsing.
Water used for pickling and washing shall not have chloride contents exceeding 30 ppm.
7.6
Equipment intended for transportation by ship shall be kept in hatch of the ship. Suitable
seaworthy packing/painting shall be applied to avoid any damage during transhipments.
7.7
The responsibility of transport, packing and forwarding of the equipment shall be of the supplier.
In case of inland transportation equipment shall be properly lashed, fixed on the wagon/trailer to
avoid any damage due to shocks in transport.
7.8
All spares shall be properly packed, marked and sent separately along with equipment.
7.9
When specified equipment shall be dispatched with N2 filling. In case of equipment assembled
and welded at site, it shall be filled with N2 after testing at site. Dry Nitrogen shall be filled at a
pressure of 0.5 Kg/cm2g and equipment shall be fitted with a pressure gauge and valve.
8.0
8.1
The equipment shall be inspected and tested (including NDT) in accordance with applicable
codes, standards and specifications referred in the enquiry. The equipment shall be inspected
during various stages of manufacturing starting from identification of raw materials to final
completion as per agreed Quality Assurance Plan (QAP) which shall be furnished by bidder
along with their bid and successful bidder after award of contract shall submit QAP to
owner/Third Party Inspection agency for their approval. However all the bought-out items must
be supplied with test certificates and inspection reports.
8.2
In case of Indian bidders, the third party inspection is in scope of Owner/PDIL and in case of
foreign bidders, the third party inspection is by any of the approved third party inspection
agencies to be finalized by Owner/PDIL.Foreign bidders shall quote the charges for third party
inspection agency separately along with the bid.
It shall be the responsibility of the Bidder to make available to the inspector all the drawings,
calculations and other documents. However the owner /inspection agency shall have free access
for inspection at vendors/sub-vendors shop at all stages of manufacturing.
Further the following tests / procedure are mandatory to be witnessed / reviewed by concerned
third party inspection agency.
i)
ii)
iii)
iv)
v)
Vi)
Vii)
Viii)
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
ix)
EM163-TS-301
DOCUMENT NO
REV
SHEET 11 OF 14
8.3
All imported raw materials shall only be inspected by TPIA. The cost of the same shall be
considered by bidder in their scope.
8.4
The equipment shall be considered acceptable for dispatch only after final certification for
acceptance is issued by concerned inspector.
8.5
Production control coupons, when required as per codes & standards shall be subjected to
mechanical tests as required. In case of heat treated equipment test coupons shall be given
similar heat treatment as for the equipment. Test plates for production testing shall be sufficient
for performing all tests.
8.6
Formed heads cold formed or hot formed below normalizing temperature shall be subsequently
normalized and weld seams if any shall be fully radio graphed after forming.
8.7
All nozzle reinforcing pads wherever applicable shall be tested pneumatically at 1.25 Kg/cm2g
pressure with soap solution on attachment welds. Vent holes shall be plugged with nonhardening mastic to prevent ingress of water.
8.8
All completed equipment shall be tested hydraulically as per the requirements of codes,
standards & specifications in presence of the inspecting authority. Pneumatic test of completed
equipment shall be carried out only when specially mentioned in the specification sheets.
Chloride content in water used for testing shall not exceed 30 ppm.Duration of test shall be as
per applicable codes& standards. Test medium/water shall be tested for the chlorine contents
before filling the equipment.
8.9
The temperature of test water shall comply with requirement of Fabrication code.
8.10
Unless otherwise stated gaskets used during testing shall be same as specified for operating
conditions. After testing, gaskets used during testing shall be replaced by new gaskets.
8.11)
a set of detailed test should be carried out on the vessel and their test certificates should be
made available to NRL/PDIL along with other certificates like
a) Detailed drawings of the fabricated vessels and associated instruments
b) CCOE approval stating that the vessels, various instruments and panels are suitable for
use in LPG service
c) Guarantee Certificate of vessels and instruments
d) Manufacturers Certificate
e) Quality Assurance Certificate for various parts of vessel
f) WPS, PQR & WPQ Certificate
g) Raw material Heat Chart
h) Vessel Dimension Inspection Report
i) Radiography Inspection Report
j) Heat Treatment Chart
k) Hydro-test Report
l) Impact Test Report
m) Stability Test Report
n) TPIA certificates
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
8.12
8.12.1
EM163-TS-301
DOCUMENT NO
REV
SHEET 12 OF 14
NDT Requirements
The following NDT requirements are mandatory in addition to codes, standards &
specification requirements.
A) UT examination:
i)
ii)
iii)
iv)
B) MP / PT examination:
i)
ii)
iii)
iv)
v)
vi)
v)
viii)
ix)
C) Radiography:
i)
ii)
iii)
iv)
All weld seams of formed head, if made in more than one segment shall be full
radiography after forming and heat treatment if any.
When spot radiography is specified, all T - Joints & minimum 10% of total weld
length excluding T joints shall be radiographed
All nozzles fabricated from plates shall be 100% radiographed
All but welds irrespective of thickness (100% radiographed) before PWHT and
hydrotest.
D) Hardness test:
Weld and Heat affected zone (HAZ) of all pressure bearing welds in Cr-Mo steel shall be
tested after final heat treatment using a portable hardness tester. Hardness value shall
not exceed 200 BHN for steel having Cr< 2 % and 240 HB for steel having Cr 2%.
9.0
9.1
Quality Assurance (QA) shall mean the organizational set up, procedures as well as test
methods and facilities developed by Bidder in order to assure that The equipment leaving
Bidders shop are of the highest possible quality i.e. either equal to or better than the
requirement specified.
9.2
Quality Control (QC), shall mean all the tests, measurement, checks and calibration which
are to be carried out in Bidders shop in order to compare the actual characteristics of the
equipment/unit/system with the specified ones, along with furnishing of the relevant
documentation (certificates/records) containing the data or result of these activities. The
bidders are required to furnish a detailed & comprehensive list of the inspection facilities
available at their shop along with the bids.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 13 OF 14
9.3
9.4
QA/QC system shall cover all products and services required for the equipment as per scope
defined in enquiry specification including job sub contracted by the Bidder.
9.5
On award of contract the vendor shall submit all the testing procedure including PWHT, NDT
etc. to PDIL/TPI/Owner for approval .Records of all the QAP & test records shall be duly
maintained and produced to the inspector visiting the vendors shop for the purpose of
inspection. The comprehensive records & all the relevant reports shall be finally sent to the
NRL respective unit along with the supply of equipment.
10.0
10.1
Mechanical Guarantees
Bidder shall guarantee the equipment against faulty design, improper material of
construction and poor workmanship, as per commercial specifications. Approval by
Owner/Third Party Inspection Agency/PDIL for design calculations, drawings & other
documents will not in any way absolve the Bidder from his responsibility. Should any repair
or replacement be necessary owing to any type of failure on account of design material and
workmanship of the item, Bidder shall in view of this guarantee be bound to replace the same
either in part or whole without any commercial implications to Owner. Repaired or replaced
part shall also be covered by same guarantee as in case of main supply.
11.0
Documentation
11.1
11.2
Detailed fabrication drawings shall be prepared by Bidder clearly indicating all design data,
nozzle data, details of all parts with tolerances, all welding joints details and detailed bill of
materials etc. Location of weld seams, construction notes, welding processes, detailed
specification of electrodes including NDT tests etc. as applicable shall be clearly indicated in
the drawing. Fabrication drawing shall also indicated Civil load datas i.e. Empty Weight,
operating weight & hydrotest weight of the equipment including base shear force and base
moment for civil foundation design. Drawing submitted for approval must be complete in all
respects and thoroughly checked and approved by Bidders competent authority before
submitting to Owner/PDIL/Third Party Inspection Agency.
i)
All drawings shall be drawn in AUTOCAD to scale. Manual drawing shall not be
accepted.
ii)
8 sets of hard copies of Rev. 0 of GA drawing, design calculation etc with soft
copies to PDIL for review.
b)
Vendor shall also submit 02 hard copies of GA drawing, design calculation etc with
soft copies to PDIL for review.
TECHNICAL SPECIFICATION
DRAIN VESSEL
NRL, NUMALIGARH
c)
12.0
EM163-TS-301
DOCUMENT NO
REV
SHEET 14 OF 14
6 sets of all final documents such as design calculations, fabrication drawings, test
certificates, material test reports, repair procedure along with the reproducible & soft
copies, hard copies etc shall be properly arranged, indexed and bound in one
folder and submitted to owner. All fabricated drawings to be furnished in
*.DWG/DXE format on rewritable CD of reputed make.
Spares (Erection & commissioning, 2 years operation & Special Spares etc.)
Completion Period
Bidder shall include all the relevant information for complete technical and commercial
evaluation of the bid as per documentation schedule doc. No. EM163-PNMV-TS301-DOC.
Further bidder shall indicate his response on checklist (Technical) Doc. No. EM163-PNMVTS301-CL01.
15.0
16.0
17.0
References List
Bidder shall provide detailed references list for executing similar jobs of similar capacity in the
last three years indicating Process Parameters, Design codes & standards, clients name,
name of Inspection agency etc. along with offer.
EM163DD45VV106
DOCUMENT NO.
REV
SHEET 1 OF 3
PROCESSDATASHEET
FOR
DRAINVESSEL
1
0
REV
17.09.2015
10.06.2015
REV DATE
17.09.2015
10.06.2015
EFF DATE
VKS/ SKK
VKS/ SKK
PREPD
SCA
SCA
REVWD
SCA
SCA
APPD
EM163-DD-45-VV-106
Doc. No
REV
Plant/Section:
2 of 3
45
Tag No:
Service:
Position
45-VV-106
Water Drain Out from Bullet
Hor: ( )
Ver: ( )
MATERIAL OF CONSTRUCTION (1)
Shell:
Carbon Steel
Lining If Any:
Yes 8)
Head:
Nozzle Neck
Nozzle Flange
Studs and Bolts
Nuts:
Gaskets:
Distributers:
Grates:
Additional Attachments Internals :
Internal Attachments:
NOZZLES
L:iquid Inlet
Liquid Drain
Vapour Outlet
Level Connection
Level Transmitter
Displacer Type
Thermo well
Safety Valve
Pressure Gauge
Utility Connection
Design Code
Manhole
Boiling Stds.
Gasket Stds.
Supports
Anchor Bolts
Location
Insulation
Type Of Insulation :
Sheet
MARK
RATING
N4A-B
SIZE
2
1.5
2
2
3
300 #
300 #
300 #
300 #
300 #
N5
N6
N7
N8
1.5
1
1
2
300 #
300 #
300 #
300 #
N1
N2
N3
L1-2
4), 6)
* Hold
* Hold
7)
No
Complete/Segments
Process Dept.
Designed by:
Checked by:
Approved by:
VKS/ SKK
SCA
SCA
Date
10.06.2015
10.06.2015
10.06.2015
No.
1
1
1
REVISION
Signature
Date
No.
REVISION
Signature
Date
LIST OF SPARES
DRAIN VESSEL
NRL, NUMALIGARH
1.0
Drain Vessel
1.1
EM163-PNMV-TS301-SP01
DOCUMENT NO
REV
SHEET 1 of 1
1.2
Note:
Supply of any additional spares if required for erection and commissioning & 2 years
operational spares whatsoever required shall be under Bidders scope. Bidder shall
furnish the list of such proposed additional spares.
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
PROJECT : EM163
BIDDERS NAME:
S.NO.
PRICE IN RUEPES:
DESCRIPTION OF PARTS
(1)
(2)
MATERIAL OF
CONSTRUCTION
MAJOR
DIMENSIONS
(3)
(4)
ERECTION &
COMM.
UNIT PRICE
(EX - WORKS)*
(5)
(6)
(7)
A)
Main Equipment:
A1
Gaskets
1.
2.
3.
4.
A2
Studs, Nuts/Bolts
1.
2.
3.
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
EM163-PNMV-TS301-F1
DOCUMENT NO
REV
15.09.15 15.09.15
REV DT
EFF DT
(5) X (7) =
(8)
(6) X( 7) =
(9)
VB
PK/NB
GC
1 OF 2
PREP
D
REVWD
APPD
SHEET NO
All rights reserved
4.
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
Clamps
2% of total for
each type / size
(minimum 5 nos.
of each size)
For Internals:
B)
Note:
EM163-PNMV-TS301-F1
DOCUMENT NO
REV
15.09.15 15.09.15
REV DT
EFF DT
VB
PK/NB
GC
1 OF 2
PREP
D
REVWD
APPD
SHEET NO
All rights reserved
DOCUMENTATION SCHEDULE
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-DOC
DOCUMENT NO
REV
SHEET 1 of 3
DOCUMENTATION SCHEDULE
DOCUMENTATION SCHEDULE
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-DOC
DOCUMENT NO
REV
SHEET 2 of 3
Sl.
No.
1.0
2.0
3.0
4.0
Name of Document
With
Bid
Y/N
For
approval
For
information
Final /
approved/ Asbuilt
5.0
6.0
After
Hydrotesting
-DO-
-DO-
-DO-
After
Hydrotesting
-DO-
13.0
-DO-
14.0
-DO-
15.0
16.0
All final As- built shop drgs. & design calculations duly
certified by CIB & inspecting authority ( ** )
Records/drawings, charts duly approved, signed and
stamped by statutory Authorities (**)
All Radiography films ( ** )
& strain gauge
measurement wherever applicable (**)
Mechanical and hydrodynamic Guarantee Certificate
( ** )
Inspectors final certificate ( ** )
-DO-DO-
-DO-
-DO-
-DO-
-DO-
7.0
8.0
9.0
10.0
11.0
12.0
17.0
18.0
19.0
20.0
GENERAL
1.0
2.0
LEGEND: Y Yes, N - No
FORM NO: 02-0000-0021F2 REV1
DOCUMENTATION SCHEDULE
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-DOC
DOCUMENT NO
REV
SHEET 3 of 3
Notes:
1.
2.
3.
Bidder shall submit document in required number of sets as stated elsewhere in commercial
part.
EM163-PNMV-TS301-CL01
DOCUMENT NO
REV
SHEET 1 of 1
Bidders reply
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
Y/N
Y/N
Y/N
Y/N
Y/N
Y/N
Y/N
Y/N
LIST OF DEVIATIONS
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-D1
DOCUMENT NO
REV
SHEET 1 of 2
The requirements and guidelines set forth in the Technical Specification are binding and
the Bidder shall take due cognizance of all the causes before submitting the Bid. If however
any deviation from Technical Specification requirements, sought by the Bidder the same
shall be indicated clearly against the relevant Technical Specification clauses in the
enclosed format. Any deviation not listed in the enclosed format shall not be considered. It
will be presumed that the Bidder has accepted all the other conditions stipulated in
Technical Specification for all intent and purposes - wherever the deviations are not clearly
earmarked.
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
LIST OF DEVIATIONS
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-D1
DOCUMENT NO
REV
SHEET 2 of 2
LIST OF DEVIATIONS
SL.
NO.
RFQ CLAUSE
REF. NO.
DESCRIPTION OF CLAUSES
PROPOSED DEVIATION
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
DEVIATION NUMBER
APPROVERS NO
EM163-PNMV-TS301-W1
DOCUMENT NO
REV
SHEET 1 of 2
OWNERS JOB NO
APPLICANT NO
DATE
PROJECT: _____________________
JOB NO. :_____________________
D W
ORDER/CONTRACT NO.____________________
DETAILS
SPECIFIED REQUIREMENTS
REQUESTED MODIFICATION
JUSTIFICATION:
Commercial impact :
Yes
No
Impact on delivery :
Yes
No
If yes, indicate time: _________ weeks.
Forward request to disposing authority
Signature: ____________________
Name
: ____________________
Ref. No.:
Date
:
DECISION
JUSTIFICATION
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
Signature: _________________________
Name
: _________________________
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
EM163-PNMV-TS301-W1
DOCUMENT NO
REV
SHEET 2 of 2
(Disposing Authority)
Signature: ____________________
Name
: ____________________
(RCM/Inspecting Officer, Owner)
COMMENTS/RECOMMENDATIONS:
Signature: _________________________
Name
: _________________________
(Originator of specified requirements)
Co-ordination with interfacing departments:
The above opinion has been arrived at in consultation and with agreement with the
following departments by this deviation:
1) ______________ 2) ______________ 3) _______________4) ________________
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
PDS : PV 002
PDIL
PROJECTION OF NOZZLES
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET
1 OF 1
VALUES OF J
Nozzle Diameter
NPS
< 3//
Rating
Rating
150#
300#
200
//
200
Rating
1500#
200
Rating
2500#
350
250
250
350
250
250
350
250
300
350
550
250
250
300
200
//
200
//
//
10
//
12
//
14
250
250
//
16
18//
20//
24//
//
Rating
600#
//
Rating
900#
350
550
300
350
350
550
300
350
450
--
Remarks
300
300
300
350
350
350
350
350
350
450
450
500
----
Refer Note-4
Refer Note-4
300
350
350
500
--
Refer Note-4
300
350
--
--
Refer Note-6
350
--
DATE
PURPOSE
PREPARED
DKM\DAYTODAY\STANDARD\MECH\PDS-PV002-F3.LWP
REVIEWED
APPROVED
EM15095110905
EM163
DOCUMENTNo
PROJECTSANDDEVELOPMENTINDIALTD
P
Rev
Page1of2
MINIMUMALLOWABLENOZZLELOADINGS
VESSELSANDS/THEATEXCHANGERS
P
Rev
19.05.15
Date
Issued
Purpose
AS
PrpdBy
AS
ChkdBy
AMAR
AppdBy
ALLOWABLENOZZLELOADINGS
VESSELSANDS/THEATEXCHANGERS
EM15095110905
EM163
DOCUMENTNo
P
Rev
Page2of2
NOTE:
Theabovelistgivesthetentativeallowablenozzleloads.Actualloadsshallbeforwardedafterstress
analysisofconnectingpiping.
ES-2001
DOCUMENT NO
REV
Page1of26
TECHNICAL SPECIFICATION
FOR
PAINT & PROTECTIVE COATINGS
ON STEEL SURFACES
0
REV
01.01.2011
REV DATE
01.01.2011
EFF DATE
FOR IMPLEMENTATION
PURPOSE
RV
PREPD
MKS
REVWD
MKS
APPD
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page2of26
CONTENTS
Section
Number
Description
Sheet Number
1.0
GENERAL
1.1
Scope
1.2
Definitions
1.3
Safety Regulations
1.4
1.5
Materials
2.0
2.1
Indian Standards
2.2
International Standards
2.3
Other Standards
3.0
SURFACE PREPARATION
3.1
3.1.1
Safety
3.1.2
Pre-cleaning
3.1.3
Surface Decontamination
3.1.4
Abrasive Blasting
3.1.5
4.0
APPLICATION
4.1
General
4.1.1
4.1.2
4.1.3
4.1.4
Application of Coatings
10
4.2.1
General
10
4.2.2
Atmospheric Conditions
10
4.2.3
11
4.2.4
Brush Application
11
4.2.5
Roller Application
11
4.2.6
Thickness of Coatings
11
4.2.7
11
4.2
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Section
Number
4.2.8
ES - 2001
DOCUMENT NO
REV
Page3of26
Description
Sheet Number
12
4.3
12
4.4
13
4.4.1
13
4.4.2
13
4.4.3
Inaccessible Surfaces
13
4.5
14
4.6
Wash-up
14
4.7
Touch- up Painting
14
4.8
Paint Storage
14
5.0
15
6.0
21
6.1
Machinery
21
6.2
21
7.0
COLOURS
21
8.0
PARTICULAR DESCRIPTION
23
9.0
24
10.0
11.0
SUBMISSION OF DATA
25
12.0
25
13.0
26
14.0
LIST OF MANUFACTURER
26
25
ATTACHMENTS
ANNEXURE- I
FormNo020000021F3Rev3AllRightsReserved
ES - 2001
DOCUMENT NO
REV
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
1.0
GENERAL
1.1
Scope
Page4of26
This specification covers the technical requirements for shop and site application of paint and
protective coatings and includes; the surface preparation, priming, application, testing and quality
assurance for protective coatings of mechanical equipment, structural steelwork, plate work,
tankage, guards, pipe work, handrails and associated metal surfaces, which will be exposed to
atmospheric for industrial plants.
1.2
1.3
Definitions
C.S
S.S
Non-ferrous
High Alloy
DFT
Safety Regulations
Protective coatings and their application shall comply with all national, state, and local codes and
regulations on surface preparation, coating application, storage, handling, safety, and
environmental recommendations.
Sand or other materials producing silica dust shall NOT be used for any open-air blasting
operations.
1.4
1.5
Materials
All paints and paint materials shall be obtained from the companys approved manufacturers list.
All materials shall be supplied in the manufacturers containers, durably and legibly marked as
follows.
Specification number
Colour reference number
Method of application
Batch number
Date of Manufacture
Shelf life expiry date
Manufacturers name or recognised trade mark.
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
2.0
ES - 2001
DOCUMENT NO
REV
Page5of26
2.1
Indian Standards:
IS-5: 1994
IS-2379: 1990
IS-2629: 1985
IS-2633: 1986
IS-8629: 1977
IS:110
IS:101
2.2
Other Standards:
2.2.1
2.2.1
2.3
The paint manufacturers, instructions shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
a)
b)
c)
d)
Application of paints and the recommended limit on time intervals between coats.
3.0
SURFACE PREPARATION
3.1
3.1.1
Safety
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TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
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Page6of26
All work in adjacent areas, which may negatively affect the quality of blast cleaning, and/or
impose safety hazards, must be completed or stopped before the blasting operation starts.
3.1.2
Pre-cleaning
Prior to surface preparation all weld spatter shall be removed from the surface, all sharp edges
ground down and all surfaces cleaned free of contaminants including chalked paint, dust, grease,
oil, chemicals and salt. All shop primed surfaces shall be water washed by means of suitable
solvent, by steam cleaning, with an alkaline cleaning agent if necessary or by high-pressure
water, to remove contaminants prior to top-coating
3.1.3
Surface Decontamination
Surface decontamination shall be performed prior to paint application when uncoated surface is
exposed to a corrosive environment or existing paint work is to be repaired.
Existing coatings shall be removed by abrasive blast cleaning, and then high pressure potable
water shall be used to clean steel surfaces.
Prior to application of coatings, the surface shall be chemically checked for the presence of
contaminants. A surface contamination analysis test kit shall be used to measure the levels of
chlorides, iron salts and pH in accordance with the kit manufacturers recommendations.
Swabs taken from the steel surface, using cotton wool test swabs soaked in distilled water shall
not be less than one swab for every 25m2 of surface area to be painted.
Maximum allowable contaminant levels and pH range is as follows:
Sodium chloride, less than 50 microgram / cm2;
Soluble iron salts, less than 7 microgram / cm2; and
pH between 6 8
If the results of the contamination test fall outside the acceptable limits, then the wash water
process shall be repeated over the entire surface to be painted, until the contaminant test is
within the specified levels.
3.1.4
Abrasive Blasting
All C.S. materials shall be abrasive blast cleaned in accordance with Codes (Ref. Clause 2.0). To
reduce the possibility of contaminating S.S., blasting is not usually specified. However, for
coatings which require a blast-cleaned surface for proper adhesion, S.S. may be blast cleaned
using clean aluminium oxide or garnet abrasives (Free from any chloride or Iron / Steel
contamination).When hand or power tool cleaning is required on S.S., only S.S. wire-brushes
(including 410 S.S.) which have not been previously used on C.S. surfaces may be used.
The surface profile of steel surfaces after blasting shall be of preparation grade Sa 2-1/2 of
Swedish Standards SIS-05-5900 (Latest Revision) or better according to ISO 8501-1 and shall be
measured using the replica tape method or the comparator method.
The roughness (profile) of blast-cleaned surfaces shall be Medium (G) according to ISO 8503-2:
1988 (appendix 1 ) unless otherwise specified. Medium defines a surface profile with a maximum
peak-to-valley height of 60-100 microns, and G indicates that the surface profile is obtained by
grit blasting. For the evaluation of surface roughness Comparator G shall be used.
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page7of26
Abrasive blast cleaning shall NOT be performed when the ambient or the substrate temperatures
are less than 3o C above the dew point temperature. The relative humidity should preferably be
below 50% during cold weather and shall never be higher than 60% in any case.
Abrasive blast cleaning shall be performed with a clean, sharp grade of abrasive. Grain size shall
be suitable for producing the specified roughness. Abrasives shall be free from oil, grease,
moisture and salts, and shall contain no more than 50ppm chloride. The use of silica sand,
copper slag and other potentially silica containing materials shall not be allowed
The blasting compressor shall be capable of maintaining a minimum air pressure of 7 kPa at the
nozzle to obtain the acceptable surface cleanliness and profile.
The blast cleaning air compressor shall be equipped with adequately sized and properly
maintained oil and water separators. The air supply shall be checked to ensure no oil and water
contamination at the beginning of each work shift.
Blast cleaning abrasive shall be stored in a clean, dry environment at all times. Recycling of used
abrasive is prohibited.
After blast cleaning, the surfaces shall be cleaned by washing with clean water (Pressure
7kg/Cm2 using suitable nozzles. During washing broom corn brushes shall be used to remove
foreign matter.
Assessment of the blast cleaned surfaces shall be carried out in accordance with reference code.
Blast cleaned surfaces which show evidence of rust bloom or that have been left uncoated
overnight shall be re-cleaned to the specified degree of cleanliness prior to coating.
All grit and dust shall be removed after blasting and before coating application. Removal shall be
by a combination of blowing clean with compressed air, followed by a thorough vacuum cleaning
with an industrial grade, heavy duty vacuum cleaner.
All cleaned surfaces shall have protection from atmospheric corrosion as per IS8629:1977
3.1.5
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TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page8of26
Hand and/or power tool cleaning shall only be used for spot repair where abrasive blasting is not
permitted or is impractical, and on items which could be damaged by abrasive blasting. Power
tool cleaning shall not be carried out with tools which polish the surface, e.g. power wire brushes.
The surfaces of equipments and prefabricated piping
etc. which are received at site
Primerised or with finish paints, depending upon their conditions, shall be touched up and
painted at site. For these surfaces sand blasting is not envisaged and these surfaces shall
be prepared using power brushes, buffing or scraping, so as to achieve a surface finish to
St-3 as per SIS-05-5900 . After wash-up the area to be touched up shall be jointly marked,
measured and recorded for payment purposes. The type of system & nos. of coat (primer and/or
finish paint) to be applied after touch up, which shall be decided by OWNER/CONSULTANT in
writing before taking up the job.
When paint is to be applied on damaged painted surfaces of equipments all loose and flaking
paint work should be removed to a firm feathered edge. Rusted spots should be cleaned by one
of the methods specified in the clauses 4.4.1 & 4.4.2 above. In case the previous paint work is
not compatible to the specified one the entire coating must be removed.
It shall be ensured that sand blasted surface/machine cleaned surface is not contaminated with
oil and grease. Water shall also not be allowed to come in contact with sand blasted surface.
4.0
APPLICATION
4.1
General
The final specification of paint systems to be used to suit the exposure conditions of equipment
and steelwork, shall be as specified on the scope of work, equipment data sheets or the
drawings.
All coatings shall be in accordance with Indian / International Standards, the coating
manufacturers product data sheets and application instructions and the requirements contained
in this specification.
4.1.1
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ES - 2001
DOCUMENT NO
REV
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
4.1.2
Page9of26
The CONTRACTOR must ensure the availability of a specialist from the paint manufacturer, at
SITE during pendency of CONTRACT within his quoted rates to ensure the quality of
painting & procedure. Addition of drying agents, pigments or other substances is not allowed
unless specifically prescribed or approved by paint manufacturer's specialist.
Name plates/tags attached to the equipments/machineries shall not be painted or removed
during painting job. Failing to comply with above, the CONTRACTOR may be required to replace
name plates/tags at his cost.
4.1.3
FormNo020000021F3Rev3AllRightsReserved
ES - 2001
DOCUMENT NO
REV
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
4.1.4
Page10of26
4.2
Application of Coatings
4.2.1
General
The application method and type of equipment to be used shall be suitable for the paint specified
and the surface being painted.
Paints and thinners shall be brought to the point of usage in unopened original containers
bearing the manufacturer's brand name and colour designation and ready-mixed unless
otherwise specified. Two-pack systems shall be mixed at the site of application to the paint
manufacturer's recommendations. The mixed amount prepared shall be no more than the
amount that can be applied during the stated pot life.
Paint shall be applied so that an even film of uniform thickness, tint and consistency covers the
entire surface and is free of pin holes, runs, sags or excessive brush marks. Film finish shall be
equal to that of first class brushwork.
Unless it is practical to do so colour shades for primer, intermediate coat and finish coat must be
different to identify each coat without any ambiguity
Paint ingredients shall be kept properly mixed during paint application.
Equipment shall be kept clean to ensure dirt, dried paint and other foreign materials are not
deposited in the paint film. Any cleaning solvents left in the equipment shall be completely
removed before painting.
To ensure the required film thickness is achieved on angles, welds, sharp external edges, nuts
and bolts, a coat shall be applied to such items/locations immediately prior to the application of
each coating to the whole area.
Care shall be taken to ensure paint application into all joints and crevices.
The contact surfaces between steelwork to be fastened by means of friction grip bolting shall be
abrasive blast cleaned and prime coated only, prior to erection.
4.2.2
Atmospheric conditions
Surface preparation and coating shall not be carried out in inclement weather and shall be
carried out such that the surface being coated is free of moisture, wind-borne or blast cleaning
dust.
Coatings shall not be applied if:
-
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page11of26
The metal temperature is less than 30C above the dew point.
There is likely hood of an unfavourable change in weather conditions within two hours
after painting.
As a general rule, sufficient ventilation, dehumidification and heating capacity to cope with local
climatic conditions must be secured before any coating related work is started.
In any case, humidity, ambient and surface temperature conditions at the time of paint
application, and curing and drying time before application of the next coat, shall be in accordance
with the paint manufacturer's recommendations. These conditions shall be recorded in the
Inspection Test Record (ITR) by the Contractor and be available for review.
4.2.3
4.2.4
Brush Application
The method of "laying-off" shall be suited to the paint specified and shall ensure minimum brush
marking.
4.2.5
Roller Application
A uniform method of application shall be adopted when painting large areas. The rolling direction
shall minimise paint joint build up. Edges and areas subject to possible roller damage shall be
brush-painted prior to rolling.
4.2.6
Thickness of Coatings
The maximum thickness DFT in any one application shall not exceed that specified in Technical
specifications/ recommended by the paint manufacturer.
Wet film thickness gauges shall be used to make frequent checks on the applied wet film.
The Contractor shall maintain at the site of painting operations, a dry film thickness tester of an
approved type with a valid current calibration.
Coating thickness checks in accordance with reference code shall be performed, and the
Contractor shall undertake remedial action if the measured thickness is less than specified.
Build up of each material to required thickness shall be made prior to the application of the
subsequent coat; final film build shall be the minimum specified.
4.2.7
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page12of26
The manufacturer's stated maximum time for re-coat has not elapsed. If the maximum
time has elapsed then pre-treatment shall be in accordance with the paint manufacturer's
recommendations; and
Damaged areas in preceding coat have been made good in accordance with this
Specification.
When multiple coat of finish paint are indicated, they shall be applied in different shades to
ensure that multiple coats have been applied.
4.2.8
4.3
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TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page13of26
All gratings and fixtures including nuts, bolts and washers that are required to be galvanised,
shall be hot dipped galvanised and all nut threads shall be re-tapped after galvanising and a
lubricant applied on Cold working of galvanised steelwork shall be avoided.
4.4
4.4.1
Pre-clean the damaged or unpainted areas in accordance with Section 4.2.1 of this
Specification;
Inorganic zinc primers subject to mechanical damage or weld etc shall be power tool
cleaned
Feather backs by sandpapering or whip blasting the original coatings surrounding the
damaged area over a 50mm distance. A rough surface shall be obtained on epoxy
coatings;
Conduct surface contaminant test in accordance with Section 4.2.2 of this document; and
Build up a new paint system over the affected area with paints equal to those originally
used and having the same dry film thickness for each coat. As an exception, damaged
inorganic zinc primers shall be repaired with epoxy organic zinc rich paint and shall be
applied within four hours of blast cleaning.
4.4.2
The new coatings shall overlap the original coating over the 50mm prepared distance and shall
be colour matched to the specified colour of the original coating.
Damaged Galvanised Surfaces
Damaged areas caused by oxy-cutting, welding or physical impact shall be treated as follows:
-
Prepare the surface by removing any weld slag followed by vigorous power wire brushing
of the coating surrounding the damaged area over a 50mm distance;
Apply two coats of organic zinc-rich primer to a minimum DFT of 100 microns.
The area to be reinstated shall be colour matched to the surrounding finish colour with 40
microns of aluminium paint to the manufacturer's written instructions.
4.4.3
Inaccessible Surfaces
Surfaces that will be inaccessible after erection of other elements of the structure, shall be fully
painted prior to the installation of the obstructing item.
4.5
FormNo020000021F3Rev3AllRightsReserved
ES - 2001
DOCUMENT NO
REV
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Page14of26
Machined surfaces, bearings, seals, grease fittings, adjusting screws and name plates, and
identification tags.
-
Valve stems;
Electrical cabling;
welding.
The rear face of piping flanges shall be shop prime coated only. Flange holes for fasteners shall
be fully coated.
4.6
Wash-Up
All surface of equipments/prefabricated piping etc. Primerised / painted at Vendor shop and
received at site if required shall be washed up as follow:
4.7
a)
Washing with clean water (Pressure 7 Kg/cm2) using suitable nozzles. During washing,
broomcorn brushes shall be used to remove foreign matter.
b)
Solvent washing, if required , to remove traces of wash up as per above procedure of all
surfaces of equipment, piping, structure etc. completely painted at contractor's shop
shall be included in the quoted rates of oil, grease etc. Wash up as per above procedure
of all surfaces of equipment, piping, structure etc. completely painted at contractor's shop
shall be included in the quoted rates.
Touch-Up Painting
Prior to the application of any coat, all damage to the previous coat(s) shall be touched-up.
Damage to finished work shall be thoroughly cleaned and re-coated.
Surface preparation shall be done as per clause no. 3.0..........................
Items supplied with the manufacturers standard coating system shall be touched-up with the
same generic coating system or recoated.
4.8
Paint Storage
The following must be ensured:
a)
All paints and painting material shall be stored only in such rooms assigned for the
purpose. All necessary precaution shall be taken to prevent fire. The Storage building
shall preferably be separate from adjacent buildings. A sign-board bearing the Words
"PAINT STORAGE- NO NAKED LIGHT" shall be clearly displayed outside. The building
shall be properly ventilated and shall be adequately protected with fire fighting equipment.
b)
Storage shall be far away from heated surface open flames, sparks & well protected from
sun rays.
c)
Ambient temperature at which paints are stored shall be intimated to paint manufacturer &
their advice sought regarding precautions to be taken if any,
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page15of26
5.0
d)
Maximum allowed storage time for various paint materials shall be clearly indicated on
individual containers. Materials which have passed expiry date shall not be used.
e)
Paints in non-original containers and/or in containers without seals, shall not be used.
The following Table 1 shall be used as a general guide for the selection of a paint system suitable for a
particular plant area application. Paint systems specified on equipment data sheets and the Drawings
shall take precedence over the general paint system area applications listed in Table 1
TABLE - 1
Ref
No.
01
02
Application
Surface Preparation
Uninsulated CS piping,
flanges, valves with
operating temp. From 90O
C to 200O C.
Generic Coating
System
Primer: Two coats
of two pack zinc
rich epoxy
polyamide cured
Primer.
Finish coat: Three
coats of two
packs. Polyamide
Cured Epoxy.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Minimum
DFT
Primer :35
microns
For each coat
(Total70microns).
Finish: 40
microns for
each coat
(Total 120
microns.
Primer: 75
microns
Finish:
25 microns for
each coat Total
- 50 microns.
Remarks
Total dry film
thickness of
paint system:
190 microns.
NOTE : Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting,
ready mixed Aluminium Paint will be applied on surface without inorganic zinc primer and surface
preparation to grade Sa-2 of Swedish Standard SIS-05-5900 (Latest).
03
Uninsulated CS piping,
flanges, valves with
operating temp. Over 200O
C.
Primer: 75
microns
Finish:
20 microns for
each coat Total
- 40 microns.
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Ref
No.
Application
Surface Preparation
Generic Coating
System
ES - 2001
DOCUMENT NO
REV
Page16of26
Minimum
DFT
Remarks
NOTE: Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting
Silicon Aluminium Paint will be applied on surface without inorganic zinc primer and surface
preparation to grade Sa-2 of Swedish Standard SIS-05-5900 (Latest).
04
05
06
Insulated CS piping
flanges, valves with
operating temp up to 90O
C
Insulated CS piping,
flanges, valves with
operating temp. From 90O
C to 200O C.
Primer :100
microns
Finish : 100
micron
Primer: 100
microns
Finish: 100
micron
NOTE : Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting,
ready mixed Aluminium Paint will be applied on surface without inorganic zinc primer and surface
preparation to grade Sa-2 of Swedish Standard SIS-05-5900 (Latest).
Blast cleaning to near Primer: One coat
Insulated CS piping,
Primer: 75
Total dry film
white metal grade 2
flanges, valves with
of Ethyl Silicate
microns
thickness of
operating temp. Over 200O , of Swedish
zinc rich with
paint system:
C.
Standards SIS-05solvent.
Finish: 25
100 microns.
5900 (Latest).
Finish coat: One
micron
Wash-up As per
coat of Heat
clause no. 4.60.
resisting Silicon
Touch-up As per
Aluminium paint.
clause no.4.70.
NOTE: Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting
Silicon Aluminium Paint will be applied on surface without inorganic zinc primer and surface
preparation to grade Sa-2 of Swedish Standard SIS-05-5900 (Latest).
07
08
Uninsulated CS
equipment with operating
O
temp. Up to 90 C, to be
treated at Manufacturers
shop.
Uninsulated CS
equipment with operating
temp. From 91O C to
200oC, to be treated at
Primer: 35
micron for each
coat. Total 70
microns.
Finish: N.A
Finish coat :
Three coats of
two pack
Polyamide Cured
Epoxy
Finish:
40 microns for
each coat Total
- 120 microns.
Primer: 75
microns
Finish:
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Ref
No.
09
Application
Surface Preparation
Manufacturers shop.
5900 (Latest).
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
Uninsulated CS
equipment with operating
temp. Over 200oC , to be
treated at Manufacturers
shop.
10
11
12
13
14
Insulated CS equipment
with operating temp. Up to
90O C, to be treated at
Manufacturers shop.
Insulated CS equipment
with operating temp. From
91O C to 200oC, to be
treated at Manufacturers
shop.
Insulated CS equipment
with operating temp. Over
200oC, to be treated at
Manufacturers shop.
ES - 2001
DOCUMENT NO
REV
Page17of26
Generic Coating
System
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Minimum
DFT
25 microns for
each coat Total
- 50 microns.
Remarks
Primer: 75
microns
Primer: 100
micron Finish:
100 microns
Primer: 100
microns
Finish:
20 microns for
each coat Total
- 40 microns.
Finish: 100
micron
Primer: 75
microns
Primer: 100
microns
Primer: 75
microns
Finish: 25
microns
Finish:
100 microns
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Ref
No.
15
Application
Surface Preparation
surface of furnaces,
external surface of flue
duct, metal stacks and
similar with operating
temp. Up to 200oC. (With
exclusion of stair ways,
walk ways etc.).
, of Swedish
Standards SIS-055900 (Latest).
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no.4.70.
Generic Coating
System
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of Heat
Resisting Silicon
Aluminium Paint.
ES - 2001
DOCUMENT NO
REV
Page18of26
Minimum
DFT
Finish:
25 microns for
each coat Total
- 50 microns.
Primer: 75
microns
Finish:
20 microns for
each coat Total
- 40 microns.
Remarks
paint system:
125 microns.
NOTE: Only for zones where it will be impossible to blast cleaning, four to five coats of Heat Resisting
Silicone Aluminium Paint will be applied on surface without inorganic zinc primer and surface
preparation to grade Sa-2 of Swedish Standard SIS-05-5900 (Latest).
16
NOTE:
17
NOTE:
18
a)
Primer: 75
microns
Finish:
25 microns for
each coat Total
- 50 microns.
All surfaces shall be galvanized at manufacturers shop with exception of the end header of air
cooled heat exchangers that shall be treated as described above at Manufacturers shop. In case
the same surfaces shall not be treated at shop, they shall be treated at site according to
environmental and operating conditions.
STORAGE TANKS
Acid / Alkali CS Storage
Tank (External Surface
Primer: 35
micron for each
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Ref
No.
b)
Application
Surface Preparation
, of Swedish
Standards SIS-055900 (Latest).
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
CS Storage Tanks,
Excluding indicated in Sl.
No. (a)
Generic Coating
System
rich epoxy
polyamide cured
Primer.
Finish coat: Three
coats of two
packs. Polyamide
Cured Epoxy.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of epoxy
amine cured tank
liner.
ES - 2001
DOCUMENT NO
REV
Page19of26
Minimum
DFT
coat. Total 70
microns.
Finish:
40 microns for
each coat Total
- 120 microns.
Primer: 75
microns
Finish:
30 microns for
each coat Total
- 60 microns.
Remarks
paint system:
190 microns.
Primer: 75
microns
Finish:
40 microns
20
Primer: 100
microns
Finish:
100 microns
21
Primer: 100
microns
Primer: 75
microns
19
22
Finish:
100 microns for
each coat
Finish:
25 microns for
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Ref
No.
Application
Surface Preparation
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
23
a)
PACKAGE:
Surface(CS) with
operating temperature
upto 90oC treated at
Manufacturers shop
ES - 2001
DOCUMENT NO
REV
Page20of26
Generic Coating
System
coats of Silicon
Acrylic Paint
Minimum
DFT
each coat Total
- 50 microns.
Remarks
Primer: 35
micron for each
coat. Total 70
microns.
Finish:
40 microns for
each coat Total
- 120 microns.
Primer: 75
microns
Primer: 75
microns
e)
Primer: 100
microns
Finish:
100 microns
f)
Primer: 100
b)
c)
d)
Finish:
25 microns for
each coat Total
- 50 microns.
Primer: 75
microns
Finish:
20 microns for
each coat Total
- 40 microns.
Finish:
40 microns
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Ref
No.
Application
Surface Preparation
Stainless Steel.
as per Sa 1.0
Swedish Standards
SIS-05-5900 (Latest)
wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
25
26
CS Equipment and
associated piping subject
to cyclic, intermittent or
regeneration operating
condition (e.g. Molecular
Sieve Driers) subjected to
very severe corrosion with
wide operating
temperature range.
24
ES - 2001
DOCUMENT NO
REV
Page21of26
Generic Coating
System
of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Minimum
DFT
microns
Finish:
100 microns
Primer: 75
microns
Primer: 125
microns
Finish:
25 microns for
each coat Total
- 50 microns.
Finish:
125 microns
Remarks
thickness of
paint system:
200 microns
6.0
6.1
Machinery
Steel surfaces shall be treated with complete paint system at Manufacturers shop. The paint
system shall be according to Manufacturers Std. However, suitable for operating condition and
the environmental condition where the machinery will operate. Where necessary machinery shall
be restored at site by Contractor with suitable finish.
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
6.2
ES - 2001
DOCUMENT NO
REV
Page22of26
7.0
COLOURS:
These shall be as required by specification and in particular for :
Description
Colour
Ra1
GREY
7035
SMOOTH
ALUMINIUM
SEA
GREEN
Correspond. Asian
Paint colors to be
defined See Note-2
Red
3002
Structures upto 2 MT
BLACK
9005
Structures above 2 MT
GREY
7010
BLACK
9005
Walkwais
GREY
7010
Handrails assemblies
YELLOW
1004
Equipment
GREY
7035
Hot equipment
SMOOTH
ALUMINIUM
RED
3002
Valves in general
GREY
7035
Hot valves
SMOOTH
ALUMINIUM
RED
3002
Valves handwheels
BLACK
9005
SKY
BLUE
5012
GREY
7035
GREY
7035
SMOOTH
ALUMINIUM
SMOOTH
ALUMINIUM
FURNACES
-
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
Description
ES - 2001
DOCUMENT NO
REV
Page23of26
Colour
Ra1
Correspond. Asian
Paint colors to be
defined See Note-2
SMOOTH
ALUMINIUM
SMOOTH
ALUMINIUM
works
-
AIR COOLER
-
GREY
7035
GREY
7035
SMOOTH
ALUMINIUM
Flare > 90 C)
TANKS
-
WHITE
9010
WHITE
9010
T-301
SMOOTH
ALUMINIUM
T-303
WHITE
9010
NOTE-1:
8.0
PARTICULAR DESCRIPTION
The abrasive to be used shall be chloride-free siliceous sand (marine sand excluded) or metal
grit.
Primerized surface shall be faultless and shall not have mud-cracking, dripping over thickness
and dry sprays.
Blast cleaning and painting shall not be carried out on wet surfaces.
Blast cleaning shall not be done when surfaces temperatures are less than 3oC above dew point
of below 5oC.
No acid washes or other cleaning solutions or solvents shall be used on metal surfaces after they
have been blasted.
The surface preparation of all steel surfaces to be coated shall be free of all mill scale, rust
corrosion product, oxides, paint, oil or other foreign matter
Only dry sand blasting procedures will be allowed. The compressed air supply used for blasting
shall be free of detrimental amounts of water and oil. Adequate separator and traps shall be
provided and these shall be kept emptied of water and oil.
All welded areas and appurtenances shall be given special attention for removal of welding flux in
crevices. Welding splatter, slivers, laminations and underlying mill scale exposed during sand
blasting shall be removed or repaired.
The blast-cleaned or power brushing surfaces shall be coated with primer within four hours of
surface preparation.
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page24of26
No primer or intermediate or finishing coating shall be applied without prior notification to the
Company.
The application of the products shall be carried out in strict compliance with the paint
manufacturers recommendation.
The Contractor shall provide suitable protection for all adjacent plants or equipment from airbone
during spraying and sand blasting.
9.0
Blast Cleaning profile shall be checked using a suitable profile meter Acceptable profile
shall be 25-30 microns.
Check of time of top coating and drying in accordance with the direction of the paint
manufacturer.
Before any coating work is preformed on the site, the contractor shall ensure that any
works applied by others is acceptable.
Any defect that are discovered, are to be notified in writing to the owner before
proceeding with the contract work. To ensure the good execution of painting work
following test shall be performed:
-
Surface Preparation
Surface contaminant tests
Surface profile tests
Coating thickness tests
Tests for cure of coatings
Adhesion tests
FormNo020000021F3Rev3AllRightsReserved
ES - 2001
DOCUMENT NO
REV
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
-
Page25of26
Continuity testing
Iron contamination
Chloride contamination
Dust Contamination
All Inspection and Test Records (ITRs) shall be submitted with the Manufacturers Data
Report (MDR) at the conclusion of the job.
Defective coated areas shall be suitably marked for rectification work to be performed in
compliance with this specification.
Access shall be granted for inspection of all paint work, and witnessing of test work. This
shall not however relieve the Contractor of their own QA/QC responsibilities.
10.0
11.0
SUBMISSION OF DATA
Contractor shall submit in phase of bid the original technical data sheet and system for all
material supplied by him to apply for the permanent works and test report for the paint in
compliance to IS101.This material shall be subject to Owners approval.
12.0
12.1
12.2
Inscriptions Colours
FormNo020000021F3Rev3AllRightsReserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page26of26
Spaces between words and assemblage of numbers shall have dimensions equal to 2A
Interspaces between letters or numbers shall have dimensions equal to A.
13.0
As a rule minimum width of colour band shall confirm to the following Table:-
14.0
Width L (mm)
3 & below
25
4 NB-6 NB
50
8 NB-12NB
75
14 OD & above
100
LIST OF MANUFACTURERS :
1. M/s Berger Paints
2. M/s Asian Paints
3. M/s GRAUER & WEIL (I) LTD, (Unit-Bombay Paints)
FormNo020000021F3Rev3AllRightsReserved
EM163-PNIN-7901-00
DOCUMENT NO
SHEET 1 of 3
1
REV
TECHNICAL SPECIFICATIONS
FOR SUPPLY AND
ERECTION / COMMISSIONING OF
INSTRUMENTATION ITEMS
Job NO
: EM163
Project
Plant
: NUMALIGARH, ASSAM
Client
: NRL
24.09.2015
--
HK
RA
SKT
14.09.2015
--
HK
RA
SKT
21.07.2015
--
HK
RA
SKT
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-PNIN-7901-00
DOCUMENT NO
SHEET 2 of 3
1
REV
CONTENTS
Sl.
No.
Document Description
No. of
pages
2.
3.
EM163-PNIN-7901-Part A
Rev. 1
EM163-PNIN-7901-TS
Rev. 1
EM163-PNIN-0701-00
Rev. 1
14
23
4.
5.
EM163-E-7047
18
6.
EM163-E-7147
40
7.
EM163-E-7052
40
8.
EM163-E-7053
15
9.
EM163-E-7044
17
10.
EM163-E-7022
19
11.
EM163-E-7058
17
12.
EM163-E-7046
16
Rev. 1
EM163-PNIN-7901-00
DOCUMENT NO
SHEET 3 of 3
1
REV
13.
EM163-E-7148
15
14.
15.
ES-7337
16.
ES-7334
17.
ES-7341
18.
ES-7340
19.
ES-7335
20.
ES-7338
21.
ES7332
22.
EM163-E-0720
Rev. 1
Rev 1
PART - D : BOQ
23.
24.
EM163-PNIN-7901-Part D
Rev. 1
EM163-PNIN-BOQ-7001
EM163-P
PNIN-7901-PA
ART A
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTA
GENERAL DOCUM
MENTS OF
O
L SPECIF
FICATIO
ONS
TECHNICAL
FOR SUPPLY
S
Y AND
ERECT
TION / C
COMMIS
SSIONING OF
INST
TRUMEN
NTS
Job
b NO
: EM
M163
Pro
oject
: IN
NSTALLA
ATION OF MOUNDED BULL
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
Clie
ent
: NR
RL
24.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
14.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 1 of 14
TECHNICAL SCOPE
OF
SUPPLY&WORK
FOR
INSTRUMENTATION
1
0
P
REV
Job NO
: EM163
Project
Plant
: NUMALIGARH, ASSAM
Client
: NRL
24.09.2015
14.09.2015
21.07.2015
REV DATE
---EFF DATE
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 2 of 14
CONTENTS
1.
GENERAL
2.
SCOPEOF TENDER
3.
SCOPE OF EXECUTION
4.
PROGRESS OF WORK
5.
6.
CALIBRATION OF INSTRUMENTS
7.
STORAGE
8.
9.
10.
FIELD INSTRUMENTS
11.
SUPPORTS
12.
13.
CONSUMABLE
14.
15.
16.
17.
18.
19.
20.
21.
2_EM163_7901_INST REQUIREMENTS_rev0
Page 2 of 14
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 3 of 14
1.00
GENERAL
1.01
M/s. NRL, Numaligarh are setting up installation of 4 nos. of new Mounded Bullet of
capacity 1760.56 m3 each along with associated Utilities & Offsite facilities inside the
Numaligarh Refinery Limited Assam as per the details given elsewhere in this Tender.
1.02
As a part of this job all instruments coming in field on the Mounded Bullets are to be
installed.
2.00
Scope of Tender:
2.01
2.02
The scope includes Supply of Inst. / Materials; Installation of Contractors supplied as well
as free issue materials; Hook-up, testing/Calibration, Commissioning & handing over to
Client of Complete Instrumentation System mentioned in the Tender.
2.03
2.04
The Supply portion mainly involves procurement and supply of New field instruments,
erection materials as detailed in the attached documents.
2.05
All Inst. & Erection materials shall be of Makes & models approved by NRL/PDIL.
Contractor/Vendor to follow Approved Sub-Vendor list attached to enquiry. Specific
approval of Owner/PDIL are to be obtained for makes outside approved list.
2.06
The Erection / Installation include Items to be supplied as per the Documents enclosed
and the free issue items.
2.07
The scope also includes residual Engineering, i.e. the Engineering involved not covered in
this Tender Documents, but essential to complete the Instrumentation job as per
requirements of basic Documents like P&IDs etc., site visits by contractor and discussions/
communications take place from time to time.
2.08
Vendors shall supply, install & commission including local cabling, cable trays etc. upto
their battery limit. All local cabling shall be terminated in Field junction boxes/local panels.
From JB/Local panel shall be taken to Main Central Control Room through Multi-core
cables. The supply of Multi-core cables shall not be in the scope of vendor.
3.00
SCOPE OF EXECUTION
Scope of execution work shall cover but not be limited to the following:
3.01
Unpacking, assorting, physical checking, cleaning & drawl of Instruments, its accessories
and erection material at contractors own stores and / or from places of storage, return of
the left over materials if necessary to owners stores with suitable return notes.
3.02
Transportation & handling of Instruments, instrument accessories & erection materials from
stores / or from places of storage to work site and / or contractors stores
3.03
Dust free & air conditioned storage of Instruments if necessary for some of the items.
2_EM163_7901_INST REQUIREMENTS_rev0
Page 3 of 14
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 4 of 14
3.04
To make arrangements for services such as transport medical, lighting canteen etc. for
working round the clock for own staff.
3.05
To arrange supply of drinking water to the contractors own staff so as to avoid personnel
inconvenience.
3.06
To make arrangement & supply of consumables like welding electrodes, industrial glasses,
cleaning fluids (such as CTC. Kerosene etc.) primer for structural. Teflon tape, insulation
tapes, sealing compound, all clamping materials for cables, tubes, trays, racks, impulse
tube like aluminum strips, screws, washers, clamps GI nuts & bolts of different sizes, cable
lugs, all identification ferrules for cables/wires structural of MS/CS .
3.07
Cutting of gaskets of various material to suitable sizes including making additional cut outs
on plane & /or to cover the existing cut outs on panels (if required) at no extra cost.
3.08
3.09
Fabrication of frames, supports, mounting stands, clamps, brackets, etc. for the racks &
trays IF APPLICABLE.
3.10
Laying & supporting of tubing on racks / trays inclusive of connection of tubes with
connectors. Tube laying shall include connection by connectors & 5% of joints by brazing if
necessary & required at few places.
3.11
Laying & supporting of multi core & single core electrical cables, multi core single core
compensating cables & any other special cables on racks/trays.
3.12
Any civil job involved in the installation of supports, mounting stands, etc. This may involve
cutting holes in walls/floors, chipping the foundations/floors & grouting and / or furnishing
after the job is over.
3.13
Testing of compensating cable & any other special cables for proper connection, continuity
& insulation.
3.14
Cleaning & painting of frames, supports, clamps, mounting stands & racks etc. ,and
retouching of painting surface of panels wherever is required at no extra cost of owner.
3.15
Base steel structures shall be painted with one coat of the red oxide zinc chromates primer
to IS:2074 (25 Microns) & two coats of synthetics enamel paint to IS:2932 (50 Microns).
Before painting the surface should be thoroughly scraped & cleaned to remove rust, grease,
plaster & any other foreign material. The quality of the paint must confirm to relevant Indian
standards & shall be approved by the consultant.
To touch up with paint all instruments mounted in the field & in the control panel with its
accessories which are scratched or damaged during handling, erection or repair without any
extra cost. The paint used shall match exactly the painted surface of the instruments or its
accessories on which touch up is done.
3.16
3.17
2_EM163_7901_INST REQUIREMENTS_rev0
Page 4 of 14
EM163-PNIN-7901-TS
3.18
DOCUMENT NO
REV
SHEET 5 of 14
Removal & re-erection of some of the instruments in panel or in field during testing and/or
calibration & functional testing if required /necessary.
NEW ITEMS
There could be new Items / erection materials or jobs not envisaged & listed in BOQ .These
generally result from Package Sub-vendor supplies or changes in supplies.
Contractor shall execute such jobs as per instructions of NRL / PDIL Site Engineer.
In such cases Unit rates shall be derived based on rates of similar items or similar type of jobs.
Either interpolated or extrapolated after mutual discussions between Contractor, NRL & PDIL site
engineer.
NRLs decision/ rate fixed after such discussions shall be binding on the Contractor.
In these cases the overall contract value limitations shall not arise.
Bidder to co-ordinate with sub-vendor supplying Radar and Servo gauges for installation,
commissioning & hookup to PLC without any extra cost.
4.00
(i)
(ii)
(iii)
(iv)
PROGRESS OF WORK
If any time in the opinion of Engineerin-charge, the contractor has fallen behind the
construction schedule, the Engineer-in-charge may, without any extra cost to OWNER
require the contractor to take such steps as may be necessary to improve his progress
(such as but not limited to )
comply overtime operations
increase the number of shifts
work on Sunday and holiday
increase his resource of deployment .
The contractor in such case, shall demonstrate the manner as to how he proposes to
maintain the construction schedule and make up the loss time period to be specified by
OWNER.
Failure of the contractor to comply with the above shall be considered a failure to executive
the contract with due diligence and then owner shall without prejudice to any other right or
remedy which shall have accrued or shall accrue thereafter, may sublet the balance job in
part or in full outside the contractors scope and get it done at contractors risk and cost.
5.00
5.01
The following describes the general guidelines for the execution and testing of works
related for the installation of instruments, control panels, accessories and to their initial
maintenance during and after installation until final checking testing and handling over to
the client are completed.
2_EM163_7901_INST REQUIREMENTS_rev0
Page 5 of 14
EM163-PNIN-7901-TS
DOCUMENT NO
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SHEET 6 of 14
5.02
The works shall be performed with perfect workmanship according to the national and
international codes and standards mentioned else where in the Tender.
5.03
The contractor will bear all expenses for repositioning and reinstalling of the instruments
accessories including those like control panels ,etc. (inside or outside control room ), in
case of any poor workmanship or wrong execution /assembly. However, the contractor shall
obtain the consultants authorization before proceeding with the same.
5.04
The contractor will bear all expenses incurred for disassembling and reassembling of
instruments / accessories for inspection and testing operation.
5.05
The supply of all types of materials required and necessary for the construction /fabrication
and installation of supports for instruments, cable conduits, control panels etc. shall be
included in the scope of supply of the contractor.
All cable tray supports shall be grinded to remove rough edges and deformities after
fabrication, sand blasted and painted as per the painting specification attached before
securely fastened in their position.
5.06
5.07
Cable trays shall be supported at a minimum interval of every 1500 mm (for 300 wide), at
every 1000 mm (for 200 wide), at every 500 mm (for 50 mm wide) trays.
5.08
All cable trays shall be fastened at a minimum of two places on each support through the
length of the trays by means of galvanized /plated corrosion resistant bolts and nuts. The
bolt head shall be round type so that they do not damage the cable sheath while pulling the
cables in the trays.
5.09
All cables shall be of single run /length only and no intermediate joints shall be permitted.
5.10
All cables shall be identified by cable markers at both ends and at every 20 Mtrs. through
the length of the cable .Individual cores /wires shall be identified using grafoplast method or
suitable color codes ferrules Wire connection shall be made using cable lugs of proper size
employing crimping Tool.
5.11
All instruments shall be protected from atmospheric agents like salt dust etc. and from any
damages caused by other contractors working in the area by suitable cardboard boxes and/
polythene bags of sufficient thickness and size properly fastened by the instrument
contractor after installation of the instruments.
5.12
The erection material mentioned in the NIT is to meet the minimum requirement for
erection/ Installation of the instrument items, however if contractor feels to include any
important item to meet site requirement same are to be included in the scope of supply. In
case any item required during erection/commissioning for completion of the work, shall be
arrange by the contractor without any extra cost to the owner.
6.00
CALIBRATION OF INSTRUMENTS
6.01
6.02
The general rules to be followed for calibration of some of the instruments are as detailed
below.
6.03
For calibration of pressure gauges, temperature gauges (dial thermometers) and other
similar local gauges the calibration shall be checked at least at five different points of the
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range span Viz., 0%,25%,50%,75% and 100%.The standard gauge employed for
comparison shall be at least 5 to 10 times better in accuracy to the gauges being calibrated.
6.04
6.05
Mercury or water manometers shall be employed for calibration check of low pressure
instruments.
7.00
STORAGE
From receipt at site until the installation of the instruments is completed, all materials
including those of erection hardware shall be kept in a store house re-wrapped in their
original weather proof packing (after site inspection)wherever possible, to keep them dry
and dust free.
The instruments /equipment and accessories taken out from the store shall be installed at
the earliest after necessary calibration, and they shall not be kept in the open without
protection for any reason.
During erection, installation all the instruments, equipment, control panels etc. shall have
weather and dust protection covering ensuring sufficient protection.
8.00
8.01
Power supply distribution to various users shall be made by the instrument Contractor
utilizing 4 Sq. mm or 2.5 Sq mm multi standard, armoured 3 core copper conductor cables.
8.02
The number of feeders available from the UPS for instrumentation systems along with their
rating will be given later on. The instrument contractor / bidder shall arrange switch fuse
units / MCBS /thermal cutouts of proper rating for each of the feeder in the instrument
cabinet connecting it to the respective loads.
9.00
9.01
The instrument contractor shall provide a high integrity grounding /earthling system for
connecting the electronic equipment .The system shall consist of two parts, one a clean
earth and the other dirty clean .Both shall be having a resistance of almost zero ohm.
9.02
All electronic systems shields and circuit grounds shall be connected to the clean earth
where as the cabinets panels etc. Shall be connected to the dirty earth.
9.03
The number of electrodes to be provided and their location will be dependent on the earth
resistance achieved. In any case the number shall be such that the resistance obtained is
almost zero.
10.00
FIELD INSRUMENTS
10.01
The selection of location for field mounted instruments such as gauges, indicators,
transmitters transducers etc. shall be based on :
-- avoidance of excessive heat and vibration
-- avoidance of mounting directly beneath drain points and above vent points.
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10.03
10.04
10.05
10.06
10.07
10.08
The gauges both pressure as well as temperature shall be mounted on brackets on the
walk way ( for valve manifolds ).In case where more than one gauge / indicator have to be
mounted in one location small stainless steel gauge boards shall be used for mounting the
gauges supported by fabricated standpipe / paddle securely fastened to the base
structures. SS impulse tubing with compression joints of stainless steel shall be used for all
impulse tubing including that of pressure gauges and transmitters.
Junction boxes shall be installed in an easily accessible location on the walk ways of valve
platform so as to facilitate maintenance ease.
All junction boxes shall have markings of the tag number / identification number of the JB
.On the front cover along with the multi core cable number being terminated in that
particular JB.
While terminating cables inside junction boxes it shall be ensured that sufficient length of
free excess cable is coiled inside after glancing for subsequent modification and or recrimping.
All cores as well as shields shall be terminated on the junction box at proper terminal points
without leaving any cores / shields loose.
All cables shall have tags tied to them with them origin identification (single pair) destination
identification (multi core cable).
The covers of junction boxes shall be perfectly closed after installation termination, testing
and final check are over and the screws ,gasket etc. shall have a coat / layer of grease on
them before fixing to avoid, rusting, infiltration of moisture, dust etc.
11.00
SUPPORTS
11.01
The brackets, pedestals, standpipes, frames and other structural steel items used for
supporting instruments, junction boxes, cable trays, conduits and various other instrument
installation shall be prefabricated at the site works / workshop of the instrument contractor.
Before moving them to the location for installation they all must be cleaned thoroughly from
rust slag and other dirty materials painted with epoxy primer two coats (rust proof) and then
with two coats of epoxy based paint (gray).
11.02
Type and exact dimensions of supports shall be decided during erection as per the
requirement and general sketches can be obtained from the consultants during
engineering. Sketches made by the bidder shall have consultants approval, or in case of
site fabrication without sketches approval shall be obtained from the site engineer of owner.
11.03
Primary connections shall be made as per the installation drawings attatched. Only
stainless steel tubing and compression joints of SS 316 shall be used for impulse tubing.
All threaded fittings (other than the compression joints) shall be provided with Teflon band
sealant on the threads.
11.04
11.05
11.06
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11.07
Power cables and Instrument Signal cables (including those of descrete signals) shall be
laid on different trays as per IEC norms.
11.08.
The following shall be compiled with while installing pneumatic tubing and impulse tubing:
-- Joints shall be through unions / straight connectors only.
-- When a tube is cut any flash, extra material inside which could reduce the cross section
has to be eliminated before making the connection by union or any other compression joint.
-- The threads of fittings shall have a Teflon sealant (taped) on the non compression joint
end.
-- In case if a joint fails due to non positioning and /non seating of ferrule properly the tube
shall be cut & a fresh joint shall be make with fresh ferrules and other components .Once
used ferrules / components shall not be used again.
11.09
Grounding of field equipment/ instrument, local panels & large size electrical equipment
shall be connected to general grounding network by 16 mm2 copper wire with PVC
insulation.
All instrument casting /body with IS circuits shall be connected to the general grounding
network by 6 mm2 copper wire PVC insulated.
The insulation cover of the grounding wire shall be green.
12.00
ELECTRICAL CONNECTIONS TO THE FIELD INSTRUMENTS :Each electrical wire connected to the instrument terminal strip shall be provided with
suitable lug, terminal number / wire number, indicating the destination details etc. with
ferrules. Shields of all cables shall be insulated & left floating at the field end.
All wiring has to be adequately supported near the terminal point to prevent the terminal
connection from supporting the cable. Wiring shall be tested after installation to confirm that
the wire are not grounded shorted or open. these tests shall be conducted before the
instruments proper are connected.
All cable shall be laid in one piece only, with interruption from control room to JB or from
individual instrument location to JB or from control room to individual instrument location
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CONSUMABLE
13.00
The instrumentation contractor shall include in the scope of supply the following
consumable in required quantities for proper execution of instrumentation work. The list
shall not be treated as a complete list. It is the responsibility of the instrumentation
contractor to include all materials required for proper installation of all systems without any
extra charges to the Consultant / Owner.
Sl.
1.
Description
Size
2.
3.
Interlocking type identification ferrules made from Suitable for core size 0.5, 1.5. 2.5, 4.0
high grade PVC of yellow colour with black and 6.0 Sq.mm
engraving, marked with alphabets from A to Z,
numericals from 0 to 9, +ve, -ve etc.
PTFE sealing tapes
10- 25 mm width
Rag bolts, washers and nuts (M.S.Galvanised)
M10 X 100, M10 x 150, M12 x 100
4.
5.
6.
7.
Metallic conduit
8.
9.
10.
11.
Insulation Taps
12.
Cleaner Solution
13.
M6 X 20, M6 x 40,
M6 x 6 M6 X 65 & above
M15 x M15 X 30 Nuts suitable for M12
OBA X //, 2BA x 1//,
4BA x 4 BA X // , 4BA x 1//,// BS
// BSW x// BS
// BSW x 1// x //
20 (0.3 mm ) X 1.6 ( 0.2 mm ) as
required.
14.00
14.01
The work being executed by the contractor will be subject to phase wise & periodical
inspection & testing by the consultant, owner or their representative. The contractor shall
bear all expenses for such tests & inspection.
14.02
Tests/inspection shall include all those procedures and operations necessary to ensure that
the instruments have been perfectly installed & interconnections made correctly. These
tests/inspection shall be taken up as and when a work or portion of work is completed by
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the contractor & offered for inspection in writing by the contactor. More guidelines on
checking, testing and calibration are described in the subsequent pages.
14.03
If the work do not correspond to the technical requirements as spelt out in the specification,
drawings, documents instruction manuals or not executed with perfect workmanship (in the
view or in the opinion of the consultant, owner or their representative) the inspecting officer
/consultant will give oral/written instruction for elimination of the defects. The contractor will
rectify/redo the work at no extra cost to the consultant /owner.
15.00
16.00
17.00
FUNCTIONAL CHECKING OF LOOPS / CIRCUITS :This operation involves actuation/ simulation of all initiating points (switches both process
as well as manual) and checking the operation of the valves for the correct functionality
along with the status indication /alarm on the shutdown/ alarm systems and/ or pressure
panels in the control room.
18.00
TOOLS TACKLES CALIBRATION & TESTING EQUIPMENT : The contractor shall make all necessary arrangements regarding tools, tackles, calibration
instruments & testing equipment required for proper execution of the work awarded to him.
A list of calibration & testing equipments to be maintained at the worksite/workshop of the
contractor within the project site during the complete execution of the job is given below.
This list is by no means complete and any additional test equipment and/or calibration
equipment found necessary the contactor shall arrange the same at no extra charge to the
owner/consultant.
a) Digital multi-meter / tester
b) Loop Tester/calibrators (portable)
c) Smart calibrator / configurator/ smart transmitter
d) Mercury / water manometer
e) Portable field calibrator (if necessary)
f) Precession calibrator manometer
g) Dead weight tester (hydraulic)
h) Standard pressure gauge
i) Thermostatic temperature bath
j) Standard test gauge for temperature.
k) Signal generator mA, mV and pulses
l) Manual hydraulic pump for hydro testing of impulse tubing
m) Decade resistance box
n) DC power supply
o) Meggar for insulation check
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Mechanical Items:
a)
Cranes, winches, chain pulley blocks etc. in required quantity and of suitable capacity.
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
19.00
19.01
All other items such as control / shut off / remote operated valves, level transmitter (DP type
/ displacer type/float type etc) and on line instruments shall be calibrated and function
checked before pre commissioning activities start.
19.02
The instrument contractor shall submit the calibration functional check and loop test reports
as per the prescribed calibration and test formats given by the consultant PDIL to the
successful bidder.
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a)
----b)
Process connections: All process primary connections impulse tubing and fittings including
those of manifolds of pressure gauges and transmitters shall be subjected to a hydraulic
test and the testing pressure to which the impulse / primaries are connected .After hydro
test process connections shall be drained and blown with air to remove water particles.
c)
Pneumatic tubing leak test: All pneumatic tubing connections and joints shall be subjected
to a pressure test by sealing a pressure in each loop and checking with soap solution on all
joints .Also including a pressure gauge in each loop the drop in seal pressure can be
observed and if no drop is noticed the connection may be passed.
d)
All pneumatic tubing and supply lines shall be blown with air for removing dust, dirt moisture
from the lines before taking up the above test procedures.
21.00
----
----
Visual check: Before testing of any instruments starts a visual check shall be made to all
instruments, equipment and their accessories to verify.
Paintings, greases oil etc. are done wherever required and covers of JB fixed properly.
All supports work is complete and the instruments and accessories fixed correctly.
Instruments, equipment and their connections have not been damaged during erection by
own or other contractors.
Instruments and equipment are free of dust, debries moisture or any other harmful matter.
The instrumentation shall be considered ready to be connected for process operation only
after completion of the following.
Check of the calibration of instruments and equipment calibrated before erection. in the
case of transmitters and receivers zero span (range) and the mid point will be rechecked.
Check for the proper functioning of control valves shut off valves and remote operated
valves as per the loop circuit.
Check set point of pressure switches, temperature switches, electronic switches and
operation of manual push buttons, limit switches etc, for alarm, shut down or start /open
/close sequence logics and other enable / inhibit interlocks.
Set pressure regulators of instrument air supply to ROVs.
Check of regular function of UPS and electrical supply to individual works.
Performance test of alarm and sequence logic / safety systems, various function check
push button stations, limit switches, electronic switches, pressure, temperature and other
switches, solenoid valves etc to verify proper operation of the systems.
Calibration check and pop-up test of safety / thermal relief valves.
FREE SUPPLY BY NRL :
Construction power, water shall be provided by NRL as given below
Free Water Inside Plant premises at single point
Free Instrument Air Inside Plant premises at single point
Power Single Phase 230 V/50 HZ NON-UPS Inside Plant premises at single point
Power Three Phase 440V NON-UPS Inside Plant premises at single point
Materials to be supplied by the contractor for the execution of jobs at his own cost, as
part of this specification -
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The procurement and supply in sequence and at the appropriate time of all materials and
consumables shall be entirely the contractors responsibility and his rates for execution shall
be inclusive for all these items. These are as but not limited to the following :A. All industrial gases like Oxygen, acetylene or inert gases, compressed air and all types
of welding electrodes, brazing rods, flux etc. for welding purpose with necessary facilities
for testing the welded joints.
B. All equipments with required accessories for Welding, pipe bending, tube bending, lifting,
installation, transporting material shall be in the scope of erection contractor.
C. PTFE tape and other pipe jointing compounds for threads and material for sealing of
cable entries to control room, local panels, insulation tapes, sealing compounds for
flame proof conduit fittings.
D. Bolts and nuts for supports, U-bolts with nuts, clamps for tubes and pipes, anchor bolts
for panels, expansion bolts (pinch anchor/raw bolts) of various sizes for fixing to
concrete structures. Polythene bags for protection of instruments against rain.
E. Paints, primers and solvents.
F. Plastic tags for identifications of tubes/wires at panel junction boxes.
G. All materials for minor civil works like grouting etc.
H. Structural steel, MS Plates, GI plates, flats, pipe etc. required for fabrication or
instruments supports and tray supports wherever required if listed in BOQ.
I.
Spool pieces, jigs, fixtures, blinds & other accessories for testing as needed.
J. Any other item not specified, but required for the completion of the job.
The contractor shall submit in sealed cellophane packets samples of all consumables like
bolts, nuts, lubricants, ferrules lugs and any other material included in their scope of supply
for approval of Engineer-in-Charge which then forms the standards for erection work.
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14.09.2015
--
HK
RA
SKT
21.07.2015
--
HK
RA
SKT
23.06.2015
--
HK
RA
SKT
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
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CONTENTS
SECTION NUMBER
DESCRIPTION
1.00
Scope
03
1.01
Environmental Conditions
03
1.02
03
2.00
General
03
2.01
Electronic Transmitters
04
2.02
Flow Measurement
06
2.03
Level Measurement
07
2.04
Pressure Measurement
08
2.05
Temperature Measurement
09
2.06
10
2.07
Safety Valves
12
2.08
13
2.09
15
2.10
Pneumatic-Instruments Supply
15
2.11
Process Connection
15
2.12
Electric-Instruments Supply
16
2.13
17
2.14
Specific Requirements
19
2.15
Notes
Annexure I
Annexure II
SHEET NUMBER
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21
23
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1.00
SCOPE
This document defines the Design Philosophy, Standards, Engineering practices to be
followed during detail engineering activities for the installation of 4 nos. of new Mounded
Bullet of capacity 1760.56 m3 each along with associated Utilities & Offsite facilities
inside the Numaligarh Refinary Limited Assam .
1.01
1.02
Environmental Conditions
Climate
[X]
Relative Humidity
[X]
Atmosphere
[X]
[X] EN (CENELEC)
[X] PTB
[X] FM
[X] UL
NOTES
1. Petroleum And Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur or Director General of Mines Safety (DGMS) in
India certificate shall be furnished for all intrinsically safe and Flame proof
enclosures.
2. For locally manufactured Flame proof enclosures, testing shall be carried out
by CMRI/ERTL in addition to certificate of Petroleum And Explosives Safety
Organisation (PESO)/ Chief Controller of Explosives (CCE), Nagpur
2.0
GENERAL
-Instrumentation Numbering Philosophy [X]
for Instrument Tag Nos.
-Control Room/Control Panel
[X]
[X]
[X]
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[X]
[X]
[X]
[X]
IEC / ISA
- Multicables
[X]
[X]
[X]
- Safety valve rule
(Refer Mechanical)
[X]
[X]
[X]
[X]
- Electric Supply
- Engineering Std.
[X]
[X]
[X]
English
- Temperature
[X] M.K.S.
[X]
C
- Flow-liquid
[X]
M3/Hr
- Gas
[X]
- Steam
[X]
KG/Hr
- Mass
[X]
KG/Hr
[X]
[X]
[X]
[X]
0-100%
mm & Meter
Kg/cm2g
Kg/cm2 A / mmWC
Level - Process
Tank /Bullet
Pressure
Vaccum
Interconnection/Communication between
mounted near base of Bullet.
pkg.
[X]
API-RP-520
ASME-SEC.VIII & I
IBR for steam, BFW (Wherever
applicable)
Existing System for existing transfering
pumps
110 V AC Ungrounded UPS
All applicable International Std.
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Insts./Radar/Servogauge
Panel
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2.01
Electronic Transmitters
Type
[X]
[X]
Signal
[X]
Precision
[X]
Rangeability
[X]
1 : 100
Circuit
Enclosure Execution
[X]
[X]
Body Material
Housing Material
Process Connection
Manifold (Supported on
2 Pipe mounting)
[X]
[X]
[X]
[X]
[X]
SS
Housing Die-Cast Aluminium Epoxy Painted
1/2 NPT F through oval flanges
Integral 3 Way Valves for Diff. Pr. Tr.
Integral 2 Way Valves for Pr. Tr.
Power Supply
[X]
2 Wire System
Electric Connection
[X]
Local Indicator
[X]
[X]
[X]
Required - Digital
All flow transmitters shall have square root
extraction function
Yes
Programming Unit/
Calibrator
[X]
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2.02
Flow Measurements
i)
[X]
[X]
[X]
Calculation
[X]
Tapping
[X]
[X]
[X]
[X]
Type
[X]
Accuracy
[X]
0.10% or better
Sensing element
[X]
Flanges
ii)
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2.03
Level Measurements
i)
Level Transmitters/Controllers
Type and Selection for
Bullets / LPG storage
Vessels
[X]
[X]
[X]
[X]
[X]
[X]
[X]
Body Material
[X]
Electric Circuits
[X]
Enclosure Execution
[X]
IP-65 min.
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Process Connections
[X]
Electric Connections
Installation
Inventory
Management
[X]
[X]
[X]
[X]
Manufacturer Std.
1/2 ANSI (NPT F), SS Plugged
Direct
With complete software package
ii )
2.04
Pressure Measurements
i)
[X]
Sensor Material
[X]
Dial
[X]
150 mm min.
Case
[X]
Zero adjust
[X]
Process connection
[X]
Precision
[X]
+/- 1% F.S.
Glycerine filling
[X]
Other accessories
[X]
As required
[X]
[X]
ii)
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2.05
Temperature Measurements
i) Field mounted gauge
Type
[X]
Dial
[X]
Enclosure Execution
[X]
[X]
IP-55
SS min
Element
[X]
Type
[X]
[X]
[X]
[X]
Sheath Material
Temperature transmitter
Temperature transmitter
iii) Thermowell
Type
Required
[X]
[X]
Remote
Location - field
[X]
Well Material
[X]
Flange Material
[X]
Process Connection
[X]
[X]
Other
[X]
[X]
Head Execution
[X]
IP-65
Electric connection
[X]
[X]
[X]
[X]
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be
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2.06
Standard
[X]
DIN 43760
Element
[X]
[X]
Sheath Material
[X]
No of temperature
l
t
Installation
[X]
[X]
In Thermowell
Nozzle
[X]
2 Flange 300#
[X]
ISA S 75.01
Base Type
[X]
[X]
[X]
[X]
Process Connection
Leakage Class
[X]
[X]
[X]
Body Material
[X]
Trim Material
[X]
[X]
[X]
Piping Connections
Minimum Rating
[X]
[X]
Actuator
[X]
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[X]
[X]
Positioner
[X]
[X]
[X]
[X]
[X]
3~ 15 Psi
[X]
Yes with
positioners
positioners
Accessories
Valve travel time
Valve Tubing
[X]
[X]
[X]
[X]
Solenoid
[X]
[X]
Solenoid Valve enclosure
Limit Switch
Handwheel
Noise level limit
ROV Operation
[X]
[X]
[X]
[X]
[X]
[X]
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Safety Valves
Sizing
[X]
[X]
Type
[X]
Bonnet construction
[X]
[X]
[X]
Body and Bonnet Material
[X]
Lifting Lever
[X]
Test Gag
[X]
Bellows requirement
[X]
[X]
For all
for relief into closed flare and slowdown
systems, if the developed back-pressure
exceeds 10% of the set pressure
specified where leakage of gas from the
seals not permitted during normal plant
operation
Piping Connections
[X]
Flanged
Spring
[X]
[X]
[X]
[X]
Blowdown
[X]
[X]
[X]
[X]
EM163_INST_DESIGN_PHIL_Rev P.docx
Between 5% to 7%.
For steam services under Power Boiler
Code as per ASME the blowdown shall
be 3% - 4%.
API 526
For thermal relief of accumulated
liquids in pipelines and vessels 1x2
size valves shall be used in general.
Thermal relief valves shall also be
flanged
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2.08
[X]
[X]
[X]
[X]
Cable entry to control room
[X]
[X]
Cable Trays
[X]
Secondary Cables
[X]
On cable tray
[X]
Insulation Grade
[X]
[X]
600 V/1000 V
It shall meet insulation resistance, voltage
and spark test requirements as per BS5308 Part-2.
Cables
[X]
[X]
[X]
Conductors
EM163_INST_DESIGN_PHIL_Rev P.docx
[X]
[X]
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 14 of 23
Insulation
[X]
[X]
Armouring
[X]
[X]
[X]
[X]
[X]
Pair/Triad Identification
[X]
Shielding
[X]
[X]
[X]
Core Insulation
[X]
Junction Boxes
Type
[X]
[X]
[X]
[X]
Material
Cable Glands
Cable Glands type
[X]
[X]
[X]
[X]
[X]
[X]
Note : Junction Boxes and cable glands will be certified according to CENELEC/IS Codes.
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 15 of 23
2.09
[X]
Remote
Impulse Piping
[X]
[X]
Paving/platform/column
Material acc. to line spec.
[X]
Impulse Tubing
[X]
[X]
[X]
[X]
[X]
[X]
Note: Pipe fittings shall be standardized in two ratings of 30000 lbs and 60000
lbs. Higher ratings wherever applicable as per pipe class.
2.10
2.11
[X]
Min. 4 Kg/cm2 g
Max. 6 Kg/cm2 g
Dew Point
[X]
[X]
Process Connection :
a) First tapping points for all pressure, d/p signals shall be 3/4 NPT. Mechanical piping
scope shall be upto 1st isolation valve(s). Subsequent reduction to 1/2 size and
impulse piping and connection shall be under the scope of instrumentation.
Mechanical scope shall be upto reduction to NPT size.
b) Wherever diaphragm seals have been used, the vessel or piping nozzle shall be 3
flanged. Flange rating shall conform to piping index.
c) All vessel or piping nozzles for temperature instruments shall be 1 1/2 flanged or 1
NPT(F) threaded.
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 16 of 23
2.12
110V DC
24V DC*
110 V AC
Non UPS
230 VAC
50Hz
a)
Distributed Digital
Control system
[X]
[ ]
[ ]
[ ]
[ ]
b)
PLC
[X]
[ ]
[ ]
[ ]
[ ]
c)
Relay based
[ ]
Interlock & Shutdown system
[ ]
[X]
[ ]
[ ]
d)
Solenoid Valves
[ X]
[ ]
[ ]
[ ]
[ ]
e)
I/P, Transmitters,
Voltage
[ ]
[ ]
[X]
[ ]
[ ]
f)
[ ]
[ ]
[X]
[ ]
[ ]
g)
Analysers and
Analyser System
[X]
[ ]
[ ]
[ ]
[ ]
h)
Level
Gauge
illumination
[ ]
[ ]
[ ]
[ ]
[X]
i)
[X]
[ ]
[ ]
[ ]
[ ]
Note-a: 24 VDC wherever required shall be provided with Redundant Bulk Power
supply unit with diode O-ring.
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 17 of 23
2.13
The following additional Standards shall be used/and taken into account during instrument
engineering and design.
OISD-GDN-144
IEC 13
IEC 534
IEC 584
Thermocouples
IEC 605
IEC 751
IEC 801
IEC 848
IEC 902
ISA S-5 .1
ISA S-5.2
ISA S-5 3
ISA-S20
ANSI/ISA S 5.1
BS 6020
DIN 3582
DIN 43760
DIN 19243
EN-50-014/020
EN 54 Part I
EN 54 Part 5
ISO 3511.1
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 18 of 23
ISO 3511.2
ISO 3511.4
ISO 4200
ISO 5167
API RP 520
API RP 521
API RP 2000
Chapter 6.2
Chapter 6.6:
Chapter 12:
Part 1 and 2
API-RP-550
ANSI - B 16.104
ISA-S 75.01
ISA S 18.1
IEC 529
ANSI B 2.1
Pipe threads
ANSI B 16.5
IEC 79.11/
IEC-79.14
IS 2148
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 19 of 23
Enclosure
[X]
[X]
3 wire transmitters
[X]
[X]
Detectors to be connected to
new PLC system
[X]
[X]
[X]
Stainless Steel
[X]
[X]
a)
[X]
Separate electrical
b)
Signal earth
[X]
c)
Barrier earth
[X]
(Only for Zener barriers, if applicable)
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 20 of 23
2.15
Notes:
1) Integral manifold shall be used for DP type flow Transmitter. Piping & SS Tubing shall
be used for Impulse lines. SS tubing shall be used between integral manifold &
transmitter. Impulse line val ves shall be gate type.
2) 1/2 SS isolation valve for each pneumatically operated instrument shall be provided.
Main Header line shall be of minimum SS irrespective of the piping material
specification.
3) For Trip Solenoid Valves, FMR (Field Manual Reset) is required at field.
4) For flow, level, Pressure & Temperature instruments, only transmitters shall be
connected directly to system for monitoring, controlling & generating alarm in DCS.
Similarly for PLC shutdown loops also, only transmitters (4 20 MA) shall be used &
the same shall be connected to PLC as AI. No direct switches shall be used. For
pump seal vessel also, only level transmitter shall be used.
Three transmitters shall be used for critical closed loop control and for all trips.
5) Thermowell flange rating shall be 300# as a minimum or better as per piping/ rating.
Flange & thermowell material shall be ASTM A 182 Gr.F316 as a minimum or better as
per piping class. This philosophy is followed for licensed as well non-licensed units.
Thermowell shall be single bar stock. Duplex type thermocouples shall be used.
6) For split range control, two I/P converters shall be used.
7) Mass flow meter shall be provided with back pressure control with necessary block
& bypass valves. Back pressure control shall be carried out through separate
transmitter and control valve.
8)
PLC and DCS earth grids shall be separate, Earth grid shall be formed by integrating more
than one earth pit.
As a minimum two earth pits shall be connected to one grid.
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 21 of 23
Annexure-I
New PLC system in existing NRMT Control room:
A new PLC system with existing Panel room and Operator Cabin room at field is required. Both the
control and shutdown philosophy shall be implemented in PLC system.
The control system scheme is attached herewith for reference. (Refer Annexure II)
The proposed system configuration is enclosed for reference.
Installation:
a. At field:
Operator Cabin Room: where the new signals from mounded bullet plant shall
be hooked-up.
One operator console for operation and control of all the process parameters like
level (2 Nos. i.e. one servo and one radar, ROVs, Deluge valves etc.).
The Engg cum operator console at NRMT control room and the console at
Operator cabin should be independent. Client Server configuration will not be
accepted.
b. At NRMT control room:
The NRMT panel room is also exhausted for new panels. However existing glass
partition to be extended suitably to accommodate new PLC panels (4 Panels
tentative).
There is no space for additional hardware console in NRMT.
Switches/PBs/Lamps etc. required for Hardware control to be mounted on the
existing control desk of NRMT Control Room by replacing existing
components/faci plate to maintain the aesthetics of existing configuration.
Auxiliary hardware console of the proposed control system (which will be hooked
up with the DI/DOs of control system of the satellite rack room via multi core/pair
cables). This console will consist of H/W selector switches/ push button for ROV
operation, indication lamp (open/ close feedback of ROVs/ valves), emergency
switch etc. as applicable. Operation and monitoring of ROVs/ deluge valves will
be carried from this console.
Redundant HMI/ workstation of the control system (which will be hooked up with
the control system of the satellite rack room via redundant FO cable network) for
GUI of the entire control/operation of the plant. One will be operator station and
other will be Operator cum Engineering station. The Operator cum Engineering
station will be server grade machine with redundant power supply and redundant
storage (RAID). Both the HMI will be independent. Failure of one HMI should not
affect the other HMI. Operation and monitoring of ROVs/ deluge valves including
all other field instruments will be carried from these HMIs through GUI.
Additionally entire system related engineering/ configuration will be carried out
from the Operator cum Engineering station
Redundant HMI/ workstation for TFMS. Atleast 2 independent system should be
provided for redundancy. Failure of one system should not affect the other
system.
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 22 of 23
c. At TFMS:
For Inventory Management, TFMS is required by Operations. Hence One Radar
Level Transmitter for each Bullet shall be independently connected to the
existing TFMS system available at NRMT Control Room.
MODBUS connectivity via OFC required from TFMS connecting radar gauges
for mounded bullet to Refinery DCS (CCR).
At present no MODBUS connectivity for the existing TFMS system to/from the
new PLC system is envisaged.
Note:
One dedicated 5KVA feeder shall be provided from the existing/ new UPS by NRL.
EM163_INST_DESIGN_PHIL_Rev P.docx
EM163PNIN070100
Page23of23
ANNEXUREII
Controlsystemschemeformoundedbullets
LevelXMTRs
(Servo)
LevelXMTRs(Radar2)
LevelXMTRs(Radar
1)
Analogprocess
value(AI)
Analogoutout(AO)
Valveopen/close
cmnd
Valveopen/close
feedback
Open/close/ESD
switches
FieldSide
DedicatdTFMS
NewPLC
(RedundantuptoI/O)
(SIL3)
(Inventorymanagementsystem)
Expansionofexisting
RedundantMODBUSconnectivity
withexistingDCS
A.AtNRMTcontrolroom:
1.DedicatedEngg.CumoperatorconsoleforPLCprogramming,operationandmonitoringofallthe
processparameterslikelevel(2Nos.i.e.oneservoandoneradars),ROVs,Delugevalvesetc.
RedundantMODBUS
connectivitywith
existingDCS
2.TFMS(expansionofexisting)forinventorymanagement.
Redundantcommunication
(PLCvendorspecific)
3.Hardwareconsole:Hardwareconsole:Thereisnospaceforadditonalhardware
console.Switches/PBs/LampsetcrequiredforHardwarecontrolshouldbemountedontheexisting
controldeskofNRMTControlRoombyreplacingexistingcomponents/faciaplatetomaintainthe
astheticsofexistingconfiguration
(PLCvendorspecific)
Newcabinetroom/SRR
Redundantcommunication
4.ExistingDCSconsole:.ExistingDCSconsolewillberetainedaccomodatingthenewsignalsviamodbus
connectivity.
TFMSconsole
WithTFMSpackage(Engg.Cum
monitoing)
FOcables
(new)
Expansionofexisting
Hardwareconsole
Lampindication
PB/Switches
Foroperation/monitoringofROVs
anddelugevalves
Engg.Cumoperatorconsole
WithPLCprog./Graphic/alarm
loggingpackage
Viewing/controlofallthe
parameters
Referpoint3
New
B.AtNRMTControlRoom/newcabinetroom
1.NewPLCpanels.
2.InterfacingdevicesofTankFarmManagementsystem(TFMS)(fornewsystem).
12Pair
signal
cables
Existing
D.Atoperatorcabin:
1.Oneoperatorconsoleforoperationandcontrolofalltheprocessparameterslikelevel(2Nos.i.e.one
servoandoneradar,ROVs,Delugevalvesetc.).
2.TheEnggcumoperatorconsoleatNRMTcontrolroomandtheconsoleatOperatorcabinshouldbe
indepenent.ClientServerconfigurationwillnotbeaccepted.
Centralcontrolroom
CCRexistingDCS
Operatorcabin
Operatorconsole
WithGraphicpackage
Viewing/controlofalltheprocess
parameters/valvestatus
New
EM163-P
PNIN-7901-PA
ART B
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTB
DE
ETAIL EN
NGINEE
ERING O
OF
TECHNICAL
L SPECIF
FICATIO
ONS
OR PROC
CUREMENT AN
ND
FO
INSTALL
LATION / COMM
MISSION
NING OF
INST
TRUMEN
NTS
Job
b No
: EM
M163
Pro
oject
: IN
NSTALLA
ATION OF MOUNDED BULL
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
Clie
ent
: NR
RL
24.09.2015
5
--
CLIENTS COM
MMENT INCO
ORPORATED
H
HK
RA
A
SKT
14.09.2015
5
--
CLIENTS COM
MMENT INCO
ORPORATED
H
HK
RA
A
SKT
21.07.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
EM163-E-7047
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
RADAR TYPE TANK LEVEL TRANSMITTER
(NON TFMS)
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7047
COMMENTS INCORPORATED
COMMENTS INCORPORATED
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7047
ENQUIRY SPECIFICATION FOR
RADAR TYPE LEVEL TRANSMITTER
(NON TFMS)
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL. DRAWINGS/
NO. DOCUMENTS.DESCRIPTION
1
2
3
4
5
15
ATTACHMENT NO.
/
DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7288
09
EM163-7047-ISP7288
02
EM163-7047-SP-7288
01
EM163-7047-BOQ7288
EM163-PNMV-DD45W-101/102/103/104
01
01
EM163-E-7047
ENQUIRY SPECIFICATION FOR
RADAR TYPE LEVEL TRANSMITTER
(NON TFMS)
DOCUMENT NO
SHEET 3 OF 3
SL.
NO.
1
2
3
4
TAG NO.
45-LT-3002
45-LT-3005
45-LT-3008
45-LT-3011
P & ID
QTY
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
01
01
01
01
EM163-45- 102
Document No.
Sheet 1 of 1
Rev.
GENERALCONDITIONS
1.0 SITE METEROLOGICAL DATA
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
90 mm
Wind
Wind code
Seismic Factor
Elevation
36 km/hr
10
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES - 7288
DOCUMENT NO.
REV.
SHEET 1 OF 9
ENGINEERING SPECIFICATION
FOR
RADAR GAUGES
24.09.15
HK
RA
DDCPN
CISC
EFF
DATE
SKT
14-03-06
REV
REV
DATE
DHPV
PURPOSE
PREPD
REVWD
APPD
ES - 7288
DOCUMENT NO.
REV.
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
INSPECTION , FACTORY
TESTS AND APPROVAL
4.0
PACKING
5.0
IDENTIFICATION AND
MARKING
6.0
SPARES
7.0
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES - 7288
DOCUMENT NO.
REV.
SHEET 3 OF 9
1.00.00
General :
1.00.01
This general specification is applicable for the radar gauges of top vessel mounted
type.
1.00.02
1.00.03
2.00.00
General Requirements :
2.00.01
2.00.02
2.00.03
Gauges shall be suitable for storage, handling & outdoor installation in wet tropical
Coastal Climate.
2.00.04
The ambient conditions if not specified otherwise in data sheets shall be min
- 40 degrees & max 70 degrees Centigrade, Relative Humidity upto 100 %.
Instruments shall be suitable for such conditions.
2.00.05
2.00.06
2.00.07
2.00.08
Flanges up to and including 600 # shall have raised face with concentric
serrations.
2.00.09
All flanges of rating 900 # and above shall have RTJ facing. All RTJ flanges shall
have groove corresponding to octagonal metal ring gaskets as per ASME B 16.20
2.00.010 In order to have antistatic construction Gaskets used if any shall be metallic or
SS304 with fibre filling for RF flanges. Ring Gaskets if any shall be octagonal
Rings of soft Iron.
2.00.011 Orientation of connection, rating, flange facing and flange face distance shall be as
sheets enclosed.
ES - 7288
DOCUMENT NO.
REV.
SHEET 4 OF 9
2.00.015 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating
2.10.00
2.10.01
2.10.02
2.10.03
2.10.04
Cable entries shall be with metallic plugs to prevent ingress of external matter.
2.10.05
2.10.06
Cable entries shall be NPTF, for Signal outputs & Power supply cabling.
2.10.07
Metallic plugs shall be provided at all cable entries to prevent ingress of external
matter till cabling at site is completed.
2.10.08
3.00.00
3.00.01
The device must use Frequency Modulated Continuous Wave (FMCW). Radar
technology which measures level based on elapsed time between send/receive of a
fixed frequency signal, (pulse or time domain) shall not be used for high performance
tank gauging. Incremental phase evaluation shall not be used since it can lead to
significant level gauging errors.
3.00.02
The radar gauge shall have a digital reference to ensure accuracy and stability.
Analog delay lines suffer from temperature and aging effects and shall not be used.
3.00.03
The RTG shall be capable of having dual, independent and galvanically isolated
gauge electronics, enabling built-in redundancy, dual level outputs or a combined
level gauging and alarm handling.
3.00.04
The RTG shall have a separate safety function suitable for use in Safety
Instrumented Systems (SIS). The function must be certified by a third party to at a
minimum meet Safety Integrity Level 2 (SIL 2) requirements as per IEC 61508.
3.00.05
The RTG subparts (antennas, electronics, housing etc.) shall be designed in such a
way that they can be freely interchanged, without recalibration.
3.00.06
The gauge shall be able to operate in a stand-alone mode (single gauge installation)
or in a network of up to at least 16 gauges and operator interface workstations in the
control room. Level update time shall not exceed one (1) second in the field data
concentrator. The standard fieldbus communication shall have a baud rate of at least
ES - 7288
DOCUMENT NO.
REV.
SHEET 5 OF 9
4800 Baud.
3.00.07
The RTG shall be equipped with dual memory banks enabling reprogramming and
configuration under continuous operation.
3.00.08
For high pressurized vessel and high accuracy applications, an optional pressure
transmitter for vapor space pressure measurement shall be incorporated into the
Radar gauging system. The pressure input shall be used by the RTG for automatic
compensation of the level indication in the field itself due to changes in vapor density.
3.00.09
The vendor shall provide at least one verification pin for the still-pipe to permit on-line
field verification of the level measurement while the tank is in operation. During
verification, the normal level reading shall also be available. A device for end-of pipe
measurement verification shall be provided.
3.00.10
The vendor shall provide an optional isolation valve at the gauge head to provide
increased safety.
3.00.11
A perforated steel pipe guided radar waves to ensures the safe measurements
undisturbed by the structures in the tank and possible boiling of the liquid gas.
3.00.12
The gauge shall be microprocessor based with inbuilt software for calculation of
densities, level; from Vessel / tank strapping tables; extensive diagnostics to detect
faults in the system, etc. and have safeguards to prevent damage to radar.
3.00.13
3.00.14
The transmitter shall have a local level indicator either inbuilt in the same casing.
3.00.15
Indicator at radar gauge casing shall have digital displays for level, calculated
volume, density, etc - in engineering units and diagnostic messages / alarms.
3.00.16
3.10.00
Outputs :
3.10.00
3.10.02
3.20.00
Remote Indicators :
3.20.01
3.20.02
3.20.03
3.20.04
Cable entries shall be 2 nos., NPTF, one for incoming & other for outgoing.
Metallic plugs shall be provided to prevent ingress of external matter till cabling at
ES - 7288
DOCUMENT NO.
REV.
SHEET 6 OF 9
site is completed.
3.30.00
Still well / pipe : Vendor shall furnish detailed dwgs of recommended still well /
pipes for correct installation of the instrument.
3.30.01
In case Still wells under equipment fabricator scope ( excluded from radar gauge
vendor scope ),equipment fabricated are to be supplied with necessary information
and vetted by OEM of radar gauge (OEM to spell out clearly all necessary
accessories for mounting the gauge).
3.30.02
Accessories like reflector kit, reference pin etc. shall be supplied along with the
radar.
4.00.00
4.00.01
If specified in data sheets, vendor scope shall include their proven software for
Tank farm management for inventory monitoring.
4.00.02
4.00.03
For this purpose all Servo gauges, if applicable, radar gauge shall be serially linked
& connected to the PC. Vendors software shall enable access to all data- level,
density , temperature, calculated values such as Volume being filled-in / pumpedout, total hold-up volume, filled capacity , etc.,
4.00.04
4.00.05
4.00.06
Software shall generate dynamic Graphic pages showing all details of tanks with
dynamic level indication (increasing / decreasing, etc.,), all other operational data
concerning tanks & fluids.
4.00.07
Operator shall be able to access the different pages easily maximum in 2 steps.
5.00.00
5.00.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test including tests to be conducted by independent
agencies. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be
conducted by vendors Quality Department and the results of tests shall be forwarded
along with the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
instruments at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
instruments in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications
ES - 7288
DOCUMENT NO.
REV.
SHEET 7 OF 9
The vendor has to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the checks/calibration as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the written
permission of PDIL/ OWENER.
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for despatch by the inspection authority.
5.00.02 The following physical checks, routine tests as a minimum shall be witnessed by PDIL /
owner inspection authority. The procedure & extent of test shall be governed by Quality
Assurance Plan mutually agreed and approved by Inspection Authority.
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
2. Process connection
B. Routine tests
1. Calibration check for accuracy, linearity, hysteresis and repeatability
2. Zero-shift
3. Hydraulic test.
5.00.03 Other Tests
Vendor shall submit following certificates from a approved laboratory or from statuary
bodies, as applicable.
1. Chemical Analysis
2. Huey test where applicable
3. Radiography/Ultrasonic examination of welded joints for rating 900# and above
5.00.04 Any other test applicable to particular equipment to establish its quality of
construction & performance.
ES - 7288
DOCUMENT NO.
REV.
SHEET 8 OF 9
6.00.0
Packing
Each radar gauges and its accessories shall be suitably packed and protected
from damage due to transportation, loading and unloading.
The radar gauges and their accessories along with spares shall be despatched as
a single consignment. Commissioning and 2 years operation spares shall be
packed separately with proper identification marking.
7.00.00
7.00.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
7.00.02
All instruments shall have a tag plate in SS screwed to the radar gauges case
indicating make, model no., sl. no. , tag no., adjustable range, set range etc.
Besides the above each instrument to have a separate circular tag number plate in
stainless steel with engraved tag number and calibration range and attached
securely to the instrument with a soft stainless wire. The size of letters and figures
shall be minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm
thick.
7.00.03
All spare parts to be supplied along with the main consignment shall be fitted with
identification plate with the following data clearly printed and easily readable.
-Spare parts name, model no. as per purchasers Instrument spec. sheet.
-Serial no.
8.00.00
ES - 7288
DOCUMENT NO.
REV.
SHEET 9 OF 9
9.00.00
Documentation:
The following documents (Technical) are required to be submitted by the vendor
along with bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION OF
DOCUMENT
Catalogue & technical literature of
Yes
Yes
Yes
Yes ( I )
Yes
Yes
Yes
Yes
Yes ( A )
within 2 weeks
Yes
Yes
Yes
( A ) for Approval
( I ) for Information
GENERAL
PROCESS DATA
2
3
4
5
6
7
Service
Eqpt No.
Eqpt Rating
Area Classification
Principle
Type
8
9
10
11
12
13
14
15
16 Tank Type
17 Tank Height
PID No.
TANK/VESSEL
SENSOR
18 Process
P
Connection
C
ti
Flange
Fl
Surface
S f
Fi
Finish
i h
19
20
21
22
23
24
Nozzle Projection
Still Well By
Nozzle I.D.
Still Well Size
Reflector/Reference Pin
Type of Application
Antenna Type
Operating Frequency
25 Temperature Inputs
26 Output Signal
27 Transmitter Type
28 Calibration Range
Display
TRANSMITTER
29
30 Mounting
31 Serial Links
Power Supply
Cable Entry
Enclosure Class/ Execution
Accuracy
32 Other Features
MATERIAL
ACCESSORIES
33 Body Flange
Electrical Housing
Gasket
Antenna
34
35 Still Well Pipe
36 Body and Wetted parts
37 Studs/Bolts/Nuts
38 O' Rings
39 Reflector/Reference Pin
40 Lightning Protection
41 Mounting Bracket
42 Additional Remote Indicator IP-65, Two cable entries
45-LT-3002,
/ 1 No.
45-LT-3005,
/ 1 No.
45-LT-3008,
/ 1 No.
45-LT-3011,
/ 1 No.
LPG
45-VV-101/ 102/ 103/ 104
VENDOR
OFFER
EM163-PNMV-DD45-W-101
7000mm
YES, 316 SS Wetted metal parts, Glass filled PTFE sealing and packings with hand lever,
Open & Close Indication
45 Interconnecting Cable
Interconnecting Cable length between Transmitter and Local Indicator shall be Vendor's
scope. Vendor to specify length.
yes
46 Overfill Protection
VENDOR
OFFER
W & M approval, CMRI / CCOE approved (CENELEC, YES, SIL2 CERTIFICATION BY TUV
47 IS - 2148), SIL Certified, OISD
48
49 Model
Serial Number
By supplier
PURCHASE
50 Purchase Order Number
51 Price
Item No.
Notes: 1. VENDOR TO SPECIFY.
2.Tank drawing EM-163-PNMV-DD45-W-101/102/103/104 is attached for your reference.
3. Separate Local Indicator shall be provided one at grade and one on top of Mound Local Level Indication to show Pressure/Temperature also.
CERTIFICATION
4. Documentation shall include sets of installation , operation & maintenance manuals , wiring diagrams , authority approvals , certificates & manufacturers test and
guarantee certificates.
5. RADAR indicator shall have scale graduations in mm.
6. Vendor scope includes configuration of tanks data, calculations, supervision of Erection, Wiring, as well as Testing and Commissioning of whole system .
7. Vendor to confirm Nozzle Size/ Still Well Size.
8. Vendor to p
provide complete
software p
package.
p
g
9. Vendor to provide system Architecture, still well design drawings, typical arrangement drawing, etc along with the offer.
10. Bidder to coordinate with vendor supplying Radar Type Level Transmitter for installation and commissioning and hook up of level instruments in PLC without any extra cost.
11 Vendor to provide temperature compensation from multipoint averaging temperature transmitter i.e. 45-LT-3002 from 45-TT-3006, 45-LT-3005 from
45-TT-3007, 45-LT-3008 from 45-TT-3008 & 45-LT-3011 from 45-TT-3009. Vendor to coordinate with Temperaure assembly vendor.
12 Pressure Temperature Compensation is required for the Radar Transmitter .Vendor to provide slots accordingly.
1
0
P
No.
AK
AK
AK
Prepared By
RA
RA
RA
Checked By
SKT
SKT
SKT
Approved By
29.09.2015
14.09.2015
21.07.2015
DATE
INSTRUMENT SPECIFICATION
RADAR TYPE LEVEL TRANSMITTER
( NON TFMS)
COMMENTS INCORP
DRAFT ENQUIRY
Purpose
EM163-7047-SP-7288
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 Years Operational spares
recommended by them.
Rev 1 / 24.09.2015
Sl
Item
Item Description
Qty
No
<-------By Vendor----->
Radar
R d Type
T
Level
L
l transmitter
t
itt
Main Transmitter
45-LT-3002
Main Transmitter
45-LT-3005
Main Transmitter
45-LT-3008
Main Transmitter
45-LT-3011
Commissioning
g Spares
p
9
Spare 1
Recommended by the
vendor
Model No / Part No
Spare 2
Recommended by the
vendor
Page 1 of 1
EM163-E-7147
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
RADAR TYPE TANK LEVEL TRANSMITTER
(TFMS)
WITH
MULTIPOINT TEMPERATURE ELEMENT
&
TEMPERATURE TRANSMITTER
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7147
COMMENTS INCORPORATED
COMMENTS INCORPORATED
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7147
ENQUIRY SPECIFICATION FOR
RADAR TYPE LEVEL TRANSMITTER
(TFMS)
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL. DRAWINGS/
NO. DOCUMENTS. DESCRIPTION
1
GENERAL CONDITIONS FOR
INSTRUMENTS
2
ENGINEERING SPECIFICATIONS FOR
RADAR TYPE LEVEL TRANSMITTER
3
INSTRUMENT SPECIFICATION FOR
RADAR TYPE LEVEL TRANSMITTER
(TFMS)
4
SPARES FOR RADAR TYPE LEVEL
TRANSMITTER
5
BOQ FOR RADAR TYPE LEVEL
TRANSMITTER
6
VESSEL DRAWING
7
10
11
12
13
14
15
ATTACHMENT NO. /
DOCUMENT NO
EM163-45-102
NO OF
PAGES
01
ES-7288
09
EM163-7147-ISP-7288
08
EM163-7147-SP-7288
01
01
EM163-PNMV-DD45-W101/102/103/104
01
ES-7323
08
EM163-7161-ISP-7323
01
EM163-7161-SP-00
01
EM163-7161- BOQ
01
EM163-SK-7323-00
01
ES-7328
07
EM163-7162-ISP-7328
01
EM163-7162-SP-00
01
EM163-7162- BOQ
01
EM163-E-7147
ENQUIRY SPECIFICATION FOR
RADAR TYPE LEVEL TRANSMITTER
(TFMS)
DOCUMENT NO
SHEET 3 OF 3
TAG NO.
45-LT-3001
45-TE-3005
45-TT-3005
45-LT-3004
45-TE-3006
45-TT-3006
45-LT-3007
45-TE-3007
45-TT-3007
45-LT-3010
45-TE-3008
45-TT-3008
P & ID
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
QTY
01
01
01
01
01
01
01
01
01
01
01
01
EM163-45- 102
Document No.
Sheet 1 of 1
Rev.
