JINDAL STEEL ODISHA LIMITED

ANGUL

BALANCE OF PLANT
CENTRAL UTILITIES & WATER SYSTEM

Doc. Type Technical Specification

Doc. Title General Specification of Pipe Work
Doc. No. 29005-WGU-GS-001 Rev. 0
Zone/Unit CUWS/OP

0 26.06.23 Design Basis of Pipe Work RpP RpP SuD

REV. PREP. CHKD. APP.
DATE DESCRIPTION
NO. BY BY BY

This document is the property of M. N. DASTUR & COMPANY (P) LTD and is issued for the specific project mentioned herein.
This is not to be copied or used for other projects unless expressly permitted by M. N. DASTUR & COMPANY (P) LTD.
29005-WGU-GS-001

GENERAL SPECIFICAION OF PIPEWORK

TABLE OF CONTENTS
Page

1. SPECIFICATION OF PIPEWORK .. 21

2. ANNEX-1
PARAMETERS FOR PIPEWORK .. 2

3. ANNEX-2
SPECIAL INSTRUCTIONS FOR OXYGEN PIPELINE .. 16

4. ANNEX-3
FIELD PRESSURE TESTING OF PIPELINES .. 12

5. ANNEX-4
THERMAL INSULATION .. 12

6. ANNEX-5
PIPING MATERIAL SPECIFICATION .. 8

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SPECIFICATION OF PIPEWORK

1.0 SCOPE

1.1 This general specification covers pipework for various systems. The term
‘pipework’ referred herein generally covers pipes, pipe fittings (such as bends,
tees, reducers, plugs, nipples, sockets, unions, flanges, crosses etc.), valves (of
various types and functions such as gate, globe, butterfly, plug, ball, check,
pressure regulating, flow control, relief, safety, manual gear operated, electrically
operated, pneumatically operated etc.), traps, strainers, drip pots, filters, spectacle
blinds, flaring devices, flexible hoses, hose couplings, hose clamps, hose nozzles,
pipe supports (such as trestles, towers, pipe bridges, pipe racks, saddles,
brackets, hangers, U-bolts, clamps, spring supports etc.), hot & cold insulation etc.

1.2 Pipework covered herein is intended to convey fluids such as various types of fuel
gases like blast furnace gas, coke oven gas, converter gas, mixed gas, natural
gas, propane, liquefied petroleum gas, liquid fuels like coal tar, compressed air,
instrument air, steam, oxygen, nitrogen, argon etc.

1.3 This general specification does not cover pipework for process fluids such as
those involved in coke by-product processing, air separation plant, chemical water
treatment etc. For such pipework, the specifications are covered in the particular
technical specifications for concerned units. Storm water drains, sewerage
systems from toilets, canteens, showers, comfort stations, drinking fountains, etc.
are also not covered in this general specification.

1.4 The design and construction of all pipework shall be suitable in every way for the
service intended and shall be oriented towards maximizing interchangeability of
components and minimizing maintenance. Pipework shall be complete in all
respects, including all accessories essential for proper installation, operation and
maintenance, irrespective of whether such items are specifically mentioned in the
General Specification or not.

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1.5 In the interest of standardization, the Purchaser reserves the right of selecting a
particular manufacturer for any item and the Contractor shall supply the item of
that make, if so desired by the Purchaser.

2.0 STANDARDS AND OTHER REGULATIONS

2.1 The pipework shall be erected, tested and commissioned as per the standards
laid down in this specification and as per technical specification (TS), bill of
quantities (BOQ) and piping construction drawings. Detailed instructions on such
aspects as are not indicated herein shall be as per the latest standards, codes
and recommendation of the Bureau of Indian Standards. Where Indian Standards
are not available, the Standards of American National Standards Institute (ANSI),
American Society for Testing and Materials (ASTM), American Water Works
Association (AWWA) or other equivalent national standards for pipework of the
country of origin shall be used as per contract for design and construction of
pipework with the approval of the Purchaser.

2.2 Wherever applicable, the Interplant Standards for Steel Industry (IPSS) developed
by the Steel Authority of India Ltd. shall be followed. Further JSOL has developed
certain company standards for equipment and auxiliaries for standardization and
inventory control. These standards shall be followed wherever applicable.

2.3 The norms indicated in this specification shall be adhered to unless adoption of
these norms would vitiate the function and/or safety of the systems offered. In
such cases and where different norms are adopted by the Contractor, the same
shall be clearly indicated with reasons and Purchaser's approval shall be
obtained.

2.4 All pipework shall comply with the statutory requirements of the Government of
India and the State Government of Odisha. Wherever required by Mandatory
Regulations, the tenderer will have to obtain the approval of the relevant
government agencies such as the Boiler Inspectorate, Explosives Inspectorate,
Factory Inspectorate etc. for the work covered in this GS.

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3.0 DESIGN BASIS

3.1 Definitions

3.1.1 Working Pressure (PW)

It is the effective operating pressure in kilogram per square centimeter gauge

(kscg) of a piping system. It shall be designated by the abbreviation PW.

3.1.2 Nominal Pressure (PN)

It is the pressure in kscg which shall be used to design all piping elements. It shall
be determined by increasing the working pressure of the system to suit the
temperature and type of fluid being carried. It shall be designated by the
abbreviation PN. The typical designation of a piping system where the nominal
pressure is 40 kscg shall be PN 40.

3.1.3 Test Pressure (PT)

It is the pressure in kscg to which all the elements of a piping system shall be
subjected to determine their adequacy. This shall be designated by the
abbreviation PT. The test pressures against various nominal pressures are given
in the GS.

3.1.4 Nominal Diameter (DN)

Every part of a piping system shall be identified by its nominal diameter. The
nominal diameter shall be designated by the abbreviation DN; the typical
designation of a pipeline system where nominal diameter is 50 mm shall be DN
50.

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3.2 Materials and Dimensional Specification

3.2.1 For the fluids covered in this specification, the materials, dimensional standards
and other required features for pipework are given in bill of quantities (BOQ) and
piping construction drawings. The design parameters, line codes and other
relevant data for each fluid are also indicated. PN rating of various pipes shall be
taken into consideration by suppliers of equipment/systems while calculating the
wall thickness of pipes not covered in this specification.

3.3 Layout

3.3.1 In general, yard pressure pipework, except for water, shall be routed overhead.
Unless otherwise specified in drawings/technical specification, yard water
pipework shall be laid below ground. All overhead yard pipework shall be routed
such that they will have a minimum clearance of 8.0 meters between bottom of
supporting structures and road crown/railway track. The pipelines laid over hot
metal tracks will have a minimum clearance of 10.0 meters; in case of using
protective shields heat shields in these places, this clearance is allowed to be
reduced to 8.0 meters. However, the branch pipelines to the repair shops and
other minor shops shall be routed such that they will have a minimum clearance of
5.0 meters from ground level and 6.0 meters from rail head respectively. All buried
pipes shall be laid with a minimum earth covering of 1200 mm in areas subject to
temporary loads and minimum earth covering of 1000 mm in areas not subject to
temporary loads, unless otherwise specified.

3.3.2 For the pipelines laid on roof, the distance from the external generatrix of the pipe
to the roof shall be at least 0.5 m. Where disc (lens) type compensators are used,
the distance from the external generatrix of the compensator to the roof shall be at
least 0.3 m. In case of laying of gas pipelines between two consecutive skylights,
the distance of both from gas pipelines shall be at least 0.8 m.

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3.3.3 All shop headers, except for gravity return fluids, shall be generally routed along
columns in multiple rows at a height 4 to 6 metres above floor level. The
connections to equipment shall be taken through suitably covered floor trenches
for shops at ground floor and for basements; for elevated operating floors, the
equipment pipework connections may be taken below the floor level. All gravity
pipes shall also be preferably taken along the same route. Isolated single pipe
connections to equipment may be buried in the flooring/equipment foundations. All
pipe trenches shall be covered by chequered plates or by concrete slabs.

3.3.4 The outlet pipes for purging lines and other exhaust pipework shall be routed
upward along columns/gable ends and/or walls to a height of 4,000 mm above the
roof level.

3.3.5 Gas branch pipes from the headers to the building through walls and the roof shall
be encased. At the same time a circular ridge shall be provided on the roof, while
the branch shall be provided with a conical hood to prevent seepage of rainwater.

3.3.6 Gas pipelines (Low pressure fuel gases, hydrogen, oxygen, Acetylene and LPG)
shall be earthed. When laid under high-voltage lines, a protective steel guarding
shall be provided above the gas pipelines. The guarding shall be earthed. The
earthing resistance shall be not over 10 ohm. All work in connection with earthing
of pipes and trestles/towers shall be generally as per IS:3043.

3.3.7 Platforms, access ladders, hand railing etc. shall be provided for operation and
maintenance of valves & instruments. In case the gear units and electric drives for
the valves are to be located at a height of more than 1.4 m from the maintenance
level, a platform with ladders shall be envisaged (either stationary or light-weight
portable ones).

3.3.8 At all the places of regular maintenance (gate valves, throttle valves, orifice plates,
etc.) if located at a height of over 2.5 m from the maintenance level provision shall
be made for stationary platforms with ladders. For individual platforms which are
used rarely, vertical ladders can be provided.

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3.4 Pipe sizing

3.4.1 The velocities for sizing pipework as given shall be adopted, unless otherwise
specified in technical specification, or warranted by considerations of pressure
drop, safety and noise abatement. The contractor shall ensure that the velocities
mentioned shall not be exceeded for the maximum flow rates envisaged.

3.4.2 In finalizing diameter of the outdoor pipelines, this should proceed from the
provision of required pressure at consumer, with the maximum flow at a given
pipe run.

3.5 Expansion and Flexibility

3.5.1 All pipework shall be designed to provide sufficient flexibility to prevent

development of undesirable forces or moments at points of connection to
equipment, at anchorages or at guide points due to thermal expansion.

3.5.2 Flexibility shall be provided by changes of direction or by the use of bends, loops,
offsets or expansion joints. Normally universal type metallic expansion joints shall
be used, if required, expansion joints of the slip joint or other types may be used
with prior approval of the Purchaser.

3.5.3 Wherever no self-compensation can be used to cater for the expansion

deformation of the pipelines, expansion loops (U-loops) or expansion joints shall
be provided. In general, expansion loops (U-loops) shall be used for pipelines of
DN 600 and under. Universal expansion joints (bellows) shall be used for
pipelines of low-pressure gases of over DN 600.

3.5.4 In the case of steam lines or other fluid pipework operating at high temperatures,
sections of pipe may be cut short and cold sprung into place. Unless otherwise
specified, all cold springing shall not exceed one-half the total expected expansion
between anchor points. Expansion joints used on low pressure fuel gas pipework
may also be cold sprung if so specified in the relevant piping drawings.

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3.5.5 For all piping systems, the provision for expansion and flexibility shall take into
consideration the maximum possible temperature differential between the design
temperature and the ambient temperature (the lowest ambient temperature in cold
season shall be considered). The co-efficient of linear expansion of the piping
materials shall be considered and means shall be provided for proper anchoring
or other methods of restraining and taking care of the anticipated expansion
without failure of pipework and without imposing excessive loads on connected
equipment, structures, supports etc. For steam pipework covered under Indian
Boiler Regulations (IBR) the provisions of relevant clauses of IBR shall be taken
into account. The forces and moments occurring during expansion/ contraction
shall be determined by calculation.

3.5.6 The contractor shall be responsible for the proper fabrication of all piping systems
with regard to expansion and flexibility, including the branch lines and connections
to equipment, even through such details might be omitted in the drawings.
Supporting shall ensure freedom for expansion and movement as well as restrict
sagging to reasonable limits.

3.6 Valves and Measuring Devices

3.6.1 Valves shall be provided on pipework for isolation of pipe sections and equipment,
control of pressure, flow and level of fluids, venting, draining, pressure relief etc.
They shall be suitable for the service conditions in all respects and located
suitably considering ease of operation and maintenance.

3.6.2 The valves provided shall include but not be limited to the following:

a) Stop valve shall be provided as follows:

- on all pipelines both at the source and consumers

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- in the branch pipes to individual buildings and shops with a

nominal diameter of 100 mm and above (if required, for smaller
diameters as well)

- in the points of sectionalization and the links between the

pipelines required to ensure the reliable supply of utilities.

b) Isolating and by-pass valves for flowmeters, filters, trap assembly etc.

c) Check valve on all pipelines requiring unidirectional flow.

d) Quick acting safety shut-off valves on air lines to furnaces and heaters as well
as before each consumer or group of consumers.

e) Pressure regulating valves together with isolating, by-pass and relief

valves for all pressure reducing installations.

f) Manual drain valves at low points and manual vent valves at all high points of
pipework. However, automatic air release valve shall be provided on water
lines wherever required.

g) Isolation of large diameter low pressure fuel gas lines may be done
with butterfly valves & goggle valves and/or water seals.

3.6.3 For fluid lines with working pressures over 16 kscg, valves of DN 300 and above
shall be provided with by-pass arrangement unless otherwise specified in
Technical Specification.

3.6.4 Manually operated shut-off valves, regulating valves of DN 300 and above shall
be complete with gear drive.

3.6.5 All valves located remotely, requiring frequent operation and/or with automatic
control shall be provided with electric drives, solenoids, etc.

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3.6.6 Shop pipework for all production and ancillary units shall have metering of flow
and pressure at the battery limits.

3.6.7 Pipework for fuel gases such as Blast Furnace Gas, Coke Oven Gas, Converter
Gas, Mixed Gas with low operating pressures shall have some means of gas tight
isolation of sections of the pipework to facilitate maintenance work. These may be
water seals, butterfly valves, spectacle blinds, slipper plates or gas tight
isolators/slide plate valves. The type to be provided shall conform to technical
specifications.

3.7 Drip Legs and Appurtenances

3.7.1 Drip legs shall be provided as required. They shall include all appurtenances
required for their operation and provisions for disposal of fluids such as
condensate, moisture, sludge etc. They shall include trap assemblies/ drip pots
(including pressure type drip pots), valves, by-passes, connections to sewers and
other items as required.

3.7.2 For steam and compressed air lines, the drip legs shall be connected to a trap and
a strainer assembly of the type specified.

