Polysilicom MFG Facility RIL Jamnagar Project

Material Requisition MR Cover Sheet
Project Details
Customer Name Reliance Industries Limited Requisition No. MT-J22N01-D1JEP-MEA001-WIPL-Q-00
Project Title Polysilicon Manufacturing Facility Requisition Title Material Requisition for Air Cooled Heat Exchanger
Jobsite Location Jamnagar, Gujarat Revision No. 01

Project No. (RIL / WORLEY) JN3102 / -
Section Section Title Notes

I Scope of Supply
II Technical Requirements for Scope of Supply
IIa Project Specification Not Applicable
III SDRL (Supplier Data Requirements List) Master
IIIa SDRL Definitions Refer Buyer Specification "RPMS-ENGG-PRA-GE-041"
Requisition Revision History and Approvals

Requisition
Revision Issue Date Signoff By Name Signature Date
Originator Ganesh Salunkhe 23-Dec-22

Checker Sachin Borse 23-Dec-22
IFQ - Issued
Discipline Lead Umesh V Poojary 23-Dec-22
00 for 23-Dec-22
Quotation SQS Coordinator
Project Approval Nishu Simlote 23-Dec-22
Customer (Optional)
Originator Omesh Shah 5-Jan-23
IFQ - Checker Sachin Borse 5-Jan-23

Re-Issued Discipline Lead Umesh V Poojary 5-Jan-23
01 5-Jan-23
for
SQS Coordinator
Quotation
Project Approval Nishu Simlote 5-Jan-23
Customer (Optional)
Professional / Chartered Certification Stamps (Use this section where required by Project; delete if not required)
Material Requisition MR Sect. I
Project Details
Project No. (RIL/WORLEY) JN3102 / -
Previous Revision Criticality Inspection Requisition

Item No. Commodity / Tag Description Total Quantity Units Inspection Level Special Inspection Requirements Delivery Site
Quantity Quantity Rating Required Revision
Supplier’s Scope for the Air cooled heat Exchanger shall include , as a minimum but not limited to, the following items
and services:
Supplier shall supply the following equipment and/or materials along with all the accessories as per attached
9 for Train-1 &
1 - datasheets, specifications and all other attachments with this Requisition. Supplier’s scope shall also include, thermal, N/A N/A Lots
9 for Train-2
structural & mechanical design, engineering, materials, Manufacturing, Painting, Inspection, Testing, Preservation,
Packing & Forwarding and Documentation
Any additional items required shall be proposed by Supplier in the bid with technical reason.
ME-EPE255-A032002 TCS Heavy Impurity Column #2 Condenser N/A N/A 1 No. 2 Yes 2 Jamnagar, Gujarat
ME-EPE255-A070002 CVD OGR TCS/STC Column Condenser N/A N/A 1 No. 1 Yes 1 Jamnagar, Gujarat
ME-EPE255-A070008 CVD OGR STC Air Cooler N/A N/A 1 No. 1 Yes 1 Jamnagar, Gujarat
ME-EPE255-A022001 Hot Cooling Water Flash Condenser N/A N/A 1 No. 3 Yes 3 Jamnagar, Gujarat
2a ME-EPE255-A022002 Low Pressure Condensate Vent Condenser N/A N/A 1 No. 3 Yes 3 Refer Licensor Inspection and Test Plan (Later) Jamnagar, Gujarat
ME-EPE255-A317102
Effluent Condenser N/A N/A 2 No. 2 Yes 2 Jamnagar, Gujarat
ME-EPE255-A317202
ME-EPE255-A320002 Crude TCS Column Condenser N/A N/A 1 No. 2 Yes 2 Jamnagar, Gujarat
ME-EPE255-A330002 STC Purification Column Condenser N/A N/A 1 No. 3 Yes 3 Jamnagar, Gujarat
ME-EPE260-A032002 TCS Heavy Impurity Column #2 Condenser N/A N/A 1 No. 2 Yes 2 Jamnagar, Gujarat
ME-EPE260-A070002 CVD OGR TCS/STC Column Condenser N/A N/A 1 No. 1 Yes 1 Jamnagar, Gujarat
ME-EPE260-A070008 CVD OGR STC Air Cooler N/A N/A 1 No. 1 Yes 1 Jamnagar, Gujarat
2b ME-EPE260-A022001 Hot Cooling Water Flash Condenser N/A N/A 1 No. 3 Yes 3 Jamnagar, Gujarat
ME-EPE260-A022002 Low Pressure Condensate Vent Condenser N/A N/A 1 No. 3 Yes 3 Refer Licensor Inspection and Test Plan (Later) Jamnagar, Gujarat
ME-EPE260-A317102
Effluent Condenser N/A N/A 2 No. 2 Yes 2 Jamnagar, Gujarat
ME-EPE260-A317202
ME-EPE260-A320002 Crude TCS Column Condenser N/A N/A 1 No. 2 Yes 2 Jamnagar, Gujarat
ME-EPE260-A330002 STC Purification Column Condenser N/A N/A 1 No. 3 Yes 3 Jamnagar, Gujarat
2c ME-EPE265-A601502A/B BCW Air Cooler N/A N/A 2 No. 3 Yes 3 Refer Licensor Inspection and Test Plan (Later) Jamnagar, Gujarat
3 Refer "Annexure-1 Scope of Work & Supply" which forms the part of this Requisition N/A N/A 9+9+2 No.
Guarantee for Thermal, Mechanical & structural design, material and workmanship. Fan blades for all items shall be
interchangeable as much as is possible.
4 - N/A N/A 9+9+2 Lots
Mechanical design shall be done by using latest version of PV-Elite software. Thermal design shall be submitted in
latest HTRI software & structural design in STAAD PRO software
Detailed mechanical design of the equipment, attachments and accessories including FEA (if applicable) as indicated
5 - N/A N/A 9+9+2 Lots
in this MR.
Fabrication and welding of tube bundle assembly, bundle frame, external attachments such as equipment support
6 - structure, platform & ladder, name plate and its bracket, lifting trunnions, grounding lugs (min. 2 nos.), insulation N/A N/A 9+9+2 Lots
cleats,Fireproofing cleats etc.
7 - Tube bundle complete in all respects with tubes, tube sheet, baffles, support plate, tie rods, spacers, sealing strips, etc. N/A N/A 9+9+2 Lots
Local load analysis of nozzles, lifting lugs and attachments (as applicable). For nozzle load analysis, if actual loads are
increasing, same will be intimated to Supplier during progress of engineering. If required, Supplier shall carry out FEA
8 - N/A N/A 9+9+2 Lots
and comply with the given actual loads or provide maximum loads / moments it can withstand based on nozzle /
junction geometry provided by Supplier. Any commercial impact is not acceptable for meeting the actual nozzle loads.
Vent, Drain & MP connection nozzles with blind flanges to be provided for each air cooler tube bundle.
9 - Inlet and outlet process nozzles on the shell side and tube side shall be provided with minimum 40 mm (1½”) NPS N/A N/A 9+9+2 Lots
Rating Class 300 multi-purpose connections complete with blind flange, gasket and bolting.
10 - Wind and Seismic design parameters shall be as per Design Basis RPMS-ENGG-DBD-MS-001. N/A N/A 9+9+2 Lots
Winterization Steam coil shall be designed, constructed and registered as per IBR in addition to design code
11 - N/A N/A 9+9+2 Lots
mentioned in Datasheet/Project specification.
All the rotating / moving parts of the equipment shall be provided with the protective guard (e.g. Coupling guard, Belt
12 - N/A N/A 9+9+2 Lots
guard etc.), of non-sparking material.
The noise level shall be limited to 85 dB(A) max. measured at a distance of one meter from the bundle at the header
13 - access platform walkways and one meter from the bay limit on motor maintenance platform. The noise level within N/A N/A 9+9+2 Lots
the air cooler bay shall be 90 dB(A) maximum, at locations defined as per API.
VENDOR shall consider below mentioned nozzle load for AFC support structure design and to evaluate the nozzle to
14 - header box junction. N/A N/A 9+9+2 Lots
- 3 x API 661 – For 150# and 300# rating
VENDOR to consider condition of structure supply in knock down condition in base quote of the offer. VENDOR to trial
15 - N/A N/A 9+9+2 Lots
fit up the structure at shop & provide match marking on parts
Project Details
If supply of air cooler in module is feasible as per above clause, VENDOR to clarify the procedure for handling /
16 - N/A N/A 9+9+2 Lots
erection of air cooler module. Post Order a detailed procedure to be submitted for handling of air cooler module.
VENDOR shall perform trial assembly of air cooler along with fan and drive unit. Dry run test of air cooler shall be
conducted at VENDOR’s works with full height support structure. Fan run in, noise level, vibration & air flow shall be
17 - checked and rectified. Minimum 1 bay per equipment is required to be checked for all these parameters. Selection of N/A N/A 9+9+2 Lots
bay for trial run test will be decided by Purchaser / PMC / Owner. VENDOR shall arrange all necessary accessories
required to demonstrate run test.
18 - VENDOR to conduct dry run test of air cooler to ensure successful working of electrical and instrument system also N/A N/A 9+9+2 Lots
Fire water sprinkler line are required for all air coolers (except for ME-EPE255-A022001, ME-EPE255-A022002, ME-
EPE260-A022001, ME-EPE260-A022002 ). Fire water line shall be supported from air cooler structure. Actual loading
19 - N/A N/A 7+7 Lots
will be furnished during detail engineering. However VENDOR to consider min. 70 kg/m2 of load on air cooler
structure due to fire water line pipes and its supporting structure. VENDOR to design air cooler structure adequately.
VENDOR to provide a min. 300 mm extension of main columns of the air cooler support, with top end plates having
20 - N/A N/A 7+7 Lots
holes for bolting to support fire water sprinkler line support structure.
Fire proofing is required for all Air coolers. Fire proofing will be by others, however necessary fire proofing cleats
21 - welded to support structure (main columns, bracings, main beams and motor suspension beams) shall be supplied by N/A N/A 9+9+2 Lots
Air Cooler VENDOR.
For air coolers having operating temperature upto 200 deg C, personnel protection using perforated guard to be
provided by the VENDOR. For above 200 deg C, personnel protection by insulation is applicable. VENDOR to provide
22 - N/A N/A 9+9+2 Lots
suitable insulation support cleats welded to the header boxes only. Insulation material supply and application by
others.
23 - All air coolers shall have walkways with minimum clear width of 900 mm. N/A N/A 9+9+2 Lots
Terminal box for motor shall be rotatable in steps of 90 degree in three position (not facing the driving end) & exact
24 - location will be commented by purchaser during vendor drawing approval. Spreader box with terminal box shall also N/A N/A 9+9+2 Lots
be considered depending on the size of the cable as per comments during detailed engineering.
25 - Separate terminal boxes for power, space heaters and thermistors shall be provided on motor by VENDOR. N/A N/A 9+9+2 Lots
VENDOR to consider following loading for air cooler structure design due to cable trays (electrical & instrumentation) :
26 - Cable tray width 750 mm, Load 120 kg per meter N/A N/A 9+9+2 Lots
Cable tray width 300 mm, Load 75 kg per meter
First fill of lubricants for moving parts shall be by VENDOR. VENDOR to also specify the lubricant type, grade,
27 - N/A N/A 9+9+2 Lots
lubrication schedule with volume.
Test flanges and test rings wherever applicable (Shall be supplied loose along with equipment with proper
28 - N/A N/A 9+9+2 Lots
marking/identification).
29 - Design of Setting bolts (i.e. size and quantity) N/A N/A 9+9+2 Lots
30 - All NDE as indicated in the Specifications/Requisition N/A N/A 9+9+2 Lots
Inspection and testing at Supplier’s workshop as per approved inspection and test plan, approved drawings,
31 - N/A N/A 9+9+2 Lots
specification and requirements of this requisition.
32 Mock-up test for tube to tubesheet joint (if required) N/A N/A 9+9+2 Lots
Material Certification of all pressure/process contact parts shall be as per EN 10204 / ISO 10474 type 3.1 and all non-
33 - N/A N/A 9+9+2 Lots
pressure parts shall be as per EN 10204 / ISO 10474 type 2.2
Positive Material Identification (PMI) for all Stainless Steel / Alloy / Non Ferrous metal and welds in accordance with
34 - N/A N/A 9+9+2 Lots
RPMS-ENGG-SPC-PP-018.
35 - Surface Preparation and Painting as per Paint Specification RPMS-ENGG-SPC-PP-014. N/A N/A 9+9+2 Lots
Packing (Nitrogen blanketing at min 0.3 kg/cm2 (g) for tube side during shipment including Nitrogen cylinder, 2
36 - pressure indicators and 2 needle valves) forwarding, insurance and transportation as per commercial terms & N/A N/A 9+9+2 Lots
conditions
Supplier to recommend Erection and Commissioning spare parts. As a minimum, the following spares shall be
considered for each gasket joints.
• Gasket 200 % spare for each installed gaskets
• Fasteners:10% studs, nuts and washers but not less than four sets of each type
• Gaskets for plugs – 100%
• Plugs and bolting – 10% (of each type)
37 - N/A N/A 9+9+2 Lots
• HTD belt and bearing- 100%
• One set of diaphragm actuator.
• One blade for each size and type of fan
• Spare fan and spare motors as per Supplier’s recommendations.
• Electrical spares as per Supplier’s recommendations.
• Instrumentation spare as per Supplier’s recommendations.
Project Details
38 - Transportation of Equipment to Delivery Site including steel transportation saddles N/A N/A 9+9+2 Lots
39 - Attendance to KOM & Technical review meetings N/A N/A 9+9+2 Lots
Submission of documents for review and final certified documents in requisite numbers as per Supplier Data
40 - N/A N/A 9+9+2 Lots
Requirement List
All activities not specifically mentioned but required to complete the equipment in all respects as per drawings,
41 - N/A N/A 9+9+2 Lots
Licensor’s specifications, codes, Standards and instructions of Buyer / Contractor.
42 - Supplier to recommend spares for 2 years normal operation - Separate quote N/A N/A 9+9+2 Lots
43 - Supplier to recommend Special tools and tackles, if any (Item wise separate quote) . N/A N/A 9+9+2 Lots
Exclusions:
• Equipment unloading, erection / installation and commissioning at job site
44 - • Supply of Settings Bolts. However,Settings bolt design is by Supplier. N/A N/A - -
• Insulation and Fireproofing.
• Foundation
Exceptions and Deviations:

• Supplier's exceptions and deviations from this Requisition and/or the documents / drawings referred hereto shall be
clearly stated in the proposal using the attachment (Section IV: Confirmation of Compliance) and subject to Buyer's
approval. Any exceptions or deviations stated anywhere in the Supplier's proposal other than the items declared with
45 - N/A N/A - -
the list shall not be accepted.
• Even if there is no deviation / exception, Supplier shall also submit the deviation / exception list declaring Supplier’s
full compliance.
• Supplier's newly proposed exceptions and/or deviations after placing the Purchase Order shall not be accepted.
Project Details
Notes Relating to Scope of Supply:

The order of precedence for all documents listed herein shall be as follows:
- Local Statutory and Regulatory requirements
- Data Sheets and Drawings
- Material Requisition
- Standard Specifications
1 - Latest Codes and Standards specifically referred.
- Other National and International Standards as Referenced
However, if any conflict generated within the Material Requisition documents shall be referred to Buyer/Contractor for resolution.
The equipment shall comply with Local Codes and Regulations at the installation site.
If national and/or local regulation exist in which some of the requirements are more stringent, Supplier shall inform the Buyer/Contractor of any deviation from the requirement of this document which is considered to be necessary in order to comply with national and/or local regulations. In general, stringent requirement will
govern.
Terminology:
Buyer: Means Reliance Industries Limited or specified Reliance Group Company
Contractor: Means Detail Engineering Contractor (Worley Engineering India Pvt. Ltd).
2
Supplier: Means the party which manufactures and/or supplies equipment, technical documents/drawings, and services to perform the duties specified by Buyer or by Contractor.
Shall: Means that the requirement is to be understood as mandatory.
Should: Means that the requirement is to be understood as strongly recommended or advised
3 Supplier shall supply as a minimum each item listed in this Requisition. Supplier shall indicate “YES” against each supplied item. Supplier can add additional items, if deemed necessary and highlight the same in the bid.
4 It's the Supplier’s responsibility to check and ensure that all the documents mentioned in this Material Requisition have been received by them. Upon receipt of the Material Requisition, in case any document is missing / not received by Supplier, same shall be communicated to the Contractor immediately.
5 Any accessories required to make the equipment complete, safe and consistent with good engineering practice shall be provided by the Supplier at no extra cost and is deemed to have been specified.
6 Deficiencies in design, workmanship, or materials shall be repaired or replaced at no cost to Contractor. Repairs, in lieu of replacement, shall be subject to the Contractor’s approval.
7 Compliance by the Supplier with the provisions of this requisition and its attachments does not relieve the Supplier of any responsibility to furnish equipment and accessories of proper design, fit for the specific purpose and service conditions and in accordance with the local codes governing health and safety.
8 Mechanical design of exchangers shall be as per latest editions of ASME Section VIII, Division 1 and API 661 as Indicated unless otherwise specified.
9 All pressure parts not covered by ASME or WRC code for local loads shall be justified by Finite Element Analysis (FEA).
10 For pressure part thickness calculation, higher allowable stress as per Note G5 to Table 1B of ASME Section II, Part D shall be considered.
11 Finite element analysis shall be performed using established FEA software for nozzles outside of WRC 107/297 limits.
12 Nozzle projection shall be provided such that there is sufficient clearanace between the back of nozzle flange & insulation cladding and the bolts can be removed & installed from vessel side.
13 All nozzles, and all internal and external attachments shall clear longitudinal and circumferential welds of head and shell by minimum 50 mm clear distance.
14 All tube to tube sheet welding shall meet the requirements specified in RPMS-ENGG-SPC-MT-006.
15 Test water quality shall be potable quality with chloride content less than 250ppm.
16 Equipment shall be hydrostatically tested in the fabricator’s shop as per design code. Unless otherwise specified in applicable design code, allowable stress during hydro test in tension shall not exceed 90% of yield point.
17 Hydrotest gasket specification shall be same as service gaskets.
18 Supplier shall provide shop hydrotest and field hydrotest pressure on GA drawing calculated based on MAP and MAWP respectively.
19 Hydraulic bolt tensioners shall be considered for bolt sizes 1-1/2” & above on girth flanges. Bolt spacing and length of bolt shall be adequate for introducing tensioning tool.
Lifting Trunnion shall be designed for twice the weight of the components to be lifted including insulation and other external attachments as applicable. Anchoring arrangement shall be provided in Plenum chamber for lifting of motor and shaft assembly. All lifting lugs/Lifting beams should be marked with proper warning signs
20
for designed load.
21 Equipment shall be thoroughly drained, dried, and purged with nitrogen before shipment.
22 The Supplier shall provide the documents on schedule as given in “Supplier Data Requirement List” (SDRL).
23 Each drawing or document shall be provided with the title block indicating Document Title, equipment Name and Tag No, Project Title, Contractor’s information and Document No. as per project standard on the templates provided by the Buyer/Contractor.
24 All Supplier Data and Drawings shall be in the ‘English’ Language and in M.K.S. system of units.
25 Supplier shall identify changes, if any, with clouding / revision marks on the content of the document. All Sub-Supplier’s documents/drawings shall be reviewed and approved by Supplier before issue to the Contractor. Revised documents without proper revision marks/clouds will not be reviewed by Contractor.
Inspection shall be as per code and specifications; Inspection and Test Plan provided along with this Requisition is to specify the minimum inspection requirements and intervention points for the Buyer Inspector (or their appointed representative) for the Equipment. However, after Order, Supplier shall submit “Inspection and
26 Test Plan” for Contractor’s approval including the details of quality check / testing carried out with their acceptance criteria. This shall be reviewed & subject to approval by the Contractor prior to start of inspection activities at the Supplier’s / sub-Supplier’s shop. Contractor or his representative reserves the right to make
inspection visits to Supplier and sub-Supplier’s facilities.
27 Buyer may arrange its own Third Party Inspection (TPI) or may request Supplier to arrange TPI at various stages as per Inspection & Test plan. Supplier / Sub- Supplier’s shall notify Buyer or its Designated Representative and the assigned Inspector at least ten (10) working days before items are ready for inspection.
28 The specifications and drawings attached with this Material Requisition are of proprietary nature and the Supplier shall not pass on any information to others without prior permission from the Buyer/Contractor.
29 In case, Supplier is required to submit the soft copies (native files) of the documentation, the same shall be submitted with the software versions as mentioned (To be advised to Supplier during detailing).
Project Details
All dimensional outline / detailed / fabrication drawings of each item shall include the following as minimum:
a. Description, Purchase Order Number and Tag Number.
b. Materials of construction.
c. Design and operating temperatures and pressures
d. Non-destructive testing requirements/details
30
e. Detail drawings showing all accessories.
f. Details, Orientation & Elevation (to be kept under HOLD until clearance is given by the Contractor)
g. Weights, Wind and Seismic loadings.
h. Overall dimensions of the equipment.
i. References to Specifications.
Supplier to provide the following Information along with the QUOTATION:
a. Confirmation of Compliance with this Material Requisition and all referenced Standards, Specifications, Drawings and codes or a comprehensive list of exceptions.
b. Scope of supply / work
c. Air cooler sizing details which includes surface area, number of bays, number of bundle per bay, bundle width, tube length, fan number & diameter, power installed etc. HTRI calculation sheet.
d. Preliminary General Assembly indicating the major dimensions, proposed thickness and total weight.
e. Material of construction for all parts.
f. Preliminary Inspection and Test Plan (ITP)
g. A list of Sub-Supplier.
31 h. Spare part list for Start-up and Commissioning (Item wise separate quote) and recommended 2 years normal operation spares
i. Complete datasheet with data marked as “Supplier to Confirm”.
j. Shop loading and proposed schedule of manufacture.
k. Past Experience list
l. Design Team Composition and capability.
m. Fabrication, testing and supply philosophy in case of ODC consignment
n. Electrical Load list.
o. Heat loss data for VFD.
p. Deviation and Clarification list against Data sheet, Specification and other documents attached with MR
32 Hazardous Substances – The presence or use of any hazardous substances (substances which have the potential to cause harm to the health of people through their use of the installation or supplied equipment) must be declared by the Supplier at Quotation and confirmed after Award of Purchase Order.
Asbestos - Asbestos, whether combined with other materials or in free form, shall NOT be used in any installation, supplied equipment or packaging thereof. If asbestos is found to exist in an installation, supplied equipment or packaging, the installation, equipment or packaging will be rejected, and the Supplier shall be
33
responsible for the removal and clean-up of all asbestos materials and all associated clean-up costs.
Material Requisition MR Sect. II
Project Details
Document
Document No. Document Applies to Line Item Number(s) Requisition Revision
Revision
Process Documents
J22N01-SP-EA-03202 Specification for TCS Heavy Impurity Column #2 Condenser 1 01
J22N01-SP-EA-07002 Specification for CVD OGR TCS/STC Column Condenser 0
J22N01-SP-EA-07008 Specification for CVD OGR STC Air Cooler 0
J22N01-SP-EA-22001 Specification for Hot Cooling Water Flash Condenser 0
J22N01-SP-EA-22002 Specification for Low Pressure Condensate Vent Condenser 0
J22N01-SP-EA-AB31702 Specification for Effluent Condenser 0
J22N01-SP-EA-32002 Specification for Crude TCS Column Condenser 1 01
J22N01-SP-EA-33002 Specification for STC Purification Column Condenser 1 01
J22N01-MEABD-EPE265-601-114 Process datasheet of BCW Air Cooler 0A
J22N01_102-032-03 Piping And Instrumentation Diagram Tcs Heavy Impurity Columns Overhead System 2
J22N01_102-070-02 Piping And Instrumentation Diagram Cvd Reactors Ogr Tcs/Stc Column Overhead System 2
J22N01_102-070-03 Piping And Instrumentation Diagram Cvd Reactors Ogr Tcs/Stc Column Sidedraw System 2
J22N01_102-220-02 Piping And Instrumentation Diagram Hot Cooling Water Flash Condensate 2
J22N01_102-220-09 Piping And Instrumentation Diagram Low Pressure Condensate System 2
J22N01_102-317-03A Piping And Instrumentation Diagram Quench Coloumn Overhead System 2
J22N01_102-320-02 Piping And Instrumentation Diagram Crude Tcs Column Overhead System 2
J22N01_102-330-02 Piping And Instrumentation Diagram Tcs Light Impurity Column Overhead System 2
RPMS-PROC-ITP-MS-007 Inspection and Test Plan for Air Cooled Heat Exchanger - 01
Worley Specification and data-sheet

J22N01-MEAD-EPE255-032002 Mechanical Datasheet for TCS Heavy Impurity Column #2 Condenser 00
J22N01-MEAD-EPE255-070002 Mechanical Datasheet for CVD OGR TCS/STC Column Condenser 00
J22N01-MEAD-EPE255-070008 Mechanical Datasheet for CVD OGR STC Air Cooler 00
J22N01-MEAD-EPE255-022001 Mechanical Datasheet for Hot Cooling Water Flash Condenser 00
J22N01-MEAD-EPE255-022002 Mechanical Datasheet for Low Pressure Condensate Vent Condenser 00
J22N01-MEAD-EPE255-317102 Mechanical Datasheet for Effluent Condenser 00
J22N01-MEAD-EPE255-320002 Mechanical Datasheet for Crude TCS Column Condenser 00
J22N01-MEAD-EPE255-330002 Mechanical Datasheet for STC Purification Column Condenser 00
J22N01-MEAD-EPE255-601502 Mechanical Datasheet for BCW Air cooler 00
Reliance Engineering Specifications

Mechanical
RPMS-ENGG-SPC-MS-001 Standard Specification for Design and Fabrication of Air-Cooled Heat Exchanger 0
RPMS-ENGG-SPC-MS-002 Standard Specification for Unfired Pressure Vessels 0
RPMS-ENGG-DBD-PS-001 Basic Engineering Design Data Jamnagar Manufacturing Division 0
RPMS-ENGG-DBD-CS-002 Design Basis for General Civil 0
RPMS-ENGG-DBD-HS-003 Design Basis for Fireproofing 0
RPMS-ENGG-DBD-MS-001 Design Basis for Wind and Seismic Analysis of Static Equipment 0
RPMS-ENGG-DBD-MS-002 Design Basis Indian Boiler Regulations Approval Procedure for Static Equipment 0
RPMS-ENGG-PRA-GE-041 Supplier Documents Requirement 0
RPMS-ENGG-PRA-GE-044 Procedure for Technical Queries (TQ) and Concession Requests (CR) 0
Procedure for Compilation of Manufacturing Record Book (MRB) & Operations & Maintenance Manual.
RPMS-ENGG-PRA-GE-050 0
[OMM]
RPMS-ENGG-SPC-MT-004 Standard Specification for Welding and welding procedure qualification requirements for Suppliers 0
RPMS-ENGG-SPC-MT-006 Standard specification for Tube to Tubesheet Joint requirements (expanded and/or welded) for Suppliers. 0
RPMS-ENGG-SPC-PP-012 Standard Specification for Hot and Acoustic Insulation 0
Material Requisition MR Sect. II
Project Details
Document
Document No. Document Applies to Line Item Number(s) Requisition Revision
Revision
RPMS-ENGG-SPC-PP-014 Standard Specification for Protective Coatings (Field and Shop Painting) 0
RPMS-ENGG-SPC-PP-018 Standard Specification for Positive Material Identification at Supplier’s Works 0
RPMS-SD-M15-010 Standard Nozzle Loads 0
RPMS-SD-M15-002 Name Plate exchanger details 0
Civil
RPMS-ENGG-DBD-CS-001 Design Basis for Structural Engineering 0
RPMS-ENGG-SPC-CS-002 Design Basis for Civil Work 0
Technical Specification for Supply of Steel Sections, Plates, Flats, Bars and Any Other Solid Shape Used for
RPMS-ENGG-SPC-CS-014 0
Structural Work
RPMS-ENGG-SPC-CS-015 Technical Specification for Supply of Bolts, Studs, Nuts and Washers Used for Structural Work 0
RPMS-ENGG-SPC-CS-023 Technical Specification for Structural Steelwork- Erection 0
RPMS-ENGG-SPC-CS-024 Guide Specification for Structural Steelwork - Detailing 0
RPMS-ENGG-SPC-CS-026 Standard Specification for Passive Fireproofing - Materials and Installation 0
RPMS-SD-C15-303 Standard cast-in anchor bolt with ductlie detailing 2
RPMS-SD-C16-402 Standard Handrail details 0
RPMS-SD-C16-403 Standard Grating details 0
RPMS-SD-C16-404 Standard Steel stair details 0
RPMS-SD-C16-406 Standard steel ladder details 0
RPMS-SD-C16-407 Standard Vessel Circular - Top Head Platform Details 0
Electrical
RPMS-ENGG-DBD-EL-001 Electrical Design Basis 0
RPMS-ENGG-SPC-EL-003 Standard Specification for HV Induction Motors 0
RPMS-ENGG-SPC-EL-004 Standard Specification for LV Motor 0
RPMS-ENGG-SPC-EL-011 Standard Specification for Low Voltage Variable Speed Drives 0
RPMS-ENGG-SPC-EL-021 Standard Specification For HV Cables 0
RPMS-ENGG-SPC-EL-022 Standard Specification for LV Power and Control Cables 0
RPMS-ENGG-SPC-EL-029 Standard Specification for Medium Voltage Variable Speed Drives 0
RPMS-ENGG-SPC-EL-035 Specification for Electrical requirements for Packaged Mechanical Equipment 0
RPMS-ENGG-GUD-EL-041 Guideline for Approved Vendor List – Electrical (Semi-Bulk Items) 0
RPMS-ENGG-GUD-EL-042 Guideline for Approved Vendor List – Electrical (Bulk Items) 0
RPMS-PROC-ITP-EL-001 Inspection and Test Plan for LT Motor 0
RPMS-PROC-ITP-EL-002 Inspection and Test Plan for HT Motor 0
RPMS-PROC-ITP-EL-020 Inspection and Test Plan for VFD/VSD 0
Instrumentation
RPMS-ENGG-DBD-CI-001 Design Basis for Control and Instrumentation 0
RPMS-ENGG-SPC-CI-007 Standard Specification for Instrumentation Cables 0
RPMS-ENGG-SPC-MR-022 Guidelines for Online Condition monitoring of Rotating Equipment 0
Annexures
Annexure-1 Scope of Work & Supply -
Annexure-2 Requirement for air fin coolers -
Annexure-3 Electrical Load List format -
Annexure-4 10080-DS-EL-45001_LV Motor datasheet -
Annexure-5 J22N01-EVPD-EPE255-001 - Guaranteed Technical Particular for LV VFD -
Notes:
Doc. Title. Section III – SDRL for Air cooled heat exchangers Page 1 of 4
Project Title. Polysilicon Manufacturing Facility Date 23-Dec-2022
SECTION III – SDRL (SUPPLIER DATA REQUIREMENT LIST) MASTER
WITH BID
FOR REVIEW
FOR INFORMATION
WEEKS AFTER AWARD
TO BE MADE PART OF MRB
CAT REMARKS
DOCUMENT DESCRIPTION
CODE
A CONTROL DOCUMENTS
A01 VDS- 001 SUPPLIER DRAWINGS AND Yes 2
DOCUMENTATION SCHEDULE
A02 FABRICATION / PRODUCTION SCHEDULE Yes Yes 2
A03 SUB-ORDER SCHEDULE/COPIES SUB ORDERS Yes * ‘*’ - To be submitted every
Month
A04 WEEKLY PROGRESS REPORT Yes 4 To be submitted every Week
with photograph
A05 JOB SPECIFIC INSP. AND TEST PLAN (ITP) Yes Yes 4 Yes
A06 CERTIFICATE OF QUALITY SYSTEM APPROVAL* Yes Yes
A07 QUALITY MANUAL* Yes 6 Yes
A08 CONTRACT SPECIFIC QUALITY PLAN Yes Yes 4 Yes
A09 CONTRACT SPECIFIC QUALITY PLAN*
B ARRANGEMENTS
B01 KEY DESIGN SKETCH
B02 GENERAL ARRANGEMENTS Yes 3 Yes a) ACHE GA Drawing showing
bundles with nozzles locations,
platforms, details of column
support, foundation load data
and Cable Tray Supports
b) Motor & VFD schematic and

GA drawing
B03 INTERFACE AND CONNECTION SCHEDULE
B04 UTILITY REQUIREMENTS Yes Yes 2 Yes Electrical Load list in Worley/RIL
format
B05 FOUNDATION DRAWINGS Yes 3 Yes To be included in B02
C SCHEMATICS
C01 PFDs AND HEAT MASS BALANCE
C02 P&IDs
C03 CAUSE AND EFFECT
C04 CONTROL PHIL. AND BLOCK LOGIC DIAG.
C05 OPERATING PHILOSOPHY Yes 8 Yes
C06 FUNCTIONAL DESIGN SPECIFICATION
D DATA SHEETS
D01 DATA SHEETS Yes Yes 3 Yes API 661 datasheet
D02 MOTOR & VFD DATA SHEET Yes 3 Yes
D03 INSTRUMENT DATA SHEETS Yes 3 Yes
D04 WEIGHT DATA SHEET Yes 3 Yes To be included in B02
WITH BID
FOR REVIEW
FOR INFORMATION
WEEKS AFTER AWARD
CAT REMARKS
CODE
D05 NOISE DATA SHEET Yes 3 Yes To be included in D01
D06 COUPLING DATASHEET

E CALCULATIONS
E01 DESIGN/CODE CALCULATION Yes 3 Yes Mechanical & Structural design
calculations, Harmonic
Spectrum Data for VFD
(Separate document)
E02 PROCESS/UTILITY CALCULATION Yes 3 Yes Thermal design calculations in
HRTI along with Thermal data
sheet
E03 STRUCTURAL FOUNDN. AND SUPPORT CALCS. Yes 3 Yes To be included in E01
E04 ROTATING ELEMENT CALCULATION
E05 INSTRUMENT SIZING CALCULATION
E06 PIPING STRESS ANALYSIS
E07 PRIME MOVER PERFORMANCE CURVE Yes 3 Yes
E08 DRIVEN EQUIPMENT PERFORMANCE CURVE Yes 3 Yes Fan performance curves &
datasheet with noise level
E09 ELECTRICAL CURVES Yes 3 Yes
E10 RELIABILITY AND AVAILABILITY
E11 PULSATION STUDIES
E13 HEAT DISSIPATION AND POWER CALCULATIONS Yes Yes 3 Yes Heat dissipation for VFD
F DETAIL MECHANICAL DRAWINGS
F01 EQUIPMENT GA & DETAIL DRAWINGS Yes 3 Yes a) Detailed Fabrication drawings
of bundle and frame with Bill of
material
b) Drive selection, motor
suspension, fan & pulley guards,
bearing block detail, QD bush
details, inlet cone details etc
c) Structural drawing including
platform & ladder
F02 ANCILLARY PIPING DRAWING
F03 CROSS SECTION
F04 PARTS LIST/BILL OF MATERIAL Yes 3 Yes To be included in F01
F05 SEAL & SEAL SYSTEM/ROD PACKING SYSTEM
F06 INSULATION/LINING DETAIL Yes 3 Yes
G DETAIL INSTRUMENT DRAWINGS
G01 INSTRUMENT LOCATION DRAWING
G02 INSTRUMENT SCHEDULE Yes 3 Yes
G03 WIRING SCHEMATIC DIAGRAM
G04 TERMINATION DETAILS
G05 PANEL / CABINET LAYOUT
WITH BID
FOR REVIEW
FOR INFORMATION
WEEKS AFTER AWARD
CAT REMARKS
CODE
G06 LOGIC DIAGRAM
G07 HOOK UP DIAGRAM
G08 LOOP DIAGRAMS
G09 CABLE BLOCK DIAGRAM
G10 INSTRUMENT OUTLINE DRAWING
G11 SERIAL LINK
G12 GRAPHICS
G13 SOFTWARE LISTING
H DETAIL ELECTRICAL DRAWINGS
H01 ELECTRICAL SINGLE LINE DIAGRAM Yes 6 Yes
H02 ELECTRICAL LAYOUT DRAWING
H03 SCHEDULE OF ELECTRICAL EQUIPMENT
H04 CABLE SCHEDULE
H05 INTERCONNECTION DIAGRAM
H06 TERMINAL BOX BLOCK DIAGRAM Yes 6 Yes
H07 DISTRIBUTION BOARD SCHEDULE
H09 WIRING DIAGRAMS Yes 6 Yes Wiring Diagram for VFD
J MANUFACTURING PROCEDURES
J01 WELD PROCEDURES (WPS AND PQR) Yes 6 Yes

J02 NDE PROCEDURES Yes 6 Yes
J03 HEAT TREATMENT PROCEDURES (INC. PWHT) Yes 6 Yes
J04 SURFACE PREP., PAINTG. AND COATG. SPEC. Yes 8 Yes
J05 MATERIAL SPECIFICATION
J06 OPERATOR QUALIFICATIONS Yes 6 Yes NDE and Welding
K TEST PROCEDURES
K01 FUNCNL. AND PERF. TEST PROCEDURES Yes 12 Yes
K02 HYDRO /PNEUM TEST PROCEDURES Yes 12 Yes
K03 MATERIAL TEST PROCEDURES Yes 12 Yes
K04 WEIGHT CONTROL/WEIGHING PROCEDURE
K05 FACTORY ACCEPTANCE TEST PROCEDURE Yes 12 Yes
K06 SITE ACCEPTANCE TEST PROCEDURE Yes 12 Yes
K07 PMI TEST PROCEDURE Yes 8 Yes
L CERTIFICATION
L01 MANUFACTURING RECORD BOOK INDEX Yes 16 Yes
L02 MANUFACTURING RECORD BOOK Yes * Yes ‘*’ – 2 Weeks after Final
Inspection
L03 MATERIALS CERTIFICATES Yes * Yes ‘*’ – 2 Weeks before Final
Inspection
WITH BID
FOR REVIEW
FOR INFORMATION
WEEKS AFTER AWARD
CAT REMARKS
CODE
L04 HAZARDOUS AREA CERTIFICATES Yes Yes
L05 CODE/STANDARD/COMPLIANCE CERTS. Yes
L06 TEST RESULTS Yes
L07 SPECIFICATION WAIVERS Yes Yes Yes If applicable
L08 TYPE TEST CERTIFICATE Yes Yes
L09 INSPECTION RELEASE NOTE Yes * Yes ‘*’ – During dispatch
M HANDLING & SITE INSTALLATION
M01 DOCUMENTS TRAVELLING WITH GOODS Yes * Yes ‘*’ - 8 Weeks prior to dispatch
M02 PACKG., SHIPG., HANDLG. & STORAGE PROCS Yes 20 Yes
M03 PRESERVATION PROCEDURE Yes 20 Yes
M04 INSTALLATION INSTRUCTIONS Yes 20 Yes
M05 FIELD FABRICATION ITEMS
N OPERATING AND MAINTENANCE MANUAL
N01 SPARE PARTS LIST OR DATA PACKAGES Yes Yes 12 Yes
N02 INSTALLATION, OPERATING AND MAINTENANCE Yes 12 Yes
MANUAL
N03 SUPPLIERS CATALOGUE
N04 LUBRICATION SCHEDULE Yes 12 Yes
NOTES:
1. This list shall be read in conjunction with Specification No. RPMS-ENGG-PRA-GE-041 – Supplier Documents Requirement.
SECTION IV - CONFIRMATION OF COMPLIANCE WITH MATERIAL REQUISITION
(Unless this form is filled up & enclosed with bid, the bid shall not be considered for evaluation)
PROJECT NO.: JN3102 REQUISITION NO.: MT-J22N01-D1JEP-MEA001-WIPL-Q-00
NAME OF THE SUPPLIER:
We hereby confirm that there is a DEVIATION  / NO DEVIATION  to this requisition (Tick √ as per applicability)
Deviations if any shall be furnished in Format 2 attached along with this enquiry, if there is no deviation then specify NO
DEVIATION in Format 2.
FOLLOWING DOCUMENTS ARE COMPLETELY FILLED IN AND ATTACHED WITH OFFER.