GENERALCONDITIONS
1.0 SITE METEROLOGICAL DATA
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
90 mm
Wind
Wind code
Seismic Factor
Elevation
36 km/hr
10
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES - 7288
DOCUMENT NO.
REV.
SHEET 1 OF 9
ENGINEERING SPECIFICATION
FOR
RADAR GAUGES
24.09.15
HK
RA
DDCPN
CISC
EFF
DATE
SKT
14-03-06
REV
REV
DATE
DHPV
PURPOSE
PREPD
REVWD
APPD
ES - 7288
DOCUMENT NO.
REV.
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
INSPECTION , FACTORY
TESTS AND APPROVAL
4.0
PACKING
5.0
IDENTIFICATION AND
MARKING
6.0
SPARES
7.0
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES - 7288
DOCUMENT NO.
REV.
SHEET 3 OF 9
1.00.00
General :
1.00.01
This general specification is applicable for the radar gauges of top vessel mounted
type.
1.00.02
1.00.03
2.00.00
General Requirements :
2.00.01
2.00.02
2.00.03
Gauges shall be suitable for storage, handling & outdoor installation in wet tropical
Coastal Climate.
2.00.04
The ambient conditions if not specified otherwise in data sheets shall be min
- 40 degrees & max 70 degrees Centigrade, Relative Humidity upto 100 %.
Instruments shall be suitable for such conditions.
2.00.05
2.00.06
2.00.07
2.00.08
Flanges up to and including 600 # shall have raised face with concentric
serrations.
2.00.09
All flanges of rating 900 # and above shall have RTJ facing. All RTJ flanges shall
have groove corresponding to octagonal metal ring gaskets as per ASME B 16.20
2.00.010 In order to have antistatic construction Gaskets used if any shall be metallic or
SS304 with fibre filling for RF flanges . Ring Gaskets if any shall be octagonal
Rings of soft Iron.
2.00.011 Orientation of connection, rating, flange facing and flange face distance shall be as
sheets enclosed.
ES - 7288
DOCUMENT NO.
REV.
SHEET 4 OF 9
2.00.015 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating
2.10.00
2.10.01
2.10.02
2.10.03
2.10.04
Cable entries shall be with metallic plugs to prevent ingress of external matter.
2.10.05
2.10.06
Cable entries shall be NPTF, for Signal outputs & Power supply cabling.
2.10.07
Metallic plugs shall be provided at all cable entries to prevent ingress of external
matter till cabling at site is completed.
2.10.08
3.00.00
3.00.01
The device must use Frequency Modulated Continuous Wave (FMCW). Radar
technology which measures level based on elapsed time between send/receive of a
fixed frequency signal, (pulse or time domain) shall not be used for high performance
tank gauging. Incremental phase evaluation shall not be used since it can lead to
significant level gauging errors.
3.00.02
The radar gauge shall have a digital reference to ensure accuracy and stability.
Analog delay lines suffer from temperature and aging effects and shall not be used.
3.00.03
The RTG shall be capable of having dual, independent and galvanically isolated
gauge electronics, enabling built-in redundancy, dual level outputs or a combined
level gauging and alarm handling.
3.00.04
The RTG shall have a separate safety function suitable for use in Safety
Instrumented Systems (SIS). The function must be certified by a third party to at a
minimum meet Safety Integrity Level 2 (SIL 2) requirements as per IEC 61508.
3.00.05
The RTG subparts (antennas, electronics, housing etc.) shall be designed in such a
way that they can be freely interchanged, without recalibration.
3.00.06
The gauge shall be able to operate in a stand-alone mode (single gauge installation)
or in a network of up to at least 16 gauges and operator interface workstations in the
control room. Level update time shall not exceed one (1) second in the field data
concentrator. The standard fieldbus communication shall have a baud rate of at least
ES - 7288
DOCUMENT NO.
REV.
SHEET 5 OF 9
4800 Baud.
3.00.07
The RTG shall be equipped with dual memory banks enabling reprogramming and
configuration under continuous operation.
3.00.08
For high pressurized vessel and high accuracy applications, an optional pressure
transmitter for vapor space pressure measurement shall be incorporated into the
Radar gauging system. The pressure input shall be used by the RTG for automatic
compensation of the level indication in the field itself due to changes in vapor density.
3.00.09
The vendor shall provide at least one verification pin for the still-pipe to permit on-line
field verification of the level measurement while the tank is in operation. During
verification, the normal level reading shall also be available. A device for end-of pipe
measurement verification shall be provided.
3.00.10
The vendor shall provide an optional isolation valve at the gauge head to provide
increased safety.
3.00.11
A perforated steel pipe guided radar waves to ensures the safe measurements
undisturbed by the structures in the tank and possible boiling of the liquid gas.
3.00.12
The gauge shall be microprocessor based with inbuilt software for calculation of
densities, level; from Vessel / tank strapping tables; extensive diagnostics to detect
faults in the system, etc. and have safeguards to prevent damage to radar.
3.00.13
3.00.14
The transmitter shall have a local level indicator either inbuilt in the same casing.
3.00.15
Indicator at radar gauge casing shall have digital displays for level, calculated
volume, density, etc - in engineering units and diagnostic messages / alarms.
3.00.16
3.10.00
Outputs :
3.10.00
3.10.02
3.20.00
Remote Indicators :
3.20.01
3.20.02
3.20.03
3.20.04
Cable entries shall be 2 nos., NPTF, one for incoming & other for outgoing.
Metallic plugs shall be provided to prevent ingress of external matter till cabling at
ES - 7288
DOCUMENT NO.
REV.
SHEET 6 OF 9
site is completed.
3.30.00
Still well / pipe : Vendor shall furnish detailed dwgs of recommended still well /
pipes for correct installation of the instrument.
3.30.01
In case Still wells under equipment fabricator scope ( excluded from radar gauge
vendor scope ),equipment fabricated are to be supplied with necessary information
and vetted by OEM of radar gauge (OEM to spell out clearly all necessary
accessories for mounting the gauge).
3.30.02
Accessories like reflector kit, reference pin etc. shall be supplied along with the
radar.
4.00.00
4.00.01
If specified in data sheets, vendor scope shall include their proven software for
Tank farm management for inventory monitoring.
4.00.02
4.00.03
For this purpose all Servo gauges, if applicable, radar gauge shall be serially linked
& connected to the PC. Vendors software shall enable access to all data- level,
density , temperature, calculated values such as Volume being filled-in / pumpedout, total hold-up volume, filled capacity , etc.,
4.00.04
4.00.05
4.00.06
Software shall generate dynamic Graphic pages showing all details of tanks with
dynamic level indication (increasing / decreasing, etc.,), all other operational data
concerning tanks & fluids.
4.00.07
Operator shall be able to access the different pages easily maximum in 2 steps.
5.00.00
5.00.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test including tests to be conducted by independent
agencies. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be
conducted by vendors Quality Department and the results of tests shall be forwarded
along with the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
instruments at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
instruments in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications
ES - 7288
DOCUMENT NO.
REV.
SHEET 7 OF 9
The vendor has to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the checks/calibration as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the written
permission of PDIL/ OWENER.
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for despatch by the inspection authority.
5.00.02 The following physical checks, routine tests as a minimum shall be witnessed by PDIL /
owner inspection authority. The procedure & extent of test shall be governed by Quality
Assurance Plan mutually agreed and approved by Inspection Authority.
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
2. Process connection
B. Routine tests
1. Calibration check for accuracy, linearity, hysteresis and repeatability
2. Zero-shift
3. Hydraulic test.
5.00.03 Other Tests
Vendor shall submit following certificates from a approved laboratory or from statuary
bodies, as applicable.
1. Chemical Analysis
2. Huey test where applicable
3. Radiography/Ultrasonic examination of welded joints for rating 900# and above
5.00.04 Any other test applicable to particular equipment to establish its quality of
construction & performance.
ES - 7288
DOCUMENT NO.
REV.
SHEET 8 OF 9
6.00.0
Packing
Each radar gauges and its accessories shall be suitably packed and protected
from damage due to transportation, loading and unloading.
The radar gauges and their accessories along with spares shall be despatched as
a single consignment. Commissioning and 2 years operation spares shall be
packed separately with proper identification marking.
7.00.00
7.00.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
7.00.02
All instruments shall have a tag plate in SS screwed to the radar gauges case
indicating make, model no., sl. no. , tag no., adjustable range, set range etc.
Besides the above each instrument to have a separate circular tag number plate in
stainless steel with engraved tag number and calibration range and attached
securely to the instrument with a soft stainless wire. The size of letters and figures
shall be minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm
thick.
7.00.03
All spare parts to be supplied along with the main consignment shall be fitted with
identification plate with the following data clearly printed and easily readable.
-Spare parts name, model no. as per purchasers Instrument spec. sheet.
-Serial no.
8.00.00
ES - 7288
DOCUMENT NO.
REV.
SHEET 9 OF 9
9.00.00
Documentation:
The following documents (Technical) are required to be submitted by the vendor
along with bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION OF
DOCUMENT
Catalogue & technical literature of
Yes
Yes
Yes
Yes ( I )
Yes
Yes
Yes
Yes
Yes ( A )
within 2 weeks
Yes
Yes
Yes
( A ) for Approval
( I ) for Information
GENERAL
PROCESS DATA
2
3
4
5
6
7
Service
Eqpt No.
Eqpt Rating
Area Classification
Principle
Type
8
9
10
11
12
13
14
15
16 Tank Type
17 Tank Height
PID No.
TANK/VESSEL
SENSOR
P
C
ti
18 Process
Connection
Fl
S f
Fi
i h
Flange
Surface
Finish
19
20
21
22
23
24
Nozzle Projection
Still Well By
Nozzle I.D.
Still Well Size
Reflector/Reference Pin
Type of Application
Antenna Type
Operating Frequency
25 Temparature Inputs
26 Output Signal
27 Transmitter Type
28 Calibration Range
Display
TRANSMITTER
29
30 Mounting
31 Serial Links
Power Supply
Cable Entry
Enclosure Class/ Execution
Accuracy
32 Other Features
MATERIAL
ACCESSORIES
33 Body Flange
Electrical Housing
Gasket
Antenna
34
35 Still Well Pipe
36 Body and Wetted parts
37 Studs/Bolts/Nuts
38 O' Rings
39 Reflector/Reference Pin
40 Lightning Protection
41 Mounting Bracket
42 Additional Remote Indicator IP-65, Two cable entries
45-LT-3001
/ 1 No.
45-LT-3004
/ 1 No.
45-LT-3007
/ 1 No.
45-LT-3010
/ 1 No.
LPG
45-VV-101/ 102/ 103/ 104
VENDOR OFFER
EM163-PNMV-DD45-W-101
7000mm
YES, 316 SS Wetted metal parts, Glass filled PTFE sealing and packings with hand
lever, Open & Close Indication
45 Interconnecting Cable
46 Overfill Protection
VENDOR OFFER
4. Documentation shall include sets of installation , operation & maintenance manuals , wiring diagrams , authority approvals , certificates &
manufacturers test and guarantee certificates.
5. RADAR indicator shall have scale graduations in mm.
6. Vendor scope includes configuration of tanks data, calculations, supervision of Erection, Wiring, as well as Testing and Commissioning of whole system .
7. Vendor to confirm Nozzle Size/ Still Well Size.
8.
Vendor
package.
8 V
d tto provide
id complete
l t software
ft
k
9. Vendor to provide system Architecture, still well design drawings, typical arrangement drawing, etc along with the offer.
10. The Radar Type Level Transmitter shall be competable for hooking up with existing TFMS System (Emerson / Honeywell).
11. Multipoint Temperature Assembly along with necessary temperature interface shall be considered along with radar type level transmitter (TFMS).
12. Bidder to coordinate with NRMT TFMS vendor (Emerson/Honeywell ) for installation,commissioning & hook up of Radar Type Level Transmitter in NRMT
TFMS in all respects including license, software etc if required without any extra cost.
13. Bidder to coordinate with vendor supplying Radar Type Level Transmitter for installation & commissioning & hook up of level instruments without any extra
cost.
14 Pressure Temperature Compensation is required for the Radar Transmitter .Vendor to provide slots accordingly.
1
0
P
No.
AK
AK
AK
Prepared By
RA
RA
RA
Checked By
SKT
SKT
SKT
Approved By
24.09.2015
14.09.2015
21.07.2015
DATE
INSTRUMENT SPECIFICATION
RADAR TYPE LEVEL TRANSMITTER (TFMS)
COMMENTS INCORPORATED
DRAFT ENQUIRY
Purpose
EM163-7147-SP-7288
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 years Operation spares
recommended by them.
EM163-7147-BOQ-7288
Sl
No
Rev 1 / 24.09.2015
Model No / Part No
<-------By Vendor----->
Radar Type Level transmitter
1
1
1
1
Item
Item Description
1
2
3
4
Main Transmitter
Main Transmitter
Main Transmitter
Main Transmitter
45-LT-3001
45-LT-3004
45-LT-3007
45-LT-3010
Commissioning Spares
Recommended by the vendor
Page 1 of 1
Qty
ES-7323
DOCUMENT NO.
REV
SHEET
1 OF 8
20.07.2015
04.02.99
REV
DATE
HK
RA
SKT
DDCPN
CISC
DHPV
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7323
DOCUMENT NO.
REV
SHEET 2
OF
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7323
DOCUMENT NO.
REV
SHEET 3
OF
1.00
General
1.01
1.02
2.00
General Requirements
2.01
Thermocouple
2.01.01 The thermoelements or sensors shall be MgO packed metal sheathed mineral
insulated thermocouples whose thermoelectric properties and limits of errors for all
temperature elements shall conform to ASME MC 96.1 or IEC584.
2.01.02 The construction of the hot junction of thermocouples from mineral insulated cables
shall be made by welding the wire ends in inert dry atmosphere. The hot junction
shall be capped with same material of that of the sheath and insulation, taking all
precautions against ingress of gas/moisture inside the cap. The cap shall be leak
tested for water /moisture.
2.01.03 Unless specified otherwise in the Instrument specification Duplex element shall be
used as a standard.
2.01.04 Hot junction type shall be ungrounded type unless otherwise specified in the
instrument data sheet.
2.01.05 Time constant i.e. 90% change in temperature span without well for elements shall
be 3.5 seconds for ungrounded junctions. The same shall be < 1.0 seconds for
grounded thermocouples.
2.01.06 Inaccuracies due to drift in readings shall be 1C/ year.
2.01.07 Insulation material shall be high purity ( 99%) compressed Magnesium Oxide of
resistivity 1012 ohms /cm at 538C.
2.01.08 Nominal wire diameter shall be 0.19 x sheath O.D. in mm.
2.01.09 In case of high temperature areas MI thermocouples shall be brought to operating
level at ambient temperature before terminating into a junction box.
2.02
2.02.01 The Resistance Temperature Detector characteristics shall conform to DIN 43760/
IEC 751 standards.
2.02.02 The Resistance detector element shall be three wire type in general, if not otherwise
specified in the instrument specification sheet.
2.02.03 The RTD element shall be encapsulated in impervious ceramic or glass bulb.
2.02.04 Platinum resistance element of resistance valve 100 ohms at 0C shall be used in
general, if not otherwise specified in instrument specification sheet.
ES-7323
DOCUMENT NO.
REV
SHEET 4
OF
2.02.05 The lead wires shall be Copper conductors with MI cable. Sheath material of MI cable
shall be 316 SS, if not otherwise specified in the instrument specification sheet. Silver
leads of 16 AWG shall be used if wires are specified as individually insulated through
bead insulators and in addition MgO powder packed in the instrument specification
sheet.
2.02.06 Clause numbers 2.01.04 and 2.01.08 for thermocouple are also applicable for RTD.
2.03
2.03.01 Wherever temperature elements for skin temperature measurement have been
specified in the instrument specification sheets, clause number 2.01 and 2.02 shall
be applicable except for shape, size and pad design. Such details shall normally be
given in the scope drawings indicated against each item and vendor shall prepare
final drawings on the basis of the same. If scope drawings are not available the
vendor shall prepare the same and submit for approval.
2.04
The scope as per enclosed instrument specification sheets may include either
Thermocouple or Resistance Temperature Detector(RTD) or skin temperature
elements or combination of any. Relevant portion of the general requirement (item
2.01 to 2.03) shall be applicable for the items covered in the instrument specification
sheets.
2.05
2.05.01 Thermocouple/ RTD terminal head shall be of aluminium alloy epoxy painted.
2.05.02 The head cover shall be screwed type with SS chain and SS screws.
2.05.03 Insulation blocks shall be ceramic (Al2O3 56%-60%) or stelite (mag.silicate6.5%)
suitable for temperature 240C.
2.05.04 Terminal screw material shall be nickel plated brass/copper.
2.05.05 Thermo element head in hazardous areas if specified ex.proof / flame proof against
each item in the individual specification sheets then the same shall conform to
CENELEC or FM or BASEEFA or IS. IS - 2148 certification must be supplemented with
the temperature classification certification confirming to IS - 8239. However, any
ex.proof/flame proof certification requiring sealing of cable entry with sealing
compound or enclosures with sealed cable entry and flying leads are not acceptable.
2.06
Thermowell
2.06.01 Thermowells can either be flanged or screwed type as specified in the instrument
specification sheet.
2.06.02 The screwed type thermowell shall have 1 NPT (M) process connection & NPT(F)
for sensor connection.
2.06.03 The flanged thermocouple shall be 1 or as specified in the instrument specification
sheet.
2.06.04 Thermowells of length 600 mm and below shall be fabricated from bar stock. Above
600 mm length bar stock-bar stock combination and bar stock-pipe combination may
be used. All weld joints shall be radiographed.
ES-7323
DOCUMENT NO.
REV
SHEET 5
OF
2.06.05 The thermowell design shall be as per sketches mentioned against each item in the
instrument specification sheets.
2.07
2.08
Vendor shall submit thermo element assembly drawings developed at their end on
the basis of the drawings indicated against each tag in the instrument specification
sheets. If scope drawings are not available the vendor shall prepare the same and
submit to the Indentor for approval.
2.09
For steam, BFW & condensate services the thermowell shall be IBR certified. For items
of foreign origin the certification shall be done by Lloyds or any other IBR approved
authorities in specific IBR formats.
2.10
For corrosive services like UREA, wetted parts of stainless steel 316L grade and CrNi-Mo 25-22-2 alloy shall be used. For these materials chemical analysis and
corrosion tests (Huey test) shall be carried out as per ASTM A 262 practice C if
Huey test is specified in the instrument specification. The tests shall be carried out in
an approved laboratory.
2.11
2.12
2.13
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
2.14
Temperature Transmitters and local indicators in hazardous areas shall either be exproof or intrinsic safe conforming to area classification & execution specified against
each item in the individual specification sheets.
Ex-proof certification conforming to CENELEC,FM, BASEEFA and IS is preferred. IS 2148 certification must be supplemented with the temperature classification
certification confirming to IS - 8239. Intrinsic safe certification shall in general conform
to CENELEC standard EN 500014 and EN 50020, if not otherwise specified in the
individual specification sheet.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test. In absence of any Inspection Agency the vendor
must submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in
such cases, shall be conducted by vendors Quality Department and the results of
tests shall be forwarded alongwith the supply.
ES-7323
DOCUMENT NO.
REV
SHEET 6
OF
The manufacturer shall give clear 15 days notice informing readiness of the instrument
at manufacturers works. The vendor shall permit the authorised representative of
PDIL/OWNER to inspect the manufacture and assembly of the temperature element
in various phases in compliance with mutually agreed quality assurance plan,
standards and specifications.
The vendor shall make available to the authorised representative of PDIL / OWNER
the results of all the checks/calibrations conducted before presenting for
PDIL/Owners inspection. Vendor to provide all the necessary facilities free of cost to
PDIL/Owners representative for carrying out the checks/calibration as per
standard/approved quality assurance plan. Under no condition inspection can be
waived off without the written permission of PDIL.
3.02
No temperature element and its accessories shall be shipped until all the required
tests are successfully completed and certified Cleared for despatch by the
inspection authority.
3.03
The procedure & extent of the following physical checks, routine tests shall be
governed by Quality Assurance Plan mutually agreed and approved by Inspection
Authority. The test procedures shall be in line with IEC 584, ASME - 220 / 230 / 230.
THERMOELEMENTS
A. Physical checks :
B. Routine test
1. Insulation resistance
2. Check of seal
3. Nitrogen leak test for thermocouple inset (For MI sensors only)
4. Check of calibration & tolerance.
THERMOWELL
A. Routine inspection & test
1. Physical dimension checking
2. Pressure test
B. Other tests
1. Radiography for bore concentricity ( 10 % ), if not otherwise specified in the
individual specification sheets.
2. Radiography for thermowells of pressure rating 100 kg/cm2 g and above ( 100 % )
3. IBR (wherever applicable)
4. Huey Test (wherever applicable)
5. NACE (wherever applicable)
4.00
ES-7323
DOCUMENT NO.
REV
SHEET 7
OF
Packing
Each temperature element or alongwith assembly shall be suitably packed and
protected from damage due to transportation, loading and unloading.
The above items alongwith spares (commissioning spares and 2 years spares for
maintenance) shall be despatched as a single consignment.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
Each temperature element assembly i.e. the sensing element alongwith head
assembly shall have a separate circular tag number plate in stainless steel with
engraved tag no and protecting sheath immersion length I and attached securely to
the head assembly with a soft stainless wire. The size of letters and figures shall be
minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm thick.
5.02
6.00
Spares
Complete thermoelement assembly of each type & range is included as spares in the
individual instrument specification sheets alongwith the main items.
However spare bare elements shall be as per enclosed spares list.
7.00
ES-7323
DOCUMENT NO.
REV
SHEET 8
OF
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final documentation
before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
(A)
DESCRIPTION OF
DOCUMENT
ALONG
WITH BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
Yes
Yes
Yes(A)
(within 2 weeks)
for information.
Sl. no. 1 to 11 shall be forwarded to PDIL / OWNER as per details outlined in enquiry / order.
Sl. no. 12 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied
as stipulated in the purchase order.
EM163-7161-ISP7323
DOCUMENT NO.
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
ORDER NO.
MANUFACTURER
:
:
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7161
1
2
3
4
5
6
ELEMENT
HEAD
HEAD EXTENSION
THERMOWELL
CERTIFICATION
PURCHASE
P&ID
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1
0
Tolerance Class
Wire Size
Element Configuration (Single/Duplex)
Sheath O.D / Material
Enclosure Class
Cable Entry Size
Blind Plug & Chain
Qty
45-TE-3005
P1 / 45-VV101
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3006
P1 / 45-VV102
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3007
45-TE-3008
Note:
P1 / 45-VV103
P1 / 45-VV104
Extension Type
Nipple Size
Extension Material
Extension Length (N)
Type (Tapered, Straight, Step down)
Construction
Flange Facing/Flange Face Finish
Instrument Connection Size
IBR
NACE
H2 SERVICE
PWHT
CCOE,BASEEFA,CENELAC
YES
Manufacturer
Model
Thermowell
Pressure
Temperature (deg C)
(Kg/cm2g)
Insertio
Process
Fluid
Lagging Ext
Element
n
Connectio
Length
Length
Length
Min Nor Max
Min
Nor
Max
n
'U'
Tag No
Line No./
Vessel No
P
REV
RTD
PT-100
100 ohm at 0 deg C
NOTE 2
Approximately 500mm from base of mounting flange
Type
Configuration
Element Material
Resistance
Measuring Junction
Measuring Range
First Measurement Point Location
Measurement Point Distribution
Insulation Material
Type
Material
Area Classification
Ex. Protection
Ex. Approval/Certification
Spring Loaded
Terminal Block
SHEET 1 OF 1
TW/ Flange
Material
IBR
SS 316
SS 316
Note 2
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
1)Vendortospecify
2)Vendortospecify(I.D.7000mm+THK42mm+MoundHeight&NozzleHeight)
3)MultipointtemperatureelementshallcovertheentireBulletheight.Nos.ofelementsshallbesuchthatthespacingbetween2elements
doesntexceed1meterasperASTMD1066.
4)Multipointtemperatureelementwiththermowellshallbesuppliedascompleteassembly.
5) ThevesseldrawingforLPGMoundedbulletsisattchedforreference.Vendortospecifyanyspecialsupportrequired,ifany.
VENDOR'S
OFFER/
DEVIATION
EM163-7161-SP- 00
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years Operation spares
recommended by them.
EM163-7161-BOQ
Rev 1, 24.09.2015
Bill of Quantity
Sl
ITEM
TAG NO.
Qty
Model No / Part No
<-------By Vendor----->
No
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
Commissioning Spares
45-TE-3005
45-TE-3006
45-TE-3007
45-TE-3008
Page 1 of 1
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEET 1 OF 7
ENGINEERING SPECIFICATION
FOR
TEMPERATURE TRANSMITTERS
00 20.07.2015
REV REV DATE
EFF DATE
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 2 OF 7
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 3 OF 7
1.00
General
1.01
1.02
2.00
General Requirements
2.01
Temperature transmitter shall have universal input for thermocouple / RTD and output
4-20mA for 2 wire system.
2.02
For all applications, the transmitter shall be supplied with smart electronics. The feature of
smart electronics shall include selectable analog/digital output mode, remote re-ranging,
self checking, diagnostics and configuration from hand held configurator or remote HART
maintenance system. The transmitter must have provision for upgrading the communication
protocol to Foundation fieldbus in future.
2.03
2.04
The transmitter shall be unaffected due to radio frequency interference. The supplied
electronic part shall have susceptibility of less than 0.5% of span for a frequency range of
20-500 MHZ in field strength of 20 volts/meter.
2.05
2.06
Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature
transmitters.
2.07
2.08
Digital output gauge shall be integral with electrical housing but there shall be partition
between electronics & output meter.
2.09
The electrical terminals shall be vibration proof. The transmitter terminals shall preferably
be located in a compartment separated from field electronics. Flying leads are not
acceptable.
2.10
2.11
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalize with them the Quality Assurance Plan for
carrying out Inspection and test. In absence of any Inspection Agency the vendor must
submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in such cases,
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 4 OF 7
shall be conducted by vendors Quality Department and the results of tests shall be
forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the instrument
at manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the instrument in various
phases in compliance with mutually agreed quality assurance plan, standards and
specifications.
The vendor shall make available to the authorized representative of PDIL / OWNER the
results of all the checks/calibrations conducted before presenting for PDIL/Owners
inspection. The vendor to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the checks/calibration as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the written
permission of PDIL.
3.02
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for dispatch by the inspection authority.
3.03
The following physical checks, routine tests, shall be in line with ISA S 55.1 The
procedure & extent of test shall be governed by Quality Assurance Plan mutually agreed
and approved by Inspection Authority.
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
B.
Routine Tests
1. Calibration check for Linearity, Accuracy, Hysteresis, Repeatability
2. Zero-shift
4.00
Packing
Each transmitter and its accessories shall be suitably packed and protected from damage due
to transportation, loading and unloading.
The transmitter and their accessories alongwith spares (commissioning spares and 2 years
spares for maintenance) shall be dispatched as a single consignment. Commissioning and 2
years operation spares shall be packed separately.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02
All instruments shall have a tag plate in SS screwed to the transmitter case indicating make,
model no., sl. no. tag no., adjustable range, set range etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved tag
number and calibration range and attached securely to the instrument with a soft stainless
wire. The size of letters and figures shall be minimum 4 mm and the plate should be 25 mm
diameter with 1-2 mm thick.
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
5.03
DOCUMENT NO
SHEE 5 OF 7
All spare parts to be supplied alongwith the main consignment shall be fitted with identification
plate with the following data clearly printed and easily readable.
- Spare parts name, model number as per purchasers Instrument specification sheet.
- Serial no.
6.00
Spares
Complete untagged transmitter of each type & range is included as spare in the specification
sheet. In addition component spares shall be supplied as per enclosed spares list.
7.0
Documentation
Technical documentation
1.1
General
All the documentation such as graphic drawings and technical specifications shall be sent
to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be supplied
on paper.
1.2
1.3
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
1.5
DOCUMENT NO
SHEE 6 OF 7
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
Hole Fill.
Resolution below 200 Dpi is not acceptable.
The following documents (Technical) are required to be submitted by the vendor along with bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
1.
Yes
2.
Yes
Yes
3.
Yes
4.
Yes
5.
Yes
Yes
6.
Yes
7.
Yes
8.
Yes
Yes(A)
(within 2 weeks)
(A)
For Approval
(I)
For information.
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 7 OF 7
Sl. No. 1 to 7 shall be forwarded to PDIL/ OWNER as per details outlined in Enquiry/ order.
Sl. No. 8 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets along with bid for approval and as final documentation shall be supplied as stipulated in
the purchase order.
8.0
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to the
equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
EM163-7162-ISP-7328
INSTRUMENT SPECIFICATION
DOCUMENT NO.
EM163
INSTALLATION OF LPG MOUNDED BULLETS
PLANT
CUSTOMER
REQ. NO.
:
:
:
NUMALIGARH, ASSAM
NRL
EM163-E-7162
ORDER NO.
24.09.15
COMMENTS INCORPORATED
HK
RA
SKT
14.09.15
COMMENTS INCORPORATED
HK
RA
SKT
MANUFACTURE:
REV
21.07.15
DRAFT ENQUIRY
DATE
PURPOSE
HK
RA
PREP CHKD
SKT
APPD
1.
FUNCTION
2.
3.
4
5
TYPE
COMMUNICATION
POWER SUPPLY
POWER SUPPLY EFFECT
TRANSMITTER OUTPUT
LOAD RESISTANCE
600 OHMS FOR DIGITAL COMM. AND 1250 OHMS FOR ANALOG OPERATION
8
9
10 ACCURACY
11 COLD JN. ACCURACY
12 UPDATE TIME
13 ISOLATION
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
SENSOR BACKUP FN
ELECTRICAL CONNECTION
MOUNTING
HUMIDITY
AMB. TEMP. LIMIT
STABILITY
BURNOUT FEATURE
IP-67 OR BETTER
EXECUTION
SELF TEST/ DIAGNOSIS
ELECTRICAL HOUSING
TRANSMITTER BODY MATL
LIGHTENING PROTECTION
BODY TRANSMITTER BOLTS/NUTS/SCREW MATL.
ACCESSORIES
(A) JUNCTION BOX
(B) MOUNTING ACCESSORIES
(C) CABLE GLAND
TEMP deg C
TAG NO.
QTY.
PID
NO.
MIN
NOR
MAX
Ex-Proof & Intrinsically Safe to Hazardous Area Zone-1, Gr. IIA IIB, T3 as per IEC
EEx-ia
FEATURES SHALL BE INBUILT OF TRANSMITTERS
Matl.-Al.Alloy Protecting Paint-Epoxy Polyster as standard
SS 316
YES
YES ( SS 316 ) IF ANY
YES ( 2" NB VERTICAL PIPE MOUNTING WITH SS CLAMP & SS NUT BOLT)
2 Nos. 1/2" NPT SS 316, DOUBLE COMPRESSION TYPE, Ex- Proof
PRESSURE
RANGE
MIN/ MAX
(Design)
deg C
MODEL
NUMBER
Kg/cm g
UL/CALIB.
45-TT-3005
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3006
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3007
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3008
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
VENDOR'S OFFER/DEVIATION
NOTES :
1.
Vendor to specify
2.
3.
Multipoint Temperature assembly along with necessary temperature interface shall be considered along with RADAR TRANSMITTER (TFMS) and non-TFMS Radar.
EM163-7162-SP-00
SPARES LIST FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years Operation spares
recommended by them.
Item
Item Description
EM163-7162-BOQ
REV 1 / 24.09.2015
Qty
Temperature Transmitter
1
Temp. Transmitter
45-TT-3005
2
3
4
Temp. Transmitter
Temp. Transmitter
Temp. Transmitter
45-TT-3006
45-TT-3007
45-TT-3008
1
1
1
Commissioning Spares
Vendor to quote spares on propotionate basis so each
range and model covers the 20% spare for all main
transmitter. Vendor to give the quantity of each model
and range quoted as spare.
Model No / Part No
<-------By Vendor----->
No
Page 1 of 1
EM163-E-7052
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
SERVO TYPE LEVEL TRANSMITTER
WITH
MULTIPOINT TEMPERATURE ELEMENT
&
TEMPERATURE TRANSMITTER
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24/09/2015
14/09/2015
21.07.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7052
COMMENTS INCORPORATED
COMMENTS INCORPORATED
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7052
ENQUIRY SPECIFICATION FOR
SERVO TYPE LEVEL TRANSMITTER
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
S
NO
1
2
4
5
6
7
10
11
12
13
14
15
DRAWINGS/
DOCUMENTS.DESCRIPTION
GENERAL
CONDITIONS
FOR
INSTRUMENTS
ENGINEERING
SPECIFICATIONS
FOR LEVEL TRANSMITTER (SERVO
TYPE)
INSTRUMENT SPECIFICATION FOR
LEVEL
TRANSMITTER
(SERVO
TYPE)
SPARES FOR LEVEL TRANSMITTER
(SERVO TYPE)
BILL OF QUANTITY FOR
LEVEL
TRANSMITTER (SERVO TYPE)
VESSEL DRAWING
ENGINEERING
SPECIFICATIONS
FOR MULTIPOINT TEMPERATURE
ELEMENT (RTD) WITH TW
INSTRUMENT SPECIFICATION FOR
MULTIPOINT
TEMPERATURE
ELEMENT (RTD) WITH TW
SPARE LIST FOR
MULTIPOINT
TEMPERATURE ELEMENT (RTD)
WITH TW
BILL OF QUANTITY FOR
MULTIPOINT TEMPERATURE
ELEMENT (RTD) WITH TW
SKETCH FOR FOR MULTIPOINT
TEMPERATURE ELEMENT (RTD)
WITH TW
ENGINEERING SPECIFICATIONS
FOR TEMPERATURE TRANSMITTER
INSTRUMENT SPECIFICATION FOR
TEMPERATURE TRANSMITTER
SPARE LIST FOR TEMPERATURE
TRANSMITTER
BILL OF QUANTITY FOR
TEMPERATURE TRANSMITTER
ATTACHMENT NO. /
DOCUMENT NO
EM163-45-102
NO
OF
PAGES
01
ES-7289
08
EM163-7052-ISP7289
02
EM163-7052-SP-7289
01
EM163-7052-BOQ-7289
01
EM163-PNMV-DD45-W101/102/103/104
01
ES-7323
08
EM163-7061-ISP-7323
01
EM163-7061-SP-00
01
EM163-7061- BOQ
01
EM163-SK-7323-00
01
ES-7328
07
EM163-7062-ISP-7328
01
EM163-7062-SP-00
01
EM163-7062- BOQ
01
EM163-E-7052
ENQUIRY SPECIFICATION FOR
SERVO TYPE LEVEL TRANSMITTER
DOCUMENT NO
SHEET 3 OF 3
SL.
NO.
1
TAG NO.
45-LT-3003
45-TE-3001
45-TT-3001
45-LT-3006
45-TE-3002
45-TT-3002
45-LT-3009
45-TE-3003
45-TT-3003
45-LT-3012
45-TE-3004
45-TT-3004
P & ID
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
QTY
01
01
01
01
01
01
01
01
01
01
01
01
EM163-45- 102
Document No.
Sheet 1 of 1
Rev.
GENERALCONDITIONS
1.0 SITE METEROLOGICAL DATA
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
90 mm
Wind
Wind code
Seismic Factor
Elevation
36 km/hr
10
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES- 7289
DOCUMENT NO.
REV.
SHEET 1 OF 9
ENGINEERING SPECIFICATION
FOR
SERVO GAUGES
14-03-06
REV
REV
DATE
PURPOSE
03 ES-7289
DDCPN
PREPD
CISC
DHPV
REVWD
APPD
ES- 7289
DOCUMENT NO.
REV.
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
2.0
GENERAL
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
7.0
SPARES
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
03 ES-7289
NUMBER OF SHEETS
ES- 7289
DOCUMENT NO.
REV.
SHEET 3 OF 9
1.00.00
General :
1.00.01
This general specification is applicable for the displacer servo gauges of top vessel
mounted type.
1.00.02
Float type with Capacitance sensor NOT to be used due to static discharge
problems associated with many fluids.
1.00.03
1.00.04
2.00.00
General Requirements :
2.00.01
Gauges in general shall be of antistatic construction for Liquefied Gases , OIL and
other applications where Static build-up is likely.
2.00.02
2.00.03
Gauges shall be suitable for storage, handling & outdoor installation in wet tropical
Coastal Climate.
2.00.04
The ambient conditions if not specified otherwise in data sheets shall be min 4
degrees & max 50 degrees Centigrade , Relative Humidity min 10 & , max 95 % .
inst. shall be suitable for such conditions.
2.00.05
2.00.06
The process connection size shall be min. 4 ASME B16.5 flanged connection if not
specified in individual Instrument specification sheets.
2.00.07
2.00.08
Flanges up to and including 600 # shall have raised face with concentric
serrations.
2.00.09
All flanges of rating 900 # and above shall have RTJ facing. All RTJ flanges shall
have groove corresponding to octagonal metal ring gaskets as per ASME B 16.20
2.00.010 In order to have antistatic construction Gaskets used if any shall be metallic or
SS304 with fibre filling for RF flanges . Ring Gaskets if any shall be octagonal Rings
of soft Iron.
2.00.011 Orientation of connection, rating, flange facing and Displacer /
flange
distance shall be as indicated in individual Instrument specification sheets.
face
specification
sheets enclosed. As a minimum displacers of SS 304 / 316 are to be provided.
03 ES-7289
ES- 7289
DOCUMENT NO.
REV.
SHEET 4 OF 9
2.00.014 Displacer shall be attached to hook with feature that shall prevent displacer from
2.10.01
2.10.02
2.10.03
2.10.04
Cable entries shall be with metallic plugs to prevent ingress of external matter.
2.10.05
2.10.06
Cable entries shall be NPTF , for Signal outputs & Power supply cabling.
2.10.07
Cable entry & gland for temperature elements shall be as per vendor standard to suit
the cable from multi-element assembly to servo-gauge.
2.10.08
Metallic plugs shall be provided at all cable entries to prevent ingress of external
matter till cabling at site is completed.
2.10.09
3.00.00
3.00.01
The steel rope attached to the float is guided over a drum located in the transmitter
housing. This motor drives the drum to maintain tension in the rope. The two are
guided by servo mechanism.
3.00.02
Displacer of known weight is also utilised for determining the density of fluid and
interface level.
3.00.03
The gauge shall be microprocessor based with inbuilt software for temperature
compensation for calculation of densities, level ; volume from Vessel /tank strapping
tables; extensive diagnostics to detect faults in the system including snapping of
wire, jamming of wire, etc., and have safeguards to prevent damage to servo
system.
3.00.04
3.00.05
The transmitter shall have a local level indicator either inbuilt in the same casing.
03 ES-7289
ES- 7289
DOCUMENT NO.
REV.
SHEET 5 OF 9
3.00.06
Indicator at servo gauge casing shall have digital displays for level, calculated
volume , density , Temperature, interface level, etc - in engineering units and
diagnostic messages / alarms.
3.00.07
3.10.00
Outputs :
3.10.00
3.10.02
3.20.00
Remote Indicators :
3.20.01
One additional IP-65 , weatherproof intrinsically safe certified field mounted Remote
indicator for mounting at the grade / ground level included in scope.
3.20.02
3.20.03
3.20.04
Cable entries shall be 2 nos. , NPTF , one for incoming & other for outgoing.
Metallic plugs shall be provided to prevent ingress of external matter till cabling at
site is completed.
3.30.00
Still well / pipe : Vendor shall furnish detailed dwgs of recommended still well /
pipes for avoiding displacer swing.
3.30.01
3.30.02
Still wells under equipment fabricator scope ( excluded from Servo gauge vendor
scope ).
Temperature Elements :
Multi Spot Temperature Element Assemblies
4.10.00
4.10.01
4.10.01
Unless specified otherwise in data sheets , Servo Gauge vendor scope includes
supply of Multi Spot Temperature measurement Element assembly.
4.10.02
4.10.03
4.10.04
Flanges for liquefied gases shall be 316 SS unless specified otherwise in data
sheets.
4.10.05
4.10.06
Depending upon height of tank / equipment, typically one measurement at middle &
others at identical gaps above & below the centre are selected.
03 ES-7289
ES- 7289
DOCUMENT NO.
REV.
SHEET 6 OF 9
4.10.07
The elements unless specified otherwise shall be ungrounded 3 wire Pt 100 Ohms
at 0 Deg C RTD ( Class B , DIN 43760 ) in 316SS sheath.
4.10.08
4.10.09
In case of low pressure equipment / tanks, sheathed elements may be strapped tight
so that elements do not come / spring-out while handling / installation. They shall be
installed in Stillwell provided by equipment vendor,
4.20.00
4.20.01
4.20.02
Such assemblies shall measure the average temperature of the zone ,instead of
spot temperatures.
4.20.03
Except for this difference all other constructional details such as flanges ,
connections, etc., shall be similar to multi spot measurement assemblies.
5.00.00
5.00.01
If specified in data sheets, vendor scope shall include their proven software for Tank
farm management for inventory monitoring.
5.00.02
5.00.03
For this purpose all Servo gauges shall be serially linked & connected to the PC.
Vendors software shall enable access to all data- level, density , temperature,
calculated values such as Volume being filled-in / pumped-out, total hold-up volume,
filled capacity , etc.,
5.00.04
5.00.05
5.00.06
Software shall generate dynamic Graphic pages showing all details of tanks with
dynamic level indication ( increasing / decreasing, etc.,), all other operational data
concerning tanks & fluids.
5.00.07
Operator shall be able to access the different pages easily maximum in 2 steps.
6.00.00
6.00.01 Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for carrying out
Inspection and test including tests to be conducted by independent agencies. In absence of any
Inspection Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality Department and the
results of tests shall be forwarded along with the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
instruments at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
ES- 7289
DOCUMENT NO.
REV.
SHEET 7 OF 9
Packing
Each servo gauges and its accessories shall be suitably packed and protected from
damage due to transportation, loading and unloading.
The servo gauges and their accessories along with spares shall be despatched as a
single consignment. Commissioning and 2 years operation spares shall be packed
separately with proper identification marking.
8.00.00
03 ES-7289
ES- 7289
DOCUMENT NO.
REV.
SHEET 8 OF 9
8.00.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
8.00.02
All instruments shall have a tag plate in SS screwed to the servo gauges case
indicating make, model no., sl. no. , tag no., adjustable range, set range etc.
Besides the above each instrument to have a separate circular tag number plate in
stainless steel with engraved tag number and calibration range and attached
securely to the instrument with a soft stainless wire. The size of letters and figures
shall be minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm thick.
8.00.03
All spare parts to be supplied along with the main consignment shall be fitted with
identification plate with the following data clearly printed and easily readable.
9.00.00
Spare parts name, model no. as per purchasers Instrument spec. sheet.
Serial no.
10.00.00 Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
DESCRIPTION OF
DOCUMENT
Catalogue & technical literature of
level transmitter alongwith their
accessories, installation drgs,
sketch diagrams.
Deviation if any, from the technical
spec. giving justification for the
same.
Dimensional and sectional drawing
against each tag showing material
of construction of each part.
Chemical analysis and material
test certificates from an approved
laboratory.
Certificates from recognised
authority for (a) degree of
protection against environment (b)
Intrinsic safety/ Ex-proof
execution.
Instruction Manual for
maintenance.
Calibration and performance test
certificates.
03 ES-7289
Yes
Yes
Yes
Yes ( I )
Yes
Yes
Yes
Yes
Yes
Yes
ES- 7289
DOCUMENT NO.
REV.
SHEET 9 OF 9
8.
( A ) for Approval
Yes
Yes ( A )
within 2 weeks
( I ) for Information
Sl. No. 8 shall be mutually finalised with Inspection Authority specified in the
order.
Number of sets along with bid for approval and as final documentation shall
be supplied as stipulated in the purchase order.
03 ES-7289
SERVO TYPE
TANK LEVEL TRANSMITTER
OP. DATA
GENERAL
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
1 TAG NO. /
: EM163
: INSTALLATION OF MOUNDED BULLETS
: NUMALIGARH, ASSAM
1 24/09/2015
: NRL
0 14/09/2015
:
P 21/07/2015
:
:
REV
DATE
QTY. / P&I
LT-3003 / 01 No. / P1
MOUNTING NOZZLE
STILL WELL
FLUID
PRESSURE ,Min./Nor./Max./Design Kg/cm2 g
TRANSMISSION
AREA
MATERIALS
GENE
ERAL
OPTIONAL
DOCUMENT NO.
REV.
COMMENTS INCORP
COMMENTS INCORP
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PRPD
RA
RA
RA
CHKD
SKT
SKT
SKT
APPD
LT-3006 / 01 No. / P1
LT-3009 / 01 No. / P2
LT-3012 / 01 No. / P2
TOTAL = 4 Nos.
LPG / 45-VV-101 / 45-VV-102 / 45-VV-103 /45-VV-104
DISPLACER, SERVO MOTOR
LPG BULLET: I.D. =7000mm TL ~ TL =52000mm HEIGHT: Bullet I.D
(7000mm) +Bullet Thickness(42mm) + Mound height(1000mm)+Dome upto
top of Nozzle (250mm) (Tentative) (Drawing attached)
2 SERVICE / LOCATION
3 PRINCIPLE
4 TANK DETAILS
5
6
7
8
9
10
EM163-7052-ISP-7289
14
15
16
17
MEASURING RANGE
0 - 8292mm (Note-1)
ACCURACY
DISPLAY
OTHER FEATURES
18
19
20
21
COMPENSATION - AUTOMATIC
LIGHTNING PROTECTION
TEMPERATURE INPUTS
DISPLACER DIMENSION / MOVEMENT
YES
2" Nozzle with 2" Thermowell for Multielement Averaging sensor
Displacer dia. & movement from max. level to min. level shall be within
limits so that displacer do not touch Still Well pipe internals.
22
23
24
25
26
27
28
SS316
SS with Weather Proof Hood
SA350 Gr LF2 Cl 1
SA320 Gr L7 / SA 194 Gr 4
Spiral Wound SS-304 Graphite filled with SS Centre Ring
Vendor to specify
316 SS with PTFE coating
Zone -1 Gr. II A / II B, Temp. class - T3 as per IS / IEC
Weather proof IP 65/ Flame Proof
EExd (e) II A/B, T3
4 ~ 20 mA, 2 Channels freely assignable ,
Digital Pulse output forLevel and Average Temperature (Note-11)
RS 485 (Twisted Pair), MODBUS RTU,
110 V , 50 Hz ,
29
30
31
32
33 SERIAL LINKS
34 ALARM POINTS - H / L / LL
35 POWER SUPPLY
36 CABLE ENTRIES
37 CALIBRATION CHAMBER
38 ISOLATION BALL VALVE, API 608, 607 &
TESTING AS PER API 598 ( HP CLOSURE)
39
40
41
42
43
03 EM163-7052-ISP-7289
SHEET
1 OF 2
SERVO TYPE
TANK LEVEL TRANSMITTER
NOTES
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
INSTALLATION OF MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
1 24/09/2015
0 14/09/2015
P 21/07/2015
DATE
REV
EM163-7052-ISP-7289
DOCUMENT NO.
REV.
COMMENTS INCORP
COMMENTS INCORP
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PRPD
RA
RA
RA
CHKD
SKT
SKT
SKT
APPD
VENDOR TO SPECIFY.
Documentation shall include sets of installation, operation & maintenance manuals, wiring diagrams, authority approvals, certificates & manufacturers test and
guarantee certificates.
Separate Local Indicator shall be provided one at grade and one on top of Mound Local Level Indication to show Temperature also.
RS 485 Communication with Accessories required ie Booster amplifier, Repeaters etc. to be provided as required .
Interconnecting Cable length between Transmitter and Local Indicator shall be in Vendor's scope.Vendor to specify length.
Vendor to provide system Architecture, still well design drawings, typical arrangement drawing, etc along with the offer.
10 Vendor scope includes configuration of tanks data, calculations, supervision of Erection, Wiring, as well as Testing and Commissioning of whole system .
11 Servo gauge shall have the provision for connection with TFMS. Howver, it will be connected to PLC (Control System), not TFMS.
12 Bidder to coordinate with vendor supplying Servo Type Level Transmitter for installation & commissioning & hook up of level instruments in PLC without any extra
cost.
13 Multipoint Temperature Assembly along with necessary temperature interface shall be considered with Servo Type Level Transmitter.
14 Pressure Temperature Compensation is required for the Servo Transmitter .Vendor to provide slots accordingly.
03 EM163-7052-ISP-7289
SHEET
2 OF 2
EM163-7052-SP-7289
DOCUMENT NO.
REV
SHEET
OF
NOTE: The vendor shall also indicate the additional/ applicable 2years Operational spares
recommended by them.
EM163-7052-BOQ-7289
Bill of Quantity
Sl
Item
No
1
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
Spare 2 Years
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No
Spare 2 Years
Model No / Part No
<----------By Vendor---------------------->
Spare 2 Years
3
Qty
Spare 2 Years
Item Description
Rev 1 / 24.09.2015
ES-7323
DOCUMENT NO.
REV
SHEET
1 OF 8
20.07.2015
04.02.99
REV
DATE
HK
RA
SKT
DDCPN
CISC
DHPV
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7323
DOCUMENT NO.
REV
SHEET 2
OF
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7323
DOCUMENT NO.
REV
SHEET 3
OF
1.00
General
1.01
1.02
2.00
General Requirements
2.01
Thermocouple
2.01.01 The thermoelements or sensors shall be MgO packed metal sheathed mineral
insulated thermocouples whose thermoelectric properties and limits of errors for all
temperature elements shall conform to ASME MC 96.1 or IEC584.
2.01.02 The construction of the hot junction of thermocouples from mineral insulated cables
shall be made by welding the wire ends in inert dry atmosphere. The hot junction
shall be capped with same material of that of the sheath and insulation, taking all
precautions against ingress of gas/moisture inside the cap. The cap shall be leak
tested for water /moisture.
2.01.03 Unless specified otherwise in the Instrument specification Duplex element shall be
used as a standard.
2.01.04 Hot junction type shall be ungrounded type unless otherwise specified in the
instrument data sheet.
2.01.05 Time constant i.e. 90% change in temperature span without well for elements shall
be 3.5 seconds for ungrounded junctions. The same shall be < 1.0 seconds for
grounded thermocouples.
2.01.06 Inaccuracies due to drift in readings shall be 1C/ year.
2.01.07 Insulation material shall be high purity ( 99%) compressed Magnesium Oxide of
resistivity 1012 ohms /cm at 538C.
2.01.08 Nominal wire diameter shall be 0.19 x sheath O.D. in mm.
2.01.09 In case of high temperature areas MI thermocouples shall be brought to operating
level at ambient temperature before terminating into a junction box.
2.02
2.02.01 The Resistance Temperature Detector characteristics shall conform to DIN 43760/
IEC 751 standards.
2.02.02 The Resistance detector element shall be three wire type in general, if not otherwise
specified in the instrument specification sheet.
2.02.03 The RTD element shall be encapsulated in impervious ceramic or glass bulb.
2.02.04 Platinum resistance element of resistance valve 100 ohms at 0C shall be used in
general, if not otherwise specified in instrument specification sheet.
ES-7323
DOCUMENT NO.
REV
SHEET 4
OF
2.02.05 The lead wires shall be Copper conductors with MI cable. Sheath material of MI cable
shall be 316 SS, if not otherwise specified in the instrument specification sheet. Silver
leads of 16 AWG shall be used if wires are specified as individually insulated through
bead insulators and in addition MgO powder packed in the instrument specification
sheet.
2.02.06 Clause numbers 2.01.04 and 2.01.08 for thermocouple are also applicable for RTD.
2.03
2.03.01 Wherever temperature elements for skin temperature measurement have been
specified in the instrument specification sheets, clause number 2.01 and 2.02 shall
be applicable except for shape, size and pad design. Such details shall normally be
given in the scope drawings indicated against each item and vendor shall prepare
final drawings on the basis of the same. If scope drawings are not available the
vendor shall prepare the same and submit for approval.
2.04
The scope as per enclosed instrument specification sheets may include either
Thermocouple or Resistance Temperature Detector(RTD) or skin temperature
elements or combination of any. Relevant portion of the general requirement (item
2.01 to 2.03) shall be applicable for the items covered in the instrument specification
sheets.
2.05
2.05.01 Thermocouple/ RTD terminal head shall be of aluminium alloy epoxy painted.
2.05.02 The head cover shall be screwed type with SS chain and SS screws.
2.05.03 Insulation blocks shall be ceramic (Al2O3 56%-60%) or stelite (mag.silicate6.5%)
suitable for temperature 240C.
2.05.04 Terminal screw material shall be nickel plated brass/copper.
2.05.05 Thermo element head in hazardous areas if specified ex.proof / flame proof against
each item in the individual specification sheets then the same shall conform to
CENELEC or FM or BASEEFA or IS. IS - 2148 certification must be supplemented with
the temperature classification certification confirming to IS - 8239. However, any
ex.proof/flame proof certification requiring sealing of cable entry with sealing
compound or enclosures with sealed cable entry and flying leads are not acceptable.
2.06
Thermowell
2.06.01 Thermowells can either be flanged or screwed type as specified in the instrument
specification sheet.
2.06.02 The screwed type thermowell shall have 1 NPT (M) process connection & NPT(F)
for sensor connection.
2.06.03 The flanged thermocouple shall be 1 or as specified in the instrument specification
sheet.
2.06.04 Thermowells of length 600 mm and below shall be fabricated from bar stock. Above
600 mm length bar stock-bar stock combination and bar stock-pipe combination may
be used. All weld joints shall be radiographed.
ES-7323
DOCUMENT NO.
REV
SHEET 5
OF
2.06.05 The thermowell design shall be as per sketches mentioned against each item in the
instrument specification sheets.
2.07
2.08
Vendor shall submit thermo element assembly drawings developed at their end on
the basis of the drawings indicated against each tag in the instrument specification
sheets. If scope drawings are not available the vendor shall prepare the same and
submit to the Indentor for approval.
2.09
For steam, BFW & condensate services the thermowell shall be IBR certified. For items
of foreign origin the certification shall be done by Lloyds or any other IBR approved
authorities in specific IBR formats.
2.10
For corrosive services like UREA, wetted parts of stainless steel 316L grade and CrNi-Mo 25-22-2 alloy shall be used. For these materials chemical analysis and
corrosion tests (Huey test) shall be carried out as per ASTM A 262 practice C if
Huey test is specified in the instrument specification. The tests shall be carried out in
an approved laboratory.
2.11
2.12
2.13
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
2.14
Temperature Transmitters and local indicators in hazardous areas shall either be exproof or intrinsic safe conforming to area classification & execution specified against
each item in the individual specification sheets.
Ex-proof certification conforming to CENELEC,FM, BASEEFA and IS is preferred. IS 2148 certification must be supplemented with the temperature classification
certification confirming to IS - 8239. Intrinsic safe certification shall in general conform
to CENELEC standard EN 500014 and EN 50020, if not otherwise specified in the
individual specification sheet.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test. In absence of any Inspection Agency the vendor
must submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in
such cases, shall be conducted by vendors Quality Department and the results of
tests shall be forwarded alongwith the supply.
ES-7323
DOCUMENT NO.
REV
SHEET 6
OF
The manufacturer shall give clear 15 days notice informing readiness of the instrument
at manufacturers works. The vendor shall permit the authorised representative of
PDIL/OWNER to inspect the manufacture and assembly of the temperature element
in various phases in compliance with mutually agreed quality assurance plan,
standards and specifications.
The vendor shall make available to the authorised representative of PDIL / OWNER
the results of all the checks/calibrations conducted before presenting for
PDIL/Owners inspection. Vendor to provide all the necessary facilities free of cost to
PDIL/Owners representative for carrying out the checks/calibration as per
standard/approved quality assurance plan. Under no condition inspection can be
waived off without the written permission of PDIL.
3.02
No temperature element and its accessories shall be shipped until all the required
tests are successfully completed and certified Cleared for despatch by the
inspection authority.
3.03
The procedure & extent of the following physical checks, routine tests shall be
governed by Quality Assurance Plan mutually agreed and approved by Inspection
Authority. The test procedures shall be in line with IEC 584, ASME - 220 / 230 / 230.
THERMOELEMENTS
A. Physical checks :
B. Routine test
1. Insulation resistance
2. Check of seal
3. Nitrogen leak test for thermocouple inset (For MI sensors only)
4. Check of calibration & tolerance.
THERMOWELL
A. Routine inspection & test
1. Physical dimension checking
2. Pressure test
B. Other tests
1. Radiography for bore concentricity ( 10 % ), if not otherwise specified in the
individual specification sheets.
2. Radiography for thermowells of pressure rating 100 kg/cm2 g and above ( 100 % )
3. IBR (wherever applicable)
4. Huey Test (wherever applicable)
5. NACE (wherever applicable)
4.00
ES-7323
DOCUMENT NO.
REV
SHEET 7
OF
Packing
Each temperature element or alongwith assembly shall be suitably packed and
protected from damage due to transportation, loading and unloading.
The above items alongwith spares (commissioning spares and 2 years spares for
maintenance) shall be despatched as a single consignment.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
Each temperature element assembly i.e. the sensing element alongwith head
assembly shall have a separate circular tag number plate in stainless steel with
engraved tag no and protecting sheath immersion length I and attached securely to
the head assembly with a soft stainless wire. The size of letters and figures shall be
minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm thick.
5.02
6.00
Spares
Complete thermoelement assembly of each type & range is included as spares in the
individual instrument specification sheets alongwith the main items.
However spare bare elements shall be as per enclosed spares list.
7.00
ES-7323
DOCUMENT NO.
REV
SHEET 8
OF
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final documentation
before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
(A)
DESCRIPTION OF
DOCUMENT
ALONG
WITH BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
Yes
Yes
Yes(A)
(within 2 weeks)
for information.
Sl. no. 1 to 11 shall be forwarded to PDIL / OWNER as per details outlined in enquiry / order.
Sl. no. 12 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied
as stipulated in the purchase order.
:
:
:
:
:
ORDER NO.
MANUFACTURER
:
:
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7061
1
2
3
4
5
6
ELEMENT
HEAD
HEAD EXTENSION
THERMOWELL
CERTIFICATION
PURCHASE
P&ID
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Tolerance Class
Wire Size
Element Configuration (Single/Duplex)
Sheath O.D / Material
Enclosure Class
Cable Entry Size
Blind Plug & Chain
Qty
45-TE-3001
P1 / 45-VV101
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3002
P1 / 45-VV102
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3003
45-TE-3004
Note:
P1 / 45-VV103
P1 / 45-VV104
Extension Type
Nipple Size
Extension Material
Extension Length (N)
Type (Tapered, Straight, Step down)
Construction
Flange Facing/Flange Face Finish
Instrument Connection Size
IBR
NACE
H2 SERVICE
PWHT
CCOE,BASEEFA,CENELAC
YES
Manufacturer
Model
Thermowell
Pressure
Temperature (deg C)
(Kg/cm2g)
Insertio
Process
Fluid
Element
Lagging Ext
n
Connectio
Length
Length
Min Nor Max
Min
Nor
Max
Length
n
'U'
Tag No
Line No./
Vessel No
SHEET 1 OF 1
Type
Configuration
Element Material
Resistance
Measuring Junction
Measuring Range
First Measurement Point Location
Measurement Point Distribution
Insulation Material
Type
Material
Area Classification
Ex. Protection
Ex. Approval/Certification
Spring Loaded
Terminal Block
EM163-7061-ISP7323
DOCUMENT NO.
TW/ Flange
Material
IBR
SS 316
SS 316
Note 2
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
1)Vendortospecify
2)Vendortospecify(I.D.7000mm+THK42mm+MoundHeight&NozzleHeight)
3)MultipointtemperatureelementshallcovertheentireBulletheight.Nos.ofelementsshallbesuchthatthespacingbetween2elements
doesntexceed1meterasperASTMD1066.
4)Multipointtemperatureelementwiththermowellshallbesuppliedascompleteassembly.
5) ThevesseldrawingforLPGMoundedbulletsisattchedforreference.Vendortospecifyanyspecialsupportrequired,ifany.
VENDOR'S
OFFER/
DEVIATION
EM163-7061-SP- 00
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years Operation spares
recommended by them.
EM163-7061-BOQ
Rev 1, 24.09.2015
Bill of Quantity
Sl
ITEM
TAG NO.
Qty
Model No / Part No
<-------By Vendor----->
No
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
COMMISSIONING SPARES
5
SPARE
45-TE-3001
45-TE-3002
45-TE-3003
45-TE-3004
Page 1 of 1
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEET 1 OF 7
ENGINEERING SPECIFICATION
FOR
TEMPERATURE TRANSMITTERS
00 20.07.2015
REV REV DATE
EFF DATE
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 2 OF 7
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 3 OF 7
1.00
General
1.01
1.02
2.00
General Requirements
2.01
Temperature transmitter shall have universal input for thermocouple / RTD and output
4-20mA for 2 wire system.
2.02
For all applications, the transmitter shall be supplied with smart electronics. The feature of
smart electronics shall include selectable analog/digital output mode, remote re-ranging,
self checking, diagnostics and configuration from hand held configurator or remote HART
maintenance system. The transmitter must have provision for upgrading the communication
protocol to Foundation fieldbus in future.
2.03
2.04
The transmitter shall be unaffected due to radio frequency interference. The supplied
electronic part shall have susceptibility of less than 0.5% of span for a frequency range of
20-500 MHZ in field strength of 20 volts/meter.
2.05
2.06
Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature
transmitters.
2.07
2.08
Digital output gauge shall be integral with electrical housing but there shall be partition
between electronics & output meter.
2.09
The electrical terminals shall be vibration proof. The transmitter terminals shall preferably
be located in a compartment separated from field electronics. Flying leads are not
acceptable.
2.10
2.11
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalize with them the Quality Assurance Plan for
carrying out Inspection and test. In absence of any Inspection Agency the vendor must
submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in such cases,
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 4 OF 7
shall be conducted by vendors Quality Department and the results of tests shall be
forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the instrument
at manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the instrument in various
phases in compliance with mutually agreed quality assurance plan, standards and
specifications.
The vendor shall make available to the authorized representative of PDIL / OWNER the
results of all the checks/calibrations conducted before presenting for PDIL/Owners
inspection. The vendor to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the checks/calibration as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the written
permission of PDIL.
3.02
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for dispatch by the inspection authority.
3.03
The following physical checks, routine tests, shall be in line with ISA S 55.1 The
procedure & extent of test shall be governed by Quality Assurance Plan mutually agreed
and approved by Inspection Authority.
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
B.
Routine Tests
1. Calibration check for Linearity, Accuracy, Hysteresis, Repeatability
2. Zero-shift
4.00
Packing
Each transmitter and its accessories shall be suitably packed and protected from damage due
to transportation, loading and unloading.
The transmitter and their accessories alongwith spares (commissioning spares and 2 years
spares for maintenance) shall be dispatched as a single consignment. Commissioning and 2
years operation spares shall be packed separately.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02
All instruments shall have a tag plate in SS screwed to the transmitter case indicating make,
model no., sl. no. tag no., adjustable range, set range etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved tag
number and calibration range and attached securely to the instrument with a soft stainless
wire. The size of letters and figures shall be minimum 4 mm and the plate should be 25 mm
diameter with 1-2 mm thick.
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
5.03
DOCUMENT NO
SHEE 5 OF 7
All spare parts to be supplied alongwith the main consignment shall be fitted with identification
plate with the following data clearly printed and easily readable.
- Spare parts name, model number as per purchasers Instrument specification sheet.
- Serial no.
6.00
Spares
Complete untagged transmitter of each type & range is included as spare in the specification
sheet. In addition component spares shall be supplied as per enclosed spares list.
7.0
Documentation
Technical documentation
1.1
General
All the documentation such as graphic drawings and technical specifications shall be sent
to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be supplied
on paper.
1.2
1.3
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
1.5
DOCUMENT NO
SHEE 6 OF 7
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
Hole Fill.
Resolution below 200 Dpi is not acceptable.
The following documents (Technical) are required to be submitted by the vendor along with bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
1.
Yes
2.
Yes
Yes
3.
Yes
4.
Yes
5.
Yes
Yes
6.
Yes
7.
Yes
8.
Yes
Yes(A)
(within 2 weeks)
(A)
For Approval
(I)
For information.
ES7328
ENGINEERING SPECIFICATION FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEE 7 OF 7
Sl. No. 1 to 7 shall be forwarded to PDIL/ OWNER as per details outlined in Enquiry/ order.
Sl. No. 8 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets along with bid for approval and as final documentation shall be supplied as stipulated in
the purchase order.
8.0
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to the
equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
EM163-7062-ISP-7328
INSTRUMENT SPECIFICATION
DOCUMENT NO.
:
:
:
:
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
24.09.15
HK
RA
SKT
REQ. NO.
EM163-E-7062
14.09.15
HK
RA
SKT
ORDER NO.
21.07.15
DRAFT ENQUIRY
HK
RA
SKT
DATE
PURPOSE
P
REV
MANUFACTUR:
1.
2.
3.
FUNCTION
4
5
6
TYPE
COMMUNICATION
POWER SUPPLY
POWER SUPPLY EFFECT
TRANSMITTER OUTPUT
LOAD RESISTANCE
8
INTEGRAL DIGITAL OUTPUT INDICATOR
9 ZERO & SPAN ADJUSTMENT
10 ACCURACY
UPDATE TIME
ISOLATION
SENSOR BACKUP FN
ELECTRICAL CONNECTION
MOUNTING
17 HUMIDITY
18 AMB. TEMP. LIMIT
19 STABILITY
0-95 % RH
UPTO 85 C
+/- 0..075 % OF UPPER RANGE LIMIT FOR 6 MONTHS
20 BURNOUT FEATURE
21 ENVIRONMENTAL PROTECTION CLASS
22 AREA CLASSIFICATION
23
EXECUTION
24 SELF TEST/ DIAGNOSIS
EEx-ia
FEATURES SHALL BE INBUILT OF TRANSMITTERS
25
26
27
28
29
Ex-Proof & Intrinsically Safe to Hazardous Area Zone-1, Gr. IIA IIB, T3 as per IEC
ELECTRICAL HOUSING
TRANSMITTER BODY MATL
LIGHTENING PROTECTION
BODY TRANSMITTER BOLTS/NUTS/SCREW MATL.
ACCESSORIES
(A) JUNCTION BOX
(B) MOUNTING ACCESSORIES
(C) CABLE GLAND
TEMP deg C
TAG NO.
QTY.
PID
NO.
MIN
NOR
MAX
YES ( 2" NB VERTICAL PIPE MOUNTING WITH SS CLAMP & SS NUT BOLT)
1/2" NPT SS 316, DOUBLE COMPRESSION TYPE, Ex- Proof
PRESSURE
RANGE
MIN/ MAX
(Design)
deg C
MODEL
Kg/cm2 g
UL/CALIB.
NUMBER
45-TT-3001
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3002
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3003
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3004
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
VENDOR'S OFFER/DEVIATION
NOTES :
1.
Vendor to specify
2.
3.
EM163-7062-SP-00
SPARES LIST FOR
TEMPERATURE TRANSMITTER
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years operational spares
recommended by them.
Item
Item Description
EM163-7062-BOQ
REV 1 / 24.09.2015
Qty
Temperature Transmitter
1
2
3
4
5
Model No / Part No
<-------By Vendor----->
No
Temp Transmitter
Temp.
45-TT-3001
Temp. Transmitter
45-TT-3002
Temp. Transmitter
45-TT-3003
Temp. Transmitter
45-TT-3004
Commissioning Spares
Vendor to quote spares on propotionate basis so each
range and model covers the 20% spare / min. 1 No. for
all main transmitter. Vendor to give the quantity of each
model and range quoted as spare.
Spare for 2 Years
Vendor to quote spares on propotionate basis so each
range and model covers the 20% spare / min. 1 No. for
all main transmitter. Vendor to give the quantity of each
model and range quoted as spare.
Page 1 of 1
1
1
1
1
EM163-E-7053
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
PRESSURE GAUGE
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7053
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7053
ENQUIRY SPECIFICATION FOR
PRESSURE GAUGE
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
DRAWINGS/
DOCUMENTS.DESCRIPTION
2
3
4
5
ATTACHMENT NO.
/
DOCUMENT NO
EM163-PNIN-0000
NO OF PAGES
01
ES-7303
08
EM163-7053ISP7303
EM163-7053-SP-00
04
01
EM163-7053-BOQ
02
EM163-E-7053
ENQUIRY SPECIFICATION FOR
PRESSURE GAUGE
DOCUMENT NO
SHEET 3 OF 3
SL.
NO.
TAG NO.
P & ID
QTY
1
2
3
4
5
45-PG-3001
45-PG-3002
45-PG-3003
45-PG-3004
45-PG-3016
P1 (EM163-45-0021)
P1 (EM163-45-0021)
P2 (EM163-45-0022)
P2 (EM163-45-0022)
P4 (EM163-45-0024)
01
01
01
01
01
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
aligarh, Golaghat Distrrict
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
mbient Air Temperature
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
eismic Facttor - 0.04
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions
12
Precipitation Annual me
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
DOCUMENT NO
SHEET 1 OF 8
ENGINEERING SPECIFICATION
FOR
PRESSURE GAUGES
00 20.07.2015
REV REV DATE
EFF DATE
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
DOCUMENT NO
SHEE 2 OF 8
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
DOCUMENT NO
SHEE 3 OF 8
1.00
General
1.01
1.02
2.00
General Requirements
The supply shall be strictly in line with the technical requirements specified in the
Instrument specification. In addition the supply must comply with the following.
2.01
In general, construction, design and testing of the pressure gauges shall be as per IS
3624, unless otherwise deviations stated in the enclosed Instrument specification.
2.02
2.03
All the wetted parts, movements, casing shall be of stainless steel unless otherwise
specified deviation in the Instrument specification. No component and accessories
should be of copper and its alloys.
2.04
The dial shall be white, non rusting metal or plastic with black figures.
2.05
2.06
All gauge casing shall be of safety pattern design. Baffle/solid front between dial and
sensor shall be provided for ranges 25 kg/cm2 g and above. Below 25 kg/cm2 g is
optional.
2.07
IBR certificate shall be required for accessories like pig tail siphon for steam, condensate
& BFW services. For items of foreign origin the certification shall be done by Lloyds or
any other IBR approved authorities in specific IBR format.
2.08
2.09
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
2.10
2.11
The standard measuring element shall be a seamless bourdon tube of AISI 316 stainless
steel, except where the process fluid requires the use of special material. Bourdon tubes
shall be welded to socket and tip and stress relieved as required.
2.12
The gauge pointer shall be adjustable without removing it from its shaft.
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
2.13
DOCUMENT NO
SHEE 4 OF 8
3.00
4.00
Packing
Each gauge and its accessories i.e. siphon, snubber, gauge saver etc. wherever
applicable shall be suitably packed and protected from damage due to transportation,
loading and unloading.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
Each gauge to have a separate circular tag number plate in stainless steel with
engraved tag no and range and attached securely to the gauge with a soft stainless
wire. The size of letters and figures shall be minimum 4 mm and the plate should be 25
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
6.00
DOCUMENT NO
SHEE 5 OF 8
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
7.0
Documentation
Technical documentation
1.1
DOCUMENT NO
SHEE 6 OF 8
General
All the documentation such as graphic drawings and technical specifications shall be
sent to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be
supplied on paper.
1.2
1.3
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
1.5
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
Hole Fill.
Resolution below 200 Dpi is not acceptable.
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
DOCUMENT NO
SHEE 7 OF 8
The following documents (Technical) are required to be submitted by the vendor alongwith bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL. NO.
DESCRIPTION OF
DOCUMENTS
ALONG
WITH BID
1.
Yes
For approval/
information
within six weeks
Yes (I)
2.
Yes
Yes
Yes
Yes (I)
Yes
Yes
Yes
Yes
Yes
Yes
x
x
x
x
Yes
Yes
3.
4.
5.
6.
7.
8.
9.
10.
11.
(A)
For Approval
(I)
Final documents
before dispatch of
consignment
Yes
Yes (A)
(Within 2 week)
For Information.
Sl. no. 1 to 10 shall be forwarded to PDIL/OWNER as per details outlined in enquiry / order.
Sl. no. 11 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as stipulated in the
purchase order.
ES-7303
ENGINEERING SPECIFICATION FOR
PRESSURE GAUGES
8.0
DOCUMENT NO
SHEE 8 OF 8
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to the
equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
EM163-7053-ISP7303
DOCUMENT NO.
PRESSURE GAUGE
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
GENERAL
TYPE
MOUNTING
DIAL SIZE
DIAL COLOUR
CASE MATERIAL
BEZEL RING
ELEMENT MATERIAL
BLOW OUT PROTEC.
LENS
ACCURACY
OVER RANGE PROTEC.
ENCLOSURE PROTEC.
PRESSURE ELEMENT
BOURDON SIZE
MOVEMENT MATL.
PROCESS CONN.
POINTER TYPE
ZERO ADJUSTMENT
FACILITY
:
:
:
:
:
:
:
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7053
:
:
:
:
:
:
:
:
:
:
:
:
Direct reading
Local
150mm
Black numerals on white background
SS 304
SS 304
Refer against Indivisual tag
Required as per IS 3624
Shatter Proof Glass
1% on full scale
Required as per IS 3624 or Latest
IP 65 or better
:
:
:
:
:
QTY.
LINE NO./
EQUIPMENT NO
P&ID
45-PG-3001
01
45-VV-101
P1
45-PG-3003
45-PG-3004
45-PG-3016
01
01
01
01
TAG NO.
45-PG-3002
45-VV-102
45-VV-103
45-VV-104
45-VV-106
P1
P1
P1
P4
24.09.15
Clients Comment
Incorporated
HK
RA
SKT
14.09.15
Clients Comment
Incorporated
HK
RA
SKT
P 21.07.15
REV
DATE
DRAFT ENQUIRY
PURPOSE
HK
RA
PREP CHKD
SKT
APPD
VENDOR'sOFFER/
DEVIATION
OPTIONS
A1) PIG TAIL SYPHON ASTM A 106 Gr. B, 1/2" NB
Seamless pipe, Sch 80, Both ends Plain with IBR
A2) PIG TAIL SYPHON ASTM A TP 304 SS, 1/2" NB
Sch. 80s Seamless pipe, Both ends Plain with IBR
A3) PIG TAIL SHYPON ASTM A TP 347H SS, 1/2" NB
Sch. 80s, Both ends Plain with IBR
A4) PIG TAIL SYPHON Specify as required
B1) SNUBBER AISI 304 SS, 1/2 " NPT(F) Gauge side,
1/2" NPT(M) Process side, Rating & Temp. to suit service pressure,
Dampning : Adjustable
B2) SNUBBER Specify as required
C1) GAUGE SAVER AISI 304, 1/2" NPT(F) Gauge side,
1/2" NPT(M) Process side
C2) GAUGE SAVER AISI 304L, 1/2" NPT(F) Gauge side,
1/2" NPT(M) Process side
D) MOVEMENT DAMPING Specify as required
E) SAFETY PATTERN GAUGE
WITH BAFFLE WALL
F) NACE CERTIFICATE
FLUID
/ LINE /VESSEL
OP.MIN /
NOR / MAX
/DESIGN
K / 2( )
OPTIONS
RANGE
KG/CM2(G)
ELEMENT
TYPE
ELEMENT
MATERIAL
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / L
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
SHEET 1 OF 1
VENDOR'sOFFER/
DEVIATION
EM163-7053-SP-00
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 Years Operation spares
recommended by them.
EM163-7053-BOQ
Bill of Quantity
Sl
No
1
2
3
4
5
Item
Item Description
PRESSURE GAUGES
45-PG-3001
45 PG 3001
45-PG-3002
45-PG-3003
45-PG-3004
45-PG-3016
Rev 1/ 24.09.2015
Model No / Part No
Qty
<-------By Vendor----->
1
1
1
1
1
Commissioning Spares
6
Spare - 3
Pressure
gauge, Seamless Bourdon
Spare - 4
Spare - 5
SNUBBER
Spare - 6
Pressure
gauge, Seamless Bourdon
20% of
each
model /
range/
min. 1 no.
EM163-E-7044
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
PRESSURE TRANSMITTERS &
DIFF. PRESSURE TRANSMITTER
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7044
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7044
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
ATTACHMENT NO./
DOCUMENT NO
EM163-PNIN-0000
NO OF
PAGES
01
ES-7308
08
EM163-7044-ISP7308
02
EM163-7044-SP-00
01
EM163-7044-BOQ
01
EM163-E-7044
DOCUMENT NO
SHEET 3 OF 3
SL.
NO.
TAG NO.
P & ID
QTY
1
2
3
4
45-PT-3013 A/B/C
45-PT-3014 A/B/C
45-PT-3015 A/B/C
45-PT-3016 A/B/C
P1 (EM163-45-0021)
P1 (EM163-45-0021)
P2 (EM163-45-0022)
P2 (EM163-45-0022)
3 Nos.
3 Nos.
3 Nos.
3 Nos.
SL.
NO.
TAG NO.
P & ID
QTY
45-LT-3017
P4 (EM163-45-0024)
1 No.
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
aligarh, Golaghat Distrrict
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
mbient Air Temperature
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
eismic Facttor - 0.04
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions
12
Precipitation Annual me
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE
TRANSMITTER
DOCUMENT NO
SHEET 1 OF 8
ENGINEERING SPECIFICATION
FOR
PRESSURE AND
DIFFERENTIAL PRESSURE TRANSMITTERS
00 20.07.2015
REV REV DATE
EFF DATE
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
DOCUMENT NO
SHEET 2 OF 8
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
DOCUMENT NO
SHEET 3 OF 8
1.00
General
1.01
1.02
2.00
General Requirements
2.01
Pressure Transmitters
2.01.01
Flanged integral type 2-valve manifold shall be used with transmitters having either
flanged or oval flanged adopter with 1/2 NPT (F) process connection. Otherwise, 1/2
NPT (F) screwed 2 valve manifold shall be used.
2.01.02
One complete bolt sets shall be provided for flanged connections at both ends.
2.02
2.02.01
Flanged integral type 3-valve manifold shall be used with transmitters having either
flanged or oval flanged adopter with 1/2 NPT (F) process connection. Otherwise, 1/2
NPT (F) screwed 3 valve manifold shall be used.
2.02.02
One complete bolt sets shall be provided for flanged connections at both ends.
2.03
For all applications, the transmitter shall be supplied with smart electronics. The feature
of smart electronics shall include selectable analog/digital output mode, remote reranging, self checking, diagnostics and configuration from hand held configurator or
remote HART maintenance system. The transmitter must have provision for upgrading the
communication protocol to Foundation fieldbus in future.
2.04
Studs & nuts for flange adapter & oval flanges shall be of stainless steel if otherwise not
specified in the data sheet. If no special requirements are stipulated all gaskets/O rings
in contact with process fluid shall be of Teflon or equivalent. For liquid ammonia service
low temp application (sub-zero temp.), gaskets/O rings shall be EP-851 or equivalent.
2.05
2.06
The transmitter shall be unaffected due to radio frequency interference. The supplied
electronic part shall have susceptibility of less than 0.5% of span for a frequency range of
20-500 MHZ in field strength of 20 volts/meter. The transmitter shall be vibration and
shock proof.
2.07
2.08
2.09
Digital output gauge shall be integral with electrical housing but there shall be partition
between electronics & output meter.
2.10
The electrical terminals shall be vibration proof. The transmitter terminals shall
preferably be located in a compartment separated from field electronics. Flying leads are
not acceptable.
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
DOCUMENT NO
SHEET 4 OF 8
2.11
All transmitters without chemical seal shall have 1/2 NPT (F) connection.
2.12
The scope as per enclosed instrument specification sheets may include either Pressure or
Differential pressure Transmitters or combination of any. Relevant portion of the general
requirement (item 2.01 to 2.02) shall be applicable for the items covered in the instrument
specification sheets.
2.13
2.14
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
2.15
Body pressure rating shall be 100 bar minimum and measuring capsules shall be able to
withstand pressure up to the body rating in either direction without damaging the instrument.
2.16
The body and other wetted parts material shall be SS 316L minimum. Other materials such
as hastelloy, Monel or tantalum may be used as per process requirement.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection Agency
specified in the order and finalize with them the Quality Assurance Plan for carrying out
Inspection and test. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be conducted by
vendors Quality Department and the results of tests shall be forwarded alongwith the
supply.
The manufacturer shall give clear 15 days notice informing readiness of the instrument at
manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the instrument in various phases
in compliance with mutually agreed quality assurance plan, standards and specifications.
The vendor shall make available to the authorized representative of PDIL / OWNER the
results of all the checks/calibrations conducted before presenting for PDIL/Owners
inspection.Vendor to provide all the necessary facilities free of cost to PDIL/Owners
representative for carrying out the checks/calibration as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the written
permission of PDIL.
3.02
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for dispatch by the inspection authority.
3.03
The following physical checks, routine tests, shall be in line with ISA S 55.1 The procedure &
extent of test shall be governed by Quality Assurance Plan mutually agreed and approved
by Inspection Authority.
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
DOCUMENT NO
SHEET 5 OF 8
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
2. Process connection
3. Manifold
B.
Routine Tests
4.00
Packing
Each transmitter and its accessories shall be suitably packed and protected from damage due
to transportation, loading and unloading.
The transmitter and their accessories alongwith spares (commissioning spares and 2 years
spares for maintenance) shall be dispatched as a single consignment. Commissioning and 2
years operation spares shall be packed separately.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02
All instruments shall have a tag plate in SS screwed to the transmitter case indicating make,
model no., sl. no. tag no., adjustable range, set range etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved tag
number and calibration range and attached securely to the instrument with a soft stainless
wire. The size of letters and figures shall be minimum 4 mm and the plate should be 25 mm
diameter with 1-2 mm thick.
5.03
All spare parts to be supplied alongwith the main consignment shall be fitted with identification
plate with the following data clearly printed and easily readable.
- Spare parts name, model number as per purchasers Instrument specification sheet.
- Serial no.
6.00
Spares
Complete untagged transmitter of each type & range is included as spare in the specification
sheet. In addition component spares shall be supplied as per enclosed spares list.
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
7.0
Documentation
Technical documentation
1.1
DOCUMENT NO
SHEET 6 OF 8
General
All the documentation such as graphic drawings and technical specifications shall be
sent to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be
supplied on paper.
1.2
1.3
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
1.5
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
Hole Fill.
Resolution below 200 Dpi is not acceptable.
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
DOCUMENT NO
SHEET 7 OF 8
The following documents (Technical) are required to be submitted by the vendor along with bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
1.
Yes
2.
Yes
Yes
3.
Yes
4.
Yes
5.
Yes
Yes
6.
Yes
7.
Yes
8.
Yes
Yes(A)
(within 2 weeks)
(A)
For Approval
(I)
For information.
Sl. No. 1 to 7 shall be forwarded to PDIL/ OWNER as per details outlined in Enquiry/ order.
Sl. No. 8 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets along with bid for approval and as final documentation shall be supplied as stipulated in
the purchase order.
ES7308
ENGINEERING SPECIFICATION FOR
PRESSURE & DIFF. PRESSURE TRANSMITTER
8.0
DOCUMENT NO
SHEET 8 OF 8
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to
the equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
INSTRUMENT SPECIFICATION
EM163-7044-ISP-7328
DOCUMENT NO
FOR TRANSMITTER
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
ORDER NO.
MANUFACTURER
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7044
1.
2
3
4
5
6
7
8
9
10
11
12
13
FUNCTION
FILL FLUID
VERSION/COMMUNICATION
MEASUREMENT PRINCIPLE/TYPE
POWER SUPPLY
TRANSMITTER OUTPUT
LOAD RESISTANCE
INTEGRAL DIGITAL OUTPUT INDICATOR
14
15
16
17
18
ELECTRICAL CONNECTION
MOUNTING
HUMIDITY
STABILITY
OVER PRESSURE
19
20
21
PROCESS CONNECTION
O' RING
ENVIRONMENTAL PROTECTION CLASS
AREA CLASSIFICATION
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
TURNDOWN RATIO
STATIC PR. COMPENSATION
AMBIENT TEMPERATURE COMPENSATION
STATIC PR. SHIFT
AMBIENT TEMPERATURE SHIFT
AMB. TEMP. LIMIT
DRAIN OR VENT ARRANGEMENT
MATERIAL
1
0
P
REV
24.09.15
14.09.15
HK
HK
RA
RA
SKT
SKT
21.07.15
DRAFT ENQUIRY
HK
RA
SKT
DATE
PURPOSE
PREP CHKD
APPD
EXECUTION
SELF TEST/ DIAGNOSIS
TRANSMITTER BODY MATL /DRAIN & VENT VALVE MATL.
TRANSMITTER BODY, BOLTS/NUTS/SCREW MATL.
SQUARE ROOT EXTRACTION
LIGHTENING PROTECTION
OPTIONS
(A) MOUNTING ACCESSORIES
YES ( 2" NB VERTICAL PIPE MOUNTING WITH CLAMP & SS NUT BOLT)
(B)THREE VALVE MANIFOLD
YES, T-TYPE, SS316 MATERIAL
(C) CABLE GLAND
1/2" NPT SS 316, DOUBLE COMPRESSION TYPE, Ex- Proof
(D) TWO VALVE MANIFOLD
YES
Universal Handheld Configurator complete with all accessories i.e. Battery, Charger, Interfacing cable & carry case with with 1 GB memory
VENDOR's OFFER /
DEVITION
EM163-7044-ISP-7328
DOCUMENT NO
:
:
:
:
:
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7044
1
0
24.09.15
14.09.15
ORDER NO.
21.07.15
DRAFT ENQUIRY
MANUFACTURER
REV
DATE
PURPOSE
TAG NO.
QTY.
PID NO.
Nos.
LINE NO./
EQUIP. NO
FLUID
NOR /
NOR / MAX
MAX PR.
CALIB.
TEMP.
2
RANGE (Kg/cm2g)
Kg/cm
0
DEG( C)
(g)
BODY
RTG.
ELEMENT
MATERIAL
COVER/
BODY/WET OPTION
PARTS MATL
45-PT3013 A/B/C
P1
45-VV-101
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
45-PT3014 A/B/C
P1
45-VV-102
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
45-PT3015 A/B/C
P2
45-VV-103
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
45-PT3016 A/B/C
P2
45-VV-104
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
NOTES :
1. Mounting Bracket for mounting on 2" pipe with U-clamp & bolts, Matl.SS.
2.Body rating selected by manufacturer shall be suitable for the given pressure & temp.
3. MANUFACTURER TO SPECIFY.
4. In case of High Temp. i.e more than 200 deg. C, Suitable 'O' Ring material to be quoted by the manufacturer.
5. Each transmitter shall be supplied with NPT SS plug for auxiliary electrical connection.
6. Vendor shall indicate full model codes for the transmitters offered and shall submit relevant decoding sheet also
7. Valve manifold & transmitter body shall be tested Hydraulically separately
HK
HK
RA
RA
HK
RA
SKT
SKT
SKT
PREP CHKD
APPD
MODEL
VENDOR's
OFFER /
DEVIATION
EM163-7044-ISP-7328
DOCUMENT NO
:
:
:
:
:
ORDER NO.
MANUFACTURER
TAG NO.
LT-3017
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7044
24.09.15
14.09.15
REV
DATE
PURPOSE
QTY.
NOS
. PID NO.
LINE NO.
1
EM163-45- 45-VV-106
0024
FLUID
LPG/
WATER
MAX./
MAX./NOR NOR PR.
TEMP.
Kg/cm2
0
(g)
DEG( C)
(-)27/55
2.35-6.51
/ 14.5
BODY
C-C / RANGE
RTG./
(mmWC) / CALL. FLANGE
ELEMENT
RANGE
MATERIAL MATERIAL
800 / - /NOTE-3
1.5",
SS316
300#RF
HK
RA
HK
RA
PREP CHKD
DENSITY
FLUID
COVER/
IN Kg/m3 /
BODY/WET
PARTS MATL
VISC.
SS316
1000 / 0.756
SKT
SKT
APPD
OPTI
ON
MODEL
A,C
VENDOR's
OFFER /
DEVIATION
EM163-7044-SP-00
DOCUMENT NO
SHEET 1 OF 1
NOTE: 1 The vendor shall also indicate the additional/ applicable 2 years spares recommended by them.
EM163-7044-BOQ
Item
Item Description
Qty
<-------By Vendor----->
PRESSURE TRANSMITTERS
45-PT-3013 A/B/C
45-PT-3014 A/B/C
45-PT-3015 A/B/C
45-PT-3016 A/B/C
45-LT-3017
Main Transmitter
Main Transmitter
Main Transmitter
Main Transmitter
Main Transmitter
3
3
3
3
1
Commissioning Spares
Spare 1
Pressure
Transmitter
Spare 3
10
Spare 4
Page 1 of 1
EM163-E-7022
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
SAFETY RELIEF VALVE
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
11.09.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7022
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7022
ENQUIRY SPECIFICATION FOR
SAFETY RELIEF VALVE
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
2
3
4
5
6
DRAWINGS/
DOCUMENTS.DESCRIPTION
GENERAL CONDITIONS FOR
INSTRUMENTS
ENGINEERING SPECIFICATIONS
FOR SAFETY RELIEF VALVE
INSTRUMENT SPECIFICATION FOR
SAFETY RELIEF VALVE
SPARE LIST FOR SAFETY RELIEF
VALVE
BOQ FOR SAFETY RELIEF VALVE
SKETCH FOR SAFETY RELIEF
VALVE
ATTACHMENT NO. /
DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7234
09
EM163-7022-ISP-7234
03
EM163-7022-SP-7234
01
EM163-7022-BOQ-7234
EM163-7022-SK-7234
01
01
EM163-E-7022
ENQUIRY SPECIFICATION FOR
SAFETY RELIEF VALVE
DOCUMENT NO
SHEET 3 OF 3
TAG NO.
45-PSV-3001A/B
45-PSV-3002A/B
45-PSV-3003A/B
45-PSV-3004A/B
45-PSV-3007A/B
P & ID
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
EM163-45-0024(P4)
QTY
02
02
02
02
02
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
aligarh, Golaghat Distrrict
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
mbient Air Temperature
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
eismic Facttor - 0.04
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions
12
Precipitation Annual me
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES-7234
DOCUMENT NO
REV
SHEET 1 OF 9
ENGINEERING SPECIFICATION
FOR
SAFETY RELIEF VALVES
0
REV
05.02.1999
REV DATE
EFF DATE
DDCPN
PREPD
CISC
REVWD
DHPV
APPD
ES-7234
DOCUMENT NO
REV
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
1.0
DESCRIPTION
GENERAL
SHEET NUMBER
2.0
3.0
4.0
5.0
6.0
7.0
SPARES
8.0
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7234
DOCUMENT NO
REV
SHEET 3 OF 9
1.00
General
1.01
This general specification together with the data sheets and inspection standards
attached herewith define the technical requirement for the supply of Safety / Relief
valves, spares, documentation, inspection-testing and shipping.
1.02
2.00
2.01
The pressure relieving devices design, manufacture, installation and testing shall be in
accordance with the following codes and recommendations and as specified in the
individual specification sheets:
a) ASME Boiler and pressure vessel code section I
- Design, manufacture and calculation for steam services in fired pressure
vessels.
b) ASME Boiler and pressure vessel code section VIII
- Design, manufacture and calculation for steam, gas, vapour and liquid services in
unfired pressure vessels
c) API-RP-520, part I and II sizing, selection & installation of pressure
system in refineries.
relieving
3.01
The manufacturer shall furnish calculations in accordance with the code specified in the
individual instrument specification sheets. Each manufacturer to state its own K factor
and actual measurable area. In addition, approx. weight of each valve shall be specified.
ES-7234
DOCUMENT NO
REV
SHEET 4 OF 9
All the above information shall be submitted at the time of bidding, approval after order
placement & alongwith final despatch.
3.02
The percent over-pressure and accumulation used in calculation for sizing of relieving
devices shall be considered as indicated in the individual specification sheet.
3.03
For Steam, BFW & condensate services the instrument shall be IBR certified. For items of
foreign origin the certification shall be done by Lloyds or any other IBR approved
authorities in specific IBR format.
3.04
3.05
For corrosive services like UREA wetted parts of stainless steel 316L grade and Cr-Ni-Mo
25-22-2 alloy shall be used. For these materials chemical analysis and corrosion tests
(Huey test) shall be carried out as per ASTM A 262 practice C. The tests shall be carried
out in an approved laboratory.
3.06
All safety valves of inlet rating 900# and above shall be subjected to
radiography/ultrasonic test as per procedures outlined in ASME-B16.34 and mutually
agreed quality assurance plan, if not otherwise stated in the individual specification sheet
.
3.07
In general, safety / relief valves for thermal expansion (on liquids) shall be 3/4 x 1, NPT
ASME B 2-1 unless otherwise specified in specification sheet.
3.08
All valves except thermal relief ones shall be full nozzle type. All valves shall have the
facility of blow-down adjustment except thermal relief valves. Base/modified or seminozzle types shall be specified for thermal relief valves.
3.09
Lifting Levers shall be furnished for exposed spring bonnets on valves in steam and hot
water service, on air and hot water valves with closed bonnets. All the lifting levers shall
be packed type unless the valve is handling inert gas at ambient temperature.
3.10
Bonnets shall be plain closed ones for toxic or inflammable gases as well as for vapours
and liquids. Exposed spring bonnet shall be specified for steam service and in boiler feed
water service above 2000 C. Extension type of bonnet shall be used above 4000 C &
cryogenic service.
3.11
Balancing or Sealing Bellows shall be used under the following conditions or as specified
in the individual specification sheet.
a) When the back pressure exceeds 10% of the set pressure.
b) The back pressure is variable.
c) The valve is handling corrosive fluid.
3.12
Material Of Valve Body shall conform to the material specified in the enclosed individual
instrument specification sheets. In general valve body material and rating shall conform
to upstream line specification or specification of the vessel wherever it is mounted.
3.13
Material of nozzle and disc shall be, in general, SS 316 (A182 F316) and 17.4 pH or
316SS with stellite facing, for high pressure drop/abrasive services if not otherwise stated
in the individual instrument specification sheets.
ES-7234
DOCUMENT NO
REV
SHEET 5 OF 9
3.14
Springs shall be carbon steel cadmium plated (rust proof) for normal process operating
temperature (-) 250 C to 2000 C and tungsten/ alloy steel for high temperature above 2000
C. Below (-) 250 C stainless steel may be used. Carbon steel (Rust proof) is permitted
above 2000 C when the bonnet is open.
3.15
Test Gag shall be furnished on all safety and relief valves and they shall be handed over
to owner after testing clearly labelled with the tag number of the valve they belong to.
3.16
The manufacturer must specify Cold Differential Set Pressure (CDSP) for each pressure
relieving devices at 250 C.
3.17
Rupture disc if specified used at inlet of safety valves shall have fragmentation free burst.
The stamped capacity of safety valves shall be derated by 20%, unless the combined
capacity of the rupture disc and safety relief valve is established by the disc
manufacturer.
3.18
The space between safety valve and rupture disc shall be vented during normal
operation. The disc holder shall be supplied with 4 telltale pressure gauge with SS
body, wetted parts, pipe nipple, excess flow valve. The excess flow valve and pressure
gauge shall have 1/2 NPT connections.
3.19
Burst sensors with rupture discs in hazardous areas shall either be ex-proof or intrinsic
safe confirming to area classification & execution specified against each item in the
individual specification sheets.
Ex-proof certification confirming to CENELEC, FM, BASEEFA and IS is preferred. IS 2148 certification must be supplemented with the temperature classification certification
confirming to IS - 8239.
Intrinsic safe certification shall in general confirm to CENELEC standard EN 500014 and
EN 50020, if not otherwise specified in the individual specification sheet.
3.20
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
4.00
4.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test. In absence of any Inspection Agency the vendor must
submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in such cases,
shall be conducted by vendors Quality Department and the results of tests shall be
forwarded alongwith the supply.
4.02
The manufacturer shall give clear 15 days notice informing readiness of the valves at
manufacturers works.
4.03
The vendor shall permit the authorised representative of PDIL/OWNER to inspect the
manufacture and assembly of the valves in various phases in compliance with approved
drawings, standards and specifications.
4.04
The vendor should make available to the authorised inspector the results of all the
checks/calibrations conducted before presenting for PDIL/Owners inspection.
ES-7234
DOCUMENT NO
REV
SHEET 6 OF 9
4.06
The vendor to provide all necessary facilities free of cost to PDIL/Owners inspector for
carrying out the checks/calibration as per standard/approved quality assurance plan. In
no condition inspection can be waived off without the written permission of PDIL.
4.07
No assembly shall be shipped until all the required tests are successfully completed and
certified Cleared for despatch by the inspection authority.
4.08
b)
a) For valve calibration < 5 kg/cm2, +/- 2.8% of the calibrated value.
For valve calibration > 5 kg/cm2, +/- 3% of the calibrated value.
4.09
The following tests shall be carried out as a minimum for safety valves
(i)
(ii)
Hydraulic pressure tests for primary parts (Refer ANSI B 96.1 for terminology) shall be
tested at 1.5 times the set pressure.
(iii)
Pneumatic shell test for closed bonnet valves on secondary side shall be at 1.5 times
back pressure (or) 2 kg/cm2 whichever higher when back pressure is zero or not stated.
For positive back pressure test pressure shall be 1.5 times the back pressure.
(iv)
Seat leakage test for metal to metal seated safety valves shall be done in accordance
with API-527. For steam, soft seat, pilot valves and special cases where leakage test is
not covered in API-527, the procedure for testing in such cases shall be mutually
decided and recorded in the Quality assurance plan.
(v)
Foundry /forge shop test certificate to be provided for verification of body, bonnet, nozzle
for conformance to standards.
(vi)
(vii)
(viii)
(xi)
(xii)
Corrosion test (Huey test) wherever applicable. refer clause no. 3.05
(xiii)
4.10
5.00
provided.
ES-7234
DOCUMENT NO
REV
SHEET 7 OF 9
6.00
6.01
Each safety / relief valve shall be fitted with a stainless steel permanently fixed
name plate with the following minimum information:
-
All valves are applied two coats of red oxide metal primer, prior to applying two final coats
of synthetic enamel paint. The second coat of synthetic enamel paint is applied just
before despatch.
7.00
Spares
Spares shall be as per enclosed spares list.
ES-7234
DOCUMENT NO
REV
SHEET 8 OF 9
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final documentation
before despatch of consignment.
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
1.
Yes
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Yes
Yes(I)
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes
Yes
Yes
Yes
(approx. weight)
X
Yes(I)
Yes
Yes
Yes
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
12.
15.
16.
Radiography inspection
certificate for steel
castings and forgings
wherever applicable.
Impact test results for LT
steel castings and forgings
wherever applicable.
Installation, operating and
maintenance manual (12
sets) including parts lists.
Transparency for each tag
no. dimensional drawings.
Quality Assurance Plan
13.
14.
17.
18.
19.
20.
(A)
for Approval
(I)
ES-7234
DOCUMENT NO
REV
SHEET 9 OF 9
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information.
Sl. no. 1 to 19 shall be forwarded to PDIL/OWNER as per details outlined in Enquiry / order.
Sl. no. 20 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
:
:
:
:
:
:
:
EM163
LPG MOUNDED BULLETS
NUMALIGARH,ASSAM
NRL
EM163-E-7022
MATERIAL
ACCESS.
16. BELLOWS
17. CAP
18. LIFTING LEVER
19. TEST GAG
20. PILOT BODY/ NOZZLE MATERIAL
21. FLUID/ FLUID STATE
22. RELIEVING CAPACITY
23. % ALLOWANCE OVER PRESSURE
24. % BLOWDOWN REQUIRED
25. OPERATING/SET PRESSURE
26. OPERATING/ RELIEVING TEMP.
1 24.09.2015
0 14.09.2015
P 21.07.2015
REV
DATE
EM163-7022-ISP-7234
DOCUMENT NO.
AK
AK
AK
PREP
RA
RA
RA
CHKD
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
'0.62-2.26 Kg/cmg
-
'0.62-2.26 Kg/cmg
-
13974.09 ft
249.6 cm(124.8cmforeachPSV)
42.19 inch (26 inch for each valve)
T
NOTE-1
13974.09 ft
249.6 cm(124.8cmforeachPSV)
42.19 inch (26 inch for each valve)
T
NOTE-1
30.
31.
34.
35.
LIQ.PH.
33.
37.
38.
39.
BACK PR.
2
36. ACCULUMATION % MAWP (Kg/cm g)
41.
42.
44.
45.
46.
TUBE FAILURE
40.
43.
47.
48.
49.
50.
ORIFICE
32.
FIRE
29.
GAS PHASE
ENVIRONMENTAL FACTOR
EXPOSED WET AREA
OPTION
MODEL NO. :
SKT
SKT
SKT
APPD
1. Vendor to Specify.
2. LPG Bullet is horizontal , ID =7000mm , TL-TL : 52000 mm. Both ends of Bullet are hemispherical.
3. Vendor to submit safety valve sizing calculations and reconfirm the size.
:
:
:
:
:
:
:
EM163
LPG MOUNDED BULLETS
NUMALIGARH,ASSAM
NRL
EM163-E-7022
MATERIAL
ACCESS.
16. BELLOWS
17. CAP
18. LIFTING LEVER
19. TEST GAG
20. PILOT BODY/ NOZZLE MATERIAL
21. FLUID/ FLUID STATE
22. RELIEVING CAPACITY
23. % ALLOWANCE OVER PRESSURE
24. % BLOWDOWN REQUIRED
25. OPERATING/SET PRESSURE
26. OPERATING/ RELIEVING TEMP.
1 24.09.2015
0 14.09.2015
P 21.07.2015
REV
DATE
EM163-7022-ISP-7234
DOCUMENT NO.
AK
AK
AK
PREP
RA
RA
RA
CHKD
45-PSV-3003A,B / 02 /EM163-45-0022(P2)
LPG
8"-P-45-3030,3028-B1A / 45-VV-103
SAFETY RELIEF VALVE
14.5 Kg/Cm2g / (-)27 to 55 Deg. C
CLOSED
API 520 / ASME SECTION VIII
EXTERNAL FIRE
8" 300#RF
10" 150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cadmium Plated Carbon Steel (Rust Proof)
SS316L
SCREWED
PACKED LIFTING LEVER
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40 / 65 C
45-PSV-3004A,B / 02 /EM163-45-0022(P2)
LPG
8"-P-45-3039,3037-B1A / 45-VV-104
SAFETY RELIEF VALVE
14.5 Kg/Cm2g / (-)27 to 55 Deg. C
CLOSED
API 520 / ASME SECTION VIII
EXTERNAL FIRE
8"300#RF
10" 150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cadmium Plated Carbon Steel (Rust Proof)
SS316L
SCREWED
PACKED LIFTING LEVER
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40/ 65 C
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
'0.62-2.26 Kg/cmg
-
'0.62-2.26 Kg/cmg
-
13974.09 ft
249.6 cm(124.8cmforeachPSV)
42.19 inch (26 inch for each valve)
T
NOTE-1
13974.09 ft
249.6 cm(124.8cmforeachPSV)
42.19 inch (26 inch for each valve)
T
NOTE-1
30.
31.
34.
35.
LIQ.PH.
33.
37.
38.
39.
BACK PR.
2
36. ACCULUMATION % MAWP (Kg/cm g)
41.
42.
44.
45.
46.
TUBE FAILURE
40.
43.
47.
48.
49.
50.
ORIFIC
32.
FIRE
29.
GAS PHASE
ENVIRONMENTAL FACTOR
EXPOSED WET AREA
OPTION
MODEL NO. :
SKT
SKT
SKT
APPD
1. Vendor to Specify.
2. LPG Bullet is horizontal , ID =7000mm , TL-TL : 52000 mm.Both ends of Bullet are hemispherical.
3. Vendor to submit safety valve sizing calculations and reconfirm the size.
:
:
:
:
:
:
:
EM163
LPG MOUNDED BULLETS
NUMALIGARH,ASSAM
NRL
EM163-E-7022
ACCESS.
17. CAP
18. LIFTING LEVER
19. TEST GAG
20. PILOT BODY/ NOZZLE MATERIAL
21. FLUID/ FLUID STATE
22. RELIEVING CAPACITY
23. % ALLOWANCE OVER PRESSURE
24. % BLOWDOWN REQUIRED
25. OPERATING/SET PRESSURE
26. OPERATING/ RELIEVING TEMP.
1 24.09.2015
0 14.09.2015
P 21.07.2015
REV
DATE
45-PSV-3007A,B/02/EM163-45-0024(P4)
LPG
1"-FL-45-3078-B1A
SAFETY RELIEF VALVE (BELLOWS)
18 Kg/Cm2g /
90 Deg. C
CLOSED
API 520 / ASME SECTION VIII
EXTERNAL FIRE
1" 150#RF
2" 150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cd Plated Carbon Steel (Rust Proof)
SS316L
SCREWED
PACKED LIFTING LEVER
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40 / 65 C
28.
30.
31.
33.
34.
35.
LIQ.PH.
32.
39.
BACK PR.
37.
38.
41.
42.
44.
45.
46.
TUBE FAILURE
40.
43.
48.
50.
ENVIRONMENTAL FACTOR
EXPOSED WET AREA
ORIFIC
OPTION
'0.62-2.26 Kg/cmg
-
47.
49.
NOTES
52.8 / 64 Kcal/kg
0.84
1.17
-
2
36. ACCULUMATION % MAWP (Kg/cm g)
FIRE
29.
GAS PHASE
44.615 ft
0.7968 cm
0.196 inch
E
NO
NOTE-1
1. Vendor to Specify.
2. Vendor to submit safety valve sizing calculations and reconfirm the size.
EM163-7022-ISP-7234
DOCUMENT NO.
AK
AK
AK
PREP
RA
RA
RA
CHKD
SKT
SKT
SKT
APPD
EM163-7022-SP-7234
DOCUMENT NO
SHEET
1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years spares recommended
by them.
EM163-7022-BOQ-7234
Bill of Quantity
Rev 1/ 24.09.2015
Sl
No
1
Item
Item Description
SAFETY RELIEF VALVES
PSV-3001A/B
Main Valve
Gasket
Commissionin 'O' RING
g Spares
Other Vendor Recommended Spares
2 Nos
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Main Valve
PSV-3002A/B
2 Sets
2 Nos
Commissionin Gasket
g Spares
'O' RING
Other Vendor Recommended Spares
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Main Valve
PSV-3003A/B
2 Sets
2 Sets
2 Nos
Commissionin Gasket
g Spares
'O' RING
Other Vendor Recommended Spares
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Main Valve
2 Nos
Gasket
2 Sets
2 Sets
2 Sets
PSV-3004A/B
Commissionin
'O' RING
g Spares
Other Vendor Recommended Spares
Qty
45-PSV-3007A/B
Gasket
Commissionin
'O' RING
g Spares
Other Vendor Recommended Spares
Spare 2 Years Gasket
'O' RING
DISC INSERT
NOZZLE
SPRING
Other Vendor Recommended Spares
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Nos
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Model No / Part No
<----------By Vendor---------------------->
OVERALL DIMENSIONS OF
EM163-E-7022-SK-7234
DOCUMENT NO.
REV
OF 1
SHEET 1
INLET
TAG NO.
45-PSV-3001A
45-PSV-3001B
45-PSV-3002A
45-PSV-3002B
45-PSV-3003A
45-PSV-3003B
45-PSV-3004A
45-PSV-3004B
45-PSV-3007A
45-PSV-3007B
SIZE
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
RATING
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
OUTLET
SIZE
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
RATING
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
DIMENSIONS (MM)
A
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
B
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
C
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
WEIGHT IN Kg.
REMARKS
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
NOTE1: BY VENDOR
EM163-E-7058
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
DIAL THERMOMETERS
(BIMETAL THERMOMETER)
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7058
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
EM163-E-7058
ENQUIRY SPECIFICATION FOR
DIAL THERMOMETERS
(BIMETAL THERMOMETER)
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
2
4
5
6
DRAWINGS/
DOCUMENTS.DESCRIPTION
GENERAL CONDITIONS FOR
INSTRUMENTS
ENGINEERING SPECIFICATIONS
FOR DIAL THERMOMETERS
(BIMETAL THERMOMETER)
INSTRUMENT SPECIFICATION
FOR DIAL THERMOMETERS
(BIMETAL THERMOMETER)
SPARE LIST FOR DIAL
THERMOMETERS
BILL OF QUANTITY FOR DIAL
THERMOMETERS
SKETCHES FOR DIAL
THERMOMETERS
ATTACHMENT NO./
DOCUMENT NO
EM163-45-102
NO. OF PAGES
01
ES-7321
08
EM163-7058-ISP7321
01
EM163-7058-SP-01
01
EM163-7058-BOQ
01
EM163-7058SK7321-00
02
EM163-E-7058
ENQUIRY SPECIFICATION FOR
DIAL THERMOMETERS
(BIMETAL THERMOMETER)
DOCUMENT NO
SHEET 3 OF 3
TAG NO.