3.7.3 The drip legs for Blast Furnace Gas, Coke Oven Gas, Converter Gas, Mixed Gas
lines shall be led to drip pots.

3.8 Drains

3.8.1 Drains shall be provided at all low points of liquid pipelines. They shall be of size
adequate to drain the lines within the desired time period but in no case more than
30 minutes. Only gate valves or plug valves shall be used for the drains. Pipe plug
or blind flanges may be used where space is limited, with prior approval from
Purchaser.

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3.8.2 To ensure the condensate drainage, the gas pipelines shall be laid with a gradient
of about 0.005 towards the water drains.

3.8.3 The height of the water drains hydraulic seal shall be determined according to the
maximum pressure in all low pressure fuel gas lines, but shall be at least 3,000
mm for all low pressure fuel gas pipelines. Water drains shall be equipped with
bleeders. Inside the shops, the water drains shall be provided with additional U-
shaped pipe seals of at least 1.5 m height. From the water drains, water shall be
disposed into the sewerage system by a discontinued stream. From the individual
remote water drains, condensate can be disposed into the water-tight pits.

Height of water seals on low pressure fuel gas pipelines shall also be determined
according to the maximum pressure in the pipeline, but shall be at least 3000 mm.

3.8.4 In the lower points of the steam pipelines and before vertical lifts the permanent
drainage of steam pipelines shall be provided. At these places and on the straight
runs of the steam pipelines, the starting drainage of steam pipelines shall be
provided spaced every 400-500 m in case of the gradient in the same direction
and in every 200-300 m in case of the adverse gradient unless otherwise specified
in technical specification. Actual distance will be selected based on the
condensate drainage capacity of the steam traps used. Diversion of condensate
from the permanent drainage into the pressure condensate pipeline shall be
allowed provided the pressure in the drainage condensate pipeline exceeds that in
the pressure condensate pipeline by at least 1 kscg. In all the other cases,
condensate shall be disposed into the gravity-flow condensate pipelines or outside
(to the ground surface or into the special drain wells).

3.9 Vents/Air Release

3.9.1 Pipelines subjected to Air locking shall be provided with Air Release Valve or vent
with valve at high points.

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3.9.2 Pipelines subjected to hydraulic test shall be provided with vent with valves at high
points.

3.9.3 Bleeders on all the gas handling devices and pipelines shall be installed in such a
way as to have the possibility of purging and venting any space of the gas
pipeline. The purging bleeders of different gas pipelines are not allowed to be
combined into one bleeder. The same is true for the runs of one pipeline
separated by valves. The bleeder shall be taller than the gas pipeline or roof of the
building (in case of the shop pipelines) by 4 metres, but not lower than 12 metres
from the ground level. In the presence of the aeration monitors on the roof of the
building, the bleeder shall be arranged so as to eliminate the possibility of gas
getting inside the premises during purging.

3.9.4 Purging

3.9.4.1 Gas pipelines of Blast Furnace Gas, Coke Oven Gas, Converter Gas and Mixed
Gas shall be equipped with nitrogen inlets. The connection of nitrogen pipeline to
the gas pipeline must be done by means of flexible hoses only during the period of
purging out the gas pipelines.

3.10 Flaring Devices

3.10.1 Flaring Devices comprising Flare Stack of suitable diameter and height, along with
piping for the gas to be flared, ignition gas pipes, burners, controls and
instruments shall be provided, when required, to dispose of large quantities of
excess fuel gas (B.F. Gas, C.O. Gas, Converter Gas, Mixed Gas), so as to
prevent undue pressure rise in the connected piping system.

3.10.2 The control valves and control panel for the flare stacks shall be located
sufficiently away from the flare stack at a location which is safe for remote
operation and suitable for maintenance.

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3.11 Pipe Heating Systems

3.11.1 Pipe heating systems by steam tracing shall be suitably provided where the
temperature of the fluid conveyed is to be kept above minimum desired values for
process requirements or for reduction of viscosity.

3.11.2 The steam tracer lines shall be insulated together with the service line. The steam
tracer lines shall be provided with adequate trap assemblies and other
appurtenances.

3.11.3 The heating systems shall be designed for automatic and safe operation and for
energy conservation. Thermostatically operated isolating devices shall be
provided to cut-off supply of steam to the heating systems when the temperature
of the heated fluid exceeds the pre-set value and to supply steam/power when the
temperature of heated fluid falls below the pre-set value. The heating systems
shall be designed such that overheating at isolated spots does not occur.

3.12 Supports for Above-ground Pipework

3.12.1 Pipe supports shall be according to ASME B31.1, B31.2, B31.3, B31.4 & B31.5 as
relevant or equivalent. Design, material and workmanship for structural steelwork
used for pipe supports shall conform to relevant Indian Standards for Structural
Steelwork and Civil Engineering Work.

3.12.2 The Contractor shall provide all required pipe supports like saddles, shoes & U-
bolts for free, guide, anchor & axial stops, hangers, rollers, clamps, spring
supports, vertical guide, duck foot support, vibration dampers, etc. for aligning and
controlling the pipework. Supports shall prevent, under operating conditions and
under excessive stresses and excessive vibration of supporting elements from
possible resonance with imposed vibrations.

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3.12.3 The movable supports of the pipelines shall be of the following types:

Sliding supports .. independent of direction of horizontal

displacement of the pipelines.
Sliding supports with .. for large diameter piping, the sliding
teflon strips support may be provided with teflon
strips below saddles to reduce friction
force.
Roller type supports, .. In places of vertical displacement of the
Spring type supports or pipes.
Hangers,
Rigid hangers .. At overhead laying of the pipelines

3.12.4 All supporting elements, except for springs, shall be designed for the weight of the
pipe filled with the medium transported and the weight of the insulation used.
Exceptions may be made for lines (e.g. low pressure fuel gas lines, other gas
lines, compressed air lines, exhaust steam or safety valve relief piping etc.) only
when there is no possibility whatsoever of such lines becoming full of water or
other liquid during testing, operation and at any other time. Thrust load shall be
considered wherever significant. Other loads such as thermal and frictional load,
weight of fittings, walkways, platforms, stairs, lining, live loads, accumulated dust,
condensate, internal pressures, wind loads, and special loads due to cracks in
compensators, settlement of supports etc. shall be considered wherever
applicable.

4.0 FABRICATION OF PIPEWORK

4.1 Pipe Joints for Metallic Pipework

4.1.1 All black steel pipework shall be of butt-welded construction. Flanges shall be
provided on straight lengths at suitable intervals and at other joints as may be
required for ease of maintenance and replacement. Flanged joints shall also be
provided to match the connecting ends of equipment, valves, non-ferrous fittings

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etc. Where specific equipment connection necessitates, screwed joints and unions
shall be provided.

4.1.2 Galvanized steel pipework shall be of screwed and socketed construction.

Galvanized screwed unions shall be provided at suitable intervals on a straight
lengths and at other joints as necessary for easy erection and maintenance.
Screwed unions shall be provided at connection to valves etc. as required. In
case, flanged connections are required for pipe sizes DN 80 and above,
galvanized screwed flanges shall be used.

4.1.3 All lined steel pipework shall have seamless steel pipes, with flanged joints for
each pipe length, which shall not exceed 2 metres for size DN 40, 3 metres for
size DN 50 to DN 65 and 6 metres for larger sizes. Flanges shall also be provided
at both ends of the pipe fittings, e.g. bends, tees, reducers, etc as well as for
connection to equipment and valves.

4.1.4 All stainless steel pipelines shall be of butt or socket welded construction using
shielded arc welding process. Flanges shall be provided on straight lengths at
suitable intervals and at other joints as required for ease of maintenance and
replacement.

4.1.5 Joints shall be assembled ensuring the inside of all pipes, and fittings smooth,
clean and free from burrs blisters, scale, welding slag, sand and dirt. The inside
edges of pipes and tubes shall be reamed after cutting to remove burrs. Where
required, the inside of the weld without backing rings shall be ground smooth.

4.2 Welding for Metallic Pipework

4.2.1 All jointing by electric arc and gas welding processes shall be as per IS:823,
IS:9595, IS:10234 and IS:1323 or equivalent. However, the provisions of
mandatory codes such as Indian Boiler Regulations, Explosive Manual, Petroleum
and Carbide of Calcium Manual and IS:6044 (Part I & II), Fire Protection Manual
of the Insurance Association of India etc. shall be met where required.

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4.2.2 Welded Carbon Steel Piping need not be stress relieved except where specified.
Such stress relieving may be done by uniformly heating welded area with
nichrome/induction coil to 660 + 15 deg C, holding the temperature for one hour
for each 25 mm of wall thickness or fraction thereof and then cooling at a rate not
in excess of 315 deg C per hour in still air.

4.2.3 Alloy and stainless steel pipework shall be heat treated after welding and cold
working in accordance with the relevant codes to maintain their composition and
grain structure and to keep their strength and corrosion-resistant properties. Non-
ferrous pipework need not be heat treated after welding or cold working.

4.3 Bending for Metallic Pipework

4.3.1 Smooth bends may be fabricated by bending pipes. Cold bending may be adopted
for DN 50 and lower size of pipes. For higher sizes, hot bending, if specified for
0 0
carbon steel pipes shall be done at a temperature between 800 C and 1100 C.
After hot bending, the pipe shall be allowed to cool slowly in still air.

4.3.2 Pipe bends shall be true to angle and shall have a smooth surface free of flat
spots and wrinkles. Actual inside diameter at any portion of the pipe shall not
deviate by more than +3 per cent from the inside pipe diameter. Thinning due to
bending shall be not more than 12.5 per cent of nominal thickness.

4.3.3 Standard bends and elbows shall have dimensions as per relevant IS or
equivalent code for the service. Bends and elbows shall have butt welding ends
unless otherwise specified.

4.3.4 Mitred bends fabricated from pipes to be used if specified in the BOQ. They will
have a radius of 1.0/1.5 times the pipe diameter and shall comprise at least 4
segments for a 90o bend unless otherwise stated in the piping construction
drawings.

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4.4 Other Pipe Fittings for Metallic pipework

4.4.1 Other fittings such as tees, reducers etc. shall conform to the specifications given
in BOQ.

4.4.2 Site fabrication of bends, tees, reducers etc. shall be avoided as far as possible.

5.0 ERECTION

5.1 General

5.1.1 All pipework shall be erected in conformity with relevant ASME codes or
equivalent, for pressure piping.

5.1.2 Pipes shall be cut to measurement and installed without forcing or springing
except where cold springing is explicitly specified.

5.1.3 Unions or flanges shall be installed in all piping connections to equipment, valves,
instruments, steam traps and miscellaneous specials to facilitate dismantling for
maintenance.

5.2 Supports for Overhead Pipework

5.2.1 All supports, anchors, hangers, spring supports, rollers, clamps, guides, sway
bracings, vibration dampeners etc. required for aligning, supporting and controlling
the pipework shall be installed. These shall include all structural steel piping
supports in open yards. The work shall include installation of such protection as
may be needed to prevent mechanical damage to piping. Such installations shall
be made in a manner satisfactory to the Purchaser.

5.2.2 Timber or wire shall not be used as permanent support of pipework except where
specifically indicated for hydraulic and lubrication pipework.

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5.2.3 Vertical cast iron or steel pipework shall be supported at intervals of approximately
3,500 mm and at the base of each riser.

5.3 Pipe Sleeves

5.3.1 Pipe sleeves shall be provided for pipelines passing through foundations, walls,
floors, roofs etc. They shall be of sufficient size to permit the passage of flanges or
fittings assembled with the line.

5.3.2 Sleeves in floors or roofs shall be projected sufficiently above the floor or roof to
prevent drainage through them. Approved hoods and flashings shall be provided
for sleeves and pipework passing through roofs. Where sleeves are located in
floors, outside walls, walls of pressurised rooms or other similar installations, they
shall be packed with mineral wool, grout or other approved material after
installation of pipeline and ends closed with cover plates or other approved
means.

5.3.3 Generally, sleeves shall be indicated on the drawings, but unless specifically
shown as omitted, they shall be installed.

5.4 Structural Platforms and Supports

5.4.1 All required operating platforms, valve stands, access ladders, handrails etc. shall
be erected complete, after the piping has been installed. Structural steelwork in
connection with those item shall conform to the relevant Indian Standards for
Structural Steelwork.

5.5 LP Gas

5.5.1 LP gas pipework shall meet the requirements of IS-6044 and shall be erected as
per ASME B31.2/B31.4 or equivalent. Care shall be taken that all parts as erected
shall be free of oil, grease, scale and dirt.

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5.5.2 Exposed pipelines shall not be erected under or near high voltage overhead
power lines. Underground pipelines shall not be installed in trenches or tunnels
occupied by power lines.
5.5.3 Trenches, ducts and tunnels shall be properly vented. In addition to the
specification set forth in Clause 5.3 for protection of lines under railway tracks or
roadways, encasement for LP gas pipelines shall be vented at both ends.

5.5.4 The contractor shall install such protection as may be needed to prevent
mechanical damage to pipework. Such protection shall be made in a manner
satisfactory to the Purchaser or as shown in the approved drawings.

5.5.5 All station outlets and section shut-off valves shall be identified by a metal tag
attached to or placed in the immediate vicinity of the valves.

5.6 Natural Gas & Propane Pipework

5.6.1 Care shall be taken that all parts, when in erected assembly, shall be free of oil,
grease, scale and dirt. All components of natural gas & propane systems shall be
cleaned in accordance with the service requirements.

5.6.2 Exposed pipelines shall not be erected under or near high voltage overhead
power lines. Underground pipelines shall not be installed in trenches, ducts or
tunnels occupied by power lines. Valves must never be placed in pits.

5.6.3 Trenches, ducts and tunnels shall be properly vented. In addition to the
specification set forth for protection of lines under railway tracks or roadways,
encasement for natural gas & propane pipelines shall be vented at both ends.

5.6.4 The contractor shall install such protection as may be needed to prevent
mechanical damage to pipework. Such protection shall be made in a manner
satisfactory to the Purchaser or as shown in the drawings.

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29005-WGU-GS-001

5.6.5 The pipelines shall be purged with nitrogen immediately before commissioning.
No purging shall be required if a line is commissioned immediately after
completion of the final pressure test with nitrogen.

5.6.6 DN 15 purging connections with approved valve shall be provided on either side of
main line sectionalising valves and at downstream side of main branch valves.

5.6.7 All station outlets and section shut off valves shall be identified by a metal tag
attached to or placed in the immediate vicinity of the valves.