(* Strike Out, as applicable)
1. Confirmation of Compliance with Material Requisition *YES / NO
2. Preliminary GA drawing indicating thickness, weight and MOC *YES / NO
3. Preliminary Inspection and Test Plan *YES / NO
4. Sub-Supplier List *YES / NO
5. Spare part list for Start-up and Commissioning (Item wise separate quote) *YES / NO
6. Recommended 2 years normal operation spares *YES / NO
7. Complete datasheet with data marked as “Supplier to Confirm” *YES / NO
8. Shop loading and proposed schedule of manufacture *YES / NO
9. Past Experience list *YES / NO
10. Vendor data requirement sheet (Format attached with enquiry) *YES / NO
11. Design Team Composition and capability *YES / NO
Supplier's authorized signatory
Name & Designation of authorised signatory
Company Seal
PROJECT NO.: JN3102 REV. NO. / ISSUE DATE 00 / 23-Dec-2022
Requisition Title: Material Requisition for Air Cooled Heat Requisition No.: MT-J22N01-D1JEP-MEA001-
Exchanger WIPL-Q-00
FORM TO BE FILLED AND FURNISHED WITH BID

FORMAT NO. 2
EXCEPTIONS AND DEVIATIONS
S.R TENDER DOCUMENT REFERENCE SUBJECT DEVIATION

NO. PART NO. / PAGE NO. CLAUSE
VOLUME NO.
NOTE:
1. Supplier shall stipulate deviations to the requirements of the Tender document, only in this
format. Separate sheets can be added following this format.
2. Supplier shall furnish Technical and commercial deviations, if any, separately.
3. Any deviations stated elsewhere in the bid shall not be taken into account and may render the
bid non-responsive and liable to be rejected.
Signature Company seal

Specification for
TCS Heavy Impurity Column #2 Condenser
Item No: EA-03202
Project No: J22N01
Polysilicon Manufacturing Facility

Reliance Industries Limited
Jamnagar, Gujarat, India
CONFIDENTIAL - This document is the property of Advanced Material

Solutions LLC. All patents, designs, trade secrets, know how, technical
information, and other intellectual property contained in this document are
property of Advanced Material Solutions LLC. and may not be reproduced,
published or disclosed to others without the express written consent of
AMS. Any use of the information contained in this package, other than for
the purpose stated, is prohibited.
Project Manager_________________________ Date____________
1 29-Dec-22 Updates per Client Review ENG SPH

0 29-Oct-22 Initial Issue ENG SPH Customer__________________________________Date____________
Issue Date Description By Appr'd Sheet 1 of 3 Spec No: J22N01-SP-EA-03202

AIR COOLED HEAT EXCHANGER DESIGN DATA
Client: Reliance Industries Limited Project No: J22N01 Item No: EA-03202
Unit: 032 - TCS Heavy Impurity Columns Location: Jamnagar, Gujarat, India
Service: TCS Heavy Impurity Column #2 Condenser Manufacturer:
Bay Size: * Width: * Length: * Type: Forced Draft No. of Bays: * REV
2
Surface Area per Unit: Finned Tube: * m Bare Tube: * m2
Heat Exchanged: 35.54 MMkcal/hr MTD, Eff.: * °C
Transfer Rate, Service: Finned Tube: * Bare Tube: * Clean: * kcal/m2-°C-hr
PERFORMANCE DATA - TUBE SIDE
Fluid Name: Chlorosilanes IN OUT
Total Fluid Entering: 782118 kg/hr (includes +20% design margin) Density Liquid Vap + NC kg/m3 - 25.05 1260 -
IN OUT Sp. Heat Liq. Vap + NC kcal/kg-°C - 0.151 0.213 -
Temperature °C 86.94 60.09 Therm. Cond. Liq. Vap + NC kcal/m-hr-°C - 0.0092 0.091 -
Liquid kg/hr 782118 Freeze Point < -10 °C 1
Vapor kg/hr Mol. Wt. 782118 135.3 Bubble Point (Note 1) °C
Noncond. kg/hr Mol. Wt. Latent Heat (Note 1) kcal/kg
Steam kg/hr Inlet Pressure 4.0 (Note 4) kg/cm²g
Water kg/hr Press. Drop / Max Allow. * / 0.50 kg/cm²
Visc. Liq. Vap + NC cP 0.0141 0.2446 Fouling Resist., Inside 0.0002 m²-°C-hr/kcal
PERFORMANCE DATA - AIR SIDE
Air Quantity, Total * kg/hr (Nm3/hr) Altitude above Sea Level 21 (Note 11) m
Air Quantity/Fan * act. m3/hr Temperature In (Design Dry Bulb) 41.0 °C
Actual Static Pressure * mbar Temperature Out * °C
Face Velocity * Nm/s Mass Velocity (Net Free Area) * kg/hr-m2 Minimum Design Ambient 7.5 °C
DESIGN - MATERIALS - CONSTRUCTION
Design Pressure 7.0 / FV kg/cm²g Test Pressure kg/cm²g Design Temperature 7.5 / 160 °C 1
TUBE BUNDLE HEADER, Type Cover Plate (Note 10) TUBE, Material CS
Size, Width * m Length * m Material CS
No./Bay * No. Tube Rows * No. Passes** * OD * in Min. Thick. 2.8 mm
Arrangement Plug Material CS No./Bundle * Length * m
Bundles * Gasket Material (Note 5) Pitch *
Bays * Corrosion Allowance 3.0 mm FIN, Type *
Bundle Frame Slope 20 mm/m No., Size Inlet Nozzle * x * in Material *
MISCELLANEOUS (Note 2) No., Size Outlet Nozzle * x * in OD in Stock. Thick. mm
Struct. Mount. (Note 6) c/c Special Nozzles No./in. Fin Design Temp. °C
Surface Preparation Rating & Facing 150# ANSI RF WN Code ASME Sec. VIII, Div. 1 Stamp
Louvers None TI PI SPECS. 1
Vibration Switches Chem. Cleaning
MECHANICAL EQUIPMENT
FAN, Mfr. & Model DRIVER, Type SPEED REDUCER, Type
No./Bay * rev./min MFR. Mfr. & Model
Dia. * mm No. Blades No./Bay * kW/Driver No./Bay
Pitch * Angle rev./min AGMA Rating HP Ratio :1
Material, Blade * Hub Enclosure IEC Zone 2, Group IIC, T4 Support
HP/Fan, Des. * At Min. Amb. * Volt, Phase, Cycle 415 V, 3, 50 Hz (Note 8)
Control Action on Air Failure - Fan Speed Maximum cooling Louvers N/A 1
Degree Control of Outlet Process Temperature (Note 7) (± 2 °C)
Recirculation Steam Coil
Plot Area * m2 Weight - Bundle kg
** Give tube count of each pass when irregular.

Notes:
1) See Sheet 3 for isobaric heat curves.
2) Tubes to be strength welded to tubesheet.
3) * - Vendor to specify.
4) Column overhead pressure = 4.0 kg/cm²g. Overhead piping allocated pressure drop = 0.1 kg/cm², for exchanger inlet pressure = 3.9 kg/cm²g.
5) Spiral wound gaskets with outer and inner guides and graphite filler.
6) Air cooler to be mounted above piperack if possible. DEC to confirm equipment placement.
7) Temperature shall be controlled with a combination of variable speed fans and fan on/off controls. Fan curves should be such that operation at 60% of design air flow
is possible.
8) DEC to confirm electrical supply conditions.
9) Vendor to provide for motor status transmitter.
10) Provide access for mechanical cleaning of tubes.
11) Site elevation to be confirmed by DEC.
ISSUE SHEET
1 2 of 3
AMS - CONFIDENTIAL
HEAT EXCHANGER DESIGN DATA
Unit: 032 - TCS Heavy Impurity Columns Manufacturer:
Service: TCS Heavy Impurity Column #2 Condenser Location: Jamnagar, Gujarat, India REV.
Pressure: 3.996001 kg/cm²g
Enthalpy Heat Capacity Density Viscosity Therm. Cond. Surface Liq. Critical Liq. Critical
Temp. Wt. Frac. Change kcal/kg-°C Vap. Avg. kg/m3 Mol. Frac. cP kcal/m-hr-°C Tension Pressure Temp.
°C Vapor kcal/kg Vap. Liq. M.W. Vap. Liq. Liq. Vap. Liq. Vap. Liq. mN/m kg/cm²g °C
89.94 1.0000 -868.16 0.1507 - 24.766 - 0.0142 - 0.0093 - - - -
86.94 1.0000 -868.62 0.1506 0.2258 25.050 1197.99 0.0141 0.2077 0.0092 0.0832 31.907 - -
86.94 0.8870 -873.09 0.1506 0.2258 25.046 1198.01 0.0141 0.2077 0.0092 0.0832 31.908 - -
86.93 0.7740 -877.56 0.1506 0.2258 25.042 1198.03 0.0141 0.2077 0.0092 0.0832 31.910 - -
86.92 0.6611 -882.03 0.1506 0.2258 25.035 1198.05 0.0141 0.2077 0.0092 0.0832 31.912 - -
86.90 0.5482 -886.50 0.1506 0.2258 25.026 1198.09 0.0141 0.2078 0.0093 0.0832 31.915 - -
86.88 0.4353 -890.98 0.1506 0.2258 25.013 1198.15 0.0141 0.2078 0.0093 0.0832 31.919 - -
86.84 0.3225 -895.45 0.1507 0.2258 24.990 1198.25 0.0141 0.2078 0.0093 0.0832 31.927 - -
86.81 0.2742 -897.37 0.1507 0.2257 24.974 1198.31 0.0141 0.2078 0.0093 0.0832 31.932 - -
86.77 0.2260 -899.28 0.1507 0.2257 24.952 1198.40 0.0141 0.2079 0.0094 0.0832 31.939 - -
86.71 0.1779 -901.20 0.1507 0.2257 24.919 1198.54 0.0141 0.2080 0.0094 0.0832 31.950 - -
86.61 0.1300 -903.12 0.1508 0.2256 24.862 1198.78 0.0141 0.2081 0.0095 0.0833 31.969 - -
86.41 0.0828 -905.03 0.1510 0.2255 24.746 1199.28 0.0141 0.2083 0.0097 0.0833 32.007 - -
85.79 0.0378 -906.95 0.1514 0.2252 24.397 1200.76 0.0141 0.2090 0.0102 0.0835 32.123 - -
82.61 0.0074 -908.87 0.1540 0.2235 22.677 1208.30 0.0141 0.2125 0.0130 0.0844 32.719 - -
70.52 0.0000 -911.82 0.1684 0.2177 17.013 1236.38 0.0140 0.2278 0.0251 0.0877 35.011 - -
67.52 0.0000 -912.47 - 0.2163 - 1243.32 - 0.2324 - 0.0886 35.590 - -

Enthalpy Heat Capac. Density Viscosity Therm. Cond. Surface Liq. Critical Liq. Critical
°C Vapor kcal/kg Vap. Liq. M.W. Vap. Liq. Liq. Vap. Liq. Vap. Liq. mN/m kgf/cm²g °C
86.94 1.0000 -868.44 0.1495 - 22.261 - 0.0141 - 0.0092 - - - -
101.10 1.0000 -868.52 0.1495 - 22.306 - 0.0141 - 0.0092 - - - -
86.80 1.0000 -868.60 0.1495 - 22.351 - 0.0140 - 0.0092 - - - -
75.70 1.0000 -868.68 0.1494 - 22.396 - 0.0140 - 0.0092 - - - -
72.30 1.0000 -868.76 0.1494 - 22.441 - 0.0140 - 0.0091 - - - -
70.50 1.0000 -868.84 0.1494 - 22.487 - 0.0140 - 0.0091 - - - -
69.40 1.0000 -868.93 0.1493 - 22.533 - 0.0140 - 0.0091 - - - -
68.50 1.0000 -869.01 0.1493 - 22.578 - 0.0139 - 0.0091 - - - -
67.60 1.0000 -869.09 0.1492 0.2235 22.625 1208.60 0.0139 0.2133 0.0091 0.0844 32.7290 - -
66.80 0.8306 -875.88 0.1493 0.2235 22.619 1208.62 0.0139 0.2133 0.0091 0.0844 32.7309 - -
65.70 0.6612 -882.67 0.1493 0.2235 22.611 1208.66 0.0139 0.2133 0.0091 0.0844 32.7337 - -
64.30 0.4918 -889.46 0.1493 0.2235 22.598 1208.72 0.0139 0.2133 0.0091 0.0844 32.7385 - -
62.40 0.3226 -896.26 0.1493 0.2235 22.571 1208.84 0.0139 0.2134 0.0092 0.0844 32.7482 - -
59.40 0.1540 -903.05 0.1494 0.2234 22.486 1209.22 0.0139 0.2136 0.0093 0.0845 32.7786 - -
54.50 0.0073 -909.84 0.1530 0.2213 20.416 1218.89 0.0139 0.2185 0.0130 0.0856 33.5556 - -
46.50 0.0000 -913.37 0.1731 0.2146 14.187 1252.86 0.0138 0.2391 0.0287 0.0897 36.3987 - -
35.00 0.0000 -914.01 - 0.2134 - 1259.64 - 0.2442 - 0.0905 36.9815 - -
ISSUE SHEET
1 3 of 3
AMS - CONFIDENTIAL
Specification for
CVD OGR TCS/STC Column Condenser
Item No: EA-07002
Project No: J22N01


0 1-Nov-22 ISSUED FOR REVIEW ENG JS Customer__________________________________

Date____________

Unit: 070 - CVD OGR TCS/STC Separation Location: Jamnagar, Gujarat, India
Service: CVD OGR TCS/STC Column Condenser Manufacturer:
2 2
Surface Area per Unit: Finned Tube: * m Bare Tube: * m
3
Total Fluid Entering: 488164 kg/hr (includes +20% design margin)Density Liquid Vap + NC kg/m - 19.63 1258 13.09
IN OUT Sp. Heat Liq. Vap + NC kcal/kg-°C - 0.148 0.214 0.159
Temperature °C 76.44 60.00 Therm. Cond. Liq. Vap + NC kcal/m-hr-°C - 0.0089 0.091 0.0195
Liquid kg/hr 487653 Freeze Point 10 °C
Vapor kg/hr Mol. Wt. 488164 134.5 414 102.42 Bubble Point (Note 1) °C
Visc. Liq. Vap + NC cP 0.0136 0.2443 0.0134 Fouling Resist., Inside 0.0002 m²-°C-hr/kcal
Design Pressure 6 / FV kg/cm²g Test Pressure kg/cm²g Design Temperature 7.5 / 160 °C
Louvers N/A TI PI SPECS. 0
Material, Blade * Hub Enclosure Zone 2, II C, T4 Support
Control Action on Air Failure - Fan Pitch Maximum cooling Louvers N/A 0
2
Plot Area * m Weight - Bundle kg

Notes:
4) Column overhead pressure = 2.9 kg/cm²g. Overhead piping allocated pressure drop = 0.1 kg/cm²g, for exchanger inlet pressure = 2.8 kg/cm²g.
is possible.
ISSUE SHEET
0 2 of 3
AMS - CONFIDENTIAL
Unit: 0 Manufacturer:
Service: CVD OGR TCS/STC Column Condenser Location: Jamnagar, Gujarat, India REV.
79.68 1.0000 -866.18 0.1484 - 19.360 - 0.0137 - 0.0090 - - - -
76.68 1.0000 -866.62 0.1481 0.2205 19.575 1223.51 0.0136 0.2218 0.0089 0.0858 32.952 - -
76.58 0.8880 -871.20 0.1482 0.2205 19.556 1223.36 0.0136 0.2217 0.0089 0.0858 32.948 - -
76.48 0.7762 -875.77 0.1482 0.2206 19.533 1223.26 0.0136 0.2217 0.0089 0.0858 32.947 - -
76.36 0.6645 -880.35 0.1483 0.2206 19.506 1223.20 0.0136 0.2217 0.0090 0.0858 32.949 - -
76.22 0.5530 -884.92 0.1484 0.2206 19.470 1223.20 0.0136 0.2217 0.0090 0.0858 32.941 - -
76.04 0.4418 -889.49 0.1486 0.2206 19.422 1223.26 0.0136 0.2218 0.0090 0.0858 32.957 - -
75.80 0.3311 -894.07 0.1488 0.2206 19.349 1223.46 0.0136 0.2219 0.0090 0.0857 32.985 - -
75.65 0.2838 -896.03 0.1489 0.2206 19.306 1223.61 0.0136 0.2220 0.0090 0.0856 33.004 - -
75.47 0.2369 -897.99 0.1491 0.2205 19.249 1223.83 0.0136 0.2222 0.0091 0.0856 33.030 - -
75.22 0.1902 -899.95 0.1493 0.2205 19.171 1224.15 0.0136 0.2224 0.0091 0.0855 33.067 - -
74.87 0.1442 -901.91 0.1497 0.2204 19.059 1224.66 0.0136 0.2227 0.0092 0.0853 33.123 - -
74.32 0.0993 -903.87 0.1502 0.2202 18.884 1225.52 0.0136 0.2233 0.0093 0.0850 33.213 - -
73.36 0.0567 -905.83 0.1512 0.2199 18.577 1227.09 0.0136 0.2243 0.0094 0.0845 33.378 - -
71.41 0.0195 -907.79 0.1533 0.2192 17.966 1230.40 0.0136 0.2264 0.0098 0.0835 33.720 - -
68.74 0.0000 -909.19 0.1564 0.2183 17.147 1235.04 0.0135 0.2295 0.0103 0.0822 34.198 - -
65.74 0.0000 -909.84 - 0.2170 - 1241.95 - 0.2342 - 0.0829 34.787 - -

76.68 1.0000 -866.44 0.1471 - 16.855 - 0.0136 - 0.0089 - - - -
101.10 1.0000 -866.54 0.1471 - 16.894 - 0.0136 - 0.0089 - - - -
86.80 1.0000 -866.64 0.1470 - 16.934 - 0.0135 - 0.0089 - - - -
75.70 1.0000 -866.74 0.1469 - 16.975 - 0.0135 - 0.0089 - - - -
72.30 1.0000 -866.83 0.1469 - 17.015 - 0.0135 - 0.0088 - - - -
70.50 1.0000 -866.93 0.1468 - 17.056 - 0.0135 - 0.0088 - - - -
69.40 1.0000 -867.03 0.1468 - 17.097 - 0.0135 - 0.0088 - - - -
68.50 1.0000 -867.12 0.1467 - 17.138 - 0.0134 - 0.0088 - - - -
67.60 1.0000 -867.22 0.1466 0.2180 17.179 1236.00 0.0134 0.2296 0.0088 0.0872 33.9882 - -
66.80 0.8320 -874.18 0.1467 0.2181 17.153 1235.78 0.0134 0.2295 0.0088 0.0872 33.9814 - -
65.70 0.6644 -881.14 0.1468 0.2181 17.118 1235.66 0.0134 0.2295 0.0088 0.0873 33.9827 - -
64.30 0.4971 -888.10 0.1470 0.2182 17.067 1235.66 0.0134 0.2295 0.0088 0.0872 33.9803 - -
62.40 0.3307 -895.05 0.1473 0.2181 16.980 1235.87 0.0134 0.2297 0.0089 0.0872 34.0164 - -
59.40 0.1667 -902.01 0.1480 0.2180 16.775 1236.77 0.0134 0.2304 0.0090 0.0869 34.1229 - -
54.50 0.0194 -908.97 0.1522 0.2168 15.686 1243.04 0.0133 0.2349 0.0096 0.0849 34.7868 - -
46.50 0.0000 -910.45 0.1558 0.2158 14.852 1248.30 0.0133 0.2387 0.0103 0.0835 35.3357 - -
35.00 0.0000 -911.09 - 0.2145 - 1255.08 - 0.2438 - 0.0841 35.9282 - -
ISSUE SHEET
0 3 of 3
AMS - CONFIDENTIAL
Specification for
CVD OGR STC Air Cooler
Item No: EA-07008
Project No: J22N01


0 1-Nov-22 ISSUED FOR REVIEW ENG JS Customer__________________________________

Date____________

Unit: 070 - CVD OGR TCS/STC Separation Location: Jamnagar, Gujarat, India
Service: CVD OGR STC Air Cooler Manufacturer:
2 2
Heat Exchanged: 0.78 MMkcal/hr MTD, Eff.: * °C 0
Fluid Name: STC IN OUT 0
3
Total Fluid Entering: 21600 kg/hr Density Liquid Vap + NC kg/m 1266.0 28.16 1292.0 27.98 0
IN OUT Sp. Heat Liq. Vap + NC kcal/kg-°C 0.2075 0.1427 0.2033 0.1427 0
Temperature °C 114.70 104.30 Therm. Cond. Liq. Vap + NC kcal/m-hr-°C 0.0758 0.0088 0.0769 0.0088 0
Liquid kg/hr 21600 Freeze Point < 7.5 °C 0
Vapor kg/hr Mol. Wt. 21600 Bubble Point (Note 1) °C 0
Steam kg/hr Inlet Pressure 3.78 kg/cm²g
Visc. Liq. Vap + NC cP 0.2269 0.0138 0.2427 0.0138 Fouling Resist., Inside 0.0003 m²-°C-hr/kcal 0
Design Pressure 7.0 / FV kg/cm²g Test Pressure kg/cm²g Design Temperature 160 °C
Louvers N/A TI PI SPECS.
Control Action on Air Failure - Fan Pitch Maximum cooling Louvers N/A
2

Notes:
4) Deleted
is possible.
ISSUE SHEET
0 2 of 3
AMS - CONFIDENTIAL
Unit: 070 - CVD OGR TCS/STC Separation Manufacturer:
Service: CVD OGR STC Air Cooler Location: Jamnagar, Gujarat, India REV.
117.68 1.000 -921.20 0.1427 27.857 0.0139 0.0089 - -
114.68 1.000 -921.62 0.1427 0.2075 28.163 1265.97 0.0138 0.2269 0.0088 0.0758 35.365 - -
114.65 0.800 -928.40 0.1427 0.2075 28.159 1265.94 0.0138 0.2269 0.0088 0.0758 35.365 - -
114.63 0.600 -935.17 0.1427 0.2075 28.154 1265.92 0.0138 0.2269 0.0088 0.0758 35.365 - -
114.60 0.400 -941.94 0.1427 0.2075 28.148 1265.90 0.0138 0.2269 0.0088 0.0758 35.366 - -
114.56 0.200 -948.71 0.1427 0.2075 28.140 1265.87 0.0138 0.2269 0.0088 0.0758 35.366 - -
114.52 0.000 -955.48 0.1427 0.2076 28.131 1265.84 0.0138 0.2269 0.0088 0.0758 35.367 - -
113.50 0.000 -955.70 0.2071 1268.50 0.2284 0.0759 35.559 - -
112.48 0.000 -955.91 0.2067 1271.15 0.2299 0.0760 35.751 - -
111.46 0.000 -956.12 0.2062 1273.79 0.2314 0.0761 35.943 - -
110.45 0.000 -956.33 0.2058 1276.42 0.2330 0.0762 36.136 - -
109.43 0.000 -956.53 0.2053 1279.04 0.2345 0.0763 36.328 - -
108.41 0.000 -956.74 0.2049 1281.65 0.2361 0.0765 36.521 - -
107.39 0.000 -956.95 0.2045 1284.25 0.2377 0.0766 36.714 - -
106.38 0.000 -957.16 0.2041 1286.84 0.2394 0.0767 36.907 - -
105.36 0.000 -957.37 0.2037 1289.43 0.2410 0.0768 37.100 - -
104.34 0.000 -957.57 0.2033 1292.00 0.2427 0.0769 37.294 - -

114.68 1.000 -921.28 0.1407 21.655 0.014 0.0088 - -
113.67 1.000 -921.42 0.1407 21.729 0.014 0.0087 - -
112.65 1.000 -921.56 0.1406 21.805 0.014 0.0087 - -
111.63 1.000 -921.71 0.1406 21.880 0.014 0.0087 - -
110.61 1.000 -921.85 0.1406 21.957 0.014 0.0087 - -
109.60 1.000 -921.99 0.1406 22.034 0.013 0.0086 - -
108.58 1.000 -922.14 0.1405 22.112 0.013 0.0086 - -
107.56 1.000 -922.28 0.1405 22.191 0.013 0.0086 - -
106.54 1.000 -922.42 0.1405 22.270 0.013 0.0085 - -
105.53 1.000 -922.57 0.1404 22.350 0.013 0.0085 - -
104.51 1.000 -922.71 0.1404 0.2034 22.430 1292.15 0.013 0.2427 0.0085 0.0769 37.291 - -
104.49 0.800 -929.68 0.1404 0.2034 22.427 1292.13 0.013 0.2427 0.0085 0.0769 37.292 - -
104.46 0.600 -936.66 0.1404 0.2035 22.423 1292.10 0.013 0.2427 0.0085 0.0769 37.292 - -
104.43 0.400 -943.63 0.1404 0.2035 22.418 1292.08 0.013 0.2427 0.0085 0.0769 37.293 - -
104.39 0.200 -950.60 0.1405 0.2035 22.412 1292.04 0.013 0.2427 0.0085 0.0769 37.293 - -
104.34 0.000 -957.58 0.1405 0.2035 22.403 1292.00 0.013 0.2427 0.0085 0.0769 37.294 - -
101.34 0.000 -958.18 0.2023 1299.53 0.2477 0.0772 37.866 - -
ISSUE SHEET
0 3 of 3
AMS - CONFIDENTIAL
Specification for
Hot Cooling Water Flash Condenser
Item No: EA-22001
Project No: J22N01

Polysilicon Manufacturing Facility Project
This document is the property of AMS ADVANCED MATERIAL

SOLUTIONS and the information contained herein is
proprietary information. Any copies, distribution or disclosure
of this document without the written consent of AMS
ADVANCED MATERIAL SOLUTIONS is expressly prohibited.
0 1-Nov-22 Issued for Review JMD HJ Customer__________________________________Date____________

Unit: 220 - CVD Reactors HCW System Location: Jamnagar, Gujarat, India
Service: Hot Cooling Water Flash Condenser Manufacturer:
Bay Size: * Width: * Length: * Type: Forced Draft No. of Bays: * REV.
2 2
Heat Exchanged: 117.9 (Note 1) MM kcal/hrMTD, Eff.: * °C
2
Transfer Rate, Service: Finned Tube: * Bare Tube: * Clean: * kJ/m -hr-°C
Fluid Name: Steam IN OUT
Total Fluid Entering: 229,516 (Note 1) kg/hr Density, Liquid Vap + NC kg/m3 - 1.92 926.9 -
IN OUT Sp. Heat, Liq. Vap + NC kcal/kg-°C - 0.55 1.02 -
Temperature °C 140 139 Cond. Liq. Vap + NC kcal/m-hr-°C - 0.02 0.59 -
Liquid kg/hr Point °C
Vapor kg/hr Mol. Wt. Bubble Point 140 °C
Noncond. kg/hr Mol. Wt. Latent Heat 513 kcal/kg
Steam kg/hr 229,516 Inlet Pressure 2.66 kg/cm²g
Water kg/hr 229,516 Press. Drop / Max Allow. 0.143 / 0.3 kg/cm²
Visc. Liq. Vap + NC cP - 0.0136 0.1979 - Fouling Resist., Inside 0.0002 m²-°C-hr/kcal
3
Air Quantity, Total 79755^ kg/hr (Nm /hr) Altitude above Sea Level 21 (Note 11) m
Air Quantity/Fan 2131^ act. m3/hr Temperature In (Design Dry Bulb) 41 °C
Actual Static Pressure * mbar Temperature Out 126.04^ °C
Face Velocity 2.13^ Nm/s Mass Velocity (Net Free Area) * kg/hr-m2 Minimum Design Ambient 8 °C
Design Pressure 4.2 / FV kg/cm²g
Test Pressure barg Design Temperature 160 °C
Size, Width 4.267^ m Length 7.3^ m Material CS
No./Bay 1 No. Tube Rows 8^ No. Passes** * OD 1.0 in Min. Thick. mm
Arrangement Plug Material CS No./Bundle 528^ Length 7.3^ m
Bundles 1^ Gasket Material (Note 5) Pitch 63.5
Bays 20^ Corrosion Allowance 3.0 mm FIN, Type *
Bundle Frame Slope 20 mm/m No., Size Inlet Nozzle * X * in Material *
MISCELLANEOUS (Note 2) No., Size Outlet Nozzle * X * in OD in Stock. Thick. mm
Louvers Manual TI PI SPECS.
Material, Blade * Hub Enclosure Zone 2, II A&B, T1 Support
HP/Fan, Des. * At Min. Amb. * Volt, Phase, Cycle 415 V, 3,50 Hz (Note 8)
Control Action on Air Failure - Fan Pitch Maximum cooling Louvers
2
Notes: ** Give tube count of each pass when irregular.
1) Flow and duty represent client requested design. This is a fully specified design therefore no additional margin is to be added by DEC or equipment vendor.
3) * - Vendor to specify. ^ Vendor to Confirm
4) A minimum of 10% overdesign is required.
7) Temperature shall be controlled with a combination of variable speed fans and fan on/off controls. Fan curves should be such that operation at 60%
of design air flow is possible. Two bays (bays 1 and 2) to be provided with 100% variable speed fans. See P&ID 102-220-09 for details.
ISSUE SHEET
0 2 of 2
CONFIDENTIAL: Not to be communicated to third parties without ADVANCED MATERIAL SOLUTIONS' written consent.
Specification for
Low Pressure Condensate Vent Condenser
Item No: EA-22002
Project No: J22N01

Polysilicon Manufacturing Facility Project
This document is the property of AMS ADVANCED MATERIAL

SOLUTIONS and the information contained herein is
proprietary information. Any copies, distribution or disclosure
of this document without the written consent of AMS
ADVANCED MATERIAL SOLUTIONS is expressly prohibited.
0 1-Nov-22 Issued for Review JMD HJ Customer__________________________________Date____________