P&ID NO.
QTY
1.
45-TG-3005
P4
01
EM163-45- 102
Document No.
Sheet 1 of 2
Rev.
GENERALCONDITIONS
1.0 SITE METEROLOGICAL DATA
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
90 mm
Wind
Wind code
Seismic Factor
Elevation
36 km/hr
10
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEET 1 OF 8
ENGINEERING SPECIFICATION
FOR
TEMPERATURE GAUGES & THERMOWELL
00 02.01.2010
REV REV DATE
EFF DATE
FOR ENQUIRY
PURPOSE
SK
PREPD
SKT
REVWD
SKT
APPD
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEE 2 OF 8
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEE 3 OF 8
1.00
General
1.01
1.02
2.00
General Requirements
2.01
2.01.01
The Bi-metallic type Dial Thermometers shall be heavy duty precision type.
2.01.02
The thermometer shall be either rigid straight or rigid axial stem or swinging stem with
rotable head as specified against individual specification sheets.
2.01.03
2.02
2.02.01
The Mercury/ gas filled in Steel type Dial Thermometers shall be heavy duty precision type.
2.02.02
2.02.03
2.02.04
2.03
Thermowell
2.03.01
2.03.02
The screwed type thermowell shall have 1 NPT (M) process connection & NPT (F) for
sensor connection.
2.03.03
2.03.04
Thermowells of length 600 mm and below shall be fabricated from bar stock. Above 600
mm length bar stock-bar stock combination and bar stock-pipe combination may be used.
Welding joints shall be radiographed.
2.03.05
The thermowell design shall be as per sketches mentioned against each item in the
instrument specification sheets.
2.04
The scope as per enclosed instrument specification sheets may include either Bimetallic
Type or Mercury/ gas filled in Steel Type Dial Thermometers. Relevant portion of the
general requirement (item 2.01 to 2.02) shall be applicable for the items covered in the
scope.
2.05
Vendor shall submit thermometer assembly drawings developed at their end on the basis of
the drawings indicated against each tag in the instrument specification sheets. If scope
drawings are not available the vendor shall prepare the same and submit to the Indenter
for approval.
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEE 4 OF 8
2.06
For steam, BFW & condensate services the thermowell shall be IBR certified. For items of
foreign origin the certification shall be done by Lloyds or any other IBR approved authorities
in specific IBR formats.
2.07
For corrosive services like UREA, wetted parts of stainless steel 316L grade and Cr-Ni-Mo
25-22-2 alloy shall be used. For these material chemical analysis and corrosion tests
(Huey test) shall be carried out as per ASTM A 262 practice C if Huey test is specified in
the instrument specification. The tests shall be carried out in an approved laboratory.
2.08
Wherever NACE certificate requirement has been specified in Instrument specification, the
material composition & hardness tests shall be conducted only as per MR-0175 latest
edition. The tests shall be carried out in an approved laboratory.
2.09
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection Agency
specified in the order and finalize with them the Quality Assurance Plan for carrying out
Inspection and test. In absence of any Inspection Agency the vendor must submit the
quality Assurance Plan for OWNERs approval. All tests, in such cases, shall be conducted
by vendors Quality Department and the results of tests shall be forwarded alongwith the
supply.
The manufacturer shall give clear 15 days notice informing readiness of the instrument at
manufacturers works. The vendor shall permit the authorized representative of OWNER to
inspect the manufacture and assembly of the instrument in various phases in compliance
with mutually agreed quality assurance plan, standards and specifications. The vendor
shall make available to the authorized representative of OWNER the results of all the
checks/calibrations conducted before presenting for Owners inspection. The vendor to
provide all necessary facilities free of cost to Owners representative for carrying out the
checks/calibration as per standard/approved quality assurance plan. Under no condition
inspection can be waived off without the written permission of OWNER.
3.02
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for dispatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall be
governed by Quality Assurance Plan mutually agreed and approved by Inspection
Authority.
THERMOMETER ELEMENTS
A. Physical checks
B. Routine test
1. Leak test for Mercury in steel type Dial Thermometers.
2. Check for calibration
C. Type test
1. Response time
2. Vibration test
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEE 5 OF 8
THERMOWELL
A. Routine inspection & test
1. Physical dimension checking
2. Hydro test (at minimum 1.5 times of Maximum Pressure)
B. Other tests
1. Radiography for bore concentricity (10%), if not otherwise specified in the
individual specification sheets.
2. Radiography for thermowells of pressure rating 100 kg/cm2 g and above (100 %)
3. Die Penetration Test
3. IBR (wherever applicable)
4. Huey Test (wherever applicable)
5. NACE (wherever applicable)
4.00
Packing
Each thermoelement or alongwith assembly shall be suitably packed and protected from
damage due to transportation, loading and unloading.
The above items alongwith spares (commissioning spares and 2 years spares for
maintenance) shall be dispatched as a single consignment.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
Each temperature element assembly i.e. the sensing element alongwith head assembly
shall have a separate circular tag number plate in stainless steel with engraved tag no and
protecting sheath immersion length I and attached securely to the head assembly with a
soft stainless wire. The size of letters and figures shall be minimum 4 mm and the plate
should be 25 mm diameter with 1-2 mm thick.
5.02
Each thermowell shall have the following marking at position X or XX as shown in the
respective drawings.
(i) Tag no.
(ii) Thermowell model no. / Manufacturers item no.
(iii) Material of construction
(iv) Immersion length
(v) Flange size / rating / facing / material
6.00
Spares
Complete dial thermometer with well of each type & range is included as spares in the
individual instrument specification sheets. Other spares as per enclosed spares list.
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
7.0
Documentation
Technical documentation
1.1
DOCUMENT NO
SHEE 6 OF 8
General
All the documentation such as graphic drawings and technical specifications shall be
sent to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be
supplied on paper.
1.2
1.3
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
1.5
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
Hole Fill.
Resolution below 200 Dpi is not acceptable.
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEE 7 OF 8
The following documents (Technical) are required to be submitted by the vendor along with bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
Yes
(A)
For Approval
(I)
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
For information
Sl. no. 1 to 10 shall be forwarded to PDIL/ OWNER as per details outlined in enquiry/order.
Sl. no. 11 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
ES7321
ENGINEERING SPECIFICATION FOR
TEMPERATURE GAUGES & THERMOWELL
8.0
DOCUMENT NO
SHEE 8 OF 8
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to
the equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
INSTRUMENT SPECIFICATION
EM163-7058-ISP7321
DIAL THERMOMETERS
DOCUMENT NO.
SHEET 1 OF 1
(BIMETAL THERMOMETER)
CASE
GENERAL
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
INSTALLATION OF LPG MOUNDED BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7058
1
24.09.15
0
14.09.15
P
21.07.15
REV
DATE
HK
RA
HK
RA
HK
RA
PREP CHKD
SKT
SKT
SKT
APPD
1. ELEMENT/ TYPE
2.
3.
4.
5.
6.
7.
8.
9.
1/2" NPT(M)
ADJUSTABLE LENGTH , RIGID STEM
SS 316
6 MM
DIRECT ACTING
SS 304
STD BI-METAL
SS 304
10.
11.
12.
13.
14.
ENCLOSURE TYPE
GLASS
DIAL SIZE & COLOUR
SCALE LENGTH
SCALE GRADUATION
IP -65 or better
SHATTER PROOF GLASS
150 MM & BLACK NUMERALS WITH WHITE BACKGROUND
CIRCULAR 270 , SEGMENT
1 div. per C upto span of 100C , 2 div. per C above 100C upto of 300C,
5 div. per C above 300C upto of 400C , 10 div. per C above span of 400C
150 C span - Less than equal to 105 seconds up to 95% span and 50 seconds
from 95% to100% span.
Above 150 C - Less than equal to 180 seconds up to 95% span and 95 seconds
from 95% to100% span.
MICROMETER SCREW AT THE BACK, SS 304 MATERIAL
1% FSD.
OPTIONS
VENDOR OFFER /
DEVIATION
45-TG3005
01
P4
SERVICE
DRAIN
VESSEL
FOR LPG
LINE NO./
EQUIPMENT
NO
45-VV-106
MIN/NOR./MAX.
PRESS.
TEMP.
Kg/cm 2 g
deg C
-/ 2.35/14.5
RANGE
DEG C
(-27) / 10-27 to 60
40 /55
IMMERSION
LENGTH
"I. L." mm
400
THERMOWELL
PROCESS MATERIAL /
CONN.
SKETCH NO
1 1/2"
300#RF
ASTM A 182
Gr. F316 or
better /Note 1
VENDOR OFFER/
DEVIATION
EM163-7058-SP- 00
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 Years Operational spares
recommended by them.
EM163-7158-BOQ
Rev 1/14.09.2015
Bill of Quantity
Sl
No
1
ITEM
TAG NO.
TEMPERATURE GAUGE
45-TG- 3005
SPARE 1
Model No / Part No
<-------By Vendor----->
(
DIAL THERMOMETERS (BIMETAL
THERMOMETER)) WITH THERMOWELL
Commissioning Spares
2
Qty
SPARE 2
Page 1 of 1
EM163-7058SK7321-00
DOCUMENT NO.
SHEET 1
OF 2
Swing Head
( 0 - 180 Rotation )
150
Adjustable
Compression Joint
()
NPT M
Bulb 6 mm
NOTES :
1.
2.
3.
DIMENSIONS ARE TENTATIVE MAY VARY WITH EQUIPMENT SIZE & CAPACITY.
4.
1
0
P
24.09.2015
14.09.2015
20.07.2015
REV
REV DATE
EFF DATE
HK
HK
HK
RA
RA
RA
PURPOSE
PREPD
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-7058SK7321-00
DOCUMENT NO.
OF 2
200+/0.5
SHEET 2
8 mm +/- 0.2 mm
1
0
P
24.09.2015
14.09.2015
20.07.2015
REV
REV DATE
EFF DATE
HK
HK
HK
RA
RA
RA
PURPOSE
PREPD
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7046
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
MAGNETIC TYPE LEVEL GAUGE
1
0
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7046
AK
AK
PREPD
RA
RA
REVWD
SKT
SKT
APPD
EM163-E-7046
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
DRAWINGS/
DOCUMENTS.DESCRIPTION
GENERAL CONDITIONS FOR
INSTRUMENTS
ENGINEERING SPECIFICATIONS
FOR MAGNETIC TYPE LEVEL
GAUGE
INSTRUMENT SPECIFICATION
FOR LEVEL GAUGE
SPARES FOR LEVEL GAUGE
ATTACHMENT NO.
/ DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7278
09
EM163-7046-ISP7278
EM163-7046-SP7278
EM163-7046-BOQ7278
01
01
01
EM163-E-7046
DOCUMENT NO
SHEET 3 OF 3
SL.
NO.
TAG NO.
45-LG-3016
P & ID
EM163-45-0024(P4)
QTY
01
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
aligarh, Golaghat Distrrict
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
mbient Air Temperature
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
eismic Facttor - 0.04
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions
12
Precipitation Annual me
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEET 1 OF 9
ENGINEERING SPECIFICATION
FOR
LEVEL GAUGES
00 07.07.2011
REV REV DATE
EFF DATE
FOR IMPLEMENTATION
PURPOSE
PREPD
REVWD
APPD
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 3 OF 9
1.00
General
1.01
This Engineering specification is applicable for the transparent, reflex type and Magnetic
type level gauges.
This Engineering specification together with the Instrument specification attached
herewith define the technical requirement for the supply of Level gauges, their
accessories, name plate marking, documentation, testing-inspection and packing.
1.02
2.00
General Requirements
2.01
Chamber
2.01.1
The liquid chamber section (single or multiple sections) shall be made out of one piece of
solid block of carbon steel or stainless steel as per requirement. The material to be used
shall be suitably treated and chosen with care to meet exactly the physical and chemical
characteristics of the working condition.
2.01.2
The glass sealing gasket shall be suitable for the handled fluid. Both the sealing and the
cushion gaskets shall be designed to ensure uniform pressure on the glass.
2.01.3
Wherever combined sections are required to be used, they must not exceed four.
Deviations if any, are listed against each tag in the enclosed individual specification sheets.
2.01.4
The pressure rating shall be in accordance with the instrument individual specification
sheets. However, minimum pressure rating shall be 300 lbs or 40 kg/cm2 g.
2.02
Cover
The covers shall be made out of drop forged temperature resisting steel or from solid bar of
steel.
2.03
Glasses
2.03.1
The glasses shall be flawless, perfectly flat, toughened boro-silicate, polished to ensure
optimum transparency and thermally pre-stressed. They shall be suitable for use at high
temperature and pressure.
2.03.2
2.03.3
Reflex glasses wherever applicable shall be with moulded grooves at 90 deg. angles.
2.03.4
Glasses on steam services shall be protected by means of high quality mica shield.
For other erosive services kel-F shield may be used, if not otherwise stated in the
specification sheet.
2.04
Illuminators
2.04.1
Illuminators shall be provided for all transparent gauges wherever specified in Instrument
specification sheet. All illuminators shall be suitable for area classification indicated in the
specification sheet. If Indian Standard IS 2148 certification is specified in the individual
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 4 OF 9
specification sheets for Ex. proof enclosures then IS - 2148 certification must be
supplemented with the temperature classification certification confirming to IS - 8239.
2.04.2
Power supply for lamps shall be 240V 10% AC 50 Hz, cable entry 1/2 NPT (F) complete
with cable gland. The cable glands, in general, shall be double compression type of SS316
, if not otherwise specified in the individual specification sheets. The lamp holder shall be
suitable for tropical condition and shall be designed to prevent unscrewing of the lamp due
to vibration. Lamps shall be under rated for extended lifetime and shall be included in
supply. The terminals should be suitable for 3 X 2.5 mm2 Cu conductors.
2.04.3
The diffuser must not cover more than two sections for transparent gauges and it shall be
suitable for the maximum working temperature.
2.04.4
The Illuminators shall be easily removable without interfering with the operation of the level
gauges.
2.05
MAGNETIC TYPE
2.05.01 Magnetic type level gauges shall be used for the measurement of all liquids, including
dangerous, toxic or flammable fluids where glass breakage would cause a hazard.
Magnetic type level gauges shall be considered for:
Cryogenic services
Fluids that attack glass (e.g., strong acids, alkalies, boiler feed water)
Light ends services
Toxic services
Pressures above 500 psig (3450 kPa) special consideration must be given to the design
of float for high pressure
2.05.02 Magnetic- type level gauges shall consist of a liquid chamber enclosing a float which is
magnetically coupled to a rotary wafer-type indicator. The liquid chamber shall be onepiece construction with a minimum internal diameter of 50 mm, provided with a bottom
flange for removal of the float, vent and drain connections. Indicator shall be adjustable
around the chamber with provisions to indicate float failure.
2.05.03 Magnetic level gauges shall be top or side mounted type and shall consist of a float with
extended rod and magnet at the end of extension, magnet tube / chamber and float guide
pipe. When the float moves up and down with the liquid level inside the vessel, the magnet
moves up and down inside the magnet tube/chamber which in turn operates the indication
mechanism.
2.05.04 The indication shall consist of bi-colour (red/white) magnetic rollers mounted on outside the
magnet chamber. As the float rises or falls with the liquid level each roller rotates 180 Deg
and so presents a contrasting colour.
2.05.05 The accidental rotation of rollers shall be prevented by the construction/design such as
edge magnetization.
2.05.06 Floats shall be designed and manufactured for the specific conditions specified on
datasheets. It shall be designed to be adequate for hydrostatic test conditions.
2.05.07 Floats shall be hermetically sealed, no vented or pressure equalized construction shall be
allowed.
2.06
Gauge Valves
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 5 OF 9
The gauge valves shall be connected at top and bottom through 3/4 NPT unions and the
body material of gauge valves shall be same as that of chamber. Valve trim and safety ball
shall be of stainless steel. Drain and vent valves shall also be of same material and shall be
furnished with 1/2 NPT (F) connection with plug for drain and vent pipe. Requirement of
both, either or none for vent and Drain valves including quantities shall be indicated in the
option column. Hand wheel material for all gauge/drain/vent valves shall be C.S.
Deviations, if any, are listed in the individual specification sheets.
2.07
Steam Jacketing
For heavier and slurry services like reduced crude oil, heavy vacuum gas oil, slop-cut, short
residue, vac. residue, Bitumen, urea service, etc. the level gauge shall be provided with
steam jacketing arrangement. The steam jacketing connections shall be 1/2 NPT (F).
2.08
Anti-Frosting Extension
Shall be mounted on opposite side of the illuminator where the minimum operating
temperature is below zero. The extension block shall be attached with visible width of glass
and thickness shall be selected on the basis of the temperature to ensure that extension is
always ice-free.
2.09
IBR certificate
For steam, BFW and condensate services the gauge shall be tested and certified by Indian
Boiler Regulation Authorities (IBR). For items of foreign origin the certification
shall be done by Lloyds or any other IBR approved authorities in specific IBR formats.
2.10
Wherever NACE certificate requirement has been specified in Instrument specification, the
material composition & hardness tests shall be conducted only as per MR-0175 latest
edition. The tests shall be carried out in an approved laboratory.
2.11
The scope as per enclosed instrument specification sheets may include either Reflex level
gauge or transparent level gauge or combination of both. Relevant portion of the general
requirement (item 2.01 to 2.07) shall be applicable for the items covered in the scope.
2.12
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection Agency
specified in the order and finalize with them the Quality Assurance Plan for carrying out
Inspection and test. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be conducted by
vendors Quality Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the gauges at
manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the gauges in various phases in
compliance with mutually agreed quality assurance plan, standards and specifications.
The vendor shall make available to the authorized representative of PDIL / OWNER the
results of all the checks/calibrations conducted by them, if any before presenting for
PDIL/Owners inspection.
The vendor to provide all necessary facilities free of cost to PDIL/Owners representative
for carrying out the checks/calibration as per standard/approved quality assurance plan.
Under no condition inspection can be waived off without the written permission of PDIL.
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 6 OF 9
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for dispatch by the inspection authority.
3.02
The following physical checks and other tests shall be witnessed by PDIL / owner
inspection authority. The procedure & extent of test shall be governed by Quality
Assurance Plan mutually agreed and approved by Inspection Authority.
A) Physical Checks
1) Name Plate details
- Tag no.
- Model no.
- Range and C.C. distance visibility
- Execution (IP, Ex `d etc. for illuminators)
2) Process connection/Electrical connection.
3) Provision of all accessories as per specification.
4) Steam jacketing arrangement and their connection.
B) Other Tests
1) Liquid chamber hydraulic test at 1.5 times of the rated pressure (flange rating) or
kg/cm2 g whichever is greater.
40
2) Steam jacketing chamber hydraulic test up to 1.5 times the steam pressure being
used for heating purposes.
3) Functioning checking of illuminators.
4) IBR/ NACE Certification wherever applicable.
4.00
Packing
Each level gauges and its accessories shall be suitably packed and protected from damage
due to transportation, loading and unloading.
The level gauges alongwith spares for maintenance shall be dispatched as a single
consignment.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02
All level gauges shall have a tag plate in SS screwed to the level gauge case indicating
make, model no., Sl. no. , tag no., centre to centre distance etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved tag
number and attached securely to the instrument with a soft stainless wire. The size of
letters and figures shall be minimum 4 mm and the plate should be 25 mm diameter with 12 mm thick.
5.03
All spare parts to be supplied alongwith the main consignment shall be fitted with
identification plate with the following data clearly printed and easily readable.
- Spare parts name/model no. as per purchasers Instrument specification sheet.
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 7 OF 9
- Serial no.
6.00
Spares
Spares shall be as per enclosed spares list.
7.0
Documentation
Technical documentation
1.1
General
All the documentation such as graphic drawings and technical specifications shall be
sent to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be
supplied on paper.
1.2
1.3
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
1.5
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 8 OF 9
Hole Fill.
Resolution below 200 Dpi is not acceptable.
The following documents (Technical) are required to be submitted by the vendor alongwith bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes
x
Yes
x
x
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
Sl. no. 1 to 11 shall be forwarded to PDIL/ OWNER as per details outlined in enquiry / order.
Sl. no. 12 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
in the purchase order.
stipulated
ES7278
ENGINEERING SPECIFICATION FOR
LEVEL GAUGES
DOCUMENT NO
SHEE 9 OF 9
8.0
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to
the equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
INSTRUMENT SPECIFICATION
MAGNETIC LEVEL GAUGE (INTERFACE MEASUREMENT)
NRL
PROJECT
PLANT
NUMALIGARH, ASSAM
DOC NO
NO.
EM163-7046-ISP-7278
STEAM
M
JACKETI
TING
TESTING
CHECK /
DRAIN & VENT
VALVES
GAUGE
PROCESS
S
CONDITION
NS
GENERAL
CLIENT
1
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
27
28
29
30
31
45-LG-3016 / 1 No.
SERVICE
P & ID No
LINE NO. / EQUIPMENT NO.
LPG + WATER
EM163-45-0024 (P4)
- , 45-VV-106
IEC ZONE 1, Gr IIA IIB,T3
LPG/WATER
2.33
8.6 / 14.5
2.33-8.6
10-40 / 55
14.5
kg/cm2 g
-27/55
Deg C
558/1000
kg/m3
0.152/cP
MAGNETIC TYPE FOR INTERFACE MEASUREMENT
ALUMINIUM, BI COLOUR (Red & White)
NA
800 mm
800 mm
2" 300#RF (125-250 AARH)
SIDE -SIDE
2" NB,SCH 40S/ SS 316
SS-316
SPIRAL WOUND SS 304
SS316
ASTM A-105
ASTM A193 Gr B7 / ASTMA194Gr2H
IP 65 OR BETTER
BALL VALVE
ASTM A-105
SS316
TEFLON
800#
-
32
AREA CASSIFICATION
FLUID (UPPER/LOWER)
PRESSURE Nor/Max(Kg/cm2 g)
TEMPERATURE Nor/Max C
DESIGN PRESSURE
DESIGN TEMPERATURE
DENSITY (UPPER /LOWER)
VISCOSITY
TYPE
INDICATOR TYPE (FLAPPER)
SECTIONS REQUIRED
C-C DISTANCE
VISIBLE LENGTH
PROCESS CONNECTION SIZE & FINISH
CONNECTION ARRANGEMENT
BODY OR CAGE SIZE /MATERIAL
SCALE MATERIAL
GASKET MATERIAL
FLOAT MATERIAL
FLANGE MATERIAL
STUD & NUT MATERIAL
INGRESS PROTECTION
TYPE
BODY MATERIAL
TRIM MATERIAL
GLAND PACKING
RATING
HYDROGEN SERVICE REQUIREMENT
33
34
IBR REQUIREMENT
35
STEAM JACKETING
36
STEAM PARAMETER
37
NOTE
Bottom Flange Connection shall be suitable for easy removal of Float for maintenance in case of failure.
1
0
REV
24.09.15
14.09.15
DATE
AK
AK
PREPD
RA
RA
CHKD
SKT
SKT
APPD
EM163-E-7146-SP-7278
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 years Operational
spares recommended by them.
Bill of Quantity
Sl
No
Item
Item Description
45-LG-3016
EM163-E-7046-BOQ-7278
Qty
1 set
1 set
1 set
1 set
1 set
1 set
Rev 1 /24.09.2015
Model No / Part No
<-------By Vendor----->
EM163-E-7048
PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
DISPLACER TYPE LEVEL TRANSMITTER
1
0
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
REV DATE
EFF DATE
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7048
AK
AK
PREPD
RA
RA
REVWD
SKT
SKT
APPD
EM163-E-7048
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
2
5
6
DRAWINGS/
DOCUMENTS.DESCRIPTION
GENERAL CONDITIONS FOR
INSTRUMENTS
ENGINEERING SPECIFICATIONS
FOR DISPLACER TYPE LEVEL
TRANSMITTER
INSTRUMENT SPECIFICATION
FOR DISPLACER TYPE LEVEL
TRANSMITTER
SPARES FOR DISPLACER TYPE
LEVEL TRANSMITTER
BOQ FOR DISPLACER TYPE
LEVEL TRANSMITTER
ATTACHMENT NO.
/ DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7287
07
EM163-7048-ISP7287
01
EM163-7048-SP7287
EM163-7048-BOQ7287
01
01
EM163-E-7048
DOCUMENT NO
SHEET 3 OF 3
SL.
NO.
TAG NO.
P & ID
QTY
45-LT-3013
EM163-45-0024(P4)
01
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
aligarh, Golaghat Distrrict
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
mbient Air Temperature
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
eismic Facttor - 0.04
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions
12
Precipitation Annual me
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES-7287
DOCUMENT NO.
REV
SHEET
OF
LEVEL TRANSMITTER
05.02.99
REV
DATE
DDCPN
PREPARED
CISC
REVIEWED
DHPV
APPROVED
ES-7287
DOCUMENT NO.
REV
SHEET
OF
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7287
DOCUMENT NO.
REV
SHEET
OF
1.00 General
1.01 This general specification is applicable for the displacer type level transmitter with external
chamber or top vessel mounted type without chamber.
This Engineering specification together with the Instrument specification attached herewith
define the requirement for the supply of Displacer type Level transmitters, its spares,
documentation and testing.
1.02 In the event of any conflict between Engineering specification and Instrument specification
the later shall prevail.
2.00 General requirements
2.01 The displacer chamber for external mounted type shall have 1 1/2 ASME B16.5 flanged
connection or Butt weld type as per ASME B16.25 or as specified in individual Instrument
specification sheets.
2.02 All flanges and their facings shall be as per ASME B 16.5. All raised face flanges shall
have concentric serrated facing. All flanges of rating 900# and above shall have RTJ
facing. All RTJ flanges shall have groove corresponding to octagonal metal ring gaskets
as per ASME B 16.20.
2.03 Orientation of connection, rating, flange facing and centre to centre distance shall be as
indicated in individual Instrument specification sheets enclosed.
2.04 The vessel top mounted type without any external chamber shall have 4 ASME B 16.5
flanged connection or as specified in individual Instrument specification sheet.
2.05 The material of construction for external chamber, displacer, range spring, torque tube
shall be as per individual Instrument specification sheets enclosed. The construction shall
be with rotatable head and plain extension. In case the operating temperature is above
1500 C, radiating finned extension shall be provided.
2.06 The level transmission between displacer and transmitter shall be either through torque
tube or magnetic coupling.
2.07 The transmitters shall be intelligent SMART version with 4-20 mA DC analog output
superimposed with digital signal for maintenance through HART protocol. The transmitters
must have provision for upgrading the communication protocol to fieldbus in future.
2.08 Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
2.09 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating 900 lbs.
and above.
2.10 The transmitter shall have protection against reverse polarity connection.
2.11 The transmitter shall be unaffected due to radio frequency interference. The supplied
electronic part shall have susceptibility of less than 0.5% of span for a frequency range of
20 - 500 MHz in a field strength of 20 volts/ metre.
2.12 Cables entries shall be plugged to avoid damage during transit.
ES-7287
DOCUMENT NO.
REV
SHEET
OF
The external chamber, and other wetted parts in steam , BFW and condensate services
shall be tested and certified by Indian Boiler Regulation Authorities (IBR). For items of
foreign origin the certification shall be done by Lloyds or any other IBR approved
authorities in specific IBR formats.
2.14 For corrosive services like UREA and wetted parts of stainless steel 316L grade and CrNi-Mo 25-22-2 alloy shall be used for these material chemical analysis and corrosion tests
(Huey test) shall be carried out as per ASTM A 262 practice C. The tests shall be carried
out in an approved laboratory.
2.15 Wherever NACE certificate requirement has been specified in Instrument specification, the
material composition & hardness tests shall be conducted only as per MR-0175 latest
edition. The tests shall be carried out in an approved laboratory.
2.16 The electrical terminals shall be vibration proof . The transmitter terminals shall preferably
be located in a compartment separated from field electronics. Flying leads are not
acceptable.
2.17 Transmitters and switches in hazardous areas shall either be ex-proof/flame proof or
intrinsic safe conforming to area classification, execution and execution standard
specified against each item in the individual specification sheets. Indian Standard(IS)
certification IS T2148 for Ex-proof certification must be supplemented with the
temperature classification certification conforming to IS - 8239. However, any
ex.proof/flame proof certification requiring sealing of cable entry with sealing compound
or enclosures with sealed cable entry and flying leads are not acceptable.
3.01 Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test including tests to be conducted by independent agencies.
In absence of any Inspection Agency the vendor must submit the quality Assurance Plan
for PDIL/OWNERs approval. All tests, in such cases, shall be conducted by vendors
Quality Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the instruments at
manufacturers works. The vendor shall permit the authorised representative of
PDIL/OWNER to inspect the manufacture and assembly of the level transmitter in various
phases in compliance with mutually agreed quality assurance plan, standards and
specifications.
The vendor shall make available to the authorised representative of PDIL / OWNER the
results of all the checks / calibrations conducted by them on the basis of approved Quality
Assurance Plan for PDIL/Owners inspection.
The vendor to provide all necessary facilities free of cost to PDIL/Owners representative
for carrying out the checks/calibration as per standard/approved quality assurance plan.
Under no condition inspection can be waived off without the written permission of PDIL.
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for despatch by the inspection authority.
ES-7287
DOCUMENT NO.
REV
SHEET
OF
3.02 The following physical checks, routine tests as a minimum shall be witnessed by PDIL /
owner inspection authority. The procedure & extent of test shall be governed by Quality
Assurance Plan mutually agreed and approved by Inspection Authority.
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
2. Process connection
B. Routine tests
1. Calibration check for accuracy, linearity, hysteresis and repeatability
2. Zero-shift
3. Hydraulic test.
3.03 Other Tests
Vendor shall submit following certificates from a approved laboratory or from statuary
bodies ,as applicable.
1. Chemical Analysis
2. Huey test where applicable
3. Radiography/Ultrasonic examination of welded joints for rating 900# and above
4. IBR for steam BFW & steam condensate services.
4.00 Packing
Each transmitter and its accessories shall be suitably packed and protected from damage
due to transportation, loading and unloading.
The transmitters and their accessories alongwith spares shall be despatched as a single
consignment. Commissioning and 2 years operation spares shall be packed separately
with proper identification marking.
5.00 Identification and Marking
5.01 Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02 All instruments shall have a tag plate in SS screwed to the transmitter case indicating
make, model no., sl.no., tag no., adjustable range, set range etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved
tag number and calibration range and attached securely to the instrument with a soft
stainless wire. The size of letters and figures shall be minimum 4 mm and the plate
should be 25 mm diameter with
1-2 mm thick.
5.03
All spare parts to be supplied alongwith the main consignment shall be fitted with
identification plate with the following data clearly printed and easily readable.
- Spare parts name, model no. as per purchasers Instrument specification sheet.
ES-7287
DOCUMENT NO.
REV
SHEET
OF
ES-7287
DOCUMENT NO.
REV
SHEET
OF
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
x
x
x
x
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A) (within 2
weeks)
(A)
for Approval
(I)
for Information
Sl. no. 1 to 11 shall be forwarded to PDIL/ OWNER as per details outlined in enquiry / order.
Sl. no. 12 shall be mutually finalised with Inspection authority specified in the order.
: EM-163
PROJECT
PLANT
: NUMALIGARH, ASSAM
CUSTOMER
: NRL
OPTIONS
TRANSMITTER
PROCESS
DATA
DISPLACER
BODY
GENERAL
REQ. NO.
: EM163-E-7148
ORDER NO.
:
MANUFACTURER
:
1. TAG NO./ QTY.
2. SERVICE
3. P&I NO./ VESSEL NO.
4. AREA CLASSIFICATION
5. BODY / CAGE MATERIAL
6. NOZZLE SIZE/ORIENTATION
7. NOZZLE RATING & MATERIAL
8. NOZZLE C/C DISTANCE
9. CASE MOUNTING
10. TRANSMISSION
11. TORQUE TUBE MATERIAL
12. RANGE SPRING MATERIAL
13. DRAIN / VENT CONNECTION
14. DRAIN / VENT VALVE MATERIAL
15. VENT VALVE SIZE & RATING
EM163-E-7148-ISP-7287
DOCUMENT NO.
24.09.15
0 14.09.15
Issued For Enquiry
REV DATE
PURPOSE
45-LT-3013 / 1 No. FOR INTERFACE MEASUREMENT
AK
RA
SKT
AK
PREP
RA
CHKD
APPD
LPG / WATER
EM163-45-0024 (P4) / 45-VV-106
ZONE-1, IIA IIB , T3 as per IEC Norms
SS316
3" / Side-Side
300# / ASTM A105
800 mm
Note-1
LVDT / Torque Tube
SS 316
SS 316
1/2" NPT , Vent conn. shall be plugged
Body: A105 ; Trim: SS 316
1/2", 800# , Qty. 2 Nos.
Note-1
Note-1
SS 316
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
SS 316
LPG / Water
-/558 / 1000 Kg/m3
0.152 / CP
30.
31.
32.
33.
34.
35.
36.
ACCURACY
OUTPUT ACTION: LEVEL RISE
ENVIRONMENTAL PROTECTION
EXECUTION
OUTPUT METER LINEAR
ELEC. POWER/ AIR SUPPLY
CABLE GLAND CONNECTION
38. RANGEABILITY
3:1
39.
40.
41.
42.
43.
CALIBRATION
IBR/ NACE CERTIFICATE
RADIOGRAPHY / ULTRASONIC
CORROSION (HUEY) TEST
HAND HELD CALIBRATOR
SKT
Yes
REQUIRED
REQUIRED. DIGITAL, Loop Powered with mounting accessories, visible from Deadman
type valve + SS Plug, IP-65 with two nos. cable entries.
REQUIRED
Note-1
NOTES :
1. Manufacturer to specify.
2. Interconnecting Cable between Displacer Level Transmitter and Local Indicator shall be in Vendor's
scope. Vendor to specify length.
EM163-E-7048-SP-7287
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 Years Operational spares
recommended.
EM163-E-7048-BOQ7287
Bill of Quanity
Rev 1 / 24.09.2015
Sl
No
Item
Item Description
Qty
Model No / Part No
<-------By Vendor----->
DISPLACER TYPE LEVEL TRANSMITTER
45-LT-3013
1
Main Transmitter
2
3
COMMISSIONING SPARES
Gasket
Spare 1
DISPLACER
Spare 2
1 SET
1 SET
EM163-PNIN-7901-PA
ART C
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTC
SPECIF
FICATIO
ONS FOR
R ERECT
TION MA
ATERIALS OF
TECHNICAL
L SPECIF
FICATIO
ONS
OR PROC
CUREMENT AN
ND
FO
INSTALL
LATION / COMM
MISSION
NING OF
INST
TRUMEN
NTS
Job
b NO
: EM
M163
Pro
oject
: IN
NSTALLA
ATION OF MOUNDED BULL
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
ent
Clie
: NR
RL
24.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
14.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
21.07.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
ES-7337
DOCUMENT NO.
REV
SHEET
1 OF
INSTRUMENT VALVES
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7337
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7337
DOCUMENT NO.
REV
SHEET 3
OF 5
1.00
General
1.01
1.02
2.00
General Requirements
2.01
2.02
The instrument isolation valves shall be globle pattern forged / barstock with inside
screwed bonnet. The body and trim material, body rating and end connections
shall be as specified in the technical specification. The threadings shall be as per
ANSI B 2.1. The packing material shall be teflon unless otherwise specified. The
handwheel material shall be carbon steel zinc plated. Flow direction shall be
marked on the body. IBR certificate in form IIC, NACE certificate as per NACE
MR-0175-94 shall be furnished wherever required.
2.03
The air line valves shall be three piece full bore ball valves. Body material shall be
SS304 and trim material shall be SS 316 unless otherwise specified in technical
specification. The rating shall be 800#.
2.04
The 3-valve manifolds shall be designed for direct coupling to differential pressure
transmitters having 2 bolt flanges. The manifolds shall contain two main block
valves and an equalising by-pass valve. The valves shall be needle type. They
shall use self aligning 316SS ball seats. The manifold shall be suitable for
mounting on 2 pipe. Packing and O ring material shall be Teflon body material
shall be SS316 and minimum rating 100 kg/cm unless otherwise specified. The
process connection shall be 1/2 NPT(F). The manifolds shall be supplied with
mounting accessories (Cadmium plated) and bolts and nuts.
2.05
The 2 valve manifolds for pressure gauges shall be needle type with vend screw.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
material at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
material in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications.
ES-7337
DOCUMENT NO.
REV
SHEET 4
OF 5
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
The following checks shall be carried out on 10% of each size of fittings selected
by the inspector.
4.00
Packing
Each valve shall be suitably packed and protected from damage due to
transportation, loading and unloading. Threaded fittings shall have plastic caps to
protect the threadings.
The valve and spare ferrules shall be packed separately by sizes and grades in
individual chlorine free water proof packets and tagged.
5.01
Each valve shall have the following details punched at the sides easily visible.
- Valve size with part no.
- material
- rating
- threaded standard, if any (NPT)
- Manufacturers model no.
- IBR stamping for IBR fittings.
5.02
In addition each valve shall have a SS tag plate 25mm dia 1.2 mm thick securely
tied with soft annealed SS wire. The tag plates shall contain on both sides the part
no., size, material rating, threading standards where applicable. The size of
lettering and figures shall not be less than 4mm.
6.00
ES-7337
DOCUMENT NO.
REV
SHEET 5
OF 5
Spares
Spares quantities are included in the main item quantity.
7.00
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
x
x
x
Yes(A)
(within 2 weeks)
Yes
x
for information
Sl. no. 1 to 8 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 9 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets along with bid for approval and as final documentation shall be supplied
as stipulated in the purchase order.
ES-7334
DOCUMENT NO.
REV
SHEET
OF
COMPRESSION FITTINGS
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7334
DOCUMENT NO.
REV
SHEET 2
OF 6
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7334
DOCUMENT NO.
REV
SHEET 3
OF 6
1.00
General
1.01
1.02
2.00
General Requirements
2.01
2.02
2.03
Straight bodies, nuts and ferrules shall be from forged barstock 316SS conforming
to ASTM-A-276, ASTM-A-316 and ASTM-A-473.
2.04
Fittings shall be free from all burrs and loose scale which might become dislodged
in usage and all other defects which might affect their serviceability. All sealing
surfaces must be smooth to one micron.
2.05
2.06
The tube fittings shall provide a leak-proof, torque-free seal at all tubing connection
and eliminate costly, hazardous leaks in instrumentation and process tubing. Nuts
and ferrules of particular size shall be interchangeable for each type.
2.07
The tube fittings shall be such that all the action in the fittings moves along the
tube axially instead of with a rotary motion. Since no torque is transmitted from the
fittings to the tubing, there is no initial strain which might weaken the tubing.
2.08
The tube fittings shall be such that no end preparation of the tubes is required
other than the tubes are cut square and joint is made by the compression of two
ferrules on the outside wall of the tube.
2.09
The tube fittings shall be such that they are easily installed without any special
tools.
2.10
The fittings shall be fully tightened in 1 turn after hand tight of nut.
2.11
The tube fittings when assembled with the respective tubings must withstand the
following forces and/or combination of forces.
- Internal pressure
- Tension
- Compression
- Torque
- Vibration
- Temperature variation
ES-7334
DOCUMENT NO.
REV
SHEET 4
OF 6
2.12
2.13
All fittings shall have American national standard taper pipe threads (NPT) as per
ANSI B2.1. Spanner hold shall be metric.
2.14
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
material at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
material in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications.
The vendor shall make available to the authorised representative of PDIL /
OWNER the results of all the tests conducted before presenting for PDIL/Owners
inspection.
Normally the vendor shall have their own quality control requirements and
procedures for conducting the type tests. If the same is not acceptable by PDIL/
OWNER representative, the procedure & extent of type test requirement shall be
mutually discussed and agreed upon by vendor & PDIL/OWNER representative
and shall be covered in Quality Assurance Plan. Vendor must submit to the
Inspection authority all the results of the type tests conducted by them for their
approval. However, if the PDIL/OWNER representative is not satisfied with the
results, he may ask for witnessing the specific test(s) at vendors cost.
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
The following checks shall be carried out on 10% of each size of fittings selected
by the inspector.
- Complete check of the threads with applicable gauges or profile projector
- Complete check of OD of the fittings and ferrules.
- Visual check under magnification of ferrule surfaces; body seats and threads.
- Dimensions.
ES-7334
DOCUMENT NO.
REV
SHEET 5
OF 6
Hydrotest:
The fittings when assembled with
appropriate SS tubing shall withstand an internal pressure of 375 kg/cm for atleast
one hour without any visible leakage.
Hardness test: The hardness of the ferrules shall be more than rockwell 76 on 30T
scale.
Reassembly : One percent of each type of leak tight assemblies shall be
deassembled and reassembled 25 times. After the twenty fifth assembly the
fittings shall pass hydrotest.
If specifically asked the vendor shall carry out following test
- Helium leak test
- Vibration checks
- Temperature cycling
- Pressure cycling
4.00
Packing
Each fitting shall be suitably packed and protected from damage due to
transportation, loading and unloading. Threaded fittings shall have plastic caps to
protect the threadings. Fittings and spare ferrules shall be packed separately by
sizes and grades in individual chlorine free water proof packets and tagged.
The above items shall be despatched as a single consignment.
5.00
5.01
Each fittings shall be marked with the part no. If this is not feasible, the size of the
tubing and material shall be mentioned.
5.02
6.00
Spares
7.00
ES-7334
DOCUMENT NO.
REV
SHEET 6
OF 6
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
x
x
x
Yes(A)
(within 2 weeks)
Yes
x
for information
Sl. no. 1 to 6 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 7 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
ES-7341
DOCUMENT NO.
REV
SHEET
OF
S.S TUBES
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7341
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7341
DOCUMENT NO.
REV
SHEET 3
OF 5
1.00
General
1.01
1.02
2.00
General Requirements
2.01
2.02
Manufacture
The seamless stainless steel tubes as per ASTM-A-269 shall be made by the
seamless process. Tubes shall be cold finished. Tubes shall be white pickled free
from scale and soft annealed and suitable for bending. The finished tube should
be reasonably straight and free from dents and injurious defects and shall have
good finish and smooth ends.
2.03
Carbon (max)
Manganese (max)
Phosphorous (max)
Sulphur (max)
Nickel
Chromium
0.08%
2.00%
0.04%
0.03%
8.11%
18-20%
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
ES-7341
DOCUMENT NO.
REV
SHEET 4
OF 5
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
The following checks shall be carried out on 10% of each size of fittings selected
by the inspector.
3.04
Type-Test
Following type test (one per batch) shall be performed and certificates will be
furnished:
1) Material test: Chemical and physical properties.
2) Flaring test: The flaring test shall be performed on specimens from one
end of the tube with the help of the flering tool having on included angle
60.
3) Hardness test: Rockwell hardness shall not exceed 74 on the 30T scale and
88 on 15T scale. 5% tubes shall be tested for hardness.
4) Hydraulic Test: The tubes are subjected to hydrostatic test. The tubes
should withstand the hydrostatic test pressure of 1000 psi for a minimum period
of 15 seconds.
4.00
Packing
Each tube shall be suitably packed and protected from damage due to
transportation, loading and unloading. Threaded fittings shall have plastic caps to
protect the threadings. Fittings and spare ferrules shall be packed separately by
sizes and grades in individual chlorine free water proof packets and tagged.
ES-7341
DOCUMENT NO.
REV
SHEET 5
5.00
5.01
6.00
Spares
OF 5
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information
Sl. no. 1 to 5 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 6 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
ES-734-
DOCUMENT NO.
REV
SHEET
OF
56
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7340
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
1.00
General
DESCRIPTION
NUMBER OF SHEETS
DOCUMENT NO.
REV
SHEET 3
OF 5
1.01
1.02
2.00
General Requirements
2.01
2.02
The fittings shall be manufactured, tested and supplied strictly as per ANSI and
ASTM materials grade mentioned against each item.
Dimension
Rating
Material
Surface
Tolerance
Threading
Marking
Certification
ES-7340
: ANSI B 16.11
: ANSI Class 3000# and 6000# as specified.
: As indicated against each part no.
: The suface or seats (conical or spherical) shall
not have roughness and/or scoring ascertained
on sight or on touch.
: As per ANSI B 16.11
: AS per ANSI 2.1
: As per ANSI B 16.11
: Indian boiler regulation certificate in the form
of IIIC/NACE certificate as per NACE MR-0175-1994
wherever indicated.
2.03
All carbon steel and alloy steel fittings and AD/condensate pots shall be protected
against rusting using suitable paint.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
material at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
material in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications.
The vendor shall make available to the authorised representative of PDIL /
OWNER the results of all the tests conducted before presenting for PDIL/Owners
inspection.
Normally the vendor shall have their own quality control requirements and
procedures for conducting the type tests. If the same is not acceptable by PDIL/
OWNER representative, the procedure & extent of type test requirement shall be
mutually discussed and agreed upon by vendor & PDIL/OWNER representative
ES-7340
DOCUMENT NO.
REV
SHEET 4
OF 5
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
The following checks shall be carried out on 10% of each size of fittings selected
by the inspector.
4.00
Packing
Each fitting shall be suitably packed and protected from damage due to
transportation, loading and unloading. Threaded fittings shall have plastic caps to
protect the threadings. Fittings and spare ferrules shall be packed separately by
sizes and grades in individual chlorine free water proof packets and tagged.
5.01
Each fittings shall have the following details punched at the sides easily visible.
- Part no. / stock no.
- size
- material
- rating
- threaded standard, if any (NPT)
- IBR stamping for IBR fittings.
5.02
6.00
Spares
Spares quantities are included in the main item quantity.
7.00
Documentation
ES-7340
DOCUMENT NO.
REV
SHEET 5
OF 5
1.
2.
3.
4.
5.
6.
7.
8.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
x
x
x
Yes(A)
(within 2 weeks)
Yes
x
for information
Sl. no. 1 to 8 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 9 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
ES-7335
DOCUMENT NO.
REV
SHEET
1 OF
CABLE TRAY
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7335
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7335
DOCUMENT NO.
REV
SHEET 3
OF 5
1.00
General
1.01
1.02
2.00
General Requirements
2.01
The material of construction for cable tray shall be Aluminium as per IS:737:1934
Grade 19000H2 or GI as specified in specification.
2.02
The tray shall be box type with webs for top cover screwing and of 2.5 meter
length.
2.03
2.04
The thickness of trays shall be uniform bend shall be smooth without too much of
reduction area at corners, (bending radious shall be approx. 600mm), free from
cracks, surface defects. Perforations shall be of staggered pattern with large
uniform holes for adequate ventilation.
2.05
Trays shall be supported at 2000mm intervals. The design of the cable tray shall
be such that apart from imparting sufficient mechanical strength under all
conditions, the deflection of the tray shall not exceed 3mm. The trays shall be
capable of withstanding the maximum permissible uniformly distributed loading.
The coupler plate and bolting shall also be designed suitably.
2.06
Each tray/section shall be supplied with holes drilled on the four sides for the
coupler plates / bolts for joining different lengths / sections. The trays shall be
supplied with coupler plates, boltsand nuts. All coupler nuts and bolts shall be of
SS.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
material at manufacturers works. The vendor shall permit the authorised
ES-7335
DOCUMENT NO.
REV
SHEET 4
OF 5
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
The following checks shall be carried out on 10% of each size of fittings selected
by the inspector.
4.00
Packing
Each tray shall be suitably packed and protected from damage due to
transportation, loading and unloading. Threaded fittings shall have plastic caps to
protect the threadings.
The tray and spare ferrules shall be packed separately by sizes and grades in
individual chlorine free water proof packets and tagged.
5.01
The packing shall clearly be marked on the outside (on top side and ends) in
indelible ink the following minimum details:
- part no.
- size of tray (Length x Width x Height)
- No. of trays / sections, total length
- material specification
- customers name
- manufacturers name
6.00
ES-7335
DOCUMENT NO.
REV
SHEET 5
OF 5
Spares
Spares quantities are included in the main item quantity.
7.00
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information
Sl. no. 1 to 6 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 7 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
ES-7338
DOCUMENT NO.
REV
SHEET
1 OF
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7338
DOCUMENT NO.
REV
SHEET 2
OF 6
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7338
DOCUMENT NO.
REV
SHEET 3
OF 6
1.00
General
1.01
1.02
2.00
General Requirements
2.01
2.02
The junction boxes shall either be weather-proof and ex-proof type as specified in
technical specification..
2.03
The enclosure shall be as IS-2147 for weather-proof junction boxes and for
explosion proof it shall be as per IS-2148 suitable for the area classification
specified.
2.04
The entries should normally be from bottom unless otherwise specified and the
number of entries shall be as per technical specification..
2.05
The terminals shall be spring loaded, vibration proof clip on type (Weidmuller/
Phoenix), 2.5 mm. The terminals shall be mounted on DIN rail 46277/1 (vertical
mounting). The terminal material shall be melamin duroplast type as per DIN 7708
page 3 type 156 complete with end cover and clamps for each row. Terminals
colour shall be blue and certified for instrinsically safe circuits and manufacturers
standard colour for other circuits. Terminal numbers shall be marked on both
sides. Stickers/paint shall not be used for numbering.
2.06
Junction box material shall be Die cast aluminium LM6 or equivalent of minimum
5mm thick to withstand a load of atleast 80kg. Gasket should be neoprene rubber.
Mounting brackets (MS epoxy painted) and 4 nos bolts.nuts per JB shall be under
vendors scope of supply.
2.07
Junction box shall be provided with cadmium plated brass bar with non-loosening
screws for cable shields.
2.08
Junction boxes shall be provided with telephone plug and sockets. It should have
both internal and external earthing screws.
2.09
Depth of JB shall be as per manufacturers standard, but not less than 100mm for
2-3 cable entries and 150mm for more than 3 cable entries.
2.10
Ex-proof JBs shall have detachable cover which is fixed to be box by means of
cadmium plated triangular /hexagonal head screws. Weatherproof JBs shall have
doors which shall be hinged type and these shall be fixed with cadmium plated
countersunk screws.
2.11
Surface shall be prepared for painting. It shall be smooth and devoid of rust and
scale. Two coats primer and two final coats of epoxy paints shall be applied both
for interior and exterior surfaces. Colour shall be as specified in technical
specification.
ES-7338
DOCUMENT NO.
REV
SHEET 4
OF 6
2.12
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
material at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
material in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications.
The vendor shall make available to the authorised representative of PDIL /
OWNER the results of all the tests conducted before presenting for PDIL/Owners
inspection.
Normally the vendor shall have their own quality control requirements and
procedures for conducting the type tests. If the same is not acceptable by PDIL/
OWNER representative, the procedure & extent of type test requirement shall be
mutually discussed and agreed upon by vendor & PDIL/OWNER representative
and shall be covered in Quality Assurance Plan. Vendor must submit to the
Inspection authority all the results of the type tests conducted by them for their
approval. However, if the PDIL/OWNER representative is not satisfied with the
results, he may ask for witnessing the specific test(s) at vendors cost.
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
4.00
Packing
Each junction box and cable gland shall be suitably packed and protected from
damage due to transportation, loading and unloading. Threaded fittings shall
have plastic caps to protect the threadings.
The junction box and cable gland and its accessories alongwith spares shall be
despatched as a single consignment.
ES-7338
DOCUMENT NO.
REV
SHEET 5
OF 6
5.00
5.01
Each junction box shall have SS nameplate firmly fixed on the front over through
SS screws. The following details shall be punched / engraved with letter sizes not
less than 4mm.
- part no.
- size
- terminal type/mode
- No. of terminals
- Enclosure certification
- Manufacturers name
- Manufacturers model no.
5.02
Each JB shall have 1 additional SS tag plate 25mm high x 100 mm long x 1mm
thick securely tied with soft annealed SS wire for tag no. of the JB.
6.00
Spares
Spares quantities are included in the main item quantity.
7.00
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for Approval
2)
ES-7338
DOCUMENT NO.
REV
SHEET 6
OF 6
Sl. no. 1 to 6 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 7 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
ES-73332
DOCUMENT NO.
REV
SHEET
OF
INSTRUMENT CABLE
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED
ES-7332
DOCUMENT NO.
REV
SHEET 2
OF 7
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
4.0
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS
ES-7332
DOCUMENT NO.
REV
SHEET 3
OF 7
1.00
General
1.01
1.02
2.00
General Requirements
2.01
Overall Drain wire shall be of annealed copper wire in continuous contact with
aluminium side of shield. No of strands, dia and cross sectional area shall be 7,
0.3mm and 0.5mm respectively.
2.02
Communication pair shall be placed in central position with the bundle of pairs.
Material of conductor shall be bare copper, no of strands-7, size-0.5mm insulation
PVC and colour-white.
2.03
2.04
2.05
+ 10%
+ 5%
+4%
+ 2.5%
Cable drum used shall be of high quality. Second hand drum or recycled drum is
not acceptable. The vendor shall submit a detail sketch of each type of drum
intended to be used for this order. It should indicate clearly the designed load of
the drum and the factor of safety considered for transportation and shipment.
Protective coating shall be applied on the outer surface of cable drum to protect
against rain/weather.
In case the cable is received at site in damaged drums, a penalty as indicated in
the special clause shall be levied.
2.06
Special clauses:
- In case at any stage during cable/laying/installation, if it is noticed that there is a
joint in a cable drum the entire cable with cable drum shall be replaced by vendor,
free of charge to the purchaser.
ES-7332
DOCUMENT NO.
REV
SHEET 4
OF 7
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be submitted to the representative of
PDIL/OWNER during inspection.
The manufacturer shall give clear 15 days notice informing readiness of the
material at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
material in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications.
The vendor shall make available to the authorised representative of PDIL /
OWNER the results of all the tests conducted before presenting for PDIL/Owners
inspection.
Normally the vendor shall have their own quality control requirements and
procedures for conducting the type tests. If the same is not acceptable by PDIL/
OWNER representative, the procedure & extent of type test requirement shall be
mutually discussed and agreed upon by vendor & PDIL/OWNER representative
and shall be covered in Quality Assurance Plan. Vendor must submit to the
Inspection authority all the results of the type tests conducted by them for their
approval. However, if the PDIL/OWNER representative is not satisfied with the
results, he may ask for witnessing the specific test(s) at vendors cost.
The vendor to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the tests as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the
written permission of PDIL.
3.02
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
ES-7332
DOCUMENT NO.
REV
SHEET 5
OF 7
ES-7332
DOCUMENT NO.
REV
SHEET 6
OF 7
Packing
Each cable drum shall be suitably packed and protected from damage due to
transportation, loading and unloading.
Sealing
Both the ends of the cable shall be sealed using PVC or Rubber caps,
additionally sealing tapes can be used if required. The caps should not be easily
removable during transportation. Main purpose of the sealing caps is to avoid
ingress of moisture during transportation and storage.
5.00
5.01
5.02
6.00
Spares
Spares quantities are included in the main item quantity.
7.00
ES-7332
DOCUMENT NO.
REV
SHEET 7
OF 7
Documentation
The following documents (Technical) are required to be submitted by the vendor
alongwith bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
for Approval
(I)
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information
Sl. no. 1 to 6 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Sl. no. 7 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
EM163-PNIN-7901-PA
ART D
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTD
BILL O
OF QUAN
NTITY
FOR
SU
UUPLY OF
O INSTR
RUMENTATION
N ITEMS AND ERECTIO
ON
ATERIAL
LS
MA
Job
b NO
: EM
M163
Pro
oject
: IN
NSTALLA
ATION OF MOUNDED BULL
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
ent
Clie
: NR
RL
24.09.2015
5
--
CL
LIENTS COM
MMENTS INCO
ORPORATED
D
H
HK
RA
A
SKT
14.09.2015
5
--
CL
LIENTS COM
MMENTS INCO
ORPORATED
D
H
HK
RA
A
SKT
21.07.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
NUMALIGARH, ASSAM
(TENTATIVE)
PART /
ITEM
EM163-PNIN-BOQ-7001
Quantity
DESCRIPTION
No.
PREAMBLES ( THIS PREAMBLES ARE APPLICABLE FOR ALL BOQs APPEARING in THIS RFQ ):1) Vendor to submit erection material quantity as per installaion drawings attached elsewehere and fill in the BOQ accordingly
2) Inst. supports fabricated out of 2 MS pipe as per Drawings.
A.1
7047
FIELD INSTRUMENTS
4
nos
7147
Radar Type Level Transmitter (TFMS) with multipoint temperature element and
Temperature Transmitter
4 with TE & TT
nos
7052
Servo Type Level Transmitter (non TFMS) with multipoint temperature element and
Temperature Transmitter
4 with TE & TT
nos
7053
Pressure Gauge
nos
7044
Presssure Transmitter
12
nos
7022
Safety Valves
10
nos
7058
no
7146
g
Level Gauge
g
Magnetic
no
7148
no
A.2
ERECTION MATERIAL
SEAMLESS PIPE
0103 SCH. 160, API 5L GR.B
Mtrs.
NIPPLE
0176 NPTM x PLAIN, SCH. 160, A105, 100MM LONG
0153 PLAIN x PLAIN, SCH. 160, A105, 100MM LONG
Nos.
Nos.
EQUAL TEE
0261 SW x SW x SW, 3000#, ASTM A105
Nos.
COUPLING
0004 SW x SW, 3000#, ASTM A105
Nos.
CAP
0624 NPTF, 3000#, ASTM A105
Nos.
GATE VALVE
0929 SW x SW, 800#, ASTM A105, 13% CR.TRIM
Nos.
FLANGE
0799 SW WITH STUDS, NUTS AND GASKETS, 300# ASTM A105
Mtrs.
(TENTATIVE)
PART /
ITEM
EM163-PNIN-BOQ-7001
Quantity
DESCRIPTION
No.
SEAMLESS TUBE
1088 1/2" OD x 0.065 THK, A269 TP304
Mtrs.
MALE CONNECTOR
0932 NPTM x OD, ASTM A105, COMPLETE WITH DOUBLE FERRULE
Nos.
FEMALE CONNECTOR
0962 NPTF x OD, ASTM A105, COMPLETE WITH DOUBLE FERRULE
Nos.
REDUCER
0562 3/4 NPTF x SW, 3000#
Nos.
Nos.
Ton
CANOPIES :
MS rain protection cover for instruments like (PT, any other electronic instrument, etc
Nos.
JUNCTION BOX:
Nos.
CABLE
mtrs
CABLE TRAY
Nos.
EM163-PNINBOQ-7001
BILL OF MATERIALS
DOC. NO.
1 / 24.09.2015
HK
RA
RA
0 / 14.09.2015
HK
RA
RA
P / 21.07.2015
HK
RA
RA
Rev / DATE
PREPARED
REVIEWED
APPROVED
EM
M163 -TS-080
01
DO
OCUMENT N
NO.
RE
EV.
SHEET 1 of 32
PART
T-II TEC
CHNICA
AL
TE
ECHNIC
CAL SPE
ECIFICA
ATION
FOR
R
CTION SYSTEM
CATH
HODIC PROTE
P
M
ED BUL
OF
F LPG MOUND
M
LLETS
ED BUL
P
PROJEC
CT: INST
TALLAT
TION OF
F LPG MOUND
M
LLET
AT NRL, ASSAM
A
1
24.09.15
24.09.15
0
15.09.15
15.09.15
P
10.08.15
10.08.15
REV
REV. DATE
EFF. DATE
FORM NO: 02-0000-0021F
F1 REV4
D
DKG
D
DKG
D
DKG
PREP
HS
H
H
HS
HS
H
H
HS
HS
H
H
HS
RE
EVWD
APP
PDD
All Rights Res
served
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2 of 32
CONTE
ENTS
SR. NO.
DESCRIPTIO
ON
SHEET NO.
N
1.0
Introducttion
2.0
3.0
4.0
Instructio
on to Bidde
er
5.0
Type of Contract
C
6.0
7.0
System Implementa
ation
8.0
Basic Su
urvey for So
oil Resistivvity Measurement
9.0
System Details
D
10.0
Design Requireme
R
nt
11.0
Criteria For
F Protecttion
10
11.3 Sch
heme for Cathodic
C
Protection System.
S
10
11.3.2.1 CP Transsformer Re
ectifier Unit.
11
.11.3.2.2
2 Anode Disstribution Box.
B
12
12
11.3.2.4 Permanen
nt Reference Cell.
13
11.3.2.5 Cables
14
11.3.2.6. Monitoring
g J.B..
14
11.3.2.7. PDB
14
11.3.2.8 Anodes.
15
16
11.3.2.10
0.Solid Sta
ate Polariza
ation Cell.
16
11.3.2.11
1.Measurement Juncction Box.
16
11.3.2.12
2.Earthing J.B..
16
11.4.1.14
4. Monolith
hic Isolating
g Joint.
16
11.3.2.15
5. Electrica
al Separation.
16
Miscellan
neous Poin
nts related to System
m Design.
17
12.0
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 3 of 32
13.0
Detailed Engineerin
ng Works to
t be perfo
ormed by Bidder
B
for C
CP
System of
o Mounded Storage Vessels
18
14.0
Earthing
20
15.0
CP Mate
erials
21
16.0
21
16.1 Cab
ble Laying.
21
16.2 Permanent Re
ef. Cells.
21
16.3 Stra
aight Throu
ugh Joint fo
or Cables.
21
16.4 Cab
ble Connecction to Bullets.
22
17.0
22
18.0
Commisssioning Re
equirementts
22
19.0
Material Inspection
n & Testing
g
25
20.0
Pre Com
mmissioning
g
25
21.0
Commisssioning
26
20.1. Perrmanent IC
CCP System.
26
22.0
Guarante
ee
27
23.0
27
24.0
Instrume
ents, Tools and Spare
es
28
25.0
Schedule
e of Quanttities
29
LIST OF ATTACH
HMENTS
NU
UMBER OF
O
SHEETS
Data She
eet for Catthodic Prottection sys
stem of LP
PG Mounde
ed
Bullet
II.
III.
TS- Tran
nsformer Rectifier
R
Un
nit for CP System
S
17
IV.
TS- Rem
mote Monittoring Unit of TR Unitt for CP System
V.
TS- Ano
ode junction
n box for CP
C System
m
VI.
TS- Cath
hode junction box cu
um Test Sttation for CP
C System
m
VII.
TS-Cu/C
CuSo4 pe
ermanent Reference
e Electrode for C
CP
System
VIII.
I.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 4 of 32
IX.
ables for CP
C System
TS- -Ca
X.
TS - Mo
onitor Jn. Box.
B
for CP
P System
XI.
TS - PD
DB. for CP System
XII.
TS -Ano
odes for CP System
XIII.
TS -Surrge Diverte
er for CP System
S
XIV.
TS -Solid State Po
olarisation Cell for CP
C System
XV.
TS - Ea
arthing Jn. Box for CP
C System
TS - Mo
onolithic Iso
olation Joint. for CP System
XVII.
Master Vendor
V
Lisst for CP Syystem
XVIII.
XVI.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
1.0
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 5 of 32
INTRODU
UCTION
Numaliga
arh Refinery Limited ( NRL ) situated in Assam State, has
s planned to
install 4 Nos. of Mounded
M
B
Bullets
for LPG. Forr proper fu
unctioning of Mound
ded
s
and economy point of vie
ew, the bu
ullets shall be protectted
bullets, both from safety
orrosion fo
or their long
g & trouble
e free operration. Thiss specificattion specifiies
against co
the requirrement of Basic Survvey, Desig
gn, Enginee
ering, Supply of Mate
erial, Testiing
of Cathod
& Comm
missioning, installatio
on and Monitoring
M
dic Protec
ction syste
em
complete in all resp
pects.
2.0
SCOPE OF
O WORK
K
The scop
pe of workk under th
his section
n shall consists of B
Basic Surv
vey, Desig
gn,
Engineering, Supp
ply of all Material, installatio
on, Testin
ng & Com
mmissionin
ng,
Monitorin
ng of the Ca
athodic Prrotection sy
ystem com
mplete in all respects for mound
ded
storage bullets,
b
all with
w semispherical en
nds within the plant.
The com
mplete imp
plementation of CP
P system should b
be carried
d out und
der
supervisio
on of NAC
CE Certifie
ed CP Eng
gineer with valid license for certifying
c
t
the
Design, Engineering
E
g, Procedu
ures and Commission
C
ning Resullts.
This speccification defines
d
the
e basic gu
uidelines to
o develop an Impres
ssed Curre
ent
Cathodic Protection
n (ICCP) system
s
forr the bulle
et required
d to be pro
otected. The
T
essed Currrent Catho
odic Protecction shall be minimu
um 30 yea
ars.
design liffe for Impre
All data required in
n this rega
ard shall be
b taken into consid
deration to
o develop an
acceptable design and for proper
p
eng
gineering of
o the sysstem. Com
mpliance with
w
these spe
ecificationss and/or approval of any of the
e Bidders documentts shall in no
case relie
eve the bid
dder of his contractua
al obligations.
The bidd
der should supply materials
m
sttrictly as per
p specifiications an
nd approvved
Vendors list attache
ed. Bidder shall give performan
nce guaran
ntee of min
nimum 5 yrs.
y
for CP Syystem.
3.0
DETAILE
ED SCOPE
E OF WOR
RK
3.1
3.2
Developm
ment of De
etailed En
ngineering Documen
nt on the B
Basic Surv
vey Data and
optimize the
t ICCP System.
S
3.3
Site visit to
t decide the
t location
n of propos
sed Anode
e Bed, T/R unit, Test Station etcc.
3.4
Calculatio
on of Polyymeric An
node quan
ntities and their size
es based on maxim
mum
current re
equirementt and desig
gn life.
3.5
Sizing ca
alculation for
f T/R unit, Anode loop resistance and potential profile on the
protected
d structuress.
3.6
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 6 of 32
Procurem
ment of Material
M
an
nd equipments for complete
c
ICCP sys
stem includ
ding
incoming and outgo
oing cabless.
3.8
ngs for ca
able trays, fixing deta
ails, cable sizing, ca
able sched
dule,
Constructtion drawin
interconn
nection diag
gram, and cable tray
y details forr complete ICCP system.
3.9
Installatio
on details including location and
a
fixing details of T/R unit, junction box.
b
Anodes and
a controll equipmen
nts.
3.10
Installatio
on details of Anode
e bed, refe
erence ce
ell, junction
n box etc. of comp
plete
Impresse
ed Current Cathodic Protection
P
System.
3.11
The Bidd
der need to
o supply all
a materialls, consum
mables in h
his scope of supply and
provide all
a construcction toolss, tackles equipment
e
and perso
onnel nece
essary forr the
work.
3.12
3.13
Field-testting of ind
dividual co
omponents
s of C.P. System a
as per ap
pproved detail
engineeriing packag
ge. Final commissio
oning of in
nstalled syystem as per appro
oved
procedure
e.
3.14
Installatio
on and erecction of ICCP System
m.
3.15
Developm
ment of system
interferen
nce testing.
3.16
Energizin
ng, Testing and Comm
missioning
g of ICCP System.
S
3.17
After Com
mmissionin
ng of the C.P.
C
Syste
em, if it is found that structure
e to electro
olyte
potential achieved at some lo
ocation is in the rang
ge which iss below ac
cceptable limit
ode, then a supplem
mentary C.P. System
m need to be installe
ed to bring the
as per co
potential level at such location
ns within acceptable limit as me
entioned.
3.18
Preparation and Su
ubmission of
o As-built drawings, Operation
n &Mainten
nance manual.
3.19
3.20
t
testing
and
comm
missioning
procedurres
includ
ding
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 7 of 32
4.0
INSTRCU
UTIONS TO
O BIDDER
R
4.1
4.2
Owner/co
onsultant shall
s
have the
t right to
o inspect th
he following
g:
Worksho
op & production facilitties availab
ble with BIDDER or its tie up ag
gency.
Fabrication/testing of materia
al/equipme
ent to be supplied
s
b
by BIDDER
R or its tie
e up
ncy for C.P
P. system.
agen
It shall be bidderr's respon
nsibility to arrange access ffor ownerrs/consulta
ants
personne
el for such visits. All
A costs related with
w
travel,, boarding
g, lodging for
owners/cconsultants personne
el for such visits (if any) shall b
be borne by
y owner.
4.3
4.4
Warrantyy
Bidder ne
eeds to re
eplace/rep
pair or rein
nstall free of cost a
any material/ equipm
ment
supplied or installed by him in
i case it fails to op
perate due to defective materia
al or
workmanship as pe
er requirem
ments of this
t
specifiication with
hin 12 (Tw
welve) mon
nths
from the date of isssue of com
mpletion ce
ertificate an
nd accepta
ance of the
e C.P. Sysstem
by Ownerr. Bidder shall replacce at his ow
wn cost if any
a item fo
ound defec
ctive or misssed
before ha
anding over the syste
em to owne
er.
5.0
TYPE OF
F CONTRA
ACT
The contrract under the above
e scope of work
w
shall be on LST
TK basis.
6.0
6.1
The syste
em design
n, performa
ance and materials
m
to
o be supplied shall conform
c
to
o the
requirements of the
e latest revvision of folllowing sta
andards
NACE Standard
S
R
RP-0285:
Recomme
ended Practice forr Corrosio
on Control of
Undergro
ound Storage Tank Systems
S
by
y Cathodic Protection
n
NACE Standard
S
RP-0177: Standard
d Recom
mmended Practice Mitigation of
Alternatin
ng Currentt and Ligh
htning Effe
ects on Metallic
M
Structures and
a
Corrosion
Control Systems.
S
OISD 11
13: Classiification of
o Areas for Electrrical Insta
allation at Hydrocarrbon
Processin
ng and Han
ndling Faccilities.
OISD 147
7: Inspectio
on and Saffe Practice
es during Electrical
E
In
nstallations
s.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
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ALLATION OF
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BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
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Sheet 8 of 32
OISD 149
9: Design Aspects
A
for Safety in Electrical Systems.
OISD 150
0: Design and
a Safetyy Requirem
ments for LPG Mound
ded Storag
ge Facility.
DNV RP--B403: Reccommende
ed Practice
e Monitorin
ng of Catho
odic Protec
ction Syste
ems.
DNV RP--B401: Catthodic Systtem design
n.
IS: 8062: Code of Practice
P
forr Cathodic Protection
n of Steel S
Structures.
IS: 1554 Part I: PVC
C insulated
d (heavy du
uty) cabless.
IS: 7098 Part-I: PVC
C insulated
d PVC she
eath cable.
IS: 5571 Guide For Selection of Electric
cal Equipment For Ha
azardous Areas
A
IS: 5572 Classifica
Areas (O
ation of Hazardous
H
Other than
n mines) For Electrical
Installatio
ons: Areas having Fla
ammable Gases
G
and Vapors.
IS: 60079
9-Part 1 Fla
ame proof Enclosure
es For Elecctrical Appa
aratus.
Any otherr standard applicable
e for the eq
quipment being
b
used for CP Sy
ystem.
Indian ele
ectricity act and ruless framed th
here underr.
Fire insurrance regu
ulations
ons laid by Chief Elecctrical Insp
pector of Sttate.
Regulatio
ons laid by Chief Con
ntroller of Explosives.
E
.
Regulatio
on laid by Factory
F
Insspector of State.
S
Regulatio
Petroleum
m Act, 197
76(Govt. off India, Corrosion control in Pe
etroleum prroduction TPC
T
Publicatio
on No.5)
Any otherr standard applicable
e for the eq
quipment being
b
used for CP Sy
ystem.
6.2
6.3
The equ
uipment sh
hall also confirm to the provissions of India Electricity rules and
other statutory regu
ulations currently in fo
orce in the
e country.
6.4
In case of
o any con
ntradiction between various
v
referred stan
ndards / specificatio
s
ons /
datashee
et and statu
utory regullations the following order
o
of prriority shall govern:
Stattutory Regulations
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
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BULLETS
OWNER : NRL,AS
SSAM
7.0
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 9 of 32
Data
a Sheets
Thiss Specifica
ation
Cod
des and Sta
andards
SYSTEM
M IMPLEME
ENTATION
N
All work to be perfformed an
nd supplies
s to be efffected as a part of contract shall
s
require specific revview of ow
wner or his
s authorize
ed represe
entative. Major
M
activvities
requiring review sha
all include but not be
e limited to the followiing:
8.0
Corro
osion survey data intterpretation
n report an
nd design b
basis for C.P.
C System
m.
C.P. System de
esign packkage.
Basicc engineerring packag
ge
Deta
ailed engine
eering pacckage.
Purcchase requisition for major
m
equipment.
Field
d-testing an
nd commisssioning procedure.
.As built
b
docum
mentation
BASIC SURVEY FO
OR RESIS
STIVITY MEASUREM
M
MENT
For this re
efer enclossed relevant specifica
ation.
9.0
SYSTEM
M DETAILS
S
All equip
pment sha
all be ne
ew and procured
p
from app
proved ma
anufacture
ers.
Equipmen
nt offered
d shall be
b field proven.
p
Equipment requiring specializzed
maintena
ance or operation
o
shall be avoided as far ass possible
e. Prototyype
equipmen
nt shall not
n
be acccepted. Equipment
E
shall con
nform to the releva
ant
specificattions enclo
osed with the
t
tenderr documen
nt. All equipment inclluding CPT
TR
Unit, Ano
ode Junctio
on Boxes cum Test Station, and
a
Cathod
de Junction Boxes etc.
e
shall be located
l
in safe non--hazardous
s areas. Where
W
it is essential to install the
t
equipmen
nt in hazarrdous area
a, such equ
uipment sh
hall be flam
meproof ty
ype and sh
hall
meet the requireme
ent of IS: 60079-1 or equivalentt Internatio
onal Standa
ard and sh
hall
o
suitable for gas group IIA
A/IIB, tem
mperature class T3 (200 C). Indigeno
ous
equipmen
nt shall be
e certified by CMRI or any oth
her recogn
nized testin
ng body and
a
shall be approved
a
b the conccerned stattutory auth
by
hority
An area around
a
bullets as perr Hazardou
us Area Cla
assification
n drg. ( To be preparred
by bidde
er during detail
d
eng
gg.) , as minimum to be con
nsidered as
a explosiion
hazardou
us area ( Gas
G Group IIA/II B, Zo
one -1, Tem
mp. class T
T3)
10.0
DESIGN REQUIRE
EMENT
Permanent Cathod
dic protecttion system
m by Imp
pressed Current sys
stem shalll be
mum 30 years
y
life. The syste
em shall cconsist of suitable nos.
n
designed for minim
automaticc transform
mer rectifier unit (B
Bidder sha
all calculatte the qua
antity), Po
ower
distributio
on Board((If required), Anode
e Junction
n Boxes with resis
stor, Cath
hode
Junction Boxes, Monitoring
M
Junction Boxes,
B
Ea
arthing Jun
nction Box
xes with Solid
S
State Polarization Cells,
C
Cu/C
CuSO4 & Zinc
Z
Refere
ence Electrrodes, & Pre packa
aged
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
10 of 32
CRITERIA
A FOR PR
ROTECTIO
ON
11.1.
The strucctures to so
oil potentia
al only shalll be used for effectivve cathodic
c protection
n off
potential on all parts of the tanks and sh
hall be eith
her equal o
or more ne
egative than (-)
0.85V witth referencce to Cu/Cu
uSo4.
11.2.
When anaerobic co
onditions and
a activity
y of sulpha
ate reducin
ng bacteria
a is presen
nt or
likely then
n the OFF potential shall
s
be eq
qual or morre than 0.95V. On no
n accountt the
OFF pote
entials sha
all be morre than 1.15V.The structure (bullets / tanks) will be
considere
ed protected when a A minim
mum 100 mV of Ca
athodic po
olarization.The
formation
n or decay of polariza
ation may be
b used to satisfy the
e criteria.
11.3.
11.3.1
Impresse
ed current Cathodic
C
p
protection
is to be considered fo
or preventiion of soil side
s
corrosion
n of mounded storage
e vessels.
Continuous distribu
uted close
e anode strings co
onsisting o
of Conductive polyymer
anodes shall
s
be insstalled. The
e quantity of strings shall be a
as per actu
ual calculattion,
ensuring uniform distribution of
o current but minim
mum 4 loop
ps per bulle
et. The strrings
f from natural air cooled,
c
Tra
ansformer--Rectifier u
unit (There shall be One
O
shall be fed
Working + One Standby T/R
R units forr the Moun
nd) of 50V
V/50A rating through one
common Anode Disstribution Box
B ( ADB)) & Anode
e Junction Boxes (AJ
JB) ,two ( One
O
on each end ) seperarate for each bulllet. T/R Units
U
( Wo
orking & Standby
S
) shall
s
have one
e common outgoing positive
p
he
eader cable
es; positivve header cable shalll be
terminate
ed to wall / structure mounted ADBs to be
b installed ( may be on retain
ning
wall of the
t
mound
d ) at each
h end alon
ng the axiss of bulletss. Positive header ca
able
shall interconnect each
e
end AJBs
A
of th
he bullet. As
A such A
Anode Strin
ngs get po
ower
from both
h end AJB
Bs. Joint of Anode Strings
S
from
m mound & electrica
al cables from
f
AJBs sha
all be placced outside
e the mou
und so tha
at the said
d joints rem
main availa
able
accessiblle for inspe
ection & repaires.
T/R Units shall have
h
one out going
g negative
e header cable, which shall be
interconn
nected by looping
l
arrrangementt to require
ed nos. of cathode junction bo
oxes
cum test station (CJJB). Each CJB cum test
t
station
n (CJB) sha
all be locatted at one end
along the
e axis of bu
ullet so tha
at each bullet can havve one CJB
B cum testt station (C
CJB)
for its dra
ainage con
nnection and
a
potential measurrement. Tw
wo drainag
ge cables and
two meassurement cables
c
from
m each bullet shall be
e terminate
ed to its CJ
JB.
Cables frrom 17 no
os of ref. electrodes
e
per bullet shall be tterminated
d in respecctive
CJB. 1 no.(25CX2.
n
.5 sqmm) or 2 nos. X(12CX2.5 sqmm) Cu conduc
ctor armou
ured
from each
h CJB shall be laid to
o monitiorin
ng Junction ox installed in Swittch room.
One stan
ndby T/R unit
u of the same 50V
V/50A rating shall be connected
d in paralle
el to
the opera
ating T/R Unit,
U
so tha
at initially when coatting condittion is good, always one
T/R unit can
c be ma
ade operating and the other ca
an be kept stand by in switched
d off
condition or hot sta
andby as per
p mode selected.
s
A
After
wardss when coa
ating condition
deteriorattes both T/R
T unit can work in parallel also. Powerr supply fo
or the T/R Unit
shall be drawn from
m the Electrical Pan
nel i.e.PMCC ( LPG
G Bullets) located in the
ectrical Ro
oom near Bullets
B
. Bidder
B
shall supply , lay , terminate requ
uired
same Ele
nos. of power
p
feed
der cables ( One 1( 3.5 x 35 Sq.mm) from said
d PMCC (L
LPG
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
11.3.2
11.3.2.1
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
11 of 32
Bullets) to
o each T/R
R units..
Monitorin
ng of C.P. System performance shall be done by installation of perman
nent
reference
e cells in th
he vicinity of
o mounded Storage vessels. T
The referen
nce cell cables
and the measurem
ment cables from each
e
vesssel shall be routed
d through the
respective cathode
e junction box cum test station (CJB) to a sing
gle Monito
oring
B), which shall be located ne
ear the T//R Units and
a
have the
Junction Box (MJB
provision of measurrement of vessel to soil
s potentiial. Also fo
or monitorin
ng of vesse
el to
ntials at th
he T/R unit, monitorring cabless consistin
ng of referrence cell and
soil poten
measurem
ment cable
es shall be
e laid betw
ween MJB and T/R u
unit for co
onnection of
o at
least two reference cells to T//R Unit pan
nel.
e laying ca
able trays with
w tray su
upporting structures
s
a
along pipe
es on groun
nd &
For Cable
in Cable Trenches
T
& on wall etc.,has
e
to be installe
ed .
Thermit welding
w
sh
hall not be
e used, only mechan
nical mean
ns shall be
e used for the
connectio
on of draina
age cabless and measurement cables
c
to tthe vessels
s.
For ease of accessibility of sp
plice joint shall be kep
pt outside tthe mound
d
hall carryo
out detaile
ed enginee
ering, proccurement, installation
n, testing and
Bidder sh
commissiioning of the follow
wing majorr materialss/ equipme
ents as per
p the ab
bove
explained
d basic sch
heme for Cathodic
C
prrotection syystem for tthe buried bullets:
CP Trans
sformer Rectifier
R
U
Units
(TRU
U)
The C.P. Units shall have Automatic/Ma
anual conttrol mode sselector sw
witch and shall
s
be metal clad, com
mpact, suita
able for ind
door installlation, air n
natural coo
oled, dust and
vermin proof
p
. Th
he compon
nents of the
t
units shall be designed for maxim
mum
operating
g efficiencyy.
The supp
ply, Installa
ation, Testing and Commissio
C
oning of in
ndoor type
e CP T/R Unit
shall be included in
n Bidders scope.
s
The
ere shall be one worrking + one
e stand by T/R
for each bullet. Standby T/R units can be automa
atically use
ed in the event
e
of faiilure
of running
g T/R unit.
T/R units shall be fe
ed individu
ually, electrrical power from PMC
CC, using 3.5 x25 mm2,
m
Al power cable.
The CP TR
T Unit sh
hall be insstalled in non-hazard
n
dous (safe)) area. The CP TR Unit
shall be in
nstalled in a Indoor. There shall be one set
s T/R unitts (1Running+1Stand
dby)
for supplyying DC su
upply to An
nodes and Cathodes and it sho
ould be rate
ed for 50 V,
V 50
A. CP TRU
T
shalll be man
nufactured as per enclosed specification. Make
e of
equipmen
nt and com
mponent sh
hall be as per
p clause No. 15.1 o
of this spec
cification.
TRU shalll also have
e the follow
wing featurres:
a. Vo
oltmeter, Ammeters
A
s
shall
be witth 1% mea
asuring acccuracy on the
t full sca
ale.
b. All cables shall
s
be clearly
c
iden
ntified. DC
C cables A
AC cables
s shall run
n in
se
eparate PV
VC/GI conduits. The
ese could be single core or multi-core
m
with
armored to meet systtem requirrement an
nd shall be
e of 1.1KV
V grade PVC
P
FR
RLS insulated of Al/C
Cu conducttors.
c. Th
he unit sha
all be proviided with automatic
a
p
potential
ccontrol. A selector
s
sw
witch
forr auto/man
nual also shall be pro
ovided.
d. Cu
urrent con
ntrol to ind
dividual ta
anks/bullets shall be
e negative
e connections
thrrough suita
able contro
ol resistors
s in junction boxes to
o adjust the
e imbalancce in
cu
urrent requirement be
etween tanks.
e. Se
eparate dra
ain cables for each of the bulllet with suitable diod
des in juncction
bo
ox shall be provided to
t prevent equalizatio
on currentss to flow be
etween bullets
du
uring ON/O
OFF potential measurrements.
f. Su
uitable shu
unts in ano
ode junctio
on boxes shall
s
also be installe
ed to meassure
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
12 of 32
ind
dividual an
node currents and als
so in nega
ative conne
ections to measure
m
d
drain
cu
urrent in ea
ach bullet.
g. Th
he potentia
al measuring circuit shall be ca
apable of working with
w Cu/CuSO4
an
nd zinc refe
erence cells. At any given time
e, system sshall be eitther contro
olled
byy one type
e of referen
nce cell and the oth
her type sh
hall be kept on stan
ndby
mo
ode.
h. To
o avoid ovverprotectio
on of the bullets, the
e control ssystem in TRU shall be
pro
ovided witth adjustable voltage and currrent limiting circuits
s and alarrms.
Po
otential free
e contact of
o one norm
mally open
n and one normally closed
c
shall be
wired to term
minal blockk for remo
ote alarm in Control room. A panel-moun
p
nted
eter shall be
b provide
ed to read the structu
ure to soil potential at
a the seleccted
me
co
ontrol refere
ence cell.
i. Su
uitable con
ntrol resisto
ors in Junction Boxess, to adjustt the imbala
ance curre
ents.
j. Po
otential fre
ee contaccts shall be wired
d to existting Control Room, to
an
nnunciate alarm
a
there
e.
k. Th
he T/R Unit
U
installed for Cathodic
C
P
Protection
nded Storrage
of Moun
Bu
ullets/Tankks shall have inbuiltt RMU fea
atures to M
Monitor all specified T/R
Un
nit Parameters, Ala
arms and Cathodic Protection Referen
nce Electrrode
Pa
arameters and comm
municate th
he Data to
o the Cen
ntral Comp
puter Netw
work.
Th
he T/R Un
nit RMU shall
s
be provided
p
b the m
by
manufacture
er, which can
Mo
onitor the specified
s
C Parame
CP
eters.
l. Th
he T/R Unit RMU Hardware shall be
b expand
dable for incorpora
ating
ad
dditional I/O
O Channels in future..
11.3.2.2
11.3.2.3
D
n Box.(AD
DB)
Anode Distributio
Positive haeder cable shalll be terminated in one
o
ADB.T
This ADB shall feed
d to
all AJB
i)
Exxplosion prroof Enclossure.( Gas group II A / II B.) & in
n LM6 con
nstruction.
ii)
Re
esistors witth shunts for
f current control to individual bullet.
iii)
Su
uitable explosion proo
of cable gla
ands for in
ncoming & outgoing cables.
c
iv)
Pro
ovision forr 30 % add
ditional (as spare ) in outgoing feeders fo
or future usse to
be
e kept.
Ground Beds
a. Su
upplier sha
all submit design
d
calc
culation off the groun
nd bed res
sistance ba
ased
on
n the meassured soil/ssand resistivity data
b. Th
he anodess shall be
b Longline Condu
uctive Po
olymeric anode
a
facctory
Prrepackaged
d.
11.3.2.4
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
13 of 32
is higher should be
e kept spa
are at each
h AJB for connection
n of Anode
es .The sp
pare
cable enttries should
d b e close
ed with a th
hreaded plug.
The anod
de junction box sho
ould have power re
esistors in series with shuntss for
current distribution to individu
ual anode string circu
uit. The po
ower resisttors should
d be
CRESSO
OL or equivvalent makke, strip typ
pe with adjustable arm
m in series
s with shun
nt of
0.5% acccuracy. Th
he rating of
o resistor//shunt sha
all be decided keepiing in view
w of
voltage drop
d
and te
emperature
e rise. The
e junction box
b shall h
have at lea
ast 30% sp
pare
terminals.
Cathode junction box shall ha
ave powerr resistors in series w
with shunts
s to adjustt the
nt requirem
ment betwe
een bulletss. The pow
wer resisto
ors and shu
unts
imbalance in curren
shall be similar
s
to one
o being used in AJB
A
and de
escribed in
n above po
oint exceptt for
their currrent rating and of sa
ame make as AJB. The CJB shall also have suita
able
diodes in
n circuit to
o prevent equalizatio
on currentts to flow between bullets du
uring
ON/OFF PSP meassurement. The catho
ode junctio
on box sha
all also hav
ve 30% sp
pare
terminals.
The AJB and CJB shall
s
be of explosion proof type
e suitable ffor hazardo
ous area zone
z
1, gas gro
oup IIA/IIB and in LM
M-6 constru
uction.
For otherrs, refer enclosed rele
evant spec
cifications.
11.3.2.5
ent Refere
ence Cells
s for U/G Vessels
V
Permane
Cu/CuSO
O4 Perman
nent referrence cells
s shall be
e as per enclosed specificattion.
Permanent reference cells sh
hall be ins
stalled in the
t
sand ccushion su
urrounding the
vessel att a distancce of 150mm from the vesse
el for mon
nitoring of C.P. Systtem.
Minimum 16 nos. of
o referencce cells to be installe
ed for each
h vessel. Four
F
refere
ence
cells shall be place
ed in one row at ea
ach locatio
on and the
ere will be
e four rows of
e cells at fo
our equidisstant locatio
ons along the length of each ve
essel.
reference
Nearest row
r
facing
g CJB should be con
nsidered as
a first row
w of refere
ence cells and
consecutive rows shall be con
nsidered as
a second, third and ffourth rows
s respectivvely,
in each ro
ow referen
nce cells shall
s
be pla
aced at 45
50,1350, 2250 and 315
50 location
ns in
0
anti clockk wise dirrection con
nsidering 0 at 6 Oclock
O
possition. The
e identifica
ation
numbers of reference cell for each bulle
et shall sta
art with B and afterr B first suffix
b
numb
ber, second suffix sh
hall be row number off reference
e cell and third
t
shall be bullet
suffix sha
all be refere
ence cell angular
a
pos
sition as sh
hown below
w:
Bullet No
o. /
Row No..
Iden
ntification Number
N
of Each Refe
erence Celll at Differe
ent Angular
Locatio
ons
0/3
3600
450
135
50
2250
3150
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
14 of 32
Cables
Cables fo
or C P Systtem shall be
b as per enclosed
e
specification.
11.3.2.7
11.3.2.8
Power Distribution
D
n Board (P
PDB) ( If Required)
R
The Pow
wer distribu
ution boarrd (PDB) ,if
, require
ed for the
e CP System, shalll be
installed in non-cla
assified lo
ocations near a single or gro
oup of T/R Unit . The
enclosure
e of shall be
b IP-55 ass per relev
vant IEC/N
NEC codess. The Pow
wer distribu
ution
board (PD
DB) shall be
b compossed of one
e no.3 pha
ase, 4-wire
e 125A, inc
coming MC
CCB
and required numbers (includ
ding 20% spares)
s
of 1 phase, 6
63A-outgo
oing MCB. The
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
15 of 32
Anodes
nded vesse
els: Anode
es employe
ed for C.P. System of mounded
d vessels shall
s
For moun
be Long Line cond
ductive polymer anod
de. The ge
eneral spe
ecifications
s of Long Line
L
conductivve polymerr anode are
e enclosed
d.
Type of Anode
A
sha
all be of Anode
A
Flex
x 1500-01 Type. Th
he Anode flex (1500
0) of
Raychem
m/equivelen
nt make sh
hall be insta
alled at 1,3
3,5,7,9,11 Oclock po
ositions at four
regular in
ntervals alo
ong the entire length of bullet making
m
a lo
oop from 1 to 11 Occlock
positions and like wire
w for 3 to
o 9 Oclock
k positionss and 5 to 7 Oclock positions. The
anodes should
s
not be installe
ed as indiv
vidual strin
ngs but a loop covering the en
ntire
dish end of the bulllet at one location an
nd exiting the mound
d for splicing with an
node
tail cable at the oth
her end. There shall be no com
mmon Ano
ode flex fo
or two or more
m
bullets.
Anod
des shall be installe
ed in the sand cush
hion surro
ounding the
e vessel at
a a
dista
ance of 100
00mm (min
n.) from the vessel. Minimum
M
4 nos. ano
ode strings per
bulle
et shall be provided
p
(a
actual quantity shall be calculatted by ven
ndor).
Botto
om anode strings in between two conse
ecutive vesssels as well
w as for the
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
16 of 32
vessels at both
h end of th
he mound shall be installed m
matching with
w the botttom
surfa
ace of the
e mounded
d vessels. Separatio
on distancce between
n consecu
utive
String anodes and betwe
een string anodes to mounded vessels shall
s
be as per
draw
wing.
Actual length of
o Anode Strings
S
sha
all be calcculated by bidder and furnished to
owne
er/consulta
ant for App
proval durin
ng detail en
ngineering stage.
A minimum 8 number
n
of Anode Fle
ex Splice Kits
K for eacch bullet of similar make
m
as th
he anode, too, shall be used
d for Anod
de Stringss. The splicing shalll be
perfo
ormed outsside the mo
ound, for fu
uture checcking/ moniitoring purp
pose.
Anod
des shall be fed from both the ends
e
of the
e loop spliccing
osed releva
ant specific
cation.
For this, refer enclo
11.3.2.14 Monolith
hic Isolatin
ng Joint
For this,
t
refer enclosed
e
re
elevant spe
ecification..
11.3.2.15 Electrica
al Separation
Each bu
ullet shall be
b electrica
ally isolated
d from the other bulle
et, pipeline
es, any burried
as given
n structuress in the viccinity and electrical/in
e
nstrumenta
ation earthing system
m.
Suitable
e Monolithicc isolating joints shalll be installed above g
ground in all
a piping
attached
d to each bullet
b
as pe
er OISD 15
50. These joints
j
shalll be suitable for
expected
d temperature range
e in the des
sign data.
The ressistance across th
he Monoliithic insullation join
nts shall be recorrded
immedia
ately before
e welding into the piipeline and
d shall not be less th
han one Mega
M
ohm. Monolithic Issolating jo
oints with contrast
c
co
olor paint shall be done
d
for easy
e
identifica
ations.
- To avoid surge acrross the inssulating joints use off spark gap
p surge arresters sho
ould
be envissaged for each
e
insula
ated joint.
-Safety & instrume
ent earthing installe
ed on the
e bullets shall be provided with
FORM NO: 02-0000-0021F
F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
17 of 32
polarizatio
on cells to avoid losss of cathod
dic protectiion currentt while maiintaining a low
resistance to earth
h. Polariza
ation cells shall be installed iin the earrthing of each
e
individuall bullet to ensure
e
elecctrical insu
ulation betw
ween the vvessels.
12.0
Miscellan
neous poiints relate
ed to Syste
em Design
n
1
12.1
The follow
wing criterria shall be followed to
t determin
ne the prottection leve
els :
Maxim
mum allowa
able vesse
el to soil po
otential witth respect to Cu/CuS
SO4 ref. Ce
ell:
- 1.50V (ON) or 1.10V (In
nstant OFF
F)
Minim
mum allowa
able vessell to soil pottential with
h respect to
o Cu/CuSO
O4 ref. Celll: 850mV
V (OFF) or
o -100mV polarizatio
on shift (O
Off) or -. Discretion to
o use any of
the criteria shall solely rest with Own
ner/Owner's Represe
entative.
Interfe
erence Critteria: +100
0mV positiv
ve shift
1
12.2
1
12.3
While de
eciding num
mber of modular typ
pe 50V/50A
A T/R unitss, conside
erations mu
ust
be given that no T/R
T unit is loaded mo
ore than 75%
7
of its rated outp
put voltage
e&
current capacity
c
throughout design
d
life while feed
ding load tto a single
e or group of
anode be
eds.
1
12.4
1
12.5
1
12.6
1
12.7
1
12.8
Whereve
er specific guideline
es are nott furnished
d for cath
hode struc
cture curre
ent
density or
o separattion distan
nce of anode from cathode structure and spaciing
between consecutive anode
es, a prote
ective currrent density for coa
ated catho
ode
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
1
12.9
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
18 of 32
1
12.10
13.0
List of materiials/equipm
ments to be procured from Indian market/forei
m
ign
markket.
Calculation and
d Preparattion of Bill of Quantitties for all C.P. syste
em materia
als
and equipment
e
t required.
Prep
paration & submissio
on for app
proval of Hazarodous Area Classificati
C
ion
drgs.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
19 of 32
Also fabricatio
on drawin
ngs & sc
chematic drawings for internal termin
nal
arran
ngements and
a installa
ation draw
wings for a typical AJB
B/CJB/MJB
B.
Anod
des: Total nos. of Anode
A
strin
ngs and an
node string
g to anode
e lead cab
ble
joint details fo
or entire C.P.
C
System
m and the
eir layout arrangeme
ent drawin
ngs
show
wing no. off anode strrings in ea
ach bullet. Construction drawin
ngs and wo
ork
proce
edures forr anode to
o cable jo
ointing and
d also forr installatio
on of ano
ode
string
gs.
Desig
gn calculations show
wing: --
Cable to vesse
el joint: Tota
al quantity
y of joints and
a details of a typica
al joint.
h T/R unit is
T/R unit wise C.P. Systtem layout drawing showing how each
conn
nected with
h group of anode
a
strin
ngs/vessels through AJB/CJB/M
MJB.
Prep
paration of testing & commissio
c
ning proce
edure for C
C.P. System
m.
Prep
paration off construcction draw
wings with soft copies before
e starting of
insta
allation/proccurement work, Preparation of
o Soft & h
hard copie
es of as bu
uilt
draw
wings after completion
n of C.P. System
S
worrk shall alsso be furnis
shed.
Quan
ntified list of the major con
nstruction equipmen
nt, tools, tackles etc.
e
including Diesel engine pump sett for dewa
atering at cable/pipe
e trench the
t
SUPPLIER pro
oposes to use
u for exe
ecution of the
t work.
Bar chart
c
giving details how
h
SUPP
PLIER plan
ns to execu
ute the wo
ork within the
t
speccified time schedule.
s
Prep
paration & submission
s
n for appro
oval of Qua
ality Assura
ance Plans
s/Procedurre.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
20 of 32
perfo
ormed in a planned, systematic
c manner to
t the bestt quality sttandards and
a
properly docum
mented to provide confidence
c
e that matterials sup
pplied and/or
workk executed
d and servvices perfformed by him confform to th
he applicab
ble
speccifications and all the require
ements off contract documen
nt and wo
ork
execcuted by him shall perform sattisfactorily over the e
entire period of its liife.
The Quality Assurance
A
Systems Plans/Pro
ocedures of the BIIDDER sh
hall
gene
by
erally cove
er the follo
owing asp
pects/details, which shall be furnished
f
SUPPLIER alo
ong with, his detail en
ngineering package.
i.
ii.
Com
mplete details pertaining to the responsibil
r
lity authoritty and acc
countabilityy of
the Quality
Q
Asssurance of the Bidderr at site.
iii.
Installation
Equipments, material,
m
E
Erection,
n, Testing
g and com
mmissionin
ng,
Quallity Controll Plans for quality tes
sting/inspecction etc.
iv.
QAP
P to be submitted by the
t succes
ssful bidder.
v.
vi.
Conttrol Proced
dures/Plan
ns for calib
bration an
nd safe up
p-keep of instrumen
nts,
gaug
ges and sim
milar testing equipme
ents etc.
Quallity Assura
ance Sysstem Plan
ns/Procedu
ures of th
he BIDDE
ER shall be
furnisshed in the
e form of a QA manu
ual. SUPPL
LIER shall be require
ed to proviide
expla
anation pe
ertaining to
o the deta
ails furnish
hed by him in acco
ordance with
w
proviisions contained in this
t
clause
e and any further de
etails, as sought
s
for by
owne
er/consulta
ant. In add
dition, all the
t
Qualityy Assurance Progra
ams/Plans as
per specificatio
s
ons enclossed with th
he Contracct shall be fully complied with by
the Bidder.
B
Earthing
Central earthing
e
system for bullets
b
shalll be designed and e
executed by
b the bidder.
Mounded
d bullets sh
hall be connected to
o a centra
al earthing system th
hrough sollid-
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
21 of 32
state pola
arization ce
ells, which
h shall be suitably
s
rated for the
e expected
d voltage and
a
currents. Two nos. solid-state
e polarization cell ratted for 5KA
A should be installed
d in
one earth
hing junctio
on box. Ind
dividual ca
able from each
e
bullett shall be connected
c
to
one end of polarization celll and the
e other en
nd of pola
arization cell
c
shall be
connected to earth
h bus bar. All polarrization ce
ells shall b
be housed
d in earthiing
junction box
b made of
o S.S. Sizze of earthiing cable shall
s
be minimum 1C
C X 35 sq.m
mm
unarmore
ed, PVC, Alluminium/
A
/ copper co
onductor.
Earthing network shall
s
be independen
ntly conne
ected and develope
ed. Requissite
numbers of earth piits are also
o included in Bidderss scope.
15.0
CP Materrials
The CP materials to be proccured from
m approve
ed manufaccturer/vend
dor list ha
ave
been ind
dicated in Make of
o Equipm
ment/Comp
ponent forr Cathodic
c Protectiion
System. Make of ite
em not me
entioned in the enclossed vendo
or list shall be subjectted
to owne
er/consulta
ant apprroval. All materia
als shall be ins
spected by
owner/co
onsultants representtative at ma
anufacture
ers work be
efore dispa
atch.
16.0
DESCRIP
PTION OF CONSTRUCTION WORK
W
16.1
Cable La
aying
The cab
ble conne
ections sh
hall be done
d
by mechanica
al means
s. Mechan
nical
connectio
ons shall be
b made above
a
grou
und only using
u
cable
e glands, lugs, nuts and
serrated washers. All grou
und electtrical conn
nection to
o the bu
ullet shall be
encapsulated.
All cabless shall be sized such
h that no excessive
e
voltage drrops occur which red
duce
the capaccity of the system. All
A cables shall
s
be inssulated and sheathed to withsttand
the preva
ailing site condition. Drain cables ( 1CX
X 50 mm2
2, Cu) and
d ground bed
feeder ca
ables shalll be armou
ured. Electrical cable
es ( shall be 1.1 KV
V grade, PVC,
P
FRLS , Al
A / Cu conductor.) for
f CP of bullets fro
om TR unitts in Electtrical Room
m to
Bullets , shall be la
aid in cable
e trays ov
verhead in below LPG pipe rac
cks. Cable
es in
ground , shall be la
aid buried in soft san
nd at a dep
pth of at le
east 0.5m, provided with
cable pro
otection tile
es or wind
ding tape as
a conside
ered suitab
ble for the
e area. All the
cables sh
hall be iden
ntified by cable
c
tag where
w
they come abovve ground.
D.C cable
es & A.C. cables
c
will run in sep
parate PVC
C / GI conduits.
16.2
Permane
ent Refere
ence Cells:
The perm
manent refe
erence cells shall be
e installed in naturall soil conditions as per
p
the reco
ommendattions of the cell manufaccturer. In
nstallations
s in high
hly
acidic/alkkaline soil and
a soil co
ontaminated by hydro
ocarbons shall be avo
oided
16.3
Straight through jo
oint for ca
able
As far ass possible any straig
ght throug
gh joint sha
all be avo
oided for any
a
cable run,
however for unavo
oidable situations the
t
straigh
ht through
h joint kit of Raych
hem
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
22 of 32
Equivalen
nt make may be conssidered forr jointing ca
able.
16.4
Cable Co
onnection to Bullets
s
All cable--to-vessel connectio
ons shall be
b made using
u
weld
ding, pin brazing
b
or by
mechaniccal means. Thermit welding or brazing to
t the vesssel shall not
n be use
ed.
The cab
ble connecctions sha
all be do
one by mechanica
m
l means. Mechaniccal
connectio
ons shall be
b made above ground only ussing cable glands, lu
ugs, nuts and
a
serrated washers.
w
All ground
d electrical connectio
on to the bullet shall be encapssulated
17.0
FIELD TE
ESTING AND COMM
MISSIONIN
NG:
1
17.1
System Testing
T
att Site
The system testing
g at site described
d
below shall be app
plicable fo
or Impresssed
Current CP
C system.
Field testts as per the
t
ownerr reviewed//approved field testing and co
ommissioniing
procedure
es prepare
ed by the Bidder
B
sha
all be carrie
ed out on tthe equipm
ment/system
ms
before th
hese are put
p into se
ervice. Acc
ceptance of
o the com
mplete installation sh
hall
contingen
nt upon insspection an
nd test resu
ults.
Bidder sh
hall carry out
o pre-com
mmissioning operatio
ons after co
ompletion of
o installatiion
of the syystem inclu
uding all pre-commi
p
ssioning checks,
c
se
etting of all equipme
ent,
control an
nd protection devicess. All site tests,
t
reliab
bility and p
performanc
ce tests sh
hall
be carried
d out by Biidder.
Before th
he CP sysstem facilities are pu
ut into ope
eration, ne
ecessary te
ests shall be
carried out to establish that all equipm
ment, devicces, wiring
g and conn
nection ha
ave
been corrrectly insta
alled, conn
nected and
d are in good working
g condition
n as requirred
for the in
ntended op
peration. Owner/Own
O
ners repre
esentative may witne
ess all tessts.
Intimation
n shall be given
g
at lea
ast one we
eek before commenccing the tes
sts.
18.0
COMMIS
SSIONNG REQUIREM
R
MENTS
1
18.1
Visual exxamination
n of all system components, checking
c
o
of all cable
e connections
and polarrity.
1
18.2
Checking
g of all perm
manent refference ce
ells with resspect to a portable re
eference Cell
C
before en
nergizing th
he system.
1
18.3
Measurements of natural
n
pote
entials at each
e
perma
anent mon
nitoring loca
ation.
1
18.4
Energizin
ng the systtem and cu
urrent adjustment to approxima
a
ate protection potentia
als.
1
18.5
Checking
g of the ele
ectrical isollation of ea
ach vessel
1
18.6
Measurements of ground
g
bed
d resistance
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
1
18.7
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
23 of 32
(
(i)
Visu
ual Inspection: Co
omparison with dra
awings, specifications, detailled
phyysical inspe
ection and,, if necessa
ary; by taking apart the compon
nent parts..
Tessting: Simu
ulation testss of equipm
ment to determine itss operation
nal fitness.
Cables
(
(ii)
able No.
Ca
Vo
oltage grad
de
Co
onductor crross sectio
on
Co
ontinuity ch
heck
Inssulation ressistance va
alues betw
ween each core & earrth, betwee
en cores.
Alll cables sh
hall be teste
ed by 500 V Megger.
Insulatin
ng Joint
(
(iii)
(
(iv)
Lo
ocation
Pip
pe to soil potential of both protected
p
and non-p
protected sides of the
t
inssulating joint before and
a after Energisatio
E
n of CP syystem.
Surge Diiverter
Lo
ocation / ide
entification
n number
Ra
ating
Tyype
Ch
heck for he
ealthiness
Ch
heck for pro
oper conne
ection
Polarizattion Cell
Lo
ocation / ide
entification
n number
Tyype
Ra
atings
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
(
(v)
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
24 of 32
Ch
heck for wiring
Ch
heck stand
dby currentt drain afte
er CP Sysstem Energ
gisation. (C
Current dra
ain
witth respect to voltage across the
e cell shall be recorded).
De
etails of gro
ounding prrovided for the polarizzation cell..
Anode
(
(vi)
(
(vii)
entification
n
Ide
Tyype
Ch
heck prope
er cable to anode spliicing
Ch
heck for acctual layoutt and comp
pliance with drawingss.
Re
esistance of
o each ind
dividual ano
ode and to
otal resistan
nce of ano
ode loop..
Cu
urrent outp
put of anode loop.
Cu
urrent outp
put of each anode
Referenc
ce Cell
Lo
ocation
Tyype of cell
Po
otential rea
ading
Insstalled on top
t / bottom
m level of bullet
b
tanks.
nction Boxxes.
Test Stattions / Jun
Lo
ocation / Ide
entification
n number.
Ch
heck for wiring as perr schematics.
He
ealthiness of shunts and
a resisto
ors
Ch
heck the he
ealthiness of referenc
ce cell.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
19.0
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
25 of 32
MATERIA
AL INSPEC
CTION AN
ND TESTIN
NG
Owners/cconsultants represe
entative will
w visit th
he works during manufacture
e of
various equipment to
t assess the progre
ess of workk as well ass to ascerttain the quality
of raw materials
m
ussed all ne
ecessary assistance
a
shall be p
provided by
b Bidder and
vendor du
uring such inspection
n.
The minimum testiing and in
nspection requiremen
r
nts for all components/equipm
ment
shall con
nform to re
equiremen
nts as defined in the relevantt codes and standa
ards.
Detailed inspection
n and testing proced
dure along with acce
eptance crriteria shall be
al.
prepared by Bidder for Ownerrs approva
Test certiificates inccluding test records, performan
nce curves etc., shalll be furnish
hed.
All test certificates
c
s shall be endorsed
d with suffficient info
ormation to
t identify the
equipmen
nt to which
h certificate
es refer and
d must carrry project titles.
Owner re
eserves the
e right to ask
a for inspection of all or any item unde
er the conttract
and witne
ess all tessts and ca
arryout ins
spection or
o authorizze his representative
e to
witness te
ests and carryout
c
inspection. Bidder sha
all notify th
he owner / consultan
nt at
least 20 days
d
in advvance givin
ng exact details of te
ests dates a
and addres
ss of locations
where the
e tests wou
uld be carrried out.
The follow
wing minim
mum tests must
m
be ca
arried out and
a record
ded for all equipments
e
s:
g :
Checking
Inspection :
Testing
:
2
20.0
Visual inspe
V
ection, Com
mparison with
w drawin
ngs and sp
pecification
ns
D
Detailed
physical insp
pection & Dimensions
D
s measurement
S
Simulation
tests of equipmen
nt to dete
ermine its operation
nal
fiitness
MMISSION
NING
PRE-COM
The Bidder shall fin
nish the de
etailed field
d testing and
a pre-com
mmissionin
ng procedu
ures
oval. Field tests as per these approved
a
p
procedures
s shall be carried out on
for appro
the equip
pment / syystems be
efore these are put into servvice. Acceptance of the
complete installatio
on shall be continge
ent upon inspection and test results. Field
F
hall include
e but not be
e limited to
o the follow
wing:
testing sh
Bidder sh
hall carry out
o pre-com
mmissionin
ng operatio
ons after ccompletion of installa
ation
of the syystem including all pre-commissioning checks, se
etting of all
a equipm
ment,
control an
nd protecttive device
es. All site tests relia
ability and performan
nce tests shall
s
be carried
d out by Biidder.