6.0 INSPECTION AND TESTING

6.1 General

6.1.1 All components of the pipework shall be subjected to visual inspection and testing
as per the relevant codes specified. Routine and type tests for various
components shall be performed at the manufacturer's works and test certificates
including those for materials/equipment/ accessories shall be furnished.

6.1.2 The procedure for inspection and shop testing of pipework components at
manufacturer's works shall conform to the General Conditions of Contract and the
Technical Specifications.

6.2 Tests at Site

6.2.1 The pipework as erected shall be tested in sections at site for strength and
leakage. Systems under vacuum conditions shall be tested at 1.5 kg/cm2 greater
than the nominal external pressure of the system. Services having temperature of
400oC or above shall be tested at 2.5 times the PW.

6.2.2 Expansion joints and/or other elements intended for absorbing stresses through
directional movement shall be separately tested at 1.25 times the PW or the pipe

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29005-WGU-GS-001

test pressure, whichever is higher. Valves, traps, strainers, separators etc. shall
be tested as specified/approved by Purchaser.

6.2.3 Fire protection pipework shall be tested as per statutory regulations for these
services, as applicable.

6.2.4 The contractor shall provide the pumps, barrels, tanks, bulkheads, blanks,
connections, test gauges, and all other equipment necessary for pressure testing.
Compressed air shall be arranged by the contractor from portable air compressors
unless otherwise indicated by the Purchaser. The contractor shall provide, install
and dismantle all temporary lines to the system under test.

6.2.5 For fuel gas pipework, LP gas, hydrogen, oxygen and hydraulic system pipework,
radiographic/ ultrasonic tests shall be carried out for welded joints as per relevant
standards and Mandatory Regulations, as applicable and if specified in Technical
Specification. Number of joints to be tested shall be as specified or as per relevant
codes/standards. Radiographic/ Ultrasonic testing of welded joints of steam lines,
if required, shall be as per stipulations in Indian Boiler Regulations.
Radiographic/ultrasonic tests for other lines shall meet the requirements of
relevant IS/ASTM codes or equivalent. Contractor's scope of work shall include
the certified interpretation of the results of radiographic/ultrasonic tests by a
recognized and approved agency.

7.0 COMMISSIONING

7.1 General

7.1.1 The cleaning, flushing/purging and commissioning of the pipework shall be carried
out after completion of hydraulic/pneumatic and other tests. Cleaning shall be
carried out prior to erection as well as after erection as per these specifications.

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7.2 Cleaning

7.2.1 The piping elements shall be thoroughly cleaned of all foreign matters such as
scales, dirt, oil, grease etc. by wiping and wire brushing before fabrication and
erection/ assembly. All components of pipework shall be cleaned, degreased,
pickled, passivated and commissioned as per the special instructions. All
components of oxygen pipelines shall be pickled/degreased as per relevant
Annex.

7.3 Flushing/Purging

7.3.1 All pipelines shall be flushed/purged till all dirt, scales and foreign matters are
removed immediately prior to commissioning. The minimum duration of purging/
flushing shall be 30 minutes. During flushing valves and pipelines accessories
such as filters, cylinders, bearings, etc. shall be isolated and by-passed where
required.

7.3.2 Pipework for compressed air, steam and nitrogen shall be flushed with the fluids
for which the pipework is intended, unless otherwise approved by Purchaser. Fuel
gas and LP gas pipework shall be primarily flushed with nitrogen followed by the
fluid for which the pipework as intended, slowly replacing the nitrogen.

7.3.3 Pipework for water, condensate, pressure and gravity type industrial sewerage,
rinse water, acidic and alkaline effluents etc. shall be flushed with water.
Concentrated acid systems shall be flushed with water and completely drained
prior to commissioning, unless otherwise approved by Purchaser.

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ANNEX - 1

PARAMETERS OF PIPEWORK

Working Design Design Design Test Pressure, kscg

Sl. Line Test
Service Pressure Pressure Temp Velocity
No. Code Medium Pneumatic Hydraulic
(kscg) (Kscg) (0C) (m/s)
1 Compressed Air CA 6-9 10 60 10 Air 11
2 Instrument Air IA 6-9 10 60 10 Air 11
3 Low Pressure Nitrogen LPNT 6-8 10 60 10 Nitrogen 11
4 Medium Pressure Nitrogen MPNT 18-20 25 60 10 Nitrogen 28
5 Argon AR 15-16 25 60 10 Nitrogen 22
6 Low Pressure Oxygen LPOX 8-10 15 60 8 Nitrogen 17
7 Medium Pressure Oxygen MPOX 18-20 25 60 8 Nitrogen 28
8 High Pressure Oxygen HPOX 36-38 40 60 8 Nitrogen 44
9 Propane PG 2.0-2.5 4 60 8 Nitrogen 5
10 Blast furnace gas BFG 0.08 0.2 60 15 Air 0.22
11 Coke oven gas COG 0.08 0.2 60 15 Air 0.22
12 Mixed gas MG 0.08 0.2 60 15 Air 0.22
13 Converter gas LDG 0.09 0.2 60 15 Air 0.22
14 Low Pressure Steam LPST 5-7 IBR 190 ~35 Water IBR
15 Medium Pressure Steam MPST 19 IBR 230 ~35 Water IBR
16 Condensate CD 6 10 170 2 Water
17 Coal Tar CT 12.0 15 60 1.5 Water 22
18 Make up water MW 2 4 50 1.5 Water 6
19 Chilled Water (Supply) CHW(S) 4-8 10 7 1.5 Water 15
20 Chilled Water (Return) CHW(R) 2-6 10 14 1.5 Water 15

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29005-WGU-GS-001

SUPPORTING SPANS OF PIPEWORK

The supporting span of pipes shall be as per the following table. Supporting span at bend is equal
to 0.75 times the span as given above.

Supporting span (M) of straight pipes

Sl. Pipe size Other pipes
No. DN (mm) Water Fuel Gas
(other than fuel
filled Pipes
gas)
1. 15 1.5 2.0
2. 20,25,32 2.0 2.5
3. 40 3.0 4.0
4. 50,65 3.0 4.0
5. 80 3.5 4.5
6. 100 4.0 5.0
7. 150 5.0 6.0
8. 200 5.5 7.0
9. 250 6.0 8.0
10. 300 7.0 9.0
11. 350 7.5 9.5
12. 400 8.0 10.5
13. 450 8.5 11.0
14. 500 9.0 11.5
15. 600 9.5 12.0 12
16. 700 10 12.0 12
17. 800 12 19
18. 900 12 20
19. 1000 12 21
20. 1100 22
21. 1200 23
22. 1300 24
23. 1400 25
24. 1500 25
25. 1600 28
26. 1800 30
27. 2000 34
28. 2200 34
29. 2400 36
30. 2500 36
31. 2600 36
32. 2800 37
33. 3000 38
34. 3200 40
35. 3400 42
36. 3500 44

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29005-WGU-GS-001

ANNEX - 2

SPECIAL INSTRUCTIONS FOR OXYGEN PIPELINES

1.0 GENERAL

1.1 It is the purpose of these special instructions to familiarize all parties concerned
with designing, specifying, purchasing, supplying, erecting, commissioning and
operating pipework and accessories for oxygen service regarding the nature of
hazards associated with oxygen and the special care to be taken in executing
their work. There are many precautions to be taken for the safe handling of
oxygen and these special instructions are intended to provide a framework by
which the jobs mentioned above may be performed safely and satisfactorily.

1.2 These special instructions have been prepared taking into consideration available
codes and practices and considering their application under Indian conditions.
These have been reviewed and revised based on the latest published literature
and also experience gained in the large number of projects executed over the
years.

1.3 These special instructions do not cover equipment for generation and
compression of oxygen. These instructions also do not cover storage, pipework
and pumping equipment for liquid oxygen, as well as vessels and cylinders for
gaseous oxygen storage. These cover only piping for gaseous oxygen at

pressures upto 40 kscg and temperature between 0° C and 60°C.

1.4 Safety aspects in handling gaseous oxygen

1.4.1 Gaseous oxygen supplied for both process and general purpose use has purity
above 99% and dew point lower than (-)40oC. Gaseous oxygen is colourless,
odourless tasteless, non-toxic and slightly heavier than air. It is itself non-
flammable but will vigorously support combustion when ignition temperature has

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29005-WGU-GS-001

been reached. At increased oxygen pressure the ignition temperatures of all

materials are reduced. Oil and grease are major hazards and will burn in oxygen
with explosive force. Oxygen can saturate clothing which can burst into flames if a
minute spark (from cigarette, grinding operation etc) falls on it.

1.4.2 To produce a fire or explosion in an oxygen pipeline, there are three factors which
are required and, therefore, not be allowed to coincide. They are ignition, material
for combustion and, of course, oxygen to support combustion. Ignition can be
caused by the kinetic energy of the gaseous oxygen in the pipeline which can
provide ignition energy by accelerating the entrained particles and impacting them
against valve discs or other objects protruding in the gas stream, scraping them
along the surface of the pipe, or abrasion of the particles against each other, thus
generating by friction the temperature necessary for ignition. The kinetic energy of
the gas can also provide ignition energy by vibrating a protruding gasket or tearing
loose a filter screen or a valve disc or some other part of a pipeline. Ignition
energy can also be produced when a valve is suddenly opened between high and
low pressure sections. Such an action results in rapid compression of the low
pressure gas and may produce temperatures approaching the adiabatic
compression temperature.

1.4.3 Maintenance of a very high degree of cleanliness in the preparation, fabrication

and installation of any oxygen pipeline is extremely important. A pipeline system
can only be considered clean for oxygen service when all internal organic,
inorganic and particulate matter are removed. Removal of contaminants such as
oils, greases, rust, dust, scale, weld spatter, paints and degreasing agents is
essential before oxygen is introduced into the system.

1.5 All work concerning oxygen service shall be carried out only by persons or
organizations having good experience with respect to oxygen service. Suppliers
for pipework, valves, fittings, instruments etc. as well as agencies for erection of
oxygen pipework shall be selected primarily on the basis of their proven ability in
carrying out similar work. Operation and maintenance personnel shall also be
selected on a similar basis.

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1.6 When work in connection with supply, fabrication, erection, testing, cleaning and
commissioning of pipework for oxygen service are carried out by different
organizations, the confirmation of the work at each stage in accordance with these
special instructions by the different organizations shall be properly certified and
documented. Without verifying such certificates and documentation at each stage,
subsequent stages of work shall not be carried out.

1.7 At any stage, wherever clarifications or explanations with regard to the

interpretation of these special instructions are needed, the Purchaser's written
opinions shall be obtained before carrying out further work.

1.8 Changes to these special instructions may be made by the Purchaser when
availability of new information dictate the same or when conditions pertaining to
the specific contract necessitate such changes.

2.0 DESIGN OF OXYGEN PIPEWORK

2.1 This section deals with the routing, supporting and sizing of oxygen gas piping.

2.2 Routing

2.2.1 Oxygen piping can be laid together with other pipework on common supports,
keeping a clear distance of at least 300 mm. However, for Fuel Gas lines the
permissible gap shall be at least 800 mm. Suitable precautions should be taken to
protect the oxygen pipeline from sources of heat and vibrations. The temperature
of the wall of a pipe containing oxygen shall not be allowed to exceed 100oC.

2.2.2 The distance between oxygen piping and electrical cables should be not less than
100 mm for insulated cables and 1 metre for bare conductors, except with special
permission from Purchaser. Oxygen pipelines should not be laid in tunnels or
closed conduits together with electric or telephone cables, acetylene, fuel gas and
fuel oil pipelines.

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2.2.3 Oxygen piping shall be continuously electrically bonded and effectively earthed.
Electrical jumper connections shall be provided across flanges to maintain
electrical continuity, so as to avoid build-up of static electrical charges and provide
protection against damage from lightning. The electrical resistance to earth should
not exceed 7 ohms for lightning protection and 1 Mega ohm for static. Where
cathodic protection of underground pipelines is provided, the underground pipe
section shall be insulated from pipeline above ground by use of insulating flanges.
These insulating flanges should be installed in vertical portion of line to prevent
settlement of electrically conductive dust.

2.2.4 Oxygen pipes passing through walls, ceilings, and other structures of buildings or
construction shall be encased in a steel pipe having inside diameter at least 50
mm more than that of the oxygen pipe. The oxygen pipe shall have no joints in
the section at such crossings. The gap between the oxygen pipe and the outer
pipe shall be filled with non/inflammable material but allowing vertical and
horizontal movement.

2.2.5 Underground oxygen lines shall be laid in trenches back-filled with soil, unless
specifically permitted otherwise by Purchaser. Cathodic protection of the
underground sections of the pipeline is recommended in addition to passive
protection by coating and wrapping.

2.2.6 All buried oxygen pipes shall have a minimum horizontal distance of 1 metres
from edge of buildings and 1 metres from the edge of railway tracks. Between
buried oxygen lines and other underground piping, L.T. cabling etc. a minimum
distance of 600 mm shall be kept.

2.2.7 No laying of overhead oxygen pipelines together with electric wires and cables is
allowed. All overhead oxygen lines shall have a distance in plan of at least 3
metres from rail tracks and shops storing explosive material and a distance of 10
metres from high voltage overhead lines running parallel, unless otherwise
specifically approved by Purchaser.

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29005-WGU-GS-001

2.2.8 In the shops consuming oxygen, pipelines shall be laid along walls or columns of
the buildings. Laying of oxygen pipeline along with other pipeline is allowed
provided the oxygen pipelines are fixed to individual brackets or hangers and in
case of using the common brackets the oxygen pipelines are laid at one end away
from crane hook to protect it from damage and also provided that there is
provision for easy access to the same for inspection and repairs.

2.2.9 Each run of the oxygen pipelines between the fixed supports shall be designed for
compensation of thermal expansion. The compensation of thermal expansion can
be accomplished either by selecting, a routing configuration which is self-flexible
or by using looped compensators made from seamless pipes with right angle long
radius bends, arranged either horizontally (preferred) or vertically upwards.

2.2.10 Vent lines for discharge of oxygen into open air should be preferably of stainless
steel or copper. They shall be securely anchored to resist the thrust of venting
oxygen. Oxygen should be discharged in a safe area, at least 2 metres above the
building, clear of any personnel and into an area which has no naked flame or
combustable material. The position of discharge end shall not be less than 6
metres above ground level or from a frequently used platform or plant level.