Unit: 220 - CVD Reactors HCW System Location: Jamnagar, Gujarat, India
Service: Low Pressure Condensate Vent Condenser Manufacturer:
Bay Size: * Width: * Length: * Type: Forced Draft No. of Bays: * REV.
2 2
Heat Exchanged: 5.217 (Note 1) MM kcal/hrMTD, Eff.: * °C
2
Transfer Rate, Service: Finned Tube: * Bare Tube: * Clean: * kJ/m -hr-°C
Fluid Name: Steam IN OUT
Total Fluid Entering: 9747 (Note 1) kg/hr Density, Liquid Vap + NC kg/m3 - 0.8575 950.1 -
IN OUT Sp. Heat, Liq. Vap + NC kcal/kg-°C - 0.5083 1.0115 -
Temperature °C 110.8 108 Cond. Liq. Vap + NC kcal/m-hr-°C - 0 0.585 -
Liquid kg/hr Point °C
Noncond. kg/hr Mol. Wt. Latent Heat 532 kcal/kg
Steam kg/hr 9,747 Inlet Pressure 0.5 kg/cm²g
Water kg/hr 9,747 Press. Drop / Max Allow. 0.299 / 0.3 kg/cm²
Visc. Liq. Vap + NC cP - 0.0126 0.2518 - Fouling Resist., Inside 0.0002 m²-°C-hr/kcal
3
Air Quantity, Total 7980^ kg/hr (Nm /hr) Altitude above Sea Level 21 (Note 11) m
Air Quantity/Fan 2132^ act. m3/hr Temperature In (Design Dry Bulb) 41 °C
Actual Static Pressure * mbar Temperature Out 78.9 °C
Face Velocity 2.98^ Nm/s Mass Velocity (Net Free Area) * kg/hr-m2 Minimum Design Ambient 8 °C
Design Pressure 3.5 / FV kg/cm²g
Test Pressure barg Design Temperature 160 °C
Size, Width 3.719^ m Length 6^ m Material CS
No./Bay 1^ No. Tube Rows 4^ No. Passes** * OD 1.0 in Min. Thick. 3.0 mm
Arrangement Plug Material CS No./Bundle 230^ Length 6^ m
Bundles 1 Gasket Material (Note 5) Pitch 63.5^
Bays 2 Corrosion Allowance 3.0 mm FIN, Type *
Bundle Frame Slope 20 mm/m No., Size Inlet Nozzle * X * in Material *
MISCELLANEOUS (Note 2) No., Size Outlet Nozzle * X * in OD in Stock. Thick. mm
Material, Blade * Hub Enclosure Zone 2, II A&B, T1 Support
Control Action on Air Failure - Fan Pitch Maximum cooling Louvers Manual/Remote
2
Notes: ** Give tube count of each pass when irregular.
1) Flow and duty represent a 30% design margin. This is a fully specified margin therefore no additional margin is to be added by DEC or equipment vendor.
3) * - Vendor to specify. ^ Vendor to Confirm
4) A minimum of 10% overdesign is required.
7) Temperature shall be controlled with a combination of variable speed fans and fan on/off controls. Fan curves should be such that operation at 60%
of design air flow is possible. One bay (Bay 1) to be provided with 100% variable speed fans. See P&ID 102-220-09 for details.
ISSUE SHEET
0 2 of 2
CONFIDENTIAL: Not to be communicated to third parties without ADVANCED MATERIAL SOLUTIONS' written consent.
Specification for
Effluent Condenser
Item No: EA-A31702

EA-B31702
Project No: J22N01


0 11-Nov-22 Initial issue to client ENG MJF Customer__________________________________

Date____________
Issue Date Description By Appr'd Sheet 1 of 3 Spec No: J22N01-SP-EA-AB31702

Client: Reliance Industries Limited Project No: J22N01 Item No: EA-AB31702
Unit: 317 - Quench System Location: Jamnagar, Gujarat, India
Service: Effluent Condenser Manufacturer:
2
3
Total Fluid Entering: 329142 kg/hr (includes +20% design margin)Density Liquid Vap + NC kg/m - 54.18 1355 10.34
IN OUT Sp. Heat Liq. Vap + NC kcal/kg-°C - 0.199 0.194 0.611
Liquid kg/hr 297429 Freeze Point 10 °C
Vapor kg/hr Mol. Wt. 329142 77.0 31712 6.57 Bubble Point (Note 1) °C
3
Air Quantity, Total * kg/hr (Nm /hr) Altitude above Sea Level 21 (Note 11) m
Face Velocity * Nm/s Mass Velocity (Net Free Area) * kg/hr-m2 Minimum Design Ambient Temp 7.5 °C
Design Pressure 32.6 / FV kg/cm²g Test Pressure kg/cm²g Design Temperature 250 °C
Control Action on Air Failure - Fan Pitch Maximum cooling Louvers

Notes:
7) Fan curves should be such that operation at 60% of design air flow is possible.
12) Provide two indentical units, one for Train A, and one for Train B.
ISSUE SHEET
0 2 of 3
AMS - CONFIDENTIAL
Client: Reliance Industries Limited Project No: J22N01 Item No: EA-AB31702
Unit: 317 - Quench System Manufacturer:
Service: Effluent Condenser Location: Jamnagar, Gujarat, India REV.
3
Temp. Wt. Frac. Change kcal/kg-°C Vap. Avg. kg/m Mol. Frac. cP kcal/m-hr-°C Tension Pressure Temp.
143.59 1.0000 -888.78 0.1987 - 53.677 - 0.0169 - 0.0481 - - - -
140.59 1.0000 -889.38 0.1988 0.2254 54.180 1158.33 0.0168 0.1604 0.0477 0.0723 30.034 - -
137.07 0.8885 -893.35 0.2036 0.2232 50.772 1167.86 0.0167 0.1630 0.0510 0.0728 30.628 - -
133.19 0.7824 -897.32 0.2097 0.2210 47.226 1178.28 0.0166 0.1661 0.0548 0.0733 31.290 - -
128.89 0.6821 -901.28 0.2173 0.2187 43.552 1189.66 0.0165 0.1697 0.0591 0.0739 32.031 - -
124.12 0.5879 -905.25 0.2271 0.2163 39.764 1202.14 0.0164 0.1741 0.0640 0.0745 32.862 - -
119.91 0.5172 -908.43 0.2368 0.2143 36.668 1212.98 0.0163 0.1783 0.0684 0.0751 33.600 - -
115.33 0.4509 -911.60 0.2489 0.2123 33.529 1224.65 0.0162 0.1831 0.0733 0.0757 34.412 - -
110.32 0.3892 -914.78 0.2641 0.2102 30.370 1237.21 0.0160 0.1888 0.0788 0.0764 35.306 - -
104.86 0.3322 -917.95 0.2833 0.2081 27.215 1250.73 0.0159 0.1954 0.0847 0.0771 36.290 - -
98.90 0.2800 -921.13 0.3078 0.2059 24.095 1265.26 0.0156 0.2033 0.0912 0.0779 37.375 - -
93.51 0.2403 -923.78 0.3337 0.2041 21.547 1278.20 0.0154 0.2111 0.0969 0.0787 38.363 - -
87.72 0.2042 -926.42 0.3663 0.2022 19.071 1291.91 0.0151 0.2201 0.1029 0.0795 39.434 - -
81.50 0.1715 -929.07 0.4077 0.2003 16.691 1306.42 0.0148 0.2306 0.1090 0.0803 40.593 - -
74.83 0.1424 -931.71 0.4608 0.1983 14.433 1321.75 0.0144 0.2428 0.1151 0.0812 41.848 - -
67.68 0.1168 -934.36 0.5297 0.1964 12.324 1337.92 0.0139 0.2570 0.1210 0.0822 43.203 - -
60.03 0.0945 -937.00 0.6198 0.1944 10.388 1354.91 0.0133 0.2734 0.1265 0.0833 44.664 - -

140.59 1.0000 -889.31 0.1984 - 52.908 - 0.0168 - 0.0477 - - - -
101.10 1.0000 -889.51 0.1984 0.2247 53.074 1161.83 0.0167 0.1620 0.0476 0.0725 30.2224 - -
86.80 0.8894 -893.47 0.2033 0.2227 49.770 1171.18 0.0166 0.1647 0.0509 0.0729 30.8088 - -
75.70 0.7841 -897.42 0.2093 0.2205 46.329 1181.40 0.0166 0.1677 0.0546 0.0734 31.4629 - -
72.30 0.6843 -901.37 0.2169 0.2182 42.760 1192.57 0.0165 0.1714 0.0588 0.0740 32.1943 - -
70.50 0.5906 -905.32 0.2265 0.2159 39.078 1204.82 0.0164 0.1758 0.0637 0.0746 33.0146 - -
69.40 0.5201 -908.48 0.2362 0.2140 36.065 1215.46 0.0163 0.1799 0.0681 0.0752 33.7435 - -
68.50 0.4540 -911.65 0.2481 0.2120 33.009 1226.92 0.0162 0.1847 0.0729 0.0758 34.5449 - -
67.60 0.3923 -914.81 0.2630 0.2100 29.930 1239.27 0.0160 0.1904 0.0783 0.0765 35.4271 - -
66.80 0.3353 -917.97 0.2818 0.2079 26.851 1252.56 0.0158 0.1970 0.0842 0.0772 36.3988 - -
65.70 0.2831 -921.13 0.3059 0.2058 23.803 1266.86 0.0156 0.2049 0.0906 0.0780 37.4695 - -
64.30 0.2433 -923.77 0.3314 0.2039 21.310 1279.59 0.0154 0.2125 0.0963 0.0787 38.4448 - -
62.40 0.2069 -926.40 0.3633 0.2021 18.884 1293.09 0.0151 0.2215 0.1022 0.0795 39.5018 - -
59.40 0.1741 -929.03 0.4038 0.2002 16.548 1307.38 0.0148 0.2319 0.1083 0.0804 40.6467 - -
54.50 0.1447 -931.67 0.4557 0.1983 14.329 1322.50 0.0144 0.2441 0.1144 0.0813 41.8855 - -
46.50 0.1188 -934.30 0.5229 0.1964 12.252 1338.44 0.0139 0.2581 0.1203 0.0822 43.2241 - -
35.00 0.0963 -936.94 0.6107 0.1944 10.342 1355.22 0.0133 0.2744 0.1259 0.0832 44.6678 - -
ISSUE SHEET
0 3 of 3
AMS - CONFIDENTIAL
Specification for
Crude TCS Column Condenser
Item No: EA-32002
Project No: J22N01


Solutions LLC. All patents, designs, trade secrets, know how,
technical information, and other intellectual property contained in this
document are property of Advanced Material Solutions LLC. and may
not be reproduced, published or disclosed to others without the
express written consent of AMS. Any use of the information contained
in this package, other than for the purpose stated, is prohibited.
1 29-Dec-22 Updates Per Client Review ENG SPH


Unit: 320 - Crude TCS/STC Separation Location: Jamnagar, Gujarat, India
Service: Crude TCS Column Condenser Manufacturer:
2
Heat Exchanged: 20 MMkcal/hr MTD, Eff.: * °C
Total Fluid Entering: 452068 kg/hr (includes +20% design margin) Density Liq. Vap + NC kg/m3 - 19.199 1260 13.006 1
IN OUT Sp. Heat Liq.Vap + NC kcal/kg-°C - 0.1474 0.2135 0.1611
Liquid kg/hr - 450923 Freeze Point < - 10 °C 1
Vapor kg/hr Mol. Wt. 452068 135.0 1145 99.15 Bubble Point (Note 1) °C 1
Design Pressure 5.5 / FV kg/cm²g Test Pressure kg/cm²g Design Temperature 7.5 / 160 °C
No./Bay * No. Tube Rows * No. Passes** * OD * in Min. Thick. mm
Surface Preparation Rating & Facing 150# ANSI RF WN Code ASME Sec. VIII, Div. 1 Stamp 1

Notes:
is possible.
ISSUE SHEET
1 2 of 3
AMS - CONFIDENTIAL
Unit: 320 - Crude TCS/STC Separation Manufacturer:
Service: Crude TCS Column Condenser Location: Jamnagar, Gujarat, India REV.
78.74 1.0000 -868.91 0.1476 - 18.988 - 0.0137 - 0.0090 - - - -
75.74 1.0000 -869.35 0.1474 0.2202 19.199 1224.72 0.0136 0.2225 0.0089 0.0863 33.386 - -
75.72 0.8799 -874.26 0.1474 0.2202 19.192 1224.74 0.0136 0.2225 0.0089 0.0863 33.388 - -
75.70 0.7598 -879.17 0.1474 0.2202 19.183 1224.76 0.0136 0.2225 0.0089 0.0863 33.390 - -
75.66 0.6398 -884.08 0.1474 0.2202 19.172 1224.80 0.0136 0.2226 0.0089 0.0863 33.394 - -
75.63 0.5498 -887.77 0.1474 0.2202 19.160 1224.84 0.0136 0.2226 0.0089 0.0864 33.398 - -
75.59 0.4599 -891.45 0.1475 0.2202 19.144 1224.91 0.0136 0.2226 0.0090 0.0864 33.404 - -
75.54 0.3700 -895.13 0.1475 0.2202 19.122 1225.00 0.0136 0.2227 0.0090 0.0864 33.412 - -
75.45 0.2804 -898.81 0.1476 0.2202 19.087 1225.17 0.0136 0.2228 0.0091 0.0864 33.426 - -
75.39 0.2357 -900.65 0.1476 0.2201 19.060 1225.30 0.0136 0.2228 0.0091 0.0864 33.436 - -
75.30 0.1911 -902.49 0.1477 0.2201 19.022 1225.48 0.0136 0.2229 0.0092 0.0865 33.451 - -
75.16 0.1468 -904.34 0.1478 0.2200 18.964 1225.78 0.0136 0.2231 0.0093 0.0865 33.475 - -
74.92 0.1030 -906.18 0.1480 0.2199 18.862 1226.30 0.0136 0.2234 0.0094 0.0866 33.517 - -
74.42 0.0607 -908.02 0.1484 0.2197 18.642 1227.44 0.0136 0.2240 0.0098 0.0867 33.610 - -
72.84 0.0242 -909.86 0.1498 0.2190 17.959 1231.02 0.0136 0.2260 0.0112 0.0872 33.907 - -
67.76 0.0062 -911.70 0.1552 0.2167 15.862 1242.58 0.0136 0.2331 0.0161 0.0886 34.889 - -
60.00 0.0020 -913.54 0.1665 0.2135 13.036 1259.94 0.0136 0.2450 0.0246 0.0907 36.407 - -

75.74 1.0000 -869.25 0.1468 - 17.549 - 0.0136 - 0.0089 - - - -
101.10 1.0000 -869.48 0.1466 - 17.651 - 0.0135 - 0.0088 - - - -
86.80 1.0000 -869.71 0.1465 0.2188 17.754 1232.19 0.0135 0.2271 0.0088 0.0872 34.0011 - -
75.70 0.8819 -874.58 0.1465 0.2188 17.747 1232.20 0.0135 0.2272 0.0088 0.0872 34.0029 - -
72.30 0.7639 -879.44 0.1465 0.2188 17.739 1232.22 0.0135 0.2272 0.0088 0.0872 34.0054 - -
70.50 0.6460 -884.31 0.1465 0.2188 17.729 1232.26 0.0135 0.2272 0.0088 0.0872 34.0090 - -
69.40 0.5280 -889.17 0.1466 0.2187 17.715 1232.31 0.0135 0.2272 0.0088 0.0872 34.0143 - -
68.50 0.4102 -894.04 0.1466 0.2187 17.693 1232.41 0.0135 0.2273 0.0089 0.0873 34.0227 - -
67.60 0.2927 -898.90 0.1467 0.2187 17.656 1232.58 0.0135 0.2274 0.0089 0.0873 34.0378 - -
66.80 0.2487 -900.73 0.1467 0.2187 17.634 1232.70 0.0135 0.2274 0.0090 0.0873 34.0470 - -
65.70 0.2048 -902.55 0.1468 0.2186 17.603 1232.85 0.0135 0.2275 0.0090 0.0873 34.0601 - -
64.30 0.1612 -904.38 0.1469 0.2186 17.558 1233.09 0.0135 0.2277 0.0091 0.0874 34.0798 - -
62.40 0.1179 -906.20 0.1470 0.2185 17.482 1233.50 0.0135 0.2279 0.0093 0.0874 34.1129 - -
59.40 0.0756 -908.03 0.1473 0.2184 17.335 1234.30 0.0135 0.2284 0.0095 0.0875 34.1789 - -
54.50 0.0364 -909.85 0.1482 0.2179 16.942 1236.46 0.0135 0.2296 0.0104 0.0878 34.3587 - -
46.50 0.0105 -911.68 0.1517 0.2164 15.557 1244.31 0.0135 0.2345 0.0136 0.0888 35.0275 - -
35.00 0.0030 -913.50 0.1611 0.2135 13.006 1260.09 0.0135 0.2454 0.0211 0.0907 36.4086 - -
ISSUE SHEET
1 3 of 3
AMS - CONFIDENTIAL
Specification for
STC Purification Column Condenser
Item No: EA-33002
Project No: J22N01


1 29-Dec-22 Updates Per Client Review ENG SPH


Unit: 320 - Crude TCS/STC Separation Location: Jamnagar, Gujarat, India
Service: STC Purification Column Condenser Manufacturer:
2
Fluid Name: STC Purification Column OVHD Line IN OUT 1
Total Fluid Entering: 113716 kg/hr (includes +20% design margin) Density Liquid Vap + NC kg/m3 1361.3 11.13 1376.3
IN OUT Sp. Heat Liq. Vap + NC kcal/kg-°C 0.1942 0.1352 0.1925
Temperature °C 76.00 69.36 Therm. Cond. Liq. Vap + NC kcal/m-hr-°C 0.0800 0.0077 0.0807
Liquid kg/hr 113716 Freeze Point < - 10 °C 1
Vapor kg/hr Mol. Wt. 113716 169.8 Bubble Point (Note 1) °C 1
Design Pressure 4.0 / FV kg/cm²g Test Pressure kg/cm²g Design Temperature 160 °C 1

Notes:
is possible.
ISSUE SHEET
1 2 of 3
AMS - CONFIDENTIAL
Unit: 320 - Crude TCS/STC Separation Manufacturer:
Service: STC Purification Column Condenser Location: Jamnagar, Gujarat, India REV.
79.00 1.000 -925.80 0.1354 11.022 0.0123 0.0077 - -
76.00 1.000 -926.21 0.1352 0.1942 11.133 1361.29 0.0122 0.2996 0.0077 0.0800 43.476 - -
76.00 0.833 -932.43 0.1352 0.1942 11.132 1361.28 0.0122 0.2996 0.0077 0.0800 43.476 - -
75.99 0.666 -938.65 0.1352 0.1942 11.132 1361.28 0.0122 0.2996 0.0077 0.0800 43.476 - -
75.98 0.499 -944.87 0.1352 0.1942 11.131 1361.27 0.0122 0.2996 0.0077 0.0800 43.477 - -
75.97 0.332 -951.10 0.1352 0.1942 11.130 1361.26 0.0122 0.2996 0.0077 0.0800 43.477 - -
75.96 0.166 -957.32 0.1352 0.1942 11.128 1361.25 0.0122 0.2996 0.0077 0.0800 43.478 - -
75.70 0.000 -963.54 0.1354 0.1942 11.057 1361.78 0.0122 0.3001 0.0079 0.0800 43.525 - -
74.99 0.000 -963.68 0.1940 1363.40 0.3018 0.0801 43.660 - -
74.29 0.000 -963.81 0.1938 1365.02 0.3034 0.0802 43.796 - -
73.59 0.000 -963.95 0.1936 1366.63 0.3051 0.0802 43.932 - -
72.88 0.000 -964.09 0.1934 1368.24 0.3068 0.0803 44.067 - -
72.18 0.000 -964.22 0.1932 1369.85 0.3085 0.0804 44.203 - -
71.47 0.000 -964.36 0.1930 1371.45 0.3102 0.0805 44.339 - -
70.77 0.000 -964.49 0.1928 1373.05 0.3119 0.0805 44.475 - -
70.07 0.000 -964.63 0.1926 1374.65 0.3137 0.0806 44.611 - -
69.36 0.000 -964.76 0.1925 1376.24 0.3154 0.0807 44.747 - -

76.00 1.000 -926.10 0.1347 9.211 0.012 0.0077 - -
75.22 1.000 -926.21 0.1346 9.235 0.012 0.0076 - -
74.43 1.000 -926.31 0.1345 9.259 0.012 0.0076 - -
73.64 1.000 -926.42 0.1345 9.283 0.012 0.0076 - -
72.86 1.000 -926.52 0.1344 9.307 0.012 0.0076 - -
72.07 1.000 -926.63 0.1344 9.331 0.012 0.0076 - -
71.29 1.000 -926.73 0.1343 9.355 0.012 0.0075 - -
70.50 1.000 -926.84 0.1343 9.380 0.012 0.0075 - -
69.72 1.000 -926.95 0.1342 0.1925 9.404 1375.65 0.012 0.315 0.0075 0.0807 44.689 - -
69.71 0.857 -932.35 0.1342 0.1925 9.404 1375.65 0.012 0.315 0.0075 0.0807 44.689 - -
69.71 0.714 -937.75 0.1342 0.1925 9.404 1375.64 0.012 0.315 0.0075 0.0807 44.689 - -
69.70 0.571 -943.15 0.1342 0.1926 9.403 1375.64 0.012 0.315 0.0075 0.0807 44.690 - -
69.69 0.428 -948.56 0.1342 0.1926 9.402 1375.63 0.012 0.315 0.0075 0.0807 44.690 - -
69.68 0.285 -953.96 0.1342 0.1926 9.402 1375.62 0.012 0.315 0.0075 0.0807 44.690 - -
69.67 0.142 -959.36 0.1342 0.1926 9.400 1375.61 0.012 0.315 0.0075 0.0807 44.691 - -
69.36 0.000 -964.77 0.1345 0.1925 9.326 1376.24 0.012 0.315 0.0077 0.0807 44.747 - -
66.36 0.000 -965.34 0.1917 1383.01 0.323 0.0810 45.329 - -
ISSUE SHEET
1 3 of 3
AMS - CONFIDENTIAL
RELIANCE INDUSTRIES LIMITED
Process Datasheet
BCW Air Cooler (ME-EPE265-A601502A/B)
PROJECT : POLYSILICON MANUFACTURING FACILITY
DOCUMENT N0 : J22N01-MEABD-EPE265-601-114
RIL/WIPL PROJECT : J22N01 / 413102-00055
Worley Engineering India Private Limited

New Energy House, Ramkrishna Mandir Road,
Kondivita, Andheri East, Mumbai-400058, India
© Copyright 2022 Worley ACN 096 090 158. No part of this document or the information it contains may be reproduced or transmitted in any form or by any means
electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from Worley.
1
www.worley.com
PROJECT - POLYSILICON MANUFACTURING FACILITY – Process Datasheet – BCW Air Cooler
Worley Revision Customer

Rev Description Originator Reviewer Approval Date
Approver Date Approver
0A Issued for 13 Dec 2022
Review
Priyanka Ghuge Sunil Joshi Sunil Joshi
2
Client: Reliance Industries Limited Project No: J22N01 Item No: ME-EPE265-A601502A/B
Unit: 601- Baseplate Cooling System Location: Jamnagar, Gujarat, India
Service: BCW air cooler Manufacturer:
Finned Tube: * Bare Tube: * m2
Surface Area per Unit: m2
Heat Exchanged: 35.88 /16.31 (Design/Normal) MMkcal/hr (Note 9) MTD, Eff.: * °C
Fluid Name: Base plate cooling water IN OUT
Total Fluid Entering: 3262320 kg/hr (includes +20% design margin) Density Liquid Vap + NC kg/m3 - 983.6 985.7 -
IN OUT Sp. Heat Liq. Vap + NC kcal/kg-°C - 1.004 1.004 -
Temperature (Nor/Max) °C 60/70 55 Therm. Cond. Liq. Vap + NC kcal/m-hr-°C - 0.56 0.55 -
Liquid kg/hr 3262320 3262320 Freeze Point 0 °C
Noncond. kg/hr Mol. Wt. Latent Heat - kcal/kg
Steam kg/hr Inlet Pressure 6 kg/cm²g
Water kg/hr Press. Drop / Max Allow. 0.5 kg/cm²
Air Quantity, Total * kg/hr (Nm3/hr) Altitude above Sea Level (Note 8) 21 m
Air Quantity/Fan * act. m3/hr Temperature In (Design Dry Bulb) (Note 8) 41°C
Face Velocity * Nm/s Mass Velocity (Net Free Area) * kg/hr-m2 Minimum Design Ambient (Note 8) 7.5 °C
Design Pressure 12/FV kg/cm²g Test Pressure kg/cm²g Design Temperature 90 °C
No./Bay * No. Tube Rows * No. Passes** * OD * in
Min. Thick.
Bays * Corrosion Allowance 3.0 m FIN, Type *
Bundle Frame Slope * mm/m No., Size Inlet Nozzle * x * in Material *
MISCELLANEOUS (Note 1) No., Size Outlet Nozzle * x * in OD in mm Stock. Thick.
Louvers N/A TI PI SPECS.
Material, Blade * Hub Enclosure - Support
HP/Fan, Des. * At Min. Amb. * Volt, Phase, Cycle 415 V, 3, 50 Hz
Control Action on Air Failure - Fan Pitch Maximum cooling Louvers N/A
Recirculation Steam Coil *

Notes:

4) Air cooler to be mounted above piperack.
5) Temperature shall be controlled with a combination of variable speed fans and fan on/off controls. Fan curves should be such that operation at 60% of design air flow is possible.
8) Refer BEDD RPMS-ENGG-DBD-PS-001 Rev 02 for site condition details.
9) Design heat duty is calculated based upon design BCW flowrate(Ref - J22N01-SP-UTIL_SUM_REV_2A_WIP) with 10% margin.
ISSUE SHEET
0A 1 of 1
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
E-03204 EA-03202 V-03201
MATCH LINE
MATCH LINE
TCS HEAVY IMPURITY COLUMN II PRODUCT TCS HEAVY IMPURITY COLUMN II TCS HEAVY IMPURITY COLUMN II OVERHEAD
DWG. NO.
DWG. NO.
COOLER CONDENSER RECEIVER
A TUBESIDE: DESIGN PRES : 16.5/FV KG/CM²G TYPE: AIR COOLER DIA : 3600 mm
DESIGN TEMP: 65°C DESIGN PRESSURE 6.5/FV KG/CM²G TL-TL: 10800 mm
SHELLSIDE: DESIGN PRES: 21.0/FV KG/CM²G DESIGN TEMP 160°C DESIGN PRES: 6.5/FV KG/CM²G
DESIGN TEMP: 90°C DESIGN TEMP: 160°C
102-032-02
SIGNAL FROM 032-PY-117
B H L
Nitrogen Supply A01U A01P
EPE255-000-510 N VH-2
2-N-910XXX-A01U-N FC FC 8-VG-911XXX-A01P-N
H
C
8-VG-032017-A01P-N
8-VG-032016-A01P-PP
42-P03-032014-A01P-PP
102-032-02 FROM C-03202
NO POCKETS
D
H L
NO POCKETS
EA-03202
NOTE 9 18-P02-032015-A01P-N
M
2o3
HH LL
8-P02-032023-B01P-HC
MIN. FLOW STARTUP ONLY- NNF 6-P02-032026-B01P-N
102-125-02
TCS TO T-12504A/B
E B01P
A01P Mo3
A2 A1 P V K L1/L3/L5/L7
H L SP
A/B/C/D
H L V-03201
HHLL 2330
HLL 2090 M
NLL 1480 6-P02-032025-B01P-N
T 102-125-03
F LLL 820 PURE TCS TO T-12505A/B/C
LLLL 500 SET @ HOLD FC FC
KG/CM²G
ELEV: 6100 mm
NOTE 2 B L2/L4/L6/L8
XX-CWR-904XXX-A01U-N
H
PH 1.5-P02-032052-B01P-N
14-P02-032022-B01P-HC NOTE 5
102-032-02
TO C-03202
FO
G
Cooling Water Return
20-P02-032018-A01P-HC
CWR EPE255-000-503
4-CWR-904XXX-A01U-N
B1 B2
2-CWS-904XXX-A01U-N
E-03204
A1 A2
H PP
Cooling Water Supply
4-CWS-904XXX-A01U-N
6-P02-032024-B01P-PP
CWS EPE255-000-503
14 x 10
10-P02-032056-B01P-HC 10 x 14
10 x 14
J
14 x 20
A01P
B01P
14-P02-032019-B01P-HC
14-P02-032021-B01P-HC
14-P02-032020-B01P-HC
K
10-P02-032058-B01P-HC
10-P02-032057-B01P-HC
PP-03202 A/B/C
TCS HEAVY IMPURITY COLUMN II
OVERHEAD RECEIVER PUMP
DESIGN FLOW: 304 CMPH TS TS TS
L ΔP: 9.1 KG/CM³

PP-03202 C PP-03202 B PP-03202 A
Description
CONFIDENTIAL - This document is the property of ADVANCED
MATERIAL SOLUTIONS LLC. All patents, designs, trade secrets, know POLYSILICON MANUFACTURING FACILITY
how, technical information, and other intellectual property contained in Drawing Type
PIPING AND INSTRUMENTATION DIAGRAM
this document are the property of ADVANCED MATERIAL SOLUTIONS
M LLC. and may not be reproduced, published or disclosed to others without TCS HEAVY IMPURITY COLUMNS OVERHEAD SYSTEM
the express written consent of AMS. Any use of the information contained Drawing No. Project No. Issue
J22N01
ISS. DATE ISS. BY DESCRIPTION ENG. P.M. CLIENT
102-032-03 Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
E-07002 V-07001 E-07004
MATCH LINE
MATCH LINE
CVD OGR TCS/STC CVD OGR TCS/STC COLUMN CVD OGR TCS/STC KNOCK-BACK
DWG. NO.
DWG. NO.
COLUMN CONDENSER OVERHEAD RECEIVER CONDENSER
A TYPE: BEM DIAMETER: 3010 mm TYPE:
DESIGN PRES: 5.5/ FV KG/CM²G TL-TL: 8900 mm TUBESIDE: DESIGN PRES: 6.0/FV KG/CM2G
DESIGN TEMP: 160°C DESIGN TEMP: 160°C DESIGN TEMP: 160 °C
DESIGN PRES: 6.0 / FV KG/CM²G SHELLSIDE: DESIGN PRES: 5.0/FV KG/CM2G
DESIGN TEMP: 65 °C
102-070-01
SIGNAL FROM 070-PY-010 SET @ 5.0
KG/CM2G
NOTE 1 2-N-910XXX-A01U-N A01U A01P
B H L
Nitrogen Supply
EPE255-000-510
VH-3 N VH-2
XX-VG-911XXX-A01P-N FC FC 2-VG-911XXX-A01P-N
2-P03-070035-A01P-N
NOTE 1
C
SET @ 5.0
KG/CM2
4-P02-070018-A01P-N
NOTE 1 X-CWR-904XXX-A01U-N
ph
B2
D 36-P03-070016-A01P-PP EA-07002
102-070-01 FROM C-07001 NOTE 9 L
A
ELEV: HOLD Cooling Water Return
NOTE 67
CWR EPE255-000-503
B1 2-CWR-904XXX-A01U-N
E-07004 NOTE 27 1.5-CWR-904XXX-A01U-N

NO POCKETS
M
16-P02-070017-A01P-N A1
E CWS EPE255-000-503
2-CWS-904XXX-A01U-N
CSO
6-P02-070030-B01P-N
B01P A01P
A3 A2 A1 A4 P V K L1/L3/L5/L7 Mo3
V-07001
HHLL 2030mm A/B/C/D
H L
M2
HLL 1800mm M1 2o3
10-P02-070015-B01P-N NLL 1260mm
F 102-070-01 TCS TO C-07001
HH LL
LLL 680mm
T LLLL 390mm
CSO CSO FC CSO ELEV: 6100
NOTE 2
B L2/L4/L6/L8
G CSO B01P A01P
CSO
3-P02-070023-B01P-N
H STARTUP ONLY - NNF
4-P02-070026-B01P-N
TCS TO T-12508 A/B 102-125-04
SP
14 x 18
18-P02-070019-A01P-N
6-P02-070024-B01P-N
J TCS TO T-12509 A/B 102-125-05
6-P02-070024-B01P-N FC
B01P A01P B01P A01P
10-P02-070029-B01P-N 6-P02-070022-B01P-N
18 x 8
2-P02-070025-B01P-N
NOTE 11 NOTE 11
B01P A01P B01P A01P
NOTE 5
14-P02-070028-B01P-N
14-P02-070027-B01P-N
8-P02-070021-B01P-N
8-P02-070020-B01P-N
PP-07002 A/B PP-07004 A/B

CVD OGR TCS/STC COLUMN CVD OGR TCS/STC COLUMN
OVERHEAD RECEIVER PUMP DISTILLATE PUMP
DESIGN FLOW: 292 CMPH DESIGN FLOW: 126 CMPH
ΔP: 7.3 KG/CM² ΔP: 4.2 KG/CM²
TS TS TS TS
L
PP-07002 B PP-07002 A PP-07004 B PP-07004 A
Description
PROCESS AND INSTRUMENT DIAGRAM
M LLC. and may not be reproduced, published or disclosed to others without CVD REACTORS OGR TCS/STC COLUMN OVERHEAD SYSTEM
J22N01
102-070-02 Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
EA-07008 V-07002
MATCH LINE
MATCH LINE
CVD OGR STC AIR COOLER CVD OGR STC RECIEVER
DWG. NO.
DWG. NO.
TYPE: BEM DIAMETER: 1800 mm
A DESIGN PRES: 6.0/FV KG/CM²G TL-TL: 5000 mm
DESIGN TEMP: 160°C DESIGN TEMP: 160 °C
DESIGN PRES: 6.0 KG/CM²G
2-P01-070043-A01P-N
C
VH-2
6-P01-070009-A01P-PP EA-07008
102-070-01 STC VAPOR FROM C-07001 NOTE 9
A
1.5-P01-911XXX-B01P-CC
ELEV: HOLD
NOTE 67
M 4-P01-070044-A01P-N
H MIN FLOW
1.5-P01-070049-A01P-N
2 x 1.5
E 2o3
A1 A2 P V A3 L1/L3/L5/L7 LL
V-07002
A/B/C/D Mo3
HHLL 1100mm
M HLL 950mm A01P

T
NLL 700mm B01P
CSO
LLL 450mm
LLLL 300mm
F ELEV: 4000 MIN
4-P01-070005-B01P-HC H L
102-070-01 PP-07001A/B TO E-07003 CSO
H L
4-P01-070003-B01P-HC
3-P01-070050-B01P-N
STC LIQUID TO E-06007 102-060-06
FC FC
3-P01-070051-B01P-N
G 6-P01-070002-A01P-HC
102-070-01
C-07001 BOTTOMS TO PP-07001A/B
A01P B01P 6-P01-070007-B01P-HC
A01P B01P
3-P01-070048-B01P-N
4-P01-070045-A01P-N
NOTE 11
A01P A01P
B01P B01P
NOTE 11
4-P01-070046-B01P-N
4-P01-070047-B01P-N
6-P01-070002-B01P-HC
ST ST
TS TS
J PP-07001 A PP-07001 B
PP-07005 A PP-07005 B
PP-07005 A/B
PP-07001 A/B CVD OGR TCS/STC COLUMN SIDE
CVD OGR TCS/STC COLUMN BOTTOMS PUMP DRAW PUMP
DESIGN FLOW: 65.1 CMPH DESIGN FLOW: 21.8 CMPH