Before the electrica
al facilities are put intto operation, necessa
ary tests shall be carrried
hat all equ
uipment, devices,
d
w
wiring
and connectio
on have been
b
out to esstablish th
correctly installed, connected
c
and are in
n good working cond
dition as intended forr the
required operation.
o
Owners / consulta
ants representative may witne
ess all tests. At leas
st one weeks
notice shall be given before co
ommencin
ng the testss.
All tools, equipmen
nt and insttrument an
nd instrum
ments required for te
esting shall be
provided by bidder.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
2
20.1
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
26 of 32
Anode Resistance
R
e Logging :
Resistancce Logging
g of anode strings sh
hall be done after com
mpletion off installatio
on of
anode be
ed and durring commissioning of
o CP Systtem. The p
procedure for
f same shall
s
be given by Bidderr as a part of commis
ssioning procedure d
during com
mmissioning of
CP system.
2
20.2
D
e Leads :
Holiday Detection
of Anode
To ensure
e the integ
grity of the insulation, the Bidde
er shall de
etect holida
ay of all an
node
lead cables. The sa
ame shall be
b conductted at the manufactu
m
rer works and
a witnesssed
by an autthorized re
epresentatiive from th
he ownerss side. The
e Bidder sh
hall provide
e an
approved
d holiday detection
d
in
nstrument complete with all acccessories
s for testing of
cables at the speciffied voltage
e.
al procedu
ures for the
e holiday detection
d
te
esting sha
all be in ac
ccordance with
The actua
the recom
mmendatio
on of the manufacture
er of the ho
oliday dete
ection instru
ument.
No repairr will be allowed
a
on the down
n hole ano
ode lead w
wires. Shou
uld holidayy be
detected, the entire
e cable and
d anode as
ssembly sh
hall be replaced.
2
20.3
Energisa
ation of T/R Unit :
After installation of each CP Station is complete, the Bidde
er shall ene
ergize the T/R
unit in the
e presence
e of the ow
wner/his re
epresentative to checck the func
ctioning off the
CP Syste
em.
2
21.0
COMMIS
SSIONING
2
21.1
Permane
ent ICCP System:
S
A brief co
ommission
ning proced
dure for a CP system
m of a Bulllet tanks is given be
elow
for general guidancce. Bidder shall
s
devellop detailed
d commisssioning pro
ocedure ass per
this guide
eline.
On comp
pletion of in
nstallation of
o Anode beds
b
and other
o
syste
ems as env
visaged in this
specificattion, they shall
s
be in
ndividually checked, tested and
d compare
ed againstt the
agreed sp
pecification
ns and pro
ocedure.
Electrical resistance
e of the bullets shall be checke
ed and reco
orded.
Before th
he bullets are put on
o charge by switching ON a
any of the
e CP statio
ons,
bullets to
o soil poten
ntial value
es at CJB/MJB of the system shall be measured
m
with
respect to
o Copper / Copper Sulphate refference ha
alf cell.
The TRU
U is then en
nergized and the outp
put of the TRU
T
shall then be so
o adjusted that
the sites of occurre
ence of lea
ast negativ
ve protectivve potentia
als are nott less nega
ative
than (-) 0.95 V (O
OFF) and sites
s
of oc
ccurrence of the m
most negattive protecctive
potential are not mo
ore negativve than (-) 1.1 V (OF
FF).
Care sha
all be exerccised to en
nsure that power supply rema
ains uninterrupted du
uring
the period
d of comm
missioning. In case off an interru
uption, the test in pro
ogress shall be
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
27 of 32
2
22.0
GUARAN
NTEE:
Bidder sh
hall guaran
ntee the proper perfo
ormance of
o the com
mplete imprressed currrent
cathodic protection
n system and
a
equip
pment provvided by him for a period off 24
months frrom the da
ate of comm
missioning of the PCP System.
The Bidder will mon
nitor the CP System for one ye
ear from the
e date of commission
c
ning
d
arissing shall be
b rectified
d at no extra cost.
and any defects
2
23.0
2
24.1
GENERA
AL
After issu
uance of purchase
p
o
order,
succ
cessful bidd
der shall ssubmit six copies + CD
of all drawings/data
a/manuals//calculation
ns etc for review/app
proval, with
h identifica
ation
mber and de
escriptive title with p
project nam
me, owner and
on each document by a num
consultan
nt name.
2
24.1.1.
2
24.1.2.
All drawin
ngs and do
ocuments shall
s
be in English an
nd follow m
metric syste
em.
2
24.1.3.
2
24.1.4.
Basis of system
s
design, desig
gn and sizing calcula
ations of the
e equipme
ents.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
28 of 32
2
24.1.5.
Bills of materials,
m
m
material
req
quisitions and
a purcha
ase requisittions.
2
24.1.6.
Fabricatio
on and insstallation de
etails of AJ
JB, CJB, te
est station etc.
2
24.1.7.
Connection scheme
e drawing for differen
nt type of ju
unction bo
oxes used in the cathodic
n.
protection
2
24.1.1.
Layout drawings sh
howing ano
ode, test station,
s
AJB, CJB, p
permanent reference cell
location etc.
e
2
24.1.2.
2
24.1.3.
Vendor drawings
d
and catalog
gues.
2
24.1.4.
Operation
n and main
ntenance manual,
m
Eq
quipment manufactur
m
rers docum
mentation
2
24.0
INST
TRUMENT
TS,TOOLS
S AND SPA
ARES
Bidder sh
hall provide
e a list of all
a instrum
ments, toolss and tacklles necess
sary for pro
oper
operation
n and main
ntenance of
o complete
e cathodic protection
n system and
a associa
ated
equipmen
nt along with prices.
Bidder sh
hall provide
e a list of spares
s
and
d consumables along
g with price
es, required
d for
proper operation and
a
mainte
enance of complete cathodic protection system fo
or 2
years.
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
29 of 32
2
25.0
SCHEDULE OF QUANTITIES
De
Sr.
escription of Item
No.
1. i)D
Design( In
nclusive of
o detail engg.),
e
Supply,
Erection
n,
Te
esting,
co
ommission
ning of Imp
pressed Current
C
Cathodic Prrotection syystem for 4 Nos.
off Mounded
d Bullets fo
or LPG Sttorage,
co
omplete in all respeccts as per scope
off work & specificatio
s
ons as exp
plained
on
n LSTK basis. & inclusivve of
fo
ollowings.
i) Air cooled Transfformer Re
ectifier
Unit of ratin
ng 50V/ min.50A , - 2 Nos.
one working + one Sttand by)
(o
ii))Prepackag
ged , long Line Cond
ductive
Po
olymer Anode ANOD
DEFLEX 15
50001
1 Raychem
m/Equivale
ent make
-Q
Qty:As Req
quired (Buttmin.4striings
peerbullet)
iiii). Anode flex
f
Splice Kit
)Q
Qty:Min8Nos./Bullet
iv
v). Junction
n Boxes:
a)) Anode Diistribution Box (ADB))
Classified - 1 No.
unction Boxxes (AJB) for
b)) Anode Ju
classified arreas - 8No
os
c)) Cathode Junction Boxes
B
(CJB
B) cum
Te
est Station
n for classiffied areas. 4
Nos.
ng Junction
n Box (MJB
B) for
d)) Monitorin
no
on-classifie
ed areas
- 1 No.
v..) Cables:
a)) Positive and
a negativve header cable
:-1C X 50 mm2,Al
m
Arm
moured
b)) Drainage able :- 1C
C X 50mm2
2, Cu.
c)) Power Su
upply cable
e (PMCC to
o TR
Units). :- 3.5
5C X 25mm
m2, Al,Arm
moured
Qty
C
Cost
Supply
Rem
mark
Installation
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
ix
x). Painting
g of C.P. Syystem
eq
quipment .
X)). Explosio
on Proof Ea
arthing Jun
nction
Bo
ox (Nos.)
-Q
Qty:Min 1 no.
n per bullet
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 3
30 of 32
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
(
XIi) . Surge Diverter- (Nos.)
-Q
Qty:As Req
quired
X Earth pits
Xv).
p
-Q
Qty:Min 6 nos
n ,all con
nnected in
pa
arallel
Xv
vi) Zinc Re
eference Electrode
E
- 4
Nos. (1per bullet)
b
items
A)
A
Supplly
of
above
(In
nclusive of 10% commissiioning
sp
pares)
B)
Installlation
In
nstruments, Tools & Tackles
T
forr
prroper operation & ma
aintenance
e of
Cathodic Prrotection System &
e
ts.
asssociated equipment
1LOT
1LOT
DOCUMENT
T NO
REV
V
Sheet 3
31 of 32
XXXX
XX
XXXXX
1 Lot
i.
ii.
iii.
iv.
v.
EM163-TS--0801
1 Lot
D C Voltmete
er of each tyype
D C Ammete
er of each tyype
A C Voltmete
er of each tyype
A C Ammeter of each tyype
Co
orrosion voltmeter of each
e
type
1 no
1 no
1 no
1 no
1 no
Bidde
er to
furn
nish
XXXXXX
XX
Listt of
Itemss with
Quanttities.
Spa
are
shall be
same
e as
XXXXXX
XX used
d in
offered
T/R Unit
XXXXXX
XX
XXXXXX
XX
XXXXXX
XX
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
xxiii.
Diodes
SC
CRs
D.C. Fuses fo
or output sid
de
HRC fuses fo
or Diodes
A..C fuses forr input side
D.C lighting arrestor
a
Co
ontrol transsformer
Co
oarse Volta
age Control Switch
Fine Current control Switch
Fine Voltage control Switch
Au
uto Manual Mode Sele
ector Switch
h
To
oggle Switcches
Asssorted Gla
ass Cartridge Fuses
4 set
4 set
4 set
4 set
4 set
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
20 set
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 3
32 of 32
Eachtype
andraating
Note:
1. Bidder to no
ote that quantity
q
ind
dicated in price sch
hedule is indicative & for tend
der
urpose onlly. Bidder shall calcculate/supp
ply the qu
uantity as per the approved
a
C
CP
pu
de
esign draw
wings/docum
ments submitted by bidder
b
afte
er award off order.
2. An
ny other spare
s
whicch are not specified
d here but required for safe and smoo
oth
op
peration of CP system
m shall also be quote
ed with unitt rate.
All rig
ghts reserved
TECHNICAL SPECIFICATION
CATHODIC PROTECTION SYSTEM OF
MOUNDED BULLETS
PROJECT:INSTALLATION OF LPG MOUNDED
BULLETS
OWNER : NRL,ASSAM
EM163-TS-0801
DOCUMENT NO
REV
Sheet 1 of 2
DATA SHEET
FOR
CATHODIC PROTECTION SYSTEM OF LPG MOUNDED
BULLET
TECHNICAL SPECIFICATION
CATHODIC PROTECTION SYSTEM OF
MOUNDED BULLETS
PROJECT:INSTALLATION OF LPG MOUNDED
BULLETS
OWNER : NRL,ASSAM
1.0
EM163-TS-0801
DOCUMENT NO
REV
Sheet 2 of 2
SCOPE:
This Data sheets covers the minimum technical specification for Design of Cathodic
Protection System for LPG/ Propylene mounded bullet. CP VENDOR is requested to
fill up the missing information as called for in the Data Sheet.
2.0
DATA SHEET:
Parameter
Bullets (Nos.)
LPG BULLET
4
7.0
Bullet Coating
52
-27OC to 55OC
Design Temp.
Design Life (Sacrificial)
N.A.
30Years
Safety Factor
Operating Pressure, Kg/cm
1.3
2
As Required
240V (Single Phase)
Vendor to measure at site
No
No
Yes
50 uA/m2
Structure to soil potential (P-S-P) to be
between (-) 850mV to (-) 1150mV with
reference to Cu/CuSo4 Reference
Electrode.
Note:- The above information is indicative only. Supplier shall refer Bullet
Specifications and others specifications enclosed elsewhere.
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
BA
ASIC SU
URVEY
FOR
R
SOIL RESIST
TIVITY MEASU
UREMEN
NT
R
FOR
INS
STALLA
ATION OF
O LPG MOUND
DED BU
ULLETS
S
N
NRL,AS
SSAM
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
1.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 3
SC
COPE
This specification cove
ers the req
quirements
s for carryying basic survey for designing the
Ca
athodic Pro
otection System.
2.0
CO
ODES AND
D STANDA
ARDS
The
e basic su
urvey shalll be done in accorda
ance with the latest revisions of the follo
owing
Ind
dian standa
ards. Whe
erever applicable Ind
dian Standa
ards are n
not availab
ble, the relevant
IEC
C Standard
d shall app
ply:
a)
b)
c)
d)
Wo
ork shall be
e carried out
o in accorrdance with all appliccable local laws and regulationss.
3.0
BA
ASIC SURV
VEYS :
Th
he following
g Basic Su
urveys shalll be carrie
ed out by va
arious metthods:
a. Soil Resistivity Survey 4 Point
P
Wenner Metho
od:
The Soil Resistivity Survey sh
hall be con
nducted within
w
the P
Plant/ Com
mplex for Bullets
B
and at evvery 2 km along pip
peline ROW
W at a depth of 1M, 2M, 3M,4
4M,5M,6M
M at a
matrix of 100 M in unpaved
u
areas by 4 point Wenner Metho
od and a co
ontour plott shall
be preparred.
b. Soil Resistivity Survey Soil Box Metthod
The Soil Resistivity Survey sh
hall be con
nducted within
w
the P
Plant/ Com
mplex for Bullets
B
and at evvery 2 km along pip
peline ROW
W at a depth of 1M, 2M, 3M,4
4M,5M,6M
M at a
matrix of 100 M in unpaved areas by soil box method
m
and a contour plot sha
all be
prepared.
c. Chemical Analysis
s of Samplles of Soill Water
wing param
meters of soil water extract at evvery 5 kmss along pip
peline ROW
W and
The follow
within the
e Plant/ Co
omplex for Bullets shall be analyzed for ssamples co
ollected a depth
d
of 1M 3M and 6M att a matrix of
o 250M in unpaved areas.
a
-
H
PH
Ca
arbonates as
a Ca CO3 mg / ltr.
Biccarbonatess as Ca CO
O3 mg/ ltr.
Ca
alcium as Ca
C CO3 mg
g/ ltr.
Ma
agnesium as
a Mg CO3 mg/ ltr.
Sodium as Na mg/ ltr.
Ch
hlorides as Cl mg/ ltr.
Sulphates ass SO4 mg/ ltr.
Siliica as SIO
O2 mg/t ltr.
Tottal Dissolvved Solids (TDS) mg// ltr.
Sulphate Red
ducing Baccteria
KM
MNO4 at 10
00 C mg / lttr.
Solubility of Soil
S in Distilled water %
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 3
.
4.0
RE
EPORT
On
n completio
on of the entire field
d and laboratory wo
ork, an intterim repo
ort incorporating
ressults generrated from surveys, additional
a
data colleccted, resullts of test carried
c
outt, etc.
sha
all be subm
mitted for commentss / approval. The fin
nal report iincorporatiing comme
ents /
misssing data shall be fu
urnished fo
or records. Contracto
or shall submit the re
eport along
g with
varrious drawings, graph
hs etc. pre
epared in connection with the w
work along with six prints.
.
5.0
INF
FORMATIO
ON REQUIIRED
Supplier shall provide fo
ollowing info
ormation:
5.1
5.2
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 1 of 17
TECHNIC
CAL SPECIFICA
ATION
TRA
ANSFOR
RMER RECTIFI
R
IER UNIT
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
1.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 2 of 17
SC
COPE
al require
ements fo
or the De
esign,
This specificcation covvers the minimum Technica
Ma
anufacture,, Performa
ance, Supp
ply, Inspecttion, Testin
ng and com
mmissionin
ng of Air Cooled
Tra
ansformerss Rectifier Unit for CP
P System.
The
e Transforrmer Rectifier units shall
s
be a standard product off a manufa
acturer reg
gularly
eng
gaged in production
n of Cath
hodic Protection Power Supp
plies. The units sha
all be
sup
pplied in acccordance
e with the fo
ollowing sp
pecification
ns and data
a sheets.
2.0
CO
ODES AND
D STANDA
ARDS
e Design, Manufactu
uring, Tessting of Airr Cooled Transforme
T
er Rectifierr Unit and
d their
The
com
mponents shall be in accorda
ance with the latesst revisionss of the following
f
Indian
sta
andards, wherever
w
applicable. Where ap
ppropriate Indian Sta
andards are not available,
the
e relevant IEC
I
Standa
ard shall apply:
a)
b)
c)
d)
e)
f)
g)
t the follow
wing:
This shall incclude but not limited to
IS: 2026
IS: 3700
IS: 4400
IS: 60898
IS: 13703
IS: 60947
IS: 3070
IS: 11548
IS: 694
IS: 3961
IS: 4800
IS: 11222
IS: 1248
IS: 6236
FORM NO: 02
2-0000-0021F2 REV3
R
Power Tra
ansformer
Essential rating and
d characte
eristics of Semi-Cond
S
ductor
devices.
Methods of measure
ements on
n semicond
ductor
Devices (General)
Electrical accessorie
es-Circuit breakers fo
or over currrent
Protection
n for house
ehold and ssimilar insttallation
Specificattion for Lo
ow voltage
es fuses for voltage
e not
exceeding
g 1000V AC
A or 1500V
V DC
Specificattion for Low
w voltage S
Switchgear & controll gear
Lightning arrestors for
f AC sysstems
Capacitorrs for surrge protecction for use
u
in Vo
oltage
system ab
bove 650V
V and up to
o 33kV
PVC insu
ulated unsh
heathed an
nd sheathe
ed cables//cords
for workin
ng voltagess up to and
d including 450/750 volts
v
Recomme
ended currrent rating for cables
Enameled
d round winding wires
Dial, sca
ales and indexes for indica
ating analogue
Measuring instrume
ents
Direct acting indica
ating analo
ogue electrical meassuring
instrumen
nts and the
eir accesso
ories
Direct rec
cording ele
ectrical mea
asuring ins
strument
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
IS: 2419
IS: 8573
IS
S: 3043
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 3 of 17
In case of conflicting
requireme
c
ents amon
ngst any of
o the abo
ove standards, the most
striingent requ
uirement shall
s
be folllowed.
3.0
TR
RANSFORM
MER
The
e Main Tra
ansformer will be the
e isolation type havin
ng separatte primary and secondary
win
ndings. An
n electrostatic shield, compo
osed of he
eavy copp
per foil, shall
s
be placed
p
bettween the two windin
ngs and grrounded to
o the rectifier cabinet, for this purpose a visible
v
lea
ad should be
b brought out from the coppe
er foil whicch shall be
e connecte
ed to any of
o the
mo
ounting stu
ud of the trransformerr core. Insu
ulation class of wind
ding shall be
b class F type.
The
e winding assemblyy shall be dipped in the therm
mo-setting vvarnish an
nd backed. The
Ca
abinet air temperatur
t
re will nott exceed 85
8 0 C at 110
1
% fulll load currrent at am
mbient
tem
mperature of up to 45
5oC. Transsformer full load efficiiency will n
not be less
s than 95%
%. The
auttotransform
mer shall be
b similar to
o main tran
nsformer except
e
it will have single winding
g and
tap
pping for manual
m
mod
de of contrrol.
4.0
ECTIFYING
G ELEMEN
NT
RE
Re
ectifier shalll be Silicon type of approved
a
make
m
with adequate cooling arrrangemen
nt with
mo
oisture and
d humidity resistant finish.
f
It sh
hall be mo
ounted on spindles or
o other su
uitable
sup
pports. The
e Power Rectification
R
n shall be through Diodes/SCR
Rs which shall be pro
operly
selected to have adequ
uate Safetyy Margin. Itt shall have
e configura
ation suitable for full wave
recctification.
The
e Thyristorrs/diodes shall
s
be mounted on heat sinkss which sh
hall prefera
ably be ma
ade of
exttruded alu
uminum. The
T
diodess shall be connecte
ed in Bridg
ge circuitrry for full wave
recctification. Adequate
A
filtering in the form of
o L-C filte
ering circuitt shall be provided
p
o the
on
outtput side to
o limit the ripple
r
content to less
s than 5% at
a rated ou
utput. The input &output of
the
e Rectifierr shall be protected
d by HRC
C fuses of
o suitable rating. Transient
T
s
surge
sup
ppressors shall also be provide
ed across DC
D output terminals and AC input terminals to
pro
otect the re
ectifier aga
ainst surge
es. Each diode and SCR
S
shall be provide
ed with su
uitable
surrge suppre
essers, and
d also with suitably designed sn
nubber circcuits.
The
e current and
a voltage
e ratings of Thyristorrs, diodes shall
s
be at least two times
t
the actual
a
ma
aximum de
evice curre
ent and miinimum tw
wo times th
he actual m
maximum voltage co
oming
acrross the de
evice respe
ectively.
5.0
A.C
C. INPUT
e transforrmer rectiffier units shall be designed to operate on 240
0V/415V+ 10%
The
single/three phase AC
C, 50 Hz + 5% pow
wer supplyy. Inrush ccurrent lim
miting reacttor of
suitable rating to be pro
ovided at input
i
line of
o the Main
n Transforrmer to avo
oid possibiility of
nuiisance tripping of MC
CB while cllosing circu
uit using MCB.
M
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
6.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 4 of 17
D.C
C. OUTPU
UT
The
e Transforrmer rectifier shall be
e designed to operate
e continuously at 110
0% rated output
o
currrent and 110% ra
ated outpu
ut voltage at input supply voltage 240V/415V single
s
pha
ase/three phase
p
AC without
w
dam
maging any
y compone
ents.
7.0
D.C
C. OUTPU
UT ADJUST
TMENTS
e D.C. outtput contro
ol shall be available in any of th
he following modes, with the help of
The
a selector
s
sw
witch.
8.0
8.1
MO
ODES OF OPERATIO
O
ON:
MA
ANUAL MO
ODE
Ou
utput voltag
ge at 36 eq
qual steps up to 110%
% rated vo
oltage shalll be availab
ble by mea
ans of
coa
arse and fine
f
tap ch
hanging sw
witches forr rated inp
put supply voltage and
a
110% rated
outtput curren
nt.
Tapping for output
o
volttage contro
ol shall be
e taken from a separrate Autotrransformerr. The
con
ntrolled ou
utput voltag
ge of the autotransfo
a
ormer shall be fed to
o main tra
ansformer input.
The
e output off the Main Transform
mer shall be
e rectified for
f D.C loa
ad supply.
8.2
AU
UTO MODE
E:
Either consta
ant currentt control or
o constantt pipe to soil
s potenttial control mode sha
all be
pro
ovided in Auto
A
mode as per datta sheet for Bullets.
8.2.1 AU
UTOMATIC
C VOLTAG
GE-CURRE
ENT CONT
TROL MOD
DE (AVCC
C MODE)
The
e output vo
oltage of th
he unit sha
all be adjus
stable to an
ny value frrom 0V to rated
r
voltage by
me
eans of a step
s
less vo
oltage setter potentio
ometer. The voltage rregulation shall be within
w
0.2
25V.
The
e output current
c
of the unit shall
s
also be
b adjusta
able to anyy value fro
om 0A to rated
currrent by means
m
of a step lesss currentt setter po
otentiometter. The current
c
sha
all be
reg
gulated within 1.0 A for bulletss.
The
e independ
dent curren
nt limit circcuit capable of proteccting the unit even un
nder dead short
circcuit acrosss output sh
hall be provided. The
e unit will be
b suitable
e of sustain
ning dead short
circcuit acrosss output ind
definitely without
w
deg
grading or damaging
g any intern
nal components
in this
t
mode.
8.2.2 AU
UTO REFR
RENCE MO
ODE
For Mounded
d Bullets operation off the unit in this mod
de shall be controlled
d by a reference
s
be in
nstantaneo
ous to suppress exxtremely fa
ast acting external stray
signal and shall
currrents if prresent. The
e output D.C. voltage
e of the un
nit in this m
mode shalll vary rightt from
0V to rated voltage
v
and
d form 0A to
t rated cu
urrent to maintain
m
the
e reference
e signal within
20 mV of the set value under all operating
o
conditions.
c
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 5 of 17
T/R
R UNIT WITH REMO
OTE MONIT
TORING FACILITY
F
T/R
R Units sh
hould be provided
p
w
with
transd
ducers for providing 4-20 mA
A output siignals
req
quired for remote mo
onitoring unit
u
(RMU)) interface
e for remotte monitorring of T/R
R Unit
outtput voltag
ge and current. Nece
essary term
minals are to be provvided at su
uitable loca
ations
of the T/R unit panel for easyy termination of onw
ward wirin
ng by others for re
emote
mo
onitoring pu
urpose.
Faccility will be
e provided
d for remote
e monitorin
ng of follow
wing signalls
1. Analog
g Parameters
a) PSP
b) DC O/P Voltage
V
c) DC O/P Current
C
d) AC Supply Voltage
e) AC Supply time Tota
aliser
2. Alarm Paramete
ers
a) Under Pro
otection
b) Over Prottection
e fail
c) Reference
d) AC Supply Fail
e) TR unit Door open
For details please referr specificattion for rem
mote monito
oring, attacched elsew
where.
10.0
T/R
R UNIT CO
ONTROL
The
e Transforrmer / Recctifier units electron
nic control circuitry sshould be able to accept
a
rem
motes as well
w as loccal referen
nce contro
ol signal fo
or setting o
of output current
c
/ output
o
voltage. The control signal for setting
s
sho
ould be se
elected ussing a sele
ector switcch for
rem
mote or loccal control.. At selecto
or switch in local possition, the potentiome
eter provid
ded in
T/R
R Units forr continuous currentt and volta
age adjusttment in auto mode should prrovide
loccal control reference
e signal byy manual adjustmen
nt to the p
potentiome
eter. At selector
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 6 of 17
switch in rem
mote posittion the electronic
e
circuitry
c
sh
hould be suitable to
o accept digital
d
refe
erence control signa
als through
h Ethernett link from central control room
m computer for
rem
mote settin
ng of outpu
ut current / voltage / PSP. In th
his case if Ethernet Link
L
fails th
he set
poiints should
d be maintained to the
t
presett values sttored in m
memory till communiccation
ressumes and
d new value
es are prog
grammed.
11.0
T/R
R UNIT IN INTERRUPTION
T/R
R units sho
ould be prrovided witth inbuilt Microproce
M
essor base
ed current interrupter with
GP
PS Receive
er with Exte
ernal Antenna for me
easuremen
nt of OFF P
PSP. The interrupter clock
sho
ould also accept
a
exte
ernal time synchroniz
zing signal from rem
mote monito
oring syste
em for
inte
errupted offf PSP reccording, syynchronizin
ng with other T/R uniits. The intterrupter should
be programm
mable to pe
erform inte
erruption in
n the time ratio
r
selecctive form 0-9999
0
secconds
in increment
i
of 0.1 secc. The curre
ent interrupter should
d have me
embrane ke
eypad and
d LCD
dissplay for prrogramming of day, date,
d
time, ON/OFF Time,
T
Syncchronization Signal etc.
12.0
DC
C OUTPUT
T RIPPLE
The
e filter circcuit shall be designed
d in such a manner that Ripple
e Factor does not exxceed
5%
% at rated lo
oad both in
n auto and
d manual mode.
m
13.0
INP
PUT OVER
RLOAD PR
ROTECTIO
ON
Pro
otection fro
om overloa
ads on the
e input sha
all be provvided by M
Miniature circuit breakker of
suitable ratin
ng on the
e input side. The trip point shall be
e unaffecte
ed by am
mbient
tem
mperature. The trip handles
h
of individual poles of circuit
c
brea
aker shall be
b mechan
nically
linkked so tha
at all lines are opene
ed when an
n overload
d occurs. In
n addition to above MCB,
HR
RC fuse of suitable ra
ating shall be connected beforre MCB so
o that A.C. input currrent is
limited to maxx. 10% exccess rated input current.
14.0
OU
UTPUT OV
VERLOAD PROTECT
TION
Pro
otection fro
om overloa
ad on the output
o
in auto mode for T/R un
nit having either
e
Auto
omatic
voltage-curre
ent control mode or Automatic reference
e mode will be provided by an
nother
clo
ose loop SCR
S
contro
ol circuitry giving auttomatic co
onstant currrent same
e as menttioned
(intterruption) except th
hat it will act as back up co
ontrol to m
main auto mode co
ontrol.
Separate PC
CB shall be
b used fo
or main au
uto mode control an
nd the bac
ck control. The
currrent limit for backup
p control iss to be se
et by two limit switch
hes marked Coarse
e and
Fine. The limits of the
e two switcches shall be algebra
aically add
ditive and shall
s
give equal
ste
eps of 2A each
e
up to 110% rate
ed current.
ne scale ca
alibrated in
n Ampere shall
s
be pro
ovided with
h each limit switches
s so that cu
urrent
On
limit can be set
s by operrator at anyy desired value
v
in 2A
A step. In a
any circumstances evven in
casse of shortt circuit the
e T/R unit output
o
currrent should
d not exce
eed the currrent limit set
s by
the
e backup control.
c
In addition to
o above electronic
e
c
current
lim
miting featu
ure HRC fu
use &
MC
CB of suita
able rating to be use
ed at posittive and ne
egative terrminals to disconnecct T/R
uniit quickly in
n case of over
o
loads in the outp
put circuit.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
15.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 7 of 17
VO
OLTAGE SURGE
S
PR
ROTECTIO
ON
Each silicon controlled
c
rectifier (S
SCR) and Diodes
D
sha
all be prote
ected from Voltage Surges
by means off R-C circuitry. Thesse R-C cirrcuits will be rated as recomm
mended by
b the
ma
anufacturerr of the SCR/Diode
S
es so thatt they will conduct heavily be
efore the Peak
Invverse Volta
age ratingss of the SCR / Diodes
s are reach
hed.
In addition, Lighting
L
Arrestors and Zener ba
arrier type
e or MOV ttype Surge
e Diverterss shall
C. input and
d D.C. outtput circuit of the Tra
ansformer Rectifier as
a per
be provided in the A.C
datta sheet.
16.0
CO
OOLING
The
e Transfo
ormer/Recttifier will be naturral air co
ooled, completely enclosed IP55
con
nstruction. The temperature of the transfo
ormer shall not be more than 85oC for am
mbient
tem
mperature of up to 45
5oC.
17.0
INP
PUT AND OUT PUT TERMINA
ALS
DC
C terminalss made off tinned pllated copp
per shall be
b located convenient to the cable
enttrance. The terminalss shall be suitable fo
or required
d cable size
es. Two ne
egative and two
possitive outpu
ut terminalls shall be provided.
AC
C terminalss shall be insulated to withstand 2000 vo
olts 50 Hz to the enc
closure, shall be
shielded to prevent acccidental con
ntact and shall
s
be sizzed to take
e required cable
c
sizess.
18.0
ETERS
ME
The
e transforrmer rectiffier units shall be equipped
e
with sepa
arate conttinuous reading
Voltmeter an
nd Ammete
er for the D.C
D outputt and the A.C
A input voltage, cu
urrent and
d PSP
me
easuremen
nt. All mete
ers shall be
b electron
nic digital type
t
with L
LED displa
ay arrange
ement
and
d should be
b able to
o indicate the curren
nt and volttage up to
o full rang
ges and ha
ave a
ressolution of one decim
mal place for
f DC Am
mmeter & Voltmeter
V
and 3 dec
cimal place
es for
PS
SP meter. Digit
D
size should
s
be 12.5
1
mm (m
minimum). All meterss shall be square
s
in shape
s
and
d accurate
e to within
n 2% at fu
ull load at ambient temp.
t
The
ey shall be
e Tempera
atures
com
mpensated
d to vary no
o more tha
an 1% per 10% temp
perature ch
hanges.
All AC & DC voltmeterss shall be provided
p
with
w separa
ate fuse and Toggle switch
s
whe
ere as
all Ammeterss shall be provided
p
w only To
with
oggle switcch.
19.0
AN
NNUCIATIO
ON
Each Transfo
ormer Rectifier shall be supplie
ed with a continuous
c
signal ligh
ht, which will
w go
on to this each
e
T/R unit should be given Annunciatio
A
on for
outt at loss off A.C. inputt. In additio
autto and ma
anual mod
de of operration by continuous
c
s signal lig
ght. T/R unit
u
should
d also
ind
dicate high temperature of insttrument ch
hamber ass well as th
he failure of each fu
use in
brid
dge rectifie
er and two DC outputt fuses by an independent LED
D for each.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 8 of 17
Audio / Visu
ual alarm for the fo
ollowing alarms with
h potential free conttact for re
emote
exttension:
i.
ii.
iii.
iv.
v.
Ne
ecessary te
erminals are to be provided
p
at suitable locations inside T/R
R Unit pan
nel for
termination of
o wiring req
quired for central
c
mo
onitoring an
nd control purpose.
18.1
AN
NNUNCIAT
TION FOR FUSE FA
AIL
T/R
R Unit sho
ould be pro
ovided witth Electron
nic Fuse fa
ail indicato
or. The fus
se fail indicator
sho
ould sense
e signals frrom each fuse
f
in serries with diiode in the
e rectifier circuit
c
as well
w as
eacch fuse in DC outputt circuit and
d on its faiilure, it sho
ould identiffy the fuse failed with
h help
of an independent LED
D for each fuse for lo
ocal visual alarm and
d potentiall free NO & NC
con
ntacts shou
uld be provvided for re
emote visu
ual alarm extension
e
fo
or remote monitoring
g.
18.2
NNUNCIAT
TION FOR HIGH TEM
MPERATU
URE
AN
T/R
R Unit sho
ould be pro
ovided with
h 2 nos. of
o thermosttats along with nece
essary Rela
ays &
pottential free
e NO & NC
C contacts for remote
e monitorin
ng & LED d
display forr local indiccation
of high temp
perature of
o instrume
ent chamb
ber. The thermostat
t
t should have
h
adjusstable
tem
mperature setting ran
nge from 45
5oC to 110
0oC.
20.0
EN
NCLOSURE
E
The
e enclosurre of T/R unit
u shall be
b plinth mounted
m
& outdoor h
having one
e compartm
ments
con
ntain Main Transform
mer, Auto-T
Transformer, DC cho
oke. Panel shall be of
o free standing
typ
pe and all cable
c
entrie
es shall be
e from the bottom
b
only.
The
e SCRs, Diodes, indicatin
ng meters, protecctive deviices, elec
ctronic co
ontrol
circcuits/contro
ol cords ettc. and sha
all be prov
vided with a Plexigla
ass viewing window. Both
the
e comparttments sh
hall be co
ompletely enclosed type ha
aving IP 65 for Bullets
B
con
nstruction.
The
e enclosure shall be
b made of
o minimu
um 12SWG
G (2.67 m
mm) sheett steel. Size of
encclosure sh
hould be specified
s
b Vendor.. An integrated/detachable sun/rain sha
by
ade of
suitable size to be provvided by ve
endor.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 9 of 17
The
e transform
mer rectifie
er shall be provided with
w the following acccessories.
Steel channel
c
un
nder the ba
ase for plin
nth mountin
ng.
Lifting lugs of sizze suitable for lifting complete
c
transformer rectifier unit.
u
Sunsh
hade / rain shade.
Lockable controll cabinet with
w viewing
g windows to IP55 ass a minimu
um.
Acccessibility shall be provided by
b hinged and removable fro
ont and ba
ack shutte
ers. A
Ple
exiglas view
wing windo
ows shall be
b provided at the fro
ont shutterr to allow th
he meters to be
rea
ad without opening th
he front shutter. One drawing pocket
p
shalll be made
e at inner side of
the
e front shutter. One holder
h
for 60
6 watt CF
FL connecction shall be provide
ed at a stra
ategic
poiint inside th
he cabinett to facilitatte proper illumination
n during op
peration and maintena
ance.
The
e enclosu
ure shall be supplied with an
a engravved warning label with the word
DA
ANGER. Two juncction boxe
es shall be provid
ded at bo
oth sides of the upper
u
com
mpartmentt, one for A.C cable
e entries and
a
other for D.C cable entrie
es. Gland plate
sho
ould be pro
ovided aga
ainst each junction box
b for fixin
ng single ccompressio
on cable glands
g
for AC/DC control
c
/ monitoring
m
c
cables.
Tw
wo 240 V, 6A Socke
et shall be
e provided
d at a
ategic poiint inside the cabin
net to fac
cilitate connection of soldering iron during
d
stra
ma
aintenance. After fabrication the
e entire en
nclosure sh
hall be epo
oxy paint/P
Powder Co
oating
of shade RA
AL 7032 Siiemens gre
ey with proper pre-treatment a
and primer applicatio
on as
perr standard Industrial Practice to
t achieve thickness of 120m.
21.0
NCLOSURE
E EARTHIING
EN
All normally dead
d
meta
allic parts shall
s
be ellectrically continuous
c
s. Earthing
g terminalss shall
be suitable for
f 35 mm
m2 cable co
onnections
s to powerr supply e
earthing an
nd two earthing
terminals sha
all be made
e for earthiing connec
ction to the
e local eartthing pits.
e earth connection
c
points shall be protected
p
a
against
co
orrosion. It
I shall no
ot be
The
neccessary to
o scrap th
he paint away
a
in orrder to ma
ake an efffective ea
arth conne
ection.
Pro
ovision shall also be made adjacent
a
to
o each gla
and plate for cable gland earthing
con
nnection. Enclosure
E
e
earthing
co
onnection stud size shall
s
not less than 12
2mm.
1 no.
n nickel plated
p
copp
per earth bus
b bar sha
all be proviided.
22.0
Ca
able Terminations
22.1
Ca
able glandin
ng and terrminating facilities
f
an
nd terminals shall be
e suitable for
f the spe
ecified
cab
ble type an
nd conductor size. Considerati
C
on and pro
ovision sha
all be take
en by the Bidder
B
on the equipm
ment desig
gn for the use
u of cablles with alu
uminum co
onductors. Cable glan
nds &
cab
ble lugs sh
hall be in th
he scope of
o supply fo
or CP syste
em installation contra
actor.
Terminal bloccks shall be
b arrange
ed and pos
sitioned to afford eassy access for carryin
ng out
extternal cablle termination, testin
ng, inspecttion and maintenanc
m
ce. There shall be ample
a
cle
ear space allowed
a
be
etween the
e terminal block and
d gland pla
ate for the
e spreading
g and
termination of
o external conductorss.
All terminal blocks
b
sha
all be shrouded or provided wiith transpa
arent coverrs. Pinch screw
s
typ
pe terminals are not acceptable
a
e.
Terminals forr different voltages
v
sh
hall be sep
parated by partitions.
Three positivve and thre
ee negative post types D.C ou
utput terminals shall be provide
ed for
E
post shall
s
be fittted with do
ouble nuts and washe
ers.
recctifier transsformers. Each
22.2
22.3
22.4
22.5
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 10 of 17
22.6
A terminal box
b
or ch
hamber with underline gland plate or entry pan
nel of suffficient
dim
mensions to
t terminatte the specified inco
oming and outgoing cables sha
all be provvided.
Dirrection of cable
c
entryy shall be frrom bottom
m.
22.7 Termination of
o single co
ore cabless shall through a non-magnetic gland platte and provvision
ma
ade for bon
nding and earthing
e
an
ny armor and/or
a
conccentric ground condu
uctors.
22.8 Ca
able termin
nal arrange
ements forr power an
nd control cables ma
ay be integ
grated pro
ovided
tha
at a barrier separatess the two.
22.9 Auxiliary wiriing shall have
h
copp
per conduc
ctors of th
he manufa
acturers standards sizing
s
(su
ubject to bu
uyers apprroval).
22.10 Suitable term
minals for two nos. ref. cell cables,
c
on
ne no. measurement cables and
a
a
selector switcch for perm
manent reff. cell to be
e provided for T/R un
nit panel fo
or connection to
PS
SP meter.
Wiring shall be
b crimped
d using selff-insulated
d compresssion type te
erminal blo
ocks which
h shall
be suitably id
dentified. Conductor
C
rs shall be
e fitted with
h sleeve fe
errules bearing the same
ide
entification as the terrminal to which
w
they are conne
ected. Minimum cond
ductor size
e shall
2
be 1.5 mm .
23.0
NA
AME PLAT
TE
A permanent
p
tly stampe
ed stainless steel me
etal plate shall be a
attached to
o outside of
o the
casse with the
e following information.
a.
b.
c.
d.
e.
f.
g.
h.
24.0
Manuffacturers name
n
AC inp
put voltage
e & currentt rating
AC fre
equency / Phase
P
Output DC volts and Ampss. Rating
Weigh
ht in Kg of T/R
T unit
Model number
Serial number
o Manufaccture
Year of
ECOMMEN
NDED LIST
T OF SPAR
RE PARTS
S
RE
e Bidder shall supplyy the follow
wing spares
s for T/R units
The
-
D C Voltmeter
D C Ammeter
A C Vo
oltmeter
A C Am
mmeter
Corrossion voltme
eter
Diodess
SCRss
D.C. Fuses
F
for output
o
side
HRC fuses
f
for Diodes
D
A.C fu
uses for inp
put side
D.C lig
ghting arre
estor
A C Circuit breakker MCB of
o each rating
Electro
onic Contro
ol Cards each type
Filter Circuit
C
Cap
pacitor
FORM NO: 02
2-0000-0021F2 REV3
R
No
os.
No
os.
No
os.
No
os.
No
os.
Se
et
Se
et
Se
et.
Se
et
Se
et
No
os.
No
os.
No
os.
No
os.
1
1
1
1
1
4
4
4
4
4
2
2
2
2
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
25.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 11 of 17
No
os.
No
os.
No
os.
No
os.
No
os.
No
os.
No
os.
No
os.
Se
et
2
2
2
2
2
2
2
2
20
0
DA
ATA SHEE
ET OF T/R UNIT
A.C
C Input Voltage
: 240V
V/415V+ 10
0% Volt, 1/3
3 phase 50
0Hz+5
% Hz
A.C
C Input Current
: to be
e specified by Bidder
D.C
C Power Output
O
: to be
e specified by Bidder
KV
VA Rating of
o transform
mer.
: To be
e specified
d by Bidderr
C Output Voltage
V
D.C
: 50V
D.C
C Output Current
C
: 50A
Current Ratin
ng of SCR
: to be
e specified by Bidder
g of Diode
Current rating
: to be
e specified by Bidder
Re
eference ce
ell
: Copp
per / Coppe
er Sulphatte Saturate
ed
eference ce
ell for contrrol
Number of re
: to be
e specified by Bidder
eference EM
MF Setting
g
Re
: 0-300
00 mV
Re
egulation off Referencce
: to be
e specified by Bidder
De
erating Facctor for Transformer
: 30 % excess cu
urrent capa
acity
De
erating Facctor for Diod
des / SCR
Rs
: To be sp
pecified by
y bidder
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 12 of 17
Filttering Circu
uit
: L.C Filter
F
Rip
pple and Hum
H
: Lesss than 5% a
at rated loa
ad
Surge Diverte
ers for Diodes / SCR
Rs
: For Diodes
D
/ SC
CRs: RC circuitry
c
of rating
as advvised by m
manufacture
er of SCR &
Diode Metal oxid
de varistors /Zener
Diodes/R-C
T unit
For input of T/R
2 noss. Zener D
Diodes of voltage rating
300V RMS, sp
park over voltage 1000V
(Peak) or equivvalent apprroved type
e and
make
Lig
ghtening Arrrestors
2 nos.. each at th
he input an
nd output of
o the
T/R unit
u
of vo
oltage ratin
ng 500V RMS
Maxim
mum 1.2/50
0 micro Se
econds im
mpulse
spark over vo
oltage 2.5
5 kV (P
Peak),
Maxim
mum disch
harge resid
dual voltag
ge at
5kA, 8/20
8
micro
o second impulse
i
cu
urrent
wave 2.5KV @1
1.5KA, Ma
aximum im
mpulse
nt discharrge capac
city 4/10 micro
curren
second impulse
e current wave 10
0 kA
(Peak), LAMCO
O L.T-2.8 or equivvalent
approvved make.
Zenerr Barrier Type, Volta
age rating 500V
rms Spark
S
over voltage 2500V
2
(pea
ak) at
Input and
a outputt
Pro
otection
Me
eters / Instrruments
Digita
al Panel M
Meters (96 mm x 96 mm)
Accura
acy -2% 1 Digit of Full Scale 1 No
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 13 of 17
AC Vo
oltmeter, 0
0-400 Volts, Resoluttion 1
V
1 No. AC Amm
meter, Currrent Transd
ducer
Opera
ated, 0 99
9.9 A, Resolution 0.1 A,
1 No. DC Voltm
meter, 0-110 V, Reso
olution
0.1 V with
w built in
n 4-20 mA
A transduce
er
1 No. DC Amm
meter, 0-10
00 A with shunt
25 A / 75 mV forr Bullets, Resolution
R
0.1 A
with built in 4-20
0 mA transd
ducers.
o. Corrossion Voltm
meter, 9--0-9V,
1 No
0.001V
V Resoluttion with built
b
in 4-2
20mA
transd
ducer.
Vissual indicattions
: The following
f
V
Visual signal light
Indica
ators shall b
be provided.
a) AC
A Mains O
ON
b) Auto
A
Mode
c) Manual
M
Mod
de
d) Unit
U in AVC
CC mode
e) Over
O
Curren
nt Alarm
f) Over
O
Voltag
ge Alarm
g) Over
O
Tempe
erature
h) All
A reference
e fail
i) Reference
R
ccell 1 lowest
j) Reference
R
ccell 2 lowest
k) Reference
R
ccell 3 lowest
l) Reference
R
1 fail
m) Reference
R
2 fail
n) Reference
R
3
3fail
o) In
ndividual Fuse failure
e LED indiccation
Identiffying failure
e of each Diode
D
and
DC Ou
utput Fuse
e with audio
o alarm.
her Accesssories
Oth
Co
ooling
The cabinet is n
natural air cooled an
nd the
tempe
erature risse not ex
xceeding 45oC
above
e the am
mbient. The
T
maxximum
tempe
erature rise
e shall be up
u to 850 C.
C
Me
easuremen
nt and conttrol termina
als
Shrouded termin
nal blocks
s of properr size
shall be
b provide
ed in the control jun
nction
box an
nd on the D
DC Board.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 14 of 17
Climate Cond
ditions
: Moderate to
o heavy rainfall during
d
Monso
oon and re
elative hum
midity of 100%.
Enclosure
Comp
pletely encllosed. Plin
nth Mounte
ed, IP
65 fo
or Bulletss, construction with
h an
integra
ated sun sshade. The
e top cabinet is
made from 12
2SWG mild steel. The
contro
ol cabinetss have hin
nged frontt and
rear doors
d
and a
are pad lo
ockable. A glass
viewin
ng window is provide
ed for frontt door
for re
eading of all the meters without
w
openin
ng the doo
or.
The enclosure iss also prov
vided with lifting
lugs of
o size and location su
uitable for lifting
the co
omplete recctifier unit.
Dim
mension off TR Unit
: To be
e specified
d by Bidderr
We
eight of TR
R Unit
: To be
e specified
d by Bidderr
Inp
put and Ou
utput Termiinals
Ca
able entriess
For An
node, Cath
hode, Pow
wer, Contro
ol and
measu
urement ca
ables throu
ugh cable gland
plate at
a the botto
om of the T/R
T unit.
Painting Schedu
ule
- Surfface prepa
aration SA 2
- Hot dipped ga
alvanizing to
t 100um
- Firsst coat of ziinc rich epoxy primerr
- Two
o coats of e
epoxy pain
nt
- Tota
al painting thickness--120 micro
ons.
- Colo
or scheme
e
- lightt grey shad
de 631 IS: 5
- Bakked Epoxy paint/Powder Coatin
ng of
shade 631 IS: 5 with pro
oper pretrea
atment and
d primer ap
pplication.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 15 of 17
Na
ame Plates and Labels
All co
omponent identification labels shall
be scrreened/ alu
uminum an
nodized.
- A sta
ainless ste
eel rating plate
p
along
g with
manuffacturers name, ad
ddress, da
ate of
manuffacture, model number,
n
serial
numbe
er, weight etc. will be
e provided..
- A DA
ANGER lab
bel on the Rear Doorr.
Ovver Voltage
e Setting
0-50V
V in 25 ste
eps of 2V each with
h two
selector switche
es with an
n accuracyy of +
10% in
n AUTO M
Mode.
COAR
RSE: 0, 10V
V, 20V, 30
0V, 40V, 50
0V
FINE: 0, 2V, 4V,, 6V, 8V, 10V
The two swittches are
e algebra
aically
additivve but ma
aximum do
oes not exxceed
50V.
0-50A
A in 25 ste
eps of 2A each with
h two
selector switche
es with an
n accuracyy of +
10% in
n AUTO M
Mode.
COAR
RSE: 0, 10A
A, 20A, 30
0A, 40A, 50
0A
FINE: 0, 2A, 4A,, 6A, 8A, 10A
e algebra
aically
The two swittches are
aximum do
oes not exxceed
additivve but ma
50A.
Mo
odes of Autto Operatio
on
Prottected
structu
ure to ssoil potential (PSP
P) is
sense
ed with respect to CU-C
CuSO4
. The
(Saturrated) refe
erence to electrodes
e
electro
onic contro
ol circuit scans
s
up to
o two
reference electrrodes for actual
a
PSP
P and
matically selects the minimum
autom
negatiive value of actual PSP obttained
from any
a of the two refere
ence electrrodes.
The desired S
SET PSP
P referencce is
compa
ared with the minimum selected
value of actual P
PSP and th
he output power
p
of the CPTR is set autom
matically so
o that
the measured
m
value always rem
mains
close to the SET
T PSP valu
ue.
UTO AVCC
C MODE
(ii) AU
In thiss mode of operation Output vo
oltage
& currrent can be
e varied co
ontinuouslyy by a
potenttiometer depending upon the
Coarsse and Fine switch settings.
s
Control
of output voltage and current
c
thrrough
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 16 of 17
TE
ESTING OF
F T/R UNIT
T:
All T/R units shall be te
ested by co
ontractor and
a inspeccted by purrchaser/his
s represen
ntative
beffore dispa
atch. Testiing shall be conducted in accordance
e with cod
des, stand
dards,
app
proved QA
AP and encclosed specifications.
Bid
dder /vendo
or shall pro
ovide all th
he necessa
ary facilities to carry out all testts of CP TR
R unit
in his
h premise
es at his expenses.
27.0
DR
RAWINGS / DOCUMENTS:
awings / do
ocuments shall be fu
urnished byy bidder fo
or approval before starting
Following dra
n/manufactturing. App
proved dra
awing afterr incorpora
ation of co
omments (if any
of fabrication
from OWNER
R shall be furnished
f
i 6 copies
in
s along with reproduccible during
g the delive
ery of
T/R
R units.
Fabriccation draw
wings, GA drawings and
a data sheet
s
of T//R unit giving dimenssions,
rating, weight, in
ncluding insstallation / foundation
n arrangem
ment details.
Front view and typical
t
secctions of T//R unit pan
nel with arrrangemen
nt of equipment,
ol, protectio
on and mettering.
contro
Data sheet
s
of all accessoriies and circ
cuit element of T/R U
Unit including rating.
Schem
matic and wiring
w
diag
gram of T//R unit circcuitry givin
ng auto / manual
m
mo
ode of
contro
ol including circuit dettails of all control
c
carrds.
28.0
INS
STRUCTIO
ON BOOK
e instructio
on book/ operationa
o
al manual in 10 hard
d copies+ soft copy in CD sha
all be
The
pre
esented in such manner as to enable
e
it to
o be used by
b personn
nel who are
e unfamilia
ar with
the
e operation
n and main
ntenance of
o the T/R unit.
u
The in
nstruction book/ ope
erational manual
to be
b furnishe
ed along with
w supply of T/R unit.
The
e instructio
on book/ operational manual sh
hall contain
n the follow
wing:
A description of th
he T/R unit.
-
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 17 of 17
CO
OVERING OF
O THE IN
NSTRUCTION BOOK
KS/ OPER
RATIONAL
L MANUAL
LS
The
e instructio
on book/ operationa
o
al manuals
s shall be presented in a stiff covered binder
b
with the follow
wing inform
mation prin
nted on the
e cover:
The clie
ents name
The loca
ation of the
e installatio
on
The nam
me of the in
nstallation
The title
e of the instruction bo
ook
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
TECHNIC
CAL SPECIFICA
ATION
T
TRANSF
FORMER
R RECT
TIFIER UNIT
U
RE
EMOTE MONITO
ORING
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION SYSTEM OF
O
MOUN
NDED BULLETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUN
NDED
B
BULLETS
OWNE
ER : NRL,AS
SSAM
1.
E
EM163-TS-08
801
D
DOCUMENT
NO
REV
SHEET 2 of 3
SC
COPE
e T/R Unitt installed for Cathodic Protec
ction of Mo
ounded Storage Bulllets/Tanks shall
The
havve inbuilt RMU feattures to Monitor
M
all specified T/R Unit Parameters, Alarmss and
Ca
athodic Pro
otection Re
eference Electrode
E
Parameters
P
s and com
mmunicate the Data to
t the
Ce
entral Computer Netw
work. The T/R Unit RMU shall be provid
ded by the
e manufaccturer,
which can monitor
m
the specified CP Param
meters. The
e T/R Unitt RMU Hardware shall be
exp
pandable for
f incorpo
orating add
ditional I/O
O Channelss in future.. The T/R Unit RMU shall
me
eet all the specificatio
s
on requirem
ments conttained here
ein.
2.
MO
ONITORING FEATURES
e T/R Uniit shall have Monito
oring Circu
uit, which should
s
mo
onitor the Analog Siignals
The
con
nfigurable in real tim
me as userr defined schedule.
s
The resolu
ution shou
uld be 12 bit
b for
ana
alog input channels. The Volta
age Range
e should be
e calibrated to suit th
he Analog Input
Sig
gnal requirrement. All inputs Analog
A
Sig
gnals shou
uld be iso
olated to 3000Vrms
3
. The
Mo
onitoring Rate
R
should
d be progrrammable from 01 Reading
R
pe
er Second to 01 Reading
perr 99 Days.
The
e T/R Unit shall monitor the following ope
erating and
d cathodic protection parameters
listed as follo
ows:
2
2.1
The
e T/R Unit should mo
onitor the Analog
A
Output DC Vo
oltage and
d Current Signals
S
in re
eal
tim
me as per user
u
defined schedule
e and shou
uld generatte alarms iin case of Over
O
Volta
age
and
d Over Current Cond
ditions.
2
2.2
Each T/R Un
nit should monitor
m
the
e Referenc
ce Electrod
de Analog Signals frrom the Field in
al time as per
p user de
efined sche
edule and should gen
nerate an a
alarm in ca
ase of Ove
er and
rea
Under Protecction Conditions. The
e input Imp
pedance off the Monittoring Circu
uit shall be
e high
ough to measure
m
th
he Referen
nce Electrrode Analo
og Signalss without loading.
l
A the
All
eno
Re
eference Electrode in
nstalled to monitor protective
p
potentials of Bullets
s/pipeline and
a
it
sho
ould be disstributed to
o the everyy T/R Unit installed to
t be monitored by connecting
c
them
to the
t T/R Un
nit RMU.
The
e CP Con
ntractor sh
hould insta
all Perman
nent Type Cu/CuSo4
4 Referenc
ce electrode of
app
proved ma
ake and exxtend the signals
s
to the T/R uniit through a Monitorin
ng Junction box
using Multi co
ore Cable of size 2.5
5 Sq mm Cu
C PVC inssulated and PVC she
eathed arm
mored
cab
ble. Supply and insstallation of
o Reference Electro
odes, conn
necting ca
able shall be in
sco
ope of CP Contractorr.
2
2.3
The
e T/R Unit should monitor th
he status of 05Nos Digital Issolated Ala
arms inputts for
Re
ectifier overr Cabinet over
o
Temp
perature, Oil
O Tank ove
er Temperrature, Fus
se Fail and Input
MC
CB Trip, AC
A Input Failure. In case
c
of Allarm the T/R
T Unit R
RMC should
d generate
e and
upd
date the Data on the Network as
a per Use
er defined schedule.
s
3.
GE
ENERAL FEATURES
F
S OF REMOTE MON
NITORING UNIT (RM
MU)
Sta
and Alone RMU for TR
T Unit
Issolated Ana
alog Input Channels for Remotte Monitoring and Da
ata Logging
g
Issolated Dig
gital I/O Ch
hannels forr Alarms an
nd Interrup
ption Contrrol
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION SYSTEM OF
O
MOUN
NDED BULLETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUN
NDED
B
BULLETS
OWNE
ER : NRL,AS
SSAM
E
EM163-TS-08
801
D
DOCUMENT
NO
REV
SHEET 3 of 3
Ethernet
E
Co
onnectivity for local control
c
Ethernet/RS
E
S 485 conn
nectivity for Commun
nication
In
nput/ Outpu
ut Short Ciircuit Prote
ection
AC/DC
A
Surg
ge Protection
Pluggable
P
c
cards
for ea
asy mainte
enance
Dual
D
Processsor for Fa
ast Monitorring with sp
peed of 250 kilo samples per se
econd
Single
S
Inputt Power Su
upply
4.
RE
EMOTE MO
ONITORIN
NG UNIT (R
RMU) DIGIITAL CONDITIONING UNIT FE
EATURES
Signal
S
Inputt Power Su
upply
Output
O
4-20
0mA
In
nput 0-100% VDC/AD
DC/PSP
Natural
N
Air Cooled
C
DIN
D Rail Mo
ounting
Easy
E
to Rem
move/Repllace
In
nput/ Outpu
ut Protectio
on
Electronic
E
S
Short-Circu
uit Protectio
on
AC/DC
A
Surg
ge Protection
Weather
W
Prroof-NEMA
A 4 Constru
uction
Natural
N
air Cooled
C
(Ind
door)
Epoxy/PU
E
F
Finish
5.
EN
NCLOSURE
ES AND OPERATIN
O
NG ENVIRO
ONMENT
The
e T/R Unit should ha
ave a separate airtigh
ht housing of RMC Ellectronic to
o keep it
mo
oisture and
d dust free. The T/R RMC
R
Circu
uit should be
b robust a
and shall be operating
g at
tem
mperaturess between 400 C to + 700 C att 90% Rela
ative Humid
dity.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 4
TE
ECHNIC
CAL SPE
ECIFICA
ATION
ANODE JUNC
CTION BOX
B
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 4
1.0 SCOP
PE
s
n covers the
t minimu
um technic
cal requirements for the design
n, manufaccturer
This specificatio
and Su
upply of An
node Junction Boxess for ICCP system.
The ju
unction boxxes should
d be a stan
ndard of th
he manufa
acturer regularly used
d for impre
essed
curren
nt cathodicc protection
n system. This spec
cification confers req
quirement for type, rating,
r
manuffacture and
d testing off different types
t
of junction boxxes. The W
Weather pro
oof junction
n Box
& Flam
meproof Ju
unction Bo
ox shall be
e used for bullets respectively. Junction boxes sha
all be
supplie
ed in accordance witth the follow
wing speciifications and
a data sh
heets.
2.0 CODE
ES AND STANDARD
DS
The Weatherpro
W
oof & Flam
meproof Ju
unction Bo
oxes shall be in acccordance with the latest
revisio
ons of the fo
ollowing In
ndian stand
dards, whe
erever appllicable.
a)
b)
c)
d)
Indian sta
andards in
nstitution (ISI)
Internatio
onal electro
o technical commission (IEC)
American
n standard
ds institutio
on (ANSI)
British sttandards in
nstitution (B
BS)
Where
e appropria
ate Indian standard
s
a not ava
are
ailable, the relevant IE
EC standards shall apply.
a
3.0 DATA
A SHEET:
DC Input
I
Volta
age
DC Input
I
Curre
ent
Shun
nt type
Shun
nt Rating
Resiistor Rating
g
50V Maximum
m
50 A Maximum
m
Mag
ganin Alloy
To be
b Specifie
ed
Cressol Type Strip Wou
und (To be calculated
d by CP
conttractor)
Diod
de Rating
To be
b Specifie
ed
Bus bar
Tinn
ned Coppe
er Bus Bar - 50 mm x 6 mm for bullets
Term
minal Boarrd material
08 mm
m thick FRP
F
Num
mber of open/ outp
put / As required
r
(3
30% spare terminals shall be prrovided)
circu
uits
Inpu
ut Terminals
02 Nos.
N
10 mm
m Dia. Staiinless Stee
el stud with
h double nu
ut,
sprin
ng and plain washer.
Outp
put Termin
nals
As required
r
Dime
ension
To be
b specified
d by bidde
er
Enclosure Ratting for bullets Explosion Proof Zone 1-- Gas Grou
up IIA & IIB
B Tempera
ature
Classs T3
Cable entries
Cable entries are
a through FLP Cab
ble Glands.
Insulation Leve
el in betwe
een
3 kV
V & 2 kV fo
or 1 minute
e at 50 HZ
Z for Bullets
s.
term
minals & bo
ody
Surfface Painting
Firstt coat of Ziinc rich epoxy primerr
Intermediate Cost
C
of Epo
oxy
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 4
Two
o Coats of Polyamide
e epoxy paint
Tota
al painting thickness 200 micron(minimum
m)
Colo
our Schem
me for bullets
Stattion Termin
nals
Insu
ulator insside Juncction
Box
Nam
me plates and
a Labels
Enclosure
Quantity
Makke
Outp
put circuit Configurat
C
tion
Yello
ow paint Shade
S
SS 316
3 Nuts & Bolts
DMC
C
All in
nternal com
mponent id
dentification Labelling
g is done using
u
perm
manent Screening /m
marker
Nam
me plate sh
hall be engraved whitte lettering in black
Man
nufactures name, Add
dress, Date
e of Manuffacture, CM
MRS
No. Model No.., Serial No
o., Weight etc. shall be
b provided on
shuttter
Com
mpletely enclosed,
e
Outdoor type, Wa
all / Struccture
Mou
unted of folllowing typ
pes:
a Flamep
a.
proof type Exd Natural Air Coo
oled, dust and
vermin proof IP 65 Consttruction. The
T
cabine
et is
made from
f
Die cast Alum
minium Allloy-LM-6, with
threade
ed SS Plate
P
inse
erts and SS Do
ouble
compre
ession FLP
P Cable Gla
ands.
b Dust & vermin proof, nattural Air Cooled,
b.
C
IP
P 55
constru
uction. The
e cabinet is made
e from LM
M 6
constru
uction die Cast
C
constrruction
The cabinet shall
s
have hinged fro
ont doors with neoprene
gaskket and shall be Pad Lockable.
As Required
R
Refe
er list of Ap
pproved Ve
endors
Ano
ode Bus ou
utput distrib
buted into 20 circuits
s and 04 spare
circu
uit in line with
w Curren
nt Measurin
ng Shunt &Resister
&
4.0 CONS
STRUCTIO
ONAL FEATURES FO
OR ANODE JUNCTIION BOX
Anode
e lead cable from disttributed an
node groun
nd beds sh
hall be term
minated to the
t junction box
and fu
urther exte
ended to T/R
T Units. The
T
junctio
on box should have a tinned copper bu
us bar
50mmx6mm for connection of positivve headerr cable from
m the transformer re
ectifier unitt. The
numbe
er of anode
e circuits should
s
be as per abo
ove data sheet.
s
The anode lea
ad cable iss feed
from output
o
circcuit throug
gh a shunt of suitable rating and an
n adjustab
ble strip wound
w
CRES
SSOL type ZO resisto
or of suitab
ble rating. All termin
nals should
d be SS-30
04 materia
al and
size M-8
M (08mm
m) nut, bo
olts, spring washer. The term
mination b
boards sho
ould be Fabric
F
reinforrced Polyester of min
nimum 08 mm
m thickness. The enclosure
e
should be fabricated
d from
LM-6. The consttruction sh
hould be Flameprooff, Air-coole
ed, Dust an
nd Vermin proof. Jun
nction
box sh
hould have
e a card po
ocket insid
de the doorr. Degree of protection should be IP65 as
a per
IS: 2147/1962. The enclo
osure shou
uld be stand-alone/w
wall mountted type with
w
canop
py for
rainwa
ater protecction. The gasket sh
hould be of neoprene
e rubber. The enclo
osure shou
uld be
provided with fro
ont excesss door witth pad and
d panel ke
ey locking arrangem
ment. Contrractor
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 4 of 4
needs to fabrica
ate and takke approva
al of ownerr/consultan
nt then pro
oceed with manufacturing.
The junction boxx should be
with details.
e provided with stainlless steel nameplate
n
5.0TESTING & INSPECTION:
Weath
her Proof & Flameproof Junctio
on Boxes shall be in
nspected b
by owner before
b
disp
patch,
testing
g shall be
e conducte
ed in acccordance with
w
codess and sta
andards sp
pecified in
n this
docum
ment, as per
p
routine tests done
d
by manufactu
m
rer and a
additional tests don
ne by
manuffacturer..
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 4
TE
ECHNIC
CAL SPE
ECIFICA
ATION
CAT
THODE JUNCTI
J
ION BO
OX CUM TEST S
STATION
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 4
1.0 SCOP
PE
This specificatio
s
on covers the
t minimu
um technic
cal require
ements for the design
n, manufaccturer
and Supply
S
of Cathode
C
Ju
unction Boxxes for ICC
CP System
m.
The ju
unction bo
oxes shoulld be a standard pro
oduct of the manufa
acturer reg
gularly use
ed for
impressed curre
ent cathod
dic protection system
m. This sp
pecification
n confers requirement for
type, rating, ma
anufacture and testin
ng of diffe
erent typess of junctio
on boxes. Weather proof
junctio
on Box & Flameproo
of Junction
n Box shall be used
d for pipeline & bulle
ets respecttively.
Junctiion boxes shall be supplied
s
in
n accordan
nce with th
he following specifica
ations and
d data
sheetss.
2.0 CODE
ES AND STANDARD
DS
The Weatherpr
W
roof & Fla
ameproof Junction
J
boxes
b
shall be in acccordance with the latest
revisions of the following Indian
I
stan
ndards, wh
herever app
plicable.
a) Indian stan
ndards insttitution (ISI)
b) Internation
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wherre approprriate Indian standard
d are not available,, the relevvant IEC standards
s
shall
applyy.
3.0 DATA
A SHEET:
D Input Voltage
DC
V
DC Input Curre
ent
Outp
put Circuit Rating
Shunt type
Shunt Rating
Diod
de Rating
Bus bar
Num
mber of open/ In
nput/
outp
put / looping circuits
Term
minal Boarrd material
Inpu
ut/ Looping
g Terminalss
50V
V Maximum
m
50 A Maximum
m
50V
V/50A
Mag
ganin Alloy
y
To be
b Specifie
ed
To be
b Specifie
ed
Tinn
ned Coppe
er Bus Bar - 50 mm x 6 mm for bullets
As required
r
(3
30% spare terminals shall be prrovided)
06 mm
m thick FRP
F
02 Nos.
N
10 mm Dia. Sta
ainless Ste
eel stud with double nut,
sprin
ng and pla
ain washer..
Outp
put Termin
nals
As required
r
Dimension
To be
b specified by bidde
er
Enclosure Ratting for bullets Explosion Proof Zone 1-- Gas Grou
up IIA & IIB
B Tempera
ature
Classs T3
Cab
ble entries
Cab
ble entries are through FLP Cab
ble Glands
s
Insu
ulation Levvel in betw
ween 3 kV
V & 2 kV fo
or 1 minute
e at 50 HZ
Z for Bullets
s
term
minals & bo
ody
Surfface Painting
Firstt coat of Ziinc rich epoxy primerr
Intermediate Cost
C
of Epo
oxy
Two
o Coats of Polyamide
e epoxy paint
Tota
al painting thickness 200 micron(minimum
m)
FORM NO: 02
2-0000-0021 F2
2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
Colo
our Schem
me for bullets
Stattion Termin
nals
Insu
ulator insside Juncction
Box
Nam
me plates and
a Labelss
Enclosure
Qua
antity
Makke
Outp
put circuit Configurat
C
tion
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 4
Yello
ow paint Shade
S
SS 316
3 Nuts & Bolts
DMC
C
All internal component
c
t identifica
ation Labe
elling is done
d
usin
ng permane
ent Screen
ning /marke
er
Nam
me plate sh
hall be eng
graved whitte lettering
g in black
Man
nufactures name, Address,
A
Date of Manufacture,
CMR
RS No. Model
M
No., Serial No
o., Weightt etc. shalll be
provvided on sh
hutter
Com
mpletely enclosed,
e
Outdoor type, Wa
all / Struccture
Mou
unted of folllowing typ
pes:
a Flamep
a.
proof type Exd Natural Air Coo
oled, dust and
vermin proof IP 65 Consttruction. The
T
cabine
et is
made from
f
Die cast Alum
minium Allloy-LM-6, with
threade
ed SS Plate
P
inse
erts and SS Do
ouble
compre
ession FLP
P Cable Gla
ands.
b Dust & vermin proof, nattural Air Cooled,
b.
C
IP
P 55
constru
uction. The
e cabinet is made
e from LM
M 6
constru
uction die Cast
C
constrruction
The cabinet shall
s
have hinged fro
ont doors with neoprene
gaskket and shall be Pad Lockable.
As Required
R
Refe
er list of Ap
pproved Ve
endors
FOR
R BULLETS:
Thiss JB works
s as cJB cum
c
test sttation all cables
c
from
m Cu
and Zn refere
ence electtrode and cathode cable
c
shalll be
minated in the
t box
term
4.0 Catho
ode cum Test
T
junctio
on Boxes:
Draina
age(2 nos.)), and reference elecctrode(17nos) cable from
f
the Bullet are te
erminated to
t the
cathod
de cum tesst junction box and further
f
exttended to T/R Units.. The junction box should
have a Tinned Copper
C
buss bar 50mm x 6mm for connecction of ne
egative hea
ader cable
e from
the tra
ansformer Rectifier unit.
u
The number
n
of cathode circuits
c
sho
ould be 01 + 01 including
spare. The catho
ode lead cables
c
feed
d from outp
put circuit through a suitable shunt
s
of su
uitable
rating and adjusttable strip wound Re
eputed mak
ke type ZO
O resistor o
of suitable rating.
r
All terrminals sho
ould be SS
S-304 mate
erial and siize M-8 (08
8mm) nut, bolts, sprin
ng washerr.
The enclosure should
s
be fabricated
f
from die Cast
C
Alum
minium Allo
oy LM 6. The
T constru
uction
shall be
b Flameprroof & Wea
atherproof for bullets
s & pipeline
es respectively. Air-co
ooled, Dusst and
Vermin
n proof. Ju
unction boxx should have a card
d pocket in
nside the d
door. Degre
ee of prote
ection
should
d be IP 65 for bullets .
The te
ermination boards sho
ould be Fa
abric reinfo
orced Polysster of minimum 06 mm
m thickne
ess.
The enclosure
e
should be
e stand a
alone / wa
all mounte
ed type w
with canopy for rainwater
protecction. The gasket
g
sho
ould be of neoprene
n
rubber.
r
The
e enclosurre should be
b provided
d with
FORM NO: 02
2-0000-0021 F2
2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 4 of 4
front excess
e
doo
or with bolte
ed arrange
ement openable with Allen key.. Contracto
or needs to
o take
prior approval for GA dwg & data sheet
s
beffore proce
eeding with
w
fabriccation
works//manufactu
uring.
The junction boxx should be
e provided with stainlless steel nameplate
n
with details.
5.0 TESTING & INS
SPECTION
N:
her Proof & Flamep
proof Juncction Boxe
es shall be
b inspectted by pu
urchaser before
b
Weath
dispatcch. Testin
ng shall be
b conducted in accordance with latesst codes, standardss and
enclossed specificcations.
FORM NO: 02
2-0000-0021 F2
2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 2
TE
ECHNIC
CAL SPE
ECIFICA
ATION
REFER
RENCE ELECTR
E
RODE CU-CU
USO4
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV4
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 2
1.0 SCOP
PE
This specificatio
s
on covers the minim
mum techn
nical requ
uirements for supply
y of permanent
referen
nce electro
ode for cathodic prote
ection systtem.
The pe
ermanent reference electrode shall be a standard product o
of a manuffacture reg
gularly
engaged in prod
duction. Th
he permane
ent referen
nce electro
ode shall b
be supplied
d in accord
dance
with th
he following
g specifica
ation and data sheets
s.
2.0 CODE
ES AND ST
TANDARD
DS
The permanent
p
reference electrode
e shall be in accorda
ance with tthe latest revisions of
o the
follow
wing Indian standardss, whereve
er applicable. Where appropriatte Indian standard
s
arre not
availa
able, the re
elevant IEC
C standardss shall app
ply.
dian standa
ards institu
ution (ISI)
a) Ind
b) Inte
ernational electro tecchnical com
mmission (IEC)
(
c) Am
merican sta
andards insstitution (A
ANSI)
d) British standa
ards institu
ution (BS)
Where
e appropria
ate Indian standard
s
a not ava
are
ailable, the relevant IE
EC standards shall apply.
a
3.0 DATA
A SHEET:
Type
Cop
pper/Copper Sulphatte (Cu/Cu S
S04)
Make
Borrin U.S.A/ MC
M Miller
Model
Borrin U.S.A/ MC
M Miller
Dimensio
ons
Diameter: 4.0
0 cm mm
ngth: 18.0 cm
c
Len
Lead wirre
2.5 Sq mm. CU
C Cable, Lead wire, 1.5 long
Tempera
ature
0 to
o 55 Degre
ee C
Stability
Tube Ma
aterial
Spa
ace age ce
eramic tube
e with Yello
ow cap
Application
Forr External CP
C Only
FORM NO: 02
2-0000-0021 F2 REV3
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TEC
CHNICA
AL SPEC
CIFICAT
TION
REFE
ERENCE
E ELECT
TRODE (ZINC)
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
1.0
SC
COPE
1.1
2.0
CO
ODES AND STANDAR
RDS
2.1
The
e Zinc Refference Ele
ectrode sh
hall be in accordance
a
e with the latest revis
sions of the
following Indian standards, where
ever applica
able. Where approprriate Indian
n Standards
are
e not availa
able, the re
elevant IEC
C standards shall app
ply.
a) Indian
I
stan
ndards insttitution (ISII)
b) Internation
I
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
ATA SHEET
T
DA
Mo
odel
Sensing Area
a
Ele
ectrode
Ele
ectrode Composition
Ele
ectrode con
nfiguration
Ele
ectrode Connection
Inssert type
Inssert plating
Cable
Cable Conne
ection
Cable Length
h
Tecchnical Lite
erature/
cattalogue
Bacckfill Mixtu
ure
Dim
mensions
Gro
oss Weight
Quantity
Ma
ake
To be specified
To be specified
Ele
ectrolytic Grade
G
Zinc Metal
Basic Zinc metal 99.99 %
Sin
ngle Rod Centre
C
Con
nnected
Threaded He
ead with nu
uts fitting te
ermination
Mild Steel witth TOR Ro
od of 8 mm
m dia.
Ele
ectro galva
anized
06 Sq. mm Unarmored
U
, Cu, XLPE
E/PE insula
ated
Epoxy Resin Seal
As required
To be furnish
hed by Bid
Gyypsum 75%
% + Benton
nite 20 % + Sodium Sulphate
S
5
%
150
0 mm (L) 40
4 mm X 40 mm (Min
nimum)
To be Specifiied
As Required
Ple
ease Referr Approved
d Vendors list
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
4.0
INS
SPECTION
N & TESTS
S:
4.1
The
e testing shall
s
be conducted in
n accordan
nce with co
odes and sstandards enclosed
e
in
thiss documen
nt, as per routine tessts done by
b the man
nufacture. Test Certificate sha
all
furn
nish.
TECHNICAL
L SPECIFICA
ATION
THODIC PRO
OTECTION SYSTEM
S
OF
F
CAT
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DOCUMENT NO
REV
Sheet 1 o
of 6
TEC
CHNICA
AL SPEC
CIFICAT
TION
CABLES
S
FO
OR CATHODIC PROTE
ECTION SYSTE
EM
FORM NO
O: 02-0000-0021
1 F2 REV3
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 2 o
of 6
1.0
SCO
OPE
1.1
This standard
d covers the technical requirements of design,
manu
ufacture, te
esting at works
w
and dispatch
d
in
n well packked conditio
on of
powe
er and control cabless.
2.0
STANDARDS TO BE FO
OLLOWED
D
2.1
Cro
oss linked
d polyeth
hylene in
nsulated PVC
she
eathed cab
bles for wo
orking voltages upto and
inclluding 1100 volts.
PVC
C insulate
ed (heavy duty) elecctric cables
s for
worrking voltag
ges up to and
a including 1100 volts.
v
PVC
C insulate
ed (heavy duty) elecctric cables
s for
worrking volta
ages from 3.3 kV up
p and inclu
uding
11 kV.
Cro
oss Linke
ed polyethylene in
nsulated PVC
she
eathed cab
bles for wo
orking volta
ages up to
o and
inclluding 1100 Volts.
Cro
oss Linke
ed polyethylene in
nsulated PVC
she
eathed cab
bles for wo
orking volttages form
m 3.3
kV up to and including 33
3 kV
Cro
oss
Lin
nked
po
olyethylene
e
insullated
The
ermoplastic
c sheathe
ed cabless for worrking
volttages up to
o 66 kV an
nd up to 22
20 kV
IS: 692
Pap
per insula
ated lead sheathe
ed cables for
elecctrical supply
IS: 694
PVC
C insulated
d cables fo
or working voltages up
u to
inclluding 1.1 kV
IS: 5831
PVC
C sheath and
a insulattion for electric cables
2.2
2.3
FORM NO
O: 02-0000-002
21 F2 REV3
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
3.0
SERVIC
CE CONDIITIONS
3.1
Ambien
nt Conditio
ons
3.2
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 3 o
of 6
Maximum Ambien
nt Temp
50 oC
Minimum
m Ambientt Temp
5 oC
45 oC
Relative
e Humidity
100%
<1000m
System
m Details
These shall
s
be 3 Phase
P
415
5 V +/- 10%
%, and 50 Hz
H +5%, -5
5%.
4.0
OPERA
ATING REQ
QUIREMENTS
The cables shall be suitab
ble for op
perating co
ontinuouslyy at the rated
r
capacityy as speciffied in rele
evant IS un
nder the am
mbient con
nditions witthout
exceediing the permissible temperatur
t
re rise and
d without a
any detrime
ental
effect on any part.
5.0
RAL DESIG
GN AND CONSTRUC
C
CTIONAL FEATURE
ES
GENER
5.1
The de
esign, manufacture and workmanship of cabless shall be in
accorda
ance with the latest standard
s
prractice.
5.2
All mate
erials to be
e used shall be new, unused an
nd of the be
est quality.
5.3
Conduc
ctors
The po
ower cable
es shall be
e of stranded Aluminum / co
opper roun
nd or
shaped conducto
ors and control
c
ca
ables shall be of a
annealed high
conducttivity stran
nded copp
per round conductorrs. The co
onductors shall
comply with the re
equirementts of IS: 81
130.
5.4
Insulatiion
The co
onductor in
nsulation shall
s
be XLPE
X
type
e and sha
all comply with
relevantt IS.
5.5
Fillers
The cables shall have suittable fillers
s whereve
er required
d, laid up with
conducttors to provvide substantially circ
cular crosss section b
before the inner
i
sheath is applied.
5.6
Inner Sheath
S
Inner sheath sha
all be ST1
1/ST2 type
e compound applied
d by extru
usion
processs.
5.7
Armourring
All power and con
ntrol cables shall be armoured as specifiied. The single
core cables shall be armourred with ha
ard drawn Aluminum
A
taps / wire
es or
her suitablle nonmag
gnetic matterial. All other cables shall have
h
any oth
galvanizzed steel wire
w / strip armoring conforming
c
g to IS: 397
75.
FORM NO
O: 02-0000-002
21 F2 REV3
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
5.8
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 4 o
of 6
Outer Sheath
S
The ou
uter sheath shall be ST2 type, FRLS
S compoun
nd applied
d by
extrusio
on process and su
uitable to withstand
d atmosph
heric pollu
ution,
resistan
nce to term
mites, fire re
etardant an
nd coloured black.
5.9
Screening
Screeniing over conductor and insu
ulation sha
all be pro
ovided as per
relevantt standard unless sp
pecified otherwise. The
T
screen
ning for co
ontrol
cables if specifie
ed shall be
b of aluminum, Mylar
M
or e
equivalent and
ain wire which
w
sha
all be co
ontinuous and
provided with tinned dra
nently conn
nected to th
he screen.
perman
5.10
Identification
dividual co
ores of ca
ables shall be colou
ured as pe
er relevant IS.
The ind
Where it is not po
ossible to distinguish
d
the cores by colour, coloured strip
shall be
e applied on
o the core
es or core nos, shall be marked
d on each core
at regular interva
als. All cab
bles shall carry the manufactu
urers nam
me or
trade mark,
m
the cable
c
size, voltage rating
r
and year of m
manufacturre at
intervalss not exce
eeding 100
0 meters. Running
R
m
meter
markkings shall also
be provvided throughout the length of th
he cable.
5.11
Dimens
sion
The ove
erall dia. an
nd dia. und
der armourr of the cab
bles shall b
be indicate
ed by
the vendor in the technical particulars
p
. These sh
hall be gua
aranteed with
w a
tolerancce of + 5% but not exxceeding 2 mm.
5.12
6.0
SPECIA
AL PURPO
OSE CABL
LES
6.1
Flame Retardant
R
t Low Smo
oke Cables
s
Flame retardant low smoke
e cables, where spe
ecified, sh
hall have outer
o
aving follow
wing values
s.
sheath of PVC ha
Minimum
m oxygen index - 29%
Minimum
m tempera
ature indexx - 250OC
Maximu
um acid ga
as generatio
on - 20%
Maximu
um smoke density ratting - 60%
6.2
Heat Re
esistant Cables
C
Heat resistant cab
bles where
e specified shall be of
o silicon ru
ubber insullated
laid circcular with asbestos worming
w
and
a
overalll glass fibe
er braided and
varnishe
ed. Silicon
n rubber inssulating co
ompound shall
s
confo
orm to IS: 6380
6
and the constructiional features shall conform
c
ge
enerally to IS:9968.
FORM NO
O: 02-0000-002
21 F2 REV3
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 5 o
of 6
7.0
CABLE
E DRUM
7.1
The cab
bles shall be supplie
ed in non-rreturnable wooden d
drums (or steel
drums if specifiied) of heavy
h
con
nstruction. The wo
ood used for
construction of th
he drums shall
s
be properly se
easoned, ssound and free
from de
efects.
7.2
7.3
The tole
erance on each drum
m of cable shall not exceed
e
+2.5%. Howe
ever,
no nega
ative tolera
ances are acceptable
a
e.
7.4
8.0
8.1
i)
Routine
e Tests
ii)
Accepta
ance tests - On repre
esentative length of each
e
size
iii)
Type tests
8.2
i)
Oxygen
n and temp
perature ind
dex test as
s per ASTM
M-D-2863
ii)
iii)
A
843
Smoke density tesst as per ASTM-D-28
iv)
8.3
The ab
bove menttioned testts shall be carried out in the
e presenc
ce of
purchassers repre
esentative. In addition the cablles shall b
be subjecte
ed to
stage in
nspection at
a works an
nd inspectiion at site for
f final accceptance.
8.4
These tests
t
and inspection shall, how
wever, not absolve th
he vendor from
their responsibilityy for making good any defecct which m
may be notticed
uently.
subsequ
9.0
SIZING OF CABL
LES:
- On all cables
c
ecified on one
o cable drum
d
of ea
ach size
- Wherever spe
The min
nimum size
e of various cables are as per following,
f
h
however biidder
shall re
ecommend sizes for various type of cables which
h is subject to
ownerss/consultan
nts approvval:
1. Posiitive & Neg
gative Header Cable : From th
he TRU to
o the cath
hode
Juncction Boxx and An
node Disttribution Box
B
: 1C
Cx50mm2 (Al)
1Cx50mm2 (All/Cu) Armo
oured
2. Drainage Cablle: From th
he cathode
e Junction Box
B to the bullet:
1Cx50 mm2 (C
Cu)
FORM NO
O: 02-0000-002
21 F2 REV3
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 6 o
of 6
3. Anode Interme
ediate cab
ble : From anode Distribution Box to An
node
Juncction Box : 1Cx50 mm
m2 (Cu)
4. Anode Tail Cable:
C
Fro
om the Anode
A
Jun
nction Boxx to Anode :
2
1Cx10mm (Cu
u)
5. Mea
asurement Cable an
nd Refere
ence Elecctrode Cab
ble: From the
Refe
erence elecctrode to CJB
C cum Test
T
Staion:1Cx6 mm
m2 (Cu)
6. Mon
nitoring Cable:
C
Fro
om the CJB
C
cum
m Test S
Staion to the
MJB
B(installed in safe are
ea) 12Cx2.5 mm2 (2
2 run/bulle
et) or 25C
Cx2.5
2
mm (1 run/bullet) Armou
ured
7. Eartthing cable
e: From th
he earthin
ng connecttion of the
e bullet to
o the
Pola
arisation Ce
ell 1Cx35m
mm2 (Cu)
8. Pow
wer Cable: From the PMCC Pa
anel to the TRU 3.5
5C x 25 sq mm
(Al) Armoured.
Cable size
s
for anyy other purrpose subje
ect to owne
er/consulta
ant approval.
Cable with
w coppe
er conducto
or of equiv
valent size in place o
of Al condu
uctor
cable may
m also be
e provided.
The cab
bles for pa
anel wiring
g shall be of unarmo
oured type
e with stran
nded
copper Conducto
or and insu
ulation. Ca
able sizes shall be to suit current
requirem
ment but not less tha
an 2.5 mm2
2.
LSTK Contractor
C
shall furn
nish cable size selecction base
ed on volta
ages
drop ca
alculation and curre
ent capacitty for own
ners/consu
ultants re
eview
/approvval before procureme
p
nt.
10.0
DEVIAT
TIONS
Deviatio
ons, if anyy, from this standard
d shall be
e clearly in
ndicated in
n the
offer with
w
reasons thereo
of. Deviatio
ons, from the data
a indicated in
specificcation shee
et shall be shown clea
arly by enccircling and
d indicating
g the
revised data in sp
pecification sheet.
FORM NO
O: 02-0000-002
21 F2 REV3
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
ONITORIING JUN
NCTION
N BOX
MO
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
1.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
SC
COPE
CO
ODES AND STANDAR
RDS
The
e Junction
n Box shalll be in acccordance with the latest revissions of th
he following
Ind
dian standa
ards, where
ever appliccable:
a) Indian
I
stan
ndards insttitution (ISII)
b) Internation
I
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Circuit Configuration
asurement
Mea
Num
mber
of
Inpu
ut/output/
Term
minals
Term
minal
Board
Mate
erial
Insu
ulation le
evel in
betw
ween
te
erminals
and body
Cab
ble Entries
Inpu
ut/looping
Term
minals
Outp
put Termin
nals
Enclosure
Busbar
Degree of Prottection
Mou
unting
Gassket
FORM NO: 02-0000-0021 F2 REV3
Cable from
m bullet Re
eference Electrode in
n/out cables
s
As Require
ed
10mm FRP
3KV for 1 minute at 50Hz
5
As per deisgn
02nos. 10mm dia. Stainless
S
stteel stud w
with double
e nut, sprin
ng and
plain wash
her
As Requirred, 10mm
m dia. Sta
ainless ste
eel stud with
w
double
e nut,
spring and
d plain was
sher
Completely enclos
sed, Indo
oor type, Natural Air Cooled.
e
s
shall
be prrovided with two term
minals
weatherproof. The enclosure
for earthing.
Tinned Co
opper Busb
bar-50mmX
X6mm
IP-65 as per
p IS: 2147
7/1962
Back Plate
e Wall/Stru
ucture Mou
unted
Neoprene Rubber
All rights reserved
r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
Dimension
Cab
ble entries
Surfface Painting
To be Spe
ecified
Cable entrries through cable gla
ands
First coat of
o zinc rich
h epoxy priimer Interm
mediate co
oat of epoxxy Two
coats of polyamide
e epoxy paint
p
Tota
al painting thicknesss 200
micron (minimum)
Colo
our scheme
e
Yellow paiint shade
Station termina
als
SS 316 Nu
uts & Bolts
s
Juncction boxx inside DMC
insulator
Nam
me plates and All interna
al compone
ent identification labe
elling shall be done using
labe
els
permanent screening
g/marker. Name platte shall be Engraved
d white
lettering in black Manufaccturers na
ame, add
dress, da
ate of
ure,., mode
el number,, serial num
mber, weig
ght etc. sh
hall be
manufactu
provided on
o shutter.
Qua
antity
As require
ed
Makke
Refer List of Approve
ed Vendorrs
4.0
INS
SPECTION
N & TESTS
S:
Jun
nction Boxes shall be
e inspected
d by owner/consultan
nt before d
dispatch. Testing
T
sha
all
be conducted
d in accord
dance with codes and
d standards enclosed
d in this do
ocument, as
a
ests done by
b manufaccturer and additional tests done
e by manufacturer.
perr routine te
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
WER DIS
STRIBUT
TION BO
OARD
POW
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
1.0
SC
COPE
1.1
2.0
CO
ODES AND STANDAR
RDS
2.1
The
e Power Distribution
D
n box shall be in ac
ccordance with the la
atest revis
sions of the
following Indian standards, where
ever applica
able:
a) Indian
I
stan
ndards insttitution (ISII)
n (IEC)
b) Internation
I
nal electro technical commissio
c
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Sysstem
Construction
Bussbars
Cable entry
Paint
Me
easuring Instruments
Wirring
FORM NO: 02-0000-0021 F2 REV3
415
5 V 3Ph 4 wire 50 Hzz AC
Flo
oor mounte
ed Fixed tyype double front
com
mpartmenttalized dusst and verm
min proof suitable for
IP 55 protection
ame : 2.0 mm
Fra
Do
oors : 1.6 mm
m
Co
overs : 1.6 mm
Base Channe
el : 3.0 mm
m
250
0 A copperr : 50 mm X 6 mm & N
Earth Bus shall be of Copper
C
50 m
mm X 6 mm
m
Bus bars sha
all be suppo
orted on S
SMC/DMC insulators
Bus bars sha
all have hea
at shrinkab
ble PVC sleeve with
Co
olor bands at regular interval forr phase ide
entification
All incoming & Outgoing
g cable en
ntries shall be at
botttom
Ou
utside : Epo
oxy light grrey shade RAL 7032 of IS : 5
Insside : (MTG
G plate, gla
and plate, sside plate, side
parrtitions, sid
de covers trolley)
t
: Gllossy white
e
All meters sh
hall be of 24
40-degree taut band scale and
size shall be 96 mm x 96
9 mm for I/Cs
Min
nimum pow
wer wiring shall be off 2.5 Sq mm
m
All rights reserved
r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
Ga
asket
Name Plates
Ferrruling
Quantity
Ma
ake of components
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
min
nimum con
ntrol wiring shall be o
of 1.5 Sq mm
m for
con
ntrol circuitt and CT/P
PT circuit.
Wiring shall be
b done wiith FRLS g
grade wire of 1.1 kV
gra
ade
All doors and
d covers wiill be provid
ded with neoprene
rub
bber gaske
ets
Each feeder will
w be provided with Al anodize
ed
nam
meplate with white le
etter on bla
ack background
havving FDR No.,
N rating tag No., F
Feeder deta
ail
Each control wire will be provided
d ferrule at both endss.
Ferule at con
ntractor sha
all be TC-2
2 and terminal strip it
sha
all be C1-C
C16 i.e. cro
oss Ferrulin
ng
As required
Re
efer list of Approved
A
V
Vendors
4.0
INS
SPECTION
N & TESTS
S
4.1
Pow
wer Distrib
bution Boa
ard shall be
b inspectted by owner/consulltant beforre dispatch
h,
tessting shall be conduccted in acccordance with
w codes and stand
dards enclo
osed in thiis
doccument.
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
TE
ECHNIC
CAL SPE
ECIFICA
ATION
ANOD
DE
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 3
1.0 SCOP
PE
This specification
n covers the minimum
m technical requirements for the
e design, manufacture
m
er and
Supplyy of Longline continuou
us Conducttive Polyme
eric Anodefflex, factoryy prepackag
ged with ca
alcined
petrole
eum coke brreeze.
The ma
agnesium Anode
A
shall be a standard of the manufacture
m
er regularly engaged in
n production
n. The
Anode shall be su
upplied in acccordance with
w the follo
owing specifications an
nd data she
eets.
2.0 CODE
ES AND STANDARD
DS
The An
nodes shall be in accordance with
w
the lattest revisio
ons of the following In
ndian stand
dards,
wherevver applicab
ble.
a)
b)
c)
d)
Where
e appropria
ate Indian standard
s
a not ava
are
ailable, the relevant IE
EC standards shall apply.
a
3.0 DATA
A SHEET:
Anode Typ
pe
Model
Conductive
e Polymer OD
O
Anode Len
ngth
Anode Maxximum Currrent Outputt
Conductive
e Polymer Volume
V
Ressistivity
Anode We
eight
Anode Dessign Life at Maximum Current
C
Outtput
Max length
h of each an
nodeflex strring
Anode Ope
erating Current Outputt
Maximum permissible
e potential attenuation
a
a
within the anode
Adhesive seam
s
bond strength off nylon
jacket
Anode Dessign Life at Operating Current
C
Outtput
Anode tail Cable Prim
mary Insulatiion
Anode tail Cable Seco
ondary Insu
ulation
Anode to Cable
C
Conn
nection
Coke breeze requirem
ment
Coke breeze fix carbo
on
Coke breeze resistivitty
Make
Long
L
Line Conductive
C
P
Polymer An
node
Anodeflex
A
1500 of RAY
YCHEM make
0.5Inch
0
(13m
mm) minimu
um
To
T be speciffied by bidd
der
52mA/m
5
1.1
1 to 1.9 oh
hm-cm
1.Kg(
1
Min)
20Yrs.
2
300
3 m
To
T be speciffied by bidd
der
1%
800N/25mm
8
m
50Yrs.
5
(Miniimum)
XLPE
X
PVC
P
FRLS
To
T be speciffied by bidd
der
1.15Kg.
1
/m
99.7%
9
0.05
0
to 15 ohm-cm
o
Tyco
T
adhes
sives USA (formerly Raychem)
R
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 3
4.0 TEST
T CERTIFC
CATES
The tessting shall be
b conducted in accorrdance with
h codes and
d standardss specified in
i this docu
ument,
as per routine tessts done by manufacturer and add
ditional testts done by manufacturrer. The folllowing
um tests sha
all be performed by bid
dder.
minimu
a.
b.
c.
d.
e.
Anode Co
omposition per lot
Anode we
eight - Net / Gross
Anode Su
urface Finish check
Anode to Cable Jointt Resistancce
ackfill Comp
position by weight.
w
Anode ba
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 2
TE
ECHNIC
CAL SPE
ECIFICA
ATION
SURGE DIIVERTE
ER FOR INSULA
ATING J
JOINTS
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV3
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 2
1.0 SCOP
PE
This specificatio
s
on covers the minimum technic
cal require
ements for Supply off Surge Divverter
for Ca
athodic Pro
otection Syystem.
The surge
s
Dive
erter shall be a standard product of the manufactu
urer regula
arly engag
ged in
produ
uction. The Surge Diverter shall
s
be supplied in accordance with
h the follo
owing
speciffications and data sh
heets.
2.0 CODE
ES AND STANDARD
DS
The Surge
S
Dive
erter shall be in acco
ordance with
w the late
est revisions of the following
f
Indian
stand
dards, whe
erever applicable. Wh
here appro
opriate Ind
dian standa
ard are no
ot available
e, the
releva
ant IEC sta
andards sh
hall apply.
a) Indian sta
andards insstitution (IS
SI)
b) International electro
o technical commissio
on (IEC)
c) American standardss institution
n (ANSI)
d) British sta
andards insstitution (B
BS)
Wh
here appro
opriate Ind
dian standa
ard are no
ot available
e, the rele
evant IEC standards shall
app
ply.
3.0 DATA
A SHEET:
Sr No Item Desc
cription
1 Lightning impulse Current (10//350) Iimp
2 Nominal Discharge
D
C
Current
(8//20) In
100% Ligh
htning impulse sparkkover voltag
ge
3 Uas 100
4
5
6
7
Power freq
quency spark over vo
oltage (50 HZ)
Uaw
Degree off protection
n
Length of Enclosure
e
Diameter of enclosu
ure D
8 Enclosure
e material
9 Cable Len
ngth
10 Make
EXFS
50 KA
100
0 KA
< 2.5
2 KV
< 1.2 KV
IP 65/
6 Explossion proof
90 mm
63 mm
Die
e Cast zincc with
Moisture proo
of
100 mm
DEH
HN ,Neumarkt G
Germany/ OBO
O
Germ
many
FORM NO: 02
2-0000-0021 F2
2 REV3
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
SO
OLID ST
TATE PO
OLARIZ
ZATION CELL F
FOR
CATHO
ODIC PROTEC
CTION SYSTEM
S
M
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
1.0
SC
COPE
1.1
2.0
CO
ODES AND STANDAR
RDS
2.1
The
e Solid Sta
ate Polarizzation Cell shall be in
i accorda
ance with tthe latest revisions
r
o
of
the
e following
g Indian standards,
s
wherever applicab
ble. Where
e approprriate Indian
Sta
andard is not
n available, the rele
evant IEC standards
s
s
shall
applyy.
a) Indian
I
stan
ndards insttitution (ISII)
b) Internation
I
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Ste
eady State
Rating
DC
C Blocking
Sho
ort Duratio
on fault Current
Lightening Su
urge Curre
ent
ratiing
Am
mbient Tem
mperature
Encclosures
Mo
ounting
Number of re
epeated
ope
eration
Quantity
Ma
ake
4.0
40 A Nomina
al
Op
ptimal highe
er ratings of
o Custom built
3.0
0 V Negativ
ve to 1.0 V Positive
5 kA/
k 5000 A @ 30 Cyccles
500
000 A Cres
st for 8 to 20
2 secon
nds
-45
5 C to 75 C
IP 55 Enclosu
ure for Non
n Hazardous Applica
ations
The
e cell is ma
ade to mou
unt on a fla
at surface
Virrtually unlimited und
der maximum ratings
s, provided
the
e operation
ns are not immediately repetitive.
As required
Da
airyland US
SA/ As per Approved list
SO
OLID STAT
TE POLAR
RIZATION CELL
C
REP
PLACEME
ENT
The
e device provides DC
C blocking when absolute volta
age across the termin
nals is 3.0 V
neg
gative to 1.0 V positive. The Device
D
furth
her provide
es groundiing (or cou
upling) patth
for steady sta
ate AC cu
urrent of a Magnitude
e 40 A. so
olid state d
design elim
minates the
ma
aintenance requireme
ents and th
he potentia
ally hazardo
ous electro
olytes asso
ociated witth
KO
OH type po
olarization cells and have a higher DC blocking
b
vo
oltage. The device is
i
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
ma
ade of solid
d state com
mponents, which have an instan
ntaneous rresponse with
w respecct
to voltage,
v
thereby initia
ating voltag
ge clampin
ng immedia
ately when
n the voltag
ge attemptts
to exceed
e
the
e blocking level seleccted.
5.0
TY
YPICAL AP
PPLICATIO
ON
6.0
Blocking Stray DC
D voltage
e
o cathodiccally prote
ected equ
uipment frrom utility grounding
DC issolation of
system
ms.
Over voltage
v
Prrotection fro
om AC fau
ults
Lightin
ng and Sw
witching Tra
ansients fo
or Monolithic isolation
n joints
AC Vo
oltage mitig
gation
TEST CETIFICATES:
The
e testing shall
s
be conducted in
n accordan
nce with co
odes and sstandards enclosed
e
in
thiss specification. Test Certificates
C
s shall be furnished as
a per routine tests & additiona
al
tesst done by manufactu
urer.
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
ARTHIN
NG JUNC
CTION BOX
B
EA
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
1.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
SC
COPE
Thiis specificcation covvers the minimum
m
technical requireme
ents for the
t
design
n,
ma
anufacturing and Sup
pply of Eartthing Juncttion Box.
The
e earthing junction box should be a stand
dard produ
uct of the m
manufacturrer regularly
use
ed for Imp
pressed cu
urrent Cath
hodic prote
ection system. This specification conferrs
req
quirement for type, rating,
r
man
nufacture and testing of differrent types of earthing
junction box. The Earrthing Juncction Box shall be supplied in accordance with the
following specifications and data sheets.
s
2.0
CO
ODES AND
D STANDA
ARDS
The
e earthing
g junction box shall be in acc
cordance with
w
the la
atest revisions of the
following Indiian standards, where
ever applicable:
a) Indian
I
stan
ndards insttitution (ISII)
b) Internation
I
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
DA
ATA SHEET
- Earthing Circuits
- Earthing Device
- Circuit Coonfiguration
:
:
:
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
Enclosure
e Material
Enclosure
e Protectio
on
Degree of
o Protectio
on
Cable entries
g cable from
m the bulle
et
Incoming
Outgoing
g cables to earthing grid
g
Surface Painting
P
Color sch
heme
Name pla
ates and le
evels
Quantity
Make
4.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
co
ompression
n FLP ccable gla
ands. The
ca
abinet shalll have hin
nged front doors witth
ne
eoprene gasket a
and shall be Pad
loc
ckable.
2.0
0mm thickk CRCA ste
eel enclosu
ure
Ex
xplosion Proof
P
Zone
e 1-Gas Group
G
IIA &
IIB
B Tempera
ature Classs T3.
IP
P-65
Th
hrough FLP
P double ccompressio
on glands.
1CX35
5sq.mm
1CX35
5sq.mm
First coat off zinc rich e
epoxy prim
mer
Inttermediate
e coat of ep
poxy
Tw
wo coats of polyamid
de epoxy pa
aint Total
pa
ainting thickness 200 micron(minimum)
Ye
ellow paintt shade
alll internal component identification labeling
sh
hall be done
d
using perman
nent using
pe
ermanent screening
g/ screening/marker.
Na
ame plate
e shall b
be Engra
aved whitte
letttering in black. M
Manufacture
ers name
e,
ad
ddress, date of manufacture, CMRS
C
No.,
mo
odel numb
ber, serial number, weight etcc.
sh
hall be provvided on sh
hutter.
As
s required
Re
efer List off Approved
d Vendors
INS
SPECTION
N & TESTS
S:
e earthing Junction Box shall be inspec
cted by ow
wner/consultant beforre dispatch
h,
The
tessting shall be conduccted in acccordance with
w codes and stand
dards enclo
osed in thiis
doccument, as per routtine tests done by contractorr and additional testts done by
b
con
ntractor.
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
ONITORIING JUN
NCTION
N BOX
MO
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
1.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
SC
COPE
CO
ODES AND STANDAR
RDS
The
e Junction
n Box shalll be in acccordance with the latest revissions of th
he following
Ind
dian standa
ards, where
ever appliccable:
a) Indian
I
stan
ndards insttitution (ISII)
b) Internation
I
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Circuit Configuration
asurement
Mea
Num
mber
of
Inpu
ut/output/
Term
minals
Term
minal
Board
Mate
erial
Insu
ulation le
evel in
betw
ween
te
erminals
and body
Cab
ble Entries
Inpu
ut/looping
Term
minals
Outp
put Termin
nals
Enclosure
Busbar
Degree of Prottection
Mou
unting
Gassket
FORM NO: 02-0000-0021 F2 REV3
Cable from
m bullet Re
eference Electrode in
n/out cables
s
As Require
ed
10mm FRP
3KV for 1 minute at 50Hz
5
As per deisgn
02nos. 10mm dia. Stainless
S
stteel stud w
with double
e nut, sprin
ng and
plain wash
her
As Requirred, 10mm
m dia. Sta
ainless ste
eel stud with
w
double
e nut,
spring and
d plain was
sher
Completely enclos
sed, Indo
oor type, Natural Air Cooled.
e
s
shall
be prrovided with two term
minals
weatherproof. The enclosure
for earthing.
Tinned Co
opper Busb
bar-50mmX
X6mm
IP-65 as per
p IS: 2147
7/1962
Back Plate
e Wall/Stru
ucture Mou
unted
Neoprene Rubber
All rights reserved
r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
Dimension
Cab
ble entries
Surfface Painting
To be Spe
ecified
Cable entrries through cable gla
ands
First coat of
o zinc rich
h epoxy priimer Interm
mediate co
oat of epoxxy Two
coats of polyamide
e epoxy paint
p
Tota
al painting thicknesss 200
micron (minimum)
Colo
our scheme
e
Yellow paiint shade
Station termina
als
SS 316 Nu
uts & Bolts
s
Juncction boxx inside DMC
insulator
Nam
me plates and All interna
al compone
ent identification labe
elling shall be done using
labe
els
permanent screening
g/marker. Name platte shall be Engraved
d white
lettering in black Manufaccturers na
ame, add
dress, da
ate of
ure,., mode
el number,, serial num
mber, weig
ght etc. sh
hall be
manufactu
provided on
o shutter.
Qua
antity
As require
ed
Makke
Refer List of Approve
ed Vendorrs
4.0
INS
SPECTION
N & TESTS
S:
Jun
nction Boxes shall be
e inspected
d by owner/consultan
nt before d
dispatch. Testing
T
sha
all
be conducted
d in accord
dance with codes and
d standards enclosed
d in this do
ocument, as
a
ests done by
b manufaccturer and additional tests done
e by manufacturer.
perr routine te
TECHNICA
AL SPECIFIC
CATION
ATHODIC PR
ROTECTION
N SYSTEM OF
O
CA
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 2
MASTER VEN
NDOR LIST
L
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV4
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 2
CAT
THODIC PROTECTI
P
ION VEND
DOR LIST
VENDORS
Sr. No.
1
2
4
M/s Con
nsultech
M/s Corrrosion Con
ntrol Servicces (Bomb
bay) Pvt Ltd
d
M/s CTS
S Private Limited
L
7.
8.
Undergrround pipe
eline & NDT
TS (P) Ltd.
FORM NO: 02
2-0000-0021F2 REV3
R
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
MAKE OF EQUIPMEN
NT / CO
OMPONE
ENT
ATHODIIC PROTECTIO
ON SYST
TEM
FOR CA
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 3
CATHODIC PRO
OTECTION
N MAKE OF
O EQUIPM
MENT / CO
OMPONEN
NT
Sr.
No.
1
DES
SCRIPTION OF MAT
TERIALS
Transform
mer Rectifie
er unit
Test Statio
ons/ Anode
e Junction Box/ Cath
hode
Junction Box
B
Refere
ence Electtrode Junc
ction
Box (REJJB) /
Earthing Junction
J
Bo
ox (EJB)
Cables
6
7
DC clip-on
n meter
C.P. Syste
em Power Distributio
on Board
(PDB)
FORM NO: 02
2-0000-0021F2 REV3
R
MANUFACTURERS
S / VENDO
OR
Advvance Elecctronic Sys
stems
Rayychem
Krisstons Systtems
FCG
FEPL
Flexpro
Balliga
DEHN Germa
any
OB
BO Betterm
man Germa
any
AES
IGP
P, Chennai
Alfa
a Engineerring
SR
RL Italy
Zun
nt Italy
RM
MA Italy
NETCO
ASIAN
Finolex
NIC
CCO
CC
CI
Uniiversal
KEC
Suyyog cabless,
Icon cables,
Torrrent
Ravvin Cabless
RR
R Cables
Sarrgam Meta
als Chenna
ai
Scientific Mettals Karaik
kudi
Becckmann
Fluke
Mo
otwane
HC
CK (Germany)
Kyo
oritsu Elecct (Japan)
Asssociated Switchgears
s & Projectts
Ltd. /
Auttomatic controls
Corrporation/C
Controls
& Schematics
S
s Pvt. Ltd.//Control &
Sw
witchgear C
Co. Ltd./Ele
ecmech
corrporation/H
Havells Ind
dia Limited
/Hin
ndustan Co
ontrol & Eq
quipment Pvt.
P
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 3
Ltd./ Reunion
n Electrical Manufactu
urers
Pvtt. Ltd
10
Long Line
e Conducttive Polym
mer Anode
e
Flex x 150
00
Rayychem
11
Rayychem
12
13
Cu/CuSO4
4 permane
ent reference cells
Reference
e Electrode
e (Zinc) /
Zinc Reference Cell
Solid-State type Polarization cells
c
Monitoring
g Junction Box (MJB)
Remote Monitoring
M
U
Unit
Borrin USA/Mcc-Miller/Ha
arco
14
15
16
FORM NO: 02
2-0000-0021F2 REV3
R
Borrin USA/Mcc-Miller/Ha
arco
Daiiry Land/ R
Rustrol /Kirrk/ Corrpro
Rayychem/AES or equiv
valent
Rayychem/AES
EM163-45-PNMP-PS 100
Document No.