2.3 Supports

2.3.1 The support shall be capable of taking the dead load of oxygen pipe and they
shall also be capable of taking care of the load due to blowing out of pipe by dry
nitrogen. The tapping assemblies on vertical oxygen pipe should be given guide
support.

2.4 Sizing of Pipes

2.4.1 It is recommended that oxygen pipes having pressures between 6 kscg and 20
kscg shall be designed for a velocity not more than 8 M per second at operating
conditions. For pressures between 20 kscg and 35 kscg, the velocity shall be not
more than 6 M per second.

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29005-WGU-GS-001

2.4.2 International standards and norms followed by internationally reputed companies

allow for much higher permissive velocities in gaseous oxygen pipelines.
However, considering the present standards of workmanship and cleanliness
achieved, it is considered prudent to limit the velocities to those stipulated above.

2.5 Other system design considerations

2.5.1 Filters should be installed in the oxygen pipeline system at the following points:

a) At the outlet of the oxygen plant

b) Upstream of components having soft seatings in contact with the oxygen
stream e.g. pressure regulator and control valves.
c) Upstream of components that have moving parts in contact with the oxygen
stream e.g. flow measuring and limiting devices.

Provision shall be made for safe and easy access for frequent cleaning and/or
replacement of the filter element. The larger capacity filters like (a) above should
be provided with differential pressure gauge for monitoring the condition and
providing indication for cleaning/ replacement of the filter element. The filter
bodies shall preferably be of copper and filter element of copper alloy suitably
earthed to the filter body with copper wires.

2.5.2 Two (2) or more pressure relief valves should be provided downstream of each
set of pressure reducing valves. One or more main relief valve(s) should be
capable of discharging 100% of the full oxygen flow and limiting the pressure
within the defined limits. The secondary relief valve should be sized to discharge
the nominal leakage from the pressure reducing valves. The relief valves should
be positioned as close as possible to the pressure reducing valves. The vent lines
from the relief valves should be preferably of copper.

2.5.3 Consideration should be given to providing of small size pressure equalization

bypass isolation valves across large diameter isolation valves in large pipeline
systems so as to ensure safe pressurization of the downstream pipeline. Sonic

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29005-WGU-GS-001

velocities may occur during the initial stages of valve opening with possibility of
high velocity transport of material/dirt particles in the system. If the valve opening
action is rapid, there is also a possibility adiabatic compression and heating of the
oxygen specially if additional closed valves exist downstream. The bypass
pipework and valve should be of copper or copper alloy.

2.5.4 Fire break sections may be installed in the oxygen pipeline to limit the propagation
of combustion in a steel pipeline. Fire break sections may be introduced
immediately downstream of the main isolation and throttling valves where the
velocities can be high. The fire break section will be either a length of copper pipe
having the same inside diameter as the main pipe with flanges fitted at the two
ends which is installed between the steel pipes or a copper insert tube made from
copper sheet/tube and inserted inside the steel pipe downstream of the valves.
The copper insert tube is generally used in large diameter steel pipelines.

2.5.5 In steel pipelines care should be taken to install isolation valves on straight
sections of the pipeline. Any pipeline component which is likely to cause a change
in the flow pattern like reducer, bend, tee or "Y" connection, orifice plate etc.
should be at a distance of at least four diameters away from the valve.

2.5.6 For cleaning of the gaseous oxygen pipelines after erection, provision for "pigging"
will be provided for pipelines. Extra care will have to be taken regarding
cleanliness of these pipeline during installation. For all line sizes the bends will
have a radius of 5 DN. The pipelines to be pickled and phosphated as per
approved procedure.

2.5.7 Gaseous oxygen pipework shall preferably have butt welded pipe joints. To
reduce safety hazards the number of components should be kept to a minimum
compatible with the system requirements. Flange joints are to be used only for
connection of the pipe to the system components on the pipework.

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2.6 Materials

2.6.1 The material and dimensional standards for pipework, valves, fittings, flanges,
accessories and instruments shall be as per BOQ.

2.6.2 Gaskets for all flanged valves and flanged joints shall be of LOX grade oil &
grease free teflon.

2.6.3 Packing material for valves shall be similar to that mentioned above.

2.6.4 Diaphragms of oxygen actuated diaphragm control valves and measuring

instruments shall preferably be of stainless steel. Bronze or neoprene diaphragms
may also be used.

2.6.5 Valves shall preferably be of bronze or stainless steel.

2.6.6 Teflon tape may be used as sealant on threaded joints.

2.6.7 Suitable lengths of pipes upstream and downstream of control valves shall be
made of stainless steel or copper.

2.6.8 Lubricants used in actuators for valves on oxygen lines shall be suitable for
oxygen service.

3.0 CLEANING OF PIPEWORK

3.1 Generally pipes, valves, fittings, instruments and appurtenances for oxygen
service shall be accepted for erection only after physical inspection at the
installation site and verifying the suppliers documents/certificates regarding
satisfactory compliances with the requirements for oxygen services. The important
aspects to be checked are listed below.

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3.1.1 All components of pipework should be checked for their standard of manufacture
and dimensional and material suitability.

3.1.2 The accompanying documents and certificates showing results of tests at

manufacturer's works should be verified. Without such certificates the item shall
not be used for oxygen service.

3.1.3 The packings should be checked to ensure that they are not damaged while in
transport between place of manufacture and site installations.

3.1.4 Presence of grease or oil should be checked in light on visible outer surfaces.
Inside of pipes or fittings may be checked by passing a white lint free cotton.
Alternatively the pipes and fittings can be subjected to ultraviolet radiation. Any
presence of oil or grease on the surface will create fluorescence.

3.1.5 Presence of scales should be visually checked. Presence of other foreign matters
such as fillings, scale, flux, corrosion products, common dirt, wood and metal
chips, threading compounds, sealers, tar, asphalt, moisture, paint, chalk, flushing
compound etc. should also be checked.

3.1.6 It should be ensured that all pipework are cleaned free of all foreign matter.

3.2 Cleaning by Manufacturers

3.2.1 At the manufacturer's works, all pipes and fittings shall be pickled neutralized and
phosphated as per IS:3618 after completing shop tests. Then these shall be tightly
sealed by plugs or blank flanges, packed with sachets of dry silica gel inside and
tagged "pickled for oxygen services" before despatch.

3.2.2 Valves, regulators, filters etc. shall be thoroughly cleaned and degreased, their
ends sealed by plugs or blank flanges and packed in clean polythene bags and
tagged "degreased for oxygen service" before despatch. The method of
degreasing shall be same as that described.

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29005-WGU-GS-001

3.3 Cleaning at Erection Site

3.3.1 All pipes, valves, fittings, etc. after visual examination and verification of
documents shall also be cleaned at site as described herein.

3.3.2 In case the oxygen pipes and fittings delivered to site by manufacturers/stockists
are found to contain scales, rust etc. they shall be subjected to cleaning, pickling
and phosphating as per procedure given. After this treatment they shall be dried in
open air or by blowing dry air. The ends shall then be kept sealed till degreasing
commences.

3.3.3 Pickling

3.3.3.1 Pickling is a chemical process for removal of rust, scale and other coatings from
pipes, fittings etc. This is normally done by subjecting the surface of the material
to be treated in an aqueous solution of an acid. To prevent the acid from attacking
the base metal an inhibitor may be added. Pickling bares the metal of the surface
treated which become highly susceptible to corrosion. This operation is, therefore,
followed by an anti-corrosion treatment which retards the corrosion of surfaces
that have been pickled. Phosphating is one such chemical process which deposits
a thin protective layer on the surface.

3.3.3.2 The procedure given below is applicable for pickling and phosphate treatment of
carbon steel pipes and components. The process requires the pipes to be
immersed in vats/baths of adequate dimensions to take full lengths of pipes as
supplied by the manufacturers/stockists. It also requires close supervision and
availability of a chemical testing laboratory to assure that proper control is
exercised during the process. Arrangements are also required for heating of the
chemical solutions used for the treatment.

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29005-WGU-GS-001

3.3.3.3 The pipes and fitting as supplied are cleaned to remove surface contamination.
First a high-pressure water wash is to be given on both the internal and external
surfaces. If the pipes as supplied contain excessive oil, grease or lacquer the
same has to be first removed by cleaning the surface with an approved chemical
solvent to prepare the materials for pickling.

3.3.3.4 Immerse each length of pipe in a solution of 18 to 20% Hydrochloric acid having
an inhibitor of stannine low foam or equivalent for a duration of at least 10 minutes
and not more than 20 minutes. Drain and wash in hot clean water.

3.3.4 Phosphating

3.3.4.1 Immerse the pickled pipes in the phosphating bath having solution with the
following parameters:

i) Concentration of Pyroband 847 x ..... 30-35 points

ii) Bath temperature (phosphate) 60-75oC

The duration of the immersion shall be between 15 to 20 minutes.

3.3.4.2 Rinse the pipes in hot water bath maintained at 80oC.

3.3.4.3 The phosphating procedure and coating weight per sq. metre shall generally
conform to IS:3618.

3.3.4.4 It is recommended that a production test coupon is used with each batch during
the phosphating process to ensure coating weight as per IS:3618.

3.3.5 Degreasing

3.3.5.1 Before erection, all piping components shall be degreased thoroughly, using
solvents such as trichloroethylene, carbon tetrachloride etc. suitable for oxygen

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29005-WGU-GS-001

service. Patented procedures for vapour degreasing may also be adopted, subject
to approval by Purchaser.

3.3.5.2 The degreasing solvent quality shall be checked before using the same for
degreasing.

3.3.5.3 Before degreasing, the pipework shall be dried by blowing air.

3.3.5.4 Then the outer surface of pipes shall be cleaned by wiping with cloth dipped in
solvent and then dried in open air.

3.3.5.5 Inner surfaces of pipe shall be degreased by plugging one end, filling the pipe with
solvent and then plugging the other end. The pipe shall then be kept horizontally
and rotated on its axis at least once every minute. This process shall continue for
15 minutes. After draining the solvent the pipe shall be blown with dry, oil free air
or nitrogen of at least 94.0 per cent purity at 60oC to 70oC temperature for about 5
minutes, or till the smell of solvent is completely eliminated. Alternatively, the
drying may be done in open air for a minimum period of 24 hours.

3.3.5.6 If considered necessary after site inspection the valves, fittings and instruments
shall also be degreased at site and dried in open air. The valve and fittings shall
be disassembled and kept in closed containers containing the degreasing solvent
for 5 to 10 minutes. After removing the components the same shall be dried in
open air till the solvent smell is eliminated. Degreasing of asbestos gaskets and
packings shall be done in a suitable solvent for 2 to 3 minutes and then dried.

3.4 All tools and appurtenances used for cleaning shall also be free of all oil, grease,
dirt etc. These shall also be thoroughly cleaned, degreased in a suitable solvent
and dried before use.

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29005-WGU-GS-001

3.5 All personnel involved should follow a high standard of personnel cleanliness.
They shall also take adequate safety precautions to avoid inhaling solvent
vapours arising during degreasing and shall use clean gloves and gas masks.

3.6 Cleaned components of pipework shall be well protected from recontamination by

proper packing and storing. Pipes shall be sealed with plastic end covers. It is
recommended to place small sachets of dry silica gel inside the cleaned and
degreased pipes by attaching the sachets by tape to the plastic end covers. Small
items shall be kept sealed in polythene sheet. All items shall be kept in covered
space till issue for erection. Sufficient quantities of dessicants shall be kept in
places of storage to prevent condensation of moisture on ferrous materials.

4.0 ERECTION

4.1 The entire erection of the oxygen pipeline shall be closely supervised to ensure
proper cleanliness of the pipeline quality of workmanship as a whole. The
progress of work to be rigorously followed up to prevent unforeseen hold up which
may result in deterioration of the cleanliness of the pipework.

4.2 Erection of pipelines shall be carried out as per working drawings, keeping in view
these special instructions.

4.3 Cleanliness of personnel as well as tools and tackles etc. shall be as mentioned
above.

4.4 Welding of oxygen line may be done by arc welding process by qualified welders.
Low hydrogen electrodes shall be used as per the recommendations of reputed
manufacturers. Backing rings shall not be used for welding. The root run shall be
made with argon arc (TIG) welding to prevent weld spatter in the inside surface.

4.5 All welds done at site on oxygen pipework shall be subjected to 100%
radiographic examination. The contractor shall keep identification marks for all the
welds (by letter and number punching) and also the corresponding radiographic

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29005-WGU-GS-001

films. Interpretation of the radiographs shall be done as per ASME code for
unfired pressure vessels Section-VIII Division I, Clause UW 51 and Appendix-4.
The contractor shall mark on a general arrangement drawing all the weld joint
numbers for easy identification. All defective welds shall be removed and redone.

4.6 If lengths of pipe which are made ready for erection (i.e. cleaned, degreased,
pickled and passivated and sealed with plastic end covers) cannot be erected
within one week, they shall be reinspected for deterioration of cleanliness and
recleaned if necessary.

4.7 At the end of the day all open ends of pipelines and appurtenances shall be
sealed with end caps. After erection of 100 metres of pipe, this length shall be
sectionalized and filled with nitrogen at a pressure of 1.0 kscg. If work stoppage is
envisaged for a number of days, then the portion of the erected pipeline which is
not sectionalized and sealed shall be filled with nitrogen at a pressure of 1.0 kscg
and sealed.

4.8 After erection, the oxygen pipework shall be blown with nitrogen (minimum purity
94.0 per cent) at a velocity of not less than 20 metres per second for a period of at
least 30 minutes.

4.9 Pigging, if required, will be done after completion of erection of the entire pipeline
and blowing the pipeline with nitrogen.

5.0 TESTING OF ERECTED PIPES

5.1 All erected pipework shall be tested for pressure and leakage in sections.

5.2 The line shall thereafter be pressurized to 1.1 times the nominal pressure by dry,
oil free air or nitrogen. The pressure test shall last for a period of 30 minutes. After
the pressure test, the pressure shall be reduced to the working pressure and the
welded joints, flanges etc. shall be inspected and tapped with a wooden hammer
of 1.5 kg weight.

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5.3 The pipework shall then be tested for leakage for a period of 24 hours at working
pressure. All welded and flanged joints shall be tested using soap solution during
this period. If leakage is found, the line shall be depressurised, the leaks rectified
and the whole process repeated.