ΔP: 2.9 KG/CM² ΔP: 14.7 KG/CM²
Description
M LLC. and may not be reproduced, published or disclosed to others without CVD REACTORS OGR TCS/STC COLUMN SIDEDRAW SYSTEM
J22N01
102-070-03 Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
SX-22002 EA-22001
STEAM SILENCER HOT COOLING WATER FLASH CONDENSER
MATCH LINE
MATCH LINE
TO ATMOSPHERE
DWG. NO.
DWG. NO.
DESIGN PRES: 4.2/FV KG/CM² G TYPE: AIR COOLER
(SAFE LOCATION)
A DESIGN TEMP: 160°C DESIGN PRES: 4.2/FV KG/CM² G
DESIGN TEMP: 160°C
SX-22002
EA-22001 INSTRUMENTATION DETAILS:
LOUVER ON/OFF SPEED

102-220-01 BAY NO. MOTOR NO.
SIGNAL FROM 220-PT-001 A/B/C CONTROL CONTROL CONTROL
L
1 HC-029A XY-030A SIC-031A
1
2 HC-029B XY-030B SIC-031B
B 3 HC-029C XY-030C SIC-031C
30-LPS-917005-A01U-PP CSO FC CSO 2
4 HC-029D XY-030D -
5 HC-029E XY-030E SIC-031E
3
6 HC-029F XY-030F -
CSO 7 HC-029G XY-030G SIC-031G
4
M 8 HC-029H XY-030H -
3-LPS-917103-A01U-PP 9 HC-029I XY-030I SIC-031I
5
10 HC-029J XY-030J -
C 11 HC-029K XY-030K SIC-031K
6
12 HC-029L XY-030L -
48-LPS-917001-A01U-HC 48-LPS-917001-A01U-HC 13 HC-029M XY-030M SIC-031M
102-220-01 FROM V-22001
N
NOTE 12 14 HC-029N XY-030N -
12-LPS-917104-A01U-HC
NOTE 9
NOTE 12 NOTE 12
HOLD HOLD
FO
EA-22001
EA-22001
EA-22001
EA-22001
EA-22001
EA-22001
NOTE 12
BAY N
BAY 2
BAY 3
BAY 4
BAY 5
BAY 6
F
EA-22001
ELEV= 3500 ABOVE V-22001

BAY 1
NOTE 78
FO FO FO FO FO FO FO FO FO FO FO FO
ELEV= 5000 ABOVE V-22001

NOTE 78
H
H L
6-LPC-919001-A01U-HC
102-220-01 TO V-22001
AIR COOLER
MASTER
CONTROLLER
102-220-01 SIGNAL FROM 220-PT-001 A/B/C
H L
HOLD HOLD
NOTE 12 NOTE 12
K H L
20-LPC-919002-A01U-HC
102-220-01 TO V-22001
Description
M LLC. and may not be reproduced, published or disclosed to others without HOT COOLING WATER FLASH CONDENSATE
J22N01
102-220-02 Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
V-22002 EA-22002
LOW PRESSURE CONDENSATE DRUM LOW PRESSURE CONDENSATE
MATCH LINE
MATCH LINE
VENT CONDENSER
DWG. NO.
DWG. NO.
DIA: 2600 mm
A TL-TL: 8000 mm TYPE: AIR COOLER
DESIGN PRES: 3.5/ FV KG/CM²G DESIGN PRES: 3.5/FV KG/CM²G
Xx4
48-LPS-917002-A01U-HC
102-220-01
LPS FROM V-22001
2-LPS-917XXX-A01U-HC
10-LPS-917XXX-A01-HC
TO ATMOSPHERE TO ATMOSPHERE
(SAFE LOCATION) (SAFE LOCATION)
B
XX-LPS-917XXX-A01U-PP
X-LPS-917102-A01U-HC
SET @
3.5 KG/CM² G
NOTE 1
FC
E-32001 A/B
E-03201 A/B
102-112-02B
102-112-02A
SD-A11201
SD-B11201
102-330-01
102-035-01
102-320-01
102-030-01
102-032-01
102-038-01
102-040-01
102-040-01
102-070-01
102-040-03
102-060-06
E-33001
E-03501
E-03001
E-03801
E-04001
E-07001
E-04004
E-04002
E-06017
C
C
L EA-22002
ELEV= MIN 5000
10-LPS-917101-A01U-HC A NOTE 9 ABOVE V-22002
B NOTE 89
Mo3
102-112-02D
102-112-02C
SD-C11201
SD-D11201
M
D 2o3 H
LL
1.5-LPC-919XXX-A01U-HC
2-LPC-919XXX-A01U-HC
4-LPC-919XXX-A01-HC
A/B/C/D
3-LPC-919101-A01U-HC
E
V K
P A1
L1/L3/L5/L7
A/B/C/D
2o3 NOTE 15 V-22002
F HH LL TO ATMOSPHERE
(SAFE LOCATION)
C 30-LPC-919100-A01U-HC NOTE 17
Mo3 HHLL 5980
6-LPC-919102-A01U-HC FC CSO V2 HLL 4460
NLL 3140
LLL 1810
LLLL 300
COND
HC
T H L
G H L M
H L2/L4/L6/L8
A3 FC 4-LPS-917002-A01U-HC
102-220-01 ELEV: 6000 mm
SIGNAL FROM 220-LIC-003 3-LPC-919107-A01U-HC CSO A2 NOTE 2
CSO
B
H
NOTE 5
H L
CSO
L
10-LPC-919104-A01U-HC
102-220-01 LPC TO PP-22001 A/B/C FC FC 10-LPC-919104-A01U-HC CSO
CSO
CSO CSO
12-LPC-919103-A01U-HC
12-LPC-919103-A01U-HC
10-LPC-919105-A01U-HC TO GRADE TO GRADE

BL LPC TO PLANT AT SAFE AT SAFE
K FC NNF
LOCATION LOCATION
PP-22002 A/B
CONDENSATE SYSTEM
LOW PRESSURE CONDENSATE PUMP
DESIGN FLOW: 310 CMPH
ΔP: 35.8 KG/CM²
PP-22002 B PP-22002 A
L
NOTE 3 NOTE 3
Description
M LLC. and may not be reproduced, published or disclosed to others without LOW PRESSURE CONDENSATE SYSTEM
J22N01
102-220-09 Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
MATCHLINE
MATCHLINE
DWG. NO.
DWG. NO.
EA-A31702 E-A31703 V-A31702
EFFLUENT CONDENSER EFFLUENT TRIM CONDENSER EFFLUENT RECEIVER
TYPE: AIR COOLER TYPE: BEU DIA: 2850 mm
A DESIGN PRES: 32.6/FV KG/CM²G TUBESIDE: DESIGN PRES: 25.1/FV KG/CM²G TL-TL: 8000 mm
DESIGN TEMP: 250 °C DESIGN TEMP: 65 °C DESIGN PRES: 33.5/FV KG/CM²G
SHELLSIDE: DESIGN PRES: 32.6/FV KG/CM²G DESIGN TEMP: 250 °C
DESIGN TEMP: 250 °C

H
10-P03-A317030-B01P-N
OFF GAS TO E-31803 102-318-01
SET @ 25.1 KG/CM²G
H L NOTE 1
2-P03-A317018-B01P-N X-CWR-904XXX-A01U-N pH
Cooling Water Return

CWR EPE255-000-503
4-CWR-904XXX-B01U-N
C
2-CWR-904XXX-A01U-N
10-P03-A317016-B01P-N
B01U A01U
20-P03-A317013-B01P-PP EA-A31702 A1 B1 B2
102-317-02A FROM C-A31702 NOTE 9
ELEV:
NOTE 67 E-A31703
ELEV: MIN. 11400 mm
D A2 NOTE 70
M
NOTE 27
D
20-P07-A317015-B01P-N
NO POCKETS
CWS EPE255-000-503
3-P07-A317017-B01P-N 4-CWS-904XXX-B01U-N
B01U A01U
SP
STARTUP ONLY - NNF 4-P01-A125115-B01P-PP

STC FROM PP-A12503 A/B/C
102-125-01
FC
3-P07-A317023-B01P-N
CSO
M1
A2 A1 P A3 A4 V K L2/L4/L6/L8
V-A31702
F Mo3
HHLL 1480
HLL 1330
NLL 970 M2 SIGNALS TO 317-FIC-046 102-317-04A
H L
LLL 560 A/B/C/D
LLLL 350 2o3
ELEV: 6000 mm HH LL
NOTE 2
T S B1 B2 L1/L3/L5/L7
L
CSO CSO
G
CSO
FO
8-P07-A317019-B01P-N
H
CSO
6-P07-A317024-B01P-N
CRUDE TCS/STC TO SF-A31701
102-317-04A
FC
CORIOLIS
NOTE 31
8-P07-A317021-B01P-N
102-317-02A REFLUX TO C-A31702
J
CSO
2-P07-A317103-B01P-N
102-317-01A WASH TO C-A31701 NOTE 11
CSO
CSO
CSO
CSO
K
CSO
PP-A31702 A/B
QUENCH REFLUX PUMP
ΔP: 7.4 KG/CM² B01P C04 B01P B01P C04P B01P
NOTE 3 C04P C04P
TS TS
CSO CSO
L
PP-A31702 B PP-A31702 A
NOTE 3 NOTE 3
Description
how, technical information, and other intellectual property contained in Drawing Type PIPING AND INSTRUMENTATION DIAGRAM
this document are the property of ADVANCED MATERIAL SOLUTIONS QUENCH COLOUMN OVERHEAD SYSTEM - TRAIN A
M LLC. and may not be reproduced, published or disclosed to others without (THIS SHEET TYPICAL FOR EACH TRAIN - SEE NOTE 26)
J22N01
102-317-03A Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
EA-32002 V-32001 E-32004

CRUDE TCS COLUMN CONDENSER CRUDE TCS COLUMN OVERHEAD RECEIVER CRUDE TCS COLUMN KNOCK BACK
CONDENSER
MATCHLINE
MATCHLINE
DWG. NO.
DWG. NO.
TYPE: AIR COOLER DIA: 3000 mm
A DESIGN PRESSURE: 5.0/FV KG/CM²G TL-TL: 9000 mm TYPE: -EM
DESIGN TEMP: 160°C DESIGN PRES: 5.0/FV KG/CM²G TUBESIDE: DESIGN PRES: 5.5/FV KG/CM²G
SHELLSIDE: DESIGN PRES: 7.0/FV KG/CM²G
DESIGN TEMP: 65°C
Mo3
102-320-01
B SIGNAL FROM 320-PT-017 A/B/C/D SPLIT RANGE
2o3
HH LL
Nitrogen Supply A01U A01P H L
EPE255-000-510
N VH-2
C 2-N-910XXX-A01U-N FC FC 3-VG-911XXX-A01P-N
2-VG-320015-A01P-N
H
SET @ HOLD
KG/CM²G
4-VG-320030-A01P-PP
D
NOTE 1
1.5-CWR-909XXX-A01U-N
pH
PP L
30-P03-320013-A01P-PP Cooling Water Return

E 102-320-01 TCS FROM C-32001
CWR EPE255-000-503
1.5-CWR-909XXX-A01U-N
D
1.5-CWS-909XXX-A01U-N
H L E-32004 PP
NO POCKETS NOTE 27
EA-32002 16-P01-320014-A01P-PP
C
M
NOTE 9 EPE255-000-503
CWS
NOTE 67 1.5-CWS-909XXX-A01U-N
F B01P
A01P
A2 A1 P V D K 16" L1/L3/L5/L7
Mo3
V-32001
HHLL 1940
HLL 1740 M H L
A/B/C/D
NLL 1250
T LLL 720
LLLL 470 2o3
ELEV: 6000 MIN. HH LL
G NOTE 2
B L2/L4/L6/L8
PP
16-P01-320018-A01P-N
L STARTUP ONLY- NNF 6-P07-320025-B01P-PP
CRUDE TCS TO T-12504A/B 102-125-02
SP
H FO 6-P01-320023-B01P-N
MIN. FLOW
6-P01-320024-B01P-PP
TCS TO C-03001 102-030-01
10-P01-320021-B01P-PP 10 x 6 FC
102-320-01 REFLUX TO C-32001
B01P
A01P
10-P01-320055-B01P-PP NOTE 5
1.5-P01-320026-B01P-N
A01P
NOTE 11
B01P
102-030-01
SIGNAL TO 030-FY-051
16-P01-320019-B01P-PP
16-P01-320020-B01P-PP
K
PP-32002 A/B
CRUDE TCS COLUMN OVERHEAD
RECEIVER PUMP
TS TS
PP-32002 B PP-32002 A ΔP: 8.8 KG/CM²
L
Description
MATERIAL SOLUTIONSs LLC. All patents, designs, trade secrets, know POLYSILICON MANUFACTURING FACILITY
PIPING AND INSTRUMENTATION DIAGRAM
this document are the property of ADVANCED MATERIAL SOLUTIONSs
M LLC. and may not be reproduced, published or disclosed to others without CRUDE TCS COLUMN OVERHEAD SYSTEM
J22N01
102-320-02 Sheet
1 of 1
Scale
None
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
EA-33002 V-33001
MATCH LINE
MATCH LINE
STC PURIFICATION COLUMN CONDENSER STC PURIFICATION COLUMN
DWG. NO.
DWG. NO.
TYPE: AIR COOLER OVERHEAD RECEIVER
A DESIGN PRES: 3.5/FV KG/CM²G DIA: 1950 mm
DESIGN TEMP: 160°C TL-TL: 5700 mm
DESIGN PRES: 3.5/FV KG/CM²G
DESIGN TEMP: 160 °C
Mo3
102-330-01
SIGNAL FROM 330-PT-017 A/B/C/D SPLIT RANGE
B
2o3
HH LL
H L
Nitrogen Supply A01U A01P
EPE255-000-510 N VH-2
1.5-N-910XXX-A01U-N FC FC 2-VG-911XXX-A01P-N
2-VG-330013-A01P-N
2-VG-330026-A01P-N
20-P03-330010-A01P-PP
102-330-01 FROM C-33001
E
H L
EA-33002
M
NOTE 9
NOTE 67
NO POCKETS
8-P01-330014-A01P-N
F
3-P01-330019-B01P-PP
A01P B01P
C A P V K L1/L3/L5/L7
Mo3
V-33001
HHLL 1310
G HLL 1160 M1 A/B/C/D
H L
NLL 880
T LLL 600
2o3
LLLL 450
ELEV: 5500 mm HH LL
SP
PP
6-P01-330017-B01P-PP
102-330-01 TO C-33001
H 3-P01-330020-B01P-PP
CLEAN STC 102-125-01
FC FC TO T-12503 A/B
MIN. FLOW
1.5-P01-330022-B01P-N
NOTE 5
J
6-P01-330018-B01P-PP B01P A01P
8-P01-330014-A01P-PP 2-P01-330021-B01P-PP
CLEAN STC 102-038-01
A01P B01P
TO C-03801
NOTE 11
8-P01-330016-B01P-PP
8-P01-330015-B01P-PP
PP-33002 A/B
STC PURIFICATION COLUMN
TS TS OVERHEAD RECEIVER PUMP
DES. FLOW: 118.1 CMPH
PP-33002 B PP-33002 A
ΔP: 6.6 KG/CM²
L
Description
M LLC. and may not be reproduced, published or disclosed to others without TCS LIGHT IMPURITY COLUMN OVERHEAD SYSTEM
J22N01
102-330-02 Sheet
1 of 1
Scale
None
2
Inspection and Test Plan for Air Cooled Heat Exchanger
CUSTOMER :- RELIANCE INDUSTRIES LIMITED ITP NO: RPMS-PROC-ITP-MS-007

PROJECT:- XXXXXX Rev No : 0 Date : 15.06.2020
Detail Engineering Contractor(DEC):- XXXXXX PO No: XXXXXX SQS Level: X
Ref.Docs:- ASME, API 661, Applicable code & Standards, Approved Datasheet & Drawings, Material Requisition & Statutory standards etc (as
Legends: P=Perform, R=Review W= Witness, RW=Random Witness, H= Hold, M= Monitor, A=Approve
applicable).
AGENCY
EXTENT OF ACCEPTANCE NORMS/ FORMAT OF
SR. NO. ITEM DESCRIPTION CHARACTERISTIC CHECK REFERENCE DOCUMENT REMARKS
CHECK STANDARDS RECORDS Supplier TPIA DEC/RIL
Document Approvals
All documents for IBR, Coded

Applicable code & Applicable code & Approved Drawing
equipments shall be approved by
1 Design calculation and Drawing Review 100% Standards, Data sheet, Standards, Data sheet, MR & design P - A
concern agency or authorized body in
MR etc etc calculations
addition to RIL/DEC.
Applicable code & Applicable code &

2 Inspection and Test Plan Review 100% Standards, Data sheet, Standards, Data sheet, Approved ITP P R A
MR, PO MR, PO
* R - Review for existing Qualification

Welding parameters, Chemical analysis, W - Witness for New Qualification under
Welding procedure specifications and Procedure Corrosion Test, Mechanical properties, Specification, Drawing, Specification, Drawing,
WPS, PQR, WPQ, reputed TPIA
3 Qualification Record including weld repair Heat Treatment cycles, NDE results etc 100% Applicable code & Applicable code & P R/W* A
Weld Map. Welder Performance Qualification
procedure, Weld Map etc (as applicable) Standards Standards
(WPQ) records shall be reviewed by
TPIA
Welding Parameter, Mechanical Specification, Drawing, Specification, Drawing, * R - Review for existing Qualification
Mockup test
4 Mock up Test for Tube to Tubesheet Joints properties, Percentage of Expansion, 100% Applicable code & Applicable code & P R/W* A W - Witness for New Qualification under
procedure
Corrosion Test, NDE etc Standards, EEMUA Standards, EEMUA reputed TPIA
Specification, Drawing, Specification, Drawing,

Mock up Test for Tube expansion Operator Percentage of Expansion, Tube wall Mockup test
5 100% Applicable code & Applicable code & P W A
qualification Thinning, Torque settings etc procedure
Standards, EEMUA Standards, EEMUA
a) Embedded Fins - Dimensional check,

Fin Tubes Test Procedure (as applicable) Specification, Drawing, Specification, Drawing,
Load test procedure Approved
6 a) Embedded Fins 100% Applicable code & Applicable code & P R A
b) Extruded Fins - Dimensional check, procedure
b) Extruded Fins Standards, Datasheet Standards, Datasheet
Thermal bonding test

NDE Procedure - RT, UT, MT, PT, PAUT, TOFD Approved NDE Procedure should be approved by
7 Procedure 100% Applicable code & Applicable code & P R A
etc (as applicable) procedure ASNT Level III.
Standards Standards
Specification, Applicable Specification, Applicable NDE Operators shall be ASNT Level II

8 NDE Operator & Personnel Qualification Qualification, Validity etc 100% Certificate P R R
code & Standards, Society code & Standards, Society minimum

Weld Production test Coupon (PTC) Plan Approved
(if applicable) procedure
Standards Standards
RIL Confidential Page 1 of 10 RPMS-PROC-ITP-MS-007 Rev 00


applicable).
AGENCY

Post forming Heat treatment, Post weld Heat Approved
treatment, DHT, ISR Procedure etc procedure
Standards Standards

Leak Test (Hydro, Helium, Pneumatic etc) Approved
Procedure procedure
Standards Standards

Approved
12 PMI, Hardness, Ferrite Test Procedure Procedure 100% Applicable code & Applicable code & P R A
procedure
Standards Standards

Approved
13 Shop Run/Factory acceptance test (FAT) procedure Procedure 100% Applicable code & Applicable code & P R A
procedure
Standards Standards
Surface Preparation & Painting, Pickling & Specification, Drawing, Specification, Drawing,
Approved
14 Passivation Procedure, Holiday testing etc (as Procedure 100% Applicable code & Applicable code & P R A
procedure
applicable). Standards Standards

Approved
15 Draining & Drying, Nitrogen Purging Procedure etc Procedure 100% Applicable code & Applicable code & P R A
procedure
Standards Standards

Approved
16 Packing, Shipping, Handling & Storage Procedure Procedure 100% Applicable code & Applicable code & P R A
procedure
Standards Standards
Discussion of ITP, Specification Specification, Drawing, Specification, Drawing,

PIM shall be conducted after first review
17 Pre Inspection meeting requirements, responsibilities, 100% Applicable code & Applicable code & PIM MOM H H H
of ITP, Drawings & Weld book
communication protocol etc Standards Standards
Material Identification
Visual, Dimension, Mechanical, Chemical,

Heat treatment condition, Corrosion Test, Specification, Drawing, Specification, Drawing, Identification
Identification and stamp transfer of Pressure parts
18 Simulation Test results, NDT, Approved 100% Applicable code & Applicable code & Report and MTC's P H/W R Refer Stage/Sr no 23 & Note 2 to 5
and Parts welded to pressure parts
Manufacturer etc Standards. Standards (EN 10204-3.1/3.2)
(as applicable).
Visual, Dimension, Mechanical, Chemical,

Identification and stamp transfer of Wetted parts, Heat treatment condition, Corrosion Test, Identification
19 100% Applicable code & Applicable code & P R R
Non pressure parts and Load bearing parts. NDT, Approved Manufacturer etc (as Report and MTC's
Standards. Standards
applicable).


applicable).
AGENCY
Specification, Drawing, Specification, Drawing, Carbon content shall also be checked

PMI of LAS, SS, HAS, Nonferrous material, Anodes Applicable code & Applicable code & for low & high carbon stainless steel,
20 Alloying Elements 100% Inspection Report P R R
etc (as applicable). Standards, Approved Standards, Approved and Stabilized grade material (if
Procedure Procedure specified in MR/Datasheet/PO)
Chemical, Mechanical properties, Impact,

Specification, Drawing, Specification, Drawing, Reputed make duly approved by TPIA
Corrosion, Ferrite test, Simulation test,
21 Weld Consumables 100% Applicable code & Applicable code & Batch TC P R R like TUV, ABS, IBR, SGS, LR, DNV &
Approved Manufacturer etc (as
Standards Standards BV.
applicable)
Visual, Physical verification, Make,
Inspection of Boughtout items - Fan, Fan guards,
Supplier test certificate, Balancing Test Specification, Drawing, Specification, Drawing, Motor Routine Test to be witnessed by
Bearing, Motor, Gear box, Pulley, Belts,Belt tension Test certificate,
22 report, Area Classification, Calibration, 100% Applicable code & Applicable code & P W R TPIA. Separate ITP to be submitted for
device, Vibration Switch, Transmitter, Electrical & Inspection report
Type test certificates, Approved Standards, Data sheet Standards, Data sheet Motor.
Instrumentation items etc
Manufacturer etc )as applicable)
Visual, Dimension, NDT, Chemical,
Inspection of Critical bought out items to be Mechanical properties, Impact, Corrosion Specification, Drawing, Specification, Drawing, Manufacturer Test
23 inspected by TPIA at Sub vendor's work (Sourced Test, Leak Testing, Simulation Test, 100% Applicable code & Applicable code & certificate P W R Refer note 4 & 5
within India) Approved Manufacturer etc Standards Standards (EN10204 3.1/3.2)
(as applicable)
Formed Ellipsoidal Nozzle, Cone etc Fabrication
Drawing, Specification, Drawing, Specification,

Heat treatment of formed components with Test Heat treatment
24 Heat treatment Cycle. 100% Applicable Codes & Applicable Codes & P R R
coupons (If applicable) Chart
Standards, HT Procedure Standards, HT Procedure
Surface finish, Dimensions, Knuckle

radius, Thickness check by Ultrasonic
Inspection of Ellipsoidal Nozzle after forming & Heat Thickness gauge, Profile check by
25 100% Applicable Codes & Applicable Codes & Inspection Report P W R
treatment (as applicable) Template, Template check on layout, Weld seams in Nozzle, Cone etc shall
Standards Standards
Concentricity check for Cones on layout be Radiographed & DP/MT tested after
etc as applicable. forming & subsequent Heat treatment (if
applicable)
Drawing, Specification,
NDE Examination after forming & Heat treatment Applicable Codes & NDE reports, RT
26 PT, RT, MT, UT etc (as applicable) 100% Applicable Codes & P H R
(as applicable) Standards, NDE Films as applicable
Standards, NDE Procedure
Procedure

Hardness check of Formed component etc Applicable Codes & Applicable Codes &
27 Hardness check 100% Hardness report P W R
(If applicable) Standards, Hardness Standards, Hardness
Procedure Procedure
Approved Inhouse
Simulation test coupon Testing of Heat treated Corrosion Test & Mechanical Test or NABL approved
28 100% Procedure, Applicable Procedure, Applicable P W R
components (if applicable) (as applicable) Laboratory Test
codes & standards codes & standards
reports


applicable).
AGENCY
In-process stages
Each type of extruded fin tubes shall be

subjected to "Single Tube Test"
(Thermal Bonding Test) for checking
adequacy of thermal bonding between
Visual, Dimensional, Mechanical Bond, Drawing, Specification, Drawing, Specification,
Inspection Test the aluminum sleeve and CS/SS bare
29 Inspection of Finned Tubes Thermal Bonding Test for Extruded finned 100% Procedure, Applicable Procedure, Applicable P W R
report tube. Test frequency shall be no less
Tubes, Load Test, Pull out etc codes & standards codes & standards
than 1 tube for every 500 tubes to be
installed. Vendor to submit test
procedure and acceptance criteria with
their proposal.
Weld Edge Preparation and Setup of Long seam, Visual, Dimension, Mismatch, Weld Edge
closing seam of header/Nozzle, Nozzle to Header preparation, Geometry, Alignment, NDE, Drawing, Specification, Drawing, Specification,
30 setup, End Plate, Bottom & Side plate setups, Plug Profile check by Template, Water level 100% Applicable Code & Applicable Code & Inspection Report P RW R
Sheet, Tubesheet setups etc with PTC (as check for Header, Tubesheet, Plug sheet Standards Standards
applicable) setup etc

Weld preparation and Setup of Internal & external Visual, Dimension, Mismatch, Weld Edge Internal & external attachments shall not
31 100% Applicable Code & Applicable Code & Inspection Report P R R
attachments preparation, Geometry, NDE etc foul with equipment weld seams
Standards Standards
Visual, Dimension, Go-Nogo Gauge, Hole

finish, Hole drift, gasket seating surface Drawing, Specification,
Inspection of Tube sheet & Plug sheet after NDE Procedure,
32 serrations, expansion groove & welding 100% NDE Procedure, Applicable Inspection Report P H R
machining & drilling Applicable Code &
groove profile check, Hardness check as Code & Standards
Standards
applicable.
NDE Procedure,
33 Inspection before Closing seam setups Visual, Dimensional, NDE clearance etc 100% NDE Procedure, Applicable Inspection Report P W R
Applicable Code &
Code & Standards
Standards

PreHeat, Interpass temperature, Post
Applicable Code & Applicable Code & Welding Monitor
34 Welding Heat (if applicable), Current, Voltage, 100% P R/M R
Standards, WPS/PQR, Standards, WPS/PQR, report/Log book
Heat Input etc
Weld plan Weld plan
NDE Procedure and NDE Procedure and

35 PT/MT of Root run and after Backchip Weld Soundness 100% Inspection Report P R R
Specification Specification
Drawing, Specification, If rolling or re-rolling is performed on
NDE Procedure, NDE reports, RT
36 NDE Examination NDE- RT, UT, MT, PT etc (as applicable) 100% NDE Procedure, Applicable P W R Weld joints then 100% RT & MT/PT
Applicable Code & Films as applicable
Code & Standards shall be perfomed
Standards


applicable).
AGENCY
UT at area of Header, Plates etc where lifting lugs, Drawing, Specification,
NDE Procedure, Inspection & NDE
37 tailing lugs, trunnions etc (as applicable) to be NDE - UT 100% NDE Procedure, Applicable P W R
Applicable Code & Report
welded Code & Standards
Standards
Final Inspection & NDE
Visual, Dimensions, Weld fillet size check,

Alignment, compliance of all welding
including internal, Completeness check, Inspection & NDE
38 Visual and Dimension inspection of Equipment 100% Applicable Code & Applicable Code & P H H
Flatness, skew checking, Tapped hole Report
Standards Standards
check by Go-NoGo or Thread gauge etc
(as applicable).
MT/PT on all pressure bearing butt & fillet welds, Drawing, Specification,
39 load bearing welds, temporary attachments & arc PT/MT 100% NDE Procedure, Applicable P W R
strikes after removal etc (as applicable) Code & Standards
Standards
NDE Procedure,
40 Radiography of Welds Review of RT Films 100% NDE Procedure, Applicable RT report & Films H R R
Applicable Code &
Code & Standards
Standards
Where RT is not feasible for

Drawing, Specification, inaccessible joints like the header box
NDE Procedure, Inspection & NDE corner joints, UT shall be carried out in
41 UT of Welds UT 100% NDE Procedure, Applicable P W R
Applicable Code & Report lieu of RT. A recordable UT technique
Code & Standards
Standards such as Phased Array (PAUT) is the
preferred inspection technique

Hardness Test on Parent Metal, Weld and HAZ (As Hardness Procedure, Hardness Procedure,
42 Hardness Check 100% Inspection Report H W R
welded condition) Applicable Code & Applicable Code &
Standards Standards
Specification, Drawing, Specification, Drawing, Carbon content shall also be checked

PMI of material and Welds including Anodes Applicable code & Applicable code & for low & high carbon stainless steel,
43 Alloying Elements 100% Inspection Report P W R
(if applicable) Standards, Approved Standards, Approved and Stabilized grade material & welds (if
Procedure Procedure specified in MR/Datasheet/PO)


applicable).
AGENCY

44 Ferrite content of welds (if applicable) Ferrite percentage/Number 100% Inspection Report P W R
Standards, Approved Standards, Approved
Procedure Procedure

45 Pneumatic test for RF Pad Leak tightness 100% Inspection Report P W R
Procedure Procedure

Heat treatment Cycle, Thermocouple Applicable code & Applicable code &
46 Post weld Heat treatment (If applicable) 100% Inspection Report P W R W for Loading/Unloading
locations etc Standards, Approved Standards, Approved
Procedure Procedure
Specification, Drawing, Specification, Drawing, Approved Inhouse

Mechanical Properties, Corrosion Test etc Applicable code & Applicable code & or NABL approved
47 Production test coupon (If applicable) 100% P H R
(as applicable) Standards, Approved Standards, Approved Laboratory Test
Procedure Procedure reports
Inspection & NDE after PWHT (if applicable)
Visual, Dimensions, Elevation, Projection

of Nozzles and attachments,
Prependicularity, Flatness of Flanges, "e" value to be checked of Shell, Heads
Alignment, compliance of all welding Inspection & NDE etc with Internal/ external Template
48 Visual and Dimension inspection of Equipment 100% Applicable Code & Applicable Code & P H H
including internal, Completeness check, Report (Applicable for equipment with External
Standards Standards
Flatness, skew checking, Tapped hole pressure/Full or Partial Vacuum)
check by Go-NoGo or Thread gauge etc
(as applicable).
MT/PT on all pressure bearing butt & fillet welds, Drawing, Specification,
49 load bearing welds, temporary attachments & arc PT/MT 100% NDE Procedure, Applicable P W R
strikes after removal etc (as applicable) Code & Standards
Standards
NDE Procedure,
50 Radiography of Welds Review of RT Films 100% NDE Procedure, Applicable RT report & Films H R R
Applicable Code &
Code & Standards
Standards
Where RT is not feasible for

Drawing, Specification, inaccessible joints like the header box
NDE Procedure, Inspection & NDE corner joints, UT shall be carried out in
51 UT of Welds (if applicable) UT 100% NDE Procedure, Applicable P W R
Applicable Code & Report lieu of RT. A recordable UT technique
Code & Standards
Standards such as Phased Array (PAUT) is the
preferred inspection technique


applicable).
AGENCY
Hardness Procedure, Hardness Procedure,
52 Hardness Test on Parent Metal, Weld and HAZ Hardness Check 100% Inspection Report H W R
Applicable Code & Applicable Code &
Standards Standards

Pneumatic Soap solution Test for RF Pads & Tube Applicable code & Applicable code &
53 Leak tightness 100% Inspection Report P W R
to Header weld joints (as applicable) Standards, Approved Standards, Approved
Procedure Procedure
Specification, Drawing, Specification, Drawing, Approved Inhouse

Mechanical Properties, Corrosion Test etc Applicable code & Applicable code & or NABL approved
54 Production test coupon Testing (If applicable) 100% P H R
(as applicable) Standards, Approved Standards, Approved Laboratory Test
Procedure Procedure reports
Inspection, Testing, Packing & Preservation

Leak test Procedure, Leak test Procedure,
Strength Expanded Tubes - Expansion check and Percentage of Expansion & Pneumatic
55 100% Applicable Code & Applicable Code & Inspection Report P W R
Pneumatic leak test soap solution Leak Test
Standards, Mockup Standards, Mockup
Procedure Procedure

Strength Expanded & Seal welded Tubes - NDE, Leak Test NDE, Leak Test Procedure, 1) PT of Tube to Tube sheet weld joints -
Percentage of Expansion, Pneumatic
56 Expansion check, Pneumatic leak test & Dye 100% Procedure, Applicable Applicable Code & Inspection Report P W R No indications allowed
soap solution Leak Test & PT testing
Penetrant test (PT) of seal welds Code & Standards, Standards, Mockup 2) Tube to Tube sheet weld joints shall
Mockup Procedure Procedure be minimum two run with different start
& stops location.
3) Start & Stop locations shall be fused
Drawing, Specification, Drawing, Specification, 4) Tube undercutting & Burn Through in
Strength welded & light expanded Tubes - Dye NDE, Leak Test NDE, Leak Test Procedure, Tube ID after Welding is not allowed
PT test, Pneumatic soap solution Leak
57 Penetrant test (PT) & Pneumatic leak test on both 100% Procedure, Applicable Applicable Code & Inspection Report P W R 5) Production Records of each Welder
Test & Percentage of Expansion
root & Final weld pass & Expansion check Code & Standards, Standards, Mockup & Expansion operator shall be
Mockup Procedure Procedure maintained by vendor & verified by TPIA

Visual, Dimensional, completeness check, Applicable code & Applicable code &
58 Final Inspection of Tube Bundle 100% Inspection Report P H R
locking of Tube spacers etc Standards, Approved Standards, Approved
Procedure Procedure
Leak Tightness, Pressure Gauge (Min Specification, Drawing, Specification, Drawing,

2nos), Range, Leakage, Pressure drop, Applicable code & Applicable code &
59 Hydrostatic test of Tube Bundle 100% Inspection Report P H R
deformation, Test water Chloride content Standards, Approved Standards, Approved
etc (Holding Time - 60minutes minimum) Procedure Procedure

Applicable code & Applicable code & Draining & Drying shall be witnessed by
60 Helium leak test of Tube Bundle (If applicable) Helium Leak tightness 100% Inspection Report P H R
Standards, Approved Standards, Approved TPIA before performing Helium leak test
Procedure Procedure


applicable).
AGENCY

61 Draining & Drying Cleanliness, Humidity etc 100% Inspection Report P W R
Procedure Procedure

Visual & Dimension for Structural steel, Gratings etc Visual, Dimensional, Weld fillet size, Applicable code & Applicable code &
62 100% Inspection Report P W R
(Black & Galvanised condition) Straightness, Flatness, Plumb etc Standards, Approved Standards, Approved
Procedure Procedure

63 NDE of Structural Welds UT, PT, MT etc 100% NDE reports P W R
Procedure Procedure
Visual, Coating Thickness check by Specification, Drawing, Specification, Drawing, Inspection report,
Elecometer, AdhesionTest, Preece Test, Applicable code & Applicable code & Hot Dip
64 Hot Dip Galvanising of Structural steel 100% P W R
Uniformity of Coating, Mass of Coating, Standards, Approved Standards, Approved Galvanising & Zinc
Strip test etc Procedure Procedure purity TC
Visual, Dimensional, Alignment, free

rotation of shaft, locking of Tube supports,
65 Assembly of Air Cooler with Structures proper spacing of finning, Match marking 100% Inspection Report P W W
compliance of all welding, Completeness
Procedure Procedure
check, Water level check etc

Performance air flow, Velocity, Vibration, Inspection Report
66 Shop Trial Run Test 100% Standards, Approved Standards, Approved P H W
Noise level, Temperature rise etc FAT Test Report
Procedure, Shop Run/FAT Procedure, Shop Run/FAT
Procedure Procedure

Copper Sulphate test, Visual, Litmus Applicable code & Applicable code &
67 Pickling and passivation (If applicable) 100% Inspection Report P W R
paper test etc Standards, Approved Standards, Approved
Procedure Procedure
Blasting media, Surface profile, Salt

Specification, Drawing, Specification, Drawing, Holiday test to be carried out for
contamination test, Adhesion test, DFT,
Surface preparation and painting, Cathodic Applicable code & Applicable code & Inspection Report equipments under Immersion, Buried
68 Shade verification, Holiday test, Testing 100% P W R
protection etc (as/if applicable) Standards, Approved Standards, Approved & Paint TC service, internally coated/painted
as per RIL specification etc
Procedure Procedure equipment
(as applicable).