Sheet 1 of 1
Rev.
PIPING
PIPING
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-45-PNMP-PS 100
Document No.
Rev.
PIPING
Sheet 1 of 1
CONTENTS
SN
Item
Page No
1.0
2.0
12
3.0
15
4.0
16
4.2 ES 6006
33
4.3 ES 6007
40
4.4 ES 6010
44
4.5 ES 6011
59
4.6 ES 6101
67
4.7 ES 6102
72
4.8 ES 6103
77
4.9 ES 6104
82
4.10 ES 6105
86
4.11 ES 6606
90
4.12 ES 6018
98
114
115
117
121
168
178
181
Allrightsreserved
EM163-45-PNMP-PS 102
Document No.
Sheet 1 of 3
Rev.
MINIMUMALLOWABLENOZZLELOADINGS
FORMOUNDEDBULLET
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ALLOWABLENOZZLELOADINGS
EM163-45-PNMP-PS 102
Document No.
Rev.
Sheet 2 of 3
Allrightsreserved
ALLOWABLENOZZLELOADINGS
EM163-45-PNMP-PS 102
Document No.
Rev.
Sheet 3 of 3
Allrightsreserved
EM163-45-PNMP-PS 101
Document No.
Sheet 1 of 1
Rev.
PIPINGMATERIALSPECIFCATION
&
VALVEMATERIALSPECIFICATION
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ANSI
CLASS
150#
CORROSION
1.5 MM
ALLOWANCE
-29.0
38.00
93
149
204
260
316
343
371
PRESS.KG/CM2 G 20.03
TEMP. DEG.C
20.03
18.28
16.17
14.06
11.95
9.84
8.78
7.73
40
36
E R R R R R
34
E TEES B. W.
DRAINS
SW COUPLING
H H. COUPLING
BUTTWELDED
P PIPE TO PIPE
VENTS
TEMP. CONN.
PRESS. CONN.
1.5"
FLANGED
0.75"
E R R R R R R R R
26
E R R R R R R R R R
24
22
R REINFORCED
R R R R R R R R R R
S SOCKETLETS
E R
R R R R R R R R R R
18
E R R
R R R R R R R R R R
16
E R R R
R R R R R R R R R R
14
12
32
30
W WELDOLETS
20
E R R R R
R R R R R R R R R R
E R R R R R
R R R R R R R R R R
10
E P R R R R R
R R R R R R R R R R
8.0
E P P R R R R R
R R R R R R R R R R
6.0
5.0
P P P R R R R R
R R R R R R R R R R
4.0
P P P R R R R R
R R R R R R R R R R
3.00
P P P R R R R R
R R R R R R R R R R
2.00
T E
H H H H H H H H
H H H H H H H H H H
1.50
T H
H H H H H H H H
H H H H H H H H H H
1.00
T T
T H
H H H H H H H H
H H H H H H H H H H
0.75
T T T
T H
H H H H H H H H
H H H H H H H H H H
0.50
3.5
2.50
1.25
0.25
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.5
4.0
5.0
6.0
8.0
10
12
14
16
18
20
22
24
26
30
32
34
36
40
42
44
48
PIPE JOINTS
E R R R R R R
E R R R R R R R
20
BRANCH CONNECTIONS
25
E R R R
15
BRANCH PIPE
DESCRIPTION
FLANGED (BUT TO BE KEPT MINIMUM)
42
10
SIZE
44
E R R
10
15
20
25
30
RUN PIPE
A1A
SHEET 1 OF 3
ITEM
48
R R R R
E
E R
30
NON CORROSIVE/ FLAMMABLE / NON FLAMMABLE/ NON LETHAL -PROCESS & HYDROCARBONS; LUBE OIL BEFORE FILTER;
AMMONIA, STEAM & CONDENSATE (NON IBR); UTILITIES- INST AIR(BEYOND A3A), PLANT AIR, NITROGEN, CARBONDIOXIDE;
WATER - BEYOND A3A AND A10A; IN OFFSITES ONLY BEYOND A10A;
ITEMS
S
NO.
PIPE
PIPES
FLANGE
FLANGES
TYPE
FITTING
FITTINGS
FITTING
FITTINGS
LOW
HIGH
SCH / THK /
RATING
SEAMLESS
SEAMLESS
SEAMLESS
SEAMLESS
E.FS.W
E.FS.W
NIPPLE, SEAMLESS
PE
PE
BE
BE
BE
BE
PBE
00
01
02
03
16
40
00
500
000
000
000
000
000
500
00
01
02
14
36
48
01
750
500
000
000
000
000
500
S160
XS
XS
STD
STD
XS
M
SW
WN
WN
WN
BLIND
BLIND
BLIND
FIG.8 FL
SPCR & BLN
SPCR & BLN
RF
RF
RF
RF
RF
RF
RF
FF
FF
FF
SW
SW
BW
BW
00
00
26
02
00
26
02
00
10
26
00
01
02
16
500
500
000
000
500
000
000
500
000
000
500
000
000
000
01
24
48
24
24
48
24
08
24
48
00
01
14
48
500
000
000
000
000
000
000
000
000
000
750
500
000
000
300
150
150
300
150
150
300
150
150
150
6000
3000
SCRF
SCRF
BW
PBE
00
01
02
00
500
000
000
500
00
01
48
03
750
500
000
000
6000
3000
DIAMETER RANGE
END /
FACING
ALL
EXCEPT
CAP
CAP
CAP
SWAGE
FACE FINISH /
RADIUS
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
R = 1.5D
R = 1.5D
DIMENSION /
DESIGN /
STANDARD
MATERIAL
DESCRIPTION
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 16.5
B - 16.5
B - 16.47 - B
B - 16.5
B - 16.5
B - 16.47 - B
B - 16.5
ASME B16.48
ASME B16.48
B - 16.11
B - 16.11
B - 16.9
B - 16.9
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A 105
A 105
A 105
A 105
A 105
A 105
A 105
A 516 GR 70
A 105
A 105
A234 GR.WPB
A234 GR.WPB - W
B - 16.11
B - 16.11
B - 16.9
BS - 3799
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A234 GR.WPB
A 105
A1A
CODE
NOTE
SHEET 2 OF 3
ITEMS
S
NO.
GASKET
VALVE
STUDS
GASKET
BOLTING
VALVES
TYPE
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
DIMENSION /
DESIGN /
STANDARD
MATERIAL
DESCRIPTION
NOTE
CODE
51001
B16.11
800
800
52001
53001
B16.11
B16.11
500
800
BS EN ISO 15761
58099
B16.11
16
000
150
125 AARH
BS EN ISO 17292
000
42
000
150
125 AARH
02
000
16
000
150
125 AARH
BS - 1873
RF
02
000
24
000
150
125 AARH
BS - 1868
PLUG
RF
00
500
24
000
150
125 AARH
BS - 5353
PLUG
RF
00
500
36
000
150
125 AARH
BS - 5353
BUTTERFLY
WAF
03
000
24
000
150
125 AARH
BS EN 593
BUTTERFLY
WAF
26
000
48
000
150
125 AARH
BS EN 593
B - 18.2
B - 18.2
A193 GR. B7
A194 GR. 2H
SS316 SPR.WND + GRAFIL
GATE
SW
00
250
01
500
800
GLOBE
CHECK
SW
SW
00
00
250
250
01
01
500
500
NEEDLE
SW
00
500
01
BALL
RF
00
500
GATE
RF
02
GLOBE
RF
CHECK
BOLT STUD
NUTS
SPIRAL
00
500
24
000
150 / 5 MM
B-16.20 / B 16.5
SPIRAL
26
000
48
000
150 / 5 MM
SPIRAL
00
500
24
000
300 / 5 MM
B-16.20 / B 16.5
FLGD
00
500
01
500
THRMODNMC
MNF'STD
SW
BW
BW
00
02
16
500
000
000
01
14
24
500
000
000
Y TYPE
T TYPE
T TYPE
MNF'STD
TRAP
PERM STR
PERM STR
PERM STR
150 /
125AARH
800
A1A
54301
51301
52301
53301
55301
55315
56301
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
WAFL TO
B16.5
FLANGED
TO
B16.47B
SHEET 3 OF 3
ANSI
CLASS
300#
CORROSION
1.5 MM
ALLOWANCE
-29.0
38.00
93.00
149
204
260
PRESS.KG/CM2 G 52.02
TEMP. DEG.C
52.02
47.8
46.05
44.64
42.53
316
343
40.07
371
38.66 37.26
399
427
35.5
28.82
48
30
NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHAL - HYDROCARBONS, AROMATICS, AMMONIA,
SWEET GAS, FLUSHING OIL AND OTHER UTILITIES -MP CONDENSATE, INSTRUMENT
AIR, PLANT AIR, NITROGEN, AMMONIA GAS ETC. ABOVE CLASS 'A1A'.
44
42
40
BRANCH CONNECTIONS
DESCRIPTION
32
30
BUTTWELDED
VENTS
TEMP. CONN.
PRESS. CONN.
1.5"
FLANGED
24
P PIPE TO PIPE
E R
22
R REINFORCED
E R R
20
S SOCKETLETS
E R R R
18
E R R R R
16
E R R R R R
14
0.75"
26
H H. COUPLING
W WELDOLETS
E R R R R R R
12
E R R R R R R R
10
E R R R R R R R R
8.0
E R R R R R R R R R
6.0
20
SW COUPLING
5.0
E R R R R R R R R R R R
4.0
E P P R R R R R R R R R R R
3.00
10
DRAINS
3.5
2.50
E P P P P R R R R R R R R R R R
2.00
T E H H H H H H H H H H H H H H H
1.50
T T T H H H H H H H H H H H H H H H H
1.00
T T T T H H H H H H H H H H H H H H H H
0.75
T T T T T H H H H H H H H H H H H H H H H
0.50
1.25
0.25
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.5
4.0
5.0
6.0
8.0
10
12
14
16
18
20
22
24
26
30
32
34
36
40
42
44
48
PIPE JOINTS
15
BRANCH PIPE
E TEES B. W.
10
15
20
25
30
RUN PIPE
B1A
SHEET 1 OF 3
SIZE
ITEM
MAINTE. JOINTS ALL
25
36
34
ITEMS
S
NO.
PIPE
PIPES
FITTINGS
FLANGE
FITTING
FLANGES
FITTING
FITTINGS
TYPE
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
SEAMLESS
SEAMLESS
SEAMLESS
SEAMLESS
E.FS.W
E.FS.W
E.FS.W
E.F.G.W.
NIPPLE, SEAMLESS
PE
PE
BE
BE
BE
BE
BE
BE
PBE
00
01
02
03
16
20
24
24
00
500
000
000
000
000
000
000
000
500
00
01
02
14
18
20
24
24
01
750
500
000
000
000
000
000
000
500
S160
XS
XS
STD
XS
XS
CALC
14.0
M
SW
WN
BLIND
FIG.8 FL
SPCR & BLN
RF
RF
RF
FF
FF
00
02
00
00
10
500
000
500
500
000
01
24
24
08
24
500
000
000
000
000
300
300
300
300
300
ALL
SW
SW
BW
BW
00
01
02
16
500
000
000
000
00
01
14
24
750
500
000
000
6000
3000
SCRF
SCRF
BW
PBE
00
01
02
00
500
000
000
500
00
01
24
03
750
500
000
000
6000
3000
EXCEPT
CAP
CAP
CAP
SWAGE
FACE FINISH /
RADIUS
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
R = 1.5D
R = 1.5D
DIMENSION /
DESIGN /
STANDARD
MATERIAL
DESCRIPTION
CODE
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 16.5
B - 16.5
B - 16.5
ASME B16.48
ASME B16.48
ASTM
ASTM
ASTM
ASTM
ASTM
A
A
A
A
A
B - 16.11
B - 16.11
B - 16.9
B - 16.9
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A234 GR.WPB
A234 GR.WPB - W
B - 16.11
B - 16.11
B - 16.9
BS - 3799
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A234 GR.WPB
A 105
B1A
CL
CL
CL
CL
NOTE
12
12
12
12
105
105
105
105
105
SHEET 2 OF 3
ITEMS
S
NO.
VALVE
VALVES
7
8
GASKET STUDS
BOLTING
TYPE
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
DIMENSION /
DESIGN /
STANDARD
GATE
SW
00
250
01
500
800
GLOBE
SW
00
250
01
500
800
BS EN ISO 15761
CHECK
SW
00
250
01
500
800
NEEDLE
SW
00
500
01
500
800
BALL
RF
00
500
16
000
300
125 AARH
BS EN ISO 17292
GATE
RF
02
000
24
000
300
125 AARH
GLOBE
RF
02
000
12
000
300
125 AARH
BS - 1873
CHECK
RF
02
000
24
000
300
125 AARH
BS - 1868
PLUG
RF
00
500
24
000
300
125 AARH
BS - 5353
BOLT STUD
NUTS
SPIRAL
TRAP
PERM STR
PERM STR
PERM STR
00
500
24
000
FLGD
00
500
01
500
SW
BW
BW
00
02
16
500
000
000
01
14
24
500
000
000
BS EN ISO 15761
BS EN ISO 15761
B - 18.2
B - 18.2
A193 GR. B7
A194 GR. 2H
B-16.20 / B 16.5
THRMONMC
MNF'STD
Y TYPE
T TYPE
T TYPE
MNF'STD
300 / 5 MM
300 /
125AARH
800
MATERIAL
DESCRIPTION
B1A
CODE
NOTE
51001
B16.11
52001
B16.11
53001
B16.11
58099
B16.11
54401
51401
52401
53401
55401
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
SHEET 3 OF 3
ANSI
CLASS
150#
CORROSION
1.5 MM
ALLOWANCE
TEMP. DEG.C
PRESS.KG/CM2 G 10.55
38.00
50.00
100
10.55
10.55
10.55
150
186
10.55 10.55
E TEES B. W.
DRAINS
H H. COUPLING
BUTTWELDED
P PIPE TO PIPE
VENTS
TEMP. CONN.
PRESS. CONN.
1.5"
FLANGED
0.75"
34
E R R R R R R
32
E R R R R R R R
30
E R R R R R R R R
26
E R R R R R R R R R
24
22
R R R R R R R R R R
S SOCKETLETS
E P
R R R R R R R R R R
18
E R P
R R R R R R R R R R
16
E P R P
R R R R R R R R R R
14
12
W WELDOLETS
20
E P P R P
R R R R R R R R R R
E R P P R P
R R R R R R R R R R
10
E P R P P R P
R R R R R R R R R R
8.0
E P P R P P R P
R R R R R R R R R R
6.0
P P P P P P P P
R R R R R R R R R R
4.0
P P P P P P P P
R R R R R R R R R R
3.00
P P P P P P P P
P R R R R R R R R R
2.00
T E
H H H H H H H H
H H H H H H H H H H
1.50
T H
H H H H H H H H
H H H H H H H H H H
1.00
T T
T H
H H H H H H H H
H H H H H H H H H H
0.75
T T T
T H
H H H H H H H H
H H H H H H H H H H
0.50
25
36
E R R R RRR
R REINFORCED
40
5.0
3.5
2.50
1.25
0.25
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.5
4.0
5.0
6.0
8.0
10
12
14
16
18
20
22
24
26
30
32
34
36
40
42
44
48
PIPE JOINTS
E R R R
E R R R R
20
BRANCH CONNECTIONS
42
15
BRANCH PIPE
DESCRIPTION
FLANGED (TO BE KEPT MINIMUM)
44
E R R
10
SIZE
48
10
15
20
25
30
RUN PIPE
A3A
SHEET 1 OF 3
ITEM
MAINTE. JOINTS ALL
E
E R
30
NON CORROSIVE UTILITIES (ABOVE GROUND) CATEGORY "D" FLUID - COOLING WATER, INSTRUMENT AIR(2" & ABOVE),PLANT AIR, INERT GAS, CARBON DI OXIDE
(DRY), NITROGEN, CONDENSATE & BOILER FEED SUCTION (NON IBR),COOLING WATER(UNDERGROUND). THIS CLASS DOES NOT COVER THE FIRE WATER SERVICE. FOR
SIZES ABOVE 30", TEMPERATURE AND PRESSURE RATINGS SHALL BE 70 DEG.C & 7.0 KG/CM2G RESPECTIVELY.
ITEMS
S
NO.
PIPE
PIPES
FITTINGS
FLANGE
FITTING
FLANGES
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
C.WELDED
C.WELDED
WELDED
WELDED
WELDED
WELDED
PE
BE
BE
BE
BE
BE
00
02
08
16
20
26
500
000
000
000
000
000
01
06
14
18
24
48
500
000
000
000
000
000
HVY
HVY
6.00
8.00
10.0
12.0
SW
SW
WN
SO
SO
BLIND
BLIND
FIG.8 FL
SPCR & BLN
SPCR & BLN
RF
RF
RF
RF
FF
RF
FF
FF
FF
FF
00
00
02
02
26
00
26
00
10
26
500
500
000
000
000
500
000
500
000
000
01
01
24
24
48
24
48
08
24
48
500
500
000
000
000
000
000
000
000
000
150
300
600
150
150
150
150
150
150
150
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
SW
BW
BW
00
02
08
500
000
000
01
06
24
500
000
000
3000
STD
M
R = 1.5D
R = 1.5D
SCRF
BW
BW
BW
BW
PBE
SW
00
02
08
16
16
00
00
500
000
000
000
000
500
500
01
06
48
48
48
03
01
500
000
000
000
000
000
500
3000
STD
M
M
M, M
STD, STD
3000
ALL
DIMENSION /
DESIGN /
STANDARD
MATERIAL
NOTE
DESCRIPTION
IS-1239-I
IS-1239-I
IS-3589
IS-3589
IS-3589
IS-3589
IS-1239 BLACK
IS-1239 BLACK
IS-3589 GR.330
IS-3589 GR.330
IS-3589 GR.330
IS-3589 GR.330
B - 16.5
B - 16.5
B - 16.5
B - 16.5
AWWA-C207 CL.D
B - 16.5
AWWA-C207 CL.D
ASME B16.48
ASME B16.48
MANF' STD
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
B - 16.11
B - 16.9
B - 16.9
ASTM A 105
ASTM A234 GR.WPB
ASTM A234 GR.WPB-W
B - 16.11
B - 16.9
B - 16.9
ASTM A 105
ASTM A234 GR.WPB
ASTM A234 GR.WPB
IS-3589 GR.330
IS-3589 GR.330
ASTM A 105
ASTM A 105
A
A
A
A
A
A
A
A
A
A
CODE
105
105
105
105
105
105
285 GR.C
105
105
285 GR.C
EXCEPT
FITTING
FITTINGS
TYPE
CAPS
CAPS
CAPS
MITRES
REDUCERS
SWAGE
UNION
R = 1.5D
BS-3799
BS-3799
A3A
SHEET 2 OF 3
ITEMS
S
NO.
VALVE
VALVES
TYPE
STUDS
GASKET
BOLTING
GASKET
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
DIMENSION /
DESIGN /
STANDARD
GATE
SW
00
250
01
500
800
GLOBE
SW
00
250
01
500
800
BS EN ISO 15761
CHECK
SW
00
250
01
500
800
BS EN ISO 15761
NEEDLE
SW
00
500
01
500
800
BS EN ISO 15761
BALL
RF
00
500
16
000
150
125 AARH
BS EN ISO 17292
GATE
RF
02
000
24
000
150
125 AARH
GLOBE
RF
02
000
16
000
150
125 AARH
BS - 1873
CHECK
RF
02
000
24
000
150
125 AARH
BS - 1868
WAF
03
000
24
000
150
125 AARH
BS EN 593
BUTTERFLY
DIAMETER RANGE
END /
FACING
MATERIAL
NOTE
DESCRIPTION
51001
B16.11
52001
B16.11
53001
B16.11
58099
B16.11
BOLT STUD
B - 18.2
A193 GR. B7
NUTS
B - 18.2
A194 GR. 2H
M/C BOLT
B - 18.2
B-16.20 / B 16.5
B-16.20 / B 16.5
THRMODNMC
MNF'STD
Y TYPE
T TYPE
T TYPE
MNF'STD
SPIRAL
SPIRAL
TRAP
PERM STR
PERM STR
PERM STR
00
26
500
000
24
48
000
000
FLGD
00
500
01
500
SW
BW
BW
00
02
08
500
000
000
01
06
24
500
000
000
150 / 5 MM
150 / 5 MM
300 /
125AARH
800
M
M
CODE
A3A
54321
51321
52321
53321
56321
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
WAFL TO
B16.5
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Piping and piping elements for Category 0 Fluid Service as designated in the
engineering design shall be visually examined in accordance with para 6.2 to
the extent necessary to satisfy the examiner that components, materials and
workmanship conform to the requirements of ASME B 31.3 Code, this standard
and the engineering design. Acceptance criteria are as stated in para. 3.3.2
and in Table 3.3.2 for Category 0 fluid service, unless otherwise specified.
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connection welds comparable to those shown in Fig.3.5.4E of ES 6004
shall be examined by 100% radiography in accordance with para 6.5 or (if
specified in the engineering design) by 100% ultrasonic examination in
accordance with para 6.6. Socket welds and branch connection welds
which are not radiographed shall be examined by magnetic particle or
liquid penetrant methods in accordance with para 6.3 0r 6.4.
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INSPECTION,EXAMINATION
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ES : 6005
ISSUE: SEP. '99
SHEET
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Any of the methods of examination described in para 6.0 may be specified by the
engineering design to supplement the examination required by para 3.4. The
extent of supplementary examination to be performed and any acceptance
criteria that differ from tHose in para 3.3.2 shall be specified in the engineering
design.
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The locations of welds and the points at which they are to be examined by
spot radiography shall be selected or approved by the Inspector.
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ISSUE: SEP. '99
SHEET
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intended to verify safisfactory heat treatment. The hardness limit applies to the
weld and to the heat affected zone (HAZ) tested as close as practicable (with in
2-3 mm) to the edge of the weld.
(a) Where a hardness limit is specified in Table 3 at least 10% of welds, hot
bends and hot formed components in each furnace heat treated batch and
100% of those locally heat treated shall be tested.
(b) When dissimilar metals are joined by welding the hardness limits specified
for the base and welding materials in Table 3 shall be met for each
material.
Examinations
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EXAMINATION PERSONNEL
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Examiners shall have training and experience commensurate with the needs of
the specified examinations. The employer shall certify records of the examiners
employed, showing dates and results of personnel qualifications and shall
maintain them and make them available to the Inspector.
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EXAMINATION PROCEDURES
Any examination shall be performed in accordance with a written procedure that
conforms to one of the methods sp.ecifiedin para 6.0, including special methods
(see para 6.1.2). Procedures shall be written as required in the ASME BPV
Code, Section V, Article 1, T-150. The employer shall certify records of the
examination procedures employed, showing dates and results of procedure
,qualifications and shall maintain them and make them available to the Inspector.
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the engineering design.
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POlL
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ISSUE: SEP. '99
SHEET
12 OF 17
(a)
When the basic calibration blocks have not received heat treatment in
accordance with T-542.1.1(c) and T-542.8.1.1, transfer methods shall be
used to correlate the responses from the basic calibration block and the
component. Transfer is accomplished by noting the difference between
responses received from the same reference refiecturin the basic
calibration block and in the component and correcting for the difference.
(b)
(c)
1)
2)
for sizes> NPS 2/1and < NPS 18/1,once in each 1.5 m of welding
examined.
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for sizes> NPS 18" once for each welded joint examined.
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transfer method shall be used at least twice on each type of weld joint.
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(for welding) condition of the root pass after cleaning - external and
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Normal Fluid Service
Severe Cvclic Conditions
Cateaorv D Fluid Service
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INSPECTION, EXAMINATION
OF WELDING OF PIPING
ES : 6005
ISSUE: SEP. '99
SHEET
16 OF 17
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1(1) Criteria given are for required examination. Mqre stringent criteria may be specified in
the engineering design. See also paras 3.5 and 3.5.3.
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Longitudinal groove weld includes straight and spiral seam. Criteria are not intended
to apply to welds made in accordance with a standard listed in Table A-1 or Table
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(3) Fillet weld includes socket and seal welds and attachment welds for slip-on flanges.
branch reinforcement and supports.
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All installed piping after completion of the applicable examinations, but prior to
initial operation shall be pressure tested to ensure tightness in accordance with the
requirementsof this specification. However, piping built, in conformance with the
ASME Boiler & PV code or Indian Boiler Regulation shall be pressure tested in
complianceof such code or regulations.
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Piping systems open to atmosphere, such as drains, vents, outlet piping for relief
valves discharging to atmosphere and underground sewers shall not require any
pressuretesting. These lines shall be examined visually to determine that all joints
are propertymade up.
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A preliminary test using air at no more than 170 kPa (25 psi) gauge pressure
may be made prior to hydrostatic testing to locate major leaks.
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Leak te~ts shall be conducted after any heat treatment has been completed.
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The final weld connecting piping systems or components which have bee'
successfully tested in accordance withthis engineering standard need not be>
leak tested providedthe weld is examined in process in accordance withpara
344.7 of ASME B 31.3 (para 6.7 of ES:6005)
and passes with 100%
radiographic examination in accordance with para 344.5 of ASME B 31.3
(Para 6.5 of ES 6005) or 100% ultrasonic examination in accordance with
para 344.6 of ASMEB 31.3 (Para 6.6 of ES 6005).
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TEST
examination during leak testing, except' that joints previously tested may be
insulated or covered. Alljoints may be primedand painted only after leak testing.
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Jacketed Piping
(a) The internal line shall be leak tested on the basis of the internal or external
design pressure, whichever is critical.This test must be performed before the
jacket is completed if it is necessary to provide visual access, to joints of the
intemalline.
(b) The jacket shall be leak tested on the basis of the jacket design pressure
unless otherwise specified in the engineeringdesign.
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All air present in the system to be tested shall I;)evented while admitting the test
fluid.
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Lines containing check valves shall have source of test pressure on the up-stream
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Relief valves shall be excluded from the test and shall be suitably blanked off.
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Orifice plates in horizontal lines shall not be installed till completion of test.
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Control valves shall not be field tested. All flanged control valves shall be removed
before hydraulic testing of the pipe lines. Welded end control valves shall be welded
after hydraulic test, cleaning and blowing.
Indicating 'pressure gauges mounted locally may be tested /with the lines provided
the test pressure is not in excess of their scale ratings.
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Instrument take-off piping up to the first block valve shall be tested with piping to
which it is connected. Testing of remainder of lead line ,upto instrument can also be
done at the same time provided instruments are blocked 9ft from source of pressure
and vented to atmosphere.
3.10
The test shall be carried out at ambient temperature and the water temperature shall
not be less than loCo
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Test Fluid
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The fluid shall be water unless there is the possibility of damage due to freezing or to
adverse effects of water on the piping or the process. In that case another suitable
nontoxic liquid may be used. If thd liquid is flammable, its flash point shall be at least
49C and consideration shall be given to the test environment. Hydrocarbons shall
not be permitted for Oxygen service.
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Instruments, expansion joints, filters etc., for which the maximum permissible cold
test pressures are lower than the specified hydrostatic test pressure for piping, shall
be isolated and excluded from the test.
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Pipir.g designed for vapour and gas shall be provided with additional temporary
supportsif necessary, to support the weight of test fluid.
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Hydraulic testing of ferritic material shall preferably be carried out using suitably
inhibited water, which permits an extended period between the start of testing and
drying of components. Alternatively, uninhibited water may be used but the permitted
period between the start of testing and drying of components is reduced.
Hydraulic testing of austellitic material shall preferably be carried out using
de-ionized water, chlorine c.ontent of water shall not exceet 5 ppm.
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Water Quality
The water shall be towns main supply free from oil and suspended mater. If this
water is to be inhibited, one of the inhibitors as specified below shall be added.
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Water shall be deionized water having a conductivity not greater than 1 micro
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water free from oil and suspended matter may be used.
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The period between the start of testing and drying a component shall not be longer
than 48 hours in case of inhibited water and 4 hours in case of uninhibited water.
Where difficulty may be experienced in draining and therefore' in achieving the
drying specified above, drying shall be accomplished in as short a time as is
practicable.
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4.4
Test Pressue
Except as provided in para 4.5, the hydrostatic test pressure at any point in a metalF
piping system shall be as follows:
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(a) Where the test pressure of piping attached to a vessel is the same as or less
that the test pressure for the vessel, the piping may be tested with the vessel
at the piping test pressure.
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(b) Where the test pressure of the piping exceeds the vessel test pressure, and it
is not considered practicable to isolate the piping from the vessel, the piping
and the vessel may be tested together at the vessel test pressure, provided the
owner approves and the vessel test pressure is not less than 77% of the piping
test pressure calculated in accordance with para 4.4(b).
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where traces of water cannot be tolerated or if these have been previously tested
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Pneumatic testing involves the hazard of released energy stored in compressed gas.
Particular care must therefore be taken to minimize'.the chance of brittle failure
during a pneumatic leak test. Test temperature is important in this regard and must
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be considered when the designer chooses the material of construction.
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A pressure relief device shall be provided, having a set pressure not higher than the
test pressure plus the lesser of 345 kPa (50 psi) or 10% of the test pressure.
Test Fluid
The gas used as test fluid, if not air, shall be nonflammableand nontoxic.
Test Pressure
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a) The test pressure shall be at least the lesser of 105 kPa (15 psi) gage, or ?C>%
or the design pressure.
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The pressure shall be gradually increased until a gage pressure the lesser of
one-half the test pressure or 170 kPa (25 pai) is attained, at which time a
preliminary check shall be made. Then the pressure shall be gradually
increased in steps until the test pressure is reached, Hie pressure being held
long enough at each step to equalize piping strains.
9.0
TEST RECORDS
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Records shall be made of each piping ~ystem during the testing, including:
a)
b)
c)
d)
e)
f)
Date of Test
Identification of the piping tested.
Test Method
Test Pressure and duration
Certification of results by examiner
Approval by the Inspector
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ES - 6007
ISSUE : JAN. 98
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
1 OF 4
ENGINEERING STANDARD
LEAK TESTING OF PROCESS PIPING
JAN.98
REV.
DATE
DKM\DAYTODAY\STANDARD\ES6007COVER.LWP
PREPARED
REVIEWED
APPROVED
ENGINEERING STANDARD
LEAK TESTING OF PROCESS PIPING
PDIL
ES : 6007
ISSUE : JAN.98
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 2
OF 4
1.0
SCOPE
1.1
The leak test is not a substitute for the pressure (strength) test. Leak-testing
shall be conducted for detection of leakage and to insure a tight and leak free
system for operation.
1.2
Leak-testing shall be carried out when specified in the piping specification and
generally shall include the following services:
a)
b)
c)
d)
e)
f)
g)
1.3
1.4
Before any leak-testing is performed, the piping shall have been cleaned and
inspected for clean liness. All lines which would be subjected to leak-testing
shall be blown out with dry, compressed air, prior to testing.
2.0
TEST METHOD
2.1
3.0
TEST PRESSURE
3.1
DKM/DAYTODAY\STANDARD\MECH\ES6007.LWP
PDIL
ENGINEERING STANDARD
LEAK TESTING OF PROCESS PIPING
ES : 6007
ISSUE : JAN.98
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 3
OF 4
3.2
4.0
TEST PROCEDURE
4.1
4.2
Halide Leak-detector
After estimating the capacity of the system, misture of Freon 12 (or equivalent)
and air shall be introduced into the piping with all ends closed, until the test
pressure is reached. Approximately one ounce of refrigerent for a every cubic
meter colume of piping shall be required. The general area then should be
tested for leaks by means of a General Electric type H-I leak detector set.
All joints, packing glands and seals shall be tested with the probe held about
15 mm from the surface being tested and at a rate of 15 mm per second. In
case, General Electric leak detectors are used the amount of refrigerent to be
used and the test procedure shall be in accordance with the suppliers
recommendations.
4.3
DKM/DAYTODAY\STANDARD\MECH\ES6007.LWP
ENGINEERING STANDARD
LEAK TESTING OF PROCESS PIPING
PDIL
ES : 6007
ISSUE : JAN.98
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 4
OF 4
After closing all open ends, the system shall be filled with air compressed to
an maintained at specified test pressure while under pressure, each joint,
welded or screwed, shall be coated with aprepared soap solution. Leakage will
be indicated by formation of soap bubbles. Masking tape shall be applied over
all flanged joints before applying the soap solution.
The composition of the soap solution shall be follows:
1 oz. Powder Soap
16 oz. Water
8 oz. Glycerine
4.4
Vacuum Test
Leak testing for sub atmospheric pressure system shall be conducted with the
Refrigerent or Ammonia Vapour at atmospheric conditions provided around
the joint in a suitable sponge rubber sealed casing and the system shall be
partially vacnated. The cacuum reached in the system shall be half the
operating vacuum but not less than 150 mm of water. Leaks would be
indicated at the exchauster discharge either by Halids detectors or by
burning Sulphur sticks or rags soaked in Hydrochloric Acid.
5.0
RETESTS
When a leak is detected, the same shall be marked, repaired and the test
shall be repeated until the system is free of leaks.
6.0
TEST RECORDS
Records shall be maintained for each piping system being subjected to leaktestisng. The records shall include:
a)
b)
c)
d)
e)
Date of test
Identification of the piping tested
Test method
Test pressure
Approval by the Inspector
DKM/DAYTODAY\STANDARD\MECH\ES6007.LWP
FEB. 78
ENGINEERING STANDARD
ES
6010
P.D.I.L.
pJl
BARODA
Performance
1.0
SCOPE
--
1.1
covers welding
This specification
operator performance qualification
1.2
Qualification
SHEET 1 OF
For Piping
procedure qualification
and welder and welding
for steels and Nickel alloys piping systems.
shall be conducted
in presence of POlL
Representatives.
1 3
Welding
technique
2.1
2.2
PROCEDURE
and SECTION IX of
QUALIFICATION
Scope of procedure qualification tests is to check whether with a given base material,
filler material and joint position, the welding PTQcedure can ensure the required characteristic for the joint concerned (for the various thicknesses to be welded). Therefore
the main elements which are involved
in the qualification
of a given procedure are
as follow" :
-
base material
filler material
joi nt position
thickness to be welded
welding
technique
material
separate qualilication
and parameters.
the following
groups
are
co:1sidered
is required:
A - Carbon steel
G - Carbon - Moly steel (0.5%
C - Cr-Mo steel with % Cr ,2
M)
,
:::;
2.3
ANSI-B-31.3
for every material not included in the above-mentiis also required for joints betwp.en dissimilar materials.
electorode
or
-'
wire (or
combination
thereof)
Separate
15
ENGINEERING STANDARD
p8d
ES
6010
PoDoLL.
Qualification
BA:'iODA.
:: 4 Procedure qualification
il
pipe
with
its uxis
horizontal
c - fixed
pipe
with
its axis
vertical
for position
The qualification
a deviation
tions
a qualification
not
morethan
is required
Usu,Jlly. qu"lification
main welding
OF 15
positions:
b - fixed
with
following
SHEET 2
"b"
is valid
also for
position
position
"a"
and also
for a pipe
"C",
"b"
and "c",
2,5
Each qualification
covers a given thinckness range, according to para 2,8,1 (where
11Cccssary. saparate test welds on more thickness will therefore be made). for auto!l1iJtic or semiautomatic
welding, a separate qualification
for the minimum size to
be Wdul::u may desired,
2.G
T(~5t
Technique
Weld
test
suitable
to the
thickness
,
range
for which
required (see
para 2.8,1). For arc welding,
size lessthap
less than 9.5 mm are generally not recommended.
th'e qualification
is
Filler
material, welding
pass
- current
- arc voltage ( for automatic welding only)
- welding
speed
size, trade
name and
( if used)
- number of passes
- flow rate and type of inert gas ( if used)
- type of protective
).
WIleS, as well
as type of flux
STANDARD
ENGINEERING
ES
6010
P .D.LL.
pJd
Qualification
BARODA
SHEET 3 OF 15
This record shall also show the data concerning preheating and heat treatment, if
illlY.
2.6.J
A recording
of heat treatment
( if any)
2.7.1
Tests to
be
made
for
procedure
).
qualification
the
specimens
are
otherwise,
the two
test welding
visual examination
x .rilY examination
tests
Where the pipe size does not allow to carry out all the test with the one test weld
the specimens srJdd be out from the second test welds.
2.7.3
10 mm and over:
visual examination
X-ray examination
tliVOreduced section tension tests
,.
Where thickness of test pipe is less than 19 mm, the two side bends may be replaced
by tWO face bends and two root bends, as per clause 2.7.2
2.7.4
Besides standard tests, the following ~hall be made for Cr-Mo steels:
- macro examination
Hardness
test;:;
2.7.6
Dye penetrant
tests shall
tests
~~
".
stainless steels
).
ENGINEERING STANDARD
p8d
ES 6010
P.D.I.L.
BAI10DA.
SHEET4 OF15
2.7.7
Besides standard
matic welding:
tests,'
the
- Charpy V-notch
impact test
- macro examination
at ambient
temperature
( if required)
Tension test
cases,
chardCltm::.tics
or semiauto-
further
(ferrite
special
tests may
percent, corrosion
be
required
to
determi nation of
assertain
pmticul()rs
,
28
2.8.1
Exter t of Procec'ure
Tests made on pipe
Qualification
with
thickness
given thickness
ranga
"S"
which
the procedure
type to be qualified.
(a)
and
diamater
rp, qu~lifY
either
upon "s"
to the following:
the
and
Manual shielded
matal arc welding or automatic
welding
inert -gas tUngesten-are welding or oxy-acetylene welding) :
procedure
1>. values,
in a
or upon
S::: 2s
When rp < 125 mm, S shall be < 19 mm.
(b)
2.8.2
"s"
depends
accordollg
welding or semiauto-
s.
When changes
of the
following
types are made with respect to the qualiii,;u proceprocedure qualification
shall usually be made.
or in the submJlged
are welding,
flux
composition
is changed.
another.
into position
not covered by
..
ENGINEERINGSTANDARD
JBl
P.D.I.L.
ES
6010
BARODA
Performance
SHEET 6 OF
For Piping
items:
- End preparation
- Piece alignment
- Welding variables
-
Preheating
temperature
WELDER
3.1
Qualification
3.1.1 Welder
PERFORMANCE
QUALIFICATION
Type
performane
perform
qualification
tests have the purpose to ascertain welder ability to
the required
characteristics,
using a given welding pro::edure
qualified)
and a given filler material, in given position, a given thickness.
welds
( previously
with
There shall be different welder Qualification types. depending upon the following factors:
- Welding process
- Filler material
- Thickness to be welded
- Welding position
3.1.2 For each welding process listed hereinafter
material
is subdivided
qualification
is normally
required (except when otherwise specified)~
For the use of
filler materials belonging to the same group, only one rate qualification may~ be made
for any of them (however, a separate
qualification
is required
for the electrodes
used with downward technique). Such groups are defined in the two following tables.
ELECTRODES
Group
. ',' ~
~; ,::'-;'
Coating
Type
1.
2.
High-cellulose
Low- hydrogen
3.
4.
5.
Low-hydrogen
Low-hydrogen
Neutral or high-titania
~omposition
of Weld Metal
Carbon or Carbon-Moly
15
ENGINEERING STANDARD
p8d
ES 6010
P.D.I.L.
BAHODA.
Qualification
SHEET 6 OF 15
specified,
- Qualification for Group 4 is valid also for Group 5 but not viceversa.
- A separate qualirication is required for evt::IY elt>I.:Llodetype not included in this
Table. Qualification for 7% Cr 9% Cr steel covers anyway Group 3.
WIRES
Group
11
12
13
Composition
of Deposited
Metal
Mo)
3.1.5 A welder qualified for filling on Cr-Mo steel (with low-hyd.rogen electrode) may be
LJllowedto perform filling with low-hydrogen electrodes of Group 2.
3.1.6 Each qualification covers a thickness
which the test weld has been made
in par. 34.1.
3.1.8 For gas metal-arc semiautomatic welding, a separate qualification can be required
for the minimum pipe size to be welded.
3.1.9 Separate test welds shall be made in the following welding positions:
Qualification for fixed pipe with its axis horizontal covers also rolled pipe, or pipe
with angular deviation not more than 15 degrees ficm the horizontal plane.
ENGINEERING
STANDARD
ES
P.D.LL.
fBl
BARaDA
3.2
Welding
Uucwtication
6010
SHEET 7 OF
Technique.
qualification
shall be
- Thickness suitable to the thickness range for which the qualification is requested
( in accordance
with para 3.4.1 ) and suitable size (for bend tests). As a rule
te5t welds will be performed on ON 150 size ( or over) with thickness>
5 mm
and/or ON 50 (or less) for thickness < 5 mm.
-
100 mm length
(after
bevelling)
3.2.3 The pipe sections to be welded shall be placed and fixed in the position for which
qualification is desired. They shall not be removed from such position before COmpletion of welding.
3.2.4 Filler material, welding equipment and technique
blJ sill.ilar to those used in the work.
(including
preheating if any)
shall
3.2.5 As i1 rule, a complete test weld (on the whole circumference, shall' be made for
each position or qualification type, unles otherwise specified for size greater than ON 200.
3.2.6 All test weld shall be marked
specimens are to be removed.
3.3
Tests to be made
qualification
3.3.1 According to the thickness of the pipe on which the test weld has been performed
iJnd to the wtJlding process used the following tests shall be done:
3.3.2 For oxy-acetylene
welding:
- Visual examination
- One face bend
- Three root bends
- X-ray examination ( if required)
For small size pipes, reduced with specimens may be used.
3.3.3 For metal are welding
Visual examination
- X-rt1Yexamination
- Two face bends
- Two root bends
on thicknes~,es below 10 mm :
15
ENGINEERING STANDARD
ES 6010
P.D.I.L.
{J8Ii
Qualification
BARODA.
of Welding
Performance
When pipe
required
Welder
SHEET 8
OF 15
thickness
is already qualified
visual examination
Procedure And
For Piping
by the Inspector).
may be enough.
on thicknesses
10 mm and over:
- Visual examination
- X-ray examination
- Four side bends
passes are not made with the same filler material or' with the
same welding process, two of the side, bends shall be replaced by two root bends.
For thicknesses
below 19 mm the side bends may be replaced' with face and root
bends ( as provided
in Par 3.3.3).
3,3.5 For metal arc welding on pipe with its axis vertical, instead of four bends tests as
per Par. 3.3.3 and 3.3.4, ~[only two of them made, provided that the root pass and
the filling passes are made with the same type of filler material.
33.6 Where the required X-ray examinations
are not practicable, it shall be replaced with
two bend load fractureJ[ tests on each test weld. In such case all, Dend tests shall
be made.
3,3.7 The presence of fish eyes is not a reason for test rejection. Therefore, in the case of
welding of carbon steel, it is advisable to hold the bend and,'fractur~ test specimens
at a temperature of 200 to 300C for not less than 8 hours; iil order to allow the
elimination of the diffusible hydrogen.
3,3,8 Where a welder fails in one or more tests, as a rule he 'shall carry out two further
similar test welds, on which
all the qualification
tests shall be made. Should 'same
results be still negative, the welder may undergo a new qualification examination only
after an adequate training,
Other tests (e. g. dye penetrant for Nickel alloys, impact tests for low-operatingtemperature piping)
can be required in particular cases, to be considered each
time
3,1]
separate
Iy.
Range of qualification
for we!der
performance.
3.4.1 The weld test made on pipe with thickness "5" qualifies the welder for a gIven ~hickne5s
range "S" which depends upon either the value of "5" or the type of welding
process, as follows:
a) Shielded
"
...
..'
,".,
.
r. -
s ::: s
5 mm ::: S ::: 25
S ~ 5 mm
< 5 mm
"'
-,
. ..
.' '..
STANDARD
ENGINEERING
p8d
ES 6010
P.D.I.L.
Qualification
BAkODA.
b) Oxy-acetylene
SHEET 9
OF 15
2.5 mm :S S :S s
S = s
changes
involving
passage
(upward or downward).
c) A change of base material, requiring a change of filler material from one to another
of the groups mentioned at par 3.1.3.
J.4 3 Renewal of qualification
<l) The welder
has not
C<lse it will be sufficient to repeat the qualification for one thickness , only, and thus
the whole thickness range of the preceding qualification will be, covered ).
b) The welder has left the Company where he was employed at time of qualification.
c) There are reasons
qualification.
4.0
TEST
PROCEDURE
'U
Operation
to question
AND
his ability
TECHNIQUE
sequence on testweld
4.1.1 Visual examination shall be made during and at the end of welding for preparation of
test sample for welding procedure and welder's performance qualification tests.
4.1.2 X-ray examination and if requiredt dye penetrant examination are performed. In particular cases X-ray examination is made after post-weld heat treatment.
'...1.3 Postvlield heat treatment,
to those followed during
where required,
the work.
is then
carried
out,
with procedure
similar
During such heat treatment, temperature recording over 300C shall be made, and
relevant recording chart shall be signed by POlL Inspector.
4 1.4 Specimens for the destructive tests as indicated for each case ( for the various qualification types ), shall then be removed. Such removal shall be made at the positions
as shown in PDIL : MT : 202.
~1I'o-'-.
"
, .. .
ENGINEERING
STANDARD
ES
P.D.I.L.
p8d
Qualification
BARODA
Each
the
specimen
shall be suitably
SHEET 10 OF
by
Inspector.
6010
results of tension,
impact
Test technique
is subjected
to a 180"
guided
bend
using
the equipment shown in PDS : MT : 201 and its convex surface is then examined.
In particular cases, where there is a difference of characteristic between base
metal and filler material, or between two different base metals, the specimen shall
be cut longitudinally
b) Root
to the weld.
Bend:
The specimen is shaped and sized as shown in PDS : MT : 200 and machined at
the face surface to the required thichness; at root surface, only weld reinforcement
is ground off flush with base metal.
If specimen
Corners shal,l be rounded. off. Specimen is subjected to 1800 guided bend with
root outwards, using equipment. as shown in PDS : MT : 201 and convex surface
is then examined. In particular cases, the sepecimen shall be cut longitudinally
;
c) Side Bend:
The specimen is shaped and sized as shown in PDS : MT : 200 machined on
both opposite sides corresponding to surfaces along which the weld was cut, and
weld reinforcements at face and root are gruond off flush with base metal. Corners shall be rounded off.
Specimen
described
is subjected
to 1800 bend along axis of weld, using the equipment
in PDS : MT : 201 and convex surface is then examined.
d) Reduced Section
Tension Test:
..1
15
ENGINEERING STANDARD
{J8d
P.D.I.L.
BARODA.
ES 6010
I
'
.'
SHEET 11 OF 15
Test:
The specimen is fractured by bending, so that onD notch is in tension and the
other is in compression (bend test equipment shown in PDS : MT : 201 may be used).
Practure surfaces are then examined.
'
f) Charpy U-Notch
Impact
Test:
The specimen is sized and shaped as shown in PDS: MT : 211 and notch cut,
in the weld zone.
For each test-weld a minimum of three specimens, or a ,nultiple of 1hree, is required
Specimen surfaces shall be obtained by machining.
'
Specimen is subjected to fracture at required temperature (within five seconds
from extraction from cold bath, if any) by Charpy type machine (pendulum type).
g) Charpy
V-Notch
Impact Test:
",' "
A cross section of the joi nt is properly polished and etched by suitable, e~chants,
according to the material concerned. The appearance of the etched 'surface OJ'sthen
examined.
"...
,.
",""'"..,"',',",
.",,<,,"-<'::""-~."'.:
ENGINE'ERIN,G:STANDA.R0
ES 6010
P.D.I.L.
pJl
BARODA
j) Chemical
Analysis:
Chemical analysis
exam nation.
4,2,2 Non-destructive
a) Visual
SHEET 12 OF 15
is made
on
metal
l)re as follows:
Examination:
penetration,
and dime-
examination:
c)
Examination:
Examination shall be performed on the whole test weld. Weld surface shall be
examined and any defects detected.
d) Brinell
Hardness:
Test shall be made after any heat treatment, on the w~ld metal, on the heat affeoted zone and on the base material.
Surface where test is performed shall be suitably flattened and polished,
e) Vickers
Hardness
( HV 30 )
Test shall be generally performed on the specimens prepared for macro examination
on weld metal, on heat affected zone, and on base metal, by suitable equipment,
after heat treatment ( if any).
4,3
Test
Result
Evaluation
for acceptance
Root
and
Side
of destructive
tests:
Bend:
After bending, on convex surface there shall be no open defects (caused by cracks
inclusions, blowholes etc.) exceeding 3 mm measured in any directions, excepted
those cracks occurring on the corners which are not caused by slage or other
internal defects,
b) Reduced
I'
'.
Section
~-~
'"
I.
Tension
':;,'
, :",
Test : .
,.:
i
,.:;:
..
,:.
:,."
.~,
":';
..
If rupture occurs on the weld, the tensile strength shall not bEt):lower::,than the
-'-'
..'
. ."
." ..,.';.,
"; "..'t".~~,r..."-:-~
,'...
p8d
P.D.I,L.
BARODA,
ENGINEERING STANDARD
ES 6010
SHEET 13 OF 15
specified tensile strength of the base metal (if m{lterials of different specified
tensile strength are used, the specified tensile strength of the weaker of the two
is considered). If .the specimen breaks in the base metal, the tensile strength shall
not be more that 5 per cent below the specified t<:lI"ile strength of bas metal.
c) Fracture
Test:
slag inclusions:
length:::; 3 mm
width $ 0.8 mm
U-Notch
Impact
none.
Test
The average of the values taken in 3 sets of tests, and at least two of such
values, shall be
not
"n". If this should not occur, and provided ~either the average nor more than "n",
two further sets of three specimens each (also taken from other similar testwelds)
will be allowed, e!l1Utne total average of all the values ,obtained' ( including those
of the first set of three tests)
shall be not lower than "m".
The values of "m" and"
thickness "a",
"a" (mm)
"m"
10
7.5
<5
n"
are
listed
below
,"n"
(kgm/sqcm)
(kgm/sqcm)
42
4.6
5.5
2.8
3.1
3.9
In particular cases, different values may be specified for "m" and "n",
e) Charpy
V-Notch
Impat
Test:
Wilat is spe(,ified for charpy U Notch Impect Test applies except the values "m"
and "n", which are listed below as a function of the spection thickness "a",
"a"
(mm)
"m"
"n"
(kgm/sqcm)
10
7.5
$5
3.5
3.9
4.6
(kgm/sqcm)
2
2.2
2,8
In particular cases, different values mdY bE: specified, ror "m" and "n".
,;
",
..
. .
oJ -,.
',.
", '. .. ~~
puJ
ENGINEERING STANDARD
ES 6010
P.D.I.L.
BARODA.
Qualification
f) All-Weld
Metal
Tension
SHEET 14 OF 15
Test..
The values shali be not lower than those specified for filler material considered.
g) Macro-Examination:
Macro examination shall show no cracks, in-complete fusion and penetration.
Welding passes shall show to be correctly located and penetrating each other.
h) Chemical
Analysis:
for acceptance
of
non-destructive
auto-
tests:
Examination:
The requirements specified in 3.3 and 3.2 of the concerned welding specification
shall be met with, as to penetration, undercutting, appearance and dimensions of
weld, surface defects.
b) X-ray
Examination:
by X-ray examination,
Examination:
examination
and Vickers
Brinell hardness
DOCUME=NTS
5.1
Documents
required
Documents
required
defects.
in pa~icular cases.
for procedure
qualificatinn
It shall be counter-signed
5.2
Hardness:
by the Representatives
for welder
or welding
operator
proformance
qualification.
5.2.1 Upon qualification, a Record strnilar to form QW-484 of ASME Code Section IX
(for welders or welding operat<?,rs,respectively) shall be prepared.
,.
'------
---
----
-----
ENGINEERINGSTANDARD
ES 6010
P .D.I.L.
pll
BARODA
Qualification
SHEET 15 OF 15
5,22 All qualification records of the welders belonging to a particular Employer and working
in the sarpe erection field shall be held in a special welder Register, to ba submitted
to the Rej,Jresentatives of POlL, until completion of welding work.
5.2.3 Each welder entrusted with field welding for prefabrication
have a special card with following information:
Name of welder
Stamp of welder
qualification applies
- Employer
- Field where the Card has been issued
Any restrictions
Signature of MCI Representative and date. The card shall have the welder photo,
or shall be kt:pt together with an indentity card with photo.
5.2.4 Both welders and welding operators shall always wear their own indentification card
and shall show same on request of the Representatives of PDIL.
'
POlL may not alloy at the construction field those welders or "'{elding operators found
without the identification card or with a card no correspondin'g to the type of welnieg
they are entrusted with.
6.0
REFERENCE
STANDARDS
PDS:MT212 : Standard
Tensile Specimens.
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JAN.'98
REV.
DATE
DKM\DA YTODA
FORiMPLEMENTATION
P-URPOSE
MKK.BKJ,APP,
MKD
PREPARED
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installation, testing and commissioning of all carbon steel, alloy steel stainless
steel, aluminium and aluminium alloy piping.
The piping shall be erected as shown on the purchasers drawings and in
accordance with the purchaser's specification and specific instructions issued
to the Contractor by the Owner at site.
OJ
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t:
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specified.
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SHEET 1 OF 7
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ES 6011
SCOPE
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ENGiNEERING STANDARD
GENERAL SPECIFICATiON
FOR
ERECTION OF PIPING
1.0
'E
'"
--":":":;~;,,,:~,,,--~~,~,<!,,,~,:~,,>~:.t,i";'>:"~',:~'-'
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/'
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radiography
2.0
2.1
Drawings:
and
other, non-destructive
tests
as
The drawings included with and made a part of this specification indicate
information available to-date. These drawings have been checked and
approved but are subject to modifiactions due to any change in equipment
purchases which are not yet finalised or due to some interferenceor for better
perform?lnceand economy.
I"
ENGINEERING 3TANDARD
GENERAL SPECIFICATION
PDIL
ES6011
FOR
ERECTION OF PIPING
SHEET 2 OF7
.
-i
is
Q.
(;
3.0
Reference
Following
0
"in
CI)
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Standard
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ES:2009
--
ES:2010
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Protection
ES:2401
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Procedure
ES:2404
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ES:6004
--
ES:6005
--
ES:6006
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ES:6007
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Indian Standards:
IS:554
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SUPPLY OF MATERIALS
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ES 6011
ENGINEERING STANDARD
GENERAL SPECIFICATION
FOR
ERECTION OF PIPING
POlL
ISSUE: JAN.'98
SHEET 3 OF 7
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4.2
If the contractor decides to do purl of fabrication work in his sllop to reduce cost
of fabrication arid to expedite completion of job it will be his responsibility to take
materials to his works and despatch to site.
4.3
4.4
4.5
The storage and protection of pipe and fittings after withdrawal from stores shall
be in accordance with ES:2009 and shall be the responsibility of the contractor.
In case any of them is damaged due to negligence on the part of contractor the
cost of replacement/rectification shall be borne by the contractor.
5.0
PRICE
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5.1
The price shall be quoted on a total lulllPsum basis for the complete scope of
work as enumeiated above based on the Purchaser's drawings and Bill of
Materials forming part of thi~ specification. The quantities indicated in the above
documents are preliminary and are subject to variations upto + 10%. A firm unit
price shall be quoted at the Contractors option based on the estimated
quantities for each category and the adjustment in the lumpsum price for the
total variations would be worked out on the basis of this unit price.
6.0
FABRICATION
6.1
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6.2
All steam Jackets for Piping as indicated in the drawings or isometrics shall be
fabricated and the fabrication shall be carried out in accordance with ES:6030.
6.3
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ES 6011
ENGINEERING STANDARD
GENERAL SPECIFICATION
FOR
ERECTION OF PIPING
POlL
.
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Safety valve installation & connected piping shall be,as per ES:6012.
6.5
Bending
6.4.1
Carbon steel shall be bent hot or cold. Alloy steel and stainless steel pipes shall
be bent cold. All bends in alloy steel piping shall be suitably heat - treated after
bending to result in hardness of 220 BHN maximum.
6.4.2
While bending the pipes, the pipes shall be packed with Sulphur free high
temperature silica and of adequate finness. Care should be taken to pack the
pipes by vibration using suitable mechanical or manual means.
6.4.3
Bending methods and equipment shall be such as to ensure bends free from
wrinkles, bulges and kinks. Minor bulges & wrinkles may be removed by means
of local heating and use of hanger or flatters.
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6.4.5
All hot bends shall be cleaned by means of rotary cleaner, shot blasting or
Pickling as approved.
6.5
T.hreading
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6.5.2
Threads shall be concentric with outside of pipe and shall conform to 18:554
unless, otherwise specified in the drawing.
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7.0
SCRE\tVED JOINTS
7.1
For the screwed joints on pipe materials like stainless steel to stainless steel,
alloy steel to alloy steel and aluminium to aluminium no pipe joint compound
shall be used. Such ScrewedJoints, having an operating temperature of 200C
or less, shall be madeup using Teflon thr~ad seal tape.
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Threaded carbon steel connections shall be seal welded if the line is carrying
the following:
(a)
(b)
Highly corrosivematerial.
(c)
Hydrogen
(d)
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ENGINEERING STANDARD
GENERAL SPECIFICATION
FOR
ERECTION OF PIPiNG
POlL
ES 6011
ISSUE: JAN. '98
SHEET 5 OF 7
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For other pipe materials like carbon steel to carbon steel or brass to brass etc. a
pipe joint compound suitable for specified service'shall be used, except whenonly welding or brazing is specified. Some of the recommended compounds
are:
Cooling water above ground
--
Compressed Air
Demineralizer water
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8.2
8.3
Where cold springing for piping is specified on the drawings, the expansion
loop for which it is specified shall be erected with metal fillers of the specified
thickness inserted between the expansion element and connected piping. All
connected piping and all pipe supports anchors and hangers for the expansion
element and connected piping shall be, erected and adjusted with the metal
fillers in place. The metal fillers shall be then be removed and joints between
the expansion elements and connected piping shall be completed. It is
extremely important to ensureJthat the fillers are held firmly during erection and
are not removed unit! erections i~ complete between anchor points. Care shall
be taken while placing or removing the filler pieces to avoid injury to the metal
faces of the joint.
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Except where cold springing is called for on the drawing, all assembled piping
shall be installed in place without springing or forcing and so as to clear all
opeing and equipment. Excessive cutting or otherwise weakening of structural
members to facilitate installation of pipes shall not be permitted. Before cutting
qny structural members, permission of POlL/Client shall be obtained.
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9.0
SUPPORTS
9.1
When supporting" pipe, subject to thermal expansion, hanger rods shall be set
at slight angle so that when supported pipe expands rods will be plumb.
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ES 6011
ENGINEERING STANDARD
GENERAL SPECIFICATION
FOR
ERECTION OF PIPING
PDIL
.
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10.0
VALVES
10.1
Valves should be lifted by the body or the lugs on the bonnet. They should not be handled by the hand wheel or the actuator or even dragged along the
ground.
10.2
The line and the valve should be thoroughly cleaned. Care shall be taken so
that no chips or weld drops are left in order to avoid seat damage. Control
Valve of welding ends should be welded after hydraulic test, cleaning and
blowing of the iine. Venturi type orifice shall also be weleled in position only
after blowing.
10.3
The valve flanges shall be parallel as the valves can not correct any
discontinuity. Contractor shall check the face to face dimensions of valves
before doing pre fabrication work, ~imensions shown in isometric have to be
checked at site,
10.4
Globe, Check and Gate valves with bypass or pressure relief system should be
installed according to the arrow on the body.
10.5
The valves should t:e installed in a vertical position wherever possible, having
the hand wheel 8~ top. This particularly concerns large dia gate valves.
Actuators can not operate in all positions.
11.0
EXPANSION JOINTS
11.1
Expansion joints shall be the last unit installed' in any piping system. The
installation
of
expansion
joints
shall
be
in
accordance
with
POlL/Manufacturer's instructions.
11.2
Before installation of any expansion joints all piping shall be accurately aligned
without restraint and shall be properly anchored and guided. Expansion joints
shall be cleaned with a rag or better with compressed air blow so that no
foreign matter shouid remain in bellow corrugations to interfere with the proper
flexing of the bellows.
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ES 6011
ENGINEERING STANDARD
GENERAL SPECIFICATION
FOR
ERECTION OF PIPING
PDIL
7 OF 7
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11.5
It is absolutely forbidden to sling expansion joints by means of the rods, tie bars
angles, shipping expeditents and of course on the bellow corrugations and
external 'Shrouds'. All expansion joints must be alinged on the end pipes orflanges or on the middle pipe. An extension joint must be handled with care to
prevent any shock, denting or welding shot and spatters.
11.6
During welding of expansion bellow joints, care shall be taken to ensure that
lead earth cable is not placed on the expansion joints. Any arc weld shot or
spatter shall be avoided as it may lead to leak in corrugations.
11.7
Space bars supplied by the manufacture for shipping purpose shall not be
adjusted or removed from expansion joints until after joints are in place and/or
until the line is tested. Spacer bars must be removed before the line is put in
service.
12.0
CLEANING
12.1
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Pickling and passivating of stainless steel pipe. after we.lding shall be as pe.r
ES:6008. In case of pipe welds with root run/complete made. with TIG/MIG
welding, no pickling shall be done but the lines shall be cle.aned as per ES:2404.
12.2.1
All weld joints of S.S.Pipe shall be. pickled/dressed up by grinding from outside.
13.0
TESTING
13.1
All installed piping shall be tested either by pressure testing or by leak te.sting in
accordance with the Purchaser's specifications ES:6006 and the pressure
would be in accordance with the schedule of test pressures.
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ES : 6101
ENGINEERING STANDARD
PDIL
ISSUE. : APR. 99
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 1 OF 5
1.0
GENERAL
1.1
Scope : This specification defines the responsibility of the supplier and covers
supplementary requirements relating to manufacturing, fabrication, inspection,
testing, painting, packing and despatch etc. This specification shall be read in
conjunction with relevant codes and enquiry documents. The vendor must
contact PDIL for clarification. As a general rule the most stringent requirement
shall govern and PDILs option shall be binding.
1.2
For pipes of NB > 2 and thk. > 2.9 mm, the ends shall be beveled as per
ANSI B 16.25.
1.3
1.4
1.5
1.6
1.7
The quantities mentioned are tentative, may vary + 25% and will be decided
at the time of placement of order. The price shall be firm for these variation.
2.0
2.1
2.2
The price shall be quoted on the zerox copy of the same sheet of the bill of
material attached with the enquiry specification and any deviation from the
required specification shall be marked therein. Prices typed on other format
shall not be considered for evaluation and rejected without any reference.
2.3
Any deviations from the clause stipulated, in the codes and other enquiry
documents shall be clearly mentioned in a separate Deviation Listwith
proper ref.no. In the absence of any such indications, it shall be assumed
that the offer complies with all the requirements in totality and such
assumptions shall be strictly binding on the supplier.
2.4
All testing charges shall be included in individual prices of the items. If third
party inspection charges are not indicated, it shall be assumed that it is
included in the offer. If third party inspection charges are extra, it shall be
indicated as percentage basis of individual item. In no case third party
inspection charges shall be indicated as lumpsum amount.
ES : 6101
ENGINEERING STANDARD
PDIL
ISSUE. : APR. 99
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 2 OF 5
3.0
MATERIAL
3.1
3.2
For pipes to A 312 TP 316L + G510 (CR.UR 510), ferrite content shall be
0.6% max.
3.3
4.0
TESTING
4.1
In case of seamless & welded pipes, parent material including weld and heat
effected zone for low temperature service shall be impact tested (on charpy v
notch) at the lowest design temperature in accordance with requirements of
code/ specification.
4.2
Intergrannular corrosion test shall be carried out on urea grade S.S. pipes to
ASTM A 312 TP 316L + G510 (CR.UR.510) on parent material, welds and
heat affected zone as per Snam Progettis Specn. G 510 (CR.UR.510), Rev.1.
4.3
Hydrostatic test shall be carried out on each random length of pipe as per
ASTM A 530 for pipes to ASTM specification, as per API 5L for pipes to API
5L specification, as per IS:1239 for pipes to IS:1239 and as per I.B.R.
specification for pipes under IBR.
4.4
Transverse tension test shall be carried out on pipes of nominal size 8 and
above and thickness of Sch.120 and above as per supplementary
requirements of respective standards.
4.5
Check analysis shall be carried out as per ASTM-A-530. for pipes as per
ASTM-A-312 and pipe size > 8 and thickness > Sch 120, CHECK analysis
shall also be carried out as per supplementary requirement S 1 of
ASTM-A-312.
4.6
For seamless pipes, each length of pipe with following specifications shall be
ultrasonically tested as per ASTM E 213 or ASTM A 388.
(a) Size upto 4 inches and Sch > 120
(b) Size > 5 inches and thk. > 12 mm.
Any defects producing signal greater than the appropriate reference groove
shall be unacceptable. The allowable defect shall be longitudinal flat bottom
groove on the outside or inside surface of the pipes and length not greater
than 25 mm, width not greater than 1.6 mm and depth not greater than the
smaller of 1 mm or 5% of the wall thickness.
5.0
INSPECTION
ENGINEERING STANDARD
PDIL
ISSUE. : APR. 99
ES : 6101
SHEET 3 OF 5
5.1
5.2
5.3
The inspecting authority shall be provided free access at all possible times to
those parts of suppliers work engaged in production and testing of materials
ordered.
5.4
The inspecting authority shall have the right to select random samples for
check test and reject materials, if samples furnished as above and tested as
per the specifications fail to meet the requirement specified.
5.5
All the items shall be inspected and tested in the presence of one or more
representatives of the purchaser during various stages of manufacturing
starting from identification of raw material up to completion. Material shall be
considered acceptable for despatch only after final certificate of acceptance
is issued by the Inspector.
5.6
6.0
DOCUMENTATION
6.1
The pipe shall be supplied with 8 copies of the mill test certificates indicating
the following and duly signed by the inspecting authority alongwith supply of
materials. In addition 4 copies shall be sent to PDIL.
a) Purchase order no.
b) Material specification and grade
c) Size and sch.no./thickness
d) Quantity
e) Heat and lot No.
f) Results of Chemical analysis
g) Mechanical test results (as per applicable clause)
h) Hydrostatic test results
i) Non-destructive test results (as per applicable clause)
6.2
Pipes under IBR shall be supplied with 8 copies of IBR certificates in form
IIIA duly signed by inspecting authority alongwith supply of materials. In
addition to above 4 copies of these certificates shall be sent to PDIL.
7.0
MARKING
7.1
ES : 6101
ENGINEERING STANDARD
PDIL
ISSUE. : APR. 99
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 4 OF 5
For all pipes of size 2 and above, marking shall be done by paint stenciling
using a weather resistant paint which has a guaranteed life time against rust
and moderate handling for not less than 3 years. If necessary the surface
shall be sand blasted to SA 2.5 according to ISO 55900 and primed before
marking is applied.
7.3
7.4
For pipe equal to size 1 inch or less, marking shall be done on pipe or by
die stamping on a metal tag fixed to the pipe by compression method.
7.5
In addition each length of pipe shall be given a 20 mm wide colour code strip
for the entire length. according to colour coding of pipe material as per sheet
5 of this standard.
7.6
For pipes covered under IBR inspection identification mark IBR shall be
stamped at both ends inside or outside of each random length of pipe.
Additional red colour strip of 20 mm width shall be marked for the entire
length of pipe.
7.7
Part no. appearing against each item of bill of material shall be marked on
both ends of each random length of pipe by paint stenciling and should be
able to withstand sea transport, handling and storage.
8.0
8.1
8.2
All ends shall be capped or plugged. One coat of approved anti rust paint
shall be applied on the surface of the pipe except s.s.pipes.
8.3
Pipes shall be adequately protected from both inside and outside to avoid
mechanical damage during transit and storage. For transportation overseas,
protection and packing shall be adequate to prevent damage from sea
atmosphere.
9.0
GUARANTEE
9.1
SL.NO.
MATERIAL
PIPING STANDARD
COLOUR
1.
C.S.
API 5L GR.B
Yellow
2.
C.S.
3.
C.S.
ASTM-A-106 GR.B
ASTM-A-672
Blue
4.
C.S.
DKM\DAYTODAY\STANDARD\MECH\ES6101.LWP
ES : 6101
ENGINEERING STANDARD
PDIL
ISSUE. : APR. 99
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
SHEET 5 OF 5
5.
L.T.C.S.
A-333 GR.1
A-671 GR.CC-60
Red
6.
Mo
A-335 GR.P-1
Green
7.
Mo
8.
1 Cr.
Mo
A-335 GR.P-11
Lilac
9.
1 Cr.
Mo
10.
2 Cr.
1 Mo
A-335 GR.P-22
Brown
11.
2 Cr.
1 Mo
12.
S.S. 304
A-312 GR.TP-304
A-358 GR.TP-304
White
13.
S.S.304L
A-312 GR.TP-304L
Slate
14.
S.S. 321
A-312 GR.TP-321
Alluminium
15.
S.S. 347
A-312 TP-347H
Grey
16.
S.S.316
A-312 GR.TP-316
Black
17.
S.S.316L
A-312 GR.TP-316L
A-358 GR.TP-316L
Red
18.
S.S.316L
+ G 510
A-312 GR.TP-316L
+ 510
DKM\DAYTODAY\STANDARD\MECH\ES6101.LWP
ES : 6606
FEB'99
DOCUMENT NO
ISSUE
SHEET 1 OF 8
ENGINEERING STANDARD
CASING INSULATORS AND END SEALS
1
0
REV
29.08.2008
FEB'99
REV DATE
FEB'99
EFF
DATE
Converted in MS WORD
FOR ISSUE
PURPOSE
PCC
PREPD
REVWD
HSW
APPD
rights reseved
ENGINEERING STANDARD
CASING INSULATORS AND END SEALS
ES : 6606
FEB'99
DOCUMENT NO
ISSUE
SHEET
2 OF 8
CONTENTS
SECTIONS
PART - I
PAGE NUMBER
CASING INSULATORS
1.0 SCOPE
2.0 FUNCTION
3.0 DESIGN
4.0 MATERIAL
5.0 INSPECTION AND TESTING
PART - II
CASING END-SEALS
1.0 SCOPE
2.0 FUNCTION
3.0 DESIGN
4.0 MATERIAL
5.0 INSPECTION AND TESTING
PART-III
SUPPLEMENTARY REQUIREMENTS
NOTES:
This document shall be used with relevant information contained in the documents
listed below ( in order of Priority).
Letter for invitation of bid or succeeding official confirmed order.
This document.
3. Codes and Standards referred in the above mentioned documents and in this
document.
FORM NO 02-0000 .0021F2 REVI
E5-66D6
ENGINEERING STANDARD
ES : 6606
FEB 99
DOCUMENT NO
ISSUE
SHEET 3 OF 8
SCOPE
This specification covers the minimum requirements of design, material,
manufacture and supply of casing, insulators intended to be used for cased
pipeline crossings.
2.0
FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing pipe
and electrically isolate the carrier pipe from the casing pipe at the cased crossings.
The casing insulators shall :
Resist cold flow and will not soften at design temperature.
Resist corrosion.
Resist mechanical damage while being pulled into the casing.
Have high electrical insulating value and low water absorption, thus
preventing leakage and maintain electrical isolation between carrier and
casing pipes.
Have high compressive strength in order to assure a permanent support to
the carrier pipe.
3.0
DESIGN
The arrangement of insulator shall be generally in accordance with Figure in sheet
8. It shall be made in segments duly held together with cadmium plated bolts and
nuts, to be supplied with casing insulators.
The number of segments shall be two for pipe diameters upto 12" (generally). For
larger diameters, the number of segments may be more than two, but their number
shall be kept minimum.
The skid height shall be such that it is slightly less than the value obtained by
following formula
MATERIAL
Casing insulators shall be made of injection moulded high density polyethylene or
other material equivalent or superior as approved and shall meet the following
specifications :
ENGINEERING STANDARD
CASING INSULATORS AND END SEALS
Property
5.0
Value
ES : 6606
FEB 99
DOCUMENT NO
ISSUE
SHEET 4 OF 8
Dielectric Strength
450-500 Volts/Mil
D-149
Compressive strength
3200 psi
D-695
Tensile strength
3100-5000 pai
D-638.D-651
Impact strength
D-256
Water Absorption
0.01%
D-570
4p.
41
ENGINEERING STANDARD
/LA
ES : 6606
FEB ' 99
DOCUMENT NO
ISSUE
SHEET 5 OF 8
SCOPE
This specification covers the minimum requirements of design, material,
manufacture and supply of casing end seals insulators intended to be used for
cased pipeline crossings.
2.0
FUNCTION
Casing end seals are intended to be used for sealing the annular space between
casing pipe and carrier pipe at casing ends so as to prevent ingress of moisture
and water.
3.0
DESIGN
The seals shall be suitable for the casing and carrier pipe diameters as applicable
for each case.
The casing end-seal shall be flexible to cater for the expansion and contractor of
carrier and casing pipes and shall be able to tolerate both angular and concentric
misalignment of casing pipe without loss of sealing efficiency.
The design of the casing end-seals shall permit easy installation of the seal to the
cased pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated life of
the buried pipeline.
Manufacturer shall obtain prior approval from Owner / Consultant on casing end
seals design / drawings.
4.0
MATERIAL
The casing end-seals shall be made of heat shrink high density radiation cross
linked polyethylene with an adhesive having a melt point suitable for the pipeline
service temperature and ambient temperatures foreseen during construction. Endseals material shall be resistance to heat, cold vibration, impact ,abrasion,
corrosive fluids, disbonding, organic and bio-deterioration. Manufacturer shall
confirm compatibility of end seals with carrier pipe coating.
Casing end seals shall meet following minimum property requirements :
ENGINEERING STANDARD
CASING INSULATORS AND END SEALS
Property
Minimum Value
ES : 6606
FEB99
DOCUMENT NO
ISSUE
SHEET
OF
Test Method
2200 psi
ASTM D-638
Ultimate Elongation
400%
ASTM D-638
Heat Shock
No visual cracks
ASTM D-2671
flow or drips
(at 225C,4 hrs)
Adhesive
Ring and Ball softening
90C
ASTM E-28
60 c C-25 pai
ASTM D-1002
point
Lap Shear
5 pli
(10 inch/min.)
ASTM D-1000
ENGINEERING STANDARD
ES : 6606
FEB'99
DOCUMENT NO
SHEET
ISSUE
OF
The manufacturer shall replace, at no extra cost. any material not conforming to
the material and performance requirements of this specification.
2.0
3.0
Manufacturer shall submit all the documents. test reports, records and other
information in six copies to the OWNER for record after approval as per clause
2.0 above.
ENGINEERING STANDARD
1,4s.
PDIL
FEB99
ES : 6606
DOCUMENT NO
ISSUE
SHEET 8 OF 8
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ENGINEERING STANDARD
PDIL
ISSUE: JAN.'98
UNDERGROUND PIPING
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SHEET 1 OF 15
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SCOPE
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2.0
REFERENCE STANDARDS
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Pipe fittings and valves upto size 6'/ shall be stored indoors.
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Pipe fittings and valves above size 6" may be stored outside
on wooden
sleepers on firm and well drained ground. Fittings shall be stacked such that
ingress of rain water is avoided and are in self draining position.
-1.1.5
The valves shall be stored in closed position except those with non metallic
seats (for instance butterfly valves).
J.I.6
Gate valves shall be stored in upright position while butterfly valves shall be
kept with fiange facing resting on wooden sleepers. All valves shall be
covered with tarpulin/polythene sheets.
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ES. 6018
ISSUE:JAN.'9~
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SHEET 2 OF 1~
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Valves shaH be lifted by slinging around the- body or lifting lugs provided on
the body. Valves shall not be handled from hand wheels/actuators and also
shall not be dragged.
a.
4.2
Handling
4.2.1
Pipes/pipe fittings and valves shall not be allowed to drop or strike any
objects which shall damage the same.
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4.2.2
While handling pipes and fittings, care shall be exercised to avoid distortion,
flattening, denting, scoring or any other form of damage-.
!-
4.2.3
To the extent feasible, mechanical lifting tools and tackles shall be used for
handling pipes to avoid any scoring/scratching.
-+.2.4
4.2.5
4.2.0
In stringing pipe along the right of way, gaps shall be left between adjacent
length of pipes at regular intervals and at well defined places to permit free
passage of personnel or vehicle during the time interval between stringing
-and other construction operations.
5.0
SPECIFICATION
5.1
Layout of the trenches including slope shall conform to piping layout drawings.
5.2
The cross section of trer{ches shall conform to Fig.1. The depth of the trench
at certain locations may have to be increased in consultation with POlL.
5.3
Excavation shall be carried out with conventional tools and machinery. The
excavation in rocky areas shall be carried out by controlled blasitng and/or
5.4
5.5
Soil removed during excavation shall be properly stacked and shall be used
for back filling, if it meets the requirements laid down in this standard for back
filling material.
5.6
Finished trench shall be free of rocks, hard clods, roots and/or other debris
which would damage the coating, when the pipe is lowered into the trench.
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AND CONSTRUCTION
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ENGINEERING
ES 6018
STANDARD
ISSUE: JAN.'98
POlL
UNDERGROUND PIPING
SHEET 3 OF 15
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After excavation, bed depth of 75 mm below the bottom of the pipe as shown
in Fig.1 shall be ensured.
5.S
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Clearance between the pipe and any other underground structure shall be
provided as indicated below, clearance between two adjacent pipes shall also
be as indicated below and decided considering the higher size pipe.
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Where drain is encountered, the trench shall be dug so that the pipe line may
be laid over or under such drain with a minimum clearance of 100 mm and to
such depths as may be required due to site conditions. When any drain is
.damaged, it shall be repaired immediately (See Fig.6).
The pipe line may pass through deep washes and creeks where supports shall
be provided in consultation with POll. The controlling factors will be length of
span, conditions of banks and hazards of leaving the line exposed. Maximum
unsupported span for various sizes are shown in Table-1. It shall be checked
that the combined stress due to internal pressure and external loads are within
permissible limits.
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in inches
Span in Metre
6
8
10
12
14
15
16
18
19
19
TABLE - 1
Pipe Size
Span in Metre
in Inches
16
18
20
22
24
21
24
24
25
25
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ENGINEERING
ISSUE:JAN.'98
POlL
1
-
The crossings at railway tracks and roads shall be in accordance with the
requirements of Railways or local Governament authorities./ Pipe casing or
other suitable arrangement like culverts etc. shall be provided at crossing of
roads, railway tracks, canals etc. as indicated in the drawings.
5.14
In all cases where trench has been cut across public or private roads and back
filling of the trench is not completed, temporary bridge work of full width of
road and of adequate strength shall be installed to ensure safety of traffic.
5.15
5. t (j
0.0
DEWATERING
O. I
0.2
. The trenches shall be made free of water while preparing the bed, laying of
pipes, backfilling and welding of field joints.
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LAYING OF PIPE
7.1
Laying of pipes in the trench shall be started only after the layout, depth and
slope of the trench have been approved by POlL.
7.2
Pipes shall be visually examined to ensure that the internal surface of the pipe
is clean. No earth or rock shall remain inside the pipe. The weld preparation
and adjacent pipe shall be free from dust, scale, paint and foreign material for
a distance of 2T + 50 mm where T is the thickness of the pipe.
7.3
The pipes shall be visually examined for any damage to the protective /
coating. In case any damage is observed the same shall be further examined
by spark testing to establish the extent of damage. The damaged area shall
be repaired to the satisfaction of POlL.
7.4
The open ends of sections of laid pipe shall be covered with minimum 3 mm
thk. steel plates to prevent the ingress of water, skids, animals or other
material which would interfere with the final cleaning of the pipe.
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SHEET4 OF 15
5.13
II ~2
PIPING
Where spans are greater length than those indicated in Tab!e-1, intermediate
supports shall be provided. However, in no case the unsupported length of
pipe shall be more than that indicated in Table-1.
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UNDERGROUND
5.12
ES 6018
STANDARD
The covers shall be securely attached to the pipe and shall not be removed
until the pipes are to be joined by welding.
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ENGlNEERING STANDARD
ISSUE:JAN.'98
POlL
7.6
Concrete anchor blocks shall be provided at all turning points for pipe sizes 8"
and above to absorb water hammer and pipe vibrations.
7.7
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The interior surface of the casing pipe must be free of rocks, dirts, clods or
other material which could damage the coating on the carrier pipe.
8.3
Casing shall be installed in accordance with figures 2 & 3 and shall meet the
requirements of Railway and local Government authorities.
SA
S.5
8.6
8,7
As soon as the casing is in place, the vent pipes shall be installed, the insid~
of the casing cleaned out and both ends capped.
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All rules and regulations laid down by railway and or other related Government
authorities shall be complied with while laying the pipe through rail/road
crossing.
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ES 6018
with
The area shall be cleaned up before moving away from the work site.
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ENGiNEERiNG STANDARD
ES 6018
ISSUE: JAN.'98
POlL
UNDERGROUND PIPING
SHEET 6 OF 15
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Alignment and welding set up of pipe joints shall be as per ASME B 31.3 and
shall be inspectecfby POlL before starting the welding.
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IO.I
The pipe line shall be, section by section, thoroughly cleaned by manual
means/compressed air/mechanical means. such as pigging/water as may be
permitted.
10.2
10.)
10.4
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11.0
HYDRAULIC TESTING
1\.1
The procedure for Hydraulic testing shall be iri, accordance with ES:6006
except that the specified test pressure shall be maintained on the line for a
period of one hour or time taken for inspection whichever is more and no drop
in pressure should occur. It is pressumed that all field joints are exposed for
visual inspection during hydraulic test.
11.2
113
In case, due to site conditions, Hydraulic testing of the complete system is not
feasible, the field joints in trenches shall be 100% radiographed.
12.0
E
D.
12.1
Back filling of the trench shall be started after inspection and approval of POlL.
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Before pipe is laid in the trench, sub-grade shall be made by back filling with
approved material for a depth of 75 mm from the bottom of the pipe and /
compaced by ramming/tamping.
.
12.3
All trenctJes shall be back-filled by hand from bottom of the trench upto 300
mm above the top of the pipe with back-fill material free from cinder, ashes,
refuse, vegetable or organic material, boulders, rocks, stones or other such
material which may damage the protective coating of the pipe. The back filling
shall be carried out in layers of 75 mm and thoroughly compacted by tamping.
Back-fill material shall be deposited in the trench for its full width. The back fill
material may be excavated earth, river sand, fine stone dust, sandy soil, etc. In
case, adequate quantity of excavated earth is not available, back-fill material
shall be hauled from other places by the contractor.
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STJrnUARD
ISSUE:
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SHEET 7 OF 15
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12.4
From 300 mm above the top of the pipe and upto grade level, material
containing boulders upto 80 mm in their largest dimension may be used. The
back-fill material may be filled by hand or by other approved mechanical
methods and shall be thoroughly compacted.
12.5
While back-filling and compacting, care shall be taken to avoid any injury to the
pipe and the protective coating.
12.0
12.7
The back-fill above the grade level shall be completed as indicated in FigA & 5
as applicable.
12.8
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MISCELLANEOUS
. The pipes and its branches emerging above the ground level shall be blanked
with M.S. blanks fillet welded to them. These blanks shall be removed only at
the time of connecting these lines to above ground piping.
13.2
The elevation of projected portion shall be as per piping drawing and shall be
kept free from any protective coating for a distance of 150 mm from top
elevation.
14.0
In case of cooling water lines, if it is difficult to drain out the water and dry out
the line completely, the test'water shall be allowed to remain in the header after
adding the inhibitor like hexametaphosphate.
15.0
Valve pits shall be constructed as per drawing and construction shall be such
as to prevent ingress of sub-soil water.
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DEVIATIONS
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Record of deviation/alteration
by the Contractor.
16.2
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ENGiNEERiNG STANDARD
ISSUE: JAN.'98
POlL
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UNDERGROUND
PIPING
SHEET 8 OF 15
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17.0
MEASUREMENTS
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The measurements shall be along centre line of piping system from end
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reducers, instrument tappings etc., but shall exclude such items as per
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ES 6018
STANDARD
ISSUE:JAN.'98
POlL
UNDERGROUND
PIPING
SHEET 9 OF 15
GROUND LEVEL
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N1
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3
4
700
700
1100
1100
225
225 .
300
300
700
1100
275
300
800
1200
300
300
10
12
14
16
18
.20
24
60
32
36
40
44
48
56
64
72
80
800
800
800
900
900
900
1000
1000
1100
1100
1200
1200
1300
1400
1500
1600
1700
1200
1200
1200
1300
1300
1300
1400
1400
. 1500
15d'0
325
350
375
375.
400
425
450
500
550
600
325
350
375
375
400
425
450
500
550
600
1600
675
675
. 1600
1700
1800
1900
2000
2100
750
800
900
1000
1100
1200
750
800
900
1000
1100
1200
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NORMAL
EXCAVATION
ROCK
EXCAVATION
NOTE:
1.
2.
3.
4.
5.
ES 6018
ENGiNEERiNG STANDARD
ISSUE: JAN.'98
UNDERGROUND PIPING
PDIL
.'
I SHEET 10 OF 15
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5 m max. spacing
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2.
In refilling the trench excavated for the pipe line, adjacent to road and across I
roads where trenching is permitted. the trench shall be promptly back filled in a
proper and workman like manner.
3.
4.
5.
Vent pipes shall be provided only in case of gases and volatile liquids such
as Ammonia. Naphtha etc.
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ENGINEERiNG 5TANDARD
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SHEET 11 OF 15
Rail Road
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Pipe line shall not be laid under rail road tracks nearer than 2 m from any rail
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3.
The trench on each side of the track shall be promptly refilled in a proper and
workman like manner.
4.
5.
6.
7.
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Vent pipes shall be provided only in case of gases and volatile liquids
such as Ammonia. Naphtha etc.
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ES 6.018
ISSUE:JAN.'98
UNDERGROUND
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ANNEXURE-1
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ENGINEERING
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STANDARD
6!J18
ISSUE:JAN.'98
UNDERGROUND
PDIL
PIPING
SHEET14 OF 15
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For safe burried pipe. above three conditions (under Clause 5.1) should be
satisfied.
Reference - Hand book of valves, piping and pipelines (book) by RH. Warring
(Gulf Publishing Campa my,Book Divn.)
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ENGINEERING
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STANDARD
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SHEET 15 OF 15
FOR U.G.PIPING
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PIPE SUPPORTS
STANDARD TYPES AND APPLICATIONS
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1 OF 13
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GENERAL
1.1
This standard lays "down guidelines for the selection and application of pipe
supports and covers standard types and installation. The modification of the
standard types of piping supports described in this standard may be made only in
exceptional cases.
2.0
GENERAL REQUIREMENTS
2.1
The supporting systems shall provide for and control the free or intended
movement of the piping including its movement in relation to that of connected
equipment. Vibration in the pipe shall be taken care of while deciding supports.
2.2
A careful study shall be made of the piping layout in relation to the surrounding
structure, adjacent piping and equipment before selecting the type of support to
be used at each supporting point. Maximum utilisation of the existing structurees
shall be made for supports.
2.3
Supports shall be selected to withstand all static and dynamic condition of loading
to which the piping and associated equipment may be subjected.
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Seismic Load
The criteria for calculating maximum spacing for horizontal pipes shall be as
indicated in Tables 1 & 2.
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3.0
MATERIAL
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PIPE SUPPORTS
STANDARD TYPES AND APPLICATIONS
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4.0
DIMENSIONAL REQUIREMENTS
4.1
Hangers and supports shall be dimensionally compatible with the outside diameter
of pipe or if specified the outside diameter of the insulation.
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Hangers for the suspension of NPS 2// and larger pipe shall be capable of
adequate vertical adjustment.
5.0
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5.1
The selection of hangers and supports shall be made to provide the piping system
with the degree of control that its operating and design' characteristics require.
The simplest assembly of components that fulfills this requirement shall be most
desirable.
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Piping supports for pipe lines at temperatures above 500oC are critical and shall
be decided more carefully considering piping layout, flexibility and the equipment
to which the piping is connected.
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PIPE SUPPORTS
STANDARDTYPES ANDAPPLICATIONS
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PIPE SUPPORTS
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Supports
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Resting
May be used
between
guides,
or other
supports
Guide
TO be used
for horizontal pipes only. where the lateral
movement
of the
pipe is to be prevented.
l$t
Maxm.Guide spacing
NPS 1""'2"-6m,2
1/2"",5"-9m,6"",10"-12m,12"",14"-15m,
18'~ 24" -18m.
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500
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Support
for vertical
insulated/bore
pipe at temp.
<200.c
when vibration
is not present.
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Supports
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100-200
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.
TO be used only when material of the pipe permits welding.
Can be used as resting,guide and anchor.
3000
1500
..
600-800
4500
6000
of vibrations.
PS 13.4
Hanger
PS 13.3
Anchor
PS 13.
Guide
400-500
NPS 1"-
12"
L=150forDN ~ 50
200forNPS > 2:'
PS 13.1a
Resting
'NPS 1/2:'-14"
NPS 'j'- -
ISSUED
Anchor
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FOR jMPLEMENTATION
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PS 13.2a
Guide
NOS
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FILE
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PDS:PS
PIPE SUPPORTS
PDIL
ISSUE:
STANDARDTYPES AND APPLICATIONS
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SHEET
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13
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Supports
or insulated
pipes.
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is more
Support
in the
welded
case
with clamps
are to be used
than '350.c)
Type with clamps
Type to be directy
shown
to the
Application
direct
pipe
without
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PS14.2
ON25-600
ON25-200
Guide
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Temperature
TO be used where
$.500.c
lateral
deflection
af the
pipe is to be prevented,
Maximum
PS14.5
ON150- 600
NPS
spacing
1"-3"
spacing
(m)
16"-24"
12
8"-14"
9
4"-6"
6
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Anchor
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Temp.
limit <500.c
linear
movement
RBI
and
'.
rotation
prevented.
Position of anchors
BID
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to be decided
PS15.6
ON50-125
by flexibility calculation.
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ON150-600
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pipe.
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pipe.
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To be used where pipe is crossing
wall or slob. Temp. limit 50gc.
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FOR IMPLEMENTATION
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Engg.Comm.
PREPARED
APPROVED
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FILE NAME:PSO1SH5.DWG
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PDS:PS
PIPE SUPPORTS
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DN 25-600
PS 15,10
PS 14.10
DN 50-600
DN 50-600
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rod types
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PS 16,1 PS 16.2
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PS 18
To be used
lfi\
reciprocating
for vibrating
pump
pipes as compressor
discharge
or
piping.
,!!!
cv
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JAN.
SHEET
EL
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PS21A.
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OF
13
Max. Max.nom. I
Load dia. of
sheet
I See
kg.
pipe
L65X65X8
300
200 I
100
L65X65X8
450
120
50
L65X65X8
600
90
50
ISMC 100
450
500
150
ISMC 100
600
400
100
ISMC 100
ISMC 150
750
300
300
1200
ISMC 150
ISMC 150
450
600
1200
900
ISMC 150
750
7501
600
100
ISMC 150 900
For details see PDS:PS21
L65X65X8
300
L65X65X8
450
L65X65X8
PS21 8.
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1:1
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u
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PS228,
u
cu
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w=
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c
II
see
50
150
2X200
600
For details.
2X120
50
2X90
50
"
150
ISMC 100
450.. 2X500
150
ISMC 100
600
;2X400
100
ISMC 100
750
2X300
ISMC 150
300,
?X120C
ISMC 150
450
bx 120(
ISMC 150
600
2X900
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750
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150
900
2X600
100
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ISMC 150
750
1800
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100
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15
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:5
'j;
I PDS:PS 01
PIPE SUPPORT
900
ISMC
1050
1800
300
ISMC 150
1200
1800
300
ISMC 150
1500
1400
150
150
Q)
""'
en
ccu
E
EL
u0:J
1:1
III
w=
>'Q)"C
O..c 00
E-:.o..c
0>-"'"
application
of
wall
be checked
>" c
the
Q)ooo
requires to
DATE
PURPOSE
EDCMH
PREPARED
'-
3:o.D
en Q)
tfl.9
V1
R
.....
o.2=SE
..c
:.c
I-
Q; .S ..... Q)
The
load indicated
PS24D.v=
0"'"
..c(jc
.....
..c
E en..c0
Q).....
.Doa::en
Note:-
III
.....Q)
PQ:.
REVIEWED APPROVED'
FILE NAME: PS01 SH7
/'
f
j\
PDIL
'-..!.---/
.J
is
a.
I BRACKETS
Indication of
Designation
Type
Representation
of support and
indicating the point of reference
in the piping plan & elevation
'0
c
0
'in
1/1
Co
EL
,
.,
==
Section
S.No.
'E
I PDS:PS 01
PIPE SUPPORT
PS25A. h=
L65X65X8
Max.nom.
dia. of
pipe
Max.
Load
kg.
200
50
50
L65X65X8
450
L65X65X8
600
90
OF
13
sheet
See
II
100
300
120
99.
JAN.
"'5
0
==
'i
EL
1/1
PS25D.
h=
h= 1200max.
For
Co
"E
details
500
ISMC 100
ISMC 100
600
400
750
300
ISMC 150
600
500
150
ISMC
150
750
500
150
ISMC 150
900
500
100
ISMC
1050
500
100
ISMC 100
ISMC 100
3
4
"0
EL
PS26A,
"0
15
x
.,
h=
u
:J
.,
"0
0
a.
EL
PS26D.
5
"0
.,
'a.
0
u
.,
h=
w=
0c
c
0
..c
EL
PS27A.
h=
PS27D,
h=
w=
600
150
150
100
50
h= 1200max.
For
"0
150
L>
0
PDS:PS25
300
450
1
2
.8
see
details
see
PDS:PS26
L65X65X8
300
2X200
100
L65X65X8
450
L65X65X8
600
2X120
2X90
50
50
-:::;
is
'ci
::;
0
'6
E
.;
E
Co
0
BJ
EL
I .
Qj
>
.,
h= 1200max,
For details
O!!
I.
1/1
u.,
'0
a:
'0
::-
+EL
Co
a.
LJ
.I
i
PS28A. h=
,-
.,
==
ISMC 100
ISMC 100
450
2x500
150
ISMC 100
600
2x400
100
2x300
50
5
6
ISMC 150
600
ISMC 150
750
2x500
2x500
150
150
ISMC 150
900
2x500
.!!!
1/1
see PDS:PS27
2x600
150
300
100
100
c:
.,
E
:J
U
0
EL
.I
PS28D.
"0
1/1
:c
I-
h=
w=
h= 1200max.
For details see PDS:PS28
1912.'c,
ISSUED
FOR
IMPLEMENTATION
EDCMH
-PC<.
DATE
PURPOSE
PREPARED
REVIEWED
I APPROVED I \.
PDIL
~
C5
Q.
'0
c
0
'iii
II)
'E
PIPE SUPPORT
BRACKETSFOR HORIZONTALPIPES
PDS:PS
SHEET
Indication of
Designation
Type
PS30A.
03
EL
~
.~
IT+'!
<U
:5
:;
0
:5
'i
II)
PS32A. h=
(;
..c
Co
"E
.8
IEL
-------
"0
..c
:g
PS32D. h=
v=
w=
99.
OF
13
Max. Max.nom.
See
Load dia. of
kg.
pipe
sheet II
Section
ISMC 100
600
1300
150
ISMC 100
750
1300
150
ISMC 100
900
1300
ISMC 100
1050
1300
150
150
ISMC 100
1200
1300
150
100
h=
PS30D. h=
v=
w=
ISSUE: JAN.
8,
~
Co
C
S.No.
01
ISMC 100
1500
1000
ISMC 150
600
2700
ISMC 150
750
2700
9
10
ISMC 150
ISMC 150
900
1050
2700
2700
11
ISMC 150
1200
2700
300
12
ISMC 150
1500
2200
300
X
<U
(;
"0
<U
0
:J
"0
0
5~
~12
18
<U
.0
q~
~~
JL-
R3
~-
~
~
EL
[f~
.8
-:J'
C5
EL
-d
::;
c
'6
.!:
EL
Qj
E
Co
0
Qj
>
<U
0
.id
II)
<U
'0
d:
'0
?:~
Co
0
5<U
:5
.!!!
~-
0
0
"0
II)
:E
I-
L65X65X8
600
600
100
2
3
L65X65X8
L65X65X8
750
900
500
400
50
50
PS33D. h=
PS34C. h=
PS34E. h=
-ffi
h= 1200 max.
r~
EL
EL
Jl-
---~
max.
j
I
L~
ISMC 100
600
1300
150
ISMC 100
750
1300
150
ISMC 100
900
1300
150
4
5
6
ISMC 100
ISMC 100
ISMC 100
1050
1200
1500
1300
1300
150
150
1000
100
7
9
2700
2700
2700
see ADS:
10
ISMC 150
1050
2700
PS35,
11
ISMC 150
1200
QJ
~'9<2'0 ~
DATE
PS35A. h =;
PS35D. h=
~ -~
h= 1200
jJ_EL g
Jl-
PS34A. h =
LJ
II)
C
<U
E
:J
PS33A. h =
EL
'0
c
"0
C
0
8,
11=
is
"0
<U
'0.
0
0
max.
PS36A. h=
I~
PS36C. h=
12
ISMC 150
1500
For detail
PS36.
2700
2200
300
L~
PURPOSE
EDCMH
PREPARED
APPROVED
"
. .8
PDS:PS
PIPE SUPPORTS
PDIL
~r;i1
01
10
OF
13
'0
c
0
'iij
fI)
'E
'QI
0..
C
'c
~
Representation
III
J::.
:;0
:5
'j
and
indicating
reference
the
in the
height
Designation
point of
SNo I Vertical
Type
h
metre
Horizontal
Max.
Section
Indication of
of support
1500
I2500
13500
Max.load kg,
fI)
:e
0
0..
ISHB150 IISMC150
-< 3
1000, -
ISHB150
ISMC150
~ 4
2200
1300,-
ISHB 150
ISMC150
2200
1300
ISHB150
ISMC225
3000
3000
2100
ISHB200
ISMC225
>4~6
<4
>4<6
3000
3000
2 100
1000
~ 4
>4~6
2200
1300'-
2200
1300
~4.
3000
3000
21 00
>4~6
3000
3000
21 00
"0
'-
PS37 A
~3
.B
"0
,....
'q
(
III
PS37B
'0
"0
III
U
:J
"0
0
1=
h =
0.
QI
'-
(;
"0
III
'1i
0
u
PS37D 1=
h =
V=
W=
III
.D
.B
"0
c
[~~
"0
C
0
-::J
i5
D..
':Q
EE
EL
l3
0
0
N
. ~
ISHB150 IISMC150
ISHB150
ISMC150
PS38A hI == 3
ISHB200
ISMC150
ISHB200
ISMC225
ISHB200
ISMC225
:.0
..s
91
PS38B
III
1=
h =
Lwr-I
~ I ~
dd
ISMC150
ISMC225
ELI PS39B
PS39D
'0
I =
,-
0..
0
V
>
QI
0
-<
=
=
W =
I
V
ISMC100
1000'
2200
1300
3000
3000
21 00
0..
0'-
0..
QI
:5
riS40C
PS40A
.!!!
IfEL
III
:J
u
0
"0
fI)
:c
I-
, ..
I~qq
,DATE
PS40A
tSMC100
ISMC150
.--
ISMC150
1.5
ISMC150
450
1000
1000 800
1
1 =
h =
FOR DETAILS SEE PDS:PS40
ISSUED FOR JMPLEMENTATION
Engg.Comm.
PURPOSE
PREPARED
PS40C
il3
APPROVED
fiLE
NMlE:PSOI
SH 1O.DVlG
"r"
"
"'.h.,.Jj
',
PDS:PS
PIPE SUPPORTS
PDIL
. ~ [j:iJ
"
'0
c
0
'in
II>
'f
'<I>
a.
c
Representation
indicating
in' the
of support
the
Indicotion
and
<I>
rr
.J::
SNo
Type
h
Section
Designation
point of reference
~
.~
of
EL
PS41A.h=
:J
0
:5
'i
h=300 Imax.
II>
EL
SHEET
11
Max,
Max.Nam.
load
dia,af
kg
pipe 'f'
L65x65x8
450
400
100
L65x65x8
600
400
100
3
4
L65x65x8
L65x65x8
750
900
400
400
50
50
PS41B.h=
(;
~,
bEL
- ---JF--
--I-&-!- -je-
v=
W=
<I>
.0
.JP- - -j\;;
EL
-kH-
--*I
PS41E.h=
EL
f---
Ib-
v
'i5
..s
PS42A.h=
I--
tc
:J
EL
old
I I
I I
I I
II>
<I>
'0'
(J
Z
(/)
a
-I
ci
W
I~
W
V1
W
:r:
a.
a.
::>
(/)
-I
::!;
~
I
I~
W
(J
~
I
I-
(/)
I-
- W
a.
;: a.
O1.!w
~ ~
0 u
~ ~
I
600
1200
100
ISMC 100
750
1200
100
3
4
ISMC 100
ISMC 100
900
1050
1200
1200
100
100
I- - .
a'0
I- 0~
ISMC 100
1200
1200
100
a.
PS428.h=
::>
(/) x
W
a. ::!;
CL :
:J
,
0...
a.
>z
-I
-I ::E
::>
-I
::E a
~ u
a
z ~
I
<I>
:ft- - ~
EL
-*+-
-je-
Ia
z
I I
1'1
I I
<I>
:J
U
0
"0
II>
:.c:
(/)
ISMC 100
?::~
a.
.~
<I>
:5
W
CD
-I
~ :5
is
a.
-:0
2
'c
'0
(J
Z
0
':::J
0:
"0
C
0
<I>
0
PS41D.h=
0
u
E
a.
0
Qj
>
(/)
V1W
W ~
U
...
"0
c
;: ::>
~
~
>
I
-I
-I
"0
<I>
U
:J
"0
0
'1i
I
(/)
W
I
I-
=4-
..;
"0
<I>
z
;:
a
-I
a
-I I
"0
13
I- :.::
u
(/) w
:5
2
'.0
OF
,~
I--
:e
0
a.
01
:1!--~
I-
I~,DATE.
2..' C\l1
~
,
rs-42D.h=
v=
I
ISSUED
W=
FOR IMPLEMENTATION
,
PURPOSE
FOR
DETAILS
SEE PDS:PS42
Engg.Camm.
PREPARED
AP~ROVED
"
"J
J... .. ,
.J
C
Q.
0
c
,2
UI
,!!!
POlL
SHEET
12 OF 13
1.
E
Q)
Co
C
Q)
pes: PS 01
PIPE SUPPORTS
STANDARD TYPES AND APPLICATIONS
Q)
;
'S
UI
Q)
:e
CII
Co
'E
FIl
;
'
;S
.s
c
:t
0
.t::
UI
0
"C
f!
=>
"C
0
Ci
0
"C
,
Co
0
0
Q)
J=>
SI.No.
Support type
1.
Resting
.s
15
c
"C
C
CII
:J
e:.
Symbolic
representation
Applicable standards
PDS:PS
10,12.1,13.1,13.1a,14.1,14.4,
11,12.2,13.2,13.2a,14.2,14.5,
14.7,14.8,15.2,15.5,15.7,15.8,17
Remarks
15.1,15.4,18,92,93
2.
Guide
3.
Clamp
><
11.2,11,3,19
4.
Rigid hanger
13.4,13:4a,14.9,14.10,14.11,
15.9,15.10,16
503,510
503
;
"C
Q)
E
:.:i
CII
:0
.E
'E
Q)
E
Co
0
Qj
>
Q)
C
GIS
5.
UI
Q)
'2'
Q.
6.
Anchor
11.1,12.3,13.3,13.3a,14.3,14.6,
15.3,15.6
Q)
Co
e
Co
0::
;
.!!!
....
N
'E
Q)
q
0
0
0
0
Q)
=>
0
0
"C
.!!!
.t::
I-
0::
W
en
,,-'
==
Z
==
0::
...
DKM\DA
J~
..'.
~...{'~
..
~..~
A
,
- ,
~
-
PDS : PS 01
PIPE SUPPORTS
STANDARD TYPES AND APPLICATIONS
PDIL
SHEET 13 OF 13
.J
15
a.
0
c
0
:1
c
QI
::::
2. Types and details of supporting structures as well as pipe support attachment shall be
entered in a tabular form as shown below.
'~
QI
SLNo. of Supporting
structure
support
:5
:;0
:5
'~
CI)
QI
S1
t:
co
a.
'E
PS 37A.1
L = 1500
H = 4500
Support Attachment
2
1
NPS 3" -PS 10.1
Foundation
Remarks
Type
:
.E
c
::
0
. J::.
CI)
'0
Q)
0
OJ
'0
0
a.
!!
a 3. In case the piping support assembly is not covered by the PDS, detailed sketch shall be
made on a separate sheet and the sketch numbers referred in the above table.
0
0
QI
.a
.E
15
c
'0
c
co
:::;
15
e:'0
2
'E
:.:i
co
U
..E
C
QI
E
a.
0
Qj
>
QI
0
c/S
CI)
U
QI
'e-
-o.0
0
>
W
D::
N
LL
....
N
0
'T
0
0
0
'T
N
0
;
.'.""..
D::
W
IX)
" .,
, ,..
,:'
r(
~"~!
.0..",
a.
QI
:5
.!!!
C
QI
E
::I
0
0
'0
CI)
:c
I-
:!:
-,
,.~
:>.
t
QI
a.
0
:!:
D::
0
LL
"
H\PDSPSO1 F2B.LWP
'{
~~
pth
a
0
PDS:PS 10
PIPE SUPPORT
PDII,
4.7.9A
ISSUE JAN..99
SHEET I or
0
I
Foundation, cxe
0a
V
Resting on structure
PS 10.1
Resting on concrete foundotion
PS 10.1a
V
S
V
0
Dor
0
ISA 65 x8
For NPS 10- - 2
17-1)fr
in. 6
=2 for UPS
r-
C
21
Material - 15:2062
Exomple of designation:
Resting NPS 1" - PS 10.1
Guide NPS 1- PS 10.2
PS 10.2
C
NPS
SLL DN
.15
2 1/7
1 1/2- 2-
4"
C
150
25
40
50
65
80
100
33.7
48.3
60.3
76.1
88.9
114.3
60
65
80
40
60X100
cxe
100X100
200
10'
12-
IC
IC
I8"
20'
24'
250
300
350
400
450
500
600
130
160
609.6
285
335
185
200
225
760
50X200
300X200
500X700
200X200
400X200
600X200
a
NOTES:
79-1-99.
DATE
PURPOSE
INGG COMM
PREPARED
REVIEWED
APPROVED
Fit UWE' PS IM OWC
PDS:PS 10
PIPE SUPPORT
RESTING, GUIDE & AXIAL STOP
I
\
1
/
-7C
400
P1PE
NPS
2C
283032
3C
SIZE
ON
650
700
750
800
900
DEVELOPED
LENGTH
L
330
356
381
406
525
560
600
640
715
457
GUIDE
GUIDE 93
150X50% / 6 1hk
SITE WELD
400
WRAPPER PLATE MATERIAL &
ISA 100X65X8
PIPE
(TO 13E WELDED WITH THICKNESS
WRAPPER PLATE)
GUIDE PLATES
MATERIAL - IS:2062
NOlt : IN CASE SLIDING I MCC IS REOUIPED 10 DC LESS. NO. OF
RODS (2-3) ARE TO DC WELDED ON THE SUPPORTING
STRUCTURE BELOW IHE PIRL.
DATE
ENGG. COMM
PRE PARED
PIPE
NPS
26
2EC
30it
SIZE
DU
650
700
750
1300
36' 900
DEVELOPED
LENGTH
330
525
560
600
640
715
356
381
406
457
201.
APPROVED
REVIEWED
I
PIMA PS I 00 DWG
PD1L
t?
0.
0
C
0
PDS:PS 10
PIPE SUPPORT
RESTING, GUIDE & AXIAL STOP
ISSUE: JAN.,99.
SHEET 3 OF 6
R
LOPM NT
SEE TABLE
1-6 0 VENT HOLE
0
0
PS 10.5
SIZE
ON
50
so
100
125
R
30
45
SHAPE
5 "Pee
IOW.
SCH0/6:1239
50/.40/15:1239
80 #1.8. P1PE
SCH.40M . 1239 HEAVY.
PLATE
DEV.