5.4 Readings shall be taken for ambient temperature, pipeline pressure at every 2
hours intervals and all readings properly noted. Pressure and temperature gauges
shall be used in duplicate and tested for their accuracy. The pressure gauges
shall have minimum calibrations of at least 0.1 kscg and temperature indicators, at
least 0.5oC.

5.5 The leakage of air, if any, shall be determined as per the following formula:

A = 100 (1 - P2 x T1)
( P1 x T2)
Where A = Percentage volume of air leakage

P1 = Pressure in the pipeline at beginning of test, ksca

P2 = Pressure in the pipeline at end of test, ksca

T1 = Absolute temperature of air at beginning of test, °K

T2 = Absolute temperature of air at end of test °K

The line shall be considered satisfactorily tested, if the leakage is less than 0.2 per
cent per hour after temperature correction.

5.6 After completing the testing the line shall be kept under a pressure of at least 1.0
kscg using nitrogen till the pipeline blowing activity is started.

5.7 After testing, the pipework shall be blown with dry oil free air or nitrogen (having
minimum purity of 94.0 per cent) at a velocity of 20 m per second. The cleanliness
of exhausted air or nitrogen shall be periodically checked by allowing the same to
impinge on white paper kept at the outlet, The blowing shall be done till the outlet

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air is found clean and acceptable. After completion of blowing the pipeline shall be
hooked up with an isolation valve with the system. Then the pipeline shall be filled
up with nitrogen at a pressure of 1 kscg and then the nitrogen supply to this
pipeline will be cutoff.

6.0 COMMISSIONING

6.1 After completion of all activities, oxygen shall be gradually introduced into the line
and nitrogen slowly exhausted through the bleeder. The purity of the exhaust gas
has to be checked until the desired oxygen purity is reached.

7.0 SAFETY PRECAUTIONS AND STAFF INVOLVED

7.1 The testing, cleaning and commissioning of oxygen pipework shall be carried out
only in the presence of and with the permission and guidance of senior engineers
and staff of the Contractor and Purchaser.

7.2 The safety engineer of the plant shall be apprised of all arrangements for cleaning
and testing and his concurrence shall be obtained in all matters. The Fire Fighting
Officer of the plant or his representative shall also be present during testing and
commissioning of oxygen pipework.

7.3 All first aid and firefighting facilities shall be readily available during the cleaning,
testing and commissioning.

7.4 Prominent placards shall be posted with clear warnings during the testing and
commissioning. Where necessary, the area around the pipelines under tests shall
be cordoned off. All solvents used for cleaning shall be kept in a cool, dry, dark
place in hermetically sealed containers and the staff in charge of stores shall be
familiar with the health hazards associated with the solvents. In areas where
solvents are stored or used, smoking shall be prohibited.

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ANNEX - 3

FIELD PRESSURE TESTING OF PIPELINES

1.0 This document covers the general requirements for the field testing of pipelines
after erection and the criteria for acceptance. This document has been prepared
on the basis of the relevant details given in Annex-1 and as per good
engineering practices.

1.1 All pipelines shall be tested in suitable sections in the field after erection in place,
irrespective of whether or not such pipelines or sections thereof have been
pressure tested prior to erection.

1.2 If any modification is carried out on the pipeline after the field testing, then the
section which includes the modified portion shall be field tested once again.

1.3 For the purpose of conducting test and accepting the tested pipes, a Testing
Commission comprising representatives of Purchaser’s and contractor’s
organization is expected to be constituted.

2.0 TEST MEDIUM, TEST PRESSURE AND TEST SECTIONS

2.1 Test medium and test pressures shall be as per Annex-1.

2.2 Sections of pipelines for a particular service to be taken up for testing shall
include the maximum amount of piping consistent with the layout and progress of
construction. Suitable sections for testing can be decided by the commission.
Number of untested joints should be minimized.

2.3 When yard pipelines of a particular zone is being tested, the test section may
extend beyond the zone-boundary, if required. In such cases, the erection
contractors of both zones shall be present during testing of piping in such

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29005-WGU-GS-001

continuous zones. Rectification of defects in a particular zone shall be done by

the erection contractor for that zone.

2.4 Pipelines which are directly open to atmosphere such as vents, drains (lines
after the vent and drain valves) and safety valve discharge lines shall not be
tested but all joints shall be visually inspected for proper installation.

3.0 TESTING PREPARATION AND TESTS

3.1 Cleaning prior to Testing

3.1.1 Pipelines for services listed in Annex-1, which are to be tested pneumatically
shall be cleaned by air blowing prior to tests. This is meant to ensure that loose
materials in the pipe do not block leakage points during tests and give erroneous
test results.

3.1.2 Inside of large diameter pipelines shall be visually examined for their cleanliness
before tests and cleaned as required.

3.1.3 Control valves, orifice plates and other constructions shall be removed during
flushing/blowing of the pipeline. If this is not possible, they shall be blocked-off
by closing the isolation valves and flushing/blowing through the bypass valves.

3.2 Preparation for Tests

3.2.1 Blind flanges, blanks, caps or plugs shall be installed to isolate piping special
equipment, instruments and associated piping systems. The requirement of
blank flanges to isolate the portion of pipeline to be tested shall have suitable
thickness and shall be provided with cross stiffeners to withstand the end thrust
arising out of the test pressure and diameter of the pipe. The stiffeners shall also
be locked with the pipe being tested. The standard drawing for blank flanges to
be followed.

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29005-WGU-GS-001

3.2.2 Prior to installation, the test gauges shall be checked against a standard gauge
or dead weight tested for accuracy.

3.2.3 At least two (2) Liquid manometer and temperature gauges shall be used for
measuring the pressure and temperature in any test section. Pressure &
Temperature shall be measured at the start and at regular intervals of testing
and also at the end of testing with the help of manometer & thermometer kept in
the line throughout the testing period.

3.2.4 In case additional drain and vent points are required specifically for the test, the
same shall be arranged by the contractor, although these may not have been
shown on relevant drawings.

3.2.5 Supply of adequate quantity of test fluid that may be required for the test, shall
be arranged before commissioning the test.

3.3 Testing

3.3.1 Test pressure shall be applied by means of a suitable compressor which shall be
suitably isolated from the system until commencement of test. The test
compressor shall be attended constantly by an authorized person during the test.

3.3.2 Air tightness and pneumatic strength test: Wherever air tightness test
(with air or nitrogen) as well as a pneumatic strength test (with air or nitrogen) is
indicated in Annex-1, the following sequence shall be observed.

a) In case any sudden drop in pressure is observed at any of the steps, the
pipeline shall be thoroughly examined for any leakage or other defects and
the same shall be rectified before proceeding further with the test.

b) The pneumatic strength test shall be conducted with the specified test
pressure which is kept for 15 minutes. If any appreciable reduction of
pressure is noted, the defects shall be identified, the pressure shall be

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29005-WGU-GS-001

released, defects to be rectified and the strength test conducted again for 15
minutes. After the strength test, the pressure is gradually reduced to the
pressure specified for air tightness test.

c) With the test pressure set at the value specified for air tightness test,
inspection shall be made within 30 minutes to check for air leakage.

d) All the welded joints, flanges etc. shall be inspected and tapped with a
wooden hammer of 1.5 kg weight. All weld joints shall be tested using soap
solution or foam indicator for leakage. If leakages are found, the line shall be
depressurised, leaks shall be rectified and the whole process to be repeated
again.

e) The suggested testing length for large diameter (DN 1000 and above) low
pressure fuel gas lines shall be 500M.

f) Minor alterations in the testing length as might be required due to site

conditions shall be jointly decided by the Testing Commission.

3.3.3 Reading of ambient temperature and pressure, pipeline test fluid temperature
and pressure shall be taken at the beginning of the test and at every 30 minutes
interval till the end of the test and shall be properly recorded in data sheet.

3.3.4 For air tightness test, the line shall be pressurized with air (or nitrogen) gradually
as per the steps indicated above. The air tightness test shall then conducted as
per above.

3.3.5 Air tightness-cum-pneumatic strength test: Wherever only air tightness-cum-

pneumatic strength test is specified in Annex-1, the specified pressure shall be
attained gradually as indicated below:

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29005-WGU-GS-001

For low pressure fuel gases (i.e. Blast Furnace Gas, Coke Oven Gas, Mixed Gas
and Converter Gas) pipelines, the specified test pressure shall be attained
gradually and then the same shall be kept for the test period, and the pneumatic
strength test and air tightness test shall be conducted.

3.3.6 Precautions for Testing

a) Any increase or decrease of test pressure after attaining its full value shall be
done gradually. In case of pneumatic testing the pressure shall be varied at a
rate of about 0.25 to 0.5 kscg in 5 minutes.

b) Inspection of section being tested shall begin 10 minutes after the test
pressure is stabilized.

c) Care shall be taken to ensure that the tests are conducted when ambient
temperature is relatively stable, as wide variation of ambient temperature
leads to wider fluctuation of the pressure test fluid in the pipeline. Local
weather conditions shall be given due considerations in selecting the time of
test such that wide variation of ambient temperature is not expected during
the test.

d) Locally mounted indicating pressure gauges may be tested together with the
piping if the test pressure does not exceed the scale range. However, the
gauge shall be blocked-off from piping during cleaning and flushing. Where
the lines to which they are connected will receive a higher test pressure, the
gauges shall be isolated by closing the gauge cock or by plugs.

e) Normally valves shall not be used for isolation during testing in order to avoid
subjecting the valve seat to excessive pressures. Wherever the use of valves
for isolation becomes inevitable, it shall be ensured that the seat test
pressure of valves at works was higher than the line test pressure at a site
after erection. In such cases, the passing of the valves (i.e. leakage through

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29005-WGU-GS-001

seat) during testing shall be kept in mind by the commission while deciding
on the accepting/rejection of the test section.

4.0 ACCEPTANCE CRITERIA

4.1 For Pneumatic Test (Air Tightness Test)

The percentage leakage shall be calculated as per the following formula:

A = 100 [1 – (Pf/Pi) (Ti/Tf) ] percent

Where, A = percent leakage

Pf, Tf = Absolute Pressure (Ksca) and absolute temperature

(Deg. K of test fluid at the end of test

Pi, Ti = Absolute Pressure (Ksca) and absolute temperature

(Deg. K of test fluid at the beginning of test

The test results shall be considered satisfactory and acceptable if the percent
leakage as per above formula is not more than 0.02% per hour.

During the testing period pressure and temperature readings are taken in the
interval of 1 hour. Duplicate gauge with least count of 0.5 kscg for pressure and
0.50C for temperature shall be used.

5.0 ACCEPTANCE AND CONTROL TESTS OF THE FUEL GAS PIPELINES

5.1 Manufactured detailed are valid for acceptance in unpainted state.

5.1.2 Acceptance and control tests of gas pipelines are carried out by the
Manufacturer’s Technical Control Department.

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29005-WGU-GS-001

5.1.3 Acceptance is carried out as follows:

a) Documentary checking of the metal marks according to the drawings.

b) Checking of documents attesting the satisfactory results of the

mechanical tests.

c) Visual examination of the welding quality according to paragraph 1.3.2.6.

d) Checking of the dimensions and compliance of the manufactured details

with drawings and these specifications.

5.1.4 In case of finding the defects by visual examination and checking the dimensions
or absence of the required documentation, manufactured articles are not allowed
for leakage test.

5.1.5 General control assembling is carried out only for straight links of the distributing
gas piping.

5.1.6 Control testing for leakage include the following:

a) Tests by the compressed air with greasing by soap solution of all joints of
links and other details of the gas pipes with flanges.

b) Checking by applying chalk and kerosene on the joints of links of the gas
pipes without flanges.

5.1.7 Tests by compressed air are carried out with excess pressure Ptest= 1.1 times the
design pressure.

5.1.8 For kerosene testing all joints are covered firstly with chalk; when chalk is dried
up, the inner surfaces of the joints are abundantly covered with kerosene. Dark

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29005-WGU-GS-001

greasy spots on the outer surface show leaks. Examination of joints is carried
out twelve hours after applying kerosene.

5.1.9 All defective sections of joints found during control tests should be cut out and
re-welded. After repairing, such details are subjected to repeated tests.

5.1.10 After testing, the statement is drawn up for acceptance of the gas pipeline and
each detail mentioning the results of examination, measurement and tests, found
defects, their character, location and method used for eliminating such defects.

6.0 DOCUMENTATION

6.1 Before testing, Purchaser shall issue a circular indicating the following:

a) Test-in charge (Name and designation)

b) List of personnel engaged in testing.

− From erection contractor

− From Purchaser (Construction & Operation)

c) Service of the pipeline, section to be tested and its length, zone, shop
name, pipe sizes (diameter x thickness) and material, local conditions and
special features, if any.

d) List of personnel with telephone nos. responsible for safety of labor, first-air
and ambulance service, fire-fighting and proper illumination (in case of
night work).

6.1.1 The persons indicated in (a) and (b) above comprise the testing commission
(hereinafter referred to as the Commission).

6.2 Before beginning any test, the following documentation shall be compiled by the
contractor and furnished in time to the Testing Commission.

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29005-WGU-GS-001

a) Piping (working) drawings for the sections to be tested.

b) Identification of the sections to be tested in the above drawings.

c) Manufacturer’s test certificates for pipes, valves and other items on the
pipelines, as applicable

d) Approved documents for modifications and deviations, if any.

e) Certified position of towers and trestles.

f) Documents certifying quality of weld joints.

g) Log books of work execution.

h) Copies of welder qualification, test certificates and their identification

marks.

i) Radiographic/ultrasonic test results, if any.

j) Certificate for completion of erection of pipelines.

k) Scheme of carrying out tests, indicating location of plugs/blanks for testing,

valves to be closed, valves, rupture discs, instruments and instrument
piping, relief valves to be isolated (or removed), control valves to be by-
passed, spring supports to be gagged etc.

l) Sequence and general requirements of testing.

m) Any other document as may be found necessary.

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29005-WGU-GS-001

6.3 The following certificates shall comprise the Acceptance Certificate for the
portion of pipeline tested:

a) Certificate No.1 – Certificate of Packing of Flanged Joints on Pipeline

b) Certificate No.2 – Certificate of Air Tightness Test and/or

Pneumatic/Hydraulic Pressure Test of Pipelines

The commission may make changes or additional formats as per requirement.

However, the same format should be uniformly used in the whole plant.