Final Inspection including Name Plate, Marking and Verification, Completion, Code Applicable code & Applicable code &
69 100% Inspection Report P H R
Stamping check. compliance, compliance with drawing. Standards, Approved Standards, Approved
Procedure Procedure


applicable).
AGENCY
N2 purging, N2 Soap solution leak test,
Dew point, Oxygen level, N2 Topup
cylinder, N2 refilling arrangement,
Caution, CG, Sling marking, Fastener rust
70 Packing & Preservation preventive application, 100% Nozzle 100% Inspection Report P H R
bolting as per flange standard, PE film
Procedure Procedure
stretch wrapping, Personal Protection for
Fin Tubes etc
(as applicable)

Visual, Dimensional, PMI & Quantity
71 Inspection of Spares 100% Applicable code & Applicable code & Inspection Report P H R
verification
Standards Standards
For IBR Equipments; Verification of IBR

Forms, IBR PTC reports, IBR inspection
reports etc
Specification, Drawing, Specification, Drawing, For PESO Equipments; Verification of
Final documentation, Sign off ITP & Manufacturer Compliance to ITP, Drawings, Requisition Inspection Report
72 100% Applicable code & Applicable code & P H R PESO Certificate of Control, PESO
record Book (MRB) & Specifications & MRB
Standards Standards inspection reports etc
For Coded Equipments; Verification of
Manufacturer's Data report/Forms (as
applicable)
For IBR Equipments; Verification of IBR

Hard punch Data & IBR
Inspecting/Competent Authority/Person
Stamp etc
Specification, Drawing, Specification, Drawing, For PESO Equipments; Verification of
Compliance to ITP, Drawings, Requisition Inspection Release
73 Stamping & Issue of Inspection Release Note 100% Applicable code & Applicable code & P H H PESO Hard punch Data & PESO
& Specifications Note
Standards Standards Competent person Hard Stamp
For Coded Equipments; Verification of
Name plate/Hard Punch data & ASME
certification Mark with applicable
designator

Engineering Clearance (EC) and Supplier Quality Compliance to ITP, Drawings, Requisition EC & SQ
74 100% Applicable code & Applicable code & H - H
(SQ) clearance for shipment Release. & Specifications Clearance
Standards Standards
Notes :
1) This is Indicative ITP only. Vendor to cover all major stages in line with Data sheet, Drawings, Relevant MR, Statutory requirements if any and Governing Code Guideline and submit detailed ITP for RIL approval.
2) Requirements of raw material, Inspection & Testing shall be as per RIL Specifications, Material Requisition, PO etc.
3) Material from China & East European countries not allowed. Material & Bought out items shall be procured from RIL Approved Sub vendors only.


applicable).
AGENCY
4) List of Items (Sourced within India) mentioned below shall be inspected by RIL approved TPIA at Subvendor works. Sub vendor ITP shall be approved by TPIA.
ii All Flanges for 600 # rating and above.

iii All body flanges, Girth Flanges and Tubesheets
iv All Tubes
v Expansion bellow
vi Fasteners above M24
vii
viii Formed components like Heads, Toricones etc
ix Critical internals like Demisters, Distributors, Coalescer Pads etc (as/if applicable)
x Final Painting (If off-loaded)
xi All Non ferrous and exotic material such as Duplex, Titanium, Monel, Inconel etc (Pipe, Fittings, Flanges, Header Plugs etc.) irrespective of Size
5) Tubes shall be 100% Hydro tested & 100% Eddy current Tested at Mill & 10% Witness by TPIA unless otherwise specified.
6) Scope & Extent of Inspection (H, W, RW, R, M) may vary based on Supplier Quality Surveillance level (SQS Level)
7) Equipment requiring statutory certification like IBR, PESO etc or Coded Equipment; TPIA shall perform Stagewise & Final Inspection as per approved ITP over & above IBR/PESO/Inspecting Authority/Competent person/Authorized Inspector (as applicable)
8) RIL representative reserves all rights to visit Manufacturer works during any stage of fabrication & Testing
P = Perform TPIA = Third Party Inspection Agency PREPARED BY CHECKED BY APPROVED BY

Bhavesh Bhirud &
W = Witness RIL = Reliance Industries Ltd Partha Das Tushar Mukherjee
Swapnil S. Bhosale
R = Review DEC = Detail Engineering Contractor
RW=Random Witness (Minimum 10%)
Issued for
M = Monitor 0 15.06.2020
Implementation
H= Hold
Rev No Date Revision Details

Mechanical Datasheet for
ME-EPE255-A032002 / ME-
Reliance Industries Limited Item Number : Project No. : JN3102
EPE260-A032002
TCS Heavy Impurity Column Polysilicon Manufacturing
Jamnagar, Gujarat, India Service Description : #2 Condenser Project Title :
Facility
032 - TCS HEAVY

Area / Unit :
IMPURITY SEPARATION
MT-J22N01-D1JEP-MEA001-
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
THIS TITLE SHEET IS THE FIRST PAGE OF THE DATA SHEET AND IS A RECORD OF EACH ISSUE OR REVISION.
THIS PAGE IS "NOT NUMBERED". THE DATA SHEET PAGES ARE NUMBERED AFTER THIS TITLE SHEET
APPROVALS
REV DATE BY CK PAGES REMARKS / COMMENTS
LEAD PROCESS CUSTOMER DATE
15-12- Sandip Sachin Umesh

0A - - - 3 Issued for Approval
2022 Kshatriya Borse Poojary
23-12- Ganesh Sachin Umesh

00 - - - 3 Issued for Quotation
2022 Salunkhe Borse Poojary
DATASHEET ISSUED FOR: APPROVAL
IN HOUSE REVIEW IFA-CLIENT APPROVAL BUDGET QUOTE IFI-INQUIRY IFP-PURCHASE IFD-DESIGN IFE-ESTIMATE CONSTRUCTION
Document No. : J22N01-MEAD-EPE255-032002 Rev. 00 Date 23-12-2022 Sheet

P.O. No.: Doc. No.: J22N01-MEAD-EPE255-032002 Page 1 of 2

1 Customer: Reliance Industries Limited Location: Jamnagar, Gujarat, India
2 Process unit: 032 - TCS HEAVY IMPURITY SEPARATION Item No.: ME-EPE255-A032002 / ME-EPE260-A032002
3 Job No.: JN3102 No. of units: 2
4 Service of unit: TCS Heavy Impurity Column #2 Condenser
5
6 DESIGN DATA MATERIALS
ASME SEC VIII DIV.1 ED 2021 + ERRATA +
HEADER (TOP / BOTTOM / PLUG
7 DESIGN CODE API STD 661 7th Ed. 2013, REAFFIRMED SA 516 GR 70
PLATE)
2018
8 QUANTITY ONE SET TUBE (SEAMLESS) SA 179
9 DESIGN PRESSURE (INT/EXT) REFER PDS NOZZLE FLANGE / BLIND FLANGE SA 105
10 DESIGN TEMPERATURE (INT/EXT) REFER PDS NOZZLE PIPE (SEAMLESS) SA 106 GR B
11 MDMT 7.5 °C TUBE SHEET SA 516 GR 70 / SA 266 GR 2
12 DRAFT TYPE FORCED DRAFT FIN G-TYPE / ALUMINIUM
CORROSION ALLOWANCE
13 3 mm FAN BLADES ALUMINIUM / FRP
(HEADER,TUBESHEET,NOZZLE)
14 SPECIAL SERVICE N.A. EXTERNAL BOLTING SA 193 GR B7 / SA 194 GR 2H
15 IMPACT AS PER CODE & SPECIFICATION GASKET - NOZZLE SPIRAL WOUND (REFER NOTE-23)
16 PWHT AS PER CODE & SPECIFICATION GASKET - PLUG HEADER SOLID SOFT METAL GASKET
17 RADIOGRAPHY Full GASKET - PASS PARTITATION (IF APPLICABLE)
METAL JACKETED GASKET
18 TEST PRESSURE (SHOP/SITE) UG 99'(c) / UG 99'(b) HEADER COVER GASKET N.A.
19 NACE REQUIREMENT (YES/NO) NO IS 2062 (E250 GR.A)
STRUCTURE/PLENUM CHAMBER/BUNDLE FRAME
20 PAINTING AS PER SPECIFICATION FITTINGS SA 234 GR WPB
INSULATION TYPE / THK (BY
21 PERSONNEL PROTECTION (PP) EARTHING LUG SS 304
OTHERS)
22 FIREPROOFING THK (BY OTHERS) YES / 50 mm NAME PLATE, NAME PLATE BRACKET SS 304 , SA 516 GR 70
23 HEADER TYPE PLUG SETTING BOLTS/ STRUCTURAL FASTNERS IS 1387 CL. 8.8
EXTERNAL WELDED ATTACHMENT
24 VIBRATION TRANSMITTER YES SA 516 GR 70
(EXT. CLEATS, PAD ETC)
TUBE TO TUBESHEET JOINT STRENGTH WELDED WITH LIGHT
25 PLUGS SA 105
TYPE EXPANSION (HOLD)
IS 2062 E250 GR. A / SA 283 GR C
26 SPEED REDUCER TYPE NOTE-21 PLATFORM/LADDER/HANDRAIL
/ ERW, IS 1239(M)
27 FIN TYPE EMBEDDED
28 FAN CONTROL NOTE-22
29 CODE STAMP N.A
30 INSPECTION BY TPIA / PURCHASER
31 IBR REQUIREMENT NONE
32 PIPE RACK (WIDTH X LENGTH) 8 X 24 m
33 WEIGHT DATA (APPROXIMATE)(**)
34 SHOP FABRICATED WEIGHT VTA Kg
35 ERECTED WEIGHT VTA Kg
36 OPERATING WEIGHT VTA Kg
37 FIELD HYDROTEST WEIGHT VTA Kg
38
39
40 WIND & SEISMIC DESIGN
41 WIND DESIGN CODE IS 875 PART 3, ED 2015 (AMD.1-2016) SEISMIC DESIGN CODE: IS 1893- PART 4, ED 2015
42 WIND SPEED 50 m/s ZONE FACTOR (Z) 0.32
43 WIND ZONE NO V SOIL TYPE HARD SOIL
44 RISK COEFFICIENT (K1) 1.08 IMPORTANCE FACTOR 2.0
45 TOPOGRAPHY FACTOR (K3) 1.00 RESPONSE REDUCTION FACTOR 2.0
46 IMPORTANCE FACTOR (K4) 1.15 DAMPING % 2.0
47 SEISMIC ANALYSIS RES. SPECTRUM.
48
1 GENERAL NOTES
2 1. ALL DIMENSION ARE IN MM UNLESS OTHERWISE STATED.
3 2. ALL FLANGE BOLT HOLES SHALL STRADDLE TUBE BUNDLE CENTER LINES UNLESS OTHERWISE NOTED.
4 3. LOCAL LOAD ANALYSIS OF ALL PROCESS NOZZLES SHALL BE CARRIED OUT AS PER WRC-537/ WRC-297.
5 NOZZLES FALLING OUTSIDE PURVIEW OF WRC BULLETINS 537 & 297 SHALL BE EVALUATED USING FINITE ELEMENT ANALYSIS.
6 4. FOR PROCESS DATA, REFER PROCESS DATASHEET J22N01-SP-EA-03202
7
8 5. EACH FAN TO BE PROVIDED WITH VIBRATION TRANSMITTER WITH CONTACT SIGNAL FOR ALARM AND TRIPPING IN DCS BASED
9 ON VIBRATION LEVEL.
10 6. LIFTING LUG SHALL BE DESIGNED AND ANALYZED CONSIDERING EQUIPMENT IN FULLY DRESSED CONDITION.
11 LIFTING LUGS SHALL BE DESIGNED FOR TWICE THE WEIGHT OF THE COMPONENTS TO BE LIFTED TO ALLOW FOR DYNAMIC EFFECTS.
12 7. LIFTING HOOK SHALL BE PROVIDED INSIDE OF PLENUM UNDER TUBE BUNDLE AT AIR SEAL BEAM IN LINE OF MOTOR,
13 ONLY FOR LIFTING MOTORS AND FAN.
14 8. AIR COOLER STOP PUSH BUTTON TO BE LOCATED AT GRADE LEVEL IN ADDITION TO START / STOP BUTTON NEAR THE FAN
15 AT PLATFORM.
16 9. FANS AND DRIVERS SHALL BE CAPABLE OF DELIVERING A MINIMUM OF 110% OF THE REQUIRED AIR FLOW
17 10. SUPPLIER SHALL GUARANTEE THERMAL & HYDRAULIC PERFORMANCE, MECHANICAL DESIGN AND NOISE GUARANTEES OF AIR COOLERS
18 11. VENDOR SHALL CONFIRM THAT NOZZLE IN ITS DESIGN CORRODED CONDITION SHALL BE CAPABLE OF WITHSTANDING 3 TIMES OF
19 THE LOADS AND MOMENTS MENTIONED IN API STD 661.
20 12. ACCESS PLATFORM SHALL BE PROVIDED WHEREVER POSSIBLE ON ALL THE FOUR SIDES, (WIDTH - 1000 MM MINIMUM) WITH STAIRS
21 ON ONE SIDE AND LADDER ON OTHER SIDE.
22 13. IS 800 SHALL BE USED AS DESIGN CODE FOR AIR COOLED EXCHANGER STRUCTURES.
23 14. TWO FANS PER BAY SHALL BE PROVIDED AS A MINIMUM.
24 15. ALL FASTENERS BOLTING FOR GIRTH FLANGES AND NOZZLE FLANGES SHALL BE UNC STUDS BELOW 1" DIA AND UN8 SERIES STUDS
25 FOR 1" AND ABOVE SIZES. NUTS SHALL BE HEAVY SERIES.
26 16. HYDRAULIC BOLT TENSIONERS SHALL BE CONSIDERED FOR BOLT SIZES 1-1/2” AND ABOVE ON FLANGES. BOLT SPACING AND
27 LENGTH OF BOLT SHALL BE ADEQUATE FOR INTRODUCING TENSIONING TOOL.
28 17. HYDRO TEST PRESSURE SHALL BE DETERMINED IN ACCORDANCE WITH PARA. UG-99(C)
29 18. HYDROSTATIC TEST WATER CHLORIDE CONTENT IS BELOW 250 PPM.
30 19. PMI SHALL BE PERFORMED FOR NON FERROUS, EXOTIC MATERIALS AND WELDS. PMI CHECK SHALL INCLUDE ALL BASE METAL
31 (INCLUDING INTERNALS) AND WELD.
32 20. ALL TUBES SHALL BE 100% EDDY CURRENT TESTED AT THE MILL FOR BOTH INTERNAL AND EXTERNAL DEFECTS.
33 ALL TUBES SHALL BE HYDRO TESTED. HYDROTEST PRESSURE OF TUBES SHALL BE HIGHER OF ACTUAL EXCHANGER TUBE SIDE TEST
34 PRESSURE OR AS REQUIRED BY ASME SEC II. MINIMUM TEST PRESSURE SHALL NOT BE LESS THAN 70 KG/CM²(G)
35 21. HIGH TORQUE POSITIVE DRIVE BELTS MAY BE USED WITH FAN MOTORS RATED UP TO 37 KW (50 HP).
36 GEAR DRIVES ARE REQUIRED FOR FAN MOTORS LARGER THAN 37 KW (50 HP).
37 22. IN GENERAL, CONTROL SHALL BE 50% OF THE DUTY BY MEANS OF FANS ON/OFF CONTROL,
38 AND 50% BY FAN VARIABLE SPEED CONTROL.
39 23. SS304L SPIRAL WOUND GASKET WITH GRAPHITE FILLED, SS 304L INNER RING & CS OUTER RING.
40 24. VENDOR TO SUPPLY MOTOR STATUS TRANSMITTAL.
41 25. SUPPLIER SHALL EVALUATE ALUMINIUM BLADE DESIGN V/S FRP (FIBER REINFORCED PLASTIC) FAN DESIGN TO SELECT BETTER
42 AND EFFICIENT BLADES.
43
44
ME-EPE255-A070002 / ME-
EPE260-A070002
CVD OGR TCS/STC Column Polysilicon Manufacturing
Jamnagar, Gujarat, India Service Description : Condenser Project Title :
Facility
070 CVD OFF GAS
Area / Unit : RECOVERY TCS/STC
SEPARATION
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS




2 Process unit: 070 CVD OFF GAS RECOVERY TCS/STC SEPARATION
Item No.: ME-EPE255-A070002 / ME-EPE260-A070002
4 Service of unit: CVD OGR TCS/STC Column Condenser
5
PLATE)
2018
CORROSION ALLOWANCE
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
38
39
48
1 GENERAL NOTES
7
15 AT PLATFORM.
43
44
ME-EPE255-A070008 / ME-
EPE260-A070008
CVD OGR STC Air Cooler Polysilicon Manufacturing
Jamnagar, Gujarat, India Service Description : Project Title :
Facility
070 CVD OFF GAS
Area / Unit : RECOVERY TCS/STC
SEPARATION
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS




2 Process unit: 070 CVD OFF GAS RECOVERY TCS/STC SEPARATION
Item No.: ME-EPE255-A070008 / ME-EPE260-A070008
4 Service of unit: CVD OGR STC Air Cooler
5
PLATE)
2018
CORROSION ALLOWANCE
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
32 PIPE RACK (WIDTH) 8 m
38
39
48
1 GENERAL NOTES
7
15 AT PLATFORM.
43
44
ME-EPE255-A022001 / ME-
EPE260-A022001
Hot Cooling Water Flash Polysilicon Manufacturing
Condenser Facility
Area / Unit : 220 HOT COOLING WATER
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS




2 Process unit: 220 HOT COOLING WATER Item No.: ME-EPE255-A022001 / ME-EPE260-A022001
4 Service of unit: Hot Cooling Water Flash Condenser
5
PLATE)
2018
CORROSION ALLOWANCE
21 HEAT CONSERVATION (HC) / 65 mm EARTHING LUG SS 304
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
31 IBR REQUIREMENT YES
38
39
48
1 GENERAL NOTES
7
15 AT PLATFORM.
43
44
ME-EPE255-A022002 / ME-
EPE260-A022002
Low Pressure Condensate Polysilicon Manufacturing
Vent Condenser Facility
Area / Unit : 220 HOT COOLING WATER
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS




2 Process unit: 220 HOT COOLING WATER Item No.: ME-EPE255-A022002 / ME-EPE260-A022002
4 Service of unit: Low Pressure Condensate Vent Condenser
5
PLATE)
2018
CORROSION ALLOWANCE
21 HEAT CONSERVATION (HC) / 65 mm EARTHING LUG SS 304
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
31 IBR REQUIREMENT YES
32 PIPE RACK (WIDTH X LENGTH) 8X8 m
38
39
48
1 GENERAL NOTES
7
15 AT PLATFORM.
43
44
Effluent Condenser
ME-EPE255-A317102 / ME-
EPE260-A317102
ME-EPE255-A317202 / ME-
EPE260-A317202
Effluent Condenser Polysilicon Manufacturing
Facility
Area / Unit : 317 QUENCH SYSTEM
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS



Effluent Condenser

ME-EPE255-A317102 / ME-EPE260-A317102
2 Process unit: 317 QUENCH SYSTEM Item No.:
ME-EPE255-A317202 / ME-EPE260-A317202
4 Service of unit: Effluent Condenser
5
PLATE)
2018
CORROSION ALLOWANCE
19 NACE REQUIREMENT (YES/NO) NO STRUCTURE/PLENUM CHAMBER/BUNDLE FRAME
IS 2062 (E250 GR.A)
OTHERS)
STRENGTH WELDED WITH LIGHT
25 TUBE TO TUBESHEET JOINT TYPE PLUGS SA 105
EXPANSION (HOLD)
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
38
39
48
Effluent Condenser
1 GENERAL NOTES
6 4. FOR PROCESS DATA, REFER PROCESS DATASHEET J22N01-SP-EA-AB31702
7
15 AT PLATFORM.
43
44
ME-EPE255-A320002 / ME-
EPE260-A320002
Crude TCS Column Polysilicon Manufacturing
Condenser Facility
320 CRUDE TCS/STC

Area / Unit :
SEPARATION
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS




2 Process unit: 320 CRUDE TCS/STC SEPARATION Item No.: ME-EPE255-A320002 / ME-EPE260-A320002
4 Service of unit: Crude TCS Column Condenser
5
PLATE)
2018
CORROSION ALLOWANCE
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
38
39
48
1 GENERAL NOTES
7
15 AT PLATFORM.
43
44
ME-EPE255-A330002 / ME-
EPE260-A330002
STC Purification Column Polysilicon Manufacturing
Jamnagar, Gujarat, India Service Description : Condenser Project Title :
Facility
330 STC PURIFICATION

Area / Unit :
COLUMN
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS




2 Process unit: 330 STC PURIFICATION COLUMN Item No.: ME-EPE255-A330002 / ME-EPE260-A330002
4 Service of unit: STC Purification Column Condenser
5
PLATE)
2018
CORROSION ALLOWANCE
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
38
39
48
1 GENERAL NOTES
7
15 AT PLATFORM.
43
44
BCW Air Cooler
Reliance Industries Limited Item Number : ME-EPE265-A601502A/B Project No. : JN3102
BCW Air Cooler Polysilicon Manufacturing

Facility
601- Baseplate Cooling

Area / Unit :
System
Inq. Req. No. :
WIPL-Q-00
Pur. Req. No. : -
APPROVALS



BCW Air Cooler

2 Process unit: 601- Baseplate Cooling System Item No.: ME-EPE265-A601502A/B
4 Service of unit: BCW Air Cooler
5
PLATE)
2018
8 QUANTITY TWO SETS TUBE (SEAMLESS) SA 179
CORROSION ALLOWANCE
OTHERS)
25 PLUGS SA 105
IS 2062 E250 GR. A / SA 283 GR C
/ ERW, IS 1239(M)
29 CODE STAMP N.A
38
39
48
BCW Air Cooler
1 GENERAL NOTES
6 4. FOR PROCESS DATA, REFER PROCESS DATASHEET J22N01-MEABD-EPE265-601-114
7
15 AT PLATFORM.
43
44
Reliance Project Management System
Standard Specification for Design and Fabrication of

Air-Cooled Heat Exchanger
RPMS-ENGG-SPC-MS-001
0 17.08.2020 Issued for Implementation ADB LS TNR / VKM
Rev Date Revision Details Prepared Checked Approved

By By By
Reliance Project Management System RPMS-ENGG-SPC-MS-001
Design and Fabrication of Air-Cooled Heat Exchanger Date: 17.08.2020, Rev. 0
STANDARDS SUB-COMMITTEE ENDORSEMENTS
Sr.
Name Signature Date (DD.MM.YYYY)
No.
1 __Anand Umakanthan___________ _________________ ___________
__Tushar Mukherjee____________ _________________ ___________

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_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

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_____________________________ _________________ ___________

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10
RECORD OF REVISIONS
Date Revision Details Revision

Number
17.08.2020 Issued for Implementation 0

Contents
1. Scope ........................................................................................................................... 5
2. References ................................................................................................................... 5
3. Conflicts and Deviations .............................................................................................. 6
4. Abbreviations & Definitions ........................................................................................ 7
5. Technical and Design Requirements ........................................................................... 8
6. Inspection and Testing .............................................................................................. 14
7. Vendor Data .............................................................................................................. 15
8. Packing, Preservation, Shipment and Storage .......................................................... 15
9. Attachments .............................................................................................................. 17
9.1 Appendix A : Vendor Data Requirement ................................................................... 17
9.2 Appendix B : Vendor Document / Data Format ........................................................ 19
9.3 Appendix C: Addendum to API-661-7th Edition, July 2013 (Reaffirmed, June 2018) 20
1. Scope
1.1 This specification defines the minimum technical requirements for design,
materials, manufacture, inspection, testing, painting, packaging, shipment and
documentation of Air-Cooled Heat Exchanger for Supplier and/or Contractor to
comply with, to achieve Buyer’s objective of standardization.
1.2 This specification shall be used in conjunction with the project specified design
Code shown on the heat exchanger data sheets, API Standard 661, Seventh Edition,
July 2013 (Reaffirmed, June 2018) plus amendments as referenced in this
Specification.
1.3 Supplier and/or Contractor shall be responsible for incorporation of relevant
process licensor requirements in the specification of equipment or systems, that
may override this standard specification.
2 References
2.1 The following specifications are applicable:
API 661 Petroleum, Petrochemical, and Natural Gas Industries-
Air-Cooled Heat Exchangers
API 614 Lubrication, Shaft-sealing and Oil-control Systems and
Auxiliaries
ASME Section VIII Div. 1 Rules for Construction of Pressure Vessels
ASME Section V Non-Destructive Examination
ASME Section IX Welding and Brazing Qualifications
ASME Section II Materials
IBR Indian Boiler Regulations
IS-875 Part 3 Code of Practice for Wind Load Design
IS-1893 Part 1 and Part 4 Criteria for Design of Earthquake Resistant Structure
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.20 Metallic Gaskets for Pipe Flanges
ASME B16.47 Large Diameter Steel Flanges
ASTM A435 Standard Specification for Straight-Beam Ultrasonic
Examination of Steel plates
NACE MR 0103 Materials Resistant to Sulphide Stress Cracking in
Corrosive Petroleum Refinery Environments
RIL Confidential Page 5 of 27

NACE MR 0175 Standard Material Requirements, Sulphide Stress

Cracking Resistant Metallic Materials for Oilfield
Equipment
NACE SP 0472 Methods and Controls to Prevent In-Service
Environmental Cracking of Carbon Steel Weldments in
Corrosive Petroleum Refining Environments
RPMS-ENGG-DBD-MS-001 Design Basis for Wind and Seismic Design and Analysis
of Static Equipment
RPMS-ENGG-DBD-MS-002 Indian Boiler Regulations - Approval Procedure for
Static Equipment
RPMS-ENGG-DBD-ST-005 Indian Boiler Regulations - Approval Procedure
RPMS-ENGG-SPC-MS-002 Standard Specification for Unfired Pressure Vessels
RPMS-ENGG-SPC-MT-004 Seller Welding Procedure Approval and Welding
Quality Requirements
RPMS-ENGG-SPC-MT-006 Tube to tube sheet welding
RPMS-ENGG-SPC-PP-012 Specification for Hot and Acoustic Insulation
RPMS-ENGG-SPC-PP-013 Specification for Cold Service Insulation
RPMS-ENGG-SPC-PP-014 Specification for Field and Shop Painting
RPMS-ENGG-SPC-PP-018 Positive material identification for piping & Mech.
Component.
RPMS-SD-C15-303 Standard Anchor Bolt details with ductile detailing.

RPMS-SD-M15-002 Name Plate Heat Exchanger
3 Conflicts and Deviations

In the event of conflict or deviation from requirements stipulated in this
specification and other applicable documents, the following order of precedence
shall govern:
1. Data Sheets and Drawings
2. The Material Requisition
3. This Standard Specification
4. Codes and Standards Specifically Referred
5. Other National and International Standards as Referenced
Latest revisions of codes and other statutory requirements as applicable at the time
of enquiry, shall be applicable. In the event of a conflict between the requirement
of the referenced codes, standards, specifications, regulations and procedures,

Supplier shall submit the recommended solution to Buyer for review and
permission to proceed prior to implementation.
Notes:
• “Data Sheets and Drawings” represent those attached to the Material
Requisition
• “Material Requisition” represents Material Requisition for Quotation,
superseded by Material Requisition for Purchase on execution of a Purchase
Order
• Any local statutory and regulatory requirement shall mandatorily be applicable
and addressed during engineering stage.
4 Abbreviations & Definitions

ANSI American national standards institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
BS British Standard
BIS Bureau of Indian Standards
EDMS Electronic Document Management System
HCN Hydrogen cyanide
IS Bureau of Indian Standards
ISO International Standards Organization
MP Magnetic Particle Examination
MR Material Requisition
NACE National Association of Corrosion Engineers
NB National Board of Boiler and Pressure Vessel Inspectors
NDT Non-destructive test
OSHA Occupational Safety and Health Administration
PT Liquid Penetrant Examination
RT Radiographic Examination
TPI Third Party Inspection
UT Ultrasonic Examination

Parties responsible for complying with an Engineering Standard

Supplier/ Party which manufactures or supplies equipment and services to
Vendor perform the function as specified by Buyer
Buyer Owner (Reliance) or Owner appointed DEC or EPC who specifies
equipment and services for purchase from Supplier
Parties referred within body of Engineering Standard

Owner Reliance Industries Limited or specified Reliance Group Company
DEC Detailed Engineering Contractor
EPC Engineering, Procurement and Construction Contractor
Contractor DEC or EPC
5 Technical and Design Requirements

5.1 General
5.1.1 It is the intention of this Specification that the Supplier provides the most
economical exchanger based on his standard equipment design and fabrication
methods provided the Supplier complies with the requirements of the specified
Design Code, API 661, and this specification.
5.1.2 To achieve value engineering and cost-effective design with required quality and
integrity following parameters / criteria shall be considered.
Standardization of size, Capacity and rating (MOC, Thickness, Length, Width)
Optimum Design (Size-In case of Air-Cooled Heat Exchangers consider having
uniform length, matching the pipe rack width and tube bundle width based on
standardized fan diameter). All blades for all items shall be the same model and
shall be interchangeable as much as is possible. Commonality of fan blades shall be
maximized.
5.2 Performance and Guarantees
Supplier shall guarantee thermal & hydraulic performance, mechanical design and
noise guarantees of air coolers in accordance with datasheets, specifications and
applicable codes.
5.3 Design
5.3.1 Design pressures, design temperatures, operating conditions, fluid properties,
pressure drops and fouling factors shall be as specified on the exchanger data
sheet.
5.3.2 The air cooler shall be designed for all operating conditions specified in the Data
sheet. The thermal design shall be carried out using HTRI software or any other
software approved by the Buyer in writing.

5.3.3 Air seals are to be provided at mid-section of tube bundle to close the air gap when
the bundles are fitted on the plenum chamber to avoid the recirculation of hot air
whenever one fan is down for maintenance or not required by process.
5.3.4 Cooler bundles shall be designed with support at the four corners only.
Intermediate side frame supports are not allowed.
5.3.5 Teflon pad up to 200°C and Stainless Steel (Polished) Pad above 200°C arrangement
should be used to reduce friction and allowing free movement of tube bundle.
5.3.6 Each bundle and plenum side frame shall be hot dip galvanized (HDG) in one piece.
Mid span joints made by bolting or welding after galvanizing are not permitted.
HDG shall be as per ASTM A123
5.3.7 Slip-on flanges are not acceptable. Nozzles shall be integrally reinforced weld-neck
or long weld neck type.
5.3.8 Based on input from Licensor/Process, operational requirements such as
intermittent operations/thermal shock and alternative operating conditions
described in 7.1.6.1.1 of API 661 shall be confirmed for applicability by Supplier
from Buyer.
5.3.9 For all Services vent and drain connections shall be flanged with the same rating
and facing as the main nozzles, and provided with a blind flange, gasket and bolting.
5.3.10 For total condensing services provide a 1-inch high point vent nozzle at the end of
the condensation section of each tube bundle for non-condensable gas.
5.3.11 Limit inlet connections to a maximum of two per bundle.
5.3.12 Headers shall be plug type or as given on data sheet. Removable cover plates may
be used when the tube side fouling factor is > 0.0004 m² °C h/kcal and pressure is
< 20 kg/cm²g. Removable cover plates shall not be permissible for lethal, explosive
and toxic services like ethylene, hydrogen, chlorine, HCN where leakage to
atmosphere is intolerable.
1) When flat covers are used they shall be through bolted with confined gaskets.
2) Bonnet headers are prohibited.
3) Cast iron headers are prohibited.
5.3.13 A split header is recommended when the difference between the inlet and outlet
process temperature of a multi-pass bundle exceeds 110°C.
5.3.14 Solid tube spacers shall be used due to their better stability and load bearing
capacity.
5.3.15 Explosion proof, manual reset vibration switches shall be provided for each fan.
Switches shall be DPDT (Double pole double throw) type.
5.3.16 If Process temperature control is required or is critical then only auto variable pitch
fans or VFD driven motors or Louvers may be opted. Requirements shall be as
provided in Data Sheets
5.3.17 Equipment allowable maximum noise levels shall be as specified on the noise data
sheet. Where noise levels are not specified the maximum noise level for each fan
and driver (completely assembled unit) shall not exceed 85 dBA measured at 1
meter below the motor and in no case shall be higher than that specified in OSHA.
Vendor shall provide a data sheet with guaranteed SPL (Sound Pressure Level) and
PWL (Sound Power Level) figures in dBA and octave bands.
5.3.18 Air coolers in special service e.g. Lethal, Hydrogen, HF (Hydro Fluoric Acid)
Alkylation, Cryogenic or high pressure gases (70 kg/cm²g and above) may be subject
to special design and inspection requirements. Such special service requirements
and associated design and inspection requirements will be identified on the air
cooler data sheet.
5.3.19 When Wet Hydrogen Sulphide Service is specified the following additional
requirements shall be included:
(a) Corrosion allowance shall be 3mm for carbon steel (except for Tubes), unless
specified in MDS.
(b) After heat treatment welds shall have a maximum Brinell hardness of 200 for
carbon steel.
(c) Tube inlet velocity shall be limited to 6.1 m/s for units with design pressure
greater than 55 kg/cm²g.
5.3.20 Additional applicable requirements as per Pressure Vessel Specification RPMS-
ENGG-SPC-MS-002 shall be followed.
5.4 Materials
5.4.1 Materials of construction shall be as specified in the exchanger data sheets. All
materials for the fabrication of exchanger shall be new and unused.
5.4.2 Materials in sour service shall comply with specification NACE MR 0103 or NACE
MR 0175 and NACE SP 0472.
5.4.3 Additional material requirements as per Pressure Vessel Specification RPMS-ENGG-
SPC-MS-002 shall be followed.
5.4.4 For carbon and carbon manganese steel the carbon content shall be 0.25%
maximum and the carbon equivalent (C.E.) shall be 0.43 maximum.
𝑀𝑛 Cr+Mo+V Cu+Ni
Where CE = 𝐶 + + +
6 5 15
5.4.5 Corrosion allowances will be specified on the exchanger data sheet.