WID1H
80
I 50
57
70
150 84
200 110
810" 250 136
12- 300 162
14" 350 173
16" 400 203
ISMO 100
ISMB 100
ISMB 150
ISMB 150
I5M8 150
19.113 200
ISMB 200
15M8 200
300
15M8 200
ISMB 250
19.18 250
ISMB 250
ISMB 250
ISMS 250
ISMB 250
ISMO 250
ISMB 250
ISMB 250
300
300
350
350
400
400
400
400
450
500
S
C
20"
22
24
PIPE
NPS
2"
s
500
550
600
2C
650
700
28
30" 750
32- 800
3e 850
38 950
254
282
305
330
356
381
406
432
457
150
180
200
200
200
250
.300
29- I -99
DAIL
ENGG. COMM
PREPARED
ritr
ze,'
REVIEWED 1
APPROVED
PDS:PS I 0
PIPE SUPPORT
RESTING, GUIDE & AXIAL STOP
PDII,
psi
ISSUE: JAN..99.
SHEET 4 Or 6
A Ti-H
SEE TABLE
0 VENT
I
HOLE
70 f
EXISTING STRUCTURE
SECTION AA
V
I'S 10.6
0
0
/
I
1
I
PIPE SIZE
NPS
ON
I 70
0
ti
0
a
0
>
Er
SHAPE AS
PER TABU
SECTION AA
SHAPE
5 22' Pr(IfJON
SC11.40/6:12)9
80
7'
50
30
S'
so
45 SOLI0/15.1215
" NIL "P IOW
100
6W
150
700
57
84
110
10
16'
250
300
350
400
18'
70'
72"
74"
450
500
550
600
12'
Te
150
136
162
178
203
15140 100
15148 150
ISMB ISO
15148 150
:SKI 200
15148 200
ISMS 200
150
200
200
200
250
300
300
228
254
280
305
15M8 200
15118 250
15148 250
15148 250
300
300
350
350
EXISTING STRUCTURE
1 WRAPPER PLATE IS ONLY USED FOR ALLOY STEEL AND
MATERIAL & THICKNESS IS
STAINLESS STEEL PIPES.
SAME AS PIPE.
2 L.-WIDTH 01- EXISTING SIRUC I URI 10 OF MEASURED AT SITE.
w4, DIVE LOP/ D WIDTH OF WRAPPER FIAT E.
29-1-99
DATE
(HOC. COMM
PREPARED
Pa ,,,a)
REVIEWED/
APPROVE()
PIPE SUPPORT
RESTING, GUIDE & AXIAL. STOP
PIML
pad
PDS:PS 10
ISSUE: JAN.,99.
SHEET 5 OF 6
PS 10.7
o.
RESTING SUPPORT
NPS ?. 16"
7\
I
4?,
I
/
1
\"<
1P0
100
i
/
760
REF. POSTS 03
Min.
tr-1
r t
_ J
r!
0
E
NOTES
LOimensions or masonary base must be Fixed with respect to the
0v
-ts
II
0
0
29 - 1 - 99
DATE
cucc. COMM.
PREPARED
REVIEWED
APPROVED
rtntE: PS I OE Not
-f
I DIL
PS 10.8
PDS:PS I ()
PIPE SUPPORT
RESTING, GUIDE & AXIAL STOP
ISSUE: JAN.,99.
SHEET 6 OF 6
RESTING SUPPORT
F
PIPING SYSTEM RUNNING HORI7ONIALLY ABOVE GROUND LEVEL.
PIPES SUBJECTED TO SLIGHT EXPANSION (Max. temp. 100 C.)
EN
/
I
EN
/ X%/
I
I"
.-e
1.--7.,
/ I
--e----,
.-
500 Min.
12
. i
7-y-rI
1
X 170
11
111
t__31sejec
80x80x220
0
;Th
F
fig
0
V
1.3
C.
0.
0.
V
C
"z
.2
C
C
4C,
0
NOTES
1 .DimENSIONS Of MASONARY BASE MUST BE FIXED WITH RESPECT TO THE NUMBERS AND
NOMINAL DIAMETER or PIPES AS WELL AS HEIGHT AND DISTANCE BETWEEN SUPPORTS TO
SUIT THE THE LOAD. THE CORNERS or THE SADDLE PLATE (8 THK SITAR BE ROUNDED.
0
0
CS
29-1-99.
DATE
ENGG. COMM
PRE f 'ARE 0
REVIEWED
APPROVED
C' I rauc . P5101 TAG
r ,,f---.
PDS:PS1 I
PIPE SUPPORT
CLAMP
PDII,
ISSUE: JAN.,99.
1 SHEET
I OF 3
Guide
NPS 1/2"-24"
U--Bolt clomp ,
PS11.1
a
c
I
- - Malefic:I-IS:2062 Cr. A
tlr
Cl
oo
2
Oa
0
-
km
-Nut-IS:1363
When thickness exceeds 16mm.
dimensions h & h 1 to be
increased Proportionally
11
la
t'0
E
Hole d;ameter=d1+
V
.)
PSI 1.1a
Anchor
U Bolt clomp ,
NPS 1/2"-2"
Le
'Ma
Example of designation
U-Doff clomp NP$ 1' -PSI 1.1
IIII
I I
if
tA
iv
tn NPS 1/2tu
a PIPE
DN
E
0
0
24-
2"
600
15
609.6
21.3
35
40
a8
62
76
94
105
135
160
192
248
302
352
402
452
497
554
648
82
88
95
109
125
140
155
190 215
245
306
360
411
460
515
570
620
720
10
dl
IA
1410
M12
hi
65
70
WT. of
U bolt 0. 10 0.11 0.12 0.15 0.25 0.79
.:tomp.Ko
20
25
14 16
6
1.120
L124
05
90
105
16
12
0.84
0.92 2.81
4.47
4.92 5.41
6.31
29-1-99
DATE
ENGG. COMM.
PREPARED
REVIEwE0
APPROVED
PIPE SUPPORTS
TRUNNION DETAILS
PDIL
ad
PDS:PS 12
ISSUE: JAN..99.
SHEET I OF 6
a
0
is
/20
A)
o
0
FIG.1
0
V
NOTES:
Application of Trunnions has been shown in 1;9.1
Load capacity of trunions con be increased by providing
reinforcement pod(motl.& thickness some os pipe) and using higher
schedule trunnions according to Fig.3.
Trunnion welding procedure shall confirm to Engg. Std. ES:6004
(CS & AS PIPING), ES:6005(SS Piping) and welding detail os per fig.2 & 3.
For thin S.S. Pipes(Sch.10S or less) o wrapper plate of some moil, and
thickness shall be used (irrespective of trunnion material) in order to
reinforce the main piping in accordance with fig.4.
-j
0
V
E
3,
4.
a
Ca'
S.
MATERIALS:
A. CARBON STEEL & LOW TEMPERATURE CARBON SWF( PIPINGTRUNNION
E
Ea
00
29-1-99.
DATE
PURPOSE
ENGG. COMM
PREPARED
24=1
REMEWE
da
APPROVED
t3/4. -.1.?
i'
o
00,
-I-.
ra
..
!:
-:
PIPE SUPPORTS
W PM'
V S1
TRUNNION WELDED TO ELBOW/PIPE`
\-__
PDS:PS12
ISSUE: JAN..9 9.
SHEET 2 OF 6
- --1-- -----
I)
-5
co
o
9
0
--I
I
ott
vu
0It0
--.
o
c
0
o
tv
i
0
6
U
C
7
..-
6
(Min.)
i'
Al
ni
00
0
Bose Plo e
Moll. IS:2062
Dimensions some
r=iLl
i_J t_
___,
---11...-2?
Vi
NPS 4-,PS:12.1,L900
1 _,
-- L 20
---1
Jr
Ov
00
ir
Example of designation
a.
0
PS 12.3 or
PS 12.3a 1
Anchor
NPS
I) -
PS 12.2 or
PS 12.2a *
Guide
XI
Bose Plo e
Mot I. IS:276
6
o
-.
c
lz
<
.1
Ll
r,
MarMill
Z3
0.
t7t
w
a.
_a-
diametrically opposite----,
\I\
1,1
0
0
......_
-,
o6
o-
1/2
4"
8'
70
10-
HL..
16
14 -
16'
_.,...I
12'
18" 20-
80 100 125 150 200 250 300 350 400 450 500 600 700 800
Supporting pipe
NPS2-Sch.40/ UPS 4- Sch.410/ NPS 8 (Seh 40) UPS 10(S 640) NPS 14(Sch.40)
5:1239 Heavy 15:1239 Heavy
300
150
200
250
400
350
260
200
0
-33
2/
18
22
1
M30
0 of bolt(nnrhnr)
M24
MI6
1)20
hill
620
length of oinc/Itil bolt
380
160
Anchor Raft type
TYPE 0
TYPE C
of POS:ST -211
_
liat, ' a
ISSUED FOR IMPLEMENTATION
29- I -99.
IENGG. COMM.
OATE
Pipe ON
50 65
PURPOSE
PREPARED
REVIEWED
APPROVED
RI NAM PSI 2e NYC
pth J
PI PE
ORTS
RUNN1ON WELDED TO ELBOW/PIPE'
PM L
ms:PS i 2
ISSUE: JAN.,99.
SHEET 3 OF 6
f.'
,..
PS 12.4
...
S
-30
c
..
g
r)
Zi
a
2
"
'xi
DN2
aw
12.4a
PS
z
Z,
0
m
. ti
LL)_
o
o
zna.
t
Z.,
a
y
LI
o
t
st)
n
ta
r4
j,
ON2-
(1.4
g
....
I IL
in
b
.-
,
;
_, m0
O
'Ai
i
IF
,,
,k
mi
'M.
NNE MINI
C,,
,;
J--
0N2
I
b2
Seasoned Vermin
proof Hardwood
all
Example of designation
NPS 4"-PS 12.4c -L700
V
0
N
6,
4,
a
0
1la
a_
NIPS
2- 2 I/7- 3'
ON
50
ON2
NPS 2- Sch.40/
15:1239 HEAVY
ra'
K
E
b2
29-1-99.
DATE
65
52
80
600
700
14"
300
NPS 4 "Sch.40/
HEAVY
102
201
18"
28"
12-
16"
20" 2e
10-
5-
18: 1 2.39
200
ISSUED FOR IMPLEMENTATION
PURPOSE
260
ENDO. COMM.
PREPARED
252
331
350
400
It? 2411
REVIEWED
APPROVED
CAI NMAC: PS I 2C .DAG
PDII
PDS:PS 12
PIPE SUPPORTS
TRUNNION WELDED TO ELBOW/PIPE
ISSUE: JAN.,99.
SHEET 4 OF 6
0
C
PS 12.6
PS 12.7
-3:1(0
A
Trunnion support at
I iorizontol/Verticol Elbow
Trunnion support at
Horizontal/Vertical Pipe
Trunnion
V0
r verticoi g.
Stiffening Bar
10 X 25
* Shims ---
V
0
Support
VC
0
V
Example of designation:
NPS
-PS12.6-t 501.1
0
n
In
o.
S
NPS
ON
TRUNNION
2'
2 I/2-
5U
Ni no 2
65
5BO
Sch 10/
IS:1239 Heovy
100
125 150
200
10-
12
250
00 350
14-
78-
32
800
16--
NPS 4 Scl .40/ NPS 6-Soh.4C UPS 101S:1239 I 'toy), 15:1239 Hew., Sch .40
18-
20-
NIPS
24'
- St.:11.41.1
7
V
O
29-1-99.
DATE
[NCO. COMM
PREPARED
REVIEWED
APPROVED
rat NNAL. PS120.0%t
--.
8,
PIPE SUPPORTS
ADJUSTABLE TRUNNION
PDIL
peUij
'
PDS:PS12
I ISSUE: JAN.,99.
SHEET 5 OF 6
PS: 12.8
Trim to suit
in field
is
`
s
r.ss
;
o
-it
e fl
Tr union .
:I 1.
Plate 1,' Squore
et
.7'.i
PO
Field shim
i c13
anti
IA,
38 Adjustment
Y
_a
13 Cap
a
'el
s'i
1.5b
.r2
I P 0 C Fire
Isui
PS: 12.9
8
0
Trim to suit
in field
..30
.-
'
8dine indent.
,- - ,
v
a
o
o
N10
2
'
;'
hole in pipe
it
/ Do not cut
. F. ;
E in _,
n
ipe
rN
r) I
--
L 0h
ti
EI
Elev.
_ _ _
Locknut
El
Do not Cut
hole in pipe
Suore Plate
4 Anchor Bolts t e 'C'
POS: ST 211
6C
Ea
if
,10"
29-1-99.
DATE
PS 12.9 1=
Anchor
Dio.
Anchor
Length
150
200
18
16
380
150
150
700
18
Id
lb
380
200
18
LI 16
380
200 260
77
20
460
200
260
22
IA
20
460
200
260
22
Al 20
460
ENGG. COMM.
PREPARED
Ikt:. 29/1
REVIEWED!
it
APPROVED
NAM
PIPE SUPPORTS
TRUNNION WELDED TO PIPE
PDII,
1)1.)S:PS12
ISSUE: JAN.,99
SHEET U OF G
Pod Width.W
pipe Pod Width
(W).rnm.
Size
1/r to r
50
8- to 16-75
18" to 32-100
Nom.
C,
through or Cut
5
0
7.1
1.
C.
0
V
Wropper Thole
S.S.)
>IV
O
O
79-1-99.
OAT(
rst owC
PDII
To
Dimensions in mm.
. 0-
,,e,0
.-
O
a
I'DS:PS 13
PIPE SUPPORTS
TYPE PS13
NPS
SHEET
Hord
wood
10
r..
ti
0
c
-
ltaio
8R
_..
i 4 Appp
..
Ina
8
0
..
-24"
E
a
'5
OF
I 10
gi...
.......
11 le"
5r)
?
:
MATERIAL
Hot
Bolts
0
0
&
Nuts
55
IS:2062 Gr.A
IS:1363
EXAMPLE OF DESIGNATION:
0
0
Resting clomp NPS 1 ,d1 = 160,PS13.1(Designotion for clamp with resting base)
DIMENSIONS:
PIPE NPS
d= OD of pipe
33.7
d1= max.
230
250
0
0
0
CC
11/2 2-
2 1/2
3-
0
0
0
a:.
0
508
622
790
840
955
570
740
685
650
100
150
200
250
Flat
100x10
150x10
200x10
M20X80,22
Wt. of clomp&bolt
kg.
c.,
100
.V
0L
of
hole.
I
200
150
Ce cn
Wt.
150
support,kg.
p (d1) shall be
C
0
300
200
Pipe NPS
2C
16-
70
L
./f
20-
14 -
it
60
Bolt&hole dio.
570
le
10"
insulation thickness.
application refer PS 01.
i /2"
T-S
4--68" - 10"
Insulation thickness
65
75
100 70
50
100 80
30
50
130
12"
2- 43 '/'
DATE
99
--
165
-
160 130
110
60
30
170
150
100
70
40
200
180
130
100
70
30
0
O
150
TABLE- 1
E=v,
Engg.Comm. A4ww R-c )4 -1134)--wik 11 -1.1
REVIEWED
APPROVED'
PREPARED
PDS:PS13
Aj.
fr.
o
,
i'15
0
0
PIPE SUPPORTS
r(3,=-4 PD11_,
.
ISSUE: JAN.
p811 j
OF
SHEET
99.
4
TYPE PS13.1
For dimension
of I&L refer
table of sh.1
NPS
-24"
I7
UPS 1-2"
"
Resting
__
":,
0
o
(.1
w
10
10
r
...
L.
1j -1--
Ua
on
2a
...
,
-ac:
_
n
0
V
o
.0
-6
..,
c.
&
1.1 d
IM
-.
.
rme)
11..
IW
si
Lo__,J Lea
II
r...,
10 1/
__YU
.."
TYPE PS13.3
Anchor
4-1
NPS 1"-2"
I
_ill
.
101
No
t
,
0
I-
Guide
0
I__
_, ...
255
.--J
L.J,...1
-..L
Apply graphite/grease on bose before placing on structure.
10 thk. plate
Mott. IS:226
7 1 T-
,
i
10
^10V
___I
Support
or
TYPE
PS13.4
Hanger
'
10
IMPLEMENTATION
ISSUED
29' I gFOR
I
DATE
fliRPOSE
Engg.Comm.
PULPARLO
/ga, Q cT--c.
FU
VIF.Wit)
APPROVED
FILE NNAE:RPO4
I DII ,
_i0
0
1
ali
PDSTS13
PIPE SUPPORTS
&Li
SHEET
OF
Dimensions in mm.
NPS 1"-14"
TYPE PS13.10
Resting
c
...)
IL
.r...
mow IS:226
d
Asbestos pocking I
IS:1363
a
ION
'50
c
-i
MI
n (1:7
00
5
13 )
-Hord wood
O
7
:
li
go
r.31
ON of pipe
c i
o
"
32
28
33 40
49
270 280 280 290
110
120
125
f
h
10
12
14"
175
480
225
570
279
620
330
700
362
740
370
430
520
570
690
155
191
255
305
200
245
315
400
359
440
650
410
2 1/2
55 67
300 340
82
360
95
370
121
420
290
127
310
320
142
140 170
150
185
105
99
130
8"
1 1/2 2"
240 250
0
0
1/2" 3/4 -
E
0
Mot1.1S226
Resting,DN25,PS 13.10
C0
aOV
._
Exomple of designation:
0
o.
0
?
4_
0
0
0
V
0
Pr,2/
3"
120 123
127
130
333
349
200
140
100
1171
495
442
525
151
159
166
193
266
220
292
dl
12
16
20
M12
260 270 275 320
M16
M20
690
250 255
335
350
405
460
550
610
720
Wt. of block
including nutkg.
NOTES:
1. For opplicotion,refcr
PS 01
0
0
O
2 9' / i q
DATE
Engg.Comm.
PREPARED
n..C_
REVIEWED
APPROVED
Pll11,
-J
PIPE SUPPORTS
FOR REFRIGERATION SERVICE
P DS: PS 13
ISSUE: JAN.99.
SHEET 4 OF 4
TYPE PS13.20
ON 15-350
Guide
Dimensio and material some os P513.10
a
44
aO
' Guide
11- Mall. IS:226
It:
0
0
0
`53-f
201-- 113
11 70
TYPE PS13.3o
ON 15-350
Anchor
Dimensio and material some as PS13.10
0
C
0
0
O
L.
TYPE PS13.40
r Tanger
Dimension and
material some as
Type PS 13.1a
ON 15-350
a
0
4)
0
0
DATE
PURPOSE
ingg.Cornm
PREPARED
t, 1./,(;',`
REVIEWED
IAPPROVED
ALE ti/v4E:PS I 39i 4
"I
PD1L
o
NPS 1.-24-
..
(4
i
in i
".
01
a
5
pipe
i.,
L 1-
LIJ
;:o.
Temp.
<300*c
Material of shoe
15.2062
65
80
100
125 150
200
48.3
60.3
76.1
88.9
114.3
139.7 1683
219.1
150
_..1
tilde
N..
"t7
IT
-3JL__JEw3
Apply grophite/greose on base
before placing on structure except
oxygen
300
200
350
300
200
>300tC400t 100(500)
15:2002 Cr.2A lor1/2Mo
50
100
-..,..,
:5 8_
40
SI 8'
--. -
c> 51,
a
- _
N.
NPS 6- -24-
ISNT/Plate
\ iii
IIII
0
tOthk.ptote
For SS.orolloy st.
in c)
pipe.5 thk.wrapper
plate of same mow _ ...I In I 25
ose plate
I
os that of pipe shall ottIS:226
I
be welded (For detail
see sheet 5)
1,42
O`%
-
09 8
el ra
NPS r-s-
in
I`
SHEET 1 OF 5
/ -- --
Resting
TYPE PS 14.1
Dimensions in mm
r>
PDS:PS 14
PIPE SUPPORT
NPS 6"--24'
\ 41).
II
I
Ill.
._,_1_3 _...1Li.
El_
Guide:
MottIS:2062
I
1j
._
in
in
NI'
He 711_ I al,
L.
lines
UPS 6'-24"
NPS 1.-5
/
/
__L _
1111
151-Cr
II
1w11ecan1 ItC-Tsva
-1.
REVIEWED ) APPROVED
NAME PS I 4A
PD1L
ISSUE: JAN. 99
TYPE PS 14.4
SHEET 2 OF 5
TYPE PS 14.5
At
PDS:PS 14
PIPE SUPPORT
r2
10 thk.plote
Mote riol some
os sheet I
ISNT/Plote(shoe)
materiot range
as type PS14 I
0
5
ISMC 150
, ISA 65X65X6
to be fixed finally
ISMC 150
600r-flax.
d4 100
7
r.)
ISA 65X65X6
to be ixed finally
3
3
Guide
refer sheet 1
3
01
T--
0
V
a0
14,
o
UPS
2-
40
6- - 1 cr
17" -16"
18" - 24"
c
.0 0
0
0
t!
600max.
d+100
ISMC 150
50
100
150
200
TYPE PS 14.6
'PS
a
1
10thik.plote
Motl.some os sheet
0
V
L10
Existing structure
2 ci I.
0Al
F.
runno,4-
F OCMH
0-1(c''')f^c.2
Rivicwio
APPROVED
PDS:PS 14
PIPE SUPPORT
ISSUE: JAN. 99
SHEET 3 OF 5
r,
NPS -24"
1 OThk.plote
Material:some os sheet 1
10Thk, plate
Material: IS:2062
a0
p.
10Min.
L..
200Min.
For
NPS 4 - -245%
0
0
0
lN
Ld+300
d +400 f
;too 400
450
- 600
a
0
10 Thk.plote
Materiall some
as sheet 1
10 Thk.plote
Mo eriol: IS:2052
0
a
a
- Material some
os sheet 1
DATE
COCMI I
PREPARED
.4/141(1'14:)
C4 24
REVIEWED APPROVED
F ILE NAME - PS14C
PD11,1
a.
1 POS:PS 14
PIPE SUPPORT
SHEET 4 or 5
Welding detoils
0
0
Material:
Except where indicated otherwise.steel of the some composition os that of the
pipe shall be used for the pipe support attochmentilectrode should be
co mpat ible with pipe and support material.
(d). The fillet weld requirement for pipe support attachment shall be os
indicated below.
O
Pipe
12
Pipe
attachment
Et;
>su
a
0
ISSUED
()ATE
FOR IMPLEMENTATION
EDCMil
tkviewED
API'ROVil)
i_PDS:PS 14
PIPE SUPPORT
PD11,1
fied
SHEET 5 OF 5
Dimensions in nun.
WRAPPER PLATE
NB'S
1,
....
E
;
f.
=
r
t0
15
I
.
.1
I F,Aahaahasi,,.w-
41r1
'l
25
'o
so
25
vD
u
1
I
3.5
--A
I 60 Vent hole
25
25
Example of designation:
Resting.DN 150.17 514.1
ON
25
32
023e
33.7
117
40
65
BO
42.4
88.9
121
50
90
100 110 125 150 175 200 225 250 300 350 400 450 500 600
1121=219.1 244.5
350
NOTES:
1.
refer
sheet
PURPOSE
422
197 210 222 237 262 278 303 329 351 411 ,
1
250
11
FOCkin
PREPARED
4.441
4?;:
4-44
REVIEWED
APPROVED
PDS:PS 15
PIPE SUPPORT
SUPPORT CLAMP
SHEET 5 OF 9
TYPE PS 15.9(11)
TYPE PS 15.9(1)
vd
Pipe spacer
CJ I L,
d+6mm
d4-6mm
(For suspension of
uninsuloted lines)
Exomple of designation:
Clomp NPS 1",PS 15.9(1).NPS/ON is nominal
1'
a
O
a
v
.....
a
2
(For suspension of
hot insulated lines)
Pipe/clomp size
NPS.in ()N,mm
A
mm
dxL
mm
El X T
mm
/I
mm
h
mm
K1
mm
K2
mm
Load
kg
I /2"
15
21.5
M8 X 30
25 X 6
40
120
200
3/4
20
27
M8 X 30
25 X 6
45
130
200
25
34
1412 X 55
35 X 6
50
150
730
570
40
49
1412 X 55
35 X 6
60
160
240
570
50
61
1412 X 55
35 X 6
65
175
250
570
M12 X55
35 X 6
75
210
315
570
M16 X 70
35 X 6
85
230
330
570
M16 X 75
65 X 10
95
255
355
1180
M16 X 75
65 X 10
110
285
385
1180
6"
M16 X 75
65 X 10
130
325
425
1180
8-
M20 X 90
65 X 10
160
385
485
1180
1 0"
1420 X 90
65 X 10
190
450
580
1180
12-
1420 X 90
65 X 10
215
500
630
1180
I4"
M24 X 100
65 X 10
230
550
680
1180
16"
1424 X 110
100 X 16
255
585
710
2360
1 8"
1424 X 110
100 X 16
285
650
800
2360
20-
M30 X 130
100 X 16
310
705
855
2360
1430 X 130
100 X 16
360
805
960
2360 1
1 1/2
22 1/2"
3"
24"
600
622
75
100
125
150
PURPOSE
EOCMH
PREPARED
REVIEWED APPROVED
FILE NAME: P5151
PDS:PS 16
PIPE SUPPORT
SUPPORT WELDED WITH PIPE
PDIL
Pad
i
Dimensions in mm.
0.0TYPE
PS
15
TYPE PS 16.1
<
A
Normal
- e-nII
MN
:--v
..
MN
,,i
ER
sumo
il
OF
TYPE OF CLIP
16.2
.".:2,
SHEET
4!
la
II
__.J
fO 0
05
8-Forr
insulated
All
pipe
IF
.1.,
0
a
7) .-
/7
.2-
al
-----\____.
,
/,
Is
5,
V
C-For
uninsuloted
elbow
"I
I1
la
IF
.n
e
?
4:, - To be welded
JO
el
V
v
0V
SnV
after assembly
(See note 2)
d
3c
EMI
co
.7
5
..
)
i:
.
:,
1r
7)
D-For
insulated
elbow
\\
t
ill
rr
I
I
Example of designation;
!longer rod d=12,L=
P516.1
To be bent and
welded after
assembly
o
d
12
16
20
25
32
36
b
60
60
80
100
120
130
b1
f1
h1
120 20
150 25
200 30
230 35
250 40
250 45
14
18
22
26
33
39
110
145
180
215
250
250
95
125
155
185
210
210
M12 30
M16 40
M20 50
M24 60
M30 80
M36 90
_4,___.
S
6
10
16
16
16
20
L min .
L max.
400-2000
500-2000
600-2000
700-2000
800-2000
900-2000
x.record
loud kg. Pipe NPS
2"
515
1
1/2"-5"
825
6"
- 24"
1230
6" - 247
2260
6"-24"
3640
6"-24"
5300
MO
NOTES:
PDII,
PDS:PS 16
PIPE SUPPORT
HANGER ROD
SHEET 2 OF 2
Dimensions in mm.
TYPE PS 16.3(W)
0
E
a
V
5O
a
a
O
0
e
0
0
03
a
O
V
For clomp
a
0
refer
o
0
0
Welded eye
6
a
151
E0
Nom.
rod size
Mox.recommended
Lood
kg.
12
100
M12
515
21
16
100
100
A116
M20
825
20
1230
21
21
25
32
150
150
M24
M30
2260
3640
31
42
36
45
48
150
200
200
M36
1145
1148
5300
6300
10000
42
Preferred lengths of the hanger rods shol be 300.350.400-100 -1400.1800 and 2000.
Material:- IS:2062 Gr.A
PuRPOS1.
EDCM Ii
1 4 R L PAHL()
iti4"
WLVILWLU
APPROVED
nl I NAME: 14S16b1
7:Eir;(*.;-.C7
PDII
Pad
SHEET 1
T ype PS 20A
PDS:PS 20
PS 21
ISSUE:APRIL,
PIPE SUPPORTS
99
OF
Type PS 20E3
100
I a
1
.C\
*7:
type PS 21A
5591
Type PS 210
1 EE
Type PS 210
Weld
IL
(1
11
70
70
Li
Tie rod M16
Tie rod PS WA
PS 50A
o.
65 x 8
I. 65 x 8
1
C
o
0
0
type PS 20E
Concrete
0
c.:
N
(A
a
0
0
SI.No,
x8
65 x 8
300
x8
450
65
600
11
f1
Tie Rod
300
150
22
M20
450
150
22
M20
600
22
22
M20
M20
27
M24
750
150
150
300
200
150
450
200
27
M24
150
150
600
750
200
200
27
27
M24
150
150
900
1050
200
700
27
M24
27
m24
r,
0
a
4
o.
Chorine! Size
ISMC
W=.... ..
100
100
100
100
150
0
V
65
72
V
Angle Size
SI.No.
8
9
10
19' 61,1
PURPOSE
I:
o.
0. ti
tr
0
c
0
"..";
0 0'
c
aa ci'1,3
M24
Fogg:Comm
PREPARC 0
o
S.
2_,Nizi
ArPnovE0
REVIEWED
Ir
UAL(C
.PC
I Dw
Pll.11
PIPE SUPPORT
BRACKETS FOR HORIZONTAL PIPES
PDS:PS 24
ISSUE:APRIL .99
SHEET I OF
Type PS 24A
Type PS 248
O
O
z
a
Existing Structure
V
O
V
O
V
0
O
Z.3
\ Herod
w=
M24 PS 50 A
for
bracket PS 240
07
Section
SLUG.
r.
Horizontal
ISMC
Bracing
Angle
150
65 x 8
600
t,
150
65 x 8
750
3
4
150
150
65 x 8
65 x 8
900
1050
150
65 x 8
1200
65 x 8
1500
150
F or opplicntion refer PS 01
For welding delakrefer P590
Engg.Comml
PREPARED
Fcc priv._
REVIEWED
APPROVUT
PDS:1)533
PIPE SUPPORT
SUPPORT FOR HORIZONTAL PIPES
SHEET 1 OF I
Type PS 33
Existing structure
Weld
V
C
EL
J 1,0
Existing structure
Type
PS 330
0
0
0
0
0
V
0
_J
Weld
xi
0
4,
PS330.1,h=
sa,
SI.No.
0.
0
0
Angle
65 x 8
600
65 x 8
750
65 x 8
900
2-0 (l'ePl
DATE
Eagg.Comrh.
PREPARED
{-GC ^..o/
REVIEWED
Cu C niniC DC I
ttscrx-cd-t
APPROVED
nwr
PIPE SUPPORT
PDIL,
SUPPORT FOR HORIZONTAL PIPES
PDS:P535
ISSUE.AP1211, ,99
SHEET 1 OF 1
Existing structure
Type PS 35 A
E
et
.0
Weld
Existing structure
Type PS 35 0
22
SI.No.
4S
2
3
4
5
6
7
8
9
10
11
12
4.
0
0
II
ISMC
Channel
size
20'9'99
DATE
100
100
100
100
100
100
150
150
150
150
150
150
600
750
900
1050
1200
1500
600
750
900
1050
1200
1500
120
120
120
120
120
120
160
160
160
160
160
160
Engg.Comm.
PREPARED
n-
REVIEWE
APPROVED
PDIL
PIPE SUPPORT
SUPPORT FOR HORIZONTAL PIPES
PDS:PS36
1SSUE:APRIL.,99.
SHEET 1 op
-Co
.t?
Type PS 36 A
I1
EL
s_
.c
Existing structure
V
0
-Weld
Existing structure
100
I1
100
600
120
150
100
750
120
150
3
4
100
V
F
SI.No
100
250
200
16
18
100
250
200
16
18
120
150
100
250
200
16
18
120
150
100
250
200
16
18
1200
120
150
100
250
200
16
18
1500
120
150
100
250
200
16
18
150
600
140
200
140
300
240
20
22
8
9
150
150
750
140
200
140
300
240
20
22
140
200
140
300
240
20
22
10
11
150
150
900
1050
140
200
140
300
240
20
22
1200
140
200
140
300
240
20
22
12
150
1500
140
200
140
300
240
20
22
6
7
0
is
900
1050
bl
100
100
100
01
Bolts
IS:1363
Concrete
POS:ST71 I
(C)
M16 x 50
MI 6 x 380
M20 x 60
M20 x 470
00
Cy
DAT E
Engg.Corrim
PREPARED
7.0/y
RE VICWCE)
a-P---
ArrRovco
PIPE SUPPORT
PDS:P840
ISSUE.APRII...99
SHEET 1 OF 1
0
F
lype PS 40 A
Type PS 40 C
0
1
EE
EE
0
0
Weld
0V
0
a
O
a
0
Weld
0
4
0
6
a
h=
a0
Designation
Vertical
Transverse
-PS4OC .1
100
50
PS 40A.2-PS40C.2
150
50
PS
tt. 'Cr
DATE
ISSUED MR IMPLEMENTATION
PURPOSE
F..nyg.Cuumn
PREPARED
o it I117-r'
Rrv1cwE6 J APPROVED
NAMI .PS40 OWG
PDII,
c?
a
0
C
PDS: PS 65
PIPE SUPPORT
ISSUE: APRIL 99
Dimension in mm.
For welding.see PS 90
SHEET I OF I
Type PS 50.A
a
V
_C
O
V
O
As per PS 07
As per PS 08
V
O
9
0
C
V
C
V
O
C
AS
a:
0
Example of designation:
Trestle PS 65.1 h=
1=
Designation
PS 65.1
.c
PS 65.2
PS 65.3
PS 65.4
E3
Section
()Transverse
Verticol
ISMB 100
ISMB 150
ISMB 150
ISMB 200
ISMB 200
ISMB 250
ISMB 250
ISMB 300
Note:
1. For opplication.refer PS 06
NAkI
I O.F.A.
P. O. I. L. I
r,TF WI TRAP
DRAIN P in
VENT
M A Y-SP)
ASSEMBLIES
PDS : P -123
SINDRI
SHEET
G AS AND
STEAM
0
"------ISEENOTEN0-11
cip
s
.- - (
FOR PRESSURE
GAS AND
RATING :LI 900
CLASS
STEAM
FOR PROCESS
CONSIDERATION
OR
.._
0 0
3
FOR PRESSURE
RATINGS 3 900
CLASS
.
*
RATING >900
CLASS
/ 'CD
( INCWDING
PIPING TEST )
Ornims...
HA
4-
DATE
1 0KO. BY :(
ASSEMBLY NO A 004
.0
0 .. 0
FOR PRESSURE
ASSEMBLY NO A 002
0.. EENOTEN0-11
" IlL
FOR PIPING
TEST ONLY
ALL CASES
1 OFi
VENTS
A
MEDIUM
LIQUID .
0
FOR PRESSURE
RATINGS .->9011)
CLASS
)
-0
il APPD. BY :
kAA---"--r-.6
IMECH
.
i
P. D. I. L.
FOS :P-12 3
SINDRI
SHEET_ .2 OF 10
DRAINS
FOR HEADER
NP 5 yi
MEDIUM
DRAIN SIZE In s
TO 11/2"
GAS
FOR PIPING
J 0
TEST ONLY
[SEENO fli/Cn-----0
NO
A 101
ASSEMBLY
CONSIDERATION
OR
RATING 4 SOO
CLASS
ASSEMBLY
FOR PRESSURE
,-(13D
FOR PRESSURE to
RATING A- 900
GLASS
0
NO A 103
5
.
,-7
FOR PRESSURE
CD -
RATING 7 500
CLASS
FOP
DATE
c,. E4-0
.-
1
1
o ETA'L
CKD. BY
NO A 104
. CO
ii....
Pre
CLASS
ASSEMBLY NO A 106
STEAM
ASSEMBLY
ALL CASES
( INCLOUNG PIPI NC.
TEST)
102
GAS
FOR PROCESS
LIQUID
NO A
REFER SHEET
. I
(t-1
NO
3454.66
APPD. BY :
MECH
P. D. I. L.
PDS:P - 123
SINDR1
.3
SHEET ,
OF
ASSEMBLY NO A
107
ASSEMBLY NO
DRN BY: S.R.SW.RMA
DATE
A 108
APPD. BY :
I mEcH
10
I L.
P. D.
VENT , OR4. I N
AND :,-TrAm
TR,
PDS. P- 123
A5SEMBLIES
SINORI
41
il)
cf,
. 57 4'
al
CN
23
.
A
V)
1.-9
Z
-
Q
m
w
cc
ST
Boo
I
ti -97 r 4 -71ct
C.
SEE NOTE- 2 2 1 f (1, 314P
1
1, - -2 2)
-/
1
sEEN
Tho-4-20i-'
'
EC4_7_t
ti)
J>
n_
roil HEADER
col
.
83
SIZE 7-17."
_ _
A 109
.1-- -- r
74
;---i
35
0._-;
z
"
Fa-,
_.(39
z 2. '2 9)-- 12
x.
0- rujc_i 35
-- ....., 5^, 4'2
ASSEMBLY NO A Ho
LAI
26
--11
13 8:
3; '< I
ASSEMBLY___NO,
0
u.
10
U)
emu
14
all
14
15
36
1r
di
I....
800
....
40
ST
, 1 (2,
FOR HEADER SIZE _>_NB1Z
17
cif
.)
0
<
U
0
VI
10
0
CI
Z
/-
w
=
C
CC
i --ra --/
2 6"! Nr" , 38
,..
190 ..- ,
Z
Lo
S
U1
20 11!'
in
"11 - 42
SEE NOTE
33 go .......,.._
0
ll-
.E.-.
I
lie
3/AMr..
<
,.,.. SEE NCIE -V21 ,
- ---- ' ' s i. 2-2-
"-I SEE
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r.t 0,NC1 -. 5
D
2
u)
3?
FOR HEADER
(;)
r-- ST
800 _
r
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t
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@3
36
ST
ASSEMBLY 0.
07 .--..,
boo
DATE
40
A II2
I
49
CLASS.
ID
_._
, 3,4'
:^_
, FOR HEADER SIZENB12'
) C..
I CKD. BY: II) j:C_
4 (:;, S2I I
',..-1
(11\p? APPD. BY :
HEcm
r7.11'...7.7.71r7-:''.7.,:
rtgagegMr1,5
/01'
P. D. I. L.
SINDRI
PDS:P 4;
SHEET. . 5
_ .0F. IQ.
HEADER
Boo
LY NO
ASSEMB
A 120
ASSEMBLY NO
DEM.
: S.ft S H.e.11.MA
A 121
I
VENT ORL,I N
POS . P- 123
H EET 4 OF 10
fg
1115; \25)
1/42.1
3
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'-
b LC
2 2;
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OR HEADER S:ZE
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L7;
+
40
1.
col
22
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.7,
3,,;
(3
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S e E t :2'
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C1/4
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ri
!1/4?,
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:
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31)
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:
m \ (If
1:
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4.55. F:0 61.N 7.0 . 1.., 123
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----
FOR HEADER SIZE 7
--rgit
. ;
o
z
u;
39,
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1_1324
35
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i 40
j
I
I
SEENOTE1 33
ASSEMDL Y NO
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(-4?
(
r,
A 125
F OR HEADER SRE 1 2
.DATEm
Ft
CKO. Gti :
APPD..
P. D. I. L.
P DS: P- 123
SINDRI
SHEET 7 OF. P
DESCRIPTIONS
Vi e
1/2
HAL F
PIP E.
0
0
NIPPLE ,
0
0 I
0
0
14
ORN. BY:
kkkan%
DATE
4 s 88 I
100
-trkti/ I
APPO BY :
l_pt!c
14
P. D. I. L.
SINORI
POS F-123
.
SHEET 8
DESCRIPTIONS
?7
28
29
30
31
32
(.13)
-
51
66-)\
3.
ES)
,-jag)
"Th
1)
El?)
EID
1
Th
E133
()RN BY
PTD5
DATE
598
CKO BY
APPO. BY
or_1.9
P. D. I. L.
SINDRI
PDS P -123
SHEET.."...0E.1
NOTE S:
DRN. BY:
S.R.SHARMA I 4 .DATE
epaia
CKD. BY
APPD. BY :
MECH
PDS: P : 12
.S.
DRIP LEG ON STEAM HEADER
P. D. I. L.
SINDRI
SHEET4.9....OPAQ.
HEADER
--i
t
t\.-.-).cf
_-
. 1I
n ck
1 1
DC)
--)
TO TRAP
ret
DRIP LEG
HEADER SIZE T
(DH)
.
BRANCH SIZE
2
( DL)
TENGTH BET.C.L
OF HEADER AND 300
WE LD OF DRIP
3'
r"-"' 6"
8"
10"
3"
4" i 6"
6"
8"
8"
350
350
400
400
12" I. 14"
16"
18"
20"
24"
10"
12"
12"
12-
12"
450
500
525
550
600
300
LEG c L )
300
I
TABLEI
DRN. BY
:ty:.
,..
I
I '. 5 ea I
DATE
cro Ps (
L.
'1
APPD. RV
m
EC
IN
NSTALLATIO
ON OF LPG MOUNDED
D BULLETS
AT NRL,A
ASSAM
CON
NSTRUCTIO
ON/ERECTIO
ON, PRE-CO
OMM, COMM
M163-E-601
EM
DOC. NO.
REV
Page 1 off 51
0
P1
P
RE
EV.
15.09.15
29.07.15
REV DATE
D
--EFF
FDATE
FORM
M NO: 02-0000-00
021F1 REV4
JKY
JKY
P
PREPD
DILIP
DILIP
REVWD
GC
GC
APPD
All rights
r
reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 2 of 51
CO
ONTENTS
S NO.
Sl.
1
2
DE
ESCRIPTION
N
REMARKS
S
General Scope of W
Works and Se
ervices
Construcction / Erectiion
General Scope of W
Works and Se
ervices
mmissioning
Pre-com
Basic Pla
an for Temp
porary Servicces
Mechaniical completion
Commissioning
LIST OF
F ANNEXU
URES
ANN
NEXURE
NU
UMBER
DE
ESCRIPTION
N
ANNEXURE-1
Contracttors Work D
Definition
ANNEXURE-2
Detail Te
echnical Sco
ope
ANNEXURE-3
Quality Control
C
Proccedures and Inspection
Requirem
ment
ANNEXURE-4
Evaluatio
on and Prog
gress Reportting
ANNEXURE-5
General Notes
ANNEXURE-6
REMARKS
S
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 3 of 51
CONSTRUC
C
CTION / ER
RECTION A
AND PRE COMMISSIO
C
ONING
1.0
G
General
sco
ope of Work
k and servic
ces - Constrruction/Erec
ction
CONTRACT
C
TOR shall be
e responsib
ble for safe transportattion, constrruction and erection
o the prefa
of
abricated Mo
ounded Bullets/Unit in
ncluding rolling of plattes, shot bllasting &
e
edge
preparration in co
ontractor sh
hop, rolling
g of plates at site is not permitted & also
b not limitted to the fo
but
ollowing:
1.1
1.2
1.3
1.4
Establish an
E
nd operate adequate m
material con
ntrol system
m in site for receipt, unloading,
u
in
nspection, maintenance
m
e, handling, storage an
nd utilization
n to ensure
e all Equipm
ment and
M
Materials
arre preserved and available as necessary fo
or completio
on of the Mounded
B
Bullets/Unit.
P
Provide
and supply all sttaff, tradesm
men and labo
ours for implementation of the WOR
RK.
1.5
E
Establishme
nt of overall construction
n policy and procedures for the Mou
unded Bullets/Unit.
1.6
1.7
Ensuring tha
E
at all parts of
o the Moun
nded Bulletss/Unit are cconstructed and tested strictly in
a
accordance
with the sp
pecifications and applica
able codes and standa
ards asked ffor in the
p
project
documents.
1.8
E
Ensuring
tha
at constructio
on is accomp
plished in acccordance with
w the Time
e/Job schedu
ules.
1.9
Provide tran
P
nsportation of
o all Equip
pment and Materials to
o be provid
ded and sup
pplied by
C
CONTRACT
TOR under th
he CONTRA
ACT either fro
om inside orr outside to Site.
S
1.10
Construct, op
C
perate and maintain
m
all temporary fa
acilities requ
uired for its personnel
p
in
nvolved in
the WORK.
1.11
Provide transsportation in
P
n the area of
o the Site and between Site and te
emporary faccilities for
a its perso
all
onnel involv
ved in the implementation of the WORK, including field
d labour,
a
administrativ
ve staff, etc.
1.12
1.13
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 4 of 51
1.14
1.15
Provision of labour and facilities for loading, unloading and transportation of the Equipment
P
w
within
the site area.
1.16
Performance
P
e and/or provvision of all other workss and/or servvices require
ed for perforrmance of
the WORK.
1.17
1.18
P
Prefabricatio
on of piping spools
s
in a sshop on the Site.
1.19
1.20
Installation of
o pipe work including fie
eld fabrication at site.
1.21
Installation and
a
testing of all instrrumentation network and equipme
ent of the Mounded
B
Bullets/Unit.
1.22
Installation and
a testing of
o electrical ssystem and equipment
e
o the Mound
of
ded Bullets/U
Unit.
1.23
Maintenance
M
e of construcction equipm
ment, vehicle
es and tackles of the Mounded
M
Bullets/Unit,
d
during
construction and erection perriod.
1.24
P
Pre-commiss
sioning, Com
mmissioning of the Moun
nded Bulletss/Unit.
1.25
C
Carrying
out Mechanical Completion
n.
1.26
P
Perform
all material
m
iden
ntification as per applicattion codes a
and standard
ds.
1.27
P
Provide
draw
wings and do
ocuments ass required.
1.28
C
Contractor
sh
hall ensure and
a shall be
e solely respo
onsible for ssafety in all activities.
a
2.0
G
General
sco
ope of WOR
RK and Serv
vices- Pre-commission
ning
CONTRACT
C
TOR shall be responsib
ble for the pre-commisssioning pha
ase of the Mounded
B
Bullets/Unit.
CONTRACT
C
TOR shall prrovide at SIT
TE an adequ
uate numbe
er of qualified pre-comm
missioning
e
engineers
to direct and control
c
pre-ccommissionin
ng activities.
CONTRACT
C
TOR shall als
so ensure th
hat all specia
al tools and test equipm
ment required
d for prec
commissioni
ng are availa
able at its ow
wn cost.
CONTRACT
C
TOR shall provide ad
dequate con
nstruction labour, con
nstruction to
ools and
e
equipment
fo
or pre-comm
missioning.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 5 of 51
Pre-commis
P
ssioning wh
hich shall be
e performed
d by CONTRACTOR sh
hall include
e, but not
limited to, th
he following
g:
2.1
Cleaning, flu
C
ushing, drain
ning and re
emoval of te
emporary bliinds and the replaceme
ent of all
p
permanent
ittems remove
ed while the WORK is in
n progress.
2.2
Cleaning
C
of any other parts,
p
which
h have corro
oded to an extent, which, will detrrimentally
affect
a
Mounded Bullets
s/Unit/Mound
ded Bullets//Unit perforrmance or run length for such
reasons
r
as in
ncreased fou
uling due to rust.
2.3
Checking, Te
C
esting, calibration simula
ation test an
nd adjustmen
nt of instrum
ments, equipment and
s
systems
inclu
uding contro
ol valves and
d safety devices, and insstallation and checking of
o orifices
p
plates
and otther sensor devices in sso far as this
s can be don
ne before acctual operation of the
ittem concern
ns of comple
ete system a
and loops.
2.4
2.5
2.6
For
F all piping
g systems, installation a
and removall of tempora
ary blinds ass required, ccirculation
and
a commiss
sioning of syystems inclu
uding processs systems, services, effluent and drainage,
d
utilities
u
distrib
bution, relieff and blow d
down and interconnecting lines.
2.7
All
A such furth
her works which
w
CONT
TRACTOR ju
udges to be necessary or in the re
easonable
opinion
o
of OWNER
O
is ne
ecessary to bring the Mounded
M
Bu
ullets/Unit to a state of readiness
r
fo
or the intro
oduction off feedstock into Proce
ess Mound
ded Bullets//Unit for prrocessing
requirements
r
s and for saffe commenccement of op
peration.
3.0
B
Basic
Plan for
f Tempora
ary Service
es
3.1
C
Constructio
on Power:
F fabricatio
For
on/constructtion works a
at site, Consttruction Pow
wer, 3-Phase
e, 4-Wire, 415 Volt
AC, 50 Hz will
A
w be availab
ble at two po
oints for Con
ntractor on frree of cost basis.
b
Contractor shall
C
s
have to
o arrange fu
urther distrib
bution which
h shall includ
de adequate
ely rated
d
distribution
and
a
sub distribution boards/feede
er pillars, po
ower supplyy cables an
nd other
a
associated
m
materials
for feeding loa
ads to carry out construcction and fab
brication acttivities at
h own cos
his
st. Contracto
or is require
ed to obtain all statutory
ry approvalss/License fro
om State
G
Govt.
C
Contractor
shall
s
arrang
ge for nece
essary elecctrical equip
pments, cab
bles etc. fo
or further
d
distribution
s
suiting
to his
s requiremen
nt at his own
n cost. The C
Contractor shall
s
engage
e licensed
e
electrician
fo
or this purpo
ose. Suitable power dis
stribution centre of inco
oming breaker feeder
a outgoing
and
g breakers & MCCB feed
ders shall be
e arranged b
by the Contra
actor.
For consume
F
ers who are
e more than
n 100m awa
ay, intermediate feeder pillar boxess shall be
in
nstalled from
m where pow
wer shall be tapped as per
p requirem
ment. Each feeder
f
pillar box shall
b outdoor type cubicle
be
e and comp
prising one incomer MC
CCB bus-ba
ar and few outgoing
M
MCCBs.
FORM NO: 02-0
0000-0021 F2 RE
EV3
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 6 of 51
3.2
Adequate no
A
os. of interconnecting e
earth pits forr connecting
g electrical equipment
e
s
should
be
c
constructed.
3.3
All interconn
A
necting cable
es shall be multicore, stranded
s
cop
pper conduc
ctor PVC ca
ables and
these shall be
b buried dire
ectly under soil.
s
3.4
Contractor shall
C
s
arrange
e all necesssary require
ements for developing
d
fabrication yyard with
b
barricading
n
nearby
the plant.
p
3.5
Water for co
W
onstruction shall be used
d from existiing net workk of water su
upply insted--of taking
the undergro
ound water. One
O point frree cost of water
w
supply shall be pro
ovided by NR
RL for the
s
same
and alll further distributions sha
all be laid byy CONTRAC
CTOR.
3.6
S
Sewage
& Refuse
R
Disp
posal
M
Mechanical
Completion
n
Mechanical
M
C
Completion
means the time when all construction, erectio
on & installation work
as
a per finallyy approved P&ID after HAZOP sttudy and p
pre-commisssioning relate
ed to the
Mounded
M
Bullets/Unit
B
ordance with the Pro
oject drawings and
is completted in acco
s, and all mechanical
specification
s
m
a
and
pressurre tests, inccluding but not limited to hydrote
esting, non-operating ad
djustments, cold alignment checks, final cleanu
up, field calib
bration of
safety
s
valves
s, calibration
n of all instru
uments, instrrument loop checking an
nd testing, m
monitoring
/ control / sa
afety system
ms checking and testing
g, and all prre-commissioning activitties have
been
b
comple
eted, all inco
oming & outg
going service
es and utilities have bee
en connected to each
Mounded
M
Bu
ullets/Unit. In
nterconnections of proce
ess lines an
nd interconne
ection are completed
c
and
a the Mou
unded Bulletts/Unit is rea
ady in everyy respect forr commissio
oning and fo
or the first
in
ntroduction of
o feed mate
erials.
Itt means that for Mechanical Com
mpletion, CONTRACTO
OR shall pe
erform all necessary
n
works,
w
tests and checks of all discipllines.
When
W
OWNER is satisffied that Me
echanical Completion of
o the Mounded Bullets//Unit has
b
been
achievved, the OWNER
O
sh
hall issue certificate of Mechan
nical Comp
pletion to
C
CONTRACT
TOR in accorrdance with tthe CONTRACT.
5.0
C
COMMISSIO
ONING
5.1
S
Schedule
fo
or Commiss
sioning
CONTRACT
C
TOR shall prepare a scchedule for commission
ning, start-u
up, and perfformance
te
esting and initial operattion in conjunction with OWNER. Th
his shall be issued at le
east three
m
months
before pre comm
missioning off the first fac
cility.
This schedule shall inclu
T
ude all activvities as deta
ailed herein and any oth
her special activities,
w
which
require
e to be perfo
ormed during
g commissio
oning.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
5.2
EM163-E-601
DOC. NO
O.
REV
V
Sheet 7 of 51
C
Commission
ning
CONTRACT
C
TOR shall be respon
nsible to perform
p
com
mmissioning
g of the Mounded
B
Bullets/Units
s and to pro
ovide necesssary facilitiies during ccommissioniing of the Mounded
B
Bullets/Unit
i
including
the
e Performan
nce Tests. CONTRACT
C
OR shall pro
ovide comm
missioning
e
engineers
an
nd supporting staff and adequate
a
co
ommissioning
g labour.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 8 of 51
AN
NNEXURE--1
CON
NTRACTOR
RS WORK DEFINITIO
ON
C
CONTRACT
TOR shall pe
erform/prov
vide the following activ
vities but no
ot limited to
o:
1.
CONTRACT
C
TOR scope of work shall
s
broadlly be conssist of consstruction / erection,
pre-commisssioning, co
r
refurbishing,
ommissioning
g and Start Up of the Mounded
M
Bu
ullets/Unit
u
under
the management
m
t of commisssioning team
m it include
es but not liimited to civvil works,
fa
abrication & erection off structural steelwork,
s
field assemb
bly, mechaniical erection
n and / or
a
assembly
an
nd installatio
on of all equ
uipment and
d machineryy, piping, ele
ectrical systtems and
n
network,
insttrumentation
n, insulation, painting, etc.,
e
except in
i so far as "Contract" otherwise
o
p
provides,
the
e provision of all temporary facilities, staff, tra
adesmen, la
ab our, tools, tackle,
equipment and materia
c
construction
als, insurancce, consuma
ables and everything
e
w
whether
of
te
emporary or permanentt nature neccessary and
d required in
n and for the
e work, so ffar as the
n
necessity
forr providing th
he same is sspecified or reasonably
r
i
inferred
in or from the co
ontract.
2.
3.
P
Perform
all equipment
e
errection workks as per Annex-2B, titled equipment erection work.
w
4.
4
P
Perform
all electrical
e
worrks as per A
Annex-2C, titled
5.
P
Perform
all in
nstrumentatiion works ass per Annex--2D, titled instrumentatio
on works.
6.
P
Perform
all in
nsulation wo
orks as per A
Annex-2E, tittled insulatio
on works.
7.
P
Perform
all painting
p
workks as per An
nnex-2F, title
ed painting work.
w
electriical work.
CONTRACT
C
TOR shall be
e responsible
e for providin
ng services and materia
als for construction of
a temporary
all
y facilities, which
w
are essential
e
forr successful completion
n of construcction and
e
erection.
The CONTR
T
RACTOR sha
all establish, operate an
nd maintain all tempora
ary facilities, such as,
b not limitss to:
but
a Labour camp/officers
a)
c
s camps.
b Fabricatio
b)
on shops/ya
ard.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 9 of 51
c Worksho
c)
op for mainte
enance of co
onstruction/te
esting equipment.
d Field drawing office.
d)
e Tempora
e)
ary warehous
ses, includin
ng open storage yards.
f)
All temporary or ap
pproach roa
ads for carrrying out th
he WORK including te
emporary
approach
h roads for access
a
to CO
ONTRACTO
ORS site offfice/worksho
op/camp, etcc. ground
preparation for heavy lifts includ
ding approacches to cran
nes for heavy lifts. OWN
NER does
not take any
a responssibility for ma
aking temporary roads.
j))
k All drain
k)
nage around the facilities create
ed for his WORK, an
nd sewage disposal
arrangem
ments for lab
bour camps/o
officers cam
mps, site officces, etc.
l))
Supply to OW
S
WNER comp
plete surveyy report within three (3) working day
ys after completion of
a survey.
any
10.
11.
P
Perform
all nondestructiv
n
ve, hydrosta
atic and pre commissioni
c
ing testing required.
12.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 10
0 of 51
13.
P
Perform
all welding
w
inclu
uding radiogrraphy requirred.
14.
P
Provide
draw
wings and do
ocuments ass required.
15.
Provide mob
P
bilization and
d demobiliza
ation, tempo
orary material and
u
utilities
required executin
ng work.
tem
mporary facilities and
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 11
1 of 51
AN
NNEXURE-2
2
D
DETAIL
TE
ECHNICAL
L SCOPE
See accomp
panying by discipline:
d
Annexure-2A
A
A
B
Annexure-2
A
Eq
quipment errection
Annexure-2C
A
C
Annexure-2
A
D
In
nstrumentatio
on work (Refer documen
nt EM163PNIN-7901-00
0 attached in
n Tender)
Annexure-2
A
E
In
nsulation worrk
Annexure-2
A
F
Pa
ainting workk
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 12
2 of 51
ANN
NEXURE-2A
PIPE PREFABRIC
P
CATION AN
ND ERECT
TION
1.0
P
PIPING
1.1
M
Magnitude
of
o Piping
CONTRACT
C
TOR shall pre
efabricate, install and te
est all piping
g as shown on
o the plan drawings
a isometric
and
cs.
2.0
P
PIPING
FAB
BRICATION AND EREC
CTION
2.1
2.2
Miscellaneou
M
us piping ma
aterials for vvents, drainss, instrumentt connection
ns, etc. on equipment
s
shall
be insta
alled using P & ID'S and
d equipment drawings.
2.3
2.4
CONTRACT
C
TOR will furn
nish OWNER
R with a marrked up set of isometrics
s identifying
g all spool
p
pieces,
and weld numb
bers. All piping spools shall be cle
early identified, per isom
metric by
m
means
of sta
ainless steel tags affixed
d with wire.
2.5
CONTRACT
C
TOR is respo
onsible for tthe fabrication and erecction of pipe
e supports, hangers,
a
anchors
and guides, as required
r
by the drawings
s and speciffications.
Spring pots and spring hangers, which
S
w
shall be provided
d by CONT
TRACTOR as
a will be
installed, ad
a
assembled,
djusted and unlocked byy CONTRAC
CTOR after hydrostatic testing of
the line. The required an
ngle iron will be decided in the field a
and supplied
d by CONTR
RACTOR.
2.6
CONTRACT
C
TOR shall be
b responsib
ble for the fabrication, installation and disma
antling of
te
emporary sp
pool pieces and blinds required for control va
alves, safety
y valves and
d in - line
in
nstruments during testting and cleaning. Requirements for these shall be m
minimized.
R
Requirement
ts for these will
w be presccribed by OW
WNER.
2.7
CONTRACT
C
TOR is resp
ponsible for the installa
ation and te
esting of all piping and steam,
e
electrical
tra
acing and all materials including all items neccessary to completely
c
cclose the
s
systems
in strict
s
accordance with th
he established test systtem procedu
ures and priorities as
d
directed
by OWNER.
O
2.8
F
Flushing
an
nd Cleaning of Piping S
Systems
i))
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 13
3 of 51
These ca
aps shall not be remo
oved until se
ections are in the course of erection after
delivery at
a SITE and then shall b
be removed for
f refuse.
iii) During fa
abrication an
nd erection th
he sections shall be insp
pected or intternal cleanliness.
abricated pip
ping shall be
e cleaned att the comple
etion of fabrication. Care
e shall be
iiii) All field fa
taken to see that all burrs, weld
ding icicles, and weld sp
patter and re
emoved by reaming,
ement, morta
ar, sand,
chipping,, filling or her to meanss. All foreign materials such as ce
heavy oiil film & loo
ose scale sshall be rem
moved from the interiorr of pipe th
horoughly
flushing with
w water.
ivv) The wate
er which will be used for testing and
a
flushing
g of the pip
ping system shall be
recollecte
ed per instru
uction given by OWNER
R.
v)
v Piping sy
ystems shalll be flushed
d with suitab
ble water ass supplied by
b Contracto
or unless
designate
ed for nitrog
gen or air ttesting. OW
WNER'S approval is required before
e start of
flushing.
v CONTRA
vi)
ACTOR shalll supply all e
equipment, pumps,
p
gaug
ges, etc. req
quired for
flushing and
a
testing
g of the pipin
ng systems.
v For hydro
vii)
o testing and
d flushing the piping CO
ONTRACTOR
R shall weld and caps an
nd
install drain plugs, remove end caps after successful hyydro test.
3.0
H
HYDRO
TES
STING
3.1
Inspection an
nd hydro tessting of the p
piping systems shall be in accordan
nce with the drawings
and specifica
a
ations and in
n strict witne
ess by OWNE
ER represen
ntatives.
3.2
A
Atmospheric
c pressure systems
s
shalll be:
-
3.3
CONTRACT
C
TOR shall tes
st all piping systems as
s per the pro
oject test dia
agrams. Tessting is to
b witnesse
be
ed and approved by OWNER and where applicable
e by the appointed
a
(independent inspection authority) ffiled inspecttor. A test schedule by test system
m shall be
p
prepared
by CONTRACT
TOR and shall be submitted to OWN
NER for App
proval.
3.4
T
Testing
and completion shall
s
be in a
accordance with
w project system
s
priorrities.
3.5
All equipme
A
ent, pumps, gauges, pressure rec
corders tem
mporary pipin
ng and fittings, test
g
gaskets
and bolting, required for tessting of the piping
p
system
ms and part of CONTRA
ACTOR'S
s
supply.
Before testing CO
ONTRACTO
OR shall calibrate its testting equipme
ent.
3.6
CONTRACT
C
TOR shall su
upply and insstall blind fla
anges when required to enable testiing of the
liines.
3.7
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 14
4 of 51
permanent gaskets
p
g
whe
ere test blin
nds are loca
ated for hyd
drostatic tessting. On successful
c
completion
o a test the permanent
of
p
g
gasket
shall be installed when the blinds are rem
moved.
3.8
Piping system
P
ms shall be tested with suitable watter. Extreme
e care shall be
b taken tha
at suitable
w
water
is used
d for stainlesss steel systtems. For sttainless stee
el the water must
m
be app
proved by
O
OWNER
and
d shall have a content off chlorides 50 mg/L
3.9
3.10
CONTRACT
C
TOR is to pe
erform the testing in a sequence so
s as to allo
ow sufficientt time for
in
nsulation an
nd/or painting
g to complette within the time frame of the projecct schedule.
3.11
3.12
Erected pipin
E
ng shall be hydrostatica
ally tested in test syste
ems, but nott through eq
quipment,
c
control
valve
es etc. excep
pt where pipiing is welded
d to equipment.
3.13
CONTRACT
C
TOR remainss responsible
e for ensurin
ng that no ittem of equip
pment, or insstrument,
iss damaged by the test pressure
p
or the test fluid
d. Suitability of test fluid to be appro
oved prior
to
o testing by the OWNER
R.
3.14
3.15
3.16
3.17
3.18
The following
T
g activities by
b CONTRA
ACTOR are included
i
for the reinstattement of pip
ping after
h
hydro
testing
g:
- CONTRA
ACTOR insta
alled temporrary testing blinds
b
to be pulled.
-
Tempora
ary spool pieces taken out.
Gaskets renewed, te
emporary rep
placed with permanent.
p
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 15
5 of 51
Flange co
onnection bo
olts tightene
ed.
Chemica
al cleaning pe
erformed.
ation of control
c
and safety va
alves and in - line instrumentts which
Reinstalla
CONTRA
ACTOR has removed for hydro-testing.
3.19
4.0
4
P
PIPING
MAT
TERIAL IDE
ENTIFICATIO
ON AND PA
AINTING
4.1
4
4.2
4
4.3
4
The governin
T
ng principle shall be tha
at in the insta
alled piping systems, all components can be
id
dentified and their origin and comp
plete specificcations can be determined. The method for
id
dentification and stamp
ping or tagging of the various
v
com
mponents of the system shall be
w
worked
out in
n coordinatio
on with OWN
NER and only be implem
mented afterr approval.
CONTRACT
C
TOR shall be
e held responsible for this requireme
ent as a min
nimum, and any
a other
r
requirements
s of local codes
c
and regulations as to identification an
nd documen
ntation of
m
materials.
4.4
4
Surface prep
S
paration and
d paint appliccation of pip
ping system by CONTRA
ACTOR, sha
all be per
p
paint
specific
cation.
4.5
4
CONTRACT
C
TOR shall asssure that no
o welds are covered by prime coatss prior to accceptance
o hydro test.
of
4.6
4
CONTRACT
C
TOR must ensure
e
that all stamping
g such as code stamp
ps, registratiion spool
id
dentification, charge num
mbers etc. shall
s
be visib
ble after pain
nt work.
5.0
W
WELDING
5.1
A welding shall
All
s
be carried out according to codes and speccifications.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 16
6 of 51
5.2
W
Welder's
qua
alification.
5.2.1
5.2.2
5.3
Welders ide
W
entification stamps
s
shall be provide
ed by CONT
TRACTOR. Each weld shall be
c
clearly
stamped with welders
w
iden
ntification. All
A welding iincluding tack welding shall be
c
carried
out by qualified
d welders. U
Unstamped welds shalll be-removed and rep
placed at
C
CONTRACT
TOR'S expen
nse.
5.4
J SITE fab
Job
brication sha
all be carried
d out under cover
c
where possible.
5.5
W
Weld
spatterr shall be kno
ocked off around all welds leaving a smooth cle
ean surface.
5.6
5.7
T interior welds
The
w
of orifice flanges sshall be grou
und smooth.
5.8
E
Electrodes,
Rods, Wire
es and Fluxe
es
Electrodes shall be store
E
ed in the ma
akers airtight containerss until require
ed for use. E
Electrode
h
heaters
shalll be used on
n Job SITE, ffor low hydro
ogen types of
o electrodess.
5.9
O
Open
Air We
elding
Where welding in the open
W
o
air is unavoidable
e, WORK must
m
be disccontinued w
where the
q
quality
of the weld mayy be impaire
ed by weath
her conditio
ons. Includin
ng but not limited to
a
airborne
moisture, sand
d or high wiinds. After rain
r
the metal surfaces
s shall be dried. For
m
metal
temperature below
w 5 0C joints to be preheated.
5.10
W
Welding
Pro
ocedure Qualification
5.11
CONTRACT
C
TOR shall supply we
elding proce
edure speccifications and
a
qualificcation in
a
accordance
with
w the rule
es as set by OWNER.
F
Fees
for ins
spection required for we
elding proce
edure and w
welders qua
alifications, supply
s
of
e
equipment
required for the qualificcation test of
o welders a
and welding proceduress are for
a
account
of CONTRACTO
C
OR.
5.12
Inspection and
a Testing
g
5.12.1
Inspection of
o welds sha
all be in acccordance with
w
the insttructions of OWNER and/or the
r
requirements
s of codes and standard
ds.
5.12.2
C
CONTRACT
TOR shall be
e responsiblle for the re
epair of faultty welds and
d for all the
e required
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 17
7 of 51
C
CONTRACT
TOR shall pro
ovide NDE sservice, acce
eptable to OWNER.
NDT inspection shall be carried out in accordance with code
N
es for all line
es as indicatted in the
p
piping
speciffication.
6.0
S
STRESS
RE
ELIEVING
6.1
CONTRACT
C
TOR shall prrovide stresss-relieving service accep
ptable to OW
WNER. Spo
ool pieces
s
shall
be stre
ess relived in an apprroved furnacce equipped
d with therm
mostatic control and
te
emperature recorder. Field
F
welds to be stresss relieved w
with electricc resistance heaters.
T
Temperature
e cycles to be monitored
d with portab
ble temperatu
ure recorderr.
6.2
7.0
T
TRANSPOR
RTATION
The following various ca
T
ategories off transportattion of pipe,, pipe fitting
gs and preffabricated
p
pipe
spools will be pe
erformed byy CONTRAC
CTOR. All categories include load
ding and
u
unloading
ma
aterials. Cattegories will consist of but not limited
d to:
-
Instrumen
nt connectio
ons (up to an
nd including the first blocck valve).
From CO
ONTRACTOR
R'S warehou
use to CONT
TRACTOR'S
S pipe prefab
b shop.
From CO
ONTRACTOR
R'S pipe pre
efab shop to CONTRACT
TOR'S paintting shop.
From CO
ONTRACTOR'S pipe pre
efab or painting shop to
o CONTRAC
CTOR'S storrage area
or workin
ng area locatted on site o
or any other location on SITE.
S
All transsportation re
equired perrforming no
ondestructive
e testing off prefabrica
ated pipe
spools.
8.0
L
LIFTING,
LIF
FTING EQUIPMENT AN
ND GEAR
8.1
Rigging and
R
d hoisting shall be exxecuted as per consttruction spe
ecification and
a
local
r
requirements
s and safetyy rules, as manufacturers instruction
ns. If there are
a stringent one shall
p
prevail.
8.2
T
Testing
And
d Certificatio
on
All CONTRA
A
ACTOR furn
nished crane
es, lifting ap
ppliances an
nd lifting ge
ear must be properly
te
ested, exam
mined and/orr inspected b
before being used on SIT
TE, and at the intervals specified
in
n the applica
able regulatiions. Copiess of the relev
vant certifica
ates must alw
ways be ava
ailable on
S
SITE
for insp
pection on re
equest by OW
WNER or otther authoritiies.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 18
8 of 51
8.3
O
Operation
8.3.1
CONTRACT
C
TOR shall no
ot permit a lifting appliance to be
e operated otherwise
o
th
han by a
p
person
traine
ed and comp
petent to do so.
8.3.2
CONTRACT
C
TOR shall take
t
expresss steps to ensure that all personnel employed by
C
CONTRACT
TOR are com
mpetent and experienced
d for their asssigned tackss.
9.0
D
DRAWINGS
AND DOCU
UMENTS
C
CONTRACT
TOR shall fill in checklistss as required
d by OWNER.
10.0
M
MISCELLAN
NEOUS
10.1
CONTRACT
C
TOR shall furrnish all field
d engineering surveying layout, and checking to
o properly
in
nstall all abo
ove ground piping to m
meet all requ
uirements off the drawings and specification.
O
OWNER
is authorized
a
to
o reject any W
WORK alrea
ady installed
d, which is no
ot in accorda
ance with
d
drawing
and specifications and of ad
dequate qua
ality.
10.2
10.3
Underground
U
d service lin
nes are marrked at their installation
n limits to above
a
groun
nd piping,
in
ndicating line size, service and line number.
10.4
During stora
D
age, fabricattion and ere
ection, care must be ta
aken to ensu
ure that san
nd, scrap
m
materials,
we
elding rods, items of clo
othing and other
o
foreign
n bodies are not allowed
d to enter
p
piping.
10.5
All connectio
A
ons which are left open
n by CONTR
RACTOR shall be well protected,
p
so that no
s
sand,
dirt or any foreign objects com
me into the syystem.
10.6
In certain in
nstances sp
pecial bolting torques might be re
equired on critical con
nnections.
CONTRACT
C
TOR will arra
ange WORK in accordan
nce with thesse requireme
ents.
10.7
10.8
10.9
10.10
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 19
9 of 51
10.11
Since CONT
S
TRACTOR is
s responsiblle for both the prefabriccation and th
he erection of all the
p
piping,
it is CONTRACT
C
TOR'S sole rresponsibility
y to ensure that all pipin
ng to be insstalled fits
p
properly
prio
or to lifting. CONTRAC
CTOR is to check all Mounded
M
Bu
ullets/Equipm
ment and
p
piping
to be piped to, for
f proper lo
ocation and orientation.. OWNER will
w not ente
ertain any
c
claims
for exxtra work.
10.12
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 20
0 of 51
ANN
NEXEURE-2
2B
EQUIPM
MENT (MOU
UNDED BU
ULLETS/DR
RAIN VESS
SEL) EREC
CTION
1.0
S
SURVEYING
G
1.1
Baseline and
B
d base elevvation will be
e furnished to the CON
NTRACTOR. CONTRAC
CTOR will
furnish all su
urveying from
m this baselin
ation.
ne and eleva
1.2
OWNER sha
O
all have the authority at any time to
o determine in accordance with the drawings
o written directives, the correctnesss or complete
or
eness of the
e lines in use
e by CONTR
RACTOR.
1.3
Any erroneo
A
ous WORK shall be co
orrected to OWNER'S
O
ssatisfaction at CONTRA
ACTOR'S
e
expense.
2.0
R
RIGGING
ST
TUDIES AND PLANS
2.1
C
CONTRACT
TOR shall supply rigging studies and
d plans as sp
pecified.
3.0
E
EQUIPMENT
T HANDLING
3.1
3.1.1
3.1.2
3.1.3
3.1.3.1
G
GENERAL
All of the Mo
A
ounded Bullets/ Drain Vessel
V
mustt be plumbe
ed, leveled and aligned
d with the
c
coordinates
n plan and elevation an
nd to the to
olerances
specified on the drawiings both in
c
called
out in the speccifications, sspecific ma
anufacturerss instruction
ns or recom
mmended
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 21
1 of 51
m
manufacture
's practices.
-
Prior to setting
s
the equipment
e
on the founda
ations, the u
underside off the equipm
ment base
plate or supports will
w be clean
ned free of oil, grease
e and otherr loose matterials by
ACTOR.
CONTRA
Mounded
d Bullets/equ
uipment sha
all be set tru
ue to line. att correct ele
evation and in proper
orientatio
on as shown
n and noted o
on the drawiings.
Maximum
m allowable setting tollerances sh
hall be in a
accordance with manufacturers
requirements or with the specificcations, whic
chever is mo
ore stringent..
The Mou
unded Bulle
ets/equipment shall be set, levele
ed, aligned and inspeccted with
precision
n tools (ste
eel straight edge, gra
aduated ma
achinist levvels, dial in
ndicators,
theodolite
es, water levvel instrume
ents, turbine levels, etc.)). Setting, le
eveling and alignment
a
shall be according
a
to
o manufacturrer's recomm
mended tolerrances and specification
s
ns.
CONTRA
ACTOR shalll remove all temporary shipping
s
sup
pports or ere
ection materials.
CONTRA
ACTOR shall do surfacce preparatio
on for, and apply coating and wra
apping on
buried ve
essels before
e installation
n.
For Moun
nded Bulletss/equipmentt with sliding
g type suppo
orts, CONTR
RACTOR will remove
dirt, grea
ase or othe
er foreign m
matter and will
w coat with graphite grease sup
pplied by
CONTRA
ACTOR on th
he support.
4.0
4
M
MATERIAL
HANDLING SYSTEM
4.1
4
E
ERECTION
& COMMISS
SIONING
4.1.1
4
4.1.2
4
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 22
2 of 51
4.1.3
4
4.1.4
4
The purchas
T
ser shall be responsible
r
for supplying
g his part off material on
nly as covere
ed
b the clausse pertaining to the wo
by
ork to be excluded
e
from Contracto
ors scope of
s
supply.
4.1.5
4
After erectio
A
on at site, related
r
Mou
unded Bulle
ets/Drain Ve
essel shall be
b tested fo
or
s
satisfactory
o
operation
for mechanica
al completion and full-lo
oad performa
ance run. Th
he
C
Contractor
shall carry ou
ut performance test as per mutually agreed prrocedure. Th
he
d
details
of th
he procedurre shall be
e submitted by the Co
ontractor forr purchaserrs
a
approval.
4.2
4
M
MECHANICA
AL COMPLE
ETION
4.2.1
4
4.2.2
4
The OWNER
T
R shall inspect and ccertify that the
t
Contracctor execute
ed the job in
a
accordance
with
w drawing
gs and speciifications.
4.2.3
4
Omissions / rectifications
O
s of minor ite
ems, if any, not affecting
g commissio
oning shall not
w
withhold
MECHANICAL COMPLETION as long as the Contractor agrees to supplyy /
r
rectify
the sa
ame within the
t specified
d period. Th
he decision of
o the OWN
NER is final in
this regard.
4.3
4
C
COMMISSIO
ONING AND
D GUARANT
TEE TEST
4.3.1
4
5.0
P
PREPARE
E
EQUIPMENT
T FOR OPER
RATION
5.1
5.1.1
R
Removal
of preservative
p
es and rust p
preventatives
s.
5.1.2
Installation of
o seals or re
emoval of ste
eel covers.
5.1.3
R
Removal
of moisture
m
abs
sorbing mate
erials.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 23
3 of 51
5.1.4
D
Draining
of oil
o reservoirss and the flusshing and filling of the in
nitial charge.
5.1.5
r's represe
Assisting eq
A
quipment manufacture
m
entatives byy final che
eckout of Mounded
B
Bullets/equip
pment
.
5.1.6
5.1.7
C
Conduct
all flushing,
f
blow
wing and chemical clean
ning required
d by the spe
ecifications.
6.0
Scaffolding sufficient
S
s
am
mount of sccaffolding required for good
g
perform
mance of th
he WORK
s
shall
be supp
plied by CON
NTRACTOR
R.
7.0
D
DRAWINGS
AND DOCU
UMENTS
7.1
CONTRACT
C
TOR will carry out all construction
n and any required prrocurement activities
d
directly
from
m the AFC construction
c
n drawings and specificcations and forming pa
art of the
C
CONTRACT
T. No additional design w
work or deve
elopment e.g
g. completio
on of drawing
gs will be
r
required
from
m CONTRAC
CTOR.
H
However,
the
e plan type drawings ca
alled out to be supplied
d by CONTR
RACTOR in previous
of this sectio
s
subsections
on are includ
ded in CONT
TRACTOR'S
S scope of WORK.
W
7.2
All of CONTR
A
RACTOR'S drawings, ca
alculations, documents, test reports
s, and test ce
ertificates
a
are
to be submitted to OWNE
ER for app
proval in 6-fold.After receiving approval
C
CONTRACT
TOR to subm
mit for final approval alll of the abo
ove and one
e (1) soft co
opy in CF
fo
ormat. CON
NTRACTOR drawings re
eceiving "Ap
pproved as Noted"
N
stamp may be worked
w
on
p
provided
all notes are incorporated
d. It is und
derstood tha
at OWNER'S
S approval shall not
r
relieve
CON
NTRACTOR from his obligations to
o timely com
mplete the WORK according to
a
approved
pro
oject schedu
ule by OWNE
ER.
7.3
CONTRACT
C
TOR'S drawin
ngs shall be
e clearly marrked with titlles, equipme
ent numberss or other
ittem identificcation.
7.4
Approval of drawings
A
d
an
nd calculation
ns by OWNE
ER in no wa
ay absolves CONTRACT
TOR from
itts responsib
bility for the accuracy orr for the des
sign, constru
uction and timely perform
mance of
the WORK.
7.5
C
CONTRACT
TOR shall pro
omptly subm
mit reports off each and every
e
test or inspection.
7.6
CONTRACT
C
TOR shall submit
s
quality records of the mate
erials, as specified
s
in previous
s
sections
and
d the applicable engineering specificcations.
7.7
CONTRACT
C
TOR shall furnish an equ
uipment insttallation reco
ord indicatin
ng date of in
nstallation
a tag number of each piece of equ
and
uipment.
7.8
CONTRACT
C
TOR shall furrnish an equ
uipment maiintenance re
ecord indicatting date an
nd type or
m
maintenance
e of each pie
ece of equipm
ment during the CONTR
RACTOR period.
7.9
C
CONTRACT
TOR shall fill out checklissts as require
ed by OWNE
ER.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 24
4 of 51
8.0
L
LIFTING,
LIF
FTING EQUIPMENT AN
ND GEAR
8.1
8.2
CONTRACT
C
TOR shall on
nly perform the lifts and
d movemen
nts in accord
dance with approved
a
C
CONTRACT
TOR submitte
ed rigging sttudies and plans.
p
8.3
Preferably, Mounded
P
M
Bullets/equipm
B
ment will be lifted in a
accordance with manufacturer's
in
nstructions, if include, using
u
lifting trunnions, liftting lugs if p
provided, or by slings atttached to
o around the
or
t
equipme
ent, with adequate prrotective me
easures to prevent da
amage to
e
equipment.
N temporarry lifting lugss shall be use
No
ed without th
he written ap
pproval of OWNER.
O
8.4
No nozzles or
N
o other app
purtenancess not intende
ed for lifting shall be ussed for attacchment of
s
slings.
8.5
Mounded Bu
M
ullets/equipm
ment shall be
e handled with
w sufficientt care to pre
event damag
ge. Slings
s
shall
have adequate protection
p
to
o prevent marring
m
the surface off equipment. Where
n
necessary,
s
sling
spread
ders shall b
be used to prevent cru
ushing or other
o
damag
ge to the
e
equipment.
8.6
T
Testing
And
d Certificatio
on
All CONTRA
A
ACTOR furn
nished crane
es, lifting ap
ppliances an
nd lifting ge
ear must be properly
te
ested, exam
mined and /o
or inspected before bein
ng used on ssite and at th
he intervals specified
in
n the applica
able regulatiions. Copiess of the relev
vant certifica
ates must alw
ways be ava
ailable on
s for inspe
site
ection on req
quest by OW
WNER or proper authoritiies.
8.7
O
Operation
8.7.1
CONTRACT
C
TOR shall not permit a lifting appliance to be
e operated otherwise
o
th
han by a
p
person
traine
ed and comp
petent to do so.
8.7.2
CONTRACT
C
TOR shall take
t
expresss steps to
o ensure th
hat all pers
sonnel employed by
C
CONTRACT
TOR are com
mpetent and experienced
d for their asssigned taskss.
9.0
WELDING
W
W
Welding
of or on equipm
ment shall only be permitted with the approval of OWNER.
10.0
M
MOUNDED
BULLETS/E
EQUIPMENT
T PAINTING
G TOUCH
Equipment to
E
t be erecte
ed by CONT
TRACTOR will be delivvered to SITE finished painted.
C
CONTRACT
TOR is respo
onsible to apply
a
remedial I touch u
mages to
up painting for any dam
p
paint,
or protective coatings on equ
uipment handled by it in
n connection
n. With any aspect of
this operations such as unloading
u
tra
ansport, han
ndling and errection.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 25
5 of 51
ANN
NEXURE-2C
C
ELECT
TRICAL WO
ORK
1.0
S
SCOPE:
ELE
ECTRICAL WORK COV
VERS
1.1
Installation and
a
erection
n of the follo
owing equipm
ment (itemss) consists of
o the prepa
aration for
in
nstallation, connection,
c
testing and pre-commis
ssioning etc. as per speccifications an
nd as per
d
drawings.
A Electrical activities ca
All
arried out at site shall be
e as per rele
evant IS, Ind
dian electricitty rules &
IE ACT with latest amen
ndment. Anyy other job which
w
is nott mentioned in this anne
exure but
n
necessary
fo
or the fulfillment of the prroject shall be
b carried ou
ut by the con
ntractor inva
ariably.
NOTE-REFE
N
ER DOCUM
MENT EM16
63-TS-0801 ATTACHED
D IN TENDER FOR
S
SCOPE
OF WORK
W
& SP
PEC.
DETAIL
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 26
6 of 51
ANN
NEXURE-2D
INSTRUME
ENTATION
N WORK
1.0
G
GENERAL
1.1
1.2
Specification
S
ns for instrum
ments and ittems of control equipme
ent are show
wn on data sheets to
b issued ass they becom
be
me available.
1.3
All materials
A
s and conne
ections for co
ontrol valves, relief valvves, level co
ontrollers an
nd similar
e
equipment
shall comply with applica
able requirem
ments for va
alves and fitttings as notted in the
p
piping
speciffication.
1.4
CONTRACT
C
TOR shall in
nstall all sh
him plates, fixing material such as but not limited to
a
anchors,
red heads, etc.
1.5
C
CONTRACT
TOR shall insstall all instru
ument equip
pment tag pla
ates.
NOTE-REFE
N
ER DOCUME
ENT-EM163
3-PNIN-7901
1-00 ATTAC
CHED IN TE
ENDER FOR
R DETAIL
S
SCOPE
OF WORK
W
& SP
PEC.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 27
7 of 51
ANN
NEXURE-2E
INSUL
LATION WO
ORK
1.0
Fabrication
F
a
and
installattion of insulation and weatherproo
w
ofing with (m
mastic) and//or metal
with specificcation, drawiings & line b
ja
acketing in accordance
a
bills schedule
es for:
-
1.1
Piping
Instruments.
Insulation ma
aterials.
CONTRACT
C
TOR shall furrnish all insu
ulation materrials of the tyype and qua
ality as speciified.
P
Painting
Spe
ecifications and
a Codes o
of Owner/PM
MC.
S
Substitute
materials mayy not be used without prior written A
Approval from
m OWNER.
Insulation ma
aterials shalll be properlyy stored in a dry place and
a shall be dry when a
applied by
CONTRACT
C
TOR.
Insulating ma
aterials (co
ompounds off mastics), which
w
can de
ecompose or polymerize
e in hot or
ccold climates
s shall be sto
ored in an aiir - condition
ned or heate
ed warehouse.
Insulating materials with
h a limited self
s
life or pot
p life shalll be marked
d with manu
ufacturers
rrecommende
ed ultimate using
u
date.
1.2
P
Piping
shall not
n be insula
ated until OW
WNER has accepted
a
or piping is rea
ady for insula
ation.
Piping which
P
h will be hyd
drostatically tested shall not be insu
ulated until such
s
tests ha
ave been
s
successfully
completed and
a accepte
ed by OWNE
ER.
2.0
D
DRAWINGS
AND DOCU
UMENTS
2.1
CONTRACT
C
TOR will carry out all insulation insttallation, we
eatherproofin
ng directly from
f
AFC
drawings/ and
c
construction
a project sspecificationss.
2.2
2.3
C
CONTRACT
TOR shall pro
omptly subm
mit reports off each and every
e
test or inspection.
2.4
CONTRACT
C
TOR shall su
ubmit qualityy records off the materials, if appliccable as specified in
p
previous
secctions and the applicable
e engineering
g specifications.
3.0
MISCELLAN
M
NEOUS
Insulation insstallation and
d weatherprroofing shall be in accord
dance with project
p
speciifications.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 28
8 of 51
ANNE
EXURE-2F
F
PAINT
TING WORK
K
PO
OLYURETHA
ANE BULLE
ET PROTECTIVE COAT
TING
The
e minimum requiremen
nts for the coating ma
aterials, equ
uipment, application, in
nspection,
rep
pair, handling
g & other asspects of exxternal (surfa
ace) corrosio
on protection
n of mounde
ed bullets
(cylindrical unfired Pressurre vessels) a
are covered under these
e technical sp
pecificationss.
1.0
SC
COPE OF WO
ORK
This specification governs the minimum
m requireme
ents for mate
erials (coatin
ng as well as surface
eparation prior to coating
g), equipme
ent, coating application, inspection, repair, hand
dling and
pre
all other aspeccts of extern
nal corrosion
n protection of Mounded
d Bullets for bulk storage of the
uefiable (haz
zardous) gas
ses under prressure.
liqu
d that the Polyurethane
P
e coating (1
100% solidss, high build
d, elastomerric)on the
It iss envisaged
external surfac
ce of the mo
ounded bulle
ets shall prov
vide a hard, tough, high
h electrical re
esistance
(forr corrosion prevention in conjuncction with Cathodic protection syystem) surfface with
outtstanding ad
dhesion and impact resisstance to prrotect againsst damage during
d
the process of
mounding (com
mpaction of graded
g
sand
d followed by
b earth cover). The coa
ating system
m shall be
suittable for serrvice temperratures betw
ween minimu
um -55 C and ambien
nt + 55 C (although
these temperatures may not
n be norm
mally achieve
ed/ encounttered) in serrvice. Also vvery high
leve
els of chlorid
des & sulphates, particu
ularly in coastal installattions, should
d be withstoo
od by the
coa
ating during entire design life span.
m
bu
ullets, with internal presssures the unfired
u
shell areas widen more than
n the ring
In mounded
stifffened region
n. The coatin
ng system sshall withstan
nd, without d
damage durring the entirre service
life span, the co
onstraint developed thus producing bending mo
oments in the mounded bullets in
longitudinal dire
ection, the maximum
m
off which occu
ur/ are likely to occur in the plane of
o the ring
stifffener.
The
e work to in
nclude furniishing all la
abour (skille
ed & unskilled), materia
als, tools & tackles,
equ
uipment & performance
p
of all operrations and incidentals necessary for
f coating handling,
storring and tran
nsporting of coated bulle
ets or part thereof. The ccoating operrations will have to be
carrried out in narrow spa
ace around the mound
ded bullet p
prior to grad
ded sand fiilling and
com
mpaction aro
ound the fabrricated bulle
et.
The
e steel surfa
ace prepara
ation prior tto actual co
ommenceme
ent of coating shall co
onform to
STE
EEL STRUC
CTURE PA
AINTING CO
OUNCIL-SUR
RFACE PR
REPARATION SPECIFICATION:
SSP
PC-SP10.
Rem
moval of all equipment and excesss materials from site, following co
ompletion off Coating
ope
erations is included in the
e scope of work.
w
or approval from ownerr / consultant shall be obtained byy the coatin
ng applicato
or for any
Prio
dev
viations from the requirem
ments of thiss specificatio
on and/ or th
he standards
s referred therein.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
2.0
DOC. NO
O.
REV
V
Sheet 29
9 of 51
REF
FERENCE DOCUMENT
D
TS:
NAC
CE TM-01-7
7
NAC
CE TM-01-7
75
3.0
EM163-E-601
CORR
ROSION CO
ONTROL SYS
STEMS OF
STEEL BULLETS
URET
THANE TOP COATS FO
OR
ATOM
MOSPHERIC
C
APPLIICAITON (TECHNICAL COMMITTE
EE
REPO
ORT)
STRUCTURAL ST
TEEL PAINT
TING COUN
NCIL:
NING
SOLVENT CLEAN
STRUCTURAL ST
TEEL PAINT
TING COUN
NCIL:
NEAR
R WHITE BLA
AST CLEAN
NING
PICTO
ORIAL SURF
FACE PREP
PARATION
STANDARD FOR
R PAINTING OF STEEL
STRUCTURES
VISUA
AL STANDA
ARD FOR SU
URFACE & N
NEW
STEEL AIR BLAS
ST CLEANED
D SAND
ABRA
ASIVES
VISUA
AL STANDA
ARD FOR SU
URFACE & N
NEW
STEEL CENTRIFU
UGALLY BL
LAST CLEAN
NED
WITH STEEL GRIIT 7 SHOT
GEN
NERAL REQ
QUIREMENT
TS:
The applicator shall submiit for ownerr / consulta
ants approvval, coating procedure including
uality contro
ol (QC) meth
hodology, prrior to comm
mencement o
of coating
quality assurancce (QA) & qu
of th
he bullets. Only
O
duly ap
pproved metthodology shall be follo
owed in coa
ating applica
ation. The
applicator shall provide
p
stan
ndard equipm
ment for coa
ating works; no improvissed equipme
ent will be
acce
epted/ allowe
ed.
The applicator shall supply all
a coating m
materials req
quired as per this specification & pro
ovide test
om standard
d laboratorie
es. The applicator shall also carry out tests on
n applied
data// reports fro
coating for adhe
esion, film th
hickness and pinhole/ holiday
h
dete
ection. The results
r
of these tests
onsultant app
proved laboratory.
shalll be through a owner/ co
Conssidering logistical and te
echnical aspects, coating
g of bullets sshall be carrried out in th
he mound
(prio
or to grade sa
and filling & compaction
n) after post weld
w
heat tre
eatment and
d hydrostaticc testing.
All manpower
m
(s
skilled, unskilled) shall be applicators responsib
bility and only
y personnel skilled in
the coating
c
appllication shall be deploye
ed by the ap
pplicator. Th
he coating shall
s
be insp
pected by
qualified inspec
ctors. The qualification
q
of inspecto
ors shall be
e verified/ approved
a
by owner/
cons
sultant.
The applicator shall provide access duriing all phase
es of work to
o the owner//consultants and their
inspe
ectors. Any expenses incurred byy the applicator due to
o owner/ consultants in
nspectors
stopping the coa
ating work because
b
it iss not being carried
c
out a
as per these
e specificatio
ons, shall
be borne by the applicator.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 30
0 of 51
All equipment
e
sh
hall be subject to owne
er/ consultan
nts approval and should
d be of good quality,
main
ntained in good
g
operatiing condition and suita
able for use
e to apply materials
m
ass per this
spec
cification.
All cleaning,
c
priming, coatin
ng machine
es shall be preferably equipped
e
wiith rubber o
or wheels
overlaid with harrd fiber to prrevent marking or denting the extern
nal surface of
o the bullet.
ating schedu
ules & engin
neering inforrmation inclu
uding drawin
ngs when
The owner shall provide coa
nsions, obstrructions and
d access to tthe surface area to be coated
c
as
availlable, showing all dimen
well as the calcu
ulations of arrea to be sprrayed.
Befo
ore, bid subm
mission, the applicators are advised
d to acclimattize themselves with site
e working
cond
ditions and owner
o
will pe
ermit such visits by applicators.
Durin
ng surface preparation
n, any acce
eptable mettal defects detected shall be imm
mediately
brought to the no
otice of owner/ consultant and the applicator sha
all hold
the work
w
on such
h steel piece
e till such tim
me as cleared for further action by th
he owner/con
nsultant.
Onlyy plural com
mponent air less spray system sha
all be used as per reccommendatio
on of the
manufacturer of Primer Polyyurethane.
4.0
4
SAFE PRACTIC
CES:
High
h performancce spray applied coating
gs may contain potentia
ally toxic ing
gredients an
nd require
all (local, state, central) saffety regulatiions to be observed
o
du
uring coating
g operationss. Proper
safetty precautions must be observed ag
gainst recog
gnized safetyy hazards evven during sstorage of
primer & coating
g materials at
a site. Appliicable (statu
utory, state, local) regula
ations goverrning safe
hand
dling practice
es shall be enforced.
e
5.0
PRIM
MER
The type of primer used sha
all be as per coating man
nufacturers specification
ns.
a) Fo
or areas not to be cathodically prote
ected: Polyvinyl Butyl (wa
ash) type
b) Fo
or areas to be
b cathodica
ally protected
d: Aluminum
m filled moisture cured
Urethane Prime
er or two (2
2) compone
ent chemica
al cured Urrethane Prim
mer Single package
sture-cured Urethane
U
prrimers conta
aining non-le
eafing Aluminum pigmen
nted, are fasst curing,
mois
chem
mical & corrrosion resisstant and e
eliminate the
e mixing & pot life lim
mitation of two
t
pack
mate
erials.
6.0
SUR
RFACE PREPARATION:
Altho
ough, Elasto
omeric 100%
% solids Polyyurethane coating
c
mate
erial has exc
cellent Corro
osion and
Erossion resistan
nt properties
s, it must h
however, be considered
d part of an
n engineered
d system
whicch includes adequate/
a
appropriate
a
ssurface prep
paration. It iss axiomatic in protective
e coating
work
k that the performance
p
of most ap
ppropriately chosen coa
ating will be
e no better than the
surfa
ace preparattion. Accordingly, the su
urface shall be
b blast clea
aned as follo
ows:
The external surface of bullets
b
(or part thereoff) shall be blast cleaned to SSPC-SP10
cification nea
ar white blas
st cleaning w
with 2-3 Mil anchor
a
profiile (or else conform
c
to SIS
S Gr Sa
spec
2-1/2
2 Specificatio
ons).
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 31
1 of 51
PRIM
MING
SYCHROME
ETER) to en
nsure Dew Point is at least
l
3 C below
b
the
Measure humidiity (using PS
er controlled
d conditions,, heating ste
eel surface may be ressorted, to
ambient temperature. Unde
ndensation problems.
p
elimiinate the con
Two component chemicals cure
c
urethan
ne primer sh
hall be sprayyed onto the cleaned surface in a
fog coat
c
as thinly as possible (approxim
mately 1 Mil)) so as to tin
nt but not mask the colo
our of the
subs
strate. The primer
p
on application sha
all be free fro
om runs & drips. The priimed surface
e shall be
prote
ected so that it will not come
c
in conttact with rain
n, Mist, Dust or other foreign substan
nces until
comp
pletely harde
ened & the Urethane
U
top
p coat has been
b
applied
d. The Urethane top coa
at shall be
applied before th
he Prime Co
oat has completely cured not less th
han two (2) hours,
h
nor more
m
than
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 32
2 of 51
five (5) days aftter the prime coat has been applie
ed. Howeverr, the Prime
e Coat at the time of
Urethane applica
ation should be hard and
d not tacky.
8.0
COA
ATING
Equipment for sp
pray application shall be
e plural comp
ponent Airless spray sysstem
ndard instrucctions from the Manufacturer shall be followed
d for Spray, material ha
andling &
Stan
stora
age. Always,, dry nitrogen (gas) blanket over ma
aterial shall b
be maintaine
ed.
minal thickne
ess of 100% solids elastomeric uretthane shall be 40 Mils (1,000 micro
o) unless
Nom
otherwise specified. The fiinished polyyurethane shall be gen
nerally smoo
oth & free of sharp
protu
uberances. A minor amount
a
of sags,
s
dimplling & curtaining, whicch otherwisse meets
spec
cifications requirement shall
s
howeve
er be not con
nsidered as ccause for rejjection.
ore actual co
oating application on the
e bullet surfa
ace, a test pa
atch shall be
e applied & inspected
Befo
for Runs,
R
drips & Gel time as
a well as T
Tack free tim
me. In case of doubt, Ad
dhesion testt shall be
carried out.
Mou
unded Bullets/Unit Repeat Area iss calculated along with the Materia
al volume in
n counter
numbers (countters are atta
ached on th
he Mounded
d Bullets/Units that mea
asure the volume
v
of
erials dispensed), apprroximate sp
peed and number
n
of passes.
p
Sprays apply requisite
mate
thickkness in mu
ultiple passe
es in single
e application
n keeping sspray gun perpendicula
p
ar to the
subs
strate. If the surface is la
arge enough
h to require more than one
o day for coating,
c
the edges of
the coated
c
area
a shall be fe
eathered and
d roughened
d with a grin
nding tool fo
or over spra
aying and
primed.
d with 100% solids Elasttomer Uretha
ane hand
Skips, if any, holidays, deteccted should be repaired
k or equiva
alent after the
e edges are roughened..
mix kit
9.0
INSP
PECTION
All work
w
under this speciffication shalll be subjecct to Inspecction by the
e owner/con
nsultants
Inspe
ector. All pa
art of the work
w
shall b
be accessiblle to the ow
wner/consulttants inspecctor. The
applicator shall correct
c
any defective
d
wo
ork indicated
d by the Insp
pector.
n to steel sh
hall be meassured using Elecometerr adhesion te
ester as per ASTM D
Pull off Adhesion
1 using a Aluminum do
olly attached
d to the coa
ating & a pe
erpendicular force applie
ed to the
4541
dollyy. Average reading
r
from
m three (3) randomly selected
s
spo
ots shall be at least 8 N/sqmm.
Adhe
esion test sh
hall be carriied out on ffully cured coating
c
(7 da
ays at 25 C) & on flatt (without
curva
ature) test area.
a
Applicator shall supply certtificate from the coating
g manufactu
urer that the
e material ussed (with
batch numbers) are free fro
om manufactturing defec
cts & will me
eet all perforrmance crite
eria when
prop
perly applied as given in this specificcations.
All above test sh
hall be witnessed & certified by owne
er/ consultan
nts inspecto
or.
Inspe
ection and Testing.
T
All painting
p
materials includ
ding primerss and thinne
ers for appliccation shall be procured directly
from manufacturers as perr specificatio
ons and sha
all be accom
mpanied by
y manufacturers test
certifficates. Pain
nt formulation
ns without ccertificates arre not appliccable.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
10.
EM163-E-601
DOC. NO
O.
REV
V
Sheet 33
3 of 51
QUA
ALITY ASSU
URANCE
The contractor shall
s
guaranttee that the chemical an
nd physical properties
p
off paint materrials used
i accordance with the specifications contained herein/to be provided
d during exe
ecution of
are in
work
k.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 34
4 of 51
AN
NNEXURE-3
3
Q
QUALITY
C
CONTROL
PROCEDU
URE AND IN
NSPECTIO
ON REQUIR
REMENTS
1.0
C
CONTRACT
TOR'S QUAL
LITY CONTR
ROL
1.1
CONTRACT
C
TOR shall provide a qu
uality contro
ol program manual incllude specific WORK
m
methods
and
d inspections
s, which asssure quality.
This quality control prog
T
gram manual must be submitted to
t OWNER for Approvval before
s
starting
the construction
c
activities.
A installation WORK mu
All
ust be in striict accordance with this approved manual.
m
1.2
T quality control
The
c
progrram shall incclude as a minimum
m
the following:
-
2.0
Shop fabrica
S
ation and fie
eld installatio
on inspection OWNERS
S REPRESE
ENTATIVE to
t ensure
s
specification
s in the follo
owing areass will be perrformed by full adheren
nce to Receiving and
in
nspection.
-
on of test ins
spection equ
uipment.
Calibratio
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
-
EM163-E-601
DOC. NO
O.
REV
V
Sheet 35
5 of 51
3.0
OWNER'S REPRESENT
O
R
TATIVE or others as authorized
a
b
by OWNER are to be permitted
a
access
to CONTRACT
C
TOR'S workk areas forr the purpo
ose of inspection of material,
e
equipment,
documentattion and other areas as require
ed in CONTRACTOR'S
S quality
a
assurance
I quality
q
contrrol program.
4.0
4
5.0
OWNER'S construction
O
c
inspections will not relieve. CONT
TRACTOR of
o inspection
n or other
es.
r
responsibiliti
6.0
7.0
CONTRACT
C
TOR shall evidence
e
its familiarity and experie
ence with the executio
on of the
in
nstallation of
o WORK to
o the requirrements of the applicab
ble codes and
a
shall pe
erform its
W
WORK
in acccordance to
o these requirements and
a
to insttructions isssued by O
OWNER'S
R
REPRESEN
TATIVE in th
his regard.
8.0
C
CHECK
ON QUALITY OF
O WORK
8.1
OWNER'S REPRESENT
O
R
TATIVE'S in
nspector sha
all have free
e access to the place where
w
the
W
WORK
is performed at all
a times, in order
o
to checck the qualityy of WORK.
8.2
9.0
C
CONTROL
S
SYSTEMS
C
CONTRACT
TOR shall inittiate and ma
aintain the fo
ollowing conttrol systems
s.
9.1
Backfilling
-
9.2
Compacttion tests.
C
Concrete
-
Design mix
m and apprroval record((s).
Batch Mo
ounded Bulle
ets/Unit insp
pection recorrd.
Slump te
est record.
Compres
ssive test reccord.
Pour rele
ease record.
Grouting release record.
n records.
Placement inspection
e curing reco
ords.
Concrete
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
9.3
DOC. NO
O.
REV
V
Sheet 36
6 of 51
Design mix
m and apprroval recordss.
Batch pla
an inspection
n records.
Placeme
ent inspectio
on records.
P
Piping
-
9.5
A
Asphalt
-
9.4
EM163-E-601
Weld x-ra
ay file.
Pipe and fitting certifficate file.PM
MI
Isometric
c weld contro
ol sheet.
Hydrostatic test recorrds.
G
Grounding
E
Earth
resista
ance test rec
cords.
9.6
E
Electrical
Ca
able and Ins
strument ca
able
-
Insulation
n resistance test recordss.
Continuitty test record
ds.
9.7
M
Material
cerrtification filles
9.8
M
Mounded
Bu
ullets/Equip
pment
-
ay file.
Weld x-ra
Material certificate
c
files.
Mounded
d Bullets/Equ
uipment insttallation reco
ords.
Equipme
ent maintena
ance record.
Hydrosta
atic test records.
Grouting release records.
Alignmen
nt records.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 37
7 of 51
AN
NNEXURE-4
4
SCHEDULE
S
E, PROGRE
ESS EVALUATION AND
A
PROGRESS REP
PORTING
1.0
G
GENERAL
1.1
2.0
D
DETAILED
& SCHEDUL
LE
2.1
Detailed con
D
nstruction sc
chedule musst cover all construction work, from
m lowest levvel up to
h
highest
level.
2.2
Activities sho
A
own by means of a bar chart must include as a minimum th
he activitiess listed in
4
4.
3.0
P
PROGRESS
S REPORTIN
NG
CONTRACT
C
TOR shall is
ssue a reporting proce
edure and a representative samp
ple of all
p
progress
rep
ports.
F
Following
schedules and
d reports mu
ust be issued
d by CONTR
RACTOR to OWNER:
O
Construction
C
n schedule. (Preliminary
(
and detailed
d)
M
Monthly
statu
us report.
W
Weekly
progress report.
M
Monthly
consstruction guide schedule
e.
D
Daily
manpower reports..
A except de
All
etailed consttruction sche
edule based on approved project construction scchedule.
4.0
4
C
CONSTRUC
CTION SCHE
EDULE
As Mutually
A
y agreed bettween NRL & PDIL, aftter that CON
NTRACTOR
R will issue separate
g
graphical
"S
S" curves fo
or the follow
wing work activities
a
off total CONT
TRACT.
5.0
INTRODUCT
TION
The introducction to the monthly
T
m
stattus report sh
hall include CONTRACT
TOR'S comm
ments on
the overall construction schedule wiith a status update line as attachme
ent, and sha
all consist
o the following items:
of
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
6.0
EM163-E-601
DOC. NO
O.
REV
V
Sheet 38
8 of 51
Goals ac
chieved last month.
m
Goals forr next month
h.
Reason for
f delay, if any.
a
Reason
n for deviatio
on of original schedule.
Average manpower by
b craft, including management and
d indirect staff.
ACTOR'S co
omments to g
general situa
ation.
CONTRA
C
CONSTRUC
CTION ACTIV
VITIES STA
ATUS
T
This
section consists of scheduled
s
vversus actual progress curves.
T progresss curves are
The
e to be comm
mented upon
n by CONTR
RACTOR.
T basis for reporting shall
The
s
be the construction
c
schedule:
T monthly status shall be reported
The
d as a percentage of the
e total WORK
K per type off WORK.
7.0
M
MANPOWER
R AVAILAB
BILITY I REQ
QUIREMENT
TS FOR THE
E MONTH COMING
C
CONTRACT
C
TOR shall submit its man
npower availlability requirements for the next mo
onth. This
s
section
conssists also of the
t schedule
ed versus the actual manpower curvves.
T
These
manpower curvves
8.0
are a
accompanied
d by CONT
TRACTOR'S comments hereon.
MAIN CONSTRUCTION
M
N EQUIPMENT AVAILABILITY I REQUIRE
EMENTS FO
OR THE
M
MONTH
COMING
CONTRACT
C
TOR shall su
ubmit its main construction equipme
ent availability / requirem
ments for
the next mo
onth. This section
s
conssists also off the sched
duled versuss actual con
nstruction
e
equipment
re
equirement curves.
c
Thesse by CONT
TRACTOR'S comments hereon.
9.0
W
WEEKLY
PR
ROGRESS REPORT
R
Progress rep
P
porting will be
b done on a weekly bassis by the acctually comp
pleted work based on
d
details
of work such ass quantitiess or piece of
o equipmen
nt as a perrcentage of the total
a
anticipated
w
work
per worrk activities a
as defined in
n item 4.
9.1
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
10.0
W
WEEKLY
PR
ROGRESS MEETING
M
10.1
W
Weekly
Worrk List
EM163-E-601
DOC. NO
O.
REV
V
Sheet 39
9 of 51
In the weekly
y progress review
r
meetting CONTR
RACTOR sha
all forecast the
t WORK itt plans to
p
perform
durin
ng the weekk by means of a weekly WORK list including itss manpower resource
a
allocation
ass per the activities listed in 4 and 6.
T
This
weekly program sha
all be in acco
ordance with
h the constru
uction guide
e schedules.
10.2
W
Work
Front
CONTRACT
C
TOR shall submit monthly and weekly a total reccapitulation of
o the total w
work front
a
available
witth estimated
d manpower requiremen
nts, materials and equip
pment which
h shall be
s
supplied
by CONTRACT
C
TOR.
11.0
M
MONTHLY
C
CONSTRUC
CTION GUID
DE SCHEDU
ULE
Based on ap
B
pproved ove
erall constru
uction sched
dule, CONTRACTOR must
m
issue a monthly
c
construction
guide sched
dule covering a two (2) months
m
perio
od, for each individual activity.
Progress updating of co
P
onstruction g
guide sched
dules must b
be weekly and
a
presented in the
w
weekly
progrress review meeting at ssite.
h individual activity:
T updated
The
d issue will show for each
-
12.0
Percent complete.
c
Weight fa
actor comple
ete.
D
DAILY
MANPOWER RE
EPORTS
C
CONTRACT
TOR shall be
e furnished d
daily manpow
wer report ass per agreed
d format.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 40
0 of 51
AN
NNEXURE-5
GEN
NERAL NOTES
1.0
D
DRAWING
AND
A
DOCUM
MENTS
1.1
CONTRACT
C
TORS drawin
ngs shall be
e on standard
d size sheetts to be mutually agreed
d upon by
b
both
parties during kick-o
off meeting.
1.2
CONTRACT
C
TORS draw
wing shall be
b clearly marked
m
with
h titles, num
mbers of otther item
id
dentification.
1.3
1.4
A Built dra
As
awings.
1.5
As built co
A
omments willl be marked up by CON
NTRACTOR on a maste
er copy
o these dra
of
awings, desiignated for this purpose, These ch
hanges are to be
a
approved
by OWNER.