7.0 SAFETY CONSIDERATIONS

7.1 It is necessary to observe the following safety precautions for the conducting of
field testing of pipelines.

7.1.1 Testing for a particular section of pipelines shall be undertaken only on the basis
of a written circular to be issued by Purchaser in each case.

7.1.2 Before testing, the following actions are to be taken by the contractor. Wherever
Purchaser’s help is required, the contractor shall specifically request the testing
commission.

a) To give prior information to personnel working in adjacent work areas,

about the time of testing and its approximate duration.

b) To mark the boundary of the test area on the ground by warning (red) flags
at suitable intervals and at suitable horizontal distance from the pipeline.

c) To post own guards at about 200 meters interval to prevent un-authorized

people to enter the test area.

d) To shift moving machinery like tower cranes outside the test area.

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29005-WGU-GS-001

e) To do thorough verification of the completeness of erection of pipelines and

fittings and their readiness for testing.

f) To verify that inside of the pipeline is devoid of any foreign objects.

g) To arrange for sand-filled gunny bags to be placed in strategic locations

(e.g. wet gunny bags at leakage points, etc.)

h) To identify with warning signs, temporary plugs, manholes, flanged joints,

isolated valves, isolated safety valves, check valves with flapper
removed/jacked up.

i) No testing during nighttime to be allowed.

j) To arrange for first-aid, ambulance and fire-fighting facilities to be in

readiness.

k) Pressure relief valves are to be provided at both inlet and outlet side of the
pipe during pneumatic testing.

7.1.3 Pressurization of the line shall be started only on clearance from the Test-in-
Charge. After test pressure has been set, any increase or decrease of test
pressure shall be done gradually.

7.1.4 Inspection of test portion shall be started 10 minutes after the pressure is
stabilized. It is prohibited to undertake inspection before pressure is stabilized,
and when pressure is being raised.

7.1.5 It is not allowed to hammer welds to remove weld defects, to repair weld any
mechanical caulking and to make any repair with the line under pressure.

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29005-WGU-GS-001

7.1.6 The test pump or compressor shall be attended by an authorized person at all
times during testing. If for any reason, the pump has to be left unattended, the
same should be disconnected from the pipeline under test.

7.1.7 If any modification is made to the pipeline after successful completion of

pneumatic/hydraulic testing, then the test section which includes the modified
portion shall be re-tested and fresh certificates will have to be issued in respect
of that section, the earlier certificate being rendered null and void.

7.1.8 If pressure of the test fluid starts increasing continuously during testing, due to
increase in ambient temperature, causing thereby undue increase in pressure,
the test pressure will have to be released manually as a safety precaution.

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ANNEX - 6
THERMAL INSULATION

1.0 SCOPE

1.1 This specification covers the thermal insulation required for hot as well as cold
services, on pipes, ducts and for various requirements. The term thermal
insulation used here generally covers all items of the assembly used to
minimize heat gain by cold services or heat loss by hot services and to avoid
injury to people due to contact with hot or very cold surfaces. Such assembly
shall include, but not be restricted to the material of insulation; the materials,
securing the insulation material to the part to which it is applied; the coating or
wrapping applied to secure the insulation and to act as a vapour seal and/or
protect the insulation material from damage due to environmental conditions
and mechanical damage and cladding to hold the insulation in position, protect
it from damage, give the insulation a neat and aesthetically pleasing
appearance, and to act as a heat reflector, etc.

1.2 The design and installation of all thermal insulation shall be complete in every
way for the service intended and suitable for achieving the desired reduction
in heat transmission as well as maintaining the surface temperature within
allowable limits. The installation shall be complete in all respects including all
items essential for proper installation, irrespective of whether the requirements
are specifically mentioned in the Technical and General Specifications.

1.3 This general specification does not cover thermal insulation for buildings and
structures. However, for specific purposes such as air conditioning of work
premises, for which thermal insulation of the conditioned space has been
considered, relevant clauses of this specification shall be considered as
applicable.

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29005-WGU-GS-001

1.4 This specification does not cover insulation for furnaces, metallurgical and
production equipment operating above 600 deg C and for cryogenic
applications.

1.5 If any special insulation system, not covered by this specification is required,
the same shall be submitted with the proposal with detailed functional
description and specification for the insulation system for Purchasers’
approval.

2.0 STANDARDS

2.1 The thermal insulation shall be designed, manufactured, tested and installed
as per the standards mentioned in this specification. Detailed instructions on
such aspects as are not indicated herein shall be as per the standards, codes
and recommendations of Bureau of Indian Standards (BIS) or as per the
national standards of the country of origin or the codes of practices followed by
the manufacturer.

2.2 These standards shall be adhered to, unless adoption of these would vitiate
the function of the insulation proposed. In such cases and where different
standards are adopted by the contractor, the same shall be clearly indicated
with reasons and prior approval of the Purchaser shall be obtained.

2.3 Wherever applicable, the Interplant Standards for Steel Industry (IPSS)
developed by the Steel Authority of India Ltd shall be followed.

2.4 The thermal insulation used for electrical equipment shall conform to the latest
codes of the International Electrotechnical Commission.

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29005-WGU-GS-001

3.0 DESIGN BASIS

3.1 Thermal insulation shall be provided for all surfaces substantially hotter or
cooler than ambient conditions. The following data shall be used for selection
of thermal insulation.

Warm Season Cold Season

o o
Dry bulb temperature .. 45 C 12 C
o o
Wet bulb temperature .. 30 C 8 C
Relative Humidity .. 70% (High) & 60% (Low)

3.2 Thermal insulation shall also be provided for spaces being served by air
conditioning systems if such insulation is specified in the relevant technical
specifications or if such is warranted by reasons of economy or aesthetics.

3.3 The thermal insulation provided shall ensure that the temperature of the outer
surface of insulation shall not exceed 10 deg C above maximum ambient
temperature for hot services or fall below 10 deg C for cold services unless
otherwise indicated in technical specification.

4.0 MATERIALS & APPLICATION

4.1 Insulation for Hot Services

4.1.1 These cover pipelines carrying hot fluids such as steam, condensate, hot
water, hot oils, hot air, hot flue gases, etc., as well as equipment operating at
elevated temperatures.

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29005-WGU-GS-001

4.1.2 Insulation Materials

4.1.2.1 Mineral wool (made from rock or slag) insulation materials shall be used for
hot services. The insulation shall be in the form of rock or slag wool mats with
wire netting on both faces. The mats shall conform to IS:3677.

4.1.2.2 Insulation material for pipes (upto DN 300) carrying steam, condensate, hot
water, hot flue gases etc. shall be light resin bonded (LRB) mineral wool in
the form of pipe sections as per IS:9842 (bulk density of 144 kg/m3). Light
Resin Bonded mineral wool mattress as per IS:8183 with a bulk density of
150 kg/m3 shall be used for insulating pipe sizes above DN 300. Valves,
flanges and other fittings shall be suitably insulated.

4.1.2.3 All hot insulation shall be provided with Aluminum cladding 0.7 mm thick (20
SWG) as per IS: 737.

4.1.3 Bulk Density of Insulation

4.1.3.1 For LRB insulating material the minimum bulk density shall be as follows.

i) For mineral wool pipe sections .. 144 kg/cu m

ii) For mineral wool mattresses .. 150 kg/cu m

4.1.4 Anti-corrosive property: The insulating material shall not cause corrosion of
the surface on which it is applied. Chloride content of the insulation material
shall not exceed 35 ppm, for application on stainless steel surface to avoid
chloride corrosion. The thermal insulation shall be chemically inert and non-
corrosive to aluminium. If chloride content of insulation exceeds 35 ppm at the
time of application, aluminium foil wrapping (0.1 mm thick) shall be provided
over the stainless steel surface before application of insulation.

4.1.5 Heat resistance: The insulating material of the selected bulk density shall be
suitable for continuous use at the maximum service temperature specified in

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29005-WGU-GS-001

the technical specification. When tested as per IS: 3144 by heating to the
maximum service temperature, the material shall maintain its general form and
shall not suffer visible deterioration of the fibrous structure.

4.1.6 Insulation thickness

4.1.6.1 For hot service equipment, the minimum thickness of insulation adopted shall
be 40 mm. Where higher thickness is required, provision shall be made to
ensure limiting the outside surface temperature of insulation to values
specified above.

4.1.6.2 For hot service piping, the thickness of insulation shall not be lower than the
thicknesses indicated in the table. Where higher thicknesses are required,
provision shall be made to ensure limiting the outside surface temperature of
insulation to value specified above.

4.1.7 Insulation Application

4.1.7.1 Cleaning of surface

The surfaces to be insulated shall be thoroughly cleaned, dried and made free
from all loose scale, dirt, rust oil and grease.

4.1.7.2 All insulating materials shall be dry before application and shall be protected
from moisture, weather and ingress of dirt.

4.1.7.3 For all types of insulation, expansion/contraction joints shall be provided at

regular intervals not exceeding 8 metres. These joints shall be made by
providing a gap of 25 mm between adjacent sections and filling up the same
by compressing loose insulation of the same material. Suitable expansion
joints shall also be provided on the metal cladding over insulation.

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29005-WGU-GS-001

4.1.7.4 Aluminium foil wrapping shall be provided over stainless surface to be

insulated.

4.1.7.5.1 The preformed pipe sections shall be snapped on to the pipe surface in a
staggered configuration. End joints of adjacent pipe section blocks (both for
straight runs and for blocks/segments for valves. bends etc.) shall be
staggered by one-and half of the length of the block. All insulation sections
shall be trimmed and tightly butted to eliminate voids. The insulation shall be
firmly secured in place with at least three (3) loops of binding wire/band - two
(2) located at 75 mm from each end and one (1) located at the middle. Mitred
sections at bends and elbows shall be secured by minimum two (2) wire loops.
Insulation at valves and other fittings shall also be suitably secured. Binding
wire shall be 16 SWG (1.63 mm) G.I. wire. Band shall be of Aluminium, 24
SWG (0.56 mm) thick, and at least 20 mm wide. For pipe sizes DN 150 mm
and below, insulation segments at bends shall be secured by spirally winding
16 SWG (1.63 mm) G.I. wire.

4.1.7.6 Application of Mattress Insulation

4.1.7.6.1 Regular surfaces: The surfaces to be insulated shall be cleaned of loose

materials. Flat surfaces and larger diameter vessels/equipment shall be
provided with M.S. spokes or studs welded to hold the insulation. Vertical
pipelines shall be provided with M.S. collars as per clause 4.3.2. The insulating
mattresses shall be fitted closely to the surfaces, butting all joints tightly and
laced down with 0.915 mm dia (20 SWG) G.I. wire joints in vertical as well as
in horizontal planes which shall be staggered at least by 150 mm.

4.1.7.6.2 Irregular surfaces: In case of irregular surfaces after securing the insulation
in place, all voids, depressions, cracks etc shall be filled with loose insulation
material. Valves shall be insulated upto bonnet flanges: the insulation shall be
applied only after initial operation has stabilised tightness and operation of
valves and specials. Insulation for a flanged joint shall be forged in the shape
of a continuous ring block, reinforced with metal lathe or equal with sleeves to

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29005-WGU-GS-001

cover adjacent pipe ends by at least 50 mm and be butted with the pipe
insulations; the flange insulation shall be applied only after pressure testing of
the pipeline. In case of flanged joints at pipe terminations and connections to
uninsulated equipment, the pipe insulation shall be nearly levelled down to the
flange so as to end inside the bolt circle.

4.1.8 Insulation Finishing

4.1.8.1 Cladding support: All insulation shall be provided with weatherproof cladding
of 0.7 mm thk (22 SWG) aluminium sheets conforming to IS:737 - 1986. The
cladding shall be supported on spacers made of 25 x 3 mm thick steel flats,
the spacers shall be fitted with 4 mm dia rivets to angle cleats, welded on to
the surface being insulated. The angle cleats shall be of size, so that the gap
between the surface being insulated and outer surface of the spacer is same
as the desired insulation thickness. Pure asbestos mill board packing of 3 mm
thickness shall be used between the cleats and spacers to minimize heat
conduction. Spacer rings are not required for 80 mm dia and smaller pipes.

4.1.8.2 Cladding application: The cladding shall be bent true to shape, grooves
made on all sides for making water tight joints and holes drilled for fixing. Each
sheet shall be fixed to the spacers by means of studs: self tapping, flat
headed, nickel plated steel screws shall be used for jointing the sheet.
Suitable bitumen washers shall be used below all screws and studs and
bituminous felt strips used between sheet metal joints to ensure water
proofing. Irregular items like flanges, valves etc. shall be clad with sheet metal
boxes fitting the contour of insulation and continuous with the main cladding.
Openings in the cladding shall be avoided as far as possible. Where openings
are essential e.g. around pipe saddles, hangers, clamps, anchors etc., they
shall be well filled with insulating material and finished smooth with the pipe
insulation.

4.1.8.2.1 The cladding shall be applied with minimum 50 mm overlap on both

longitudinal and circumferential joints. All overlaps shall be arranged to shed

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29005-WGU-GS-001

water. Aluminium bands of 24 SWG (0.56 mm) thick, 20 mm wide shall be

fixed to secure the aluminium cladding, on a maximum 300 mm centres. One
band shall be located on each circumferential joint and the distance between
the joints divided into equal band spacing.

4.1.8.2.2 Metal cladding on vertical or near vertical piping with insulation outside
diameters of 300 mm or more shall be supported from the adjacent lower
section with minimum two (2) Nos. "S" clips fabricated from 24 SWG (0.56
mm) thick aluminium sheet. The "S" clip shall be of sufficient length to allow
minimum overlap of 50 mm.

4.2 Insulation for cold services

4.2.1 These cover pipelines carrying cold fluids such as chilled water, chilled
drinking water, cold air ducts, air-conditioned spaces etc.

4.2.2 Insulation Materials

4.2.2.1 The chilled water pipes shall be insulated either by Polyurethane Foam (PUF)
or Closed cell nitrile rubber (CCNR). The thermal conductivity of PUF shall not
exceed 0.04 W/m deg C at 10 deg C mean temperature & density shall not be
less than 40 kg/m3. The same for CCNR shall not exceed 0.035 W/m deg C at
0 deg C mean temperature & density shall not be less than 40 kg/m3.