5.4.6 Fan blades may be of either aluminium or GRP (Glass Reinforced Plastic) material.
5.4.7 All material shall be supplied with mill test certificate as per relevant material
standard.
5.4.8 Nozzle flanges and plugs shall be made of forgings.
5.4.9 Nozzles of size 2” and below shall be provided with two stiffeners 90 o apart.

5.5 Fabrication and Welding Requirements

5.5.1 All welding, post weld heat treatment, Vendor Weld Procedure Approval and
Welding Quality Requirements shall comply with Pressure Vessel Specification
RPMS-ENGG-SPC-MS-002 and Welding specification RPMS-ENGG-SPC-MT-004.
All tube to tube sheet welding shall meet the requirements specified in RPMS-
ENGG-SPC-MT-006.
Weld of partition plate to plug sheet and tube sheet shall be full groove.
No welding or cutting is permitted on stress relieved air-cooled heat exchangers.
5.5.2 Welding Procedure Qualification shall be part of the mock-up test which shall
reproduce all fabrication steps using the same materials and dimensions. Each tube
size shall be qualified separately. For tube to tube sheet joints being welded
through the plug sheet hole, the most severe conditions in terms of accessibility
shall be employed. The mock-up assembly shall correspond to the smallest plughole
diameter, the thickest plug sheet and longest distance between plug sheet and tube
sheet. Mock-up procedure test is required in any of the following condition:
- If code or purchase-order warrants.
- If fabricator has no similar established procedure.
New mock up test is not required if the Supplier has a previously authenticated
mock up with exact conditions, subject to its review and acceptance by RIL.
Welding procedures shall be qualified in accordance with ASME IX section QW-193,
RPMS-ENGG-SPC-MT-006 and the additional requirements listed below:
a. Tubes and tube sheet materials to be used for the mockup qualification test shall
be the same diameter, wall thickness, grade, pitch and weld joint design as for
production.
b. If the production tube sheet is cladded or weld overlaid the mockup assembly
shall be cladded or weld overlaid with the same process and thickness.
c. If tubes are expanded after welding, a sample representing the full thickness of
the tube sheet shall be used for the procedure qualification.
d. The mockup test shall simulate all steps required for production welding,
including tube fit up with slight expansion, preheat and interpass temperatures
requirements.
e. For duplex and super duplex stainless steels, the micro-examination shall include
the measurement of the ferrite/austenite content in the weld, heat affected
zone and base metal using systematic point counting method in accordance with
ASTM E562. The measured ferrite content shall be between 35% to 65% in the
as welded condition.
5.5.3 Approval of vendor procedure for Duplex or other non-CS steel tubes to CS tube
sheet shall be hold point for TPI / Buyer.
5.5.4 For welded tube to tube sheet joints with dissimilar materials, weld overlay on tube
sheet with material suitable for process and having good weldability with both tube
and tube sheet base material should be considered.
5.6 Fan and Drive System

5.6.1 Direction of fan rotation shall be marked to be visible at all time
5.6.2 Fan shall be provided with locking devices to prevent rotation due to natural
convection during maintenance
5.6.3 Offered Fan design should be of highest efficiency achieved by improved blade
profile to achieve better aerodynamic results. Fans should be operated in the mid-
range of the fan performance curve; this should be applied to tip speed, ability to
handle the static pressure and blade angle.
5.6.4 The design shall not lie on a performance curve in proximity to the stall region
which manufacturer shall indicate on the fan curves.
5.6.5 Supplier shall evaluate aluminium blade design v/s FRP (Fiber Reinforced Plastic)
fan design to select better and efficient blades.
5.6.6 Fan hub and fasteners shall be of corrosion resistant material. Self-locking type of
fasteners should be used.
5.6.7 Recirculation disc shall be considered to improve efficiency and preventing
recirculation.
5.6.8 Further classification may be given for better efficiency/ higher air flow rates.
5.6.9 Antifriction bearing should have one side shield i.e. towards inner side of shaft at
top and bottom bearing location. Bearing housing should have facility for greasing
and at these location grease inlets and outlet connection should be provided at
each bearing location.
5.6.10 Roller bearing shall be considered for fan drive system for improved life of fan drive
system.
5.6.11 Selected shaft design shall be considered with bearing locating lock nut to control
axial thrust. In no case bearing locking by use of circlip is accepted.
5.6.12 Slingers provided on motor shaft for preventing water entry along the shaft shall
be either of rubber or FRP of required strength and shall be positively locked on
shaft of motor. Loose Slingers can entangle with driving belts.
5.6.13 To lift motors, lifting eye bolts shall be provided on side of motor body or motor
should be lifted in cage. Vertical lifting of motors using shaft shall be prohibited as
it may damage motor bearing during lifting process.
5.6.14 Anchoring arrangement shall be provided in Plenum chamber for lifting of motor
and shaft assembly.
5.6.15 Based on operating experience it is observed that in many cases belts get damaged
when they run near edges. To prevent this, Motor pulley shall have end flanges with
taper edges to prevent damage to belts which may occur due to straight edges

5.6.16 Motor junction box shall be located and oriented such that the wiring is directed
away from the motor mount and connection is easily accessible by construction
personnel. There shall be no interference with structural parts or other assemblies
that would inhibit access to wiring connection.
5.7 All header box plates shall be in single piece construction.
5.8 All tubes shall be seamless.
5.9 Accessories & Spares

5.9.1 Accessories
Unless otherwise included in MR, supply of following accessories shall be
considered by the Supplier-
i) Motor
ii) Fan Guard, Belt Guard
iii) Control Louvers (if applicable)
iv) Motor Mounting Frame
v) Temporary Cover for Tube-bundle (during transportation and installation)
vi) Belt Drive with pulleys, Bushes
vii) Bearing block assembly
viii) Gear boxes with couplings
ix) For Auto variable pitch fan or Auto Louvers:
Air filter, regulator, I/P convertor with positioner, Pneumatic actuator, pneumatic
tubing with necessary fittings.
5.9.2 Spares
Following spares shall be considered in the scope of supply:
i) Gaskets for covers and blind nozzles – 200%
ii) Gaskets for plugs – 100%
iii) Plugs and bolting – 10% (of each type)
iv) HTD belt and bearing- 100%
v) One set of diaphragm actuator.
vi) One blade for each size and type of fan
vii) Spare fan and spare motors as per Supplier’s recommendations.
Recommended 2 years Operational Spares (Supplier to provide List with price)

6 Inspection and Testing

6.1 Minimum NDT Requirements
6.1.1 Inspection, examination and testing of pressure parts shall comply with the
requirements of the applicable pressure vessel code and this specification. NDE
operators shall be certified to ASNT Level-II. NDE procedures shall be approved by
ASNT Level-III.
6.1.2 All NDT for final acceptance shall be performed after completion of any post weld
heat treatment.
6.1.3 The extent of radiography shall be in accordance with the relevant design code and
as specified in the data sheet. The header box design shall be in such a way that it
is possible to do volumetric inspection of all the joints. A scan plan for UT shall be
prepared at the design stage itself.
6.1.4 Surface Examination - All attachment welds to pressure parts which are not subject
to 100% radiography shall be subjected to Magnetic Particle or Dye Penetrant crack
detection testing performed as follows:
a) The full length of all nozzle attachment welds.
b) 100% of MP or PT is required for any attachment welds to pressure containing
parts and MP or PT (minimum 10% length) for welds to primary structural steel.
c) All carbon steel shall be examined using magnetic particle examination or dye
penetrant test method. When PWHT is involved, any such test shall be done
after PWHT. Welds in LAS materials shall be MT examined. AC or HWDC yokes
shall be used in MT examination.
d) If nozzle attachments are of the "set on" type, all weld joint preparations to the
header box plates shall be subject to 100% UT upto 4 inch around the nozzle
opening. Weld preparations in header plates shall be MT/PT examined.
e) Ultrasonic testing of header plates shall be as follows:
Sour, Hydrogen and Lethal
Thickness (t) Normal service
Service
t > 20 A578 with S1 and level B A 578 with S1 and level C
acceptance criteria acceptance criteria
6.1.5 All tubes shall be 100% eddy current tested at the mill for both internal and external
defects.
All tubes shall be hydro tested. Hydrotest pressure of tubes shall be higher of actual
exchanger tube side test pressure or as required by ASME Sec II. Minimum test
pressure shall not be less than 70 kg/cm²(g).
6.1.6 PMI shall be applicable for LAS, SS, HAS & exotic pressure part materials including
welds in accordance with RPMS-ENGG-SPC-PP-018.

6.1.7 General inspection points in addition to weld and NDE shall also include: Material
identification, execution of major repairs, trial fit up / assembly, painting/coating
verification, galvanizing / thickness verification, final inspection and dimensional
check, cleaning / drying /purging / blanking, name plate / tagging, marking /color
coding, ancillary items/spare parts inspection, preparation for shipping,
documentation review prior to release.
6.1.8 Extent of inspection for each inspection point shall be as required in MR / ITP.
Against each inspection point HP, WP, RI, RD, shall be defined and specified as
required depending on the criticality of the exchanger.
6.1.9 Helium leak tests shall be carried out after hydrotest for Tube to tube sheet joints
and Gasketed joints, when lethal service is indicated in the process data sheet.
6.1.10 Air leak test shall be done and the plug to plug sheet joint shall be done with the
soap solution before hydrotest and the pressure shall be 1.5 kg/cm2g
6.1.11 For Embedded Fins: Fin Tube pull out test to be carried out as per manufacturer
standard.
For Extruded Fins:
Each type of extruded fin tubes shall be subjected to "Single Tube Test" (Thermal
Bonding Test) for checking adequacy of thermal bonding between the aluminum
sleeve and CS/SS bare tube. Test frequency shall be no less than 1 tube for every
500 tubes to be installed. Vendor to submit test procedure and acceptance criteria
with their proposal.
6.1.12 Production weld hardness to be carried out as per API 661.
7 Vendor Data
For vendor data requirement, refer to Appendices A & B attached to this
specification.
8 Packing, Preservation, Shipment and Storage

8.1 It is the responsibility of the Supplier to ensure that all equipment, including sub-
vendor equipment is cleaned and painted in accordance with Buyer’s Specification.
All exchanger surfaces shall be cleaned to remove loose scale, rust, grease, dirt,
weld spatter, hydrotest water and other foreign matter.
8.2 Rust preventive coatings of approved brand shall be applied on bolt/fasteners of
CS and LAS. Gasket contact face of flanges also shall be given rust preventive
coatings.
8.3 All lifting lugs should be marked with proper warning signs for designed load. Stress
analysis shall be carried out for these lifting lugs to check their compliance to
desired load
8.4 Positioning of lifting lugs shall be such that horizontal balance of bundle is achieved.
8.5 In case air coolers are provided with lifting beams, these beams shall be
distinguished properly from tube support beams by painting & marking. Lifting
requirement shall be indicated on these lifting beams with warning signs.
8.6 Immediately after completion of the hydrotest, the tube bundle shall be drained
and all moisture shall be removed from the interior of tube bundle by blowing
warm air. Procedure for drying shall be provided by Supplier and commented by
the Buyer before use.
Particular care shall be taken in drying areas containing surface discontinuities, such
as nozzles, pass partitions, etc. After drying, the project may choose to internally
examine the item by borescope and swabbing of problem areas to verify absence
of moisture and debris.
Supplier shall perform Borescope inspection of header boxes prior to N2 purging,
normally performed through a nozzle (other means may be selected based on
access). If contamination is found, Supplier shall inform the Purchaser. Other areas
of headers and tubes shall be inspected (may be accessed through tube plugs) at
locations selected by Purchaser.
All bundles shall be shipped in purged condition with Nitrogen and Protective
covers provided with pressure gauges for monitoring Nitrogen pressure till bundles
are erected.
8.7 Top surface of finned tubes shall be protected by using at least 0.5 mm thick
galvanized plate. This cover plate shall be bolted in such a way that it can be opened
only when this activity is to be performed after completion of construction activities
and just prior to commissioning. In case of transporting tube bundles in stack
condition, all bundles shall be provided with individual protection plates.

9 Attachments
9.1 Appendix A : Vendor Data Requirement
The vendor data requirement shall cover the documents to be submitted by a
vendor during the following stages:
9.1.1 Along with the bid
i) Certificate of approval.
ii) Proposed schedule of manufacture.
iii) Tentative Quality plan.
iv) List of sub-suppliers.
v) Past Experience list.
vi) Data marked as “Vendor to Confirm “in inquiry datasheet.
vii) Thermal Datasheet
9.1.2 During Manufacturing / After Award of Order

i) General Arrangement drawing.
ii) Data sheet / Loading data
iii) Design Calculations (Thermal, Mechanical, Structural) / FEM Analysis (if
applicable). Vendor shall furnish native file of final Thermal Rating Calculation
on project completion.
iv) Fan data sheet and Equipment performance curve.
Motor Data sheet, curves and GA drawings
Louver performance curves
v) Detailed and Cross-sectional drawing.
vi) List / bill of material
vii) Nozzle load analysis
viii) Inspection Test Plan
ix) Weld procedure
x) NDE procedure
xi) Material test certificates
xii) Heat treatment Procedure
xiii) Test procedures (Hydro / leak / mech-running)
xiv) Specification Waiver

xv) Schedule of drawing and documents

xvi) Manufacturing schedule
xvii) Progress Reporting
xviii) Inspection release note
xix) Painting procedure
xx) Documentation required for IBR approval (wherever applicable)
9.1.3 With the supplied material

As required and agreed upon
9.1.4 After supply of material

i) Spare list
ii) Record Book (As built of all manufacturing & testing doc)
iii) Lifting & Installation Drawings /Instructions
iv) Shipping drawing & packing list
9.1.5 During training and site services

i) Operating & Maintenance Manual
ii) Supplier’s Catalogue

9.2 Appendix B : Vendor Document / Data Format

9.2.1 Scope
These instructions define the control, content and formant of documentation to be
submitted as part of contract. These instructions shall be used in conjunction with
“Vendor Data Requirements”.
9.2.2 Document / data Submission Requirements:
Documents / data required to be submitted by Supplier at different stages and
schedules shall be as per “Vendor Data Requirements”. However, “as built” data
and documents of entire manufacture and testing shall be provided in the MRB
(Manufacturing Record Book). Any submissions required to be submitted to third
party like Process Licensors/Statutory Authorities or TPI shall also be complied with.
9.2.3 Document / Data Formant Requirements:
(i) Submission of documents shall be on Buyer’s standard forms unless otherwise
agreed. Where not provided by Buyer, Supplier’s forms are acceptable.
Buyer reserves the right to substitute paper format with electronic documents/
data for completion by the Supplier. In such cases, Supplier will be responsible
for provisions and support of both hardware and software required to interface
with and use Buyer’s preferred format.
(ii) Electronic Format
Buyer requires documents / data for review to be submitted electronically, in
Abode Acrobat Portable Document Format. Buyer’s “Electronic Document
Management System (EDMS)” enable the integration of Supplier’s documents
into the Buyer’s EDMS. The Buyer’s EDMS shall facilitate the review of the
Suppliers documents and may also be used by the plant operator for continued
maintenance of the plant.
Supplier will appoint their coordinator who shall interface with Buyer
representative for smooth to and fro transfer of documents.
(iii) Language
All documents shall be legible and shall be submitted in English language unless
otherwise requested by project specific attachments to the Material
Requisition.
(iv) Documentation Quality
All images shall be legible and properly oriented for viewing.
Proper drawing size to be selected based on requirement, extent of detailing in
each drawing, legibility and ease of handling at shop / site.
Colour images need to be supplied to differentiate between details, if required.

9.3 Appendix C: Addendum to API-661-7th Edition, July 2013 (Reaffirmed,

June 2018)
The requirements of API 661 shall be supplemented as follows:
3 Terms and Definitions (Addition)
3.34 Addition
(New) - "Addition" adds the requirement following this term to the referenced API
Standard requirement. An addition does not change the API Standards
requirement.
3.35 Modification
(New) - "Modification" changes the API Standard requirement to that which follows
the term. All parts of the API Standard requirement which are not addressed remain
applicable.
3.36 Decision
(New) - "Decision" provides direction for choices which are specified by the API
Standard paragraph. Parts of bulleted paragraphs which do not require decisions
are fully applicable.
4 General
The pressure design code shall be ASME Section VIII Division 1.
6.1 Approval Information
6.1.1 Addition
The Supplier shall provide all drawings and documentation for review as defined in
the purchase order.
6.1.3 Addition
The Supplier shall compute the maximum allowable working pressure (MAWP) for
both the new and cold condition and for the hot and corroded condition. Both
MAWP’s and the limiting component shall be indicated in the Vendor’s
documentation.
7.1.1 Tube Bundle Design – General
7.1.1.13 Addition
To accommodate lateral expansion of cooler banks, Low friction sliding plates (e.g.
Teflon slide pads for up to 200 °C and Stainless Steel (Polished) pads for higher
temperature, etc.) are to be fitted under the bundle side frames. Mating slide pads
shall be supplied for fitting to the plenums, complete with the necessary bolting.
7.1.1.14 Addition

Minimum number of tube rows recommended for a tube bundle shall be four,
although three rows can be used in exceptional cases. Heating (Steam) Coil tube
bundles shall have minimum 2 tube rows.
7.1.3 Tube Bundle Design Temperature
7.1.3.3 Addition (Annex A.3.3.1)
a) Edge tension fins shall not be used.
7.1.6 Headers
7.1.6.1.3 Addition:
Split headers shall be considered for all multi pass bundles unless differential tube
expansion can be shown to be within safe limits. Special consideration shall be
given if the design temperature is much greater than the operating temperature
shown on the data sheet. Vendor to carryout detailed analysis for deciding the
requirement of split header.
7.1.6.1.6 Modification
In Table 1 - The minimum thickness of tube sheet and plug sheet for carbon and
low alloy steels shall be 25 mm plus the corrosion allowance and for high alloy steels
19 mm plus corrosion allowance.
7.1.6.2.3 Addition
The design of the joint, including cover plate, must take into account seating the
pass partition rib(s) gasket.
7.1.8.10 Addition:
(i) Two-part plugs shall be used for sour / corrosive services. All plugs will be
tightened by torque wrench only.
(ii) Plug gasket shall be of solid metal type. Soft iron or soft SS gaskets are
recommended and hardness of the same shall be 15 BHN less than plug and header.
Soft iron gasket hardness not to be exceeds 90 BHN and SS gasket hardness not to
exceed 160 BHN.
(iii)Gasket material shall be chosen to eliminate galling wherever applicable.
(iv) Plug gasket for hydrogen service shall be spiral wound.
7.1.8.11 Addition:
Plug and plug gasket material shall be equivalent or superior in corrosion resistance
to header material.
7.1.9 Nozzles and Other Connections
7.1.9.3 Modification
Threaded connections shall be avoided. However if provided, couplings shall be
socket- weld type.

Unless otherwise noted on the data sheet, all nozzles shall be flanged. Flanges
through 24 inch in size shall be per ANSI B16.5. Flanges larger than 24 in. NPS shall
conform to ASME B16.47 Series B.
Small bore nozzles on tube bundle shall be provided with stiffeners at 120° apart.
7.1.9.13 Addition
One inlet and outlet nozzle per bundle shall be provided with 40 mm (1-1/2") NPS
multi-purpose connections of 300# minimum or of same rating as parent flange,
complete with blind flange, gasket and bolting
7.1.10 Maximum allowable moments and forces for nozzles and headers: -
When at the maximum operating conditions and corroded, each nozzle shall be
capable of withstanding the simultaneous application of two times the moments
and forces listed in Table 4.
7.1.11 Tubes
7.1.11.7 Addition
Aluminum fins shall be limited to the following types and tube wall temperatures:
a. Extruded up to 288 °C
b. Embedded up to 400 °C
7.1.11.14 Addition
The number of fins shall not exceed 433 per meter (11 fins per inch) for Embedded
fins and 394 per meter (10 fins per inch) for Extruded fins. Serrated fins shall not be
used without Buyer’s prior approval.
7.1.11.15 Addition
Circumferential welds in the tubes are allowed only at the bends on U-tubes and in
serpentine bundle design. Circumferential welds in straight tubes are strictly
prohibited. Circumferential welds shall be 100% radiographed in addition to DP/MP
test.
7.1.11.16 Addition
For all finned tube bundles, the bare portion of all tubes shall be coated for
corrosion protection. As a minimum, epoxy or an equivalent coating system should
be utilized. Other methods shall be discussed and approved by the project before
award. Supplier shall advise specific coating manufacturer, recommended
temperature limits, and model number(s) in his quotation.
7.1.11.17 Addition
The use of tube inserts or “turbulators” to enhance air cooler thermal performance
is prohibited unless otherwise indicated on the equipment datasheet.
7.2.1.7 Revise first sentence as:
Fan selection at design conditions shall ensure that at rated speed the fan can
provide, by an increase in blade angle, a 10 % increase in air flow with a
corresponding pressure increase or by at least 5°, whichever is higher.
7.2.1.9 Addition
For calculation of motor size and choice of fans, overall fan efficiency shall be
limited to 75% (not including driver train losses).
7.2.1.10 Addition
Air seals shall be provided between bays to minimize air recirculation when the gap
between bays is 200 mm or more.
7.2.3 Fans and Fan Hubs
7.2.3.1 Decision:
There should be at least two fans along the tube length. However, in exceptional
cases, one single fan may be used. The design shall take into consideration lower
duty with which the cooler operates in the event of one of the fans stop functioning.
7.2.3.11 Addition
Upon loss of control air pressure, fan blades shall automatically adjust to maximum
pitch, unless otherwise noted on the data sheet.
7.2.3.15 Addition
The fan, fan hub, actuator, etc. on induced draft designs must be capable of
withstanding continuous operation exposed to the air temperature which would be
reached during fans off operation and with the process inlet at normal operating
conditions.
7.2.5 Lubrication Facilities
7.2.5.1 Addition
Bearings shall have an additional ¼” NPT hole for expelling spent grease. All
lubrication points shall be centrally located at a safe location on the maintenance
platform (pipe rack mounted air coolers) or on the ground (grade mounted air
coolers) and shall be labeled with corrosion resistant tags. Re-greasing points
should be easily accessible without requiring removal of fan guards, belt, pulley,
water slinger, etc.
7.2.7.2 Electric Motor Drives
7.2.7.2.10 Addition
Electric motors shall be painted per project painting specification.
7.2.8 Couplings and Power Transmissions
7.2.8.2.11 Modification – Complete replacement:

High torque positive drive belts may be used with fan motors rated up to 37 kW (50
hp). Gear drives are required for fan motors larger than 37 kW (50 hp).
7.2.8.2.14 Addition
All belts must be anti-static.
7.2.8.2.15 Addition
All speed reducer components shall be from the same manufacturer and intended
for use as a drive set. Speed reduction ratio shall be limited to approximately 6.5:1
(maximum).
7.2.8.2.16 Addition
All belts shall be suitable for operation in a wet marine environment with a
minimum expected life of 20,000 hours at the design conditions listed on the
equipment datasheet.
7.2.8.3.6 Addition
Design shall permit addition of oil while the unit is running.
7.2.10 Louvres
7.2.10.19 Decision
Upon loss of control air pressure, automatically controlled louvres shall fall in fully
open position, unless otherwise noted on the data sheet.
7.2.10.26 Addition
Louvres shall be located over the process bundles. Louvres positioned under the
bundles are not permitted. Louvres on top of the induced draft fan ring are not
permitted.
7.3 Structural Design
7.3.1.8 Addition
The Vendor shall provide structural columns and bracing which place the lowest
horizontal structural member providing minimum headroom clearance of 2.1m.
7.3.5 Mechanical Access Facilities
7.3.5.9 Addition
Supplier will be required to place breaks at 15-meter intervals in the handrails for
ladders with safety gates which the Buyer will provide and install. The appropriate
location of the breaks will be noted during the Supplier print review.
7.3.5.10 Addition
Each induced draft plenum chamber shall be equipped with a bolted access hatch
approximately 1 m square to provide means for personnel access to induced draft
fans and upper bearings. Bolted hatch shall be placed on a sloped side of the
plenum. Grating shall be provided above the tube bundle extending from the bolted
hatch to the fan shaft. Grating shall be 800 mm wide (min) with 800 mm (min) on
all sides of the fan shaft. External ladder and platform access to the hatch shall be
per material requisition.
7.3.6.6 Addition
Lifting eyes suitable to lift the entire bay shall be provided at points located above
the air cooler side frames, such that they are accessible and usable for bay
installation in the Buyer’s facility and for future removal of bays, if required. The
preferred number of lifting eyes is four (4). Each pad-eye/lift lug shall be designed
for a Factor of Safety of 2 to the stated safe working load (SWL).
8.1.7 Addition:
Plenum chambers, side frames, motor-suspension structure, fan guard and gratings
and platform shall be of hot dip galvanized material. Other main structures can be
given zinc chromate primer.
9.3.3 Expanded Tube to Tubesheet Joints:
9.3.3.4 Addition
Supplier shall guarantee that the yield strength of the tube material does not
critically exceed the yield strength of the tubesheet material in order to ensure
quality rolling, expanding and sealing of tubes to tube sheet is attainable. Where
necessary, the Supplier shall upgrade the tube sheet material and/or strength weld
tube to tube sheet joints.
9.3.3.5 Addition
Expanded Tube to tubesheet joints shall have minimum 2-groove and seal weld. For
hazardous services like – hydrogen, ammonia, acids, lethal, sour services the tube
to tube sheet joint shall be 2-groove expanded and Strength welded.
9.3.4 Welded Tube to Tubesheet Joints
9.3.4.1 Decision:
If design pressure exceeds 70 kg/cm2 (g) the tube to tube sheet joint shall be
expanded and strength welded.
Welding of dissimilar materials shall be avoided. Weld overlay shall be considered
to avoid dissimilar material welding.
All welded tube to tubesheet joints shall be fully expanded per paragraph 9.3.3 of
API 661.
Strength welded joints shall have a minimum of two weld runs.
For SS410 tubes, pre heat of 175 C minimum shall be applied.
Interpass temperature for austenitic SS and SS410 shall be 150 C and 175 C
respectively.
10.2 Pressure Test

10.2.3 Addition
The 30 ppm chloride limit shall also apply to martensitic (400 series) stainless steel.
For carbon steel and low alloy materials the test water shall be potable quality with
a chloride content less than 250 ppm.
10.2.6 Decision
Halogen tests are not required unless specified on the data sheet.
10.2.7 Addition
After hydrotest all water shall be completely drained and the exchanger shall be air
dried. Hot air shall not be used for drying stainless steel exchangers. The exchanger
shall be purged with dry Nitrogen and pressurized during transit and site storage as
follows:
(a) Nitrogen pressure shall be 0.3 kg/cm²(g) minimum. Oxygen Level shall be 1%
maximum.
(b) Provide 2 needle valves.
(c) Provide 2 pressure indicators with safety protection.
(d) All nozzles shall be suitably sealed with steel blanks (min. 12 mm thick),
temporary gaskets and 100% bolting.
(e) Nitrogen cylinder of 3-5 Litre capacity along with accessories to be provided for
top up.
10.3 Shop Run-In

10.3.1 Decision
Factory Acceptance Test shall be carried out for 4 hours at Supplier’s shop in no
load condition and following shall be checked:
(i) Dimensional check.
(ii) Fan assembly/tip clearance check.
(iii) Fan drive assembly run -test.
(iv) Vibration level check
(v) Noise level check. (Fan blade pitch adjustment check)
(vi) Shop run-in test shall be performed for at least 1 bay per service (and at least
one bay in twenty for larger services) at the air cooler manufacturer's shop. All run-
in tests shall be conducted with all fans in the bay running, with fan blades set at
the design operating pitch.

10.3.2 Decision
Motor-Fan Run Test – The drive assembly shall be subjected to no load run test to
ensure / verify the airside design. Following parameters shall be measured/
evaluated during the test:
(i) Air flow rate and distribution.
(ii) Motor power consumption (Actual Vs Guaranteed value).
(iii) Fan RPM.
(iv) Static pressure loss
(v) Inlet /outlet temperature.
(vi) Check for abnormal temperature rise
(vii) Fan tip speed

Standard Specification
for Unfired Pressure Vessels
RPMS-ENGG-SPC-MS-002

By By By
Specification for Unfired Pressure Vessels Date: 17.08.2020, Rev 0

Sr.
No.
1 __Anand Umakanthan___________ _________________ ___________
__Tushar Mukherjee____________ _________________ ___________

2
_____________________________ _________________ ___________

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope: ........................................................................................................................ 5
2. References: ................................................................................................................ 5
3. Conflicts and Deviations: ........................................................................................... 7
4. Abbreviations and Definitions: .................................................................................. 8
5. Technical and Design Requirements: ........................................................................ 9
6. Inspection and Testing: ........................................................................................... 22
7. Vendor Data: ........................................................................................................... 24
8. Packing, Preservation, Shipment and Storage: ....................................................... 25
9. Attachments ............................................................................................................ 27
9.1 Appendix A : Supplementary Requirements for Alloy Clad Vessels ........................ 27
9.2 Appendix B : Load Combinations ............................................................................ 30
9.3 Appendix C : Pressure Vessel Tolerances ................................................................ 32
9.4 Appendix D : Vendor Data Requirement ................................................................. 36
9.5 Appendix E : Vendor Document / Data Format ...................................................... 38
1. Scope:
1.1. This specification defines the minimum technical requirements for design,
materials, manufacture, inspection, testing, painting, certification, packing,
shipment and documentation of Pressure Vessels for Supplier and/or Contractor to
comply with, to achieve Buyer’s objective of standardization.
Supplier shall be responsible for incorporation of relevant process licensor
requirements in the specification of equipment or systems, that may override this
standard specification.
2. References:
The following documents referred here form part of this specification.
ASME Section VIII Div.1 Rules for construction of Pressure Vessels
ASME Section VIII Div.2 Alternative rules for construction of Pressure Vessel
ASME Section V Non-destructive Examination
ASME Section IX Welding & Brazing Qualifications
ASME Section II Materials
SMPV Static and Mobile Pressure Vessel (Unfired) Rules
IS-875 (Part 3) Code of Practice for Wind Load Design
IS-1893 Part-1 & 4 Criteria for design of earthquake resistant structure.
ASTM A263 Specification for Stainless Chromium Steel - Clad Plate
ASTM A264 Specification for Stainless Chromium-Nickel Steel -
Clad Plate
ASTM A265 Specification for Nickel and Nickel-Base Alloy-Clad
Steel Plate
ASTM B432 Specification for Copper and Copper Alloy Clad Steel
Plate
ASTM A578 Specification for Straight-Beam Ultrasonic
Examination of Rolled Steel Plates for Special
Application
ASTM A 388 Practice for Ultrasonic Examination of Steel Forgings
NACE MR 0103 Materials Resistant to Sulphide Stress Cracking in
Corrosive Petroleum refinery Environments

NACE MR 0175 Standard Material Requirements, Sulphide Stress

Cracking Resistant Metallic Materials for Oilfield
Equipment
NACE SP 0472 Methods and controls to prevent in-service
environmental cracking of carbon steel Weldments in
corrosive petroleum refining environments.
RPMS-ENGG-DBD-MS-001 Design Basis for Wind and Seismic Analysis of Static
Equipment
RPMS-ENGG-DBD-MS-002 Indian Boiler Regulations - Approval Procedure for
Static Equipment
RPMS-ENGG-DBD-ST-005 Indian Boiler Regulations - Approval Procedure
Welding Research Council - Local Stresses in Spherical and Cylindrical Shells due
Bulletin No. 107 (537) /297 to External Loadings
WRC Bulletin 537 Precision Equations and Enhanced Diagrams for Local
Stresses in Spherical and Cylindering Shells due to
External Loadings for Implementation of WRC
Bulletin 107
WRC 470 Recommendations for Design of Vessels for Elevated
Temperature Service
WRC 452 Recommended Practices for Local Heating of Weld in
Pressure Vessels
British Standards Institution Specification for Unfired Fusion Welded Pressure
PD 5500 Vessels
RPMS-ENGG-SPC-PP-012 Specification for Hot and Acoustic Insulation
RPMS-ENGG-SPC-PP-013 Specification for Cold Service Insulation
RPMS-ENGG-SPC-PP-014 Specification for Field and Shop Painting
RPMS-ENGG-SPC-PP-018 Positive material identification for piping & Mech.
Component.
RPMS-ENGG-SPC-MT-004 Supplier Welding Procedure Approval and Welding
Quality Requirements
RPMS-SD-C15-303 Standard Anchor Bolt details with ductile detailing.
RPMS-SD-M15-001 Name Plate Vessel
RPMS-SD-M15-010 Standard Nozzle Loads
RPMS-SD-M15-011 Standard for Skirt Opening Details

API 934A Materials and Fabrication of 21/4Cr-1Mo, 21/4Cr-

1Mo-1/4V, 3Cr-1Mo and 3Cr-1Mo-1/4V Steel Heavy
Wall Pressure Vessels for High-temperature and High-
pressure Hydrogen Service
API 934C Materials and Fabrication of 11/4Cr-1/2Mo Steel
Heavy Wall Pressure Vessels for High-pressure
Hydrogen Service Operating at or, Below 825 F
API 934E Materials and Fabrication of 11/4Cr-1/2Mo Steel
Pressure Vessels for Services above Services above
825 F
API RP941 Steels for Hydrogen Service at Elevated Temperatures
2.1. For vessels / drums containing steam / boiler feed water, IBR shall be applicable in
addition to ASME codes. Documentation requirements shall be as per IBR and
RPMS-ENGG-DBD-MS-004.
2.2. For pressure vessels like LPG bullets, spheres and/or when so stated on equipment
data sheet that SMPV rules are applicable, then such equipment shall be subjected
to Third Party Inspection like Lloyd's Register Verification Limited, BV, TUV NORD
or any other inspection agency recognized by the Petroleum and Explosives Safety
Organization (PESO), India. Third Party inspector should endorse design
calculations/drawings. Equipment shall be stamped by the Third Party inspector.
2.3. SUPPLIER shall be wholly responsible for the design and construction of the vessels
and their integral components. The design details shown on the data sheets and
standard drawings are the minimum design requirements.
2.4. SUPPLIER shall obtain appropriate approvals of his design and construction from
the Regulatory Authorities for the region where the equipment is to be installed
and operated.
2.5. BUYER's review of SUPPLIER's drawings or release of vessel for shipment by
BUYER‟s inspector shall not relieve the SUPPLIER of his responsibility for complying
with all the requirements of the purchase order.
3. Conflicts and Deviations:

3.1. In the event of conflict or deviation from requirements stipulated in this
shall govern:
1. Data Sheets and Drawings
of enquiry, shall be applicable. In the event of a conflict between the requirement
of the referenced codes, standards, specifications, regulations and procedures,
Supplier shall submit the recommended solution to Buyer for review and
permission to proceed prior to implementation.
Notes:
• “Datasheets and Drawings” refers to Equipment Datasheets and drawings
attached with the Material requisition
• “Material Requisition” refers to Material Requisition for Quotation, superseded
by Material Requisition for Purchase on execution of a Purchase Order.
• Any local statutory and regulatory requirement shall mandatorily be applicable
and addressed during engineering stage.
4. Abbreviations and Definitions:

ASTM American Society of Testing Materials
AWS American Welding Society,
BS British Standard
C.A Corrosion Allowance
C.E. Carbon Equivalent
CG Center of Gravity
CS Carbon Steel
DCBB Down comer bolting bar
DEC Detail Engineering Contractor
EDMS Electronic Document Management System
EPC Engineering, Procurement and Construction
GA General Arrangement
FEA Finite Element Analysis
HAS High Alloy Steel
HIC Hydrogen Induced Cracking
IGC Intergranular Corrosion
ITP Inspection & Test Plan
LAS Low Alloy Steel
MDS Mechanical data Sheet
MPCF Material Predictive composition factor
MR Material Requisition
MRB Manufacturing Record Book

NACE National Association of Corrosion Engineers
NDT Non-destructive test
PWHT Post Weld Heat Treatment
PQR Procedure Qualification Records
SFA Steel Framing Alliance
SS Stainless Steel
TPI Third Party Inspection
TSR Tray Support Ring
WPS Weld Procedure Specifications

Supplier/ Party which manufactures or supplies equipment and services
Vendor to perform the function as specified by Buyer
Buyer (Reliance) or Buyer appointed DEC or EPC who specifies
Owner equipment and services for purchase from Supplier

Reliance Industries Limited or specified Reliance Group
Buyer Company
5. Technical and Design Requirements:

5.1. Units of measurement shall be in accordance with the Basic Engineering Design
Data or as indicated in the Material Requisition
5.2. All vessels shall be designed, fabricated, inspected and tested in accordance with
the specified edition of the ASME Code Section VIII Div. 1 or 2. Load combinations
to be considered are shown in Appendix-B of this specification.
5.3. The wind analysis shall be as per Design Basis RPMS-ENGG-DBD-MS-001.
5.3.1. Deflection of the top of a column due to static wind load shall be limited to 1/200
of the vessel height including skirt. However, process licensor’s more stringent
requirement if any shall be followed. For vertical vessels with height to diameter
ratio >15, the effects of wind induced vibration shall be checked.