1.6
2.0
S
SAFETY
2.1
CONTRACT
C
TOR shall sttrictly comply with India
an safety & regulations. An OWNE
ER safety
o
officer
is inccluded in the
e OWNER site
s manage
ement organisation. His instructionss shall be
fo
ollowed and
d regular saffety meeting
gs shall be attended
a
by C
CONTRACT
TORS Forem
men. The
s
safety
meetin
ngs shall be chaired by tthe OWNER
RS safety offficer.
2.2
CONTRACT
C
TOR shall be
b responsib
ble for the safety of a
all OWNER supplied pe
ermanent
e
equipment
and materialss under custtody, and sh
hall rectify/re
eplace any damage or lo
oss taking
p
place
free off cost to OW
WNER.
C
CONTRACT
TOR is responsible for the safety of
o all its pe
ersonnel, an
nd shall arra
ange and
p
provide
all sa
afety applian
nces to his personnel,
p
such as bootss, goggles, safety
s
belts, helmets,
s
safety
lamps
s, etc. CONTRACTOR shall be als
so responsib
ble for safetty of all Con
nstruction
E
Equipment
and
a
Materials, all materials included
d in CONTR
RACTORS scope
s
of supply, and
a Temporarry Facilities.
all
CONTRACT
C
TOR shall prrovide for su
ufficient num
mber of fire e
extinguisherss during con
nstruction
e
erection
period.
CONTRACT
C
TORS organ
nization shalll have a sa
afety officer to supervise
e heavy liftss, work in
h
high
elevatio
ons, critical locations, work during
g nights, and constanttly be ensu
uring that
w
working
pers
sonnel strictly follow the safety requiirements.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 41
1 of 51
CONTRACT
C
TOR shall fen
nce the nece
essary areas
s whenever it is the requ
uirement forr safety of
the personn
nel, equipm
ment & materials,
m
and shall p
provide guarded entrry points
C
CONTRACT
TOR shall also provide necesssary fencin
ng around areas und
der preng to segreg
c
commissioni
gate them co
onstruction areas.
a
2.4
S
Safety
Guidelines
2.4.1
G
General
CONTRACT
C
TOR shall ad
dhere to safe
e constructio
on practice a
and guard ag
gainst hazarrdous and
u
unsafe
workiing condition
n and shall ccomply with safety
s
rules of OWNER as set forth herein.
2.4.2
F
First
Aid and Industriall Injuries
2.4.2.1
CONTRACT
C
TOR shall maintain
m
firrst aid facilities for itss personne
el and thosse of its
s
subcontracto
ors.
2.4.2.2
CONTRACT
C
TOR shall make
m
for am
mbulance service
s
and for the tre
eatment of industrial
in
njuries.
Names of th
N
hose providiing these se
ervices shall be furnish
hed to OWN
NER prior to
o start of
c
construction
and their telephone
t
n
numbers sha
all prominen
ntly posted in CONTRA
ACTORS
field office.
2.4.2.3
2.4.3
G
General
Rulles
Smoking with
S
hin the batte
ery area, tan
nk farm is sttrictly prohib
bited. Violato
ors of the no
o smoking
r
rules
shall be
e discharged
d immediate
ely.
2.4.4
C
Contractors
s Barricade
es
2.4.4.1
CONTRACT
C
TOR shall erect
e
and m
maintain ba
arricades re
equired in connection with his
o
operation
to guard or pro
otect:
a Excavatio
a)
ons
b Hoisting Areas
b)
c Areas ad
c)
djudged haza
ardous by CONTRACTO
ORS or OWNERS inspe
ectors
d OWNERS existing property
d)
p
subjject to dama
age by CONT
TRACTORS
S operationss.
e Road unlloading spotts.
e)
2.4.4.2
CONTRACT
C
TORS perso
onnel and tho
ose of his su
ubcontractorrs shall beco
ome acquain
nted with
b
barricading
p
practice
of th
he OWNER and shall res
spect the provision there
eof.
2.4.4.3
Barricades and
B
a hazardous areas ad
djacent to bu
ut not located
d in normal routes of tra
avel shall
b marked by red flasher lanterns att nights.
be
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 42
2 of 51
2.4.5
S
Scaffolding
2.4.5.1
Suitable sca
S
affoldings sh
hould be pro
ovided to workmen for all works th
hat cannot safety
s
be
d
done
from th
he ground or
o from solid
d constructio
on except su
uch short pe
eriod work as
a can be
d
done
safely from
f
ladderss.
2.4.5.2
Scaffolding or
S
o staging more
m
than 4 meters abo
ove the grou
und or floor, swing or su
uspended
from and ov
verhead sup
pport or ere
ected with stationary ssupport shall have a guard
g
rail
p
properly
atta
ached, bolte
ed, breached
d and otherrwise secured. Such sccaffolding or
o staging
s
shall
be so prevent
p
it from
m swaying ffrom the building or struccture.
2.4.5.3
2.4.5.4
2.4.5.5
2.4.6
D
Demolition/G
General Saffety
2.4.6.1
2.4.6.2
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 43
3 of 51
b During le
b)
ead painting,, the followin
ng precaution
ns should be
e taken.
-
m
shou
uld be supp
plied for use
e by the wo
orkers when
n paint is
Suitable face masks
plied in the
e form of spray
s
or a surface havving lead pa
aint dry rub
bbed and
app
scra
apped.
eralls shall be
b supplied by the CONTRACTOR
R to the worrkmen and adequate
Ove
faciilities shall be
b provided to enable the
t working painters to wash themsselves on
cesssation of WO
ORK.
2.4.6.3
2.4.6.4
No parts of any
N
a machine
e or any gear shall be loaded
l
beyo
ond safe wo
orking load except
e
for
the purpose of testing.
2.4.6.5
TION OF LP
PG MOUNDE
ED BULLET
TS
INSTALLAT
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
2.4.6.6
2.4.6.7
EM163-E-601
DOC. NO
O.
REV
V
Sheet 44
4 of 51
All scaffolds
A
s, ladders and
a
other sa
afety device
es mentione
ed or descriibed herein shall be
m
maintain
in safe condittions and n
no scaffolds, ladder or equipment shall be altered
a
or
r
removed
while it is in use
e.
T
These
safety
y provisions should be b
brought to th
he notice of all concerne
ed by displaying on a
n
notice
board at a promin
nent place at
a the work-sstop. The pe
erson respon
nsible for co
ompliance
o the safety code shall be
of
b named th
herein by the
e CONTRAC
CTOR.
2.4.6.8
2.4.6.9
2.4.6.10
Notwithstand
N
ding the above guide
elines, there in nothing gin the
ese to exe
empt the
C
CONTRACT
TOR from following all sta
atutory safetty rules, Reg
gulations or Acts in force
e in India
2.4.6.11
S cleaning
Site
g should be done
d
by CONTRACTOR
R every day.
The above safety guid
T
delines do not, in an
ny way, relieve CONT
TRACTOR from his
r
responsibility
y of safety of his perssonnel and his obligatio
on to take all necessa
ary safety
p
precautions
ures and to follow safe
e constructio
on practice during exe
ecution of
and measu
W
WORK.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 45
5 of 51
AN
NNEXURE-6
6
GEN
NERAL GU
UIDELINES
S FOR INST
TALLATION
N OF LPG MOUNDED
D BULLETS
S
Sl. NO.
1.
2.
3.
4.
5.
6.
7.
8.
DES
SCRIPTION
N
REMAR
RKS.
Introducction
Referen
nce
Pre Lift Information
Responsibility
Delegattion of Respo
onsibilities
Lifting Methodology
M
y
General Safety Plan
n
Minimum
m Requirem
ment of Equip
pments & Ea
arth
Moving Equipmentss for construction
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 46
6 of 51
1. Introduc
ction
The Purpose of this doccument is to
o provide guiidelines for the
t safe and
d efficient exxecution of the
t heavy
lift operation
n of LPG Mo
ounded Bulle
ets to verify that all nece
essary consiiderations ha
ave been ad
ddressed.
This docume
ent has been originated by PDIL forr the guidanc
ce of the Co
ontractor. Co
ontractor sha
all ensure
and submit the
t Lifting Plan for Owne
er/PDIL review and approval.
In general the procedu
ure details the Installattion method
dology, tech
hnical clarificcations and General
Safety Plan to be follow
wed during th
he Heavy Liftt Operation.
2. Referenc
ce:
This docume
ent follows PDIL
P
Genera
al Specificattions of the Erection
E
of L
LPG Mounde
ed Bullets.
3. Prelift in
nformation:
Item
m to be lifted
d : LPG Mou
unded Bulletss.
Wt.
: Approx 450
4 Mt. (Mounded Bulle
et in 6 Piece
es or more as per suita
ability of
Cranes, of
o each parrt =75 Mt.)
Dime
ensions
: 7000 I.D.X
X 52000L(m
mm)
Earth Moving Equipments
E
Proposed for
f Erection
n:
Main
n crane : Capacity
C
100
0 MT
Tailing crane: Capacity
C
75
5 MT
Hydra
: Capacity
C
10 MT
Fork
klift
: Capacity
C
10 MT
4.
4 Respons
sibility:
Contractor is responsible for the following:
Obta
aining permitts to work re
equired for th
he Installatio
on of Mounde
ed Bullets.
Unde
ertake prepa
aration, Insta
allation and clean the arrea immediattely after com
mpleting the
e job.
Barricade the en
ntire lift area
a. Unauthorizzed personn
nel are strictly not allowe
ed to enter inside the
barricaded area..
Insta
all proper sig
gn board to prevent
p
unau
uthorized pe
ersonnels en
ntry.
Ensu
ure that the crane,
c
tools and tackles used are ce
ertified and h
have their va
alid test certificates.
Ensu
ure that all riigging gearss are used in
n safe manne
ers.
Ensu
ure that the ground und
der both the crane is levveled and min
m 95 % co
ompacted an
nd survey
crew
ws verify leve
eling & comp
paction stren
ngth.
The Installation Engineer an
nd Rigging Foreman
F
sha
all ensure th
hat the perso
onnel involvved in this
operration fully un
nderstand th
heir scope off work through this proce
edure.
Ensu
ures compettency of the riggers, ope
erators and foreman.
f
Ensu
ure all the pe
ersonnel involve in lifting
g has adequate PPEs.
Ensu
ure barrier frree commun
nication betw
ween the liftin
ng crew and personnel involved.
Obta
aining founda
ation clearan
nce from PD
DIL/Client priior to erectio
on.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 47
7 of 51
5. Delegatio
on of Respo
onsibilities
CONSTRUC
CTION HEA
AD shall be re
esponsible ffor the implementation of
o
CONTRACT
TOR RIGGIN
NG SUPER
RVISOR shall work in fu
ull compliancce with Safe
ety for the movement
m
and lifting op
peration of main
m
crane and
a signal to
o main crane
e operator an
nd tailing rigging Forema
an.
with safety for the Rig
CONTRACT
TOR RIGGING FOREM
MAN shall w
work in full compliance
c
gging and
movement of
o main/tailin
ng crane.
SAFETY OF
FFICER sha
all monitor that
t
All the
t
Equipm
ment, Tools and Tackles are ce
ertified In a
accordance with the site
s
HSE
Requ
uirement.
All manpower,
m
directly or ind
directly involvved in this activity
a
has b
been informe
ed of the hazzards and
risk factor
f
by the
e activity in charge.
c
All re
egular Safety Equipments (PPE) sshall be use
ed like helme
et, goggles, work glove
es, safety
harness etc.
Stop
p unauthorize
ed entry in lifting zone.
Shall stop the liffting operatio
on if there iss any immine
ent danger to
t any perso
on/s life or da
amage to
the Mounded
M
Bu
ullets.
RIGGER sh
hall work in full complia
ance with Safety,
S
are competent,
c
c
certified
for the lifting operation,
o
correct sling
ging methodss, signals etc.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 48
8 of 51
6. Lifting Methodolog
M
gy (Mound
ded Bullets
s)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
LP
PG Bullets shall
s
be fab
bricated in 6 sections or
o more as the length shell piece shall be
de
ecided to suiit transportation & erecttion and eacch duly teste
ed,inspected
d,trial assembled only
forr connecting
g ends, matcch marked a
and stress re
elieved at sh
hop/fabricate
ed yard & tra
ansported
to site.
i proposed that hemisp
pherical end
ds will be used for these
e bullets. Ho
owever the contractor
c
It is
ma
ay wish to im
mport pre-fab
bricated hem
mispherical ends.
e
Exxternal coatin
ng of bullet sections
s
will be done priior to installing the same
e on the sand bed.
En
nsure both th
he cranes ha
ave been checked as pe
er daily checck list by the operator.
Ph
hysically che
eck each shackle
s
for any damage, check th
he slings fo
or any breakages or
da
amage. Chec
ck the shackkle for prope
er pin insertio
on and orien
ntation.
Co
onnect lifting
g tools tackle
es to the cra
anes hook block
b
as perr the tackles
s arrangeme
ent shown
in Rigging Plan.
En
nsure both crane
c
standing area & marching lo
ocation has been marke
ed on the ground for
refference of th
he lifting crew
w/Operator.
Ma
ake sure the
e mats are la
aid as per th
he lifting plan
n and march
hing route off the 100t cra
ane. Also
pla
ates 25mm being
b
laid att 75t crane lo
ocation as per the lifting plan.
To
otal weight of
o the each Mounded Bullet
B
is app
prox 450 Mtt, which nee
eds to be erected
e
at
po
osition in six equal piece
es or more a
as per suitab
bility of cranes of each part
p
having weight of
75
5 Mt.
Co
ontractor sha
all insure tha
at the positio
on of main crane
c
with m
main boom le
ength & swing radius
forr the lifting of
o Mounded Bullet
B
piecess.
Ch
heck the initial position of
o the suppo
ort crane from the lifting point of the
e Mounded Bullets
B
as
pe
er the riggin
ng plan. Sub
bsequently determine the
t
path (steel plates layout) of th
he tailing
cra
ane.
Co
onnect the tools tackless as per the rigging plan
n. Attach taglines as re
equired to co
ontrol the
loa
ad and remo
oval of slingss upon safe installation.
Th
he sections for each bullet
b
shall than be lifted and trransported to
t the sand
d bed in
acccordance with the overa
all approved Lift Plan as submitted b
by contractor.
Th
he first bullett section to be laid on the prepared
d, template and
a leveled sand bed w
will be the
se
ection adjace
ent to the R.C
C.C. Wall.
Th
he other sec
ction will be installed in ssequence an
nd each secttion aligned with
w adjacen
nt section
witthin tolerancce limits and
d tack-welded
d in place.
Th
he Contracto
or shall ensure that prior to commenccement of fin
nal circ. weld
ding, bullet ssections
tha
at are tack-w
welded togetther are dimensionally in
nspected to ensure the alignment
a
an
nd other
dimensional re
equirementss have been met.
En
nsure that all
a the temporary suppo
orts/ rollers and devices used to secure
s
the Mounded
Bu
ullet Parts du
uring the res
sting positio
on have been removed and
a the Mou
unded Bulle
et Parts is
fre
ee to be lifted
d.
Th
he 100t cran
ne will be ho
oisting until the Mounde
ed Bullet Pa
arts is almost free of th
he resting
rolller assy.
On
nce load is clear
c
from th
he Roller (~2
200mm), Th
he Hydra will remove the
e resting Ro
oller assy.
be
eneath.
No
ow the 100t crane will boom
b
down whereas the
e 75t crane will swing th
he load maintains as
de
esired radiuss. If required
d the crane has to marc
ch 1~2m to maintain sm
mooth swing
g for 100t
cra
ane.
Th
he load on th
he 100t crane (Safe Load Indicator) will be checcked.
Ho
oist down, re
emove the ta
ackles and d
demobilize th
he crane.
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 49
9 of 51
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 50
0 of 51
8. Minimum
m requirem
ment of Eq
quipments and Earth
h Moving Equipments
E
s to be deployed
by the contractor
c
as and wh
hen require
ed.
Sl.
No.
1.
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.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Descripttion
Minimum
Re
equirement
Du
uring Constn.
01
01
03
01
01
02
01
01
04
01
01
01
AS
S REQUIRED.
01
01
15
08
10
05
01
01
AS
S REQUIRE
ED.
AS
S REQUIRE
ED.
02
02
01
01
01
02
02
01
01
AS
S REQUIRED.
02
01SET
01SET
01
02SET
AS
S REQUIRED.
01
01SET
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
42.
43.
44.
45.
46.
47.
48.
49.
EM163-E-601
DOC. NO
O.
REV
V
Sheet 51
1 of 51
AS
S REQUIRED.
01
15
AS
S REQUIRE
ED.
AS
S REQUIRE
ED.
AS
S REQUIRED.
02
04
Notes:
1 Any othe
1.
er equipmen
nt required ffor completion of work but not spe
ecifically me
entioned
here, sha
all be deployyed by Contrractor withou
ut any additio
onal cost.
2 The deta
2.
ails of minim
mum critical equipments in good wo
orking condition, require
ed to be
mobilized
d by the co
ontractor, to complete the
t
work within the sc
chedule. The
e actual
deployme
ent schedule of constru
uction equip
pments shall be approvved by Engineer-incharge. Contractor
C
s
shall
augmen
nt the above
e list with ad
dditional num
mbers/categ
gories of
equipments, tools & tackles, as required
d and direccted by Eng
gineer-in-charge to
complete
e the work within
w
the com
mpletion time
e schedule and
a quoted price.
p
3 Contracto
3.
or to confirm
m that the a
above minim
mum equipm
ments are avvailable with
h him in
good worrking condition and shall be timely mobilized
m
on
n his project site. Contracctor has
the option to hire som
me of these equipments from equipm
ment-hiring agencies
a
alsso.
4 Owner/PDIL reserve
4.
es the right to physically check & verify the availability
a
o
of these
equipments prior to award
a
of work.
5 Contracto
5.
or shall repllace any de
efective/damaged equipm
ment promp
ptly to comp
plete the
work with
hout any time & cost imp
plication to th
he Owner/PDIL.
6 Instruments (as app
6.
plicable) to be made available
a
witth valid caliibration certtificates,
issued by
y NABL accrredited laborratory.
EM163-PNPM-003
Document No.
Rev.
Sheet 1 of 46
1.0
EM163-PNPM-003
Document No.
Rev.
Sheet 2 of 46
1.1
1.1.1
General
This Lumpsum Turnkey package has been prepared as a Bidding Package to the extent
enumerated in various sections and documents enclosed. The Contractors scope
comprises of detailed engineering, total procurement of all equipment and items including
construction materials, construction and installation, insulation, testing, painting,
commissioning, guarantees of supplies and works. Detail scope of work and disciplinewise technical requirements are provided in respective sections of this Tender Document.
The Contractor will execute the project on Lumpsum Turnkey basis, in accordance with
tender document. To achieve this goal and requirements of the Owner/Consultant,
Contractor will establish his project organization giving due consideration to the following
aspects:
x Effective execution and timely completion of each phase of the project.
x Maintaining high quality in each phase of the project.
x Good relation and coordination between the Owner/Consultant and the other
Contractors.
x Assignment of experienced resources and personnel for immediate and smooth
launching of the project.
EM163-PNPM-003
Document No.
Rev.
Sheet 3 of 46
Engineering
Contractors scope of work includes detailed engineering including preparation of
engineering drawings and datasheets, making use of standard specifications, standards,
design guides and technical documents enclosed in this Tender Document. Technical
requirements, technical documents, standard specifications, Consultant standards and
guides to be followed for different type of works shall be as provided in this Tender
document.
Contractor to carry out the detailed engineering defined above. Engineering required to
be done by the Contractor may arise singularly or in combination due to manufacturing,
fabrication, purchased items, construction, commissioning, statutory requirements,
Government regulations, safety requirements, site conditions, resultant total procurement
and construction, installation and testing, insulation, painting and commissioning, etc.
1.1.3
Procurement
Contractors scope includes ordering, all import formalities, fabrication/purchase of
equipment and materials, port clearance, packaging and transportation to site, stores
management which includes preservation and storage of equipment and materials,
uncovered storage, air-conditioned storage and open storage.
Vendor manuals relating to installation, operation and maintenance and test certificates
should be necessarily sent along with equipment. Please also refer Final Documentation
Submission requirement spelt out in this Tender Document, in this regard.
Before ordering, clearances for technical portion would be taken from Consultant in
respect of the critical equipments (special equipments) comprising of mechanical static,
electrical and instrumentation items. For instrumentation items, other equipment and
materials can be ordered without referring to Consultant as long as ordering is in
accordance with datasheets, drawings, standards, specifications. Any ordered items
which do not confirm to the contractual requirement identified at any stage of the project
shall be rejected. Replacement/modification and project delay arising out of this shall be
to the Contractors account.
Whenever clearances are to be taken, it would be necessary to submit details of
technically acceptable offer.
Procurement of spares for two years operation as per spare part philosophy detailed in
the scope of supply. Commissioning spares are also in the Contractors scope.
Coding system for stores management to be given by Owner/Consultant after the award
of the contract is to be adhered to by Contractor; suitable procedure based on the same
shall be developed by the Contractor for execution.
1.1.4
EM163-PNPM-003
Document No.
Rev.
Sheet 4 of 46
1.1.5
Quality Assurance
The desired quality is to be met for different activities at various stages of the project. The
quality checks by Owner and Consultant could be of audit type/involvement at all stages
of project execution by the Contractor and details of the quality plans will be furnished.
Contractor is required to submit detailed Quality Control (QC) measures to be adopted by
him for all stages/types of activities. A notice period of six weeks is to be given for
imported items and one week for indigenous items for association with respect to witness
QC steps by Owner/Consultant. Detailed methodology is enclosed in Tender Document
for compliance. Facilities at shops/site/engineering office for carrying out quality checks
by Owner/Consultant shall be provided/ organised by Contractor.
1.1.6
Project Management
The project management services will include planning, scheduling, monitoring, progress
reporting, quality assurance and quality control and overall project management
functions. Contractor shall nominate a Project Manager who will be responsible for the
total scope of work under this contract and shall respond to Owner and Consultants
Project Managers on all matters relating to this contract.
The Contractor is expected to execute the work/services under this contract on Task
Force concept with a dedicated team of specialists who will be responsible and respond
to the Project Manager. The Task Force shall be so organized as to give effective
management and control of various services to the Project Manager.
1.1.7
Organization
The organisation upto working level including period envisaged for different phases of the
project engineering, ordering, follow up for manufacture of equipment, clearances,
transportation, inspection of equipment and materials, warehousing, safety, construction,
commissioning and project management will be submitted along with the bid. Bio-data of
key personnel will also be submitted with the offer.
1.1.8
EM163-PNPM-003
Document No.
Rev.
Sheet 5 of 46
Along with bid submission, it is necessary for the Contractors to bring out variation, if any,
in related data sheets, drawings, specifications, standards, codes, scope, any other
contractual clauses and seek clarifications from Consultant/Owner. The decision of the
Consultant shall be final and binding on the bidder in such cases. For those such items,
which arise during execution of the project, the stringent specification/standards will be
applicable, and shall be binding on the Contractor. However, the decision of the
Consultant/Owner shall be final and binding on the Contractor.
1.1.9
Vendor List
All items required for project are to be purchased through approved vendors of Owner/
Consultant. Wherever such details are not available, vendor list to be proposed by
Contractor and clearance to be obtained from Owner/Consultant before initiating the
ordering process.
1.2.1
Project Management
Overall plot plan, unit plot plan, detailed technical requirements along with the detailed
scope of work and overall proposed implementation schedule is issued by Consultant.
These will form the basis for formulation of the overall project schedule of the plant by
Contractor. The Contractor is required to organise his services in a systematic manner to
ensure execution and completion of the unit as per the schedule. The bidder is required
to submit along with his bid the methodology/procedure proposed by him for this unit
together with the organisational set up proposed and bio-data of key personnel.
In order to achieve uniformity in execution of various activities of Mounded Bullet,
Consultant
has
developed
engineering
design
basis
and
project
procedures/methodologies to be adopted by the executing agency. The Contractor is
required to carry out detailed engineering, procurement, tendering, construction
supervision and management, planning scheduling, monitoring, reviewing, reporting, and
overall project management activities. All activities to be performed and services to be
rendered by the Contractor under this contract shall be monitored by Consultant and will
be subject to periodic reviews by Consultant. The Contractor shall facilitate such
reviews/monitoring by Consultant.
EM163-PNPM-003
Document No.
Rev.
Sheet 6 of 46
Immediately after the award of job, a kick-off meeting will be held to finalise and establish
the modalities and procedures to be adopted for execution of the contract based on the
enquiry document, commitments made by Contractor and subsequent agreements
reached between Owner/Consultant and Contractor during negotiations. The kick-off
meeting will be attended by key members of Owner/Consultant and Contractor. This will
address all necessary details and arrangement between Owner/Consultant and the
Contractor.
The Contractors service for engineering, procurement, tendering, construction,
supervision and management, planning, scheduling, monitoring, reporting, and overall
project management shall meet the requirements given in this section.
English language and Metric Units shall be used in all documents, drawings, reports,
correspondences etc. under this contract.
1.2.2
EM163-PNPM-003
Document No.
Rev.
Sheet 7 of 46
EM163-PNPM-003
Document No.
Rev.
Sheet 8 of 46
Procurement
The procurement services to be provided by the Contractor shall cover the purchasing,
inspection, expediting, custom clearance and transportation activities
(a)
Purchase
The purchase activities will cover all equipments and materials as per the scope of work.
The purchase group shall consist of adequate number of experienced and qualified
Purchase Officers commensurate with the number of material requisitions to be handled
and the time schedule for ordering. A procurement schedule will be prepared and
submitted to Owner/Consultant for approval. This approved schedule will be followed for
all procurement activities.
Purchasing activities shall be coordinated by an experienced purchase coordinator who
shall be responsible for:
(b)
Before ordering, clearance for technical portion for rotating, instrumentation and
electrical items as indicated in technical details would be taken from Consultant.
EM163-PNPM-003
Document No.
Rev.
Sheet 9 of 46
Analyzing the order status in detail after identifying the critical order and initiation of
suitable remedial measures.
Expediting coordinator shall be a person who is highly communicative and has sound
technical knowledge; he must be highly analytical, alert, quick in gathering up-to-date
information of the various orders.
Intimate Owner/Consultant of reservations (if any) from the vendor in purchase order
acceptance.
EM163-PNPM-003
Document No.
Rev.
Sheet 10 of 46
Follow up actions with various concerned departments regarding all the issues
discussed in the review meetings.
Ensure preparation of order close out report for each order giving complete details of
the order including ordered quality, contractual delivery date (CDD).
Date of completion, delay, if any and reasons for delay, status of final documents etc.
Preparation of final procurement closing report. The order close out reports shall be
accompanied with two sets of complete documents in respect of each order
bound/put together in a folder comprising of: purchase order, purchase requisition,
change orders (if any), inspection certificates, material test certificates, final vendor
drawings (if applicable), operation/maintenance manuals, any other document as
specified in PR.
Expeditor
Expeditors responsibility commences from the time he receives the intimation of
placement of TOI/LOI/order on vendor located in his region till the time he furnishes the
despatch particulars of the item under a particular PO. During this process expeditor shall
monitor and maintain all activities of the vendors such as:
y
EM163-PNPM-003
Document No.
Rev.
Sheet 11 of 46
Above functions may be possible only by frequent visits to vendors office and shops
including their sub-vendors establishments as the case may be. Expeditor shall be able
to visualise the problems in advance and suggest timely corrective measure. In nutshell,
expeditor is not a mere progress reporter but a vital catalyst for successful completion of
the job. Expeditors responsibilities are as below:
(c)
Communicate the person concerned the reason for vendors inability to accept the
order (if so).
Communication with the vendors whenever he finds lack of efforts on their part.
Liaise with inspection department for timely inspection, including third party
inspection/statutory inspection as specified/required.
Liaise with transportation department for sound and quick despatch of material.
EM163-PNPM-003
Document No.
Rev.
Sheet 12 of 46
Pre-inspection liaison meeting with the vendor for vendors correct understanding of
the inspection requirements.
Ensure submission of quality control procedure and approval of the same for critical
sub-orders.
EM163-PNPM-003
Document No.
Rev.
Sheet 13 of 46
Supervision of Contractors
Supervision, monitoring and coordination of above contracts for import clearance and
transportation as detailed below by Contractor.
Import Clearances
y
Monitoring and coordination with clearing agents, customs, ports, steamer agents,
airlines, railways and transport agencies for clearance of imported consignments.
(e)
EM163-PNPM-003
Document No.
Rev.
Sheet 14 of 46
Reporting
Preparing and issuing weekly, fortnightly and monthly status reports on clearance of
imported equipments/materials and movement of equipments/materials from various
despatch points to project site.
Monthly reports on Over/Short Rejected/Damaged (OSRD) items. It shall be Contractors
responsibility to arrange for timely replacement of OSRD items.
(g)
Tendering
Tendering activities of the Contractor shall be properly organised to ensure award of
various contracts in line with the project schedule. The tendering group shall consist of
sufficient number of contract engineers/officers who are having adequate professional
experience and qualifications.
Contractor shall prepare a Tender schedule for carrying out different works such as civil
and structural equipment erection, piping, electrical, instrumentation, painting etc. All
tendering activities shall be carried out in accordance with this approved tender schedule.
The Contractor shall deploy a contract coordinator for coordination of tendering activities.
The contract coordinator shall be responsible for:
y
All major tenders will be handled by the Contractor from his Head Office. However,
tenders for certain minor construction will be handled by Contractors site office.
1.3
EM163-PNPM-003
Document No.
Rev.
Sheet 15 of 46
Kick-Off Meeting
On award of job, the Contractor is required to submit the following documents which will
be discussed during the kick-off meeting to establish planning requirements, inputs and
outputs for overall schedule, monitoring and progress reporting.
y
Schedule start and finish dates of all milestone/activities in line with overall schedule
of the project.
EM163-PNPM-003
Document No.
Rev.
Sheet 16 of 46
Immediately after the award of contract and pending finalisation of overall project
schedule, detailed activity chart/network, functional schedules etc., the Contractor in
consultation with Consultant shall prepare a look ahead schedule as a guideline for the
activities to be performed during the relevant periods.
1.3.3
1.3.4
1.3.5
Functional Schedules
The Contractor should prepare resource-based detailed functional schedules in line with
detailed activity networks for functional monitoring, scheduling and control. This should
clearly reflect strategies and philosophy of execution. Owner/Consultant reserves the
right to check the functional schedule and status of activities at anytime and at any
location of performance/execution. Further, the functional schedules shall be submitted
by the Contractor on demand by the Owner/Consultant.
1.3.6
EM163-PNPM-003
Document No.
Rev.
Sheet 17 of 46
proper rational and norms and maintained throughout the project. Owner/Consultant
reserves the right to modify the methodology in part or in full.
1.3.7
1.3.8
Construction Network
The Contractor shall prepare and submit a detailed construction network with full
consideration of logistics, construction studies and method for Owner/Consultant
approval. The Contractor shall describe the resources required and special construction
equipments, Tools and tackles to be mobilized. The network shall be developed
subsequent of substantial progress of engineering and ordering with fairly known
construction workload and quantities.
1.3.9
Construction Worksheets
The Contractor shall further detail out the construction network into area-wise details in
terms of work, quantity and schedule, to firm up basis for area control. The construction
schedule should be worked out based on work front generation criteria which will call for
availability of input like drawings, materials and access for each/group of activity to be
performed. It may be in the form of resource loaded bar chart with S curve.
Owner/Consultant reserves the right to access the same.
Activity network
Engineering (Residual)
EM163-PNPM-003
Document No.
Rev.
Tendering
Sheet 18 of 46
Agenda
Venue
Owner/Consultant office
Level of participation
Contractor/Consultants
engineers
Agenda
site
in-charge
and
job
EM163-PNPM-003
Document No.
Rev.
Venue
Sheet 19 of 46
Site office
Schedule v/s actual percentage progress and progress curves for engineering,
ordering, manufacturing, delivery, contracting, construction, commissioning, overall.
Activities executed achievements during months and targets for the following month.
Annexure giving status summary for drawings material requisitions, equipment and
materials delivery, contracting and construction.
Invoice status.
Weekly Reports
This report will be prepared for Head Office and construction site in summarized fashion
and submitted on every Tuesday taking status as of Sunday by the Contractor on weekly
basis and will cover following items:
y
EM163-PNPM-003
Document No.
Rev.
Sheet 20 of 46
Constraints, if any.
Name of Document
Number of Copies
Owner
Consultant
HO
Site
Functional schedule
Construction network
Daily report
Copies shall be forwarded through Consultant. Above requirement is indicative and shall
be reconfirmed during kick-off meeting.
1.3.14 Material Control
It is essential that the Contractor follow an integrated material control system for the
project. In the system, material identification in the drawing office, procurement and
allocation, are all channelized and controlled in an orderly manner. The Contractor should
follow a system for material identification, and should give construction orientation to
material control. The Contractor, right from the beginning, at the drawing office stage will
Form No.: 02-0000-0021F2 Rev1
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Sheet 21 of 46
start identifying materials system-wise or area-wise. The system will be based upon
backing of material from the material take off stage through material requisitioning,
placement of purchase order, manufacturing at vendors shop upto receipt at site for
making the material available for performing planned and sequential construction work.
At the construction site, the Contractor will develop and implement a system of
inspection, receipt and effective utilisation of materials received by re-examining the work
front availability and priority between and amongst various systems and areas.
In the case of multiple agencies carrying out construction at site, the Contractor must
adopt methodology of allocation and de-allocation and timely issue of the materials
thereby preventing possible idle storage of items at the Contractors level. Contractor
must follow proper warehousing procedure at project store to maintain various planned
and unplanned issues and dynamic stock status records. Through periodic reviews, the
Contractor will have a system of generating hold up reports well in advance to identify
exception on material availability and to track such material by the expeditery through a
systematic follow up procedure from the vendors.
Owner/Consultant may introduce checkpoints at procurement, allocation and construction
stages to know the development, status and behaviour of the system and the Contractor
shall submit the following reports on monthly basis: bulk material status report, and
material hold up/shortage report.
1.4
1.4.1
The time for completion of the complete scope of work shall be strictly as per the time
schedule given in the tender document.
1.4.2
The tenderer shall furnish the following documents along with the bid:
(a) An overall schedule in the form of network, clearly indicating all important milestones
in design, engineering, fabrication, procurement construction, testing,
commissioning, etc. for the plant commensurate with the overall time schedule.
(b) Resource deployment schedule indicating mobilisation of all critical resources
including manpower and machinery for the smooth execution of the job at
engineering offices, fabrication shops and construction site. The resource schedule
shall also contain various construction aids envisaged to be deployed for execution.
(c) Organisation structure for effective project management and control, clearly
indicating the responsibility centre as well as bio-data of the key personnel, who are
permanent employees of the Contractor.
1.4.3
Within 30 days of issue of fax/letter of intent, the Contractor shall finalise the following as
detailed earlier:
(a) Overall Project Schedule
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Overall project schedule in line with the agreed milestone and detailed to adequate
work breakdown structure level covering all phases of the work such as detailed
engineering, procurement, manufacturing, shipment, tendering and field erection. This
schedule shall also include the interface activities to be provided by the
Owner/Engineer-in-Charge and the dates by which such facilities are needed.
Contractor shall get the scheduled submitted and reviewed by Owner/Engineer-inCharge and the agreed schedule shall form part of the Contract monitoring document
based on which performance would be reported and evaluated. This document shall
be signed by both the parties. The Owner/Engineer-in-Charge shall also review the
weightage allotted to various activities and method of reporting to be adopted by the
Contractor. During the progress of the contract if in the opinion of Owner/Engineer-inCharge, desired progress as physically/sequentially is not maintained, it would be
obligatory on the Contractor to re-programme the work schedule in order to
accommodate the backlog and/or provide work front to other agency, without any
obligation to the Owner/Consultant.
(b) Functional Schedules
y Engineering Schedule
This shall indicate list of drawings, specification and sketches to be prepared
discipline wise for each plant and scheduled date of issue of each document.
y Ordering, Manufacturing & Delivery Schedule
This will be in the form of bar chart and shall indicate item-wise all the major activities
regarding ordering, shop fabrication/manufacturing and delivery of materials.
y Construction Schedule
This will be in the form of a detailed bar chart showing all the construction activities
(civil, structural, piping, equipment erection, electrical, instrumentation, insulation,
painting, etc.) at site with their durations and workload and highlighting the inputs
namely drawings, materials availability, etc., compatible with the related functional
schedule. The Contractor shall provide on request key construction net work of any
work module for critical review and control.
y Resource Deployment Schedule
A detailed deployment schedule indicating manpower, machinery, construction,
equipment in line with the overall project schedule.
y Precommissioning and Commissioning Schedule
Contractor shall develop this schedule in the form of a bar chart and submit the same
to Consultant for review.
Form No.: 02-0000-0021F2 Rev1
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In line with the construction schedule, the Contractor shall submit a monthly programme
for site activities and the target set in shall be strictly adhered to. In all matters concerning
the extent of targets set out in the monthly programme and the degree of achievement,
the decision of Consultant/Owner shall be final and binding. The monthly programme
shall be further broken into weekly programmes. At the end of each week, a report shall
be submitted by the Contractor indicating the achievement during the week against the
targets, reason for shortfall if any and the construction programme for the following week.
Contractor shall also attend weekly/monthly review meeting conducted by Consultant or
by his representative to review project status.
1.4.5
The Contractor shall regularly submit a detailed progress report in respect of:
y
Release of drawings
Sub-ordering of materials
Manufacturing
Construction
Report indicating the critical activities governing the timely completion of the project
and actions to overcome the same to be submitted every month.
This report will be issued every month on an agreed cut off date and shall include the
following brief description of the progress achieved during the month. Reason for short
fall if any and action plan to make up short-fall.
1.4.6
The Contractor at any point of time of operating would be permitted to revise the
accepted schedule/control documents with the Owner/Engineer-in-Charge without
changing the contractual completion date.
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1.4.7
The review of the performance of work would be made at different levels of management
and Contractor is expected to ensure proper participation for effective reviewing and
action plan.
1.4.8
1.4.9
The Contractor at his own cost should maintain a control room at site highlighting all the
features, schedule and achievements of the project.
1.5
1.5.1
1.5.2
The Contractor will carry out the construction works in accordance with all relevant codes,
standards, specifications, his documents and drawings, and based on the most efficient
use of local resources. The Contractor will act as principal employer on the labor
employed for construction activities and will follow Indian Labor Act, and all statutory
regulations in this regard. The Contractor will have total responsibilities for the following:
y
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Field engineering
1.5.3
The Contractor shall establish and maintain a material testing laboratory for carrying on
field tests during execution of contracts under different disciplines by Sub-contractors, at
no extra cost to owner. Also, all material handling equipment shall be subjected by the
Contractor to required load test initially and then periodically to ensure safe/stable
operation including witnessing and maintaining records of such tests.
1.5.4
The construction organisation will include the following for effective execution, monitoring
and control: planning, scheduling, monitoring reporting, construction supervision, quality
assurance and quality control, warehouse management and material control, field
engineering/purchase, safety personnel administration.
(a) Quality Assurance and Quality Control (QA/QC): QA/QC personnel will be responsible
for ensuring quality of construction carried out by different Sub-contractors in
accordance with the approved QA/QC procedures and management of material
testing laboratory.
(b) Warehouse Management and Material Control: This discipline will be responsible for
carrying out the warehouse management and material control in accordance with the
warehousing procedure and material control procedure. The material control plan and
warehousing procedure shall be submitted by Contractor for Owner/Consultants
review/approval. The activities of the contractor will include:
y
EM163-PNPM-003
Document No.
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Inventory checks
Security
Taking with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
Intimating HO regarding short, lost, damaged items and taking up with suppliers
and taking replacement action when applicable.
(c) Field Engineering: This discipline will be responsible for controlling and issue of
technical drawings and documents, preparation of field sketches, field modifications,
checking/preparation of as-built drawings, technical assistance for field purchase and
field tendering etc. Specialist engineers from Vendor HO will also be deployed at site
as per requirements.
(d) Safety: It is the responsibility of the Contractor to ensure that safe construction
procedures are complied with. They will also ensure that adequate first aid medical
facilities are available for emergency purpose and that safety procedures as per the
approved safety procedure are followed by the different Contractors. To assist in the
development of an effective safety programme, a safety checklist for various jobs
shall be developed and the same shall be reviewed by the Contractors Site Incharge.
The responsibilities will include the following: coordination and supervision of the
details of the job safety programme; initiation and supervision of the use of accident
report and investigation form; preparation of periodic accident summaries; tallying
safety inspection of the job site and submission of summary inspection report to site
Consultant in charge.
1.5.5
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General: Document control, coordination, non-conformance report of Subcontractors, output identification and traceability, QA system review
(b) As a part of Construction and Quality Assurance, the Contractor shall also comply
with the following activities:
y
Develop welding procedures and welders qualification procedures for their work.
Take all necessary precautions to protect construction work and material from
damage by climate, outside elements and construction activities.
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(c) QA/QC procedure shall also include quality plans, mostly in tabular formats defining
the specific quality practices and flow of every identifiable activity of a discipline. All
disciplines concerned with the performance of work are to be covered. These quality
plans should indicate the following:
y
(d) QA/QC procedure and quality plans will be discussed during kick-off meeting. Hold,
witness and verification points and Owner/Consultant/audit requirements will be
finalised between Contractor and Owner/Consultant.
(e) During the performance of the contract, the Contractor shall:
y
Implement approved quality assurance programme including but not limited to:
(i) Performance of internal quality audits, preparation of audit reports and
submission for review of Consultant. Contractor shall evolve a comprehensive
system of planned and documented audit to verify whether various performed
activities comply with detailed procedures, specifications, guidelines etc. and
to determine the effectiveness of quality system. Scope of such internal audits
shall be furnished to Consultant for review. Verification documents shall be
generated during audit and submitted periodically to Consultant for review.
Throughout all stages of the scope of contract, the Contractors procedures,
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Ensure that all personnel shall be assigned tasks commensurate with their
qualification. Specialized workmen shall be qualified and certified.
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1.5.6
Quality Audit: A systematic examination of the acts and decisions by people with
respect to quality in order to independently verify or evaluate and report degree of
compliance to the operational requirement of the quality programme, or the
specifications or contract requirements of the product or service.
Construction Equipment
The Contractor is required to organize and mobilize the construction equipment and other
tools tackles in a sequential manner to ensure that plant installation is carried out in a
mechanized manner and its mechanical completion is achieved within targeted time
schedule. The Contractor shall without prejudice to his responsibility to execute and
complete the work strictly as per the specifications and other laid down procedures by
mechanizing the construction activities to the maximum extent by deploying all necessary
construction equipment/machinery of adequate capacities and numbers. For this purpose,
the Contractor shall deploy a rigging team headed by a rigging foreman reporting to Area
EM163-PNPM-003
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Engineer responsible for equipment erection. Area Engineer should be well conversant
with various erection techniques and shall be responsible for preparing erection schemes
in accordance with the approved procedures and based on crane manuals suiting to plan
layout. Area Engineer will have to foresee various other constructive activities in the
surroundings while planning erection schedules including safety aspects of man and
machinery also.
Contractor will prepare erection schedule based on the overall project schedule of the
plant in phased manner with erection schemes of various equipments, vessels and
submit to Owner/Consultant for approval, monitoring and control of erection schedule.
Erection activities will be carried out as per the approved construction procedures.
For efficient working and maintenance of construction aids, Contractor shall establish and
maintain crane yard/workshop equipped with regular maintenance facility for various
construction aids for carrying out routine field maintenance during performance for the
contract. Temporary approach road, wherever required for the movement of the crane
and other vehicles for equipment erection and transportation of material shall be properly
planned and be made by the Contractor for quick mobilisation of the transportation
system. The proper padding for the crane movement shall be done to avoid any delays of
erection schedule. Weekly/fortnightly maintenances shall be planned in such a way that it
should not hamper the erection schedule.
Contractor shall ensure the timely augmentation of the plant, equipment and machinery
depend upon the exigencies of the requirement to meet the overall project schedule.
During performances of the work, Contractor must ensure that structures, materials or
equipments are adequately braced by guys, struts or otherwise approved means which
shall be supplied and installed by the Contractor as required till the erection works is
satisfactorily completed. Such guys, shoring, bracing, strutting, planking supports etc.
shall not interfere with the work of other agencies and shall not damage or cause
distortion to other works executed by him or other agencies. Contractor to submit the
construction equipment schedule.
1.5.7
Construction Manpower
The Contractor is required to organise and mobilise construction staff in a sequential
manner to ensure that plant installation is carried out in accordance with the S curve
defined with other chapter of the Bid package. Mobilisation of construction staff should be
such that S curve based on the time schedule and progress achieved in the phased
manner should match with the overall project time schedule. For this purpose, the
Contractor shall clearly indicate in his construction methodology that work shall be done
departmentally or by engaging such Sub-contractor or the combination of both.
Contractor will prepare detailed methodology for the work to be carried out departmental
as well as by Sub-contractor clearly defining the scope and responsibility of main
Contractor and Sub-contractor.
During the execution of works at site, if the principal Contractor engages Sub-contractors
for execution of works at site as per approval obtained from Owner/Consultant in line with
EM163-PNPM-003
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contract provisions and in the event Sub-contractor complains in writing to the Owner with
regard to the non-payment of their dues from the principal contractor for the works
executed by them and site (excluding final payments and payments due after termination
of Sub-contractors' services by the main contractor), Owner reserves their right to make
such payment to the Sub-contractors based on approved measurement with due notice to
the principal Contractor. Owner shall release such payments to Sub-contractor at the cost
and risk of the main Contractor in order to ensure smart execution of work at site. The
above such payment made by Owner to the Sub-contractor shall be adjusted in the
running account bills or any other payment due to the concerned principal contractor.
Contractor to submit the construction manpower schedule.
All Sub-contractors will be managed by the main Contractor construction staff who will
perform the duties of construction management and will administer, coordinate, and
inspect the work of the Sub-contractor and be responsible for the quality. The contractor
will establish the prerequisite for successful construction of sub-contractor work.
However, by deploying the Sub-contractors as approved by Owner/Consultant for any
discipline, does not absolve the principal Contractor for his total responsibility under the
subject contract.
The Contractor to ensure that in case of Sub-contract failure to execute the works as per
standards/specifications/drawings and negligence and disobedience in carrying out any
order or instruction of Owner/Consultant will be viewed very seriously and dealt with
appropriately in accordance with provisions of the contract. Contractor to submit the
construction manpower schedule alongwith the bid.
1.6
1.6.1
1.6.2
(a)
Introduction
This specification establishes the quality assurance requirements to be met by the
turnkey bidder during execution of contracted services. in case of any conflict between
the requirements of this specification and other documents such as technical
specifications, contract conditions etc., the contractor shall notify Owner/Consultant of all
such conflicts for final resolution.
(b)
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Quality policy
Quality objective
After the award of contract, within four weeks after the award of the contract, the
Contractor shall participate in the pre-start meeting with Owner/Consultant to finalize
Project Quality Plans as regards to the following:
y
During job execution, implement approved project quality plan including but not limited to:
y
Performance of internal quality audits, preparation of audit reports and submission for
Owner/Consultant's review.
(c)
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Requirements stipulated in this specification shall be fulfilled by the Contractor/Subcontractor. All other features of QA System shall be as per Contractors standards.
The Contractor shall ensure that the quality system is clearly understood and faithfully
implemented at all levels in his organisation.
The Contractor shall develop quality consciousness among all personnel working for
the contract.
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Document No.
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The Contractor shall submit all quality records (generated during activity execution)
and audit results on well laid formats/proforma for Owner/Consultant's review. The
rights of such review are reserved by Owner/Consultant. Owner/Consultant may
review it in full, parts or selectively. However, completes correctness of the QA
records shall be the sole responsibility of the Contractor irrespective of its review by
Owner/Consultant.
Contractor shall carry out audits at Subcontractors, office/works and shall submit the
report to Owner/Consultant for information.
1.7
1.7.1
All equipment and materials are to be procured from vendors listed in the approved
Vendor List enclosed in this Bid, or from other reputed vendors after obtaining specific
approval of the Owner/Consultant. In this regard, no difference is made between the
equipment and materials purchased by the contractor directly or by his contracted
agencies.
1.7.2
After finalisation of purchase order, a detailed QA/QC plan shall be developed by the
vendor, duly reviewed by the Contractor and shall be submitted for approval of the
Owner/Consultant. It is envisaged that QA/QC plans for the critical Items shall be
reviewed/approved by the Owner/Consultant and for the balance items QA/QC plans
shall be submitted for records. The management of quality control system is to be
developed generally based on the categorisation of various equipment and materials.
Preliminary categorisation of various items involved is enclosed. For items not included
here, categorisation shall be decided during detailed engineering and Owner/Consultant
may change inspection category based on final information and quantities. For
indigenous items, consultant shall carry out inspection as deemed necessary. For
imported items, contractor should engage Owner/Consultant approved Third Party
Inspector (TPI). Each stage of inspection by the TPI, must define whether it is a hold
point, witness point, verification point or internal inspection point by the vendor.
Contractor shall make independent QA Plans through the approved Third Party Agency
EM163-PNPM-003
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1.7.3
The personnel to be deployed by the third party inspection agency must have adequate
qualification and experience for the type of work involved and the owner may ask for
approval of the personnel employed for the job and his replacement, if required.
1.7.4
The Contractor shall submit a detailed vendor's inspection schedule for the coming two
months at the beginning of each month as well as notify owner's involvement at the
appropriate inspection stage, giving a clear notice period of 15 days. The contractor shall
submit monthly inspection and expediting reports of the inspection agency regularly to the
Owner/Consultant.
1.7.5
Consultants inspector shall witness the test on a mutually agreed the date according to
contractor's inspection notification, wherever applicable.
1.7.6
1.7.7
After finalisation of the vendor, the copy of PO or technical specification for sub-ordered
items along with QAP will be submitted by Contractor to Consultant covering the location
where the sub-ordered items are manufactured. The QAP is to be duly approved by the
Consultant.
1.7.8
Contractor will be totally responsible for furnishing the complete and correct technical
document/specifications to his sub-vendor. It is responsibility of the contractor to ensure
that relevant specifications indicated in the tender documents are incorporated in the suborder/sub-order specification. Each PO shall categorically indicate involvement of various
agencies for inspection.
1.7.9
Contractor shall forward the approved copy of relevant drawings/documents to the TPI
before giving inspection call. The final inspection will he done by the TPI, based upon
drawings/documents reviewed by TPI/Consultant in Code AP (Approved) wherever
applicable.
1.7.10 Contractor will ensure presence of their inspection engineer at sub-vendor's works during
inspection by TPI or Owner/Consultant inspection engineer (wherever applicable).
1.7.11 Contractor shall expedite to ensure delivery of all the materials as per CDD.
1.7.12 All correspondence by contractor to the Consultant for submission of documents and
inspection calls shall also be intimated to Owner.
EM163-PNPM-003
Document No.
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1.7.13 A list of items generally covered in a tendered package is enclosed. The list has been
generally categorised as A, B, C, D and S.
Category A
Category B
Category C
Category D
Category S
1.8
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EM163-PNPM-003
Document No.
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Sheet 39 of 46
Category on
basis of
criticality
Cement
Coarse aggregate
Fine aggregate
Filling soil
Murrum/sand etc.
Water
Reinforcement steel
10
Structural steel
11
12
Paint
13
Sanitary wares
14
Sanitary fittings
15
16
17
AC/GI/Color-coated sheets
18
Steel doors
20
Aluminium doors
21
22
23
Grouting compound
24
25
Flush door
26
Panelled door
27
Particle board
36
37
Gratings/chequered plates
Remarks
C/C/B
Cement/epoxy grouts
B/B
All rights reserved
EM163-PNPM-003
Document No.
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Legend
A Critical sampling by contractor in presence of Consultant, verification of records by
contractor and review of records by Consultant.
B Major sampling and verification of records by contractor; visual inspection and review
of records by Consultant.
C Minor sampling and verification of records by contractors; visual inspection and
review of material receipt and inspection report of contractor by Consultant.
(Records mean manufacturer's test certificate; any outside laboratory/field laboratory test
report; material receipt report submitted by contractor; inspection report of contractor).
EM163-PNPM-003
Document No.
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Sheet 41 of 46
SN
1.
Description of Activity
Category
Remark
Contractor
Contractor
Contractor
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
2.
Visual inspection
3.
Verification of Records
a.
Manufacturer's test
certificate
Contractor
Contractor
Contractor
b.
Laboratory test
Contractor
Contractor
Contractor
c.
Contractor
Contractor
Contractor
d.
Inspection report of
contractor
Contractor
Contractor
Contractor
Review of Records
a.
Manufacturer's test
certificate
Consultant
/Owner
Consultant
/Owner
b.
Laboratory test
Consultant
/Owner
Consultant
/Owner
c.
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
d.
Inspection report of
contractor
Consultant
/Owner
Owner
Note:
Consultant
/Owner
EM163-PNPM-003
Document No.
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Sheet 42 of 46
1.
2.
3.
4.
a.
b.
5.
6.
7.
RCC in super-structure
8.
9.
10.
Steel doors/window/ventilators
11.
12.
13.
14.
Category on
basis of criticality
C
B
C for cutting
Remarks
A
C
C for cutting area
B for filled-up area
A for equipment
B for buildings
C for balance works
A for equipment
B for buildings
C for balance works
B for main buildings
C for balance sheds
B for main plant buildings
C for balance works
B for main plant buildings
C for balance works
B for all buildings
B for all works
B for all works
B for all works
Legend
A Stage-wise inspection as per ITP by Owner/Consultant in addition to Contractor.
B Stage-wise inspection by contractor as per ITP and final inspection by
Owner/Consultant along with review of records maintained by contractor during
erection/execution.
C Review of contractor's stage-wise inspection records by Owner/Consultant.
EM163-PNPM-003
Document No.
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Sheet 43 of 46
Category on
basis of
criticality
1.
a.
2.
a.
Mounded Bullet
b.
Miscellaneous
3.
4.
Remarks
Legend
A Stage-wise inspection as per ITP by Owner/Consultant in addition to Contractor.
B Stage-wise inspection by contractor as per ITP and final inspection by
Owner/Consultant along with review of records maintained by contractor during
erection/execution.
C Review of contractor's stage-wise inspection records by Owner/Consultant.
EM163-PNPM-003
Document No.
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Category on
basis of
criticality
1.
Cable trays
2.
Cable Laying
a.
LT & controls
3.
CP System
4.
Earthing
Remarks
Legend
A Stage-wise inspection as per ITP by Owner/Consultant in addition to Contractor.
B Stage-wise inspection by contractor as per ITP and final inspection by
Owner/Consultant along with review of records maintained by contractor during
erection/execution.
C Review of contractor's stage-wise inspection records by Owner/Consultant.
EM163-PNPM-003
Document No.
Rev.
Sheet 45 of 46
1.
2.
a.
b.
d.
e.
f.
g.
h.
i.
j.
k.
m.
n.
p.
r.
3.
a.
b.
c.
d.
e.
f.
Category on
basis of
criticality
Remarks
B
B
B
C
A
B
B
B
B
A
B
B
A
A
A
B
A
A
A
A
A
Legend
A Stage-wise inspection as per ITP by Owner/Consultant in addition to Contractor.
B Stage-wise inspection by contractor as per ITP and final inspection by
Owner/Consultant along with review of records maintained by contractor during
erection/execution.
C Review of contractor's stage-wise inspection records by Owner/Consultant.
EM163-PNPM-003
Document No.
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Sheet 46 of 46
1.
2.
Category
Remarks
Stage-wise inspection
Contractor,
Contractor
Contractor
as per ITP
Consultant
/Owner
Final inspection
Contractor,
Contractor
Contractor
Contractor
Contractor
Contractor
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner/
3.
Gen./verification of
stagewise inspection records
Review of stage-wise
inspection records
PROJEC
CTS & DEV
VELOPMEN
NT INDIA LTD
L
EM163-MB-ANNEX
X-HSE
DO
OCUMENT NO.
RE
EV
GENERAL
L GUIDE
ELINES
FOR
HEAL
LTH, SAFETY AND ENV
VIRONMENT (HS
SE)
AT
LIGARH REFINE
ERY, AS
SSAM
NUMAL
Abbreviations:
AERB
ANSI
BARC
BS
PDIL
ELCB
EPC
EPCC
ESI
GCC
GM
GTAW
HOD
HSE
HV
IS
IE
JSA
LOTO
LPG
LSTK
MV
PPE
RCM
ROW
SCC
SLI
TBM
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Sh.
Members :
Sh.
Sh.
Sh
Sh.
Sh.
Sh.
CONTENTS
CLAUSE
TITLE
PAGE NO.
1.0
2.0
Scope
References
5
5
3.0
3.2
3.3
5
5
5
3.1.3
Indemnification
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
Awareness
Fire prevention & First-Aid
9
9
3.1.9
3.1.10
3.1.11
Documentation
Audit
Meetings
9
10
10
3.1.12
11
3.1.13
Penalty
11
3.1.14
Accident/Incident investigation
14
House Keeping
HSE Measures
3.3.1
Construction Hazards
3.3.2
Accessibility
14
15
15
16
3.3.3
16
3.3.4
Working at height
17
3.3.5
Scaffoldings
18
3.3.6
Electrical installations
19
3.3.7
Welding/Gas cutting
21
3.3.8
22
3.3.9
3.3.10
Occupational Health
Hazardous substances
22
23
3.3.11
23
3.3.12
3.3.13
3.3.14
3.3.15
3.3.16
3.3.17
3.3.18
Radiation exposure
Explosives/Blasting operations
Demolition/Dismantling
Road Safety
Welfare measures
Environment Protection
Rules & Regulations
23
24
24
24
25
25
26
Contd to page 4
4.0
3.3.19
Weather Protection
3.3.20
Communication
3.3.21
Confined Space Entry
3.3.22
Heavy Lifts
3.3.23
Key performance indicators
3.3.24
Unsuitable Land Conditions
3.3.25
Under Water Inspection
3.3.26
Excavation
3.4
Tool Box talks
3.5
Training & Induction Programme
3.6
Additional safety requirements for working Inside a running
3.7
Self Assessment and Enhancement
3.8
HSE Promotion
3.9
LOTO for isolation of energy source
Details of HSE Management System by Contractor
4.1
On Award of Contract
4.2
During Job Execution
4.3
During short listing of the sub-contractors
Records
5.0
Appendices
1.
Standards/Codes on HSE
2.
Details of First AID Box
3.
Types of Fire Extinguishers & their Appln.
4.
Indicative List of statutory Acts & Rules
5.
Construction Hazards and their mitigation
6.
Training subjects / topics
7.
Construction Power Board ( typ)
8.
List of HSE procedures
Attachments (Reporting Formats)
I.
Safety Walk through Report
II.
Accident/Incident Report
III.
Suppl. Accident/Incident Investigation Report
Near Miss Incident Report/Dangerous occurrence
IV.
V.
Monthly HSE Report
VI.
Permit for Working at height
VII.
Permit for Working in Confined Space
VIII.
Permit for Radiation work
IX.
Permit for Demolishing/ Dismantling
X
Daily Safety Checklist
XI
Housekeeping assessment & compliance
XII
Inspection of temporary electrical booth / installation
XIII
Inspection for scaffolding
XIV
Permit for erection / modification & dismantling of
scaffolding
XV
Permit for heavy lift/critical erection
XVI
Permit Energy Isolation & De-Isolation
XVI
Permit for Excavation
Appendix-A
Appendix-B
Appendix-C
Appendix-D
Appendix-E
Appendix-F
Appendix-G
Appendix-H
HSE-1 Rev.0
HSE-2 Rev.0
HSE-3 Rev.0
HSE-4 Rev.0
HSE-5 Rev.0
HSE-6 Rev.0
HSE-7 Rev.0
HSE-8 Rev.0
HSE-9 Rev.0
HSE-10 Rev.0
HSE-11 Rev.0
HSE-12 Rev.0
HSE-13 Rev.0
HSE-14 Rev.0
HSE-15 Rev.0
HSE-16 Rev 0
HSE-17 Rev 0
26
26
27
27
27
28
28
28
29
30
31
32
32
32
33
33
34
35
1.0
SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/Vendors including their sub-contractors/sub vendors
during construction.
This specification is not intended to replace the necessary professional judgment needed to
design & implement an effective HSE system for construction activities and the contractor is
expected to fulfill HSE requirements in this specification as a minimum. It is expected that
contractor shall implement best HSE practices beyond whatever are mentioned in this
specification.
Requirements stipulated in this specification shall supplement the requirements of HSE
Management given in relevant Act(s)/legislations, General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job (Technical) Specifications.
Where different
documents stipulate different requirements, the most stringent shall apply.
2.0
REFERENCES
The document should be read in conjunction with following:
-
3.0
3.1
Management Responsibility
3.1.1
3.1.2
Management System
The HSE management system of the Contractor shall cover the HSE requirements &
commitments to fulfill them, including but not limited to what are specified under clause 1.0
and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan from PDIL /
Owner prior to commencement of any site works. Corporate as well as Site management of the
Contractor shall ensure compliance of their HSE Plan at work sites in its entirety & in true
spirit.
3.1.3
Indemnification
Contractor shall indemnify & hold harmless, Owner/PDIL & their representatives, free from any
and all liabilities arising out of non-fulfillment of HSE requirements or its consequences.
3.1.4
Safety Steward
For every 250 workmen, one safety steward shall be deployed.
As a minimum, he shall preferably possess School leaving Certificate (of Class XII with
Physics & Chemistry etc.) and trained in fire-fighting as well as in safety/occupational
health related subjects, with minimum two year of practical experience in construction
work environment and preferably have adequate knowledge of the language spoken by
majority of the workers at the construction site.
b)
Safety Supervisor
For every 500workmen, one safety Supervisor shall be deployed.
As a minimum, he shall possess a recognized Degree in Science (with Physics &
Chemistry) or a diploma in Engg. or Tech. with minimum Two years of practical
experience in construction work environment and should possess requisite skills
with construction safety & fire related day-to-day issues.
c)
to deal
(ii)
(iii)
Alternately
(i)
AICTE or State Council of Tech. Education of any Indian State) with practical
experience of working in a building, plant or other construction works (as Safety
Officer, in line with Indian Factories Act, 1958) for a period of not less than five
years, may be considered as Safety Officer, in case Owner/Client of the project
agrees for /approves the same.
d)
HSE In-Charge
In case there is more than one Safety Officer at any project construction site, one of them,
who is senior most by experience (in HSE discipline), may be designated as HSE InCharge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of Client and contractors.
In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like
the Building and Other Construction Workers Regulation of Employment and Conditions
of Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same shall be
followed.
Contractors shall ensure physical availability of safety personnel at the place of specific
work location, where Hot Work Permit is required / granted. No work shall be started at
any of the project sites until above safety personnel & concerned Site Engineer of
Contractor are physically deployed at site. The Contractor shall submit a HSE organogram
clearly indicating the lines of responsibility and reporting system and elaborate the
responsibilities of safety personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and furnish
Bio-Data/ Resume/ Curriculum Vitae of the safety personnel as above for PDIL/Owners
approval, at least 1 month before the mobilization. The Contractor, whenever required,
shall arrange submission of original testimonials/certificates of their Safety personnel, to
PDIL/Owner (for verification/scrutiny, etc.)
Imposition / Realization of penalty shall not absolve the Contractor from his/her
responsibility of deploying competent safety officer at site.
Adequate planning and deployment of safety personnel shall be ensured by the Contractor
so that field activities do not get affected because of non-deployment of competent &
qualified safety people in appropriate numbers.
3.1.5
Implementation, Inspection/Monitoring
x
The Contractor shall be fully responsible for planning, reporting, implementing and
x monitoring all HSE requirements and compliance of all laws & statutory requirements.
The Contractor shall also ensure that the HSE requirements are clearly understood &
x implemented conscientiously by their site personnel at all levels at site.
The Contractor shall ensure physical presence of their field engineers / supervisors, during
the continuation of their contract works / site activities including all material transportation
activities. Physical absence of experienced field engineers / supervisors of Contractor at
critical work spot during the course of work, may invite severe penalization as per the
x discretion of EIC, including halting / stoppage of work.
Contractor shall furnish their annual Inspection Plan, with regard to project issues /subjects,
x frequency and performers to PDIL/Owner.
The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.
3.1.6
The Contractor shall ensure important safety checks right from beginning of works at every
work site locations and to this effect format No: HSE-10 Daily Safety Check List shall
be prepared by field engineer & duly checked by safety personnel for conformance.
The Contractor shall carry out inspection to identify various unsafe conditions of work
sites/machinery/equipments as well as unsafe acts on the part of
workmen/supervisor/engineer while carrying out different project related works.
Adequate records for all inspections shall be maintained by the Contractor and the same
shall be furnished to PDIL/Owner, whenever sought.
The Contractor shall not carry-out work by engaging single worker anywhere without any
supervisor anytime during day or night.
To demonstrate involvement/commitment of site management of Contractor, at least one
Safety Walk through in a month shall be carried out by Contractors head of site (along
with his area manager/field engineers) and a report shall be furnished to PDIL/Owner as per
format No: HSE-1 Safety walk through report followed by compliance for unsatisfactory
remarks.
As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected,
tested and examined by competent people (approved by concerned State authorities) before
being used at site and also at periodical interval (e.g. during replacement,extension,
modification, elongation/reduction of machine/parts, etc.) as per relevant statutes. Hydra,
cranes, lifting machinery, mobile equipments / machinery / vehicles, etc. shall be inspected
regularly by only competent / experienced personnel at site and requisite records for such
inspections shall be maintained by every contractor. Contractor shall also maintain records
of maintenance of all other site machinery (e.g. generators, rectifiers, compressors, cutters,
etc.) & portable tools/equipments being used at project related works (e.g. drills, abrasive
wheels, punches, chisels, spanners, etc.). The Contractor shall not make use of arbitrarily
fabricated derricks at project site for lifting / lowering of construction materials.
Site facilities /temporary. installations, e.g. batching plant, cement godown, DG-room,
temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc.
and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motor
cycle/bicycle-shed, site washing facilities, First-aid centers, urinals/toilets, etc. should be
periodically inspected by Contractor (preferably utilizing HR/Admn. personnel to inspect
site welfare facilities) and records to be maintained.
3.1.7
The HSE committee of contractor shall observe individuals behavior for safe practices
adapted for utilization/execution of work for following as a minimum:PPE
Tools & equipment
Hazard Identification & control
House keeping
Confined space entry
Hot works
Excavation
Loading & unloading
Work At height
Stacking & storage
Ergonomics
Procedures
3.1.8
The Contractor shall promote and develop awareness on Health, Safety and Environment
protection among all personnel working for the Contractor.
Regular awareness programs and fabrication shop / work site meetings at least on monthly
x
basis shall be arranged on HSE activities to cover hazards/risks involved in various
operations during construction.
x
Contractor to motivate & encourage the workmen & supervisory staff by issuing /
awarding them with tokens/ gifts/ mementos/ monetary incentives / certificates, etc.
x Contractor shall assess & recognize the behavioral change of its site engineers / supervisors
periodically and constantly motivate / encourage them to implement HSE practices at
project works
Fire prevention & First-Aid
x
x
x
x
x
3.1.9
The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer
Appendix-B for details), trained personnel/nurse (male) to administer First Aid, stand-by
Ambulance vehicle and
fire protection measures such as adequate
The Contractor shall arrange installation of
number of steel buckets with sand & water and adequate number of appropriate portable
fire extinguishers (Refer Appendix-C for details) to the satisfaction of PDIL/Owner.
The Contractor shall deploy trained supervisory personnel / field engineers to cater to any
emergency situation.
In case the number of workers exceeds 500, the Contractor shall position an Ambulance /
vehicle and nurse on round the clock basis very close to the worksite.
The Contractor shall arrange FIRE DRILL at each site at least once in three months,
involving site workmen and site supervisory personnel & engineers. The Contractor shall
maintain adequate record of such fire drills at project site
Documentation
The Contractor shall evolve a comprehensive, planned and documented system covering the
following as a minimum for implementation and monitoring of the HSE requirements and the
same shall be submitted for approval by owner/PDIL.
HSE Organogram
Site specific HSE Plan
Safety Procedures, forms and Checklist. Indicative list of HSE procedures is attached as
Appendix :H
Inspections and Test Plan
Risk Assessment & Job Safety Analysis for critical works.
The monitoring for implementation shall be done by regular inspections and compliance of
the observations thereof. The Contractor shall get similar HSE requirements implemented
at his sub-contractor(s) work site/office. However, compliance of HSE requirements shall
be the responsibility of the Contractor.
Any review/approval by PDIL/Owner shall not
absolve contractor of his responsibility/liability in relation to fulfilling all HSE
requirements.
3.1.10 Audit
The Contractor shall submit an Audit Plan to PDIL/Owner indicating the type of audits and
covering following as minimum:
x
All HSE shortfalls/ non-conformances on HSE matters brought out during review/audit, shall be
resolved forthwith ( generally within a week) by Contractor & compliance report shall be
submitted to PDIL/Owner.
In addition to above audits by contractor, the contractors work shall be subjected to HSE audit
by PDIL/Owner at any point of time during the pendency of contract. The CONTRACTOR shall
take all actions required to comply with the findings of the Audit Report and issue regular
Compliance Reports for the same to OWNER/ PDIL till all the findings of the Audit Report are
fully complied.
Failure to carry-out HSE Audits & its compliance (internal & external) by Contractor, shall
invite penalization.
3.1.11 Meetings
x
The Contractor shall ensure participation of his top most executive at site (viz. Resident
Construction Manager / Resident Engineer / Project Manager / Site-in-Charge) in Safety
Committee / HSE Committee meetings arranged by PDIL/Owner usually on monthly basis
or as and when called for.
In case Contractors top most executive at site is not in a
position to attend such meeting, he shall inform PDIL/Owner in writing before the
commencement of such meeting indicating reasons of his absence and nominate his
representative failure to do so may invite very stringent penalization against the specific
Contractor, as deemed fit in Contract. The obligation of compliance of any observations
during the meeting shall be always time bound.
The Contractor shall always assist
PDIL/Owner to achieve the targets set by them on HSE management during the project
implementation.
In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most
executive at site on weekly basis and maintain records. Such internal HSE meetings shall
essentially be attended by field engineers / supervisors (& not by safety personnel only) of
the Contractor and its associates. Records of such internal HSE meetings shall be
maintained by the Contractor for review by PDIL/Owner or for any HSE Audits.
a)
b)
c)
d)
e)
f)
g)
h)
i)
The time frame for such HSE meeting shall be religiously maintained by one and all.
3.1.12 Intoxicating drinks & drugs and Smoking
x
x
The Contractor shall ensure that his staff members & workers (permanent as well casual)
shall not be in a state of intoxication during working hours and shall abide by any law
relating to consumption & possession of intoxicating drinks or drugs in force.
The Contractor shall not allow any workman to commence any work at any locations of
project activity who is/are influenced / effected with the intake of alcohol, drugs or any
other intoxicating items being consumed prior to start of work or working day.
Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
The Contractor shall ensure that all personnel working for him comply with No-Smoking
requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition
tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be
allowed inside the project / plant complex.
Smoking shall be permitted only inside smoking booths exclusively designated &
authorized by the Owner/PDIL.
3.1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of noncompliances and also for repeated failure in implementation of any of the HSE provisions,
PDIL/Owner may impose stoppage of work without any cost & time implication to the Owner
and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative
limit of
2.0% (Two percent) of the contract value for Item Rate or Composite contracts with an overall
cPDILing of 1, 00, 00, 000 (Rupees One crore)
0.5% (Zero decimal five percent) of the contract value for LSTK, OBE, EPC, EPCC or Package
contracts with an overall cPDILing of 10, 00.00.000 (Rupees ten crores)
This penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
PDIL/Owner. The same shall be binding on the Contractor. Imposition of penalty does not make
the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations is
specified below:
Sl.
No.
1.
2.
3
4.
Penalty Amount
5.
Working at height without full body harness, using Rs. 10000/- per case per day.
non-standard/ rejected scaffolding and not arranging
fall protection arrangement as required, like handrails, life-lines, Safety Nets etc.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Sl.
No.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Penalty Amount
th
Failure to submit the monthly HSE report by 5 of Rs. 10000/- per occasion and Rs.
subsequent month to Projects Engineer-in-Charge / 1000/- per day of further delay.
Owner
Poor House Keeping
Rs. 5000/- per occasion per subject
Failure to report & follow up accident (including
Near Miss) reporting system within specific timeframe.
Degradation of environment (not confining toxic
spills, spilling oil/lubricants onto ground)
x
The Contractor shall make his field engineers/supervisors fully aware of the fact that they
keep track with the site workmen for their behavior and compliance of various HSE
requirements. Safety lapses / defects of project construction site shall be attributable to the
concerned job supervisor / engineer of the Contractor, (who remains directly responsible
for safely executing field works). For repeated HSE violations, concerned job supervisor /
engineer shall be reprimanded or appropriate action, as deemed fit, shall be initiated (with
an information to PDIL & Owner) by the concerned Contractor.
Contractor shall initiate verbal warning shall be given to the worker/employee during his first
HSE violation. A written warning shall be issued on second violation and specific training shall
be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on
the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall
call for his forthright debar from the specific construction site. A record of warnings for each
worker/employee shall be maintained by the Contractor, like by punching their cards / Gate
passes or by displaying their names at the Project entry gate. Warnings, penalizations,
appreciations etc. shall be discussed in HSE Committee meetings by site Head of the
Contractor.
3.1.14 Accident/ Incident investigation
All accidents / incidents shall be informed to PDIL/Owner at least telephonically by Contractor
immediately and in writing within 24 hours on Format No. HSE-2 as applicable , by Contractor.
Thereafter, a Supplementary Accident / Incident investigation Report on Format No. HSE-3
shall be submitted to PDIL/Ownerwithin 72 hours. Near Miss incident(s),Dangerous
accidents/incident shall also be reported on Format No. HSE-4 within 24 hours. The accident/
incident shall be investigated by a team of Contractors senior Site personnel (involving Site-inCharge or at least by his deputy) for establishing root-cause and recommending corrective &
preventive actions.
Findings shall be documented and suitable actions taken to avoid
recurrences shall be communicated to PDIL/Owner.
Owner/PDIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help
and cooperation in this regard. PDIL/Owner shall have the right to share the content of this report
with the outside world.
3.2
House Keeping
The Contractor shall ensure that a high degree of house keeping is maintained and shall ensure
inter alia; the followings:
a)
All surplus earth and debris are removed/disposed off from the working areas to designated
location(s).
b) Unused/surplus cables, steel items and steel scrap lying scattered at different places within
the working areas are removed to identify location(s).
c) All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
d) Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and
bricks etc shall not be allowed on the roads to obstruct free movement of men &
machineries.
e) Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.
f) Water logging on roads shall not be allowed.
g) No parking of trucks/trolleys, cranes and trailers etc shall be allowed on roads, which may
obstruct the traffic movement.
h) Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working
areas.
i) Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
within the plant area/ or these materials shall be transported with top surface wet.
j) The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing.
k) At least two exits for any unit area shall be assured at all times same arrangement is
preferable for digging pits / trench excavation / elevated work platforms / confined spaces
etc.
l) Welding cables and the power cable must be segregated and properly stored and used .The
same shall be laid away from the area of movement and shall be free from obstruction.
m) Schedule for upkeep/cleaning of site to be firmed up and implemented on regular basis
The Contractor shall carry-out regular checks (minimum one per fortnight) as per format No:
HSE-11 for maintaining high standard of housekeeping and maintain records for the same.
3.3
HSE Measures
3.3.1
Construction Hazards
The Contractor shall ensure identification of all Occupational Health, Safety & Environmental
hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor
shall carry out Job Safety Analysis (JSA)/Risk Analysis specifically for high risk jobs/crtical
jobs like
a)
Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation
etc.) & hot works.
b) Work in confined space,
c) Deep excavations & trench cutting (depth > 2.0 mts.)
d) Operation & Maintenance of Batching Plant.
e) Shuttering / concreting (in single or multiple pour) for columns, parapets & roofs.
f) Erection & maintenance of Tower Crane.
g) Erection of structural steel members / roof-trusses / pipes at height more than 2.0 Mts. with
or without crane.
h) Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
of 100T capacity.
i) All lifts using 100T Crane plus mechanical pulling.
j) All lifts using two cranes in unison (Tandem Lifting).
k) Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
l) Laying of pipes (isolated or fabricated) in deep narrow trenches manually or
mechanically.
m) Maintenance of crane / extension or reduction of crane-boom on roads or in yards.
n) Erection of any item at >2.0 Mts. height using 100T crane or of higher capacity
o) Hydrostatic test of pipes, vessels & columns and water-flushing.
p) Radiography jobs (in-plant & open field)
q) Work in Live Electrical installations / circuits
r) Handling of explosives & Blasting operations
s) Demolishing / dismantling activities
t) Welding / gas cutting jobs at height (+2.0 Mts.)
u) Lifting / placing roof-girders at height (+2.0 Mts.)
v) Lifting & laying of metallic / non-metallic sheet over roof/structures.
w) Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with & without using
cranes
x) Calibration of equipment, instruments and functional tests at yards / work-sites.
y) Operability test of Pump, Motors (after coupling) & Compressors.
z) Cold or Hot works inside Confined Space.
aa) Transportation & shifting of ODC consignments into project areas.
bb) Working in charged/Live elect. Panels
cc) Stress Relieving works (Electrically or by Gas-burners).
dd) Pneumatic Tests
ee) Card board blasting
ff) Chemical cleaning
and take feedback from PDIL/Owner. The necessary HSE measures devised shall be put in to
place, prior to start of an activity & also shall be maintained during the course of works, by the
Contractor. Copies of such JSAs shall be kept available at work sites by the Contractor to enable
all concerned carrying out checks / verification.
A list of typical construction hazards along with their effects & preventive measures is given in
Appendix-E.
3.3.2
Accessibility
x
The Contractor shall provide safe means of access(in sufficient numbers) & efficient exit to
any working place including provisions of suitable and sufficient scaffolding at various
stages during all operations of the work for the safety of his workmen and PDIL/Owner.
x
The Contractor shall implement use of all measures including use of life line, fallarresters, retractable fall arresters , safety nets etc. during the course of using all safe
accesses & exits, so that in no case any individual remains at risk of slip & fall during their
travel.
3.3.3
The access to operating plant / project complex shall be strictly regulated. Any person or
vehicle entering such complex shall undergo identification check, as per the procedures in
force / requirement of PDIL/Owner.
Accessibility to confined space shall be governed by specific system / regulation, as
established at project site.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
3.3.4
PPEs (Helmet, Spectacle, Ear-muff, Face shield, Hand gloves, Safety Shoes, Gum
boot)
Barricading tape / warning signs
Rechargeable Safety torch (flame-proof)
Safety nets (with tie-chords)
Fall arresters
Portable ladders (varying lengths)
Life-lines (steel wire-rope, dia not less than 8.0 mm)
Full body harness (double lanyard)
Lanyard
Karabiner
Retractable fall arresters (various length)
Portable fire extinguishers (DCP type) 5 kg capacity
Portable Multi Gas detector
Sound level meter
Digital Lux meter
Fire hoses & flow nozzles
Fire blankets / Fire retardant cloth (with eyelets)
Working at height
x
The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints as specified in the attached permit (Format No. HSE-6).
He
shall also undertake to ensure compliance to the conditions of the permit during the
currency of the permit including adherence of personal protective equipments. Contractors
Safety Officer shall verify compliance status of the items of permit document after
implementation of action is completed by Contractors execution / field engineers at work
site. Job Safety Analysis (JSA) for specific works at height duly commented by
PDIL/Owner, shall be kept attached with particular Permit for Work (PFW) at site for ready
reference & follow-up.
x
Such PFW shall be initially issued for one single shift or expected duration of normal work
and extended further for balance duration, if required. PDIL/Owner can devise block-permit
system at any specific area, in consultation with project specific HSE Committee to specify
the time-period of validity of such PFW or its renewal. This permit shall be applicable in
areas where specific clearance from Owners operation Deptt. /Safety Deptt. is not
required. PDIL / Owners field Engineers/Safety Officers/Area Coordinators may verify and
counter sign this permit (as an evidence of verification) during the execution of the job.
x
All personnel shall be medically examined & certified by registered doctor, confirming
their medical fitness for working at height. The fitness examination shall be done once in
six months.
x
In case work is undertaken without taking sufficient precautions as given in the permit, PDIL
/Owner Engineers may exercise their authority to cancel such permit and stop the work till
satisfactory compliance/rectification is arranged made. Contractors are expected to
maintain a register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.
x
The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his
workers. Fall arresters are to be used while climbing/descending tall structures or vessels /
columns etc. These arresters should lock automatically against the anchorage line,
restricting free fall of the user. The device is to be provided with a double security opening
system to ensure safe attachment or release of the user at any point of rope. In order to
avoid shock, the system should be capable of keeping the person in vertical position in case
of a fall.
x
The Contractor shall ensure that Full body harnesses conforming EN361 and having
authorized C marking is used by all personnel while working at height. The lanyards and
life lines should have enough tensile strength to take the load of the worker in case of a fall.
One end of the lanyard shall be firmly tied with the harnesses and the other end with life
line. The harness should be capable of keeping the workman vertical in case of a fall,
enabling him to rescue himself.
x
The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping
roofs in order to reduce the chances of slippages and falls.
x
The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of
fall from height is present.
The safety net, preferably a knotted one with mesh ropes
conforming to IS 5175/ ISO 1140 shall have a border rope & tie cord of minimum 12mm
dia. The Safety Net shall be located not more than 6.0 meters below the working surface
extending on either side up to sufficient margin to arrest fall of persons working at different
heights.
x
In case of accidental fall of person on such Safety Net, the bottom most portion of Safety
Net should not touch any structure, object or ground.
x
The Contractor shall ensure positive isolation while working at different levels like in the
pipe rack areas. The working platforms with toe boards & hand rails shall be sufficiently
strong & shall have sufficient space to hold the workmen and tools & tackles including the
equipments required for executing the job. Such working platforms shall have mid-rails, to
enable people work safely in sitting posture.
3.3.5
x
Scaffolding shall be constructed using foot seals or base plates only.
3.3.6
Electrical installations
x
All electrical installations/ connections shall be carried out as per the provisions of latest
revision of following codes/standards, in addition to the requirements of Statutory
Authorities and IE/applicable international rules & regulations:
-
x
All electrical installations shall be approved by the concerned statutory authorities.
x
All temporary electrical installations / facilities shall be regularly
checked by the
licensed/competent electricians of the Contractor and appropriate records shall be
maintained in format no: HSE-12 Inspection of temporary electrical booth/installation at
project construction site. Such inspection records are to be made available to PDIL/Owner,
whenever asked for.
3.3.6.1 The Contractor shall meet the following requirements:
a.
Shall make Single Line Diagram (SLD) for providing connection to each equipments &
machinery and the same (duly approved by PDIL/Owner) shall be pasted on the front face of
DBs (distribution boards) or JBs (Junction boxes) at every site. ( A typical Switch Board
Sketch is attached as Appendix -G )
b.
Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per provisions
of the latest revision of the Indian Electrical/ applicable international regulations.
c.
Shall deploy qualified & licensed electricians for proper & safe installation and for regular
inspection of construction power distribution system/points including their earthing. A
copy of the license shall be submitted to PDIL / Owner for records. Availability of at least
one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be
ensured at site round the clock to attend to the normal/emergency jobs.
d.
All switchboards / welding machines shall be kept in well-ventilated & covered shed/ with
rain shed protection. The shed shall be elevated from the existing ground level to avoid
water logging inside the shed . Installation of electrical switch board must be done taking
care of the prevention of shock and safety of machine.
e.
No flammable materials shall be used for constructing the shed. Also flammable materials
shall not be stored in and around electrical equipment / switchboard. Adequate clearances
and operational space shall be provided around the equipment.
f.
Fire extinguishers and insulating mats shall be provided in all power distribution centers.
g.
Temporary electrical equipment shall not be employed in hazardous area without obtaining
safety permit.
h.
i.
All temporary installations shall be tested before energizing, to ensure proper earthing,
bonding, suitability of protection system, adequacy of feeders/cables etc.
j.
k.
Multilingual (Hindi, English and local language) caution boards, shock treatment charts and
instruction plate containing location of isolation point for incoming supply, name &
telephone No. of contact person in emergency shall be provided in substations and near all
distribution boards / local panels.
l.
m. Regular inspection of all installations at least once in a month. (Ref. Format HSE-12).
3.3.6.2 The following features shall also be ensured for all electrical installations during construction
phase by the contractor:
x
Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch shall not
exceed 1.5 M. The main switch shall be connected to the point of supply by means of
armoured cable.
x
The outgoing feeders shall be double or triple pole switches with fuses / MCBs. Loads in a
three phase circuit shall be balanced as far as possible and load on neutral should not
exceed 20% of load in the phase.
x
The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type.
Use of rewirable fuses shall be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.
x
All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.
x
All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be
provided with socket caps.
x
Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5
2
mm copper shall be used for all single phase hand tools.
x
Only metallic distribution boxes with double earthing shall be used at site.
No wooden
boxes shall be used.
x
All power cables shall be terminated with compression type cable glands. Tinned copper
lugs shall be used for multi-strand wires / cables.
x
Cables shall be free from any insulation damage.
x
Minimum depth of cable trench shall be 750 mm for MV & control cables and 900 mm for
HV cables. These cables shall be laid over a sand layer and covered with sand, brick & soil
for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of buried trench route.
When laid above ground, cables shall be properly cleated or supported on rigid poles of at
least 2.1 M high. Minimum head clearance of 6 meters shall be provided at road crossings.
x
Under ground road crossings for cables shall be avoided to the extent feasible. In any case
no under ground power cable shall be allowed to cross the roads without pipe sleeve.
x
All cable joints shall be done with proper jointing kit. No taped/ temporary joints shall be
used.
x
An independent earthing facility should preferably be established within the temporary
installation premises. All appliances and equipment shall be adequately earthed. In case of
armoured cables, the armour shall be bonded to the earthing system.
x
All cables and wire rope used for earth connections shall be terminated through tinned
copper lugs.
x
In case of local earthing, earth electrodes shall be buried near the supply point and earth
continuity wire shall be connected to local earth plate for further distribution to various
appliances. All insulated wires for earth connection shall have insulation of green colour.
x
Separate core shall be provided for neutral. Earth / Structures shall not be used as a neutral
in any case.
x
ON/OFF position of all switches shall be clearly designated / painted for easy isolation in
emergency.
3.3.7
3.3.8
3.3.9
Occupational Health
x
The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
x
For surface cleaning operations, sand blasting shall not be permitted even if not explicitly
stated elsewhere in the contract.
x
To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
shall not contain Thorium.
x
Appropriate respiratory protective devices(hood with respiratory devices) shall be used to
protect workmen from inhalation of air borne contaminants like silica, asbestos, gases,
fumes, etc.
x
Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulling
of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting
equipments.
x
For jobs like drilling/demolishing/dismantling where noise pollution exceeds the specified
limit of 85 decibels, ear muffs shall be provided to the workers.
x
To avoid work related upper limb disorders (WRULD) and backaches, Display Screen
Equipments' workplace stations shall be carefully designed & used with proper sitting
postures. Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how to
operate them safely & how to maintain good blood circulation in hands.
x
The Contractor shall arrange health check up (by registered medical practitioner) for all the
workers at the time of induction. Health check may have to be repeated if the nature of duty
assigned to him is changed necessitating health check or doubt arises about his wellness.
PDIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding, Radiography,
Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-ups shall be
conducted by registered Medical practitioner and records are to be maintained by the
Contractor.
x
The Contractor shall ensure vaccination of all the workers including their families, during
the course of entire project span.
3.3.10 Hazardous substances
x
Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, antitermite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good ventilated
area. These containers shall be labeled with the name of the materials highlighting the
hazards associated with its use and necessary precautions to be taken. Respective MSDS
(Material Safety Data Sheet) shall be made available at site & may be referred whenever
problem arises.
x
Where contact or exposure of hazardous materials are likely to exceed the specified limit or
otherwise have harmful effects, appropriate personal protective equipments such as gloves,
goggles/face-shields, aprons, chemical resistant clothing, respirator, etc. shall be used.
x
The work place shall be checked prior to start of activities to identify the location, type and
condition of any asbestos materials which could be disturbed during the work. In case
asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured
and the matter shall be reported immediately to PDIL/ Owner.
3.3.11 Slips, trips & falls
The contractor shall establish a regular cleaning and basic housekeeping programme that covers
all aspects of the workplace to help minimize the risk of slips, trips & falls. The contractor shall
take positive measures like keeping the work area tidy, storing waste in suitable containers &
harmful items separately, keeping passages, stairways, entrances & exits especially emergency
ones clear, cleaning up spillages immediately and replacing damaged carpet/ floor tiles, mats &
rugs at once to avoid slips, trips & falls.
3.3.12 Radiation exposure
x
All personnel exposed to physical agents such as ionizing & non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with adequate
shielding or protection commensurate with the type of exposure involved.
x
For Open Field Radiography works , requirements of Bhabha Atomic Research Centre
(BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
x
The Contractor shall implement an effective system of control (as described in the AERB
regulations) at site for handling radiography-sources & for avoiding its misuse & theft.
x
The contractor shall generate the Format No: HSE-8 Permit for radiation work before
start of work.
x
In case the radiography work has to be carried out at day time, suitable methodology to be
used so that other works, people are not affected.
3.3.13 Explosives/Blasting operations
x
Blasting operations shall be carried out as per latest Explosive Rules (Indian / International)
with prior permission. The Contractor shall obtain license from Chief Controller of
Explosives (CCoE) for collection, transportation, storage of explosives as well as for
x carrying out blasting operations.
The Contractor shall prepare exclusive method statement (in cognizance with statutory
requirements) for diffusing unfired explosives, if any, at project site before carrying out
actual task. Nowhere blasting shall be carried out by the Contractor or its agency without
the involvement of competent supervisor and licensed blaster / shot blaster.
3.3.14 Demolition/ Dismantling
x
The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work
x to guard against unsafe working practices.
The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, if required as directed by
x PDIL/ Owner at no extra cost.
Before carrying out any demolition/ dismantling work, the contractor shall take prior
approval of PDIL/Owner and generate theFormat No.HSE-9. For revamp jobs in operating
plants where location of underground utilities is not known with certainty, the contractor
shall depute an experienced engineer for supervision and shall make adequate arrangements
x for Fire fighting & First-Aid during the execution of these activities.
The Contractor shall arrange approved Job Safety Analysis (JSA) / Method Statement for
the specific demolition / dismantling task and corresponding action plan commensurate
with hazards / risks associated therein. In no case any activity related to demolition /
dismantling shall be carried out by the Contractor without engaging own supervision / field
engineer.
3.3.15 Road Safety
x
x The Contractor shall ensure adequately planned road transport safety management system.
The vehicles shall be fitted with reverse warning alarms & flashing lights / fog-lights and
x usage of seat belts shall be ensured.
The Contractor shall also ensure a separate pedestrian route for safety of the workers and
comply with all traffic rules & regulations, including maintaining speed limit of 20 kmph
or indicated by owner for all types of vehicles / mobile machinery. The maximum
x allowable speed shall be adhered to.
In case of an alert or emergency, the Contractor must arrange clearance of all the routes,
roads, access. The Contractor shall deploy sufficient number of traffic controllers at project
site routes / roads/ accesses, to alert reversing movement of vehicles & machinery as well
as pedestrians.
x
Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also
to & from the labour colony to & from project sites.
x
Hydras shall only be allowed for handling the materials at fabrication/ storage yards and in
no case shall be allowed to transport the materials over project / plant roads.
x
The Contractor shall not deploy any such mobile machinery / equipments, which do not
have competent operator and / or experienced banks-man / signal-man. Such machinery /
equipments shall have effective limit-switches, reverse-alarm, front & rear-end lights etc.
and shall be maintained in good working order.
x
The Contractor shall not carry-out maintenance of vehicles / mobile machinery occupying
space on project / plant roads and shall always arrange close supervision for such works.
x
For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
loading / unloading of pipes, movement of side booms, movement of vehicles on the ROW,
etc.
x
Contractors shall arrange /install visible road signs, diversion boards, caution boards, etc
on project roads for safe movement of men and machinery.
3.3.16 Welfare measures
Contractor shall, at the minimum, ensure the following facilities at work sites:
x
A crche at site where 10 or more female workers are having children below the age of 6
x years.
x Adequately ventilated / illuminated rooms at labour camps & its hygienic up-keeping.
Reasonable canteen facilities at site and in labour camps at appropriate location depending
upon site conditions. Contractor shall make use of industrial variety of LPG cylinder &
satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of
wastes from canteens & urinals /toilets shall also be made and regular review shall be made
to maintain the ambience satisfactorily hygienic & shall also comply with all applicable
x statutory requirements.
Adequately lighted & ventilated Rest rooms at site (separate for male workers and female
x workers).
Urinals, Toilets, drinking water, washing facilities, adequate lighting at site and labour
camps, commensurate with applicable Laws / Legislation.
3.3.17 Environment Protection
Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment.
Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste materials,
such as metals, plastics, glass, paper, oil & solvents. The waste that cannot be minimized,
reused or recovered shall be stored and disposed of safely. In no way, toxic spills shall be
allowed to percolate into the ground. The contractor shall not use the empty areas for dumping
the wastes.
The contractor shall strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases,
harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need
arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other
waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A
discharge plan suggesting the methods of treating the waste before discharging shall be
submitted to PDIL/Owner for approval.
For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This
fertile soil shall be placed back on top after backfilling.
For offshore construction barges, arrangements shall be made for safe disposal of human, food
& other wastes and applicable laws in this regard shall be followed.
3.3.18 Rules & Regulations
All persons deployed at site shall be knowledgeable of and comply with the environmental laws,
rules & regulations relating to the hazardous materials, substances and wastes. Contractor shall
not dump, release or otherwise discharge or disposes off any such materials without the express
authorization of PDIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is
given under Appendix-D.
3.3.19 Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, rain, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun
screen lotions, respirators, dust masks, etc. and rearranging/ planning the construction activities
to suit the weather conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle in the form
of temporary shelter shall be made at site.
3.3.20 Communication
All persons deployed at the work site shall have access to effective means of communication so
that any untoward incident can be reported immediately and assistance sought by them.
All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
For information to all, typical subjects that should be communicated are: Inside the company (Top to down)
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Quality Policy
HSE Policy contents
Environment Policy
HSE Objectives
Safety Cardinal Rules
HSE Target reached or missed
Praises & Warnings to personnel for HSE Management
Safety Walk Through Reports and safety defects / shortfalls (by management)
HSE Audit results
Revised Statutory Health & Safety provisions, if any
H & S publicity
Suggestions
Complaints
Compliances on safety defects / shortfalls
Suggestions
Proposals for changes & improvements
HSE Reports (including near-miss reports)
Number of Safety Inductions carried-out at site (for workmen & staff members)
Number of HSE inspections carried out
Number of Safety Walk Through carried-out by site-head.
Number of HSE shortfalls / lapses identified per contractor & closed-out in time.
Number of Safety Meetings conducted (in-house / with contractors)
Number of HSE Audits made (internal & external) vis--vis non conformances raised
Number of HSE Awareness / Motivational program conducted by contractors
Number of HSE Trainings conducted at site for supervisors & workmen
Study of Near miss case reported
Encouragements / Awards / Recognitions to workmen, job supervisors & field engineers.
Suggestions for improvement
Calculation of HSE statistics viz frequency rate, severity rate, LTA free manhours,etc
Analysis of incidents / accidents (nature, severity, types etc.)
Study of Incident / Accident with respect to :
Variety
The Contractor shall maintain sufficient angle of repose during excavation shall also
provide slope or suitable bench as decided by PDIL / Owner.
The Contractor shall arrange battering or benching wherever required for preventing
collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth
collapse due to heavy rain / influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid underpinning / under-cutting to prevent collapse of chunk of earth
during excavation
The Contractor shall use stoppers to prevent over-run of vehicle wheels at the edge of
excavated pits / trenches.
The Contractor shall arrange strengthening of shoring & strutting proactively to avoid
collapse of earth / edges due to vehicular movement in close proximity of excavated areas / pits
/ trenches, etc.
3.4
Section
Remarks, in any
The above record can be kept in local language, which workers can read. These records shall be
made available to PDIL/ Owner whenever demanded.
3.5
x
Records of the training shall be kept and submitted to PDIL/ Owner.
x
The Contractor shall make regular program for conducting Safety Training on various
topics related to various activities & their safe-guarding utilizing experienced persons /
outside agency / faculty. A program for Safety Training (indicative list as per Appendix F)
shall be furnished by the Contractor in its HSE Plan .
x
For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner/PDIL.
3.6
Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined Space
from Owner in the prescribed format.
b)
The contractor shall monitor record and compile list of his workers entering the operational
plant/unit each day and ensure & record their return after completing the job.
c)
Contractors workers and staff members shall use designated entrances and proceed by
designated routes to work areas only assigned to them. The workers shall not be allowed to
enter units' area, tanks area, pump rooms, etc. without work authorization permit.
d)
Work activities shall be planned in such a way so as to minimize the disruption of other
activities being carried out in an operational plant/unit and activities of other contractors.
e)
The contractor shall submit a list of all chemicals/toxic substances that are intended to be
used at site and shall take prior approval of the Owner.
f)
Specific training on working in a hydrocarbon plant shall be imparted to the work force and
mock drills shall be carried out for Rescue operations/First-Aid measures.
g)
h)
Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i)
j)
Emergency evacuation plan shall be worked out and all workmen shall be apprised about
evacuation routes. Mock drill operations may also be conducted.
k)
Flammable gas test shall be conducted prior to any hot work using appropriate measuring
instruments. Sewers, drains, vents or any other gas escaping points shall be covered with
flame retardant tarpaulin.
l)
Respiratory devices shall be kept handy while working in confined zones where there is a
danger of inhalation of poisonous gases. Constant monitoring of presence of Gas/
Hydrocarbon shall be done.
m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on live
lines and work on corroded tank roof.
n)
3.7
o)
Welding spatters shall be contained properly and in no case shall be allowed to fall on the
ground containing oil. Similar care shall be taken during cutting operations.
p)
The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe
and got it approved from Safety Department of the Owner.
q)
Plant air should not be used to clean any part of the body or clothing or use to blow off dirt
on the floor.
r)
Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's
plant operation personnel.
s)
Experienced full time safety personnel shall be exclusively deployed to monitor safety
aspects in running plants.
3.8
HSE Promotion
The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops/seminars/training programmes, celebrating HSE awareness weeks &
National Safety Day, conducting quizzes & essay competitions, distributing pamphlets, posters
& material on HSE, providing incentives for maintaining good HSE practices and granting
incentives / bonus for completing the job without any lost time accident.
3.9
Lock Out and Tag Out (LOTO) for isolation of energy source
x
Contractor shall follow the LOTO/Isolation procedure of owner for all energy source
x isolations installed/under purview by /of owner ie. Brown field
For all the other energy source (not under purview of client/owner) i.e Green field
Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel,
electrical panels from the energy source covering following as minimum:-
x
x
x
Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person carrying out
the task shall himself carry the key for the lock in /Lock out.
4.0
4.1
On Award Of Contract
The Contractor shall submit a comprehensive Health, Safety and Environment Plan or
programme for approval by PDIL/Owner prior to start of work. The Contractor shall participate in
the pre-start meeting with PDIL/Owner to finalize HSE Plans which shall including the
following:
-
4.2
to arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act, etc, as applicable.
to arrange all HSE permits before start of activities (as applicable), like permits for hot
work, working at heights (Refer Format No. HSE-6), confined space (Refer Format No.
HSE-7), Radiation Work Permit (Refer Format No. HSE-8), Demolishing/ Dismantling
Work Permit (Refer Format No. HSE-9),Permit for erection/modification & dismantling of
scaffolding(Refer Format No:HSE-14), Permit for heavy lift/critical erection (Refer Format
No:HSE-15) ,Permit for energy Isolation & De-isolation (HSE-16) ,storage of chemical /
explosive materials & its use and implement all precautions mentioned therein.
In this
regard, requirements of Oil industry Safety Directorate Standard No. Std -105 "Work
Permit Systems shall be complied with while working in existing Oil or Gas processing
plants. List of the persons involved shall be maintained as annexure to the work permit
issued for a particular activity.
to submit, timely, the completed checklist on HSE activities in Format No.HSE-1, Monthly
HSE report in Format No.HSE-5 (use of web based package (www.PDIL.co.in/conthse) is
compulsory wherever the facility is available else a hard copy is to be submitted), accident/
incident reports, investigation reports etc. as per PDIL/Owner requirements. Compliance of
instructions on HSE shall be done by Contractor and informed urgently to PDIL/Owner.
4.3
that his top most executive at site attends all the Safety Committee/HSE meetings arranged
by PDIL/Owner and carries out safety walk through regularly. Only in case of his absence
from site that a second senior most person shall be nominated by him, in advance, and
communicated to PDIL/Owner for performing the above tasks.
display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various dos & donts, etc.
identify, assess, analyze & mitigate the construction hazards & incorporate relevant control
measures before actually executing site works. (HIRAC = Hazard Identification, Risk
Analysis and Control).
carryout audits/inspection (internal & external) at his works as well as sub contractor works
as per approved HSE plan/procedure/programme & submit the compliance reports of
identified shortfalls for PDIL/Owner review.
arranging HSE training for site workmen (of his own & sub contractors) through internal or
external faculty at periodical intervals.
assistance & cooperate during HSE audits by PDIL/Owner or any other 3 party and submit
compliance report.
generate & submit of HSE records/report as per this specification.
carry-out all dismantling activities safely, with prior approval of PDIL/Owner representative.
The Contractor shall ensure that Hot works and painting works do not continue at the
same place / location at project site for which chance or probability
of fire incident
exists.
rd
5.0
RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following reporting
formats/:
Safety Walk Through Report
Accident/ Incident Report
Supplementary Accident/ Incident Investigation report
Near Miss Incident Report
Monthly HSE Report
Permit for working at height
Permit for working in confined space
Permit for radiation work
Permit for demolishing/ dismantling
Daily Safety checklist
House keeping Assessment & compliance
Inspection of temporary electrical booth/installation
Inspection for scaffolding
Permit for erection/modification &dismantling of scaffolding
Permit for heavy lift/critical erection.
Permit for Energy isolation and de-isolation.
Permit for Excavation
Inspection reports of Equipment/tools/tackles
Report of Toolbox talks
PPE issue report/register
Site inspection reports
Training records
(*) The formats shall be developed in consultation with PDIL/Owner
HSE-1
HSE-2
HSE-3
HSE-4
HSE-5
HSE-5
HSE-7
HSE-8
HSE-9
HSE-10
HSE-11
HSE-12
HSE-13
HSE-14
HSE-15
HSE-16
HSE-17
*
As indicated in
specification
*
*
*
APPENDIX-A
(Sheet 1 of 2)
A.
IS CODES ON HSE
SP: 53
Safety code for the use, Care and protection of hand operated tools.
IS: 838
Code of practice for safety & health requirements in electric and gas welding
and cutting operations
IS: 1179
IS: 1860
Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 3016
Code of practice for fire safety precautions in welding & cutting operation.
IS: 3043
IS: 3764
IS: 3786
Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents
IS: 3696
IS: 4083
IS: 4770
IS: 5121
IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557
IS: 5983
Eye protectors
IS: 6519
IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293
IS: 8519
IS: 9167
Ear protectors
IS: 11006
IS: 11016
General and safety requirements for machine tools and their operation
IS: 11057
IS: 11226
IS: 11972
IS: 13367
IS: 13416
APPENDIX-A
(Sheet 2 of 2)
B.
Safety Glasses
Safety Shoes
Hand Gloves
BS 1651
Ear Muffs
Hard Hat
Goggles
ANSI Z 87.1
Face Shield
ANSI Z 89.1
Breathing Apparatus
BS 4667, NIOSH
ANSI Z 49.1
EN-361
Lanyard
EN-354
Karabiner
APPENDIX-B
DETAILS OF FIRST AID BOX
-----------------------------------------------------------------------------------------------------------------------SL.
DESCRIPTION
QUANTITY
NO.
-----------------------------------------------------------------------------------------------------------------------1.
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.
27.
28.
29.
30.
31.
32.
33.
34.
35.
APPENDIX-C
TYPE OF FIRES VIS--VIS FIRE EXTINGUISHERS
Fire
Extinguisher
Fire
Water
Originated
from
paper, clothes, wood
Inflammable liquids
like alcohol, diesel,
petrol, edible oils,
bitumen
from
Originated
gases like LPG,
CNG, H2
Foam
CO2
Dry Powder
can control
minor surface
fires
can control
minor surface
fires
Multi purpose
(ABC)
Electrical fires
D
LEGEND :
: CAN BE USED
: NOT TO BE USED
Note: Fire extinguishing equipment must be checked at least once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next inspection date is
given. Type of extinguisher shall clearly be marked on it.
APPENDIX-D
List of Statutory Acts & Rules Relating to HSE
-
The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
The Building and Other Construction Workers (Regulation of Employment and Condition of service)
Act
TYPE OF
HAZARD
Falling into pit
EFFECT OF
HAZARD
Personal injury
Earth Collapse
Suffocation/
Breathlessness
Buried
Contact with
buried electric
cables
Gas/ Oil
Electrocution
Explosion
Pipelines
Pit Excavation
beyond 3.0m
Same as above
plus
Flooding due to
excessive rain/
underground
water
Digging in the
vicinity of
existing Building/
Structure
Movement of
vehicles/
equipments close
to the edge of cut.
Can cause
drowning situation
Building/Structure
may collapse
Loss of health &
wealth
May cause cave-in
or slides.
Persons may get
buried.
PREVENTIVE MEASURES
Provide guard rails/ barricade with warning
signal
Provide at least two entries/ exits.
Provide escape ladders.
Provide suitable size of shoring and strutting, if
required.
Keep soil heaps away from the edge equivalent to
1.5m or depth of pit whichever is more.
Don't allow vehicles to operate too close to
excavated areas. Maintain at least 2m distance
from edge of cut.
Maintain sufficient angle of repose. Provide
slope not less than 1:1 and suitable bench of 0.5m
width at every 1.5m depth of excavation in all
soils except hard rock.
Battering/benching the sides.
Obtain permission from competent authorities,
prior to excavation, if required.
Locate the position of buried utilities by referring
to plant drawings.
Start digging manually to locate the exact
position of buried utilities and thereafter use
mechanical means.
Prevent ingress of water
Provide ring buoys
Identify and provide suitable size dewatering
pump or well point system
Rock by
excavation
blasting
TYPE OF
HAZARD
Same as above
plus
Frequent cave-in
or slides
Flooding due to
Hydro- static
testing
Improper
handling of
explosives
Uncontrolled
explosion
Rock excavation
by blasting
(Contd)
Scattering of
stone pieces in
atmosphere
Entrapping of
persons/ animals.
Misfire
Piling Work
Failure of piledriving
equipment
Noise pollution
Extruding
rods/casing
Working in the
vicinity of 'LiveElectricity'
(B)
CONCRETING
EFFECT OF
HAZARD
May cause severe
injuries or prove
fatal
PREVENTIVE MEASURES
Battering/benching of sides
Provide escape ladders
Air pollution by
cement
Handling of
ingredients
May affect
Respiratory System
Hands may get
injured
Protruding
reinforcement
rods.
Super-structure
(C)
REINFORCEMENT
TYPE OF
HAZARD
Earthing of
electrical
mixers,
vibrators, etc.
not done.
Falling of
materials from
height
EFFECT OF
HAZARD
Can cause
electrocution/
asphyxiation
Continuous
pouring by same
gang
Revolving of
concrete mixer/
vibrators
Same as above
plus
Deflection in
props or
shuttering
material
Passage to work
place
Cause tiredness of
workers and may
lead to accident.
Parts of body or
clothes may get
entrapped.
Shuttering/props
may collapse and
prove fatal
Curtailment and
binding of rods
Carrying of rods
for short
distances/at
heights
Checking of
clear distance/
cover with hands
Hitting projected
rods and
standing on
cantilever rods.
PREVENTIVE MEASURES
Ensure earthing of equipments and proper
functioning of electrical circuit before
commencement of work.
(D)WELDING
AND GAS
CUTTING
TYPE OF
EFFECT OF
HAZARD
HAZARD
Falling of material May prove fatal
from height
Transportation of
rods by trucks/
trailers
Welding radiates
invisible
ultraviolet and
infra-red rays
Improper
placement of
oxygen and
acetylene cylinders
Radiation can
damage eyes and
skin.
Leakage/ cuts in
hoses
Opening-up of
cylinder
Welding of tanks,
container or pipes
storing flammable
liquids
PREVENTIVE MEASURES
Use helmets
Provide safety nets
Use red flags/lights at the ends
Do not protrude the rods in front of or by the side
of driver's cabin.
rd
Do not extend the rods 1/3 of deck length or
1.5m whichever is less
Use specified shielding devices and other PPE of
correct specifications.