4.2.2.2 The material shall be CFC/HCFC (Chlorofluorocarbon/

Hydrochlorofluorocarbon) free. The insulation material can be ready made
pipe section or precut sheet as per requirement. Aluminum cladding over
insulation shall be provided over chilled water pipes. For air conditioning
systems, entire supply air ducts and return air ducts shall be thermally
insulated by resin bonded glass wool and shall be covered with cladding. Initial
five (5) meter length of supply air duct from the outlet of each air conditioning
equipment shall be provided with resin bonded fiber glass acoustic insulation
and shall be covered with cladding.

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29005-WGU-GS-001

4.2.3 Insulation Thickness

4.2.3.1 For cold service equipments, the minimum thickness of insulation shall be 25
mm. Where higher thicknesses are required, provision shall be made to
ensure limiting the outside surface temperature of insulation to values
specified above.

4.2.3.2 For cold service piping, the thickness of the insulation shall not be lower than
the thicknesses limits indicated in the Table furnished in Annex-1. Where
higher thickness are required, these shall be provided to ensure limiting the
outside surface temperature of insulation to the values specified above.

4.2.4 Insulation Application

4.2.4.1 Regular surfaces: The surfaces to be insulated shall be thoroughly cleaned,

dried and made free from all loose, scale, dirt, oil or grease and a coat of
solvent free, anti-corrosive, suitable primer shall be applied. For galvanised
steel surface, a special primer suitable for the purpose shall be used.
Insulation blocks or shaped pieces shall be coated on the inside surfaces as
well as edges, with hot industrial bitumen of grade 85/25 or other suitable
solvent free bonding compound. The insulation shall then be stuck to the
primed surfaces with adjacent sections tightly pressed; all joints shall be
staggered and filled with bitumen. The insulation segments shall be secured
by hexagonal G.I. wire netting of 0.915 mm dia (20 SWG) and the netting
stitched with 0.915 mm dia (20 SWG), G.I. wire.

4.2.4.2 Irregular surfaces: In case of irregular surfaces such as flanged joint, valves
etc. the main insulation shall be terminated at a distance necessary for
removal of bolts. All irregularities on the surface shall be filled up with a
mixture of expanded polystyrene granules and bitumen on which suitably cut
insulation blocks or shapes shall be stuck to as in the case of regular surface,
overlapping the main insulation. The insulation shall be secured with the main

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29005-WGU-GS-001

insulation by metal bands or tape and not stuck to one another by industrial
bitumen. Valves shall be insulated upto their bonnet flanges.

4.2.5.3 The insulation shall be continuous as far as possible. Openings shall be made
for supports, brackets, clamps etc., and where required timber saddles shall
be provided on the lower half of pipe or duct in place of insulation.

4.3 Special Insulation

4.3.1 In case of special requirements not covered in this specification, the insulation
material, thickness, application and finish shall be subject to Purchaser’s
approval.

4.3.2 Vertical Insulation Supports

For all types of insulation on vertical or inclined piping (at an angle greater
than 45 degree from horizontal), 6 mm thick M.S. collars (bolted) shall be
provided at approximately 5 metres interval. O.D. of collar shall be 10 mm
less than O.D. of insulation.

4.3.3 Insulation for Steam Traced Lines

Insulation on steam traced lines shall be applied so as to enclose both main

pipe and tracer and shall fit as snugly as possible. The steam tracer
expansion loops shall be insulated and finished same as adjoining main pipe
insulation. If the traced line may at times be below dew point temperature, then
the insulation shall be suitably sealed to make all joints vapour tight.

5.0 INSPECTION AND TESTING

5.1 Routine and type tests for various items shall be performed at manufacturer's
works and test certificates including those for material/accessories furnished.

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29005-WGU-GS-001

6.0 PAINTING

6.1 Hot surfaces provided with insulation and cladding need not be painted for
corrosion protection. For cold surfaces provided with insulation and cladding, a
primer coat shall be applied.

6.2 Pipework having insulation and cladding shall however, be provided with
colour identification for the fluids handled and for indicating direction of flow.

6.3 Equipment surfaces having insulation and cladding shall also have
identification numbers and any other relevant data provided on the insulated
surface.

6.4 All painting done as mentioned above for insulated surfaces shall conform to
the relevant clauses of design basis for painting.

7.0 MEASUREMENTS

7.1 Measurements for insulation shall be taken over the finished insulation
surfaces, in accordance with the measurement clauses in IS:14164 for hot
service and IS:7240 for cold service. In case of any dispute, the decision of
the Purchaser shall be final and binding.

8.0 DRAWINGS AND OTHER DOCUMENTS

8.1 The following types of drawings and technical information shall be provided by
the Insulation Contractor:

8.1.1 Properties of the insulating materials and test certificates alongwith

Complete design data and drawings for all insulation works.

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29005-WGU-GS-001

8.1.2 Sketches/technical literature showing insulation materials, finish and method of

application. Manuals dealing with safety aspects and instructions for
combating fire arising out of insulation work. Instruction on maintenance of
insulation work and storage of spare insulating materials.

INSULATION THICKNESS FOR PIPES (IN MILLIMETRES)

Hot Service Cold Service

Pipe Size
Steam Steam Condensate Chilled water
(Supply and Return)
DN, mm (315oC) (190oC) (170oC) (7oC & 14oC)
PUF CCNR
15 60 40 40 50 25
20 60 45 40 50 25
25 60 45 40 50 25
40 65 50 40 50 40
50 70 50 40 50 40
65 75 55 40 50 40
80 75 55 50 50 40
100 80 55 50 50 50
125 90 60 50 75 50
150 90 60 50 75 50
200 90 60 60 75 75
250 100 65 75 75 75
300 100 65 75 75 75
350 100 65 75 75 75
400 100 65 75 100 75
450 100 65 75 100 75
500 100 70 75 100 75
550 105 70 75 100 75
600 110 70 75 100 75

The table above indicates the required insulation thicknesses for the specific

services. However, for any other service conditions the required thickness

shall be calculated to ensure that the temperature of the outer surface of

insulation shall not exceed 10°C above maximum ambient temperature for hot

services and shall not fall below 10°C for cold services, unless otherwise

specified.

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29005-WGU-GS-001

ANNEX - 5

PIPING MATERIAL SPECIFICATION

Material specification for BFG, COG, LDG & MG

Service:

• Blast Furnace Gas - BFG

• Coke Oven Gas - COG
• Converter Gas - LDG
• Mixed Gas - MG

ITEM SIZE SPECIFICATION

DN 15-DN 40 ERW to IS:1239 (Part 1), heavy, black, bevel ends
DN 50-DN 150 ERW to IS:1239 (Part 1), medium, black, bevel ends
Mill manufactured ERW pipe to IS:3589, Fe 410, bevel
DN 200-DN 600
Pipe ends, longitudinally welded
Mill manufactured ERW pipe to IS:3589, Fe 410, bevel
DN 600-DN 1000
ends, spirally welded
Above DN 1000 Fabricated at site from plate of IS:2062, E250
DN 15-DN 50 Cold bending at site from pipe
Seamless, butt weld end elbow (1.5D) of ASTM A234
Bend DN 65-DN 250
Gr. WPB, schedule 40, as per ASME B16.9
DN 300-DN 3500 Fabricated mitered bend from pipes at site
Socket weld end tee/reducer of ASTM A105, as per
DN 15-DN 40
ASME B16.11, class 3000
Tee & Seamless, butt weld end tee/reducer of ASTM A234 Gr.
Reducer DN 50-DN 250
WPB, schedule 40, as per ASME B16.9
DN 300-DN 3500 Branch-off Connection
For connection sizes where standard reducing tees are
Branch
All Sizes not available, branch-off connections will be used from
Connection
parent pipes.
Plate flanges of IS: 2062, E250, as per IS:6392, table-5
DN 15-DN450 with bolts of ASTM A193, Gr. B7, nuts of ASTM A194
Gr. 2H & gaskets of graphite coated ceramic rope.
Slip-on
Plate flanges of IS: 2062, E250, as per standard
Flange
drawing no. 29005-000-000-UTL-0068 with bolts of
DN 500-DN 3500
ASTM A193, Gr. B7, nuts of ASTM A194 Gr. 2H &
gaskets of graphite coated ceramic rope.
Blank flanges of IS: 2062, E250, as per IS:6392, table-5
DN 15-DN450 with bolts of ASTM A193, Gr. B7, nuts of ASTM A194
Gr. 2H & gaskets of graphite coated ceramic rope.
Blank
Blank flanges of IS: 2062, E250, as per standard
Flange
drawing no. 29005-000-000-UTL-0068 with bolts of
DN500-DN3500
ASTM A193, Gr. B7, nuts of ASTM A194 Gr. 2H &
gaskets of graphite coated ceramic rope.
DN 15 to DN 250 SPW316+Graphite, 3 mm thick
Gasket Graphite coated ceramic rope diameter for sizes up to
DN 600-DN3500 DN 1000-8mm, DN 1200 to DN 1600-12mm, DN 1800-
DN 2200-16mm, and above DN 2200-20mm.
Water Seal All Sizes As per standard drawing no. 29005-000-000-UTL-0050

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29005-WGU-GS-001

ITEM SIZE SPECIFICATION

Drip Pot All Sizes As per standard drawing no. 29005-000-000-UTL-0051
Universal type butt welded end compensators as per
EJMA, latest edition of axial movement: ± 60 mm,
lateral movement: ± 5 mm, angular movement: 5
Degree, design pressure: 0.5 kscg, air jet leak test
pressure: 2 kscg, design temperature: 60 deg C, Cycle
Life: 10000 (minimum). no. of ply x ply thickness: 4 x
0.4 (minimum), two telescopic inner sleeve of SS 304,
MS end pipe thickness: 10mm, SS 304 Middle Pipe
Compensator DN1000-DN3500 Thickness: 5 mm, bellows & center pipe of SS 304,
collar: SS 304, bracket & shipping bracket: MS, IS 2062,
E250, limit rod: MS to IS: 1367 CL 4.6, bolts as per
ASTM A193, Gr B7 & & nuts as per ASTM A194 Gr. 2H,
20 mm diameter graphite coated ceramic rope of 30M
length to be provided. long seam weld 100%
radiography, all weld joints will be as per Section-IX &
will be DP tested, flow is bi-directional, SS 304 stopper
on inner sleeve to provide
Cast Steel Plug valve to API 599, screwed ends with
DN 15 - DN 50
operating wrench with pad lock arrangement.
Class#150 Cast steel, PTFE sleeved plug valve, flanged
ends with companion flanges, bolts, nuts, non-asbestos
DN 65 - DN 300 gaskets & operating wrench (DN65-DN80)/gear unit
(DN100 to DN300). Companion flanges will be as per
ASME B16.5, Class#150 with pad lock arrangement.
Manual, heavy duty worm gear actuator with hand
wheel, double flanged fabricated butterfly valve as per
AWWA C504/AWWA C516, PN 6, Body of IS: 2062 Gr.
E250, Disc of IS: 2062 Gr. E250, Shaft of SS A276 Type
Isolation
410, Seat Ring of SS 316, Seat of Viton, Leakage
Valve DN 350-DN 3500
Class: VI, Flanged as per PN 6, SORF companion
flange of IS 2062 Gr. E250 (30 mm thick), bolts of
ASTM A193, Gr B7, nuts of ASTM A194 Gr. 2H, 30M
length graphite coated ceramic rope (diameter as per
spec) with lifting lug and MS bottom cover.

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Material specification for CA, IA, LPNT, PR

Service:
• Compressed Air - CA
• Instrument Air - IA
• Low Pressure Nitrogen - LPNT
• Propane - PR

ITEM SIZE SPECIFICATION

DN 15-DN 40 ERW to IS:1239 (Part 1), heavy, black, bevel ends

Pipe DN 50-DN 150 ERW to IS:1239 (Part 1), medium, black, bevel ends
Mill manufactured ERW pipe to IS:3589, Fe 410, bevel
DN 200-DN 600
ends, longitudinally welded
DN 15-DN 50 Cold bending at site from pipe
Seamless, butt weld end elbow (1.5D) of ASTM A234 Gr.
Bend DN 65-DN 300
WPB, schedule 40, as per ASME B16.9
DN 350-DN 600 Fabricated mitered bend from pipes to 1.5D radius
Socket weld end reducer of ASTM A105, as per ASME
DN 15-DN 40
B16.11, class 3000
Reducer
Seamless, butt weld end reducer of ASTM A234 Gr. WPB,
DN 50-DN 600
schedule 40, as per ASME B16.9
Socket weld end tee of ASTM A105, as per ASME B16.11,
DN 15-DN 40
Tee class 3000
DN 50-DN 600 Branch connections to be made from parent pipe
Class 800, full bore long pattern, two piece bolted design,
floating, ball valve of design standard BS EN ISO 17292,
DN 15 to DN 40 body of ASTM A 105, ball & stem SS316, seat & seal of
PTFE, SW end to ASME B16.11 with hand lever and pad
lock arrangement
Class 150, full bore, long pattern, two piece bolted design,
floating (DN 50 to DN 200)/ trunnion mounted (DN 250 to
Isolation
DN 600) ball valve of design standard API 6D, body of
Valve
ASTM A216 Gr. WCB, ball & stem of SS316, seat and seal
of PTFE, raised face flanged ends with SORF companion
DN 50-DN 600
flanges of ASTM A105, as per ASME B16.5 class 150,
bolts of ASTM A193, Gr B7, nuts of ASTM A194 Gr. 2H &
gaskets of 3mm thick SPW316+Graphite with hand-lever
(from DN 50 to DN 100)/manual gear actuator (from DN
150 to DN 600) with pad lock arrangement
SORF flanges of ASTM A105, as per ASME B16.5 class
Slip-on
DN 50-DN 600 150, bolts of ASTM A193, Gr. B7, nuts of ASTM A194 Gr.
Flange
2H & gaskets of 3mm thick SPW316+Graphite
Blank flanges of ASTM A105, as per ASME B16.5 class
Blank flange DN 50-DN 600 150, bolts of ASTM A193, Gr. B7, nuts of ASTM A194 Gr.
2H & gaskets of 3mm thick SPW316+Graphite
Ball float type trap with body of cast steel to ASTM A216
Trap (for
All Sizes Gr. WCB with SS 304 internals & drain cock, socket weld
CA)
ends to ASME B16.11, class 3000
Y type strainers with body of cast steel to ASTM A216 Gr.
Strainer All Sizes WCB and SS304 screen, socket weld ends to ASME
B16.11, class 3000
Socket weld end cap of ASTM A105 as per ASME B16.11,
Cap DN 15 to 50
class 3000