Option of guide support to the column can be considered if more economical in

case the thickness is governed by wind load. If the equipment is with guide support,
then integral analysis along with the structure shall be done by DEC with interface
with the vessel vendor.
5.4. The seismic analysis shall be as per Design Basis RPMS-ENGG-DBD-MS-001.
5.5. Minimum nominal wall thickness for vessels shall be as given below:
- For CS and low alloy steels: D/1000 + 2.54 + C.A (where D = Vessel inside dia (mm))
- For stainless steel: 3 mm
5.6. Minimum nominal wall thickness for columns (including skirt shell) shall be 5 mm
exclusive of any corrosion allowance.
5.7. The following minimum stress analyses shall be provided as applicable (in addition
to basic code calculation requirements): -
a) Complete detailed calculations shall be provided for lug or ring type supports, or
any other attachment or load bearing cleats when used. These shall also include
local load analysis of the vessel shell/head to the attachment considering all the
loads.
b) For vessels operating in excess of 340 Deg C and supported by Skirts, a Finite
Element Analysis of the skirt to head junction shall be made to assess the
Thermal stresses at this critical junction and if necessary, a hot box shall be
provided to reduce the thermal gradient and bring back the thermal stresses
within allowable limits.
c) Complete design calculations shall be provided for special, large diameter flanges
and closures when used. For large size flanges in severe service the maximum
rotation shall not be more than 0.5o.
d) Stresses at saddle supports.
e) Equipment shell / head to be analyzed for local loads adjacent to openings,
external attachments for external loads specified as per Piping Stress Group.
f) Thermal stress analysis shall be made in regions subjected to operational cyclic
and non-cyclic thermal stresses.
g) Ratcheting Analysis shall be considered for vessels whenever the design
temperature is 500°C or, more.
h) Design temperature and minimum design metal temperature should be specified
in Mechanical datasheet.
5.7.1. Nozzles shall be designed to withstand the external load specified in standard
RPMS-SD-M15-010, in the operating and corroded condition. Additional loads
specified for specific nozzles in Material Requisition shall have precedence over the
loads specified in this document.
5.7.2. Nozzle reinforcement shall not be the limiting factor for MAWP.
5.8. Cladding thickness shall not be considered in strength calculations, even though
permitted by the design code. Cladding thickness to be included into the design for
transport and erection of equipment.
5.9. When templates for skirt base rings are required they shall be of box type and
designed to ensure that no deformation occurs due to self-weight or during
installation of anchor bolts.
Height of box shall correspond to the height of the actual height of anchor chairs
on vertical vessel skirt. Drilling of anchor bolt holes in the template shall be carried
out with the drilling of anchor bolt holes in the skirt base ring.
5.10. Minimum diameter of anchor bolts for skirt supported vessels is to be M30 inclusive
of Corrosion Allowance. Anchor bolts shall be in multiples of 4 with minimum
number of anchor bolts as 8.
5.10.1. SUPPLIER/DEC to verify the saddle details and anchor bolt size and quantity for all
the loads. Minimum diameter of hold-down bolts for horizontal vessel support
saddles is to be M20 for vessel diameters less than 3000 mm and M30 for vessel
diameters 3000 mm and larger. Supports for low temperature horizontal vessels
with the operating temperature 0o C or below shall be provided with cold insulation
block. Anchor bolt sizes mentioned are inclusive of corrosion allowance.
5.10.2. The top part of the vertical vessel skirt support plate attached to the pressure part
shall be of the same material as that of the bottom vessel shell/ head material for
a minimum length of 1000mm or 5 x Insulation thickness whichever is greater.
5.10.3. All skirt supported columns/equipment with height 20m and above (irrespective of
weight) and weight 50 MT and above (irrespective of height) are to be provided
with tailing lug.
5.10.4. Recommended maximum saddle height shall be 250 mm, unless larger heights are
required due to significant slope requirements for the horizontal equipment.
5.10.5. Unless otherwise specified leg supports shall not be considered for vessel OD
exceeding 1500 mm.
5.10.6. Maximum permissible stress in mild steel Anchor / Setting bolts of Class 4.6 (IS
1367) shall be as follows; unless otherwise specified:
Axial tension : 120 N/mm2
Shear : 80 N/mm2
Bearing : 250 N/mm2
5.11. Internals shall be mechanically designed to the following:
a. Liquid head/fluid thrust or load or pressure drop.
b. Thermal expansion
c. Vibration or fatigue life.
d. Maintenance Load
e. Turndown as Specified

5.12. Corrosion Allowance

5.12.1. For anchor bolts embedded in concrete, corrosion allowance shall be 6mm on
diameter unless otherwise specified in the datasheet. Anchor bolts for equipment
on steel structures, the corrosion allowance shall be 3 mm on diameter unless
otherwise specified in the datasheet.
5.12.2. The specified corrosion allowance shall be added to internal surfaces of pressure
parts and each exposed surfaces of non-removable internals for Carbon Steel. For
alloy steels, the C.A should be the greater of 1.5 mm or the specified vessel
corrosion allowance.
5.12.3. One half of the specified corrosion allowance shall be applied to each exposed
surface of non-corrosion resistant removable internals.
5.13. Nozzles, Manways and Inspection Openings

5.13.1. Vessels less than 900 mm inside diameter may be provided with hand holes in lieu
of manholes. Manhole sizes shall be as follows, unless otherwise specified. In case
complete internal access is required on vessels with ID less than 900 mm, the same
shall be provided with Body Flanges.
Vessel ID 900 mm to 1500 mm 20” NPS
Vessel ID above 1500 mm 24” NPS
5.13.2. Only Weld neck flanges shall be used. However for items with very low pressure,
and at ambient temperature with non-hydrocarbon services, slip on flanges may be
used with prior approval of Buyer.
5.13.3. Sight glasses are not permitted in pressure vessels.
5.13.4. All fasteners bolting for girth flanges and nozzle flanges shall be UNC studs below
1" dia and UN8 series studs for 1" and above sizes. Nuts shall be heavy series.
Internal bolting shall be of S.S. or better material.
5.13.5. Hydraulic bolt tensioners shall be considered for bolt sizes 1-1/2” and above on
flanges. Bolt spacing and length of bolt shall be adequate for introducing tensioning
tool.
5.13.6. Fatigue analysis shall be performed for agitator mounting nozzles.
5.13.7. Minimum requirements of lifting bolt / Eye bolt shall be as mentioned below:
a. The eyebolts shall be of single piece, forged construction without welds.
b. Carbon Steel eyebolts shall meet the chemical and mechanical requirements of
ASTM A489. Alloy steel eyebolts shall meet the chemical and mechanical
requirements of ASTM F541.
c. Unless otherwise specified, minimum size of eyebolt shall be ¾” (20 mm) for
manway size up to 24” (class 600). For any other size of manway, the calculation
for eyebolt shall be submitted.
d. Type-1 eyebolts (straight shank, as defined in ASME B18.15) shall be procured
and supplied.
e. Dimensions, especially shank length shall be clearly indicated on the equipment
drawings.
f. The eyebolts shall meet the testing requirements of the applicable ASTM
standard and test certificates shall be part of final documentation.
5.14. Lugs
5.14.1. All vessels shall be provided with at least two (2) Earthing lugs welded to the vessel
supports. Earthing lug shall be of S.S.
5.14.2. All Equipment shall be provided with lifting lugs / trunnions. Lifting lugs / trunnions
shall be designed with a minimum impact factor of 1.5.
5.14.3. Reinforcement pads beneath lifting lugs / trunnions shall be UT tested to verify
absence of lamination in the steel.
5.15. Erection and Commissioning Spares

- 200 % spare gasket
- 10% spare studs with nuts/washers (minimum 4 studs/ Type)
5.16. Materials of Construction

5.16.1. General
5.16.1.1. Materials of construction shall be as specified in the pressure vessel data sheets.
Materials other than those specified may be proposed as alternate when
accompanied by their advantages and/or cost savings.
All materials for the fabrication of vessels shall be new and unused.
Materials to be used shall conform to the following (as applicable):-
i) ASME Sec II or agreed equivalent
ii) Indian Standard specification
iii) IBR
5.16.1.2. Chemical composition of the material shall be strictly as per the respective material
specification. The limits indicated for the alloying elements including micro alloying
elements specified in the material specification shall be strictly met. Any tolerance
or enhanced limit allowed by the material specification for micro alloying elements
is not allowed unless specifically agreed by the Buyer before purchase order.
5.16.1.3. Any special requirements for materials and testing will be specified in the MDS or
material requisition.
5.16.1.4. Any specific requirement including supplementary requirements for materials as
specified by the design code and ASME Sec II-Part D stress tables shall be verified
for the application/service, and the same shall be indicated in the MDS and the
drawing
5.16.1.5. All forgings having thickness ≥50 mm and Tube sheets of all thicknesses shall be
ultrasonically tested for lamination defects as per ASTM A388. Acceptance criteria
shall be as per ASME Sec VIII Div 2.
5.16.1.6. Ultrasonic testing of plates shall be as follows:

Thickness (t) Normal service Sour, Hydrogen and Lethal Service

t < 20 No Ultrasound testing A 578 with S1 and level C
acceptance criteria
t > =20 A578 with S1 and level B A 578 with S1 and level C
acceptance criteria acceptance criteria
5.16.1.7. CS and LAS Plates used for low temperature service shall be impact tested if they
do not meet the criteria of UCS 66 (a), without resorting to further impact
temperature exemption under UCS 66(b).
The criteria for selection material for low temperature service shall be as given by
licensor/DEC. The impact test requirement shall be as per SA-20 table A1.15 as a
minimum. The licensor requirement for temperature, sample direction and impact
value shall be adhered to.
5.16.1.8. Where simulation cycle is applicable as per code, one extra PWHT cycle shall be
specified to account for potential future repairs. Regardless of thickness, the
minimum holding time shall be 1 hour.
5.16.1.9. Castings shall not be used for pressure parts without the written agreement of the
BUYER.
5.16.1.10. Reinforcing pads shall be the same material as the shell/head. All non-pressure
parts welded directly to the pressure envelope shall be the same material grade as
shell / head.
5.16.1.11. For vessels which are identified on the vessel data sheet as being in sour service,
the pressure parts, welded internal attachments to the pressure parts and internals
(including bolting) shall comply with the requirements of NACE MR 0103
Weldments shall comply with NACE SP 0472.
5.16.1.12. CS, LAS, clad CS for hydrogen service above 204˚C shall be in accordance with API
RP 941. Design conditions for temperature and hydrogen partial pressure shall not
be less than 28 deg C and 25 psi below to the left of the applicable curve of API RP
941 figure-1.
5.16.1.13. Non-metallic sheet type gaskets shall not be permitted for body flanges on pressure
vessels in sour service, hydrogen, toxic or hazardous hydrocarbon services.
5.16.1.14. For service temperatures above 350 deg C, filler material for spiral wound gaskets
shall be high purity graphite, unless otherwise advised by Licensor. Compliance
certificate from Gasket manufacturer shall be obtained that gasket is suitable for
operating pressure and temperature
5.16.1.15. For high temperature, high pressure equipment with relatively quick rise in
pressure/temperature during startup and shutdown conditions, RTJ oval or
hexagonal ring gasket options shall be used.

5.17. Specific Material requirements

5.17.1. Carbon Steel and Low Temperature Carbon Steel Materials
a) For carbon steel the carbon content shall be 0.25% maximum and the Carbon
Equivalent (C.E) shall be 0.43 maximum.
𝑀𝑛 Cr+Mo+V Cu+Ni
Where, C. E = 𝐶 + + +
6 5 15
b) All Carbon steel pressure components shall be fully killed.
c) Carbon steel plates of thickness > 50 mm shall be vacuum De-gassed. Carbon
steel plates of 20 mm and above thickness or plates of all thickness which are
impact tested shall be delivered in the normalized condition.
d) All forgings and fittings shall be in normalized condition.
e) All CS pipes shall be normalized unless they are hot finished.
f) Following additional requirements shall be applicable for carbon steel pressure
vessels subjected to Hydrogen Induced Cracking.
i) Plates shall be ASME SA 516 Gr 60 with supplementary requirement S1
vacuum treatment.
ii) All parts including welds and HAZ shall meet maximum hardness of 200 BHN.
iii) Steel shall be offered as calcium treated for non-metallic inclusion shape
control except that steel with 0.001% max. Sulphur shall be exempt from
calcium treatment.
The alloying elements Boron or Titanium shall not be intentionally added, but
residuals are acceptable.
Chemical compositions shall be limited to the following
C = 0.25%, S = 0.002%, P = 0.01%, Cu = 0.4%, N = 0.4%, Mo = 0.13%, Cr = 0.3%,
V =0.03%, Nb = 0.015%
% Cr + % Mo shall not exceed 0.32%, % Ni + % Cu + % Cr + % Mo not to exceed
1.0%
iv) HIC testing shall be done if specified in requisition or datasheet.
- Each heat of plate of each thickness shall be tested as per NACE Std. TM
0284 except that test solution shall be low pH, sodium chloride / acetic
acid solution of NACE Std. TM 0177.
- Test specimen shall be taken along mill direction, near midpoint of one
end of plate. Three individual cross sections shall be examined for each
specimen.
- Crack Length Ratio (CLR) shall not exceed 15% for any individual cross
section, shall not exceed 5% for overall test.
- Cross Thickness Ratio (CTR) shall not exceed 3% for any specimen and shall
not exceed 1.5% for the overall test.
v) All plates shall be ultrasonically examined as per ASTM A578, acceptable level
B and Supplementary S1.
vi) Vessel shall be PWHT @ 621 deg C for 1 hour minimum.

5.17.2. Low Alloy Steel Materials

Requirements for LAS vessel made of 1Cr-½Mo, 1¼Cr-½Mo, 2 ¼Cr-1 Mo, and 3Cr-
1Mo:
a) When design pressure > 70 Kg/cm2(g) or vessel thickness > 50mm or design
temperature lies in creep range (> 425 deg C) nozzle reinforcement shall be
integral type, using forging.
b) All LAS materials shall be vacuum degassed and shall be normalized and
tempered.
c) Use of Carbon-Mo alloy not permitted.
d) The tempering temperature for tempered material shall be at least 15 deg C
greater than maximum intermediate or post weld heat treatment temperature.
e) Charpy-V-notch impact testing is required for all pressure containing
components and welds from each procedure. Impact tests shall be in accordance
with ASME Sec. VIII Div.1 except that there shall be no exemption from impact
testing and test temperature shall be lower of MDMT or -18 deg C for 1 Cr and
1 ¼ Cr materials and -29 deg C or MDMT for 2 ¼ Cr and 3 Cr materials.
f) Maximum room temperature tensile strength shall be limited to smaller of 7030
Kg/cm2 (100000psi) or code specified maximum tensile strength.
g) Maximum hardness of any pressure part and its welds shall not exceed 225 BHN
after post weld heat treatment.
h) LAS Plates of 20 mm and above , LAS forgings of 50 mm and above or LAS used
for hydrogen service shall be ultrasonically tested with 100% scanning as per SA
578 Level B / SA 388 with acceptance criteria as per ASME SEC VIII DIV 2.
i) When operating temperature of the 1 Cr- ½ Mo or 1 ¼ Cr – ½ Mo components
exceeds 440 deg C, plate material shall be of class-1.
j) For 1 ¼ Cr – 1/2 Mo steel, API-RP 934E shall be applicable for operating
temperature > 440 deg C when the wall thickness is 50mm and above.
k) For 1 ¼ Cr – 1/2 Mo steel in hydrogen service and thickness 50 mm and above,
API- RP 934C shall be applicable for temperature ≤ 440 deg C.
l) For 1 ¼ Cr – 1/2 Mo steel of all thicknesses and services, X-bar shall be less than
15 ppm.
m) For LAS 2 ¼Cr – 1Mo, 2 ¼Cr – 1Mo - ¼V, 3Cr – 1Mo and 3Cr – 1Mo - ¼V in
hydrogen service, with operating temperature above 345 Deg C and thickness
50 mm and above, API-RP 934A shall be applicable.
J factor shall be limited to 100 for all thicknesses and services.
5.17.3. SS and High Alloy Material

a) All SS 300 series materials shall be fully solution annealed and pickled condition.
Grades SS 321, 347 shall be given stabilization treatment in addition to solution
annealing when the operating temperature is 425 deg C or above.

b) Austenitic stainless steel components shall be subjected to IGC test as per ASTM
A262 practice E. When identified as “SS in Critical service” in the mechanical
data sheet, all the exposed material shall be subjected to IGC test as per practice-
A. This shall also be applicable to clad plates and all internal weld attachments.
5.17.4. Clad Material

a) Clad plates shall be ultrasonically tested as per ASTM A263, A264, and A265 and
the acceptance criteria shall be level 1 for equipment with criticality rating 1 and
2 and level 3 for criticality rating 3 and 4.
b) Clad vessels shall meet the requirements of Appendix - A of this specification.
5.17.5. Certification and Marking

5.17.5.1. Material certification and traceability requirements shall be in accordance with the
certification data sheet attached with the material requisition.
5.17.5.2. Stamping of materials for use in low temperature or cyclic service shall be carried
out with low stress stamps.
5.17.5.3. A system of Positive Material Identification (PMI) shall be implemented.
5.18. Fabrication and Welding Requirements
5.18.1. General Fabrication

a) Where vessels are to be transported to site in a number of sections, before
dispatch the Supplier shall ensure that all sections are shop trial assembled and
match marked, to ensure correct alignment at job site. The weld edge
preparation shall be carried out at works before dispatch and shall be protected
against damage during transportation.
b) For site assembled vessels, each section shall be clearly identified and match
marked. The Supplier shall issue assembly drawing(s) showing the assembly
sequence and the markings location on the vessel.
c) No fabrication may commence until the SUPPLIER's Quality Plan, related
fabrication drawings, weld procedures (WPS & PQR) and calculations have been
reviewed and approved acceptable for proceeding by the BUYER.
d) It is the responsibility of the SUPPLIER to submit to the BUYER all his sub-
supplier's fabrication and welding procedures and to ensure these comply with
contract requirements before submittal to the BUYER.
e) If vendor does not have PTR with the same material of construction, Service
requirements and similar dimensions, then detailed fabrication procedure shall
be submitted to the Buyer for approval.
5.18.2. Head / Dished Ends

5.18.2.1. Unless specified otherwise Deep Torispherical Dished End with Crown Radius of
90% Diameter and knuckle radius of 17% diameter or 2:1 semi ellipsoidal dished
ends shall be used for pressure vessels and heat exchangers.
Hemispherical ends shall be considered when the thickness of shell exceeds 70mm.
Flat covers may be used for atmospheric vessels or exchanger channels.

5.18.2.2. Dished ends shall preferably be of seamless construction. However, one chordal
seam is acceptable provided the width of chordal seam plate is not less than one
third of the blank diameter and it is clear of nozzle opening.
5.18.2.3. When Dish ends are made of more than 2 plates, crown and petal shall be used and
the crown area should be without seam so that when a nozzle is positioned at the
center of the Dish ends, the crown plate shall be at least 300 mm more than the
nozzle reinforcement plate.
5.18.2.4. When center hole is required for holding, during forming dished head, it shall meet
the following requirements:
i) Hole diameter shall not exceed the outside diameter of centrally located
nozzle.
ii) If there is no nozzle, then hole diameter shall be plugged with patched plate as
per approved welding procedure and shall be 100% radiographed and 100 %
MT/PT shall be done.
5.18.3. Nozzle Flanges, nozzles and reinforcing pads

5.18.3.1. Nozzles shall be attached to vessel by full penetration welds and shall be set-in type
unless otherwise specified for some specific cases.
Unless otherwise stated, the minimum nozzle size shall be 2 inch NPS. Nozzle sizes
are to be as specified on relevant vessel data sheet. LWN flanges are to be used for
any nozzle where the stated size is less than 2 inch NPS. For 2 inch NPS, if LWN
flanges are not used, then 2 nos of gussets shall be provided at 90˚ apart.
For nozzles coming out of skirt support, the standard drawing RPMS-SD-M15-011
for the same shall be followed.
Flanges up to 24 inch NPS shall conform to ASME B16.5 “Pipe Flanges and Flanged
Fittings”. Flanges greater than 24 inch NPS shall conform to ASME B16.47 Series B
“Large Diameter Steel Flanges”, unless otherwise specified.
Non-standard flanges, if specified on relevant data sheet or accepted in writing by
Buyer, shall be checked for adequacy to withstand equipment design pressure and
temperature and the nozzle loadings stated in standard RPMS-SD-M15-010.
5.18.3.2. Minimum nozzle neck pipe wall thickness shall be standard pipe thickness +
corrosion allowance. However, for CS, LAS nozzles 3” NPS or less shall have
minimum schedule 160. For SS or HAS nozzles 3” NPS or below shall be minimum
schedule 80S. The corroded thickness of nozzle necks shall be 5 mm minimum.
5.18.3.3. For all instrument nozzles the finished ID shall be mentioned in the drawing. There
shall not be any projections inside the nozzle including the weld reinforcement. The
weld surface shall be flush with inside and shall be with smooth curvature.
5.18.3.4. Nozzles 4” NPS and under may be “set-on” type, provided the attachment is a full
penetration weld with the root drilled out and prior to welding the adjacent shell is
ultrasonically examined, and found free of cracks and laminations.

5.18.3.5. Nozzle necks and fittings shall be fabricated from seamless pipe or forgings.
Manway and nozzles greater than 12” NPS may be plate fabricated with the
longitudinal butt weld subject to 100% radiography.
5.18.3.6. Self-reinforced nozzles shall be provided in the following cases:
i. For vessels subjected to HIC
ii. For vessels in which Hydrogen service is specified
iii. For vessels having thickness > 50 mm.
5.18.3.7. When tongue and groove or male and female faced flanges are used, female face
shall be on nozzle flange. However when the nozzle is located at the bottom, the
female face shall be in the cover flange.
5.18.3.8. Threaded Plug type connections shall not be used either for internal or external
attachments if subjected to pressure. All reinforcement pads shall have one ¼ inch
NPT test hole - Number of Tell Tale/Test holes shall be based on Nozzle sizes. For
RF Pads of Nozzles above 20" minimum 2nos Tell Tale/Test Hole are required.
5.18.4. Bolts and Gaskets

5.18.4.1. Studs shall exceed nuts by at least two threads and studs shall be threaded full length.
5.18.4.2. Gasket shall be of one-piece design. For solid metal gaskets like metal jacketed, ring
joint etc the hardness of gasket shall be minimum 15 BHN lower than that of the
flange face. Under tolerance in gasket width is not permitted. Minimum gasket
width requirement specified on drawing/ code shall be provided. Effective gasket
width shall be considered as the gasket width.
5.18.4.3. Liner plate or clad plate of high alloy should not be used at the gasket contact face
of a flange or blind flange. In such cases gasket contact face can be weld overlaid.
5.18.5. Internals and Externals

5.18.5.1. Removable internals shall be bolted type. All internals shall be sized in order to
facilitate their entry through the manway.
5.18.5.2. Temporary attachments shall be removed (without hammering) and vessel wall
examined by magnetic particle method (MT) or liquid penetrant method (PT).
5.18.5.3. All internal bolting shall be along with Lock nut or double nut.
5.18.6. Name Plate

Name plate shall be supplied as per name plate standard drawing RPMS-SD-M15-
001.
5.18.7. Fireproofing and Insulation

5.18.7.1. Fire-proofing and Insulation as applicable shall be considered for all
vessels/columns if specified on datasheets.
5.18.8. Welding
5.18.8.1. Weld joint efficiency of factor of 1.0 shall be considered for cladded equipment.

5.18.8.2. Backing strip type of weld joint is not allowable unless prior approval is given.
5.18.8.3. Arc air gouging is not permitted on stainless steel.
5.18.8.4. Longitudinal weld seams of adjacent shell courses shall be staggered to a minimum
chord length of the greater of 150mm or five times the thickness of the thicker shell
course.
5.18.8.5. Meridional or chordal welds of heads joining the cylindrical shell must be staggered
by a minimum distance equal to the greater of five times the thickness of thicker
plate or 150mm.
5.18.8.6. Circumferential seams shall be located to clear circumferentially welded internals
such as tray support rings, vacuum stiffener rings etc. to avoid HAZ of weld and to
facilitate NDT of circumferential joint.
5.18.8.7. Longitudinal welds in horizontal vessels shall be located above the horizontal plane
through the centerline of vessel and circumferential welds should clear the saddles
and its wear plate.
5.18.8.8. All Vessel seams shall be located to clear all external and internal permanent
attachments. The distance from the edge of the attachment weld to the edge of
main weld shall be at least 50mm or twice the thickness of the pressure part,
whichever is greater. In any case reinforcing pads or any other pads shall not cover
a welded joint. In case these cannot be met practically, then Buyer's approval shall
be obtained before proceeding for fabrication.
5.18.8.9. SUPPLIER welding procedures (WPS & PQR) are to be as per Project Specifications.
5.18.8.10. Weld seams are to clear all nozzles and attachments.
5.18.8.11. Chemistry and mechanical properties of deposited weld metal shall conform to the
ASME requirement for the base metal.
5.18.8.12. Where sour service is specified in the data sheet or purchase order, Weldments
shall comply with the requirements of NACE MR0103 and SP0472 and this section.
5.18.8.13. Weld filler metals for sour service shall comply with NACE SP 0472 Section 2.2.
5.18.8.14. Welding shall comply with the requirement of API RP 582.
5.18.8.15. For all vessels with MDMT at or below -29 ˚C, production weld coupon is
mandatory. Impact test is required for weld and HAZ.
5.18.8.16. SS 321 material shall be welded by ER/E347 consumables only.
5.18.9. Heat Treatment

5.18.9.1. When post weld heat treatment is required, this shall be carried out for the
complete vessel in a single heat treatment furnace. Any exceptions shall be clearly
stated in the SUPPLIER's bid and shall require BUYER's written approval.
5.18.9.2. The gasket faces of girth flanges and blind flanges with multiple welded Nozzle
connections shall be machined after final treatment. Flange faces and threaded
connections shall be protected during Heat treatment.

5.18.9.3. Requirement of post weld heat treatment shall be based on applicable code and
additional requirement specified in BUYERS requisition. In case of IBR equipment,
PWHT shall be as per IBR code.
5.18.9.4. Heat treatment of dished ends:
(Wherever dished end is mentioned in this clause the same is applicable for all the
formed components including toricone, torispherical or any other formed
component)
a) Heat treatment of CS & Low alloy dished ends.
i) Normalizing for CS and normalizing and tempering for LAS dished end
required if
- Hot formed dished end is not formed in normalizing range.
- Dished ends of thickness above 16 mm are cold formed or not hot formed
in the normalizing range
ii) LAS dished ends hot formed in normalizing range, shall be subsequently
subjected to tempering.
b) SS components or dished ends shall be solution annealed in the following cases
i) Cold formed dished ends of nominal thickness 16 mm and above.
ii) Hardness of dished end after cold forming exceeds 235 BHN.
iii) Hot formed shells, cones, dished ends.
iv) SS dished ends irrespective of thickness, when process fluid contains
hydrogen (partial pressure > 1 bar. g), D/t < 100 and operating temperature
is below ambient.
c) Hemispherical dished end made of LAS shall be normalized and tempered after
forming.
d) All mechanical test to be performed on material test coupon as required as per
material and project specification after heat treatment of formed components.
5.18.9.5. No welding or thermal cutting is permitted on stress relieved vessels after
completion of final post weld heat treatment (PWHT).
5.18.9.6. All pressure parts made of LAS shall be post weld heat treated.
5.18.10. Accessories:
5.18.10.1. Accessories shown on the vessel data sheet / documents shall be designed and
supplied unless excluded in MR.
5.18.10.2. TSR, DCBB, Davits, Distributers, other welded internals and welded external cleats,
rings shall be designed and provided as per relevant standard drawings.
5.18.10.3. All towers having internals shall be provided with davit arm. The capacity of davit
arms shall be as per individual tower requirement based on the weight of internal
section to be carried, but not less than 500 kgf.
5.18.10.4. Physical barrier is to be provided in following condition: -
a) Wherever fire proofing is present shielding/protection against rain water
seepage between the shell and fire proofing interface shall be provided
b) Wherever insulation type is getting changed from cold to hot, a shield shall be
provided between the two to avoid condensate seepage in bottom insulation.
c) The detail of the shield shall be as per that in the insulation specification.
6. Inspection and Testing:

6.1. NDE Requirements
6.1.1. Inspection, examination and testing shall comply with the requirements of the
design code, this specification and the material requisition. All material shall be
supplied with mill test certificate as per relevant material standard.
6.1.2. NDE operators shall be certified ASNT-Level II as a minimum. Also, all NDE
procedures shall be approved by ASNT Level-III and shall be qualified with
demonstration.
6.1.3. Welds in Dish ends & Toricones shall be 100% Radiographed & 100% PT/MT tested
after forming & subsequent Heat Treatment as applicable
6.1.4. Following welds shall be 100% DP or MP checked:
Back chipped surface of the welds.
All fillet welds of lifting lug, tailing lug and lifting trunnion.
All pressure bearing butt welds (from inside and outside surface).
All Formed (Dish or toricone) surface to be weld overlaid.
Final runs of nozzle to Vessel welds both inside and outside surfaces
Gasket contact face of machined surfaces of weld overlay.
Vessel to skirt support joint final run.
6.1.5. 100% UT shall be done for trunnion to shell joints for vessels with lifting weight >
100 MT
6.1.6. All edge preparations for welding shall be checked for cracks, flaws or laminations
by visual examination. MP examination for weld bevel preparation of LAS Vessel
shall be done.
6.1.7. For sour service vessels production welds shall be hardness tested in accordance
with NACE SP 0472 and applicable Process Licensor requirements.
6.1.8. Where weld joints in shell sections cannot be avoided prior to rolling, these joints
shall be with 100% RT and 100% MT/PT examined after rolling.
6.1.9. The areas where arc strikes are removed by grinding shall be DP/MP examined.
6.1.10. Knuckle portions of dished ends and Toricone (both inside and outside) shall be DP
examined after forming.
6.1.11. All NDT for final acceptance shall be performed after completion of post weld heat
treatment wherever applicable.
6.1.12. Helium leak tests shall be carried out after hydrotest for all gasketed flanges when
lethal service is indicated in the process data sheet.
6.1.13. For all LAS vessels in hydrogen service, WFMT (wet fluorescent magnetic particle
test) shall be carried out on welds from inside of the vessels. Outside welds shall be
checked with Wet MPT.

6.1.14. Hardness check of weld and HAZ shall be carried out after post weld heat treatment
from inside (accessible area) as well as outside.
For CS weld and HAZ max hardness permitted is 200 BHN.
For P3 & P4, materials hardness shall be 225 BHN max.
For P5 hardness shall be 235 BHN max.
6.1.15. After any heat treatment on austenitic SS, IGC test shall be carried out.
6.1.16. Radiography shall be by X-ray or Gamma ray unless agreed otherwise in writing by
the BUYER. The extent and sequence of NDT shall be in accordance with the design
code, and as identified in the equipment data sheet and the applicable Process
Licensor Requirements.
6.1.17. When spot radiography is specified, all T joints shall be radiographed. In addition
to that a minimum of 5% of total weld length excluding T-joints shall be covered.
6.1.18. All pressure containing welds of LAS shall be 100% radiographed and MP tested.
6.1.19. PMI shall be performed for LAS, SS, HAS, exotic materials and welds. PMI Check
shall include all base metal (including internals) and weld.
6.2. Pressure Testing

6.2.1. The hydrostatic test procedure, test pressure and minimum pressurization
temperature shall meet the requirements of the design code.
Equipment shall be hydrostatically tested in the fabricator’s shop as per design
code. Unless otherwise specified in applicable design code, allowable stress during
hydro test in tension shall not exceed 90% of yield point.
6.2.1.1. Hydro test shall be conducted after completion of all fabrication activities including
removal of weld spatters, weld stub, scale, dirt etc. but before any painting is
applied.
6.2.1.2. Minimum holding time shall be one hour unless mentioned otherwise in the
drawing.
6.2.1.3. All reinforcing pads shall be tested (before hydro test) with 1 barg air and soap suds
solution after completion of final post weld heat treatment.
6.2.1.4. Hot gas cycle test for Ti-clad equipment: Vessels shall be fitted with pressure relief
valve at design pressure, during this test.
6.2.1.5. Service gaskets shall be used during hydrotest for gasketed joints.
6.2.2. For ASME VIII Div. 1 equipment; test pressure shall be determined in accordance
with Para. UG-99(c). Any intermediate value between the hydrotest pressure
values calculated as per UG‐99 (b) and UG‐99(c) may be used with the concurrence
from DEC/BUYER. For ASME VIII Div. 2 equipment; test pressure shall be
determined in accordance with para. 8.2 of Code.
For IBR equipment, test pressure shall be determined based on design pressure in
accordance with IBR.
6.2.3. Pneumatic testing in lieu of hydrostatic testing shall not be performed without the
consent of the Buyer.
6.2.4. In case of titanium cladded equipment, vessel shall be hydraulically tested to the
full requirement of design code after completion of all pressure part welding,
before titanium welding of cover strips over pressure part welds.
Pre-final test shall include dye-penetration test for titanium welds. Air and soapy
water test on titanium welds. Final hydro test shall be carried out to full pressure
requirement of the code.
6.2.5. Quality of test water with respect to chloride content:
a) Hydrostatic test water shall be potable, except that vessels of austenitic stainless
steel high alloy / austenitic SS cladding or internal attachments shall be tested
with water whose chloride content is below 30 ppm.
b) However, for stainless steels in PTA (Pure Terephthalic Acid) service, the chloride
content in the water used for testing shall not exceed 25 ppm.
c) For carbon steel and low alloy materials, the test water shall be potable quality
with chloride content less than 250 ppm.
d) Water Test report shall not be earlier than three months from date of test.
TPI/RIL reserve rights to draw a sample, for water test after Hydrotest from
equipment.
e) For vessels subjected to Hydrotest in Cold countries during winter months, a
suitable antifreeze agent (e.g. Ethylene Glycol) shall be added to the test water.
The detailed proposal shall be submitted to Buyer for approval prior to actual
hydrotest.
6.2.6. Minimum two pressure gauges shall be used during hydro-test. Pressure gauge
shall be located at highest point and lowest point.
6.2.7. Immediate to hydrotest, the vessel shall be dewatered, drained and thoroughly
cleaned and dried as per approved cleaning and drying procedure.
6.3. General inspection points shall also include material identification, adherence to
agreed ITP, Radiography / NDE / execution of major repairs, alloy verification, trial
fit up & assembly of internals, holiday check of coating / lining, painting / coating
verification, pickling and passivation, final inspection and dimensional check,
Hydro, leak test, heat treatment & procedure, welding procedure, quality of test
water, ancillary items (spare parts, gaskets, nuts), cleaning / drying / purging /
blanking, name plate / tagging / colour coding, preparation for shipping as
applicable.
6.4. Extent of inspection for each inspection point shall be as required by MR. Against
each inspection point hold point, witness point, random inspection, and review
document shall be defined and specified as required depending on the criticality of
the vessel.
7. Vendor Data:
The vendor data requirement shall be as per Appendix-D to this specification.

8. Packing, Preservation, Shipment and Storage:

8.1. Shipping drawing shall be prepared by the Supplier showing details of supports,
ties, bracings, lifting points and CG of the vessel. Weight of the equipment shall be
indicated on the drawing. Prior to shipment, the equipment shall be thoroughly
cleaned and dried. For stainless steel vessels hot air shall not be used for drying.
After drying all open nozzles shall be blanked using temporary gaskets and metal
blanks of minimum 10mm thickness. If nitrogen purging or desiccant drying is
specified all bolts as per flange standard shall be used for blanking. For nitrogen
purging or desiccant drying Buyer’s requirement shall be followed.
All vessels shall be minimum desiccant protected (Silica gel bags 0.5 kg/m3).
For nitrogen purged equipment, below requirements shall be followed during
transit and site storage.
(a) Nitrogen pressure shall be 0.3 kg/cm² (g) minimum. Oxygen Level shall be 1%
maximum.
(b) Provide 2 needle valves.
(c) Provide 2 pressure indicators with safety protection.
(d) All nozzles shall be suitably sealed with steel blanks (min. 12 mm thick),
temporary gaskets and 100% bolting.
(e) Nitrogen cylinder of 3-5 Litre capacity along with accessories to be provided
for top up if required.
Caution note shall be indicated in bold on the equipment if nitrogen purged.
Desiccant bags and location shall be indicated on the shipping drawing.
8.2. All surfaces of completed vessels shall be cleaned to remove loose scale, rust,
grease, dirt, weld spatter, hydro test water and other foreign matter. This shall be
ensured before shipping of the vessel to job site.
8.3. For stainless steel vessels, thorough cleaning of internal and external surface
required to remove dirt, water, weld spatter and any foreign matter. If pickling &
passivation specified, same shall be done as per ASTM A-380. Minimum CuSO4 test
shall be conducted after pickling and passivation.
For carbon steel external surface preparations, cleaning, grit/ shot blasting and
painting shall be in accordance with standard specified by the Buyer.
Vessels undergoing ocean shipment shall be provided with corrosion inhibitors,
rubber gaskets under all nozzle shipping covers and, when external painting is not
otherwise required, one coat of primer of external surfaces.
Internal surface cleaning, preparation or any special coating shall be as per Buyers
requirements.
8.4. All exposed machined and threaded surfaces shall be thoroughly coated with a
suitable rust preventative compound and suitably protected for shipment. All
female threaded connections shall be fitted with solid pipe plugs of the same
material as the connection. All vent holes in reinforcing pads or lined nozzles shall
be plugged with heavy grease.
Rust preventive coatings of approved brand shall be applied on bolt/fasteners of

CS and LAS. Gasket contact face of flanges also shall be given rust preventive
coatings.
8.5. All loose parts shall be adequately crated and given clear markings relating the parts
to the vessel identification number.
8.6. After application of the paint, each stress relieved vessel shall have the following
stenciled along opposite sides of the vessel in large contrasting letters, in English,
and if applicable, in the native languages of the countries producing and receiving
the vessel:
“DO NOT WELD OR STRIKE ARCS - STRESS RELIEVED VESSEL”
8.7. A minimum of two steel, jackable shipping saddles shall be provided for vertical
vessels. Such saddles shall be strapped and padded to protect the vessel during
shipment.
8.8. All support saddles or shipping saddles for vessels undergoing ocean shipment shall
be designed for the following shipping forces:
a. Longitudinal: 0.6g
b. Transverse: 0.6g
c. Vertical: 1.6g
8.9. Surface areas of the vessel which may come in contact with slings during lifting shall
be covered with timber boards or other similar materials in order to prevent
scratches, chafing, dents and other damage.
8.10. Supplier shall provide special preservation instructions during transportation
(Including sea transportation) and storage at site if called for in the material
requisition.

9. Attachments
9.1 Appendix A : Supplementary Requirements for Alloy Clad Vessels
9.1.1 General Requirements

The supplementary requirements given below shall be used in conjunction with the
main body of this specification and applicable Process Licensor requirements.
These supplementary requirements apply to vessels fabricated from integrally alloy
clad base material and weld overlaid parts.
Strip lining of vessels with alloy sheet/plate shall not be used.
The cladding method used shall produce a full metallurgical bond between base
material and alloy layer. Cladding shall be achieved by roll bonding, explosive
cladding or weld overlay. The use of other cladding methods including loose nozzle
sleeve liners is subject to the written approval of the BUYER.
Heavy load bearing internal attachments shall be welded directly to the base metal
after stripping back of the cladding locally. Cladding shall be restored by weld
overlay after inspection of the attachment weld.
Where sour service is stated on the equipment data sheet, all materials including
base material alloy clad layer and welds shall comply with the requirements of
Project Specification / NACE MR0103 and NACE SP 0472. HIC testing of alloy clad
base material is not required.
Supplier GA. drawings shall clearly indicate method and extent of cladding on each
part of vessels/heat exchangers.
Post weld heat treatment (where required) shall be carried out after completion of
all welding, including all weld overlay and clad restoration unless approved
otherwise by the BUYER.
9.1.2 Clad Plate/Forgings (other than weld overlaid)

Clad plates shall comply with the following where applicable:
ASTM A263 Specification for Stainless Chromium Steel - Clad Plate
ASTM A264 Specification for Stainless Chromium-Nickel Steel-Clad Plate

ASTM A265 Specification for Nickel and Nickel-Base Alloy - Clad Steel
Plate.
ASTM B432 Specification for Copper and Copper Alloy Clad Steel Plate.
The Supplier to confirm at the bid stage their source of clad plate/forgings and the
method proposed for application of the alloy layer.
The Supplier shall also submit a Quality Control Plan for fabrication of clad material.
This shall include forming and heat treatment procedures.

Where austenitic stainless steel clad vessels requiring post weld heat treatment,
the data sheets shall indicate additional corrosion testing. The Supplier may as an
alternative offer previous test data for this purpose.
Cutting of clad plate/forgings shall be carried out using plasma cutting equipment.
9.1.3 Joints in Clad Plate

Welds in base material shall be of similar composition and mechanical properties
as that of the base material.
Cladding shall be completely stripped back for a minimum of 6mm either side of
the weld preparation.
Clad restoration shall be by welding. Restoration using a fillet welded strip is not
acceptable except for titanium clad material.
All welding procedures shall be submitted to the Buyer in accordance with Project
Specification attached with Material Requisition.
Weld procedure specifications shall include bead deposition sequence and back
gouging details.
Welding consumables and composition are subject to Buyer approval. Procedure
qualifications for clad restoration shall be as per Section IX and include a chemical
analysis of deposited weld metal in accordance with ASME Section IX and ferrite
determination where applicable. For clad restoration consumable brand is an
essential variable.
9.1.4 Weld Overlay Cladding

All weld overlay cladding procedures shall be submitted in accordance with Project
Specification attached with Material Requisition.
Welding procedures shall be selected to minimize the dilution of the alloy clad layer
by the base material.
Weld procedure qualifications for weld overlay shall include a chemical analysis of
deposited weld metal in accordance with ASME Section IX and ferrite
determination where applicable.
Clad Dish ends/Toricones shall be heat treated as per drawing/datasheet. If not
mentioned in Drawing/datasheet, supplier shall take Buyer’s approval for heat
treatment. When clad Dish ends or torricones are heat treated, 100% ultrasonic
test shall be carried out after forming. In case any heat treatment is involved UT
shall be performed after heat treatment.
Acceptance criteria shall be level 1 for equipment with criticality rating 1 and 2 and
level3 for criticality rating 3 and 4
After any heat treatment, IGC practice A for Austenitic stainless steels shall be
carried out in addition to mechanical test for the base metal of the clad plate. The
procedure shall be as explained in clause no.5.17.3.b)
Where austenitic stainless steel clad vessels require post weld heat treatment the
additional weld procedure qualification tests including bend and corrosion tests.
All welding consumables shall be supplied with a manufacturer’s batch certificate.

Welding consumables, number of layers and chemical composition are subject to
BUYER’s approval. For weld overlay cladding consumable brand (including flux) is
an essential variable.
9.1.5 Inspection And Acceptance Requirements

Inspection of base metal and cladding shall comply with the ASME code and the
applicable Process Licensor requirements.
For welding and inspection requirement, refer specification RPMS-ENGG-SPC-MT-
004.

9.2 Appendix B : Load Combinations

LOAD COMBINATIONS
Design Thickness Allowable Temperature Weight Wind Seismic Pressure Local Thermal Vessel
Case Stress (3) Mechanical Piping Appurtenance
(8) (10) (7)
Operating Corroded Per Code Design X X X X X X Fully “Dressed”
Shop Uncorroded 90% Y.S (1) Ambient (6) X X (4) - - Bare Vessel
Hydrotest
Lifting Uncorroded 90% Y.S (1) Ambient X - - - - - Part or Fully
“Dressed”
Erection Uncorroded 90% Y.S (1) Ambient X X - - - - As Lifting +
(Empty) Internals
Future Corroded 90% Y.S (1) Ambient (6) X X (2) - X (5) X - Fully “Dressed”
Hydrotest

Notes:
1. In tension only. Compressive stress to be per code at ambient.
2. During hydrotest 25% of the wind load must be taken into account.
3. Seismic loads are not to be considered coincident with wind loads.
4. Shop hydrotest shall be based upon calculated maximum allowable pressure
(MAP), uncorroded and shall not be limited by nozzle reinforcement.
For IBR equipment, test pressure shall be determined based on design pressure
in accordance with IBR.
5. Future site hydrotest shall be based upon calculated maximum allowable
working pressure (MAWP) and shall not be limited by nozzle reinforcement.
6. Test water temperature shall not be below MDMT + 17 Deg C or 10 Deg C
whichever is higher.
7. Loads arising from the dead weight of piping (including contents) or other
appurtenances attached to the vessel.
Weight of platform = 170 kgf/m2
Weight of plain ladder = 15 kgf/m
Weight of caged ladder = 30 kgf/m
8. Other design cases may also require to be considered such as horizontal shop
hydrotest of large vessels, shipping and load out.
During lifting, special consideration shall be given to column appurtenances
lifted with the column.
9. All stresses are “general membrane” stresses.
10. Y.S. = Yield Stress at “ambient” temperature.

9.3 Appendix C : Pressure Vessel Tolerances
1/4 deg = 4.35 mm per meter

1/2 deg = 8.70 mm per meter
1 deg = 17.4 mm per meter

1. (a) Tolerance for length & height from reference line to face of top nozzle ± 5.0 mm
/ 3000 mm (Max. cumulative ± 15.0 mm)
(b) Tolerance for Agitator nozzle from top tan line shall be ± 2.5 mm
(c) The depth of dishing (hi or ho) shall be less than the theoretical depth by 2.0%
of inside dia. Nor shall this depth exceed by 1.0% of the outside dia.
2. Nozzle for Agitator mounting shall have flange face aligned within 1/40 of specified
plane.
Other nozzles on dish ends shall have their flange face aligned within 1/20.
3. Height of top bubble cap slots above tray ± 0.75 mm.
4. Height of weir above tray plate ± 3.0 mm
5. Bottom of down flow plate above tray plate +3.0 mm -5.0 mm
6. Projection of nozzle from Centre line of vessel ± 3.0 mm
7. Alignment of flange face of nozzle shall be within 1/20
8. (a) Location / elevation of shell nozzle from reference line shall be ± 5.0 mm for
shop fabricated vessel or sub-assemblies and ± 10.0 mm for field assembled vessels.
When location / elevation is specified from other reference point tolerance shall be
± 3.0 mm. Radial location from true position ± 3.0 mm
(See note 2)
(b) Vertical & horizontal deflection of nozzle flange face from planes normal to
nozzle Centre line or parallel to vessel Centre line shall be within ± 1/20
9. Vertical & horizontal deflection of manhole flange face from planes normal to
manhole Centre line or parallel to vessel Centre line shall be within ± 1/2 0
10. Projection of manway from Centre line of vessel ± 12.0 mm
11. Location / elevation of manway from reference line shall be ± 12.0 mm for shop
fabricated vessel or sub-assemblies and ± 25.0 mm for field assembled vessels.
Radial location from true position ± 12.0 mm
12. Tolerance for bottom of vessel support to reference line is as follows-
For vessel dia. 1500 mm and under +0.0 -5.0 mm
For vessel dia. Over 1500 mm to 3000 mm +0.0 -8.0 mm
For vessel dia. Over 3000 mm to 5000 mm +0.0 -10.0 mm
For vessel dia. Over 5000 mm +0.0 -12.0 mm
13. Tolerance for supports located above reference line shall be same as (12) except
variation to be (-) 0.0 plus stated tolerance.
14. Alignment of cylindrical section shall be true and straight within 0.75 mm per meter
of height from reference line but shall not exceed 20.0 mm.
15. Top of tray out of level over any diameter is as follows-
For vessel dia. 1200 mm and under 3.0 mm
For vessel dia. Over 1200 mm to 2100 mm 5.0 mm
For vessel dia. Over 5000 mm 10.0 mm
16. Top of weir plate out of level over any diameter is as follows-
17. Far side of tower to weir plate ± 10.0 mm
18. Tolerance between adjacent tray plate ± 3.0 mm
19. Location of tray from reference line ± 6.0 mm
20. (a) Out of roundness (Ovality) shall be as per applicable code.
(b) Outside circumference of shell shall be within the following limits.
± 5.0 mm for nominal diameter 600 mm and under
± 10.0 mm for nominal diameter 601 mm through 1200 mm
± 15.0 mm for nominal diameter 1201 mm through 2400 mm
± 20.0 mm for nominal diameter above 2400 mm
(c) Following tolerance on diameter shall apply throughout its length for vessel with
trays and / or packing.
500 mm and under +1.5 -0.0 mm
501 mm to 750 mm +3.0 -0.0 mm
751 mm to 2000 mm ± 0.5%
2001 mm to 4000 mm greater of ± 10.0 mm or ± 0.35%
4001 mm to 8000 mm greater of ± 14.0 mm or ± 0.25%
21. Pipe or walkway support & structural attachments to vessel Centre line ± 3.0 mm,
Reference line ± 6.0 mm
22. (a) Distance between Centre line of horizontal vessel and bottom of support ± 3.0
mm
(b) Distance between Centre to Centre of support & bolt holes for horizontal vessel
may vary ± 3.0 mm.
23. Distance between reference lines to Centre line of support ± 3.0 mm. Support
located from other reference point ± 3.0 mm
24. Light Centre punch mark the principal Centre line shown on orientation plan. Circle
punches mark with paint to designated location.
25. Projection from bottom nozzle from reference line shall be within ± 5.0 mm.
26. Support out of level over any diameter is as follows-

27. Base ring bolt circle diameter may vary ± 5.0 mm for any diameter measured at
point 900 apart distance between two consecutive holes may vary ± 4.5 mm.
28. Anchor chair height for skirt supported vessel ± 3.0 mm.
29. (a) Large flange bolt holes P.C.D. ± 1.5 mm. Bolt hole spacing ± 1.5 mm. Tongue or
groove diameter ± 0.75 mm, Thickness -0.0 +3.0 mm, Distance from reference line
to face of flange ± 6.0 mm.
(b) Bolt-hole orientation of nozzle flange may vary ± 1.0 mm at bolt circle.
30. Deviation of support base for bracket support / saddle support from horizontal is
±10
Notes-
1. The tolerance apply to vertical and horizontal vessel except as otherwise noted
on design drawing relating to specific vessel.
2. Tolerance between Centre to Centre distances between any pair of instrument
connection to be as follows-
Distance between nozzles ± 1.0 mm
Orientation ± 1.0 mm
Nozzle faces inclination ± 1/20.
3. Tray column < 750 mm shall have cartridge type tray to facilitate insertion
through body flange.

9.4 Appendix D : Vendor Data Requirement

9.4.1. Along with the bid
i) Certificate of approval
ii) Proposed schedule of manufacture
iii) Tentative Quality plan
iv) List of sub-suppliers
v) Design Team Composition and capability
vi) Fabrication, testing and supply philosophy in case of ODC consignment
vii) Past Experience list
viii) Data marked as “Vendor to Confirm” in inquiry datasheet
ix) Spare List
x) Deviation List
9.4.2. During Manufacturing
i) Schedule of drawings and documents.
ii) Manufacturing schedule.
iii) Progress reporting
iv) General Arrangement drawing.
v) Nozzle Detail Drawings
vi) Body Detail Drawings
vii) Support and Anchoring Drawing
viii) Design Calculations / FEM analysis.
ix) Structural & support Calculations.
x) Nozzle load Analysis.
xi) Detailed and Cross sectional drawing.
xii) Insulation & lining details
xiii) List / bill of material
xiv) Inspection Test Plan
xv) Weld procedure
xvi) NDE procedure
xvii) Material test procedures / certificates
xviii) Heat treatment Procedure.
xix) Test procedures. (Hydro / leak / pneumatic)
xx) Surface preparation and painting
xxi) Specification Waiver
xxii) Inspection Release Note
xxiii) Lifting & Installation Drawings /Instructions.
xxiv) Spare list and Manufacturing Data Packages content.
xxv) Bolt Torque values
xxvi) Pipe Support and Ladder / Platform Cleats Drawings
xxvii) Other Appurtenance Drawings (e.g. Vessel Davit etc.)
9.4.3. With the supplied material
i) As required and agreed upon

9.4.4. After supply of material

i) Spare list.
ii) Manufacturing Record data Book. (As built of all manufacturing & testing doc)
iii) Shipping drawing & packing list.
iv) Handling & Storage Procedure.
v) Preservation Procedure

9.5 Appendix E : Vendor Document / Data Format

9.5.1. Scope:
These instructions define the control, content and formant of documentation to be
submitted as part of contract. These instructions shall be used in conjunction with
“Vendor Data Requirements”.
9.5.2. Document / data Submission Requirements:
Documents / data required to be submitted by vendor at different stages and
schedules shall be as per “Vendor Data Requirements”. However final as built data
and documents of entire manufacturing and testing shall be provided in the MRB
(Manufacturing Record Book). Any submissions required to be submitted to third
party like Process Licensors / Statutory Authorities or TPI shall also be complied
with.
9.5.3. Document / Data Formant Requirements:
(i) Submission of documents shall be on Buyer’s standard forms unless otherwise
agreed. Where not provided by Buyer, Supplier’s forms are acceptable.
Buyer reserves the right to substitute paper format with electronic documents/
data for completion by the Supplier. In such cases, Supplier will be responsible
for provisions and support of both hardware and software required to interface
with and use Buyer’s preferred format.
(ii) Electronic Format
Buyer requires documents / data for review to be submitted electronically, in
Abode Acrobat Portable Document Format. Buyer’s “Electronic Document
Management System (EDMS)” enable the integration of Supplier’s documents
into the Buyer’s EDMS. The Buyer’s EDMS shall facilitate the review of the
Suppliers documents and may also be used by the plant operator for continued
maintenance of the plant.
Supplier will appoint their coordinator who shall interface with Buyer
representative for smooth to and fro transfer of documents.
(iii) Language
All documents shall be legible and shall be submitted in English language unless
otherwise requested by project specific attachments to the Material
Requisition.
(iv) Documentation Quality
All images shall be legible and properly oriented for viewing.
Proper drawing size to be selected based on requirement, extent of detailing in
each drawing, legibility and ease of handling at shop / site.
Colour images need to be supplied to differentiate between details, if required.

Basic Engineering Design Data

Jamnagar Manufacturing Division
RPMS-ENGG-DBD-PS-001
0 31.12.2020 Issued for Implementation AKS VJK/SDK GDG

By By By
Reliance Project Management System RPMS-ENGG-DBD-PS-001
Basic Engineering Design Data Date: 31.12.2020, Rev. 0
Sr. No. Name Signature Date

(DD.MM.YYYY)
1 G D Goyal (Sub-committee Chairman) _________________ ___________
A Srinagesh___________________ _________________ ___________

2
R K Ghosh______________________ _________________ ___________

3
Kuddallur Seshadri______________ _________________ ___________

4
RECORD OF REVISIONS

Number
31.12.2020 First Issue-Based on Bechtel Review 0
Preamble
This Basic Engineering Design Data presents Owner’s overall requirements for
a given Reliance Project, comprising of design data and basis of design as
summarised in Section 1 “Purpose”. This document is intended to serve as a
template that Owner will customise for a given site and a given number of
facilities and issue for use by the design engineering entity.
Contents
1. Purpose .................................................................................................................. 10
2. Scope ..................................................................................................................... 10
3. Abbreviations & Definitions .................................................................................. 10
4. Introduction ........................................................................................................... 14
5. Codes, Standards, and Software ........................................................................... 14
Discipline Engineering Design Basis Documents ................................................... 14
Applicable Codes and Standards ........................................................................... 14
Software ................................................................................................................ 15
6. Units of Measurement (UOM)............................................................................... 15
7. Site Information ..................................................................................................... 21
Site Data................................................................................................................. 21
7.1.1. Plant site ......................................................................................................... 21
7.1.2. Marine terminal (As applicable) ..................................................................... 21
Meteorological Data .............................................................................................. 22
7.2.1. Temperatures ................................................................................................. 22
7.2.2. Atmospheric Pressure .................................................................................... 22
7.2.3. Humidity ......................................................................................................... 22
7.2.4. Rainfall ............................................................................................................ 23
7.2.5. Intensity of storms ......................................................................................... 23
7.2.6. Wind Data....................................................................................................... 23
Seismic Data........................................................................................................... 24
7.3.1. Categorization of structures / equipment for seismic design........................ 24
Metocean Data ...................................................................................................... 24
7.4.1. Wind Data – Marine facilities ......................................................................... 24
7.4.2. Tide Levels ...................................................................................................... 24
7.4.3. Surge Levels, Wave Heights, Current and Bathymetric data ......................... 24
8. Utility Information ................................................................................................. 24
General .................................................................................................................. 24
8.1.1. Process Unit Design Basis ............................................................................... 25
8.1.2. Utilities systems design .................................................................................. 25
8.1.3. Utilities systems design input data ................................................................ 25
Utilities Distribution Header Design Basis ............................................................. 25

Utilities Battery Limit Conditions........................................................................... 25
Sea Water System .................................................................................................. 25
Desalinated Water System .................................................................................... 26
Cooling Water Systems.......................................................................................... 26
8.6.1. Approach to cooling tower circuit engineering ............................................. 26
8.6.2. Cooling tower design specifications............................................................... 26
Process Water ........................................................................................................ 26
Potable Water and Service Water ......................................................................... 26
Fire Water Systems ................................................................................................ 27
Steam and Condensate System ......................................................................... 27
8.10.1. Steam system ................................................................................................. 27
8.10.2. Steam Conditions ........................................................................................... 27
8.10.3. Steam Condensate system ............................................................................. 28
Fuel Gas System ................................................................................................. 28
Fuel Oil System ................................................................................................... 29
Power ................................................................................................................. 29
8.13.1. Emergency power system .............................................................................. 30
8.13.2. Uninterrupted power supply.......................................................................... 30
Air System .......................................................................................................... 31
Nitrogen System................................................................................................. 31
Flushing Oil System ............................................................................................ 31
Closed Blowdown Systems ................................................................................ 31
8.17.1. Non congealing hydrocarbons ....................................................................... 31
8.17.2. Congealing hydrocarbons............................................................................... 32
8.17.3. Steam Generation blowdown drains ............................................................. 32
8.17.4. Caustic Drains ................................................................................................. 32
8.17.5. Acidic Drains ................................................................................................... 32
8.17.6. Spent Caustic Handling................................................................................... 32
Hazardous Blowdown System............................................................................ 33
9. Equipment Design Considerations ........................................................................ 34
Equipment Sparing ................................................................................................ 34
9.1.1. ISBL Static Equipment / ISBL Packages ........................................................... 34

9.1.2. ISBL Continuous Rotary Equipment ............................................................... 34
9.1.3. Non-critical / Intermittent Service Rotary Equipment ................................... 35
9.1.4. OSBL Critical Packages.................................................................................... 35
9.1.5. Hydrogen Service Definition .......................................................................... 35
Equipment Overdesign .......................................................................................... 35
Equipment & Utility Header Isolation ................................................................... 36
9.3.1. Battery Limit Isolation .................................................................................... 36
9.3.2. Flare Header Battery Limit Isolation .............................................................. 38
9.3.3. Heat Exchanger Isolation................................................................................ 38
9.3.4. Automatic Remote Isolation .......................................................................... 39
Equipment Maintenance Facilities ........................................................................ 40
Determination of Design Temperature and Pressure ........................................... 40
9.5.1. Design Internal Pressure ................................................................................ 40
9.5.2. Design Temperature....................................................................................... 42
9.5.3. Minimum Design Metal Temperature (MDMT) ............................................. 42
9.5.4. Vacuum design ............................................................................................... 43
Material of Construction ....................................................................................... 43
9.6.1. Corrosion allowances ................................................................................... 43
Equipment Design Guidelines................................................................................ 44
9.7.1. Vessels and Columns ...................................................................................... 45
9.7.2. Trays and packing ........................................................................................... 47
9.7.3. Tankage .......................................................................................................... 50
9.7.4. Double wall tanks ........................................................................................... 51
9.7.5. Spheres and Bullets ........................................................................................ 51
9.7.6. Shell and Tube Heat Exchangers .................................................................... 52
9.7.7. Air Cooled Heat Exchangers ........................................................................... 56
9.7.8. Heaters ........................................................................................................... 58
9.7.9. Rotating Equipment ....................................................................................... 60
9.7.10. Pumps ............................................................................................................. 61
9.7.11. Compressors ................................................................................................... 64
Instrumentation..................................................................................................... 65
9.8.1. General Requirements for Instrumentation on Process P&IDs ..................... 66

9.8.2. Standard Utility Line Instrumentation ........................................................... 68
9.8.3. Wireless Instrumentation .............................................................................. 68
Piping Related Guidelines ...................................................................................... 68
9.9.1. Engineering Design Basis ................................................................................ 68
9.9.2. Control Valve Manifold .................................................................................. 69
9.9.3. Overall Plot Plan and Equipment Layout ....................................................... 69
9.9.4. Full Rated and De-rated Piping Classes .......................................................... 70
9.9.5. Insulation, Painting and Coating requirements ............................................. 70
9.9.6. Specific Technical Requirements for Piping ................................................... 70
Electrical system design related guidelines ....................................................... 71
10. Design Optimisation and Plant Life ....................................................................... 72
11. Safety, Health and Environment Related Requirements ...................................... 72
Hazardous Properties of Chemicals ................................................................... 72
Chemical-Chemical Interaction Matrix .............................................................. 72
Chemical-Metal Interaction Matrix ................................................................... 72
Management of Highly Toxic Materials ............................................................. 73
Inherently Safer Process Design Approaches .................................................... 73
Hazard Identification.......................................................................................... 73
Hazop ................................................................................................................. 73
SIL Assessment Studies ...................................................................................... 74
Risk Analysis ....................................................................................................... 74
11.9.1. Baseline data for pollutants and dispersion modeling .................................. 74
Typical Safety Features ...................................................................................... 75
11.10.1. For prevention ................................................................................................ 75
11.10.2. For containment of incident impact .............................................................. 75
11.10.3. For emergency handling................................................................................. 82
Environmental Compliance ................................................................................ 83
11.11.1. Typical provisions for environmental monitoring.......................................... 83
11.11.2. Noise level limits ............................................................................................ 83
12. Documentation Requirements .............................................................................. 83
Equipment Numbering....................................................................................... 83
Documentation and Document Numbering ...................................................... 83

13. ANNEXURE 1 - Wind Roses at site ......................................................................... 85
14. ANNEXURE 2 - Utilities Qualities and Test Methods ............................................. 88
15. ANNEXURE 3 - Utilities Battery Limit Conditions ................................................ 118
16. ANNEXURE 4 – Rainfall Intensity Chart ............................................................... 151
1. Purpose
The purpose of this document is to provide basic design information that shall
form the basis of basic and detailed engineering. This document, taken together
with other reference documents invoked herein, comprise the overall design
basis for a specified facility or complex (the “Project”). All parties executing work,
including Detailed Engineering Contractors, EPC Contractors, Process Licensors
and third party vendors or suppliers, shall comply with information furnished in
this document.
2. Scope
Basic Engineering Design Data shall be completed in this document in all respects
for a given site such as Jamnagar, Dahej or Hazira, and thereafter shall be
applicable for all facilities at that site, including ISBL, OSBL, Jetty, Captive Power
Plant areas, Seawater desalination plants, for all new projects.
3. Abbreviations & Definitions
Abbreviations
Acronyms Description
APH Air Pre-Heater
BEC Basic Engineering Consultant
BFW Boiler Feed Water
BOD Biochemical Oxygen Demand
CA Corrosion Allowance
CBD Closed Blow Down
CPP Captive Power Plant
CS Carbon Steel
DB Design Basis
DBT Dry Bulb Temperature
DCS Distributed Control System
DMW Demineralised Water

EOT Electric Overhead Travelling Crane

Contractor
ESD Emergency Shut Down
ETP Effluent Treatment Plant
FD Forced Draft
F&G Fire & Gas
FRP Fibre Reinforced Plastic
GC Gas Chromatography
GLC Ground Level Concentration
HAS High Alloy Steel
HAZID Hazard Identification
HAZOPS Hazard and Operability Study
HHP High High Pressure
HP High Pressure
HIIR Halobutyl-Rubber
ID Inside Diameter
IPF Instrumented Protective Function
IR Individual Risk
IRI Industrial Risk Insurers
ISA International Society of Automation
ISBL Inside Battery Limits
LAS Low Alloy Steel
LP Low Pressure
LPG Liquefied Petroleum Gas
LTDS Low Total Dissolved Solids (water)
MOC Material of Construction
MOF Material Off-loading Facility

MP Medium Pressure
MTF Marine Tank Farm
NB Nominal Bore
NPSH Net Positive Suction Head
OD Outside Diameter
OISD Oil Industry Safety Directorate
OSBL Outside Battery Limit
OWS Oily Water Sewer
PESO Petroleum and Explosives Safety Organization
PN Preparer Note [Note for person preparing
document]
PS Project Specifications
PST Partial Stroke Testing
QRA Quantitative Risk Assessment
RIL Reliance Industries Limited
RO Reverse Osmosis
ROR Rate of Rise
RPMG Reliance Project Management Group
SIL Safety Integrity Level
SIS Safety Instrumentation System
SoW Scope of Work
TDS Total Dissolved Solids
TEMA Tubular Exchanger Manufacturer Association
TSS Total Suspended Solids
UPS Uninterrupted Power Supply
UV Ultra Violet
UVCE Unconfined Vapour Cloud Explosion
VFD Variable Frequency Drive

VOC Volatile Organic Compound

WBT Wet Bulb Temperature
DEFINITIONS
Supplier: Party which manufactures or supplier

equipment and/or services to perform the
function as specified by Buyer. Vendor and
Supplier are terms that may appear
interchangeably in Owner documentation
Buyer Owner (Reliance) or Owner-appointed DEC or

EPC who specifies
equipment and/or services for purchase from
Supplier
Owner Reliance Industries Limited or specified Reliance
Group Company
EPC Engineering, Procurement, Construction
Contractor

4. Introduction
Reliance Industries Limited operates the world’s largest refinery complex at
Jamnagar comprising of 2 refineries, DTA + SEZ, with 1350 kbpsd crude
throughput each. The complex produces LPG, Naphtha, Gasoline, Kerosene,
Diesel, Sulphur, Coke, Polypropylene and a number of aromatic products
including Paraxylene, Orthoxylene and Benzene. Following successful
commissioning of J3 project, RIL also operates the Ethylene and downstream
complex (C2 Complex), and the Gasification and associated projects. Other
facilities at Jamnagar site include Offsites, Utilities, Captive Power Plant,
seawater intake, pipelines, tank farm and marine facilities.
5. Codes, Standards, and Software
Discipline Engineering Design Basis Documents
Major Engineering Design Basis documents of individual Disciplines are:
Civil / Structural / Architectural RPMS-ENGG-DBD-CS-001
Seismic analysis RPMS-ENGG-DBD-CS-003
Piping RPMS-ENGG-DBD-PP-001
Electrical RPMS-ENGG-DBD-EL-001
Instruments RPMS-ENGG-DBD-CI-001
Pipe Stress RPMS-ENGG-DBD-ST-001
HSEF RPMS-ENGG-DBD-HS-001
Design Basis documents listed above in turn refer to detailed Design Basis
documents and Specifications and Standard Drawings of individual disciplines.
Applicable Codes and Standards
Refer to individual Discipline Engineering Design Basis Documents for specific
Codes and Standards that shall apply for the Projects
In the event of conflict or deviation from requirements stipulated in this design
basis and other applicable documents, the following order of precedence shall
govern:
 Indian Government Statutory Rules and Regulations specifically referenced
 Data Sheets and Drawings
 Material Requisitions
 Reliance Standard Specifications Specifically Referred
 Codes and Standards Specifically Referred
 Other National and International Standards as Referenced

Latest revisions of codes and other statutory requirements as applicable at the

time of enquiry, shall be applicable. In case of any conflict, the decision of owners
engineer in charge shall be final and seller shall implement that without any
commercial implications. All “local and statutory requirements as applicable shall
be complied to without any deviation”.
Design philosophies specified in this document shall take precedence over
guidelines specified elsewhere in any ‘iRPMS- Internal RPMS’ documents.
Software
Refer RPMS-PIMS-PRA-GE-023 for the software and their versions to be
deployed by the party executing work.
6. Units of Measurement (UOM)
Table 6.1 – UoM for PFD, Heat Material Balance and Stream Summary
Parameter UOM