Avoid thoriated tungsten electrodes for GTAW
TYPE OF
HAZARD
Ionizing
radiation
Transpor-tation
and Storage of
Radiog-raphy
source
(F) ELECTRICAL
INSTALLATION
AND USAGE
(*)
Loss of Radio
isotope
Short circuiting
EFFECT OF
HAZARD
Radiations may react
with the skin and can
cause cancer, skin
irritation, dermatitis,
etc.
PREVENTIVE MEASURES
(G) FIRE
PREVENTION
AND
PROTECTION
TYPE OF
HAZARD
EFFECT OF
HAZARD
Overloading of
Electrical
System
Bursting of system
can occur which
leads to fire
Improper laying
of overhead and
underground
transmission
lines/cables
Can cause
electrocution and
prove fatal
PREVENTIVE MEASURES
Do not allow open/bare connections
Provide all connections through ELCB
Protect electrical cables/equipment's from water
and naked flames
Check all connections before energizing
Display voltage and current ratings prominently
with 'Danger' signs.
Ensure approved cable size, voltage grade and
type
Switch off the electrical utilities when not in use
Do not allow unauthorized connections.
Ensure proper grid wise distribution of Power
Do not lay unarmoured cable directly on ground,
wall, roof of trees
Maintain at least 3m distance from HT cables
All temporary cables should be laid at least 750
mm below ground on 100 mm fine sand
overlying by brick soling
Provide proper sleeves at crossings/ intersections
Provide cable route markers indicating the type
and depth of cables at intervals not exceeding
30m and at the diversions/termination
In case a fire breaks out, press fire alarm system
and shout "Fire, Fire"
Keep buckets full of sand & water/ fire
extinguishing equipment near hazardous
locations
Confine smoking to 'Smoking Zones' only.
Train people for using specific type of fire
fighting equipments under different classes of fire
Keep fire doors/shutters, passages and exit doors
unobstructed
Maintain good housekeeping and first-aid boxes
(for details refer Appendix-B)
Don't obstruct assess to Fire extinguishers.
Do not use elevators for evacuation during fire.
Maintain lightening arrestors for elevated
structures
Stop all electrical motors with internal
combustion
TYPE OF
HAZARD
Improper
selection of Fire
extinguisher
EFFECT OF
HAZARD
It may not
extinguish the fire
(H)
VEHICULAR
MOVEMENT
Short circuiting
of electrical
system
Same as above
Can cause
Electrocution
Crossing the
Speed Limits
(Rash driving)
Personal injury
PREVENTIVE MEASURES
Move the vehicles from dangerous locations
Remove the load hanging from the crane booms
Remain out of the danger areas.
Ensure usage of correct fire extinguisher meant
for the specified fire (for details refer AppendixC).
Do not attempt to extinguish Oil and electric
fires with water. Use foam cylinders/CO2/sand
or earth.
Maintain safe distance of flammable substances
from source of ignition
Restrict the distribution of flammable materials
to only min. necessary amount
Construct specifically designed fuel storage
facilities
Keep chemicals in cool and dry place away from
heat. Ensure adequate ventilation
Before welding operation, remove or shield the
flammable material properly
Store flammable materials in stable racks,
correctly labeled preferably with catchment
trays.
Wipe off the spills immediately
Don't lay wires under carpets, mats or door ways
Use one socket for one appliance.
Use only fully insulated wires or cables
Do not allow open/bare connections
Provide all connections through ELCB
Ensure earthing of machineries and equipments
Obey speed limits and traffic rules strictly
Always expect the unexpected and be a
defensive driver
Use seat belts/helmets
Blow horn at intersections and during
overtaking operations.
Maintain the vehicle in good condition
Do not overtake on curves, bridges and slopes
Read the road ahead and ride to the left
Keep the wind screen and lights clean
Do not turn at speed.
Recognize the hazard, understand the defense
and act correctly in time.
(I)
PROOF
TESTING
(HYDROSTATI
C /PNEUMATIC
TESTING)
TYPE OF
HAZARD
Consuming
alcohol before
and during the
driving
operation
EFFECT OF
HAZARD
Same as above
Falling objects/
Mechanical
failure
Bursting of
piping
Collapse of
tanks
Tanks flying off
PREVENTIVE MEASURES
Alcohol and driving do not mix well. Either
choose alcohol or driving.
If you have a choice between hitting a fixed
object or an on-coming vehicle, hit the fixed
object
Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
Do not force the driver to drive fast and round the
clock.
Do not day dream while driving
Ensure effective braking system, adequate
visibility for the drives, reverse warning alarm..
Proper maintenance of the vehicle as per
manufacturer instructions
Prepare test procedure & obtain PDIL/owner's
approval
Provide separate gauge for pressurizing pump
and piping/equipment
Check the calibration status of all pressure
gauges, dead weight testers and temperature
recorders
Take dial readings at suitable defined intervals
and ensure most of them fall between 40-60% of
the gauge scale range
Provide safety relief valve (set at pressure
slightly higher than test pressure) while testing
with air/ nitrogen
Ensure necessary precautions, stepwise increase
in pressure, tightening of bolts/nuts, grouting, etc.
before and during testing
Keep the vents open before opening any valve
while draining out of water used for hydro-testing
of tanks.
Pneumatic testing involves the hazard of released
energy stored in compressed gas. Specific care
must therefore be taken to minimize the chance
of brittle failure during a pneumatic leak test.
Test temperature is important in this regard and
must be considered when the designer chooses
the material of construction.
(J)
WORKING AT
HEIGHTS
TYPE OF
HAZARD
(K) CONFINED
SPACES
Suffocation/
drowning
EFFECT OF
HAZARD
Unconsciousness,
death
PREVENTIVE MEASURES
A pressure relief device shall be provided, having
a set pressure not higher than the test pressure
plus the lesser of 345 KPa (50 psi) or 10% of the
test pressure.
The gas used as test fluid, if not air, shall be
nonflammable and nontoxic.
Provide guard rails/barricade at the work place
Use PPE like full body harness, life line, helmets,
safety shoes, etc.
Obtain a permit before starting the work at height
above 3 meters
Fall arrest and safety nets, etc. must be installed
Provide adequate working space (min. 0.6 m)
Tie/weld working platform with fixed support
Use roof top walk ladder while working on a
slopping roofs
Avoid movement on beams
Keep the work place neat and clean
Remove the scrap immediately
TYPE OF
HAZARD
EFFECT OF
HAZARD
PREVENTIVE MEASURES
Check for presence of hydrocarbons, O2 level
Obtain work permit before entering a confined
space
Ensure that the connected piping of the
equipment which is to be opened is pressure
free, fluid has been drained, vents are open and
piping is positively isolated by a blind flange
Presence of
foul smell and
toxic
substances
Ignition/ flame
can cause fire
(L)
HANDLING
AND
LIFTING
EQUIPMENTS
Failure of load
lifting and
moving
equipments
(M)
SCAFFOLDI
NG,
FORMWOR
K
AND
LADDERS
TYPE OF
HAZARD
Overloading of
lifting
equipments
EFFECT OF
HAZARD
Same as above
Overhead
electrical wires
Can cause
electrocution and
fire
Failure of
scaffolding
material
Same as above
Material can
fall down
Persons working at
lower level gets
injured
PREVENTIVE MEASURES
Safe lifting capacity of derricks and winches
written on them shall be got verified
The max. safe working load shall be marked on
all lifting equipments
Check the weight of columns and other heavy
items painted on them and accordingly decide
about the crane capacity, boom and angle of
erection
Allow only trained operators and riggers during
crane operation.
Do not allow boom or other parts of crane to
come within 3m reach of overhead HT cables
Hook and load being lifted shall preferably
remain in full visibility of crane operators.
Provide guard rails for working at height
Face ladder while climbing and use both hands.
Ladders shall extend about 1m above landing for
easy access and tying up purpose
Do not place ladders against movable objects and
maintain base at 1/4 unit of the working length of
the ladder.
Suspended scaffolds shall not be less than 500
mm wide and tied properly with ropes
No loose planks shall be allowed
Use PPE, like helmets, safety shoes,etc
Inspect visually all scaffolding materials for
stability and anchoring with permanent
structures.
Design scaffolding for max. load carrying
capacity.
Scaffolding planks shall not be less than 50X250
mm full thickness lumber or equivalent. These
shall be cleated or secured and must extend over
the end supports by at least 150mm and not more
than 300mm
Don't overload the scaffolds
Do not splice short ladders to make a longer one.
Vertical ladders shall not exceed 6m.
Remove excess material and scrap immediately
Carry the tools in a tool-kit bag only
Provide safety nets
(O)
PIPELINE
WORKS
(P)
GRIT
BLASTING
EFFECT OF
HAZARD
Can cause injury or
casualty
Lifting/ slipping
of material
Same as above
Erection/
lowering failure
Other
Same as above
Pollution in
neighboring
area, hit by grits
and high
pressure air
PREVENTIVE MEASURES
Do not take rest inside rooms built for welding
machines or electrical distribution system.
Avoid walking on beams at height
Wear helmet with chin strap and full body
harness while working at height.
Use hand gloves and goggles during grinding
operations
Cover or mark the sharp and projected edges
Do not stand within the operating radius of
cranes
Do not stand under the lifted load
Stack properly all the materials. Avoid slippage
during handling
Control longer pieces lifted up by cranes from
both ends
Remove loose materials from height
Ensure tightening of all nuts & bolts
Do not stand under the lifted load
Do not allow any person to come within the
radii of the side boom handling pipes
Check the load carrying capacity of the lifting
tools & tackles
Use safe Load Indicators
Use appropriate PPEs
Wear gum boots in marshy areas
Allow only one person to perform signaling
operations while lowering of pipes
Provide night caps on pipes
Provide end covers on pipes for stoppage of pigs
while testing/ cleaning operations
Ensure the blasting is done in enclosed shed.
Keep safe distance while blasting operations.
Wear positive pressure blast hood or helmet
with view window, ear-muff/plug, gloves,
overall or leather coat /apron, rubber shoes.
APPENDIX-F
TRAINING SUBJECTS / TOPICS
The Law & Safety Statutory Requirement / Applicable statutes / Duties of employer / employee
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Cranes & Other Lifting machinery Legal requirements vis--vis essential safety requirements.
15.
16.
17.
18.
19.
20.
Personnel at project
Who should be held
Safety
lanyards / Life-
APPENDIX - G
CONSTRUCTION POWER BOARD( typ)
APPENDIX-H
LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:A.
B.
FORMAT NO.
HSE-1 REV 0
(Sheet 1 of 6)
SAFETY WALK-THROUGH REPORT
(Name & signature of walk through performer to be inserted at the bottom of each page)
Project
: _____________
Report no.
: ___________
Date
: _____________
Contractor
: ___________
Inspection by
:_____________
Owner
: ___________
Frequency
: Monthly
Job no.
: ___________
ITEM
1.
a)
HOUSEKEEPING
Waste containers provided and used
b)
c)
d)
e)
Other
2.
a)
b)
Goggles; Shields
Face protection
Satisafctory
/ Yes
Non
satisfactory/
No
Remarks
Action
Hearing protection
Foot protection
e)
Hand protection
f)
g)
h)
i)
Other
3.
EXCAVATIONS/OPENINGS
a)
b)
c)
Excavations barricaded
d)
e)
Other
Safety walk-through performer (Name & Signature)..
FORMAT NO.
HSE-1 REV 0
(Sheet 2 of 6)
SL.
NO.
ITEM
4.
a)
b)
c)
d)
e)
f)
g)
Other
5.
a)
b)
c)
d)
Adequate shoring
e)
Adequate access
f)
g)
h)
Other
6.
LADDERS
a)
b)
Top of landing
c)
Properly secured
d)
e)
Other
Satisafctory
/ Yes
Non
satisfactory/
No
Remarks
Action
FORMAT NO.
HSE-1 REV 0
(Sheet 3 of 6)
SL.
NO.
ITEM
7.
a)
b)
c)
d)
e)
f)
g)
h)
Qualified operators
i)
Other
8.
a)
Proper instruction
b)
Safety devices
c)
Proper cords
d)
e)
Other
9.
a)
b)
c)
Licensed drivers
d)
Other
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Action
FORMAT NO.
HSE-1 REV 0
(Sheet 4 of 6)
SL.
NO.
ITEM
10.
TEMPORARY FACILITIES
a)
b)
c)
d)
e)
General neatness
f)
g)
Other
11.
FIRE PREVENTION
a)
c)
d)
e)
12.
ELECTRICAL
a)
b)
b)
c)
d)
e)
f)
g)
h)
f)
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Action
FORMAT NO.
HSE-1 REV 0
(Sheet 5 of 6)
SL.
NO.
14.
a)
b)
c)
15.
a)
b)
c)
d)
16.
a)
b)
c)
d)
e)
17.
a)
b)
c)
d)
e)
f)
g)
18.
a)
b)
ITEM
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Action
FORMAT NO.
HSE-1 REV 0
(Sheet 6 of 6)
SL.
NO.
ITEM
c)
d)
e)
f)
19.
HEALTH CHECKS
a)
b)
c)
d)
e)
f)
g)
h)
20.
a)
b)
c)
d)
e)
f)
g)
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Action
FORMAT NO.
HSE-2 REV 0
(Sheet 1 of 3)
ACCIDENT / INCIDENT REPORT
(To be submitted by Contractor after every Incident / Accident within 24 hours to PDIL/ Owner)
Report No.: ____________________________
Date: ______________________
Carpenter
Meson
Fitter
Helper
Gas cutter
Grinder
Welder
Electrician
Driver
Rigger
M/c.operator
Engineer
Manager
Other/specify
No formal education
Non-Matriculate
Matriculate
Graduate
Post- grad
Other/specify
NIL
2-5 yrs
5-10 yrs
11-15 yrs
Qualification
Job Experience
FORMAT NO.
HSE-2 REV 0
(Sheet 2 of 3)
Demolition
Concrete carrying
Concrete pouring
Transportation of materials
Transportation
(manually)
materials (mechanically)
Scaffold preparation
Scaffold dismantling
Piling works
Welding
Grinding
Gas-cutting
Structural fabrications
Machine works
Hydro-testing works
Electrical works
Erection activities
Other/specify
of
What exactly the victim was doing just before the incident / accident? ....................................
.
.
Nature of injury:
Bruise or Contusion
Sprains or strains
Cut or Laceration
Burn
Inhalation of toxic or
Poisonous fumes or gases
Fracture
Absorption
Amputation
Other/specify
Eyes
Throat
Fingers
Throat
Chest / Shoulder)
Leg (above ankle)
Multiple
Toes
Other/specify
Accident type:
Struck against
Struck by
caught in
caught under
caught in between
Rubbed or abraded
Vehicle accident
Contact
with
extremes)
Other/specify
(Temp./
FORMAT NO.
HSE-2 REV 0
(Sheet 3 of 3)
...
_____________________________________________________________________________
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ..
Safety Officer
To
:
:
Owner
RCM/Site-in-charge PDIL (3 copies)
Divisional Head (Constn) through RCM
Project Manager, PDIL, through RCM
FORMAT NO.
HSE-3 REV 0
(Sheet 1 of 5)
Carpenter
Meson
Fitter
Helper
Gas cutter
Grinder
Welder
Electrician
Driver
Rigger
M/c.operator
Engineer
Manager
Other/specify
No formal education
Non-Matriculate
Matriculate
Graduate
Post- grad
Other/specify
NIL
2-5 yrs
5-10 yrs
11-15 yrs
Qualification
Job Experience
FORMAT NO.
HSE-3 REV 0
(Sheet 2 of 5)
Demolition
Concrete carrying
Concrete pouring
Transportation of materials
Transportation
(manually)
materials (mechanically)
Scaffold preparation
Scaffold dismantling
Piling works
Welding
Grinding
Gas-cutting
Structural fabrications
Machine works
Hydro-testing works
Electrical works
Erection activities
Other/specify
of
What exactly the victim was doing just before the incident / accident? ....................................
.
.
Particular of tools & tackles being used and condition of the same after incident/accident:
.........................................
was
caused):
(How
the
incident
Description
of
Incident/Accident
.
Nature of injury:
Bruise or Contusion
Sprains or strains
Cut or Laceration
Burn
Inhalation of toxic or
Poisonous fumes or gases
Fracture
Absorption
Amputation
Other/specify
Face
Eyes
Throat
Fingers
Throat
Chest / Shoulder)
Leg (above ankle)
Multiple
Toes
Other/specify
FORMAT NO.
HSE-3 REV 0
(Sheet 3 of 5)
Accident type:
Struck against
Struck by
caught in
caught under
caught in between
Rubbed or abraded
Vehicle accident
Contact
with
extremes)
Other/specify
(Temp./
Name & Designation of person who provided First-Aid to the victim: ---------------------------------------
Name & Telephone number of Hospital where the victim was treated_________________________
Mode of transport used for transporting victim Ambulance / Private car / Tempo / Truck / Others
How much time taken to shift the injured person to Hospital________________________________
In case of FATAL incident, indicate clearly the BOCW Registration No. of the victim
/Company
Comments of Medical Practitioner, who treated / attended the victim/injured (attached / described
here)_____________________________________________________________________
What actions are taken for investigation of the incident, please indicate clearly (Video film /
Photography / Measurements taken etc..)
Poor housekeeping
Inadequate or improper
PPE
improper
illumination/Moving on oval
surface
Working on dangerous
equipment
FORMAT NO.
HSE-3 REV 0
(Sheet 4 of 5)
Failure to secure
Horse-play
Inattention to surroundings
Over confidence
Impulsiveness
over-exertion
Slow reaction
Others(specify)
Failure in communication
drug
or
influence
alcoholic
Basic cause
Root cause
Inadequate Engg
Improper Design
Inadequate knowledge
Inadequate skill
Inadequate supervision
Substandard performance
Inadequate maintenance
Others(specify)
Loss of man days and impact on site works, (if any)
FORMAT NO.
HSE-3 REV 0
(Sheet 5 of 5)
Remedial measures recommended by Safety Officer of Contractor for avoiding similar incident in
future
:
.
.
.
.
...
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ..
_____________________________________________________________________________
Safety Officer
(Signature and Name)
To :
:
Owner
RCM// Site-in-charge of PDIL (3 copies)
Divisional Head (Constn) through RCM
_
Project Manager PDIL, through RCM
FORMAT NO.
HSE-4 REV 0
x or interruption to work.
Dangerous Occurrence: Damage to property, equipment or interruption of work, but not
resulting in personal injury/illness, e.g. Fire incident, collapse of structure, crane failure,
etc
Report No.: _________________
Name of Site: _________________________
Date: ______________________
Contractor: __________________
__________________________________________________________________________________
Incident reported by
Location
__________________________________________________________________________________
Brief description of incident
__________________________________________________________________________________
Probable cause of incident
__________________________________________________________________________________
Suggested corrective action
__________________________________________________________________________________
Steps taken to avoid recurrence
To
:
:
Yes
Owner
RCM/Site-in-charge PDIL (3 copies)
Divisional Head (Constn) through RCM
Project Manager PDIL, through RCM
No
FORMAT NO.
:
HSE-5 REV 0
MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by each Contractor)
ITEM
THIS
MONTH
CUMULATIVE
Remarks, if any
Date:
Prepared by Safety Officer
(Signature and Name)
To : - OWNER
- RCM PDIL (2 copies)
Yes
Yes
Yes
No
No
No
FORMAT NO.
:
HSE-6 REV 0
PERMIT FOR WORKING AT HEIGHTS (ABOVE 2.0 METER)
(In duplicate to be issued daily for site and for office)
Permit No..
Name of Main Contractor
Name of work executing agency / sub agency / vendor:...
Date
Exact Location of work
Nature of work ..Duration of work (from) (to) .......
Number of workers covered within this permit
(List enclosed with name & gate pass numbers.)
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Status of compliance
(Yes / No)
Items / Subjects
Work areas / Equipments inspected
Work area cordoned off
Adequate lighting is provided
Precautions against public traffic taken
Concerned persons in & around have been alerted & cautioned
Hazards / risks involved in routine / non-routine task assessed and control
measures have been implemented at specific task
ELCB provided for electrical connection & found working
Ladder safely attached / fixed
Scaffoldings are checked and TAGs are found used correctly
Working platforms are provided and are found sound /safe for use
Safe access & egress arrangements (e.g. ladders, fall arresters, life-lines etc.)
are satisfactorily incorporated
a.
Openings on platform / floors are effectively cordoned / covered
b.
Use of following safety gadgets by people working at area under this permit, is
checked and found satisfactory Safety helmet
Safety harness (full body) with double lanyard
Safety Shoes
Safety gloves
Safety goggles
Housekeeping of work area found satisfactorily tidy / clean & clear
Adequate measures have been taken for works being continued at the ground
level, when simultaneous works are permitted overhead at that very location.
Materials are not thrown from heights on to ground
Medical examination of workers are made & found satisfactory
Responsible job engineer / supervisor found physically present at work spot for
overall administration of work as well as safety of people.
Above items have been checked & compliance has been found in place. Hence work is permitted to
start / continue at the above-mentioned location. Work shall not start till identified lapses are rectified.
Additional Precautions, if any .
..
Work Permit issued by
Contractor Engineer/RCM
Verification By
Contractor Safety Officer
FORMAT NO.
HSE-7 REV 0
power/steam/air
isolated from liquid or
gases
depressurized
&/or
drained
blanked/
blinded/
disconnected
(B)
Expected Residual Hazards
lack of O2
corrosive chemicals
gloves
protective clothing
grounded air duct/blower
/AC
Fire fighting arrangements
Y
NR
Y
NR
water
flushed
&/or
steamed
Man ways open &
ventilated
cont. inert gas flow
arranged
adequately cooled
mask
safety harness & lifeline
radiation
removed
proper
provided
sources
lighting
Signature
Contractor's
Supervisor
Contractor's
Safety Officer
Time
From
Permit Closure :
was closed
stopped
will continue on ...
(A) Entry
removed
key transferred
(C) Multilock
Ensured all men have come out
Man-ways barricaded
Remarks, if any:
To
Signature
Workman
FORMAT NO.
HSE-8 REV 0
RADIATION WORK PERMIT
:
Project
Name of the work
:
Name of site contractor :
Location of work
Source strength
Sr.No. :
Date :
Job No.:
Approved by Owner/PDIL
The following items have been checked &compliance shall be ensured during currency of the
permit:
S. No.
Item description
Safety regulations as per BARC/AERB ensured while source in use/in transit & during
storage
Area cordoned off / safe working platform provided
Lighting arrangements for working during nights ensured
Warning signs/ flash lights installed
Cold work permit taken (if applicable)
PPEs like film badges, dosimeters used
Done
:Designation:
Permit extended up to
Date
Date:
Sign of issuing authority with
date (of site contractor)
Time
FORMAT NO.
Project
Name of the work
Name of contractor
:
HSE-9 REV 0
DEMOLISHING/DISMANTLING WORK PERMIT
:
Sr.No. :
:
Date :
:
Job No. :
Name of sub-contractor :
The following items have been checked &compliance shall be ensured during currency of the
permit:
S.
No.
Item description
Done
Not
Applicable
Permission is granted.
(Permit issuing authority)
Name
Date
:
:
Completion report :
Dismantling/ Demolishing is completed on _____________ Date at ____________ Hrs.
Materials/ debris transported to identified location
Services like power, gas supply, water, etc. restored
(Permit issuing authority)
CONTRACTORs NAME
FORMAT NO.
HSE-10 REV 0
DAILY SAFETY CHECKLIST
(To make use of before start of days work)
Project
Name of the work
Name of contractor
:
:
:
Sr.No. :
Date :
Job No. :
Sl.
No
1
2
3
4
Safety Helmets
Safety Shoes
Hand Gloves
Dust Musk
Sl.
No
6
7
8
9
Safety Goggles
10
PPEs
Compliance
(Yes / No)
PPEs
Compliance (Yes
/ No)
Face Shield
Full body harness
Fall Arrest System
Safety net
Horizontal life-line made
of steel wire, (dia not
less than 8.0 mm.)
(Serial No. 1 & 2 are compulsory for everyone. Specify & ensure use of other safety gadgets as required for the job)
x
Identify following important unsafe conditions: -
Sl. No
Conditions
1
Access to work site / emergency escape clear
2
Soil / Loose earth kept away from excavated pit / slope / ladder provided
Electrical wire / welding lead lying entangled on ground / welding m/c. booth
3
accessible
4
Elevated work platform / open ends are protected
Ground area cordoned off before lifting works or erection at height / ground
5
area checked & cordoned-off before start of height works
Structural members / erected pipes / wooden boards/pieces etc. are safely
6
anchored at heights and are not likely to fall down on people when working
beneath
Rope ladders tied-up on tall steel structures, long before are removed to get
7
rid of their use
8x
Any Other
Yes / No
.
x
Specific Safety guidelines / precautions, if any (communicated thro TBT)
x
Above conditions and PPE compliances are checked by undersigned and correct status are indicated after
verification
Inspected by
Contractor Engineer
Verification By
Contractor Safety Officer
FORMAT NO.
HSE-11 REV 0
(Sheet 1 of 2)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
:
:
:
: Fortnightly
Subjects of Review
Sr.No. :
Date :
Job No. :
Satisafctory/
Non
Yes
satisfactory/No
Remarks
Action
FORMAT NO.
HSE-11 REV 0
(Sheet 2 of 2)
Sl
No.
Subjects of Review
Satisafctory/
Non
Yes
satisfactory/No
Remarks
Action
Inspected by
Contractor Engineer
Verification By
Contractor Safety Officer
FORMAT NO.
HSE-12 REV 0
SUBJECTS
Sr.No. :
Date :
Job No. :
Location:
OBSERVATION (YES /NO)
ACTION TAKEN
Inspected by
Contractor Engineer
Verification By
Contractor Safety Officer
FORMAT NO.
HSE-13 REV 0
(Sheet 1 of 2)
INSPECTION FOR SCAFFOLDING
Project
Name of the work
Name of contractor
:
:
:
Sr.No. :
Date :
Job No. :
Sl.
Description
Yes
No
1 Whether work permit is obtained to take up work at height above 1.5 Mts?
Whether atmospheric condition is stormy or raining and works at
2
heights have been permitted?
3 Whether steel pipes scaffoldings are used for units /off-site areas?
Whether scaffolding has been erected on rigid/firm/leveled surfaces /
4 ground? Whether foot-seals or base-plates are used beneath the uprights (vertical steel pipes)
Whether scaffold construction is as per IS specification with toe-board and
5
hand-rails (top-rail as well as mid-rail)?
Whether distance between two successive up-rights are less than 2.5 Mts
6 (height of scaffold & load carrying capacity governs the distance between
two uprights)
Whether all uprights are extended at least 900 mm above the top most
7
working platform (to enable fitting of handrails)?
Whether vertical distance of two successive ledgers is satisfactory?
8
(varying between 1.3 Mts. To 2.1 Mts)
Whether the peripheral areas of working at height are cordoned-off? (for
9
avoiding accident to people arising out of dropped / deflected materials)
10 Whether platform is provided? Is it safely approachable?
Whether end of scaffold platform / board are extended beyond transoms?
11
(125mm to 150 mm)
Whether CE / IS approved quality and worthy conditioned full-body safety
12 harness (with double lanyard & karabiners) are used while working at
heights?
Whether life-line of safety harness is anchored to an independent secured
13
support capable of withstanding load of a falling person?
Whether the area around the scaffold is cordoned off to prohibit the entry of
14
unauthorized person / vehicle?
Whether clamps used are of good condition, of adequate strength and free
15
from defects?
16 Whether ladder is placed at secured and leveled surface?
17 Whether water-pass and oil-spills are avoided around the scaffold structure?
18 Whether ladder is extended 1.5mts. above the landing point at height?
19 Whether more than one access/egress provided to the scaffold?
Whether ladder used are of adequate length and overlapping of short
20
ladders avoided?
Whether metallic ladders are placed much away from near-by electrical
21
transmission line?
22 Whether rungs of ladder are inspected and found in good order?
23 Whether fall-arresters provided on both the access/egress routes?
Whether diagonal (cross) bracings are provided at regular interval on the
24
scaffold?
Whether working platform on the scaffold has been made free from jolt
25
or gap?
Whether tools or materials are removed after completion of the days job at
26
heights?
Whether a valid Permit for Work (PFW) is obtained before taking up work
27
over asbestos or fragile roof?
28 Whether sufficient precaution is taken while working on fragile roof?
No
N.A
Actions
taken
FORMAT NO.
HSE-14 REV 0
(sheet 1 of 2)
PERMIT FOR ERECTION / MODIFICATION & DISMANTLING OF SCAFFOLDING
Project
:
Sr.No. :
Name of the work
:
Date :
Name of contractor
:
Job No. :
Duration: FromTo
Nature of activities
:
SL.
No.
1
2
3
4
5
6
9
10
11
12
13
14
15
16
17
18
x
x
x
x
x
SUBJECTS / ITEMS
DONE
NOT
DONE
REMARKS
Names to be
noted
This permit for work shall be available at specific work location all the time.
After completion of work, permit shall be returned to safety cell of main contractor, without fail.
This Permit shall be issued maximum upto (Monday to Sunday).
Additional Precautions, if any
Inspected by
Contractor Engineer
Verification By
Contractor Safety Officer]
FORMAT NO.
HSE-14 REV 0
(sheet 2of 2)
Everyday Site working conditions & performance of workmen shall be assessed / checked by Contractor
Site Engr. and Safety Officer shall verify the same .
Name / Sign.
Site
Engr.
Safety
Off.
MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
SUNDAY
FORMAT NO.
HSE-15 REV 0
:
:
:
:
Location of work
:
Equipment/Structure to be erected:
SL.
NO.
1)
Sr.No. :
Date :
Job No. :
Duration: FromTo
Name /Type of crane
:
Wt. of equipment/ structure to be erected :
Description of Item
Yes
8)
9)
10)
2)
3)
4)
5)
6)
7)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
COMPLIANCE STATUS
No
Not applicable
Remarks
Verification By
Contractor Safety Officer
FORMAT NO.
HSE-16 REV 0
:
:
:
Sr.No. :
Date :
Job No. :
PERMIT VALIDATION
I hereby authorize the ..personnel(performer)
to isolate the above equipment/energy source from all
sources of power and handover the equipment/energy
source for maintenance/repair.
Issuing authority
Area Incharge/RCM
Signature:
Name:
Signature:
Name:
Date:
Date:
PERFORMING AUTHORITY
The work and precautions will be carried out under my
overall responsibility.(Testing/execution engineer)
Lock No:.
Tag No:
Lock No:.
Issuing authority
Issuing authority
Area Incharge/RCM
Area Incharge/RCM
Signature:
Date:
Signature:
Date:
Name:
Name:
(*to be included by contractor in consultation with
(*to be included by contractor in consultation with
PDIL/owner)
PDIL/owner)
ENERGY DE-ISOLATION PERMIT
PERMIT VALIDATION
PERFORMING AUTHORITY
I hereby authorize the ..personnel(performer)
I herby certify that the equipment/energy source
to de- isolate the above equipment/energy source from mentioned above has been de-isolated and is ready for
all sources of power and handover the equipment/energy normal operation.(Testing/execution engineer)
source for normal operation..
Issuing authority
Area Incharge/RCM
Signature:
Name:
Signature:
Name:
Date:
Date:
Countersigned by Issuing authority
FORMAT NO.
HSE-17 REV 0
Project
Name of the work
Name of contractor
:
:
:
Sr.No. :
Date :
Job No. :
Job Description
Size of excavation
:
:
Location:
COMPLIANCE STATUS
Yes
No
Not
applicable
SL.
Description of Item
NO.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
Yes /
No
Remarks
FORMAT NO.
HSE-17 REV 0
PERMIT FOR EXCAVATION
(Sheet 2of 2)
NOTES: -
1. Slopes or benches for excavation beyond 2.0M depth shall be designed & approved by Contractors site
head.
Excavated earth to be kept at least 1.5M away from edges
Safety helmets, Safety shoes or gum-boots, gloves, goggles, Face shield, Safety Harness shall be essential
PPEs.
Permit shall be made in duplicate and original shall be available at site of work.
Permit shall be issued for maximum one week only (Monday to Sunday)
After completion of works, permit shall be closed & preserved for record purpose
2.
3.
4.
5.
6.
Sl.
No.
Validity period
From ____To ____
Working Time
From _____To _____
1.
2.
3.
4.
5.
6.
7.
Initiator (site
Engr. of Main
Contractor)
Issuing authority
(Safety Officer
of Main
Contractor)
Review by PDIL /
Owner (Remarks
with date
Installation of LPG
G Mounded Bullets at
N
NRL
VEND
DOR LIST
0
D
DOCUMENT
T NO
REV
V
SHEET 1 OF 30
VE
ENDOR
R LIST
Installatio
on of LP
PG Mou
unded Bullets
B
a
at NRL
P
REV
V
01.06.201
15
REV DATE
E
EFF DA
ATE
FORM NO: 02
2-0000-0021F1 REV2
R
FOR REVIEW
PURP
POSE
HK
PREPD
RA
R
SKT
REVWD
R
APPD
All rights reserved
LPG Mounded
M
d Bulletts at NR
RL
P
D
DOCUMENT
T NO
VEND
DOR LIST
REV
V
SHEET 2 OF 30
HODIC PR
ROTECTIO
ON VENDO
OR LIST
1.0 CATH
Sr. No.
N
VEN
NDORS
M/s Raychem
R
R
RPG
Ltd
M/s Consultech
C
h
M/s Afcons
A
Corrrosion pro
otection Pvt Ltd (Form
merly SSS Electricals
s (I) Pvt
Ltd.)
M/s Corrosion
C
C
Control
Services (Bombay) Pvt Ltd
M/s Corrtech,
C
A
Ahmedabad
d
M/s CTS
C
Private Limited
M/s Corrtech
C
In
nternationa
al Pvt Ltd
F
FOR
CEMENT (OPC
C 43 grade
e) :1
2
3
4
5
6
7
2.2
F
FOR
REIN
NFORCEMENT STEE
EL (Fe 500
0D Grade)) :1
2
3
2.3
ADIT
TYA
CEMENT CORPORATION OF INDIA LTD.
GUJR
RAT AMBU
UJA
J K CEMENT(L
C
LAXMI CEM
MENT)
LARS
SEN & TUB
BRO CEMENT
THE ASSOCIATED CEMENT COM
MPANIES LIMITED
L
SHRE
EE CEMEN
NT
STEE
EL AUTHO
ORITY OF INDIA LTD
D.
TATA
A IRON & STEEL
S
CO
O. LTD.
RAST
TRIYA ISP
PAT NIGAM
M LIMITED
D (Vishakha
apattanam
m).
F
FOR
STRU
UCTURAL
L STEEL (F
Fy 250 Mp
pa as per IS-2062) :--
1
2
3
STEE
EL AUTHO
ORITY OF INDIA LTD
D.
TATA
A IRON & STEEL
S
CO
O. LTD.
RAST
TRIYA ISP
PAT NIGAM
M LIMITED
D (Vishakha
apattanam
m).
2-0000-0021 F2 REV2
FORM NO: 02
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
D
DOCUMENT
T NO
REV
V
SHEET 3 OF 30
3.0 INSTRUMENTA
ATION
Sl.No
V
Vendors
Name
N
Gas An
nalysers (IR, Therma
al Conduc
ctivity, Parramagnetiic)
1.
ABB Ltd (BU Ana
alytical &Ad
dv)
2.
Chemtro
ols Industrie
es Limited (Maihak Make)
M
3.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
4.
Endress+
+ Hauser (India)
(
pvt. Ltd.
5
MaihakA
Aktiengesellschraft
6
Siemenss AG
7
Emerson
n Process Manageme
ent Singap
pore Ltd
8.
AmetekIn
nc
9.
M.S.A In
nternationa
al
pH, con
nductivity & ORP An
nalyser
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
2.
Endress+
+ Hauser (India)
(
pvt. Ltd. (Liquid Analyse
er)
3
ABB Indiia Limited
4
Forbes polymetron
p
n Pvt. Ltd.
5
Zellwege
er SA
6
Yokogaw
wa Electric Corporatio
on
7.
Emerson
n Process Manageme
ent Singap
pore Ltd
8
Foxbaro Far East Pte
P Ltd
9
ABB Pro
ocess Analyytics
10
Hach com
mpany
Trace Analyser/
A
I
Ion
Selecttive
1.
Forbes Polymetron
P
nPvt. Ltd
2
ABB Indiia Limited
3
Zellwege
er SA
4
Bran &Lu
uebbe Ltd
5
Hach com
mpany
SOX/ NO
OX Analyser
1.
ABB Indiia Ltd.
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
3.
Sick AG
4.
Siemenss AG
5.
Horiba Ltd.
6.
Yokogaw
wa Electric Corporatio
on
7.
Emerson
n Process Manageme
ent Singap
pore Ltd
8.
Lear Siegler Meas.. Controls Corp.
9.
M.S.A In
nternationa
al
10.
Thermo Environme
ent Instrum
ments Inc
Mass Spectrome
S
eter
1.
VG Gas Analysis Systems
S
2.
Orbital Science
S
Co
orporation
3
ABB Indiia Limited
Gas Ch
hromatogrraph
1.
Applied Automation
A
n Inc
2-0000-0021 F2 REV2
FORM NO: 02
Country
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Singapore
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
France
Ja
apan
Singapore
Singapore
U.K
U
U.S.A
U
In
ndia
In
ndia
France
U.K
U
U.S.A
U
In
ndia
In
ndia
Germany
G
Germany
G
Ja
apan
Ja
apan
Singapore
U.S.A
U
U.S.A
U
U.S.A
U
U.K
U
U.S.A
U
In
ndia
Singapore
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
D
DOCUMENT
T NO
SHEET 4 OF 30
2.
Foxbaro Far East Pte
P Ltd
3
ABB Indiia Limited
4
Emerson
n Process Manageme
ent (I) Pvtt. Ltd.
5.
ABB Pro
ocess Analyytics
Flue Ga
as Analyse
er (ZrO2 ty
ype)
1.
ABB Ltd (BU Ana
alytical &Ad
dv)
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
3.
Ametek Inc
4.
GE Pana
ametrics
H2S/ To
otal Sulphu
ur Analyse
ers
1.
Barton In
nstrument Systems Limited
L
4.
ABB Indiia Ltd.
System
m House Analysers
A
1.
ABB Ltd (BU Ana
alytical &Ad
dv)
2.
Chemtro
ols Industrie
es Limited
3.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
4.
Intech
5.
Adage Automation
A
Pvt Ltd.
Density
y Analyserrs
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd (coriolis type)
2.
Bopp & Reuther
R
MesstechnikkGmbh (co
oriolis type))
3.
Solartron
nMobrey
Moisturre Analyse
ers
1.
GE Pana
ametrics
2.
AmetekIn
nc
Gas & Fire
F Detec
ction Syste
em
1.
Andrew Yule
Y
& Company Ltd
d. (Fire)
2.
Honeywe
ell Automa
ation India Limited (G
Gas)
3.
J B Boda
a And Brotthers Pvt. Ltd. (Gas Make-Inte
ernational S
Sensor
Technolo
ogy)
4.
Pollution
n Protection
n System Mumbai
M
Pv
vt Ltd (Gass)
5.
Teledyne
e Fluid Sysstems (Gass)
6.
General Monitors (Gas)
(
Air Qua
ality Monittoring Sys
stem
1
Chemtro
ol industriess Ltd.
Flow Ellement: Orifice/ Ven
nturi/ Flow
w Nozzle
1.
Baliga Liighting Equ
uipments Limited
L
(On
nly Orifice))
2.
General Instruments Consorttium (Only Orifice)
3.
Instrume
entation Ltd
d, Palakkad
d
4.
Micro Precision Pro
oducts Privvate Ltd.
5.
Eureca Industrial Eqipments
E
Pvt Ltd.
6.
Unicontrols Instrum
ments Pvt. Ltd.
7.
Bopp & Reuther
R
MesstechnikkGmbh
8.
Technom
matic Spa
9.
ISA Conttrols Limite
ed
10.
Daniel Measureme
M
ent & Contrrol
11
Flowtech
h Instruments service
es (Orifice//Venturi)
2-0000-0021 F2 REV2
FORM NO: 02
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ndia
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aly
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ndia
Thailand
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ndia
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Chemtro
ol Industriess Ltd
Pitot Tu
ube/ Annu
ubar
1.
Control Engineers
E
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
3.
Micro Precision Pro
oducts Privvate Ltd.
4
ABB Indiia Limited
5.
Unicontrols Instrum
ments Pvt. Ltd.
6.
Technom
matic Spa
7.
ISA Conttrols Limite
ed
8
Daniel Measureme
M
ent & Contrrol
Rotame
eters
1.
Instrume
entation En
ngineers Pvvt. Ltd.
2.
Krohne Marshall
M
Pvt. Ltd.
3.
Placka In
nstrumentss & Controls Pvt. Ltd. (Purge Rotameter O
Only)
4.
Rota Insttrumentatio
on
5.
Eureca Industrial Eqipments
E
Pvt Ltd.
6.
ABB Indiia Ltd.
7
Krohne
8
Rota Yokkogawa Gm
mbh& Co. Kg
9
Tokyo Ke
eiso Co. Lttd.
10.
Yamatakke Corpora
ation
11
Emerson
n Process Mgt
12
Flowtech
h Instruments service
es
13
Chemtro
ol Industriess Ltd
Mass Flow Meterr (Coriolis Type)
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2
SIEMEN
NS Ltd.
3.
ABB Indiia Limited
4
Bopp & Reuther
R
MesstechnikkGmbh
5
Endress + Hauser Gmbh& Co.
6.
Krohne
7.
Schlumb
berger Ressource Man
nagement Ltd.
8.
Chemtro
ol Industriess Ltd
Turbine
e Flowmetter
1.
FmcSanmar Ltd.
2.
ABB Indiia Ltd.
3.
Bopp & Reuther
R
MesstechnikkGmbh
4.
Instrome
et Internatio
onal N.V
5.
Itochu Corporation (Rep.KubotaCorpn.))
6.
Yamatakke Corpora
ation
7.
Oval Ase
ea Pacific Pte
P Ltd
8.
Barton In
nstrument Systems Limited
L
9.
Emerson
n Process Mgt
10.
Emerson
n Process Mgt
11.
Rockwell Internatio
onal Corpn
n.
12.
Chemtro
ol Industriess Ltd
Vortex meter
2-0000-0021 F2 REV2
FORM NO: 02
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apan
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apan
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ndia
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ndia
In
ndia
In
ndia
Germany
G
Germany
G
Germany
G
U.S.A
U
In
ndia
In
ndia
In
ndia
Germany
G
Holland
H
Ja
apan
Ja
apan
Singapore
U.K
U
U.K
U
U.S.A
U
U.S.A
U
In
ndia
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
1.
Krohne Marshall
M
Pvt. Ltd.
2.
Yokogaw
wa Limited
3.
Siemenss Ltd.
4
ABB Indiia Ltd.
5.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
6
Bopp & Reuther
R
MesstechnikkGmbh
7.
Endress + Hauser Gmbh& Co.,
8.
Krohne
9
Itochu Corporation (Rep.KubotaCorpn.))
10
Schlumb
berger Ressource Man
nagement Ltd.
PD Meter
1.
Rockwin Flow Mete
ers (I) Pvt. Ltd.
2.
Bopp & Reuther
R
MesstechnikkGmbh
3.
Oval Ase
ea Pacific Pte
P Ltd
4.
Emerson
n Process Mgt
5.
Schlumb
berger Ressource Man
nagement Ltd.
6.
Chemtro
ol Industriess Ltd
Magnettic Flow meter
m
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2.
ABB Indiia Ltd.
3.
Endress + Hauser (India) Pvtt. Ltd.
4.
Krohne Marshall
M
Pvt. Ltd.
5.
Siemenss Ltd.
6
Bopp & Reuther
R
MesstechnikkGmbh
7
Krohne
8
Yamatakke Corpora
ation
9.
Chemtro
ol Industriess Ltd
Insertio
on Type Fllow Meter
1
Siemenss Ltd.
Ultraso
onic Flow Meter
M
1
Endress + Hauser (India) Pvtt. Ltd.
2.
Siemenss Ltd.
3.
Chemtro
ol Industriess Ltd
Orifice Meter
1
Chemtro
ol Industriess Ltd
Meterin
ng Skid
1
Chemtro
ol Industriess Ltd (for liiquid & Ga
as)
Pressure Gauges
s
1.
A N Instrruments Pvvt. Ltd.
2.
General Instruments Consorttium,
3.
H.Guru Industries
4.
Manome
eter (India) Pvt. Ltd
5.
PeejeeEngg. Workks
6.
Precision
n Industries Ltd. (stan
ndard norm
mal type)
7.
Premium
m Inst. & Co
ontrols Ltd
d.
8.
Walchan
ndnagar Ind
dustries Lttd.
9.
Ashcroft India(P) Ltd.
L (standa
ard normal type)
2-0000-0021 F2 REV2
FORM NO: 02
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ndia
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ndia
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Germany
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apan
In
ndia
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ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
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ndia
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ndia
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ndia
All rights reserved
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LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
10.
11.
12.
13.
14.
P
D
DOCUMENT
T NO
SHEET 7 OF 30
15.
Budenbe
erg Gauge Co. Ltd
Vol. Sea
al Pr. Gau
uges
1.
A N Instrruments Pvvt. Ltd. (=<
<600# Exce
ept Urea Service)
S
2.
Dresser Europe S.A
A.
3.
WikaAlexxenderWie
egandGmb
bh& Co.
4.
Spriano Spa
5.
Nagano Keiki Seisa
akusho
6.
Rueger Sa
S
7.
Budenbe
erg Gauge Co. Ltd.
Local D/P
D Indicattors
1.
Switzer Instrumentt Co.
2.
Barton In
nstrument Systems Limited
L
3.
Delta Co
ontrols Ltd.
Pressure & D/P Transmitte
T
ers
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2.
Honeywe
ell Automa
ation India Limited
3.
Yokogaw
wa Limited
4.
Siemenss Ltd.
5
Endress + Hauser (India) Pvtt.Ltd.
6.
Siemenss Ag, Germ
many
7
Yamatakke Corpora
ation
8
Yokogaw
wa Electric Corporatio
on
9
Emerson
n Process Mgt Singapore Ltd
10.
SmarSin
ngaporePte
e. Ltd.
11
Honeywe
ell Inc.
12.
Moore Products Co
ompany
Vol. Sea
al Pr./Dp Transmitte
T
er
1.
Honeywe
ell Automa
ation India Limited
2.
Yokogaw
wa Limited
3.
Siemenss Ltd.
4.
ABB Indiia Limited
5.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
6.
Endress+
+ Hauser (India)
(
Pvt.. Ltd.
7.
Fuji Elecctric System
ms Co., Ltd
d. (Except Urea Servvice)
8
Yamatakke Corpora
ation
9.
Yokogaw
wa Electric Corporatio
on
10
Emerson
n Process Mgt Singapore Ltd
11
Moore Products Co
ompany
Pressure & D/P Switches
S
Including Vol. Seal
1.
Indfos In
ndustries Lttd. (Exceptt Vol.Seal))
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
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G
Germany
G
Ita
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Ja
apan
Switzerlan
d
U.K
U
In
ndia
Germany
G
Germany
G
Ita
aly
Ja
apan
Switzerlan
d
U.K
U
In
ndia
U.K
U
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ja
apan
Ja
apan
Singapore
Singapore
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Ja
apan
Ja
apan
Ja
apan
Singapore
U.S.A
U
In
ndia
All rights reserved
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LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
2.
3.
P
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U.K
U
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U.S.A
U
In
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In
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In
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In
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Austria
A
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aly
Ita
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apan
U.S.A
U
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In
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In
ndia
In
ndia
In
ndia
Belgium
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Germany
G
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All rights reserved
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M
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RL
VEND
DOR LIST
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T NO
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3.
Magnetro
ol Internatiional N.V. (Lvdt)
4.
Dresser Masoneila
an
5.
Foxboro EckardtGm
mbh
6.
Parcol Spa (Pneum
matic Transsmission Only)
O
Nucleonic Level Transmittter
1.
Berthold Technolog
gies Gmbh
h&Co.Kg
2.
Endress + Hauser Gmbh& Co.
3.
Kay Rayy
4.
Vega Grieshaber KG
K
Capacittance Typ
pe Level Trransmitterr
1.
Magnetro
ol Internatiional N.V
2
Endress + Hauser (India) Pvtt. Ltd.
3
Siemenss Ltd.
4
Endress + Hauser Gmbh& Co.
5
Krohne
6
KdgMobrey Ltd
7.
Vega Grieshaber KG
K
Tank Le
evel Instru
uments
1.
Endress + Hauser Gmbh& Co., (Non-C
Contact & Servo)
S
2.
Krohne (Non-Conta
(
act Type)
3.
ABB Indiia Limited
4.
Emerson
n Process Manageme
ent (i) Pvt. Ltd.
5.
Siemenss Ltd. (Radar level Trransmitter, guided wa
ave Radar))
6
Tokyo Ke
eiso Co. Lttd.
7
EnrafSin
ngaporePte
e. Ltd.
8
L & J Technologiess
Resitive
e Electrod
de Type Le
evel Instru
ument
1.
Clark-Re
eliance Corrp
2.
Schlumb
berger Ressource Man
nagement Ltd.
Speciall Level Sw
witches (Viibration Fo
ork/Rf Admittance)
1.
Endress + Hauser Gmbh& Co.
2.
ABB Indiia Limited
3.
Protocon
ntrol Instrruments (I) Pvt. Ltd. (Fo
or non critical
applicatio
ons)
4.
Sor Inc.
5.
Vega Grieshaber KG
K
Ultraso
onic Level Transmittter
1.
Siemenss Ltd.
2.
Vega Grieshaber KG
K
Tank Fa
arm Management
1.
Endress + Hauser ( India) Pvvt. Ltd. (Servo,Radar))
Guided wave Rda
ar
1.
Endress + Hauser ( India) Pvvt. Ltd
Temperrature Elements (Th
hermocouple, Rtd)
1.
Altop Ind
dustries Ltd
d. (Only No
ormal Type
e (Mi))
2.
ABB Indiia Limited
3.
Detriv Instrumentattion & Elecctronics Ltd
d (Only No
ormal Type
e)
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
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France
Germany
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Germany
G
Germany
G
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U
Germany
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Belgium
In
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In
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Germany
G
Germany
G
U.K
U
Germany
G
Germany
G
Germany
G
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In
ndia
In
ndia
Ja
apan
Singapore
U.S.A
U
U.S.A
U
U.S.A
U
Germany
G
In
ndia
In
ndia
U.S.A
U
Germany
G
In
ndia
Germany
G
In
ndia
In
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In
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In
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In
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All rights reserved
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LPG Mounded
M
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RL
VEND
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4.
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Ita
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Ja
apan
Switzerlan
d
U.S.A
U
In
ndia
10.
Trend Instrument Inc.
11.
Goa Insttruments In
ndustries Ltd
L
Dial The
ermomete
er (Hg In Steel/Glass
S
s)
1.
A N Instrruments Pvvt. Ltd.
In
ndia
2.
General Instruments Consorttium,
In
ndia
3.
H.Guru Industries
In
ndia
4.
PeejeeEngg. Workks
In
ndia
5.
Waaree Instruments Ltd
In
ndia
6.
Walchan
ndnagar Ind
dustries Lttd.
In
ndia
7
Ashcroft India(P) Ltd.
L
In
ndia
8.
Goa Insttruments In
ndustries Ltd(Liquid
L
filled,
f
Gas filled Merccury in In
ndia
steel)
Radiatio
on Pyrom
meter
1.
Siemenss Ag, Germ
many
Germany
G
2
Tempsen
ns Instruments (I) Pvvt. Ltd.
In
ndia
3.
C.C.R. Technico
T
Ita
aly
4
ChinoCo
orpn.
Ja
apan
5.
Land Infrrared
U.K
U
6.
Wahl Insstruments
U.S.A
U
Temperrature Transmitters
2-0000-0021 F2 REV2
FORM NO: 02
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
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T NO
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SHEET 11 OF 30
1.
ABB Indiia Limited
2.
Endress+
+ Hauser (India)
(
Pvt.. Ltd.
3.
Siemenss Ltd.
4.
Siemenss Ag, Germ
many
5
M-System
m
Temperrature Swiitches
1.
Goa Insttruments In
ndustries Ltd
L
Gate/Plug Valves
s
1.
Audco In
ndia Limited(L&T Valvves Divn.)
2.
BHEL(Va
alves Divission)
3.
Chemtro
ols Enginee
ering Limite
ed (Plug Valves)
V
4.
Ksb Pum
mps Limited
d (Valves Divn)
D
5.
Flowservve India Co
ontrol Pvt. Ltd.(Plug Valve
V
upto
o 12300# u
upto
6 600#)
6.
Velan Incc.
7.
Malbranq
queS.A.
8.
CesareB
Bonetti
9.
Fasani S.P.A.
S
10.
Petrol Va
alves S.R.L
L
11.
Matsura H. P Mach
hine Workss Co.Ltd.
12.
Bel Valve
es
Globe / Angle Va
alves
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ndia
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apan
1.
In
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2.
3.
4.
5.
6.
7.
8.
9
10.
11
12.
13
14
15.
16
2-0000-0021 F2 REV2
FORM NO: 02
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C
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U
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18
P
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T NO
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Flowservve (=<2500
0#)
EMET Control
C
Pvtt Ltd (Glo
obe upto 4
4 300#, Angle
A
upto
o 11/2
2500#)
19.
Chemtro
ol Industriess Ltd. (for water
w
& ste
eam)
Ball Valves
1.
Tyco Vallves & Con
ntrols (I) Lttd (=< 150 #)
2.
Virgo En
ngineers Ltd. (=<600#
# With Mac
ccair Actua
ators)
3.
Anand Teknow
T
Aids engine
eering India Limited
d (upto 6,, 600#
(ON-OFF
F))
4.
Flowservve India co
ontrols Pvt. Ltd. ( upto
o 16 600#
#)
5.
Koso Flu
uid Controls pvt. Ltd. ( upto 8 ,2500# ,10
0 to 18 90
00# )
6
Rotex Manufacture
M
ers & Eng
gineers Prrivate Limited ( Shu
utdown
Valves Pdil
P approvved make , upto 6 60
00#, 6 to 10
1 150# )
7.
Velan Inc. ( ball va
alves on/o
off size: to 6 (ratting upto 2
2500#)
size 8to
o 16 ( ratin
ng upto 900
0# ) size 18 to 30 (rating
(
upto
o 300#
)
8
Perrin Gmbh ( SIZE
E TO 12 & Ratin
ng 150# to 2500# , size 14
to 18 & rating 150# to 1500
0# size 20
0 to 24 , rating 15
50 # &
300# )
9
Metso Au
utomation (=<2500#))
10.
Petrol Va
alves S.R.L
L
11.
Pibiviessse S.P.A. (Rating Uptto 2500 #)
12.
GTC Italia
13.
Metso Au
utomation (=<2500#))
14.
Orbit Vallves (=<25
500#)
15
M/s Brayy Control Pvt
P Ltd (uptto 4 300#))
16
EMET Control Pvt Ltd (upto 8
8 150#, fo
or air servicce)
Butterflly Valves
1.
Instrume
entation Ltd
d. (Palakka
ad) (=< 300
0#)
2.
Tyco Vallves & Con
ntrols (I) Lttd (=< 150 #)
3.
Virgo En
ngineers Ltd. (=<300#
#)
4.
Flowservve india co
ontrol pvt. Ltd.
L ( upto 30,300# upto
u
12 60
00#)
5.
Koso fluiid controls (pvt.) ltd. (=<
( 150#)
6.
Korea Un
nicom valvves co. Ltd.( for rating
g =< 300#))
7
Parcol Spa (=< 250
00# Urea Service
S
Als
so)
8
Orton s.rr.l (Upto 25
500#)
9
Bray Con
ntrols(=< 300#)
3
10
Keystone
e (Upto 25
500#)
11
Metso Au
utomation (Upto 2500#)
12
Leeds Va
alve Ltd
13
EMET Control
C
Pvt Ltd (upto 4
4 900#, 6 150# to 16
1 150#, d
double
eccentricc)
Saunde
ers (Pinch) Valves
1
Weir BDK VALVES
S( a unit off weir india pvt. Ltd. ) upto 1500
0#
Solenoid Valves
1.
Asco (Ind
dia) Limite
ed
2.
Rotex Au
utomation Limited
3.
IMI Norg
gren-Herion
nFluidtronicGmbh&C
Co.
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
ca
anada
Germany
G
Ita
aly
Ita
aly
Ita
aly
Ita
aly
Singapore
Singapore
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Korea
K
Ita
aly
Ita
aly
U.S.A
U
Singapore
Singapore
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
All rights reserved
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M
d Bulletts at NR
RL
VEND
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4.
Alexende
er Controlss Ltd.
5.
Asco Jou
ucomatic Ltd.
L
Prds& Spray
S
Nozzzle,Vent Valves
V
Up
pto 2500#
1.
Cci Valve
e Technolo
ogy Ab
2.
ABB
3.
Control Componen
C
nts Inc.
4.
Spx Valvves & Conttrols (Cope
es-Vulcan Ltd)
L
5.
ARCA(Forbes Marrshal)(mech
h spray no
ozzle type desuperhe
d
eater )
6.
Control Componen
C
nts Inc.
7.
Circor Flow Techn
nologies In
ndia Pvt. Ltd.
L
(1 to 20 upto 150#,
1to 10 upto 1500#
#, 1 to 8 upto 2500
0# )
8.
Chemtro
ol Industriess Ltd ( PRD
DS Combine & Split))
Electric
c Actuatorr
1.
Rotork Control
C
(De
eutschland)) Gmbh
2.
Biffi Italia
a S.R.L
3.
Limitorqu
ue, U.S.A
4.
Marsh Automation (for safe area)
a
Air Filte
er Regulattor
1.
Asea Bro
own Boverri Ltd.
2.
Divya Co
ontrol Elem
ments Pvt. Ltd.
3.
Mil Contrrols Limited
4.
Placka In
nstrumentss & Controls Pvt. Ltd.
5.
Shavo Norgren(Ind
N
dia) Pvt Ltd
d.
6.
ABB Indiia Limited
Pressure Regulator
Chemtro
ol Industriess Ltd
1
Limit/Proximity Switches
S
1.
Osna Ele
ectronics Pvt.
P Ltd. (In
ntrinsically Safe Proxximity Switcches)
2.
Pepperl + Fuch
3.
EL-O Ma
atic India Pvt
P Ltd(for non
n critical apps)
4.
Rotex Manufacture
ers & Engin
neers Pvt Ltd(for
L
non
n critical ap
pps)
5.
Protocon
ntrol Instruments (I) Pvt.
P Ltd. ( for
f non crittical applica
ations)
6
Pepperl + Fuch
7.
Pepperl + Fuchs Pte Ltd.
8.
Honeywe
ell Inc.
Valve actuator
a
(P
Pneumatic
c/ Rotary)
1.
EL-O-Ma
atic India private
p
limitted ( for no
on- critical application
ns)
2.
Rotex Manufacture
ers & Engin
neers Priva
ate Limited
d
3.
Bray Con
ntrol Pvt Lttd.
Self acttuated pre
essure con
ntrol valve
e
1
Nirmal In
ndustrial co
ontrols privvate limited
d ( size to 6 & rrating :
< =300# )
Slam Shut off valve
1.
Nirmal In
ndustrial co
ontrols privvate limited
d ( size to 6 & rrating :
< =300# )
Electroneumatic Positione
er
1.
Siemenss Limited
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
U.K
U
U.K
U
Sweden
U.K
U
In
ndia
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ita
aly
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Singapore
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
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T NO
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Turbine
e Bypass valves
v
1.
Circor Flow Techno
ologies Ind
dia Pvt. Ltd
d. ( 2 to 24 upto 2500# )
Desupe
erheater
1.
Cicor Flo
ow technologies India Pvt. Ltd
d ( upto 24
4 300# up
pto 28
1500 # Multi
M
nozzle
e 3 to 4 upto
u
2500#
#)
2.
EMET Control Pvt Ltd (1 600#
6
X 3 2500#)
Pressure reducin
ng station
1.
Cicor Flo
ow technollogies India
a Pvt. Ltd. (1 to 20 upto 1500
0#, 1 to
10 upto 1500 # 1tto 8 upto 2500#)
Safety Valves
V
& Thermal
T
R
Relief
Valv
ves Upto 2500#
2
1.
FaingerL
Leser Valve
es (P) Ltd. (Upto 600
0#, To 6)
6
2..
Instrume
entation Ltd
d. (Palakka
ad)
3.
Tyco San
nmar Ltd.
4.
Bliss ana
and private
e limited (8
( * 10 300#,
3
6 * 8 600# ,4 * 6
1500#)
5.
Mekaster engg. Ltd
d ( upto 60
00# safety 4* 6 , th
h relief * 1)
6.
Dresser Valve & Controls
7.
Parcol Spa (For Urrea Service
e Also)
8.
Tai Milan
no S.P.A (F
For Urea Service
S
Als
so)
9.
Itochu Corporation (Rep.KubotaCorpn.))
10.
Crossby Valve &En
ngg. Comp
pany Ltd.
11.
Farris
12
Dresser Industries Incorporatted
13.
Teledyne
e fluid Systtem
14.
Sapag GEC
G
Alstho
om
15.
BOPP & Reuther Messtechn
M
ic GMBH
Vaccum
m Breakers
s
1.
Braunsch
hweigerFla
ammenfilte
erGmbh
2.
Parcol Spa
3.
Tai Milan
no S.P.A
4.
Itochu Corporation
5.
Safety Systems Ukk Ltd.
6.
Whessoe
eVarec Lim
mited
Rupture
e Discs
1.
Bs&B Sa
afety Syste
ems (India)) Limited
2.
Fike Europe
3.
SapagGe
ecAlsthom
m
4.
Teledyne
e Fluid Sysstems
5.
Continen
ntal Contro
ols Inc.
Pilot relief valves
s
1.
Bliss Ana
and Private
e Limited (Size
(
1* 2 2500#)
Controll Panel
1.
Asea Bro
own Boverri Ltd.
2.
Electroniics Corporration Of In
ndia Ltd
3.
Industria
al Control Appliances
A
(P) Ltd.,
4.
Jaisun&H
Hutchisun Controls Ltd.,
L
5.
Pyrotech
h Electroniccs Pvt.Ltd.
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Canada
C
Ita
aly
Ita
aly
Ja
apan
U.K
U
U.K
U
U.S.A
U
Thailand
France
Germany
G
Germany
G
Ita
aly
Ita
aly
Ja
apan
U.K
U
U.K
U
In
ndia
Belgium
France
Thailand
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
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T NO
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6
United Electric
E
Co. (Delhi) Pvvt. Ltd. (Up
pto 10 Mtrss.)
7
Yokogaw
wa Limited
8
Instrome
et Internatio
onal N.V
9.
Prima au
utomation (India)
(
PVT
T. LTD. ( fo
or package
e equipments)
10.
TAN SW
WA technolo
ogies Inc
Panel Access.
A
( Relay,Swit
R
tch,Lamp,,Terminal,,Push Buttton)
1
Larsen & Toubro Ltd.(Contro
L
l& Automa
ation (Lamp
p, Push Bu
utton)
2
Rockwell Automation India Lttd. (Relays
s)
3.
Econix Hi-TECH
H
C
Componen
ts Pvt. LTD. (For Te
erminal Blo
ocks &
accessorries Only)
4.
Elmex co
ontros pvt. Ltd.
5.
Jyoti Lim
mited (Relay)
6.
Digitable
eThielenGm
mbh& Co
7
Phoenix Contact Gmbh&
G
Co..
8.
Siemenss Ag, Germ
many (Lamp
p,Pushbuttton,Contacctors)
9
Stahl-Un
nd Apparatebau Hanss LefferGm
mbh (Lamp
p,Pushbutto
on)
10
WagoKo
ontakltechn
nikGmbh
11
Weidmulller Ltd.
12
Omron Corporation
C
n (Relay)
13.
Pepperl + Fuchs Pte Ltd. (Sw
witch)
14.
Phoenix contact (in
ndia) pvt. Ltd.
L (for terrminal bloccks)
15
M/s Pow
wercam Ele
ectricals Pvvt Ltd (Pilott lamp, Pussh button)
Program
mable Log
gic Contro
oller
1.
Ge Fanu
uc Systemss Prvitate Limited
L
2.
Honeywe
ell Automa
ation India Limited (Safety Syste
em)
3.
Larsen & Toubro Ltd.(Contro
L
l& Automa
ation (Non Failsafe)
4.
Moore Controls
C
Ltd
d. (Failsafe
e)
5.
Rockwell Automation India Lttd. (Non Fa
ailsafe)
6
Siemenss Ltd., (Non
n Failsafe)
7.
ABB Indiia Limited
8.
Emerson
n Process Managem
ment (I) Pvt. Ltd. ( Delta V SIS
S ESID
system)
9.
Rockwell automatio
on India Pvt.
P Ltd. (N
Non failsafe
e & Failsaffe (ICS
Triplex TMR,
T
DMR
R)
10.
Siemenss Ltd. (ESD
D- Siemattic S7-400FH/PLC-Simatic S-3
300,s7400 (fmr//dmr)
11
Hima Pa
aul Hildebra
andt Gmbh
h + Co Kg (Failsafe)
12.
Marconi Italiana (N
Non Failsaffe)
13
Omron Corporation
C
n (Non Failsafe)
14.
Triconexx (Fault Tollerant Tmr)
15.
Ge Fanu
uc Automattion North America, Inc. (Fault Tolerant T
Tmr)
Distribu
uted Control System
m
1.
Honeywe
ell Automa
ation India Limited
2.
Yokogaw
wa Limited
3.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
4.
ABB Indiia Limited
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
In
ndia
In
ndia
Holland
H
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Germany
G
Germany
G
Germany
G
Germany
G
Ja
apan
Singapore
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ita
aly
Ja
apan
Singapore
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
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T NO
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5
Siemenss Ltd. (Sima
atic Pcs7
7)
6.
Siemenss Ag, Germ
many
7
Invensyss
8
Yokogaw
wa Electric Corporatio
on
9
Emerson
n Process Mgt Singapore Ltd
10.
Bailey Controls Co
ompany
11.
Honeywe
ell Inc.
Multiple
exer / Rem
mote I/O
1.
Mtl Instru
ument Limited
2.
Pepperl + Fuch
3.
Pepperl + Fuch
4.
Stahl-Un
nd Apparatebau Hanss LefferGm
mbh
5.
Pepperl + Fuchs Pte Ltd.
6.
M.T.L., U.K.
U
7.
M.system
m Co. Ltd. ( Remote I/O; Modell No.R3)
Receive
er Instrum
ments (Indicator,Con
ntroller,Re
ecorder)
1.
Chino-La
axsons (Ind
dia) Limited (Only Re
ecorder)
2.
Eurotherrm Del Indiia Limited
3.
Honeywe
ell Automa
ation India Limited
4.
Moore Controls
C
Ltd
d.
5.
Yokogaw
wa Limited
6.
Masibus Automation & Instrumena
ation Pvtt.Ltd. (Re
eceiver
Instrume
ents exceptt recorder))
7.
ABB Indiia Limited
8
Siemenss Ag, Germ
many
9.
ChinoCo
orpn.
10.
Yokogaw
wa Electric Corporatio
on
11
Heraeus Electro-Nite Internattional N.V..
12
Honeywe
ell Inc.
Alarm Annunciat
A
tor
1.
Industria
al Instruments & Conttrols
2.
Shree Ellectronics
3.
M.T.L., U.K.
U
4.
Rocheste
er Instrume
ent System
ms Ltd.
5.
Riley Panalarm
6.
Ronan Engg.
E
Co.
Barrier//Isolator/T
Trip Amplifier
1.
MTL Insttrument Lim
mited
2.
Pepperl + Fuch
3.
Digitable
eThielenGm
mbh& Co
4.
Foxboro EckardtGm
mbh
5.
Pepperl + Fuch
6.
Stahl-Un
nd Apparatebau Hanss LefferGm
mbh
7.
Yokogaw
wa Electric Corporatio
on
8.
M. Systtem Co. Ltd. (Sig
gnal Isola
ators Fittin
ngs:Model Nos.
M2VS;M
M5VS;W2VS
S;W5VS)
9.
Pepperl + Fuchs Pte Ltd.
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
In
ndia
Germany
G
Holland
H
Ja
apan
Singapore
U.S.A
U
U.S.A
U
In
ndia
In
ndia
Germany
G
Germany
G
Singapore
U.K
U
Ja
apan
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ja
apan
Ja
apan
Ja
apan
U.S.A
U
In
ndia
In
ndia
U.K
U
U.K
U
U.S.A
U
U.S.A
U
In
ndia
In
ndia
Germany
G
Germany
G
Germany
G
Germany
G
Ja
apan
Ja
apan
Singapore
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
10.
Camille Bauer
B
Ag
11
M.T.L., U.K.
U
12..
Honeywe
ell Inc.
Temperrature Sca
anner
1.
Industria
al Instrumentation
2.
Protocon
ntrol Instruments (I) Pvt.
P Ltd.
Cctv / Access
A
Sy
ystem
1.
Honeywe
ell Automa
ation India Limited
2.
Yokogaw
wa Limited
Miscelle
enous Item
ms (Rtu / ScadaEtc)
S
)
1
ABB Indiia Limited
2.
Rockwell Automation India Pvt. Ltd.
3.
Siemenss Ltd. (Sima
atic WINccc)
Energy meter
1.
M.system
m co. Ltd.( Model No. 53U)
Surge Protection
P
n Devices
1.
Phoenix Contact (India) Pvt. Ltd.
Wiring Ducts
1.
Trinity to
ouch Pvt.Lttd.
DIN Raiil
1.
Trinity to
ouch Pvt.Lttd.
Interfac
ce Module
e
1.
Trinity to
ouch Pvt.Lttd.
Cable connector
c
r
1.
Phoenix contact (In
ndia) Pvt. Ltd.
L
Machine Monitorring System
1.
Bruel&KjjaerGmbh
2.
Skf Cond
dition Monitoring Inc.
3.
Bentley NevedaLlc
N
c
Speed Indicator
I
1.
Pepperl + Fuch
2.
Shinkaw
wa Electric Co.
C
3.
Pepperl + Fuchs Pte Ltd.
4.
Jacquet
5.
Bentley NevedaLlc
N
c
Anti Su
urge Contrroller
1.
Compresssor Contro
ol Corpora
ation
2.
Invensyss Triconex
3.
Dresser Rand Co
o.
Burner Managem
ment Syste
em
1.
DuragInd
dustrieElekktronikGmb
bh& Co Kg
g
2.
Siemenss Ag, Germ
many
3.
Mitsubish
hi Heavy In
ndustries Ltd.
L
4.
Omron Corporation
C
n
5.
Yamatakke Corpora
ation
6.
Honeywe
ell Inc.
2-0000-0021 F2 REV2
FORM NO: 02
P
D
DOCUMENT
T NO
REV
V
SHEET 17 OF 30
Switzerlan
d
U.K
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Singapore
U.S.A
U
Ge
ermany
Ja
apan
Sin
ngapore
Sw
witzerland
U.S.A
Singapore
Singapore
Singapore
In
ndia
Germany
G
Ja
apan
Ja
apan
Ja
apan
U.S.A
U
All rights reserved
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LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
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T NO
SHEET 18 OF 30
Furnace
e Camera, Heater, Thermal
T
Im
mager
1.
Tempsen
ns instruments (I) Pvvt. Ltd.
Termina
al Automa
ation Systtem
1.
Asea Bro
own Boverri Ltd.
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
3.
Honeywe
ell Automa
ation India Limited
4.
Chemtro
ol Industriess Ltd
I/P Converter
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2.
Invensyss (Foxboro)
3
Yokogaw
wa Limited
4.
Yokogaw
wa Electric Corporatio
on
5.
Emerson
n Process Manageme
ent Ltd
6.
Moore Products Co
ompany
Instrum
ment Powe
er & Contrrol Cables
1.
Associatted Cabless Ltd.
2.
Associatted Flexible
es & Wiress Pvt. Ltd.
3.
Cords Ca
able Indusstries Ltd.
4.
Delton Cables
C
Ltd
5.
Insucon Cables & Conducto
ors (P) Ltd. (For Sma
aller Non-C
Critical
Projects))
6.
J K Cables Limited
d
7.
Kei Indusstries Limitted
8.
Paramou
unt Cable Corporatio
C
n
9.
T C Com
mmunicatio
ons Pvt Ltd
10.
Thermo Cables Lim
mited
11.
Toshniwal Cables
12.
Udey Pyyro Cables Pvt Ltd
Extensiion & Com
mpensating Cables
1.
Associatted Cabless Ltd.
2.
Associatted Flexible
es & Wiress Pvt. Ltd.
3.
Cords Ca
able Indusstries Ltd.
4.
Delton Cables
C
Ltd
5.
General Instruments Consorttium,
6.
J K Cables Limited
d
7.
Kei Indusstries Limitted
8.
Paramou
unt Cable Corporatio
C
n
9.
Thermop
padsPvt. Lttd.
10.
Toshniwal Cables
Cable Trays
T
& Ac
ccessories
s (Al./Gi)
1.
Globe Ellectrical Ind
dustries
2.
Indiana Engg
E
Workks Pvt Ltd
3.
Metalite Industries,,
4.
Parekh Engineerin
E
g Compan
ny
5.
Sadhana
a Engineerring Corporration
6.
Steelite Engineerin
E
ng Limited
Multi Trransit Inle
et System
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Ja
apan
U.S.A.
U
U.S.A.
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
LPG Mounded
M
d Bulletts at NR
RL
VEND
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1.
MctBrattbergAktieb
bolag
2.
RoxtecA
Ab
3.
Hawke In
nternationa
al
Junctio
on Box & Cable
C
Glan
nd
1.
Baliga Liighting Equ
uipments Limited
L
2.
Ceag Fla
ameproof Control
C
Ge
ears Pvt.Ltd
d.
3.
Flamepro
oof Equipm
mentsPvt. Ltd.
L
4.
Flexpro Electicals
E
P Ltd.
Pvt.
5.
Trinity To
ouch Pvt. Ltd.
L (Only cable Glan
nds upto size 25M)
6.
Stahl-Un
nd Apparatebau Hanss LefferGm
mbh
7.
TAN SW
WA technolo
ogies Inc (JJunction Box)
B
CS Sea
amless Pip
pes
1.
Indian Tu
ube Co(Ta
ata Div. Of Tubes &Pipes)
2.
Ismt Limited
3.
Maharasshtra Seam
mless Ltd.
4.
EtsTrouvvay&Cauvin
5.
Phoceen
nne
6.
Horst Ku
urversGmb
bh
7.
Mannesm
mann Hand
del Ag
8.
Dalmine Spa
9.
Ibf Seam
mless Pipess Spa
10.
Maruben
ni Itochu Stteel
11.
Nippon Steel
S
Corpo
oration
12.
Nissho Iw
wai Corporration
13.
Okura & Co. Ltd.
14.
Sojitz Co
orporation CS Seamless Pipes
15.
Sumitom
mo Metal In
ndustries Lttd.
16.
Hyundai Corporatio
on
17.
Vomal In
nternationa
al Limited
SS Seamless Pip
pes
1.
Choksi Tube
T
Comp
pany Ltd.
2.
Nuclear Fuel Comp
plex
3.
Rajendra
a Mechaniccal Industrries Ltd.
4.
Ratnama
ani Metals & Tubes Limited
L
5.
Matix Tu
ubes Comp
pany Pvt. Ltd.
L
6.
Phoceen
nne
7.
Tps-Tech
hnitubeRohrenwerke
eGmbh
8.
Dalmine Spa
9.
T.T.I- Tu
ubacex Tub
bos Inoxida
ables,SA(1
1/2 NB SS
S pipe)
SS Tub
bes
1.
Choksi Tube
T
Comp
pany Ltd.
2.
Nuclear Fuel Comp
plex
3.
Ratnama
ani Metals & Tubes Limited
L
4.
Matix Tu
ubes Comp
pany Pvt. Ltd.
L
5.
Itochu Corporation (Rep.KubotaCorpn.))
6
Nishitanii& Co. Ltd.
7..
Sumitom
mo Metal In
ndustries Lttd.
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
Sweden
Sweden
U.K
U
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ndia
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In
ndia
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ndia
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France
Germany
G
Germany
G
Ita
aly
Ita
aly
Ja
apan
Ja
apan
Ja
apan
Ja
apan
Ja
apan
Ja
apan
Korea
K
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
Germany
G
Ita
aly
Spain
In
ndia
In
ndia
In
ndia
In
ndia
Ja
apan
Ja
apan
Ja
apan
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
Pipe Fitttings
1.
Eby Indu
ustries
2.
Excel Hyydro-Pneum
matics Pvt Ltd,
3.
Micro Precision Pro
oducts Privvate Ltd.
4.
Precision
n Engineerring Industtries
5.
Tecnoma
atic (India)) Pvt. Ltd.
6.
Wesmecc Engineerss Pvt. Ltd.
7.
CellierS.A.
8.
Siemenss Ag Pgi
9.
Thyssen-Krupp Sta
ahlunionGm
mbh
10
CesareB
Bonetti
11
Technom
matic Spa
12.
Sumitom
mo Metal In
ndustries Lttd.
13.
Dewrancce& Co. Ltd
d.
14.
Hopkinso
ons Limited
d
15.
Thompso
on Valves Ltd.
16.
Velan En
ngineering Co. Limite
ed
17.
Anderson Greenwo
ood & Co.
18.
Crane Company In
ntl. Sales
Compre
ession Fitttings
1.
Aura Inc
2.
Baldota Valve
V
& Fitting Co.Pvvt.Ltd.
3.
Excel Hyydro-Pneum
matics Pvt Ltd,
4.
Excelsior Engg Wo
orks
5.
Panam Engineers
E
6.
Precision
n Engineerring Industtries
7.
Reliance
e Engg. & Electrical
E
C
Corpn.
8.
Vikas Ind
dustrial Pro
oducts
9.
Arya Cra
afts & Engineering Pvvt Ltd.
10.
Fluid Controls Pvt Ltd
11
Wesmecc Engineerss Pvt. Ltd.
12.
Parker Hannifin
H
Sin
ngaporePte. Ltd.
13.
Swagelo
ock Compa
any/Crexim
mco
Instrum
ment Minia
ature Valve
es
1.
Audco In
ndia Limited(L&T Valvves Divn.)
2.
Aura Inc
3.
BHEL (V
Valves Divission)
4.
Chemtro
ol Industriess Ltd
5.
Excel Hyydro-Pneum
matics Pvt Ltd,
6.
Chemtro
ols Samil(In
ndia) Pvt Ltd
7.
Hyd- Air Engineerin
ng works Lonavla
L
8.
Excelsior Engg Wo
orks
9.
Ksb Pum
mps Limited
d (Valves Divn)
D
10.
Panam Engineers
E
11.
Tecnoma
atic (India)) Pvt. Ltd.
12.
Wesmecc Engineerss Pvt. Ltd
13.
CellierS.A.
2-0000-0021 F2 REV2
FORM NO: 02
P
DOCUMENT
D
T NO
REV
V
SHEET 2
20 OF 30
In
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aly
Ita
aly
Ja
apan
U.K
U
U.K
U
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U
U.K
U
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Singapore
U.S.A
U
In
ndia
In
ndia
In
ndia
In
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In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
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ndia
In
ndia
France
All rights reserved
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LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
P
D
DOCUMENT
T NO
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14.
BfeBonn
ney Forge Valve
V
Licensee
15.
Euromisu
ure Cremo
ona
16
Technom
matic Spa
17
Kosei Sa
angyo Ltd
18
Sumitom
mo Metal In
ndustries Lttd.
19.
Dewrancce& Co. Ltd
d.
20.
Hopkinso
ons Limited
d
21.
Velan En
ngineering Co. Limite
ed
22.
Anderson Greenwo
ood & Co.
23.
Crane Company In
ntl. Sales
24.
Swagelo
ock Compa
any/Crexim
mco
Purge Rotameter
R
r
1.
Instrume
entation En
ngineers Pvvt. Ltd.
2.
Placka In
nstrumentss & Controls Pvt. Ltd.
3.
Eureca Industrial Equipments
E
s Pvt Ltd
Self Actuated Pre
essure Co
ontrol Valv
ves
1.
Nirmal In
ndustries Control
C
Pvtt Ltd (1/2 to
t 6 &<30
00#)
Slam Shut Off Va
alve
1.
Nirmal In
ndustries Control
C
Pvtt Ltd (1/2 to
t 6 &<30
00#)
AIR HEA
ADER/AD
DPOT
1
Wesmecc engineering pvt. Ltd
d.
Conden
nsate pot
1
Wesmecc engineering pvt. Ltd
d.
Valve manifolds
m
1
Wesmecc engineering pvt. Ltd
d.
Calibration equip
pment & services
1
Tempsen
ns instruments (i) pvtt. Ltd.
Enclosu
ures
1
Trinity to
ouch pvt. Lttd. (weathe
erproof siz
ze 80 * 80 mm)
m
Instrum
ment contrractor for inst. Cons
struction /erection
/
w
works
1
ANI insttrument ( upto
u
0.5 cro
ores
2.
Instrocon
n engineerrs and conttrols (I) Pvt. Ltd ( uptto 0.5 crore
es)
3.
Jasubhai engineering pvt. Ltd
d.
4.
Koso ind
dia pvt. Ltd. ( kent inttrol controll valve divn
n.)
5.
L&T ( construction contracts Divn.)
6.
Miraj insttrumentatio
on service (upto 0.5 crores)
7.
Narayan engineering (< Rs. 5 lacs (sma
all project)))
8.
Pace pro
ocess control pvt. Ltd
d.
9.
Peron en
ngg. Consttruction ltd.
10.
Protect control
c
pvt.. Ltd.
11
Technim
mont ICB ltd
d.
12.
M/s Godrej & Boycce mfg. co. ltd
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
Ita
aly
Ita
aly
Ita
aly
Ja
apan
Ja
apan
U.K
U
U.K
U
U.K
U
U.S.A
U
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
4.0
P
D
DOCUMENT
T NO
REV
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SHEET 2
22 OF 30
PIP
PING:
Ven
ndors Nam
me
Sl.No
CS Weld
ded Pipes To
T API 5L Spiral
S
Long
g. Welded (SAW/EFSW)
1.
HEAVY METAL
M
PIPE CENTRE
E (Upto 24" (Upto SCHX
XXS)
2
Jindal Pip
pes Ltd.
3
JOTINDR
RA STEEL & TUBES LTD.
L
(" to 14")
4
KALPESH
H TUBE(INDIA), (TRADER)
5
Lalit Profiles & Steel Inds. Ltd.
6.
Mann Ind
dustries
7.
Mukat Pip
pes Tarapur
8
PRATIBH
HA INDUST
TRIES NB LTD.,
L
(16" to
o 24" NB, Wall
W Thickne
ess: 6
mm to 20
0 mm)
9.
P.K.Forge
e & Fitting Industries
I
10.
Ratnamani Metals & Tubes Ltd.
11
SAIL
12
SAGAR STEEL
S
COR
RPORATIO
ON (TRADER
13
Saw Pipe
es
14
Surinder Engg. Co. Pvt.
P Ltd
15.
Surya Ro
oshini Ltd
16
THE BEN
NGAL MILL STORES SUPPLY
S
CO
O.(TRADER
R)
17
Welspun Gujarat Sta
ahl Rohren Limited (Fo
or Anjar and
d Dahej Plan
nts)
18
Phoceenne
19
ETS Trou
uvay & Cauvin
20
Mannesm
mann Hande
el AG
21
Thyssen--Krupp Stah
hlunion Gmb
bH
22
Dalmine SPA
S
23
Raccortubi SRL
24
Kosei Sangyo Ltd
25
Marubeni Itochu Ste
eel
26
Mitsubish
hi Corporatio
on
27
Nippon Kokan
K
28
Nippon Steel
S
Corporration
29
Nishitani & Co. Ltd.
30
Nissho Iw
wai Corpora
ation
31
Okura & Co.
C Ltd.
32
Sojitz Corporation
33
Sumitomo
o Metal Industries Ltd.
34
Hyundai Corporation
C
n
35
British Steel Corpora
ation
36
Corus Tu
ubes Limited
d
37
SAW pipe
es USA, Incc
CS/AS LT
L Seamles
ss Pipes
1.
BHEL
2
Indian Tu
ube Co.
3
ISMT Lim
mited
4
Jay Lakshmi steel & engineering co.
5
Jindal Sa
aw Ltd.
6.
Maharash
htra Seamle
ess Ltd.
7.
P.K.Forge
e & Fitting Industries
I
8
Phoceenne
2-0000-0021 F2 REV2
FORM NO: 02
Country
In
ndia
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ndia
In
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In
ndia
In
ndia
In
ndia
In
ndia
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In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
F
France
F
Germany
G
Germany
G
Ittaly
Ittaly
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Korea
K
U.K.
U
U.K.
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
F
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LPG Mounded
M
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RL
VEND
DOR LIST
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DOCUMENT
T NO
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9.
ETS Trou
uvay & Cauvin
10.
Mannesm
mann Hande
el AG
11
Horst Kurrvers GmbH
H
12
Dalmine SPA
S
13
Gam Racccordi S.P.A
A
14
IBF Seam
mless Pipess SPA
15.
Raccortubi SRL
16
Marubeni Itochu Ste
eel
17
Mitsubish
hi Corporatio
on
18
Nippon Steel
S
Corporration
19
Nishitani & Co. LTD..
20
Nissho Iw
wai Corpora
ation
21
Okura & Co.
C Ltd.
22
Sojitz Corporation
23
Sumitomo
o Metal Industries Ltd.
24
Hyundai Corporation
C
n
25
AB Sandvvik Steel
26
Vomal Intternational Limited
27
Corus Tu
ubes Limited
d
28
British Steel Corpora
ation
SS Seam
mless/ Welded Pipes
1.
Anil Meta
al Corporatio
on
2
Apex Tub
bes
3
BHANDA
ARI FOILS & TUBES LIMITED
L
(Seamless Up
pto 4" (Sch. 80)
& Welded
d Upto 20" (Thk.
(
<= 8
4
Choksi Tube Compa
any Ltd.
5
HEAVY METAL
M
& TUBES (Upto
o 8" (thickness upto 18
8.26 mm))
6.
HEAVY METAL
M
PIP
PE CENTR
RE (Upto 8"
8 ( Upto SCH80S)
S
(P
PDIL
approved
d Manufactu
urer's Make only))
7.
Jaylakshm
mi Steel & Engg.
E
Co
8
Jindal Sa
aw Ltd.
9.
KRYSTAL STEEL MANUFACT
M
TURING PV
VT. LTD. (U
Upto 2" (Matterial
de SS 321))
upto Grad
10.
Mardale Pipes
P
Plus Ltd
11
MODERN
N TUBE IN
NDUSTRIES
S LIMITED (Upto 2" (U
Upto SS G
Grade
321))
12
Nuclear Fuel
F
Comple
ex
13
P.K.Forge
e & Fitting Industries
I
14
Prakash Steelage Limited(0.5
L
to 20 we
elded & 0.25 to 8 smls
(upto sch
h 40s))
15.
QUALITY
Y STAINLES
SS PVT. LT
TD. ( Seam
mless: Upto
o 6" (SCH40
0S ),
Welded: Upto 20" (S
SCH40S)
16
Rajendra
a Mechanica
al Industriess Ltd.
17
Ratnamani Metals & Tubes Ltd.
18
SANDVIK
K ASIA PVT
T. LTD. (" to 2" (Thk: upto 8.74 mm))
m
19
SANGHV
VI METALS (TRADER))
20
SCOROD
DITE STAIN
NLESS (IND
DIA) PVT. LTD. (Upto 2"
2 (Upto SS
S Grade
321))
21
Shubhlaxxmi Metals & Tubes Pvvt. Ltd
22
Suraj Sta
ainless Limitted
23
THE BEN
NGAL MILL STORES SUPPLY
S
CO
O.(TRADER
R)
24
ETS Trou
uvay & Cauvin
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
France
F
Germany
G
Germany
G
Ittaly
Ittaly
Ittaly
Ittaly
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Korea
K
Sweden
S
U.K.
U
U.K.
U
U.K.
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
F
All rights reserved
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M
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VEND
DOR LIST
25
26
P
D
DOCUMENT
T NO
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Phoceenne
H. BUTTIING GmbH & CO. (Sea
amless : Up
pto 30" (upto
o 16mm thkk) &
Welded: Upto 72" (u
upto 64mm )
27
Horst Kurrvers GmbH
H
28
Mannesm
mann Hande
el AG
29
Thyssen--Krupp Stah
hlunion Gmb
bH
30
Dalmine SPA
S
31
Gam Racccordi S.P.A
A
32
IBF Seam
mless Pipess SPA
33
Raccortubi SRL
34
Marubeni Itochu Ste
eel
35
Mitsubish
hi Corporatio
on
36
Nippon Steel
S
Corporration
37
Nishitani & CO. LTD
D.
38
Nissho Iw
wai Corpora
ation
39
Okura & Co.
C LTD.
40
Sojitz Corporation
41
Sumitomo
o Metal Industries LTD
D.
42
Ab Sandvvik Steel
43
T.T.I. Tubacex
T
Tub
bos Inoxida
ables, S.A.
44
SOSTA BV
B (Upto 72
2" ( thicknesss upto 25.4
4 mm))
45
Vomal Intternational Limited
46
Corus Tu
ubes Limited
d
47
British Steel Corpora
ation
48
Hyundai Corporation
C
n
SS Seam
mless Tube
es
1.
Anil Meta
al Corporatio
on
2
APEX TU
UBES PVT. LIMITED (U
Upto 50.8 mm
m OD (Thiickness Uptto 4.00
mm))
3
BHANDA
ARI FOILS & TUBES LIMITED (Up
pto 50 mm OD)
O
4
HEAVY METAL
M
& TUBES (Upto
o 8" (thickness upto 18
8.26 mm))
5
KRYSTAL STEEL MANUFACT
M
TURING PVT. LTD. (Up
pto 50.8 OD
D
(Material upto Grade
e SS 321))
6.
MODERN
N TUBE IND
DUSTRIES LIMITED (U
Upto 50.80 OD (Upto S
SS
Grade 32
21))
7.
8
Prakash Steelage
S
Limited (0.25
5" to 4" (upto
o 5mm thickness))
9.
Ratnamani Metals & Tubes Ltd.
10.
SANDVIK
K ASIA PVT
T. LTD. (OD
D upto 60.33
3 (Thk: upto
o 8.74 mm)))
11
SCOROD
DITE STAIN
NLESS (IND
DIA) PVT.LT
TD. (Upto 50.80 OD (U
Upto SS
Grade 32
21))
12
Suraj Sta
ainless Limitted
13
T.T.I.-Tub
bacex Tubo
os Inoxidab
bles, S.A.(O
OD 15.8 mm
m to 250.0 mm,
wall thk.1.0 mm)
Fittings: CS/AS/SS
S Seamless
s & Forged
d
1.
Amforge industries
2
Anil Meta
al Corporatio
on
3
COMMER
RCIAL SUP
PPLYING AG
GENCY
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
France
F
Germany
G
Germany
G
Germany
G
Germany
G
Ittaly
Ittaly
Ittaly
Ittaly
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Sweden
S
Spain
S
Netherland
N
U.K.
U
U.K.
U
U.K.
U
Korea
K
In
ndia
In
ndia
In
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In
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In
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In
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ndia
In
ndia
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Spain
S
In
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In
ndia
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
4
5
6.
7.
8
9.
10.
11
12
13
14
15.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
P
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DOCUMENT
T NO
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25 OF 30
CSA FITT
TINGS (Forrged: " to 2" (Upto 90
000#) & Sea
amless: 2" tto 8"
(Upto SC
CH XXS))
EBY Fastteners
EBY Indu
ustries
FIT-TECH
H INDUSTR
RIES (CS (F
Forged) Elb
bow and Tee
e " NB to 1 "
NB, Ratin
ng 3000#, 6000#,
6
9000
0#
Flash Forrge(P) Ltd.
Gujarat In
nfrapipes Pvt. Ltd.
IISCO Ltd
d.
Jay Lakshmi Steel & Engineerin
ng Co.
KALPESH
H TUBE(INDIA),(TRAD
DER) (upto a max orde
er value Rs..25.0
lakh)
M.S Fittin
ngs Manufacturing Co. Pvt Ltd.
Mardale Pipes
P
Plus Ltd
National Org
O Chemiccal India Ltd
d
Navkar Forgings & Fittings
F
Pvt. Ltd
NL HAZR
RA
P.K Forge
e & Fitting industries
Parmar Techno
T
Forg
ge
Perfect Marketing
M
(P
P) Ltd,
PETROC
CHEM INDU
USTRIES (Seamless:
(
upto 16" (all Fittings) &
upto 36" (Only Capss) Sch : XXS
S/
RAJENDRA FORGE
E INDUSTR
RIES (CS: Upto
U
12" Sch
h 40 & SS: 6" Sch
40S)
SAGAR STEEL
S
COR
RPORATIO
ON (TRADER)
SANGHV
VI METALS (TRADER))
Sawan Engineers
Shivanan
nda Pipe Fitttings Ltd.,
Surya Ro
oshni Ltd
S & G En
ngineers (P)) Ltd.
STEWAR
RTS AND LL
LOYDS OF INDIA LIMITED
Teekay Tubes
T
Private Limited
THE BEN
NGAL MILL STORES SUPPLY
S
CO
O.(TRADER
R)
Topaz Piping Industries
Tube Ben
nd
Tube Pro
oducts Incorrporate(CS fitting Only))
Visvesara
aya iron & steel
s
Ltd.
Zoloto Ind
dustries
BHDT GM
MBH
Phoceenne
ETS Trou
uvay & Cauvin
Vallourecc
Seikmann
n Anlagen-T
Technik GM
MBH.
TPS-Technitube Roh
hrenwerke GMBH
G
Mannesm
mann Hande
el AG
Horst Kurrvers GmbH
H
Dalmine SPA
S
Gam Racccordi S.P.A
A
IBF Seam
mless Pipess SPA
IND Mecccanica Basssi Luigi & C.
C SPA
Mantovan
ni SpA
Raccortubi Srl
2-0000-0021 F2 REV2
FORM NO: 02
REV
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Austria
A
France
F
France
F
France
F
Germany
G
Germany
G
Germany
G
Germany
G
Ittaly
Ittaly
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T NO
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26 OF 30
51
Techno Forge
F
SPA
52
Marubeni Itochu Ste
eel
53
Nippon Kokan
K
54
Nishitani & co. Ltd.
55
Nissho Iw
wai Corpora
ation
56
Okura & co.
c Ltd.
57
Sojitz Corporation
58
Sumitomo
o Metal Industries Ltd.
59
Avesta Candvite
C
Tub
be AD
60
Helens Energy
61
Haitima Corporation
C
62
Corus Tu
ubes Limited
d
63
British Steel Corpora
ation
64
Eurotube
e Limited
65
Vomal Intternational Limited
66
Bonney Forge
F
Forged Flanges
1.
Ajay Forg
ging Pvt. Ltd
d
2
Amforge Industries
3
Anandma
ayee Forgin
ngs PVT. LT
TD.
4
C D Engineering
5
Chaudha
ary Hammerr Works (P) LTD.
6.
Echjay In
ndustries Ltd
d
7.
Ferrous Alloys
A
Forging Pvt. Ltd
8
Golden Irron & Steel Works
9.
GOOD LU
UCK ENGIN
NEERING CO.
C ("-12"" (Upto 2500#), 14"-16
6" (Upto
900#), 18
8"-32" (Upto
o 600#),
10.
J.K Forgings
11
Kunj Forg
gings Pvt. Ltd.(Materia
L
l CS/SS/AS
S)
12
MAHESH
H INDUSTR
RIES (Upto 8"
8 (150#, Material: AST
TM A105 on
nly))
13
Perfect Marketing
M
(P
P) Ltd
14
Punjab Steel
15.
RAJENDRA FORGE
E INDUSTR
RIES (CS & SS : Upto 12",
1 300#)
16
R D Forge (A Unit Of
O R D Chem
micals Pvt Ltd)
L
17
Sanghvi Forgings
F
& Engineering Ltd
18
Sawan Engineers
19
S & G EN
NGINEERS (P) LTD.
20
TECHNO
O FORGE LTD. (Upto 42"
4 (upto 30
00#), upto 24"
2 (600#), u
upto
20" (900#
#), upto 16" (1500#),
21
Tube Ben
nd (Calcutta
a) Pvt Ltd
22
Viraj, Tarrapur
23
Phoceenne
24
ETS Trou
uvay & Cauvin
25
Horst Kurrvers GmbH
H
26
I.S. Intern
national
27
Mantovan
ni spa
28
Officine Nicola
N
Galpe
erti & Figlio
o S.P.A
29
Raccortubi Srl
30
Nichinan Sangyo CO
O. Ltd.,
31
Nishitani & CO. Ltd.
32
Sojitz Corporation
2-0000-0021 F2 REV2
FORM NO: 02
REV
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Ittaly
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Sweden
S
Sweden
S
Sweden
S
U.K.
U
U.K.
U
U.K.
U
U.K.
U
U.S.A.
U
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France
F
France
F
Germany
G
Ittaly
Ittaly
Ittaly
Ittaly
Japan
Japan
Japan
All rights reserved
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T NO
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27 OF 30
33
Vomal Intternational Limited
Gate/ Globe/ Chec
ck Valves CS/SS/AS
C
<
<900
Lbs
1.
AV VALV
VES LTD. (ccast upto 42
2 ,150#) 28
8 300#, 24 (600#) & fforge
upto 2 (8
800#)
2.
Advance Valves
3.
ASSOCIATEDTOOLING
GS(I)PVT.LTTD
4.
Audco Ind
dia Limited (L&T Valve
es Divn.)
5.
Auto cap industries ( to 2 , 800#
8
(only CS & SS)
6.
Bell- O Seal valves ltd.( For zerro leakage , hazardouss fluids.)
7.
Bhel ( vallves division
n)
8.
Brightech
h Valves an
nd control pvt. Ltd. ( Up
pto 8 X 300# for Cs, A
As &
SS Matl )
9.
Chemtech industrial valves pvt. Ltd.
10.
Crawley & Ray ( Fou
under & Eng
gineers ) Pv
vt. Ltd.
11.
Datre corrporation ltd
d.
12.
Dewrance
e Macneill & co. Ltd.
13.
Econo va
alves pvt. Lttd.
14.
Expert en
ngineering enterprises.
e
.
15.
Flocon Syystems Pvt. Ltd. ( CS upto
u
6 150#)
16.
Flovel valves pvt. Ltd.( single disc , dula plate & nozzzle check va
alves
only : uptto 48 (150#
#) & 24 (uptto 600#)
17.
Fluidtech equipmentt Pvt. LTD. ( cast # CS
S & SS 2 to
o 12 150# & 2
to 8 300 # and forge
ed (CS and SS ) to 2 (800#)
18.
Forward alloys
a
& casstings ( upto
o 14)
19
Guru indu
ustrial valve
es PVt. LTD
D.( cast cs : only upto 24 (150#), 20
(300#)
20
Hawa Engineers ltd.
21
Hawa vallves India pvt.
p Ltd. ( CS
S upto, 6, 150#)
1
22
Hi-tech Valves
V
pvt. Ltd.
L (CS,<=8
800 #, size -2<=300#
# for size 2--6)
23
Intervalve
e India Ltd.. (cast upto
o 24 (upto 300#) & Upto
U
12 60
00# ,
forged up
pto 2 (800))
24
JC Valves & Controls India Pvt.. Ltd.
25
KSB Pum
mps Limited (Valves Divvn)
26
Larsen & Toubro Lim
mited (1/2" to
t 2")
27
Kirloskar brothers ltd
d.( Cs upto 12 , 300#)
28
Leader va
alves ltd.
29
M.H. valvves ltd.
30
Micon engineers (hu
ubli) [pvt. Ltd
d.(Cast upto
o 12 150# &300#, 6 6
600#
31
Microfinissh Valves ltd
d.
32
NSSL ltd.( Upto 80 ( 150#), 56 Upto 600#
# & forged upto
u
800 #)
33
Niton valvves industries pvt. Ltd.
34
Oswal ind
d. Ltd
35
S&M ind. Valves pvtt. Ltd.
36
Shreeraj Industries
37
Shalimar valves
38
Steel stro
ong
39
Venus pu
ump & engin
neering worrks.
40
Viba Fluid
d control
41
Weir BDK
K Valves
42
ZED valvves Co. Pvt. LTD.
43
Zoloto Ind
dustries. ( 40
4 mm to 20
00 mm( only
y cs &ss)))
44.
Velan Incc. ( upto 48 , 600#)
2-0000-0021 F2 REV2
FORM NO: 02
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U.K.
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Canada
C
All rights reserved
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LPG Mounded
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VEND
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48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
P
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T NO
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28 OF 30
FRIULCO
O SPA (Upto
o 32" (900#
#); 24" (1500
0#); 14" (25
500#))
Valvitalia SPA
BFE Bonney Forge Valve
V
Licen
nsee
Cesare Bonetti
B
Fasani S.P.A.
GTC Italia
a, S.R.L.
OMB S.P
P.A.
Petrol vallves S.R.L
Matsura H.
H P Machin
ne Works Co.Ltd.
C
NishitanI & Co. Ltd.
Sojitz Corporation
Redpoint Alloys BV
POYAMVA
ALVES,(AMP
POS.COOP.))
Walthan & Weir
Babcock Borsig Esp
pana , S.A
Sufa ltd.
BEL Valvves
Boteli valve group Co.
C Ltd.
Zhejianng
g Jihua valvve Co. Ltd.
Ball valv
ves (Metal Seated)
1.
AIRA EU
URO AUTO
OMATION PVT.
P
LTD. (Upto 6", Rating:
R
150
0# &
300#)
2
Brightech
h Valves An
nd Controls Pvt. Ltd. (4
4" x 150# fo
or CS, AS & SS
Material)
3
Delval Flo
ow Controlss Private Lim
mited
4
Guru Indu
ustrial Valve
es Pvt. Ltd.
5
JC valvess & Controlss India Pvt. Ltd.
6.
Microfinissh Valves (P
P) Ltd.
7.
NSSL Lim
mited (2" NB
B to 12" NB
B, Ratings:150# & 300#
# (Material: Cast
CS/AS/SS
S))
8
OSWAL INDUSTRIE
I
ES LTD. (Upto 24" (150
0#, 300#, & 600#))
9.
VIRGO ENGINEERS
E
S LTD. (Uptto16" (Upto
o 600#))
10.
WEIR BD
DK VALVES
S (A UNIT OF
O WEIR IN
NDIA PVT. LTD.)
L
(Cast: Upto
30" (150#
# & 300#); 20"
2 NB
11
VELAN IN
NC. (Size upto 16" (Ra
ating upto 600#))
12
Alfa Valvo
ole SRL
13
CESARE
E BONETTI SPA (Upto 24" (150#) & 4" (Upto 1500#) Tru
unnion
Mounted only)
14
GE powe
er (Nuovo Pignone SPA
A)
15.
GTC Italia
a, S.R.L.
16
Petrol Va
alves S.R.L
17
Valvitalia Spa
18
Red point alloys Bv
19
Metso Au
utomation
20
Orbit Valvves PLC
Gaskets
s
1.
Ferrolite Joinings
J
(P) Ltd.
2
Gaskets (India) Pvt. Ltd
3
Goodrich gasket pvt. Ltd. (upto 24")
4
Hindustan Asbestos & Allied Prroducts
5
Hindustan Compositte Ltd.
2-0000-0021 F2 REV2
FORM NO: 02
REV
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Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Japan
Japan
Japan
Netherland
Spain
S
Spain
S
Spain
S
UAE
U
U.K
U
China
C
China
C
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canada
Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Netherland
N
Singapore
S
Singapore
S
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6.
HINDUST
TAN FERREDO LTD.
7.
IGP Engineers Limited
8
Madras In
ndustrial Prroducts(upto
o 48")
9.
Mechaniccal Packing Industries Ltd.,
10.
Packingss & Jointingss (P) Ltd.
11
PRASHA
ANT ENGG STORES
12
Perfect Marketing
M
(P
P) Ltd,
13
Reinz Talbros Privatte Limited
14
Spiraseal gaskets pvvt. Ltd. (CAF & Teflon)
15.
Starflex sealing
s
india
a Pvt. Ltd.
16
THE BEN
NGAL MILL STORES SUPPLY
S
CO
O.(TRADER
R)
17
UNIQUE INDUSTRIA
AL PACKIN
NGS PVT. LTD.
L
Spirally Wound Ga
askets
1.
Gaskets (India) Pvt. Ltd
2
Goodrich gasket Pvtt. Ltd.
3
IGP Engineers Limited
4
Madras In
ndustrial Prroducts
5
Packingss & Jointingss Pvt. Ltd
6.
Perfect marketing
m
(P
P) Ltd,
7.
Prashant Engg Store
es
8
Spiraseal gaskets pvvt. Ltd.
9.
Starflex sealing
s
india
a pvt. Ltd.
10.
Uniklinge
er Gaskets, Pune
11
Garlock Sealing
S
systtems Ltd., Pune
P
12
TEADIT gaskets,
g
Mu
umbai
13
THE BEN
NGAL MILL STORES SUPPLY
S
CO
O.(TRADER
R)
14
UNIQUE INDUSTRIA
AL PACKIN
NGS PVT.LT
TD. (Upto 42"(600#)
4
& Upto
24" (2500
0#))
STRAIN
NERS (PERMANENT IN
NCLUDING
G Y-TYPE)
1.
CHEMTE
ECH INDUS
STRIAL VAL
LVES PVT. LTD
2
FLAIR ST
TRAINERS & FILTERS
S (Size upto
o 42" (Ratin
ng upto 1500
0#))
3
GRAND PRIX
P
ENGINEERING PVT. LTD. (upto 60" pipeline, upto ANSI
1500#)
4
GREAVE
ES LIMITED
D
5
GUJARA
AT OTOFILT
T
6.
KWIKFLO
O FILTERS PVT. LTD.
7.
LEADER VALVES LIMITED
L
(up
pto 300# & upto 12"sizze)
8
MOD FAB
BRICATOR
RS
9.
MULTITE
EX FILTERA
ATION ENG
GINEERS LTD
L
10.
ZOLOTO
O INDUSTRIES (15mm to 100mm))
11
BOTELI VALVE
V
GRO
OUP CO. LTD.
L
(Y - Ty
ype only: 14
4" (150#) & 3"
(300# & 600#))
6
SPRING
G SUPPORT
TS
1.
MYRICS PIPING SY
YSTEM PVT
T.LTD.
2
PIPE SU
UPPORTS INDIA PVT. LTD.
3
PIPING & ENERGY PRODUCT
TS (P) LTD..
4
SARATH
HI ENGG. ENTERPRIS
E
SES PVT. LTD.
L
5
SPRING SUPPORT
TS MFG. CO
O.
6.
FLEXIDE
ER S.P.A.
2-0000-0021 F2 REV2
FORM NO: 02
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China
C
In
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In
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ndia
Ittaly
All rights reserved
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FASTEN
NERS
1
AEP COM
MPANY
2
CAPITAL
L INDUSTRIES
3
CONSOL
LE ENGG. & FASTNER
RS INDUST
TRIES
4
EBY FAS
STNERS
5
FIT TIGH
HT NUTS & BOLTS LTD.
6
FIX FIT FASTENER
F
RS MFG. PV
VT. LTD.
7
INDUSTR
RIAL ENGIN
NEERING CORPORAT
C
TION (Size upto 4" (M100))
8
MEGA EN
NGINEERIN
NG PRIVAT
TE LIMITED
D (" to 3" Material:
M
CS/AS/SS
S)
9
METRO MECHANIC
M
CAL PVT.LT
TD.
10
NAGBHU
USHANAM INDUSTRIE
ES
11
NIREKA ENGG. CO
O. PVT. LTD
D.
12
PACIFIC FORGING & FASTEN
NERS PVT. LTD. (M 10
0 to M125)
13
PERFEC
CT MARKET
TING (P) LT
TD,
14
PIONEER
R NUTS & BOLTS
B
PVT
T. LTD.
15
PRECISION AUTO ENGINEER
RS
16
PRECISION ENGINEERING IN
NDUSTRIES
S
17
PTD FAS
STNERS PV
VT. LTD.
18
SANGHV
VI METALS (TRADER))
19
SUNDAR
RAM FASTE
ENERS LIM
MITED
20
UDHERA
A FASTENE
ERS
VEN
NDORS
SAIL
ESSA
AR
TATA
A
JINDA
AL
RASH
HTRIYA IS
SPAT NIGA
AM LTD. (V
Vizag Plan
nt)
WELS
SPUN
2-0000-0021 F2 REV2
FORM NO: 02