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29005-WGU-GS-001

Material specification for HPOX, MPOX, LPOX

Service:
• High Pressure Oxygen - HPOX
• Medium Pressure Oxygen - MPOX
• Low Pressure Oxygen - LPOX

ITEM SIZE SPECIFICATION

Seamless to ASTM A106 Gr. B dimension as per ASME
DN 15-DN 50
B36.10, schedule 80, bevel ends
Pipe
Seamless to ASTM A106 Gr. B dimension as per ASME
DN 65-DN 600
B36.10, schedule 40, bevel ends
Fabricated from pipes by hot bending to 5 DN radius
(from seamless pipe to ASTM A106 Gr B, schedule 40
Bend DN 15-DN 600
for sizes DN 65 and above & schedule 80 for DN 50 &
below)
Class 300 non-ferrous (BS 1400 HTB1) flanged
tee/reducer as per ASME B16.24 alongwith WNRF
companion flanges to ASTM A105 as per ASME B16.5
class 300, bolts of ASTM A193, Gr. B8M, nuts of ASTM
Tee &
All Sizes A194 Gr. 8M & gaskets of 3mm thick SPW Monel+PTFE
Reducer
compatible to oxygen service of design pressure 42
kscg. Hydraulic & pneumatic body test pressure will be
63 kscg & 46 kscg respectively with 100% casting
radiography.
Class 300, full bore, long pattern, two piece, bolted
design, floating (DN 15 to DN 150)/ trunnion mounted
(DN 200 to DN 600) ball valve of design standard ASME
B16.34, fire safe as per API 607, body and solid ball of
Monel as per ASTM A494, Gr. M35-1, Monel internals,
seat & seal of PTFE, raised face flanged end as per
ASME B16.5 class 300 with WNRF companion flanges
Isolation
DN 15 - DN 600 to ASTM A105 as per ASME B16.5 class 300, bolts of
Valves
ASTM A193, Gr. B8M, nuts of ASTM A194 Gr. 8M &
gaskets of 3mm thick SPW Monel+PTFE with hand lever
(from DN15 to DN 40)/manual gear actuator (from DN
50 and above) Design & manufacturing standard: API
6D, Testing standard: API 598, Leakage class: Table-6,
face to face dimension as per ASME B16.10, with pad
lock arrangement
WNRF flanges of ASTM A105, as per ASME B16.5 class
Slip-on
All Sizes 300, bolts of ASTM A193, Gr. B8M, nuts of ASTM A194
Flange
Gr. 8M & gaskets of 3mm thick SPW Monel + PTFE
Blind flanges of ASTM A105, as per ASME B16.5 class
Blank flange All Sizes 300, bolts of ASTM A193, Gr. B8M, nuts of ASTM A194
Gr. 8M & gaskets of 3mm thick SPW Monel + PTFE
Gaskets All Sizes SPW Monel + PTFE
Half Socket welded end half coupling of ASTM A105 as per
DN 15 to DN 100
Coupling ASME B16.11, class 3000

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29005-WGU-GS-001

Material specification for MPNT, AR

Service:
• Medium Pressure Nitrogen - MPNT
• Argon - AR

ITEM SIZE SPECIFICATION

Seamless to ASTM A106 Gr. B dimension as per ASME
DN 15-DN 50
B36.10, schedule 80, bevel ends
Pipe
Seamless to ASTM A106 Gr. B dimension as per ASME
DN 65-DN 600
B36.10, schedule 40, bevel ends
DN 15-DN 50 Cold bending at site from pipe
Bend Seamless, butt weld end elbow (1.5D) of ASTM A234 Gr.
DN 65-DN 600
WPB, schedule 40, as per ASME B16.9
Socket weld end tee/reducer of ASTM A105, as per ASME
DN 15-DN 40
Tee & B16.11, class 3000
Reducer Seamless, butt weld end tee/reducer of ASTM A234 Gr.
DN 50-DN 600
WPB, schedule 40, as per ASME B16.9
Class 800, full bore, long pattern, two piece bolted design,
floating, ball valve of design standard BS EN ISO 17292,
DN 15-DN 40 body of ASTM A 105, ball & stem SS316, seat & seal of
PTFE, SW end to ASME B 16.11 with hand lever and pad
lock arrangement.
Class 300, full bore, long pattern, two piece bolted design,
floating (DN 50 to DN 200)/trunnion mounted (DN 250 to
Isolation
DN 600) ball valve of design standard API 6D, body of
Valve
ASTM A216 Gr. WCB, ball & stem of SS316, seat and seal
of PTFE, raised face flanged ends with companion flanges
DN 50 & above
as per ASME B16.5 class 300, bolts of ASTM A193, Gr.
B7, nuts of ASTM A194 Gr. 2H & gaskets of 3mm thick
SPW316+Graphite with hand-lever (from DN 50 to DN
100)/ manual gear actuator (from DN 150 to DN 600) with
pad lock arrangement.
WNRF flanges of ASTM A105, as per ASME B16.5 class
Slip-on
DN 15-DN 600 300, with bolts of ASTM A193, Gr. B7, nuts of ASTM A194
Flange
Gr. 2H & gaskets of 3mm thick SPW316+Graphite
Blank flanges of ASTM A105, as per ASME B16.5 class
Blank
DN 15-DN 600 300, with bolts of ASTM A193, Gr. B7, nuts of ASTM A194
Flange
Gr. 2H & gaskets of 3mm thick SPW316+Graphite
Gaskets All Sizes SPW316+Graphite
Half Socket welded end half coupling of ASTM A105 as per
DN 15-DN 100
Coupling ASME B16.11, class 3000
Socket welded end cap of ASTM A105 as per ASME
Cap DN 15 to 50
B16.11, class 3000

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29005-WGU-GS-001

Material specification for MPST & LPST

Service:
• Medium Pressure Steam - MPST
• Low Pressure Steam - LPST

ITEM SIZE SPECIFICATION

Seamless to ASTM A106 Gr. B dimension as per ASME
DN 15-DN 50
B36.10, schedule 80, bevel ends, IBR
Pipe
Seamless to ASTM A106 Gr. B dimension as per ASME
DN 65-DN 600
B36.10, schedule 40, bevel ends, IBR
DN 15-DN 50 Socket weld end elbow of ASTM A105, as per ASME
B16.11, class 3000, IBR
Bend
Seamless, butt weld end elbow (1.5D) of ASTM A234
DN 65 –DN 600
Gr. WPB, schedule 40, as per ASME B16.9, IBR
Socket weld end tee/reducer of ASTM A105, as per
DN 15-DN 40
Tee & ASME B16.11, class 3000, IBR
Reducer Seamless, butt weld end tee/reducer of ASTM A234 Gr.
DN 50-DN 600
WPB, schedule 40, as per ASME B16.9, IBR
Class 800 forged steel gate valve, body, bonnet to
ASTM A 105 and trim material to ASTM A 182 Gr. F6,
DN 15 - DN 40 bolted bonnet, outside screwed and yoke, rising stem,
socket welded ends to ASME B16.11 with pad lock
arrangement, IBR
Class 300 cast steel gate valve, body and bonnet
material to ASTM A 216, Gr WCB, trim material to
Isolation
ASTM A 182 Gr F6, bolted bonnet, outside screwed and
Valve
yoke, rising stem, flanged ends to ASME B16.5, class
300 with pad lock arrangement. Valves shall be supplied
DN 50 to DN 600
with WNRF companion flanges to ASTM A105 as per
ASME B16.5 class 300 with bolts of ASTM A193, Gr.
B7, nuts of ASTM A194 Gr. 2H & gaskets of 3mm thick
SPW316+graphite. Gate valves of size DN300 and
above shall be manual bevel gear operated, IBR
Flanges made from carbon steel plates to IS:2002 Gr.
Slip-on
All Sizes 2A & dimensions to table H of Appendix E of IBR, along
Flange
with bolts, nuts & gaskets (SPW316 + Graphite)
Flanges made from carbon steel plates to IS:2002 Gr.
Blank flange All Sizes
2A & dimensions to table H of Appendix E of IBR
DN 15 thermodynamic trap with body of ASTM A105,
DN 15-DN 200 with SS internals & integral SS strainer, socket weld
ends with cap cover, IBR
Trap
DN 25 thermodynamic trap with body of ASTM A105,
DN 250-DN 600 with SS internals & integral SS strainer, socket weld
ends with cap cover, IBR
Gasket All Sizes SPW3316+graphite
Nut & Bolt All Sizes Bolt ASTM A193, Gr. B7, Nut ASTM A194 Gr. 2H, IBR
Socket welded end cap of ASTM A105 as per ASME
DN 15 to 50
B16.11, class 3000
Caps
Butt welded end cap of ASTM A105 as per ASME
DN 65 to DN 600
B16.9, class 300, IBR
Half Socket welded end half coupling of ASTM A105 as per
DN15 & 25
Coupling ASME B16.11, class 3000, IBR

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29005-WGU-GS-001

Material Specification for CD

Service:
• Steam Condensate - CD

ITEM SIZE SPECIFICATION

Seamless to ASTM A106 Gr. B dimension as per ASME
DN 15-DN 50
B36.10, schedule 80, bevel ends
Pipe
Seamless to ASTM A106 Gr. B dimension as per ASME
DN 65-DN 600
B36.10, schedule 40, bevel ends
DN 15-DN 50 Socket weld end elbow of ASTM A105, as per ASME
B16.11, class 3000
Bend
Seamless, butt weld end elbow (1.5D) of ASTM A234
DN 65 –DN 600
Gr. WPB, schedule 40, as per ASME B16.9
Socket weld end tee/reducer of ASTM A105, as per
DN 15-DN 40
Tee & ASME B16.11, class 3000
Reducer Seamless, butt weld end tee/reducer of ASTM A234 Gr.
DN 50-DN 600
WPB, schedule 40, as per ASME B16.9
Class 800 forged steel gate valve, body, bonnet to
ASTM A 105 and trim material to ASTM A 182 Gr. F6,
DN 15 - DN 40 bolted bonnet, outside screwed and yoke, rising stem,
socket welded ends to ASME B16.11 with pad lock
arrangement
Class 300 cast steel gate valve, body and bonnet
material to ASTM A 216, Gr WCB, trim material to
Isolation
ASTM A 182 Gr F6, bolted bonnet, outside screwed and
Valve
yoke, rising stem, flanged ends to ASME B16.5, class
300 with pad lock arrangement. Valves shall be supplied
DN 50 to DN 600
with WNRF companion flanges to ASTM A105 as per
ASME B16.5 class 300 with bolts of ASTM A193, Gr.
B7, nuts of ASTM A194 Gr. 2H & gaskets of 3mm thick
SPW316+graphite. Gate valves of size DN300 and
above shall be manual bevel gear operated
WNRF flanges of ASTM A105, as per ASME B16.5 class
Slip-on
DN 15-DN 600 300, with bolts of ASTM A193, Gr. B7, nuts of ASTM
Flange
A194 Gr. 2H & gaskets of 3mm thick SPW316+Graphite
Blank flanges of ASTM A105, as per ASME B16.5 class
Blank flange DN 15-DN 600 300, with bolts of ASTM A193, Gr. B7, nuts of ASTM
A194 Gr. 2H & gaskets of 3mm thick SPW316+Graphite
Gasket All Sizes SPW3316+graphite
Nut & Bolt All Sizes Bolt ASTM A193, Gr. B7, Nut ASTM A194 Gr. 2H
Socket welded end cap of ASTM A105 as per ASME
DN 15 to 50
B16.11, class 3000
Caps
Butt welded end cap of ASTM A105 as per ASME
DN 65 to DN 600
B16.9, class 300
Half Socket welded end half coupling of ASTM A105 as per
DN15 & 25
Coupling ASME B16.11, class 3000

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 29005-WGU-GS-001

Material Specification for CHW (S&R)

Service:
• Chilled Water (Supply) - CHW (S)
• Chilled Water (Return) - CHW (R)

ITEM SIZE SPECIFICATION

Pipe DN 15-DN 40 ERW to IS:1239 (Part 1), heavy, black, bevel ends
DN 50-DN 150 ERW to IS:1239 (Part 1), medium, black, bevel ends
Mill manufactured ERW pipe to IS:3589, Fe 410, bevel
DN 200-DN 600
ends, longitudinally welded
DN 15-DN 50 Cold bending at site from pipe
Bend Seamless, butt weld end elbow (1.5D) of ASTM A234 Gr.
DN 65-DN 300
WPB, schedule 40, as per ASME B16.9
DN 350-DN 600 Fabricated mitered bend from pipes to 1.5D radius
Socket weld end reducer of ASTM A105, as per ASME
DN 15-DN 40
B16.11, class 3000
Reducer
Seamless, butt weld end reducer of ASTM A234 Gr. WPB,
DN 50-DN 600
schedule 40, as per ASME B16.9
Socket weld end tee of ASTM A105, as per ASME B16.11,
DN 15-DN 40
Tee class 3000
DN 50-DN 600 Branch connection to be made from parent pipe
Slip-on SORF flanges of ASTM A105, as per ASME B16.5 class
Flange DN 50-DN 600 150, bolts of ASTM A193, Gr. B7, nuts of ASTM A194 Gr.
2H & gaskets of 3mm thick bonded synthetic fiber
Blank flanges of ASTM A105, as per ASME B16.5 class
Blank flange DN 50-DN 600 150, bolts of ASTM A193, Gr. B7, nuts of ASTM A194 Gr.
2H & gaskets of 3mm thick bonded synthetic fiber
Gasket All Sizes Bonded synthetic fiber, 3mm thickness
Class 800 forged steel gate valve, solid wedge type,
DN 40 & below outside screw and yoke with rising stem, body material to
Isolation
ASTM A105, SS trim, socket welded ends.
valve
Class 150, cast steel gate valves as per API 600 with
ASTM A216 Gr. WCB body, 13% Cr. facing on WCB
wedge, SS410 rising spindle, flanged ends with
companion flanges as per ASME B16.5 class 150, along
DN 50 and above
with bolts of ASTM A193, Gr. B7, nuts of ASTM A194 Gr.
2H & gaskets of 3 mm thickness bonded synthetic fiber,
with pad lock arrangement. Gate valves of size DN300
and above shall be manual bevel gear operated.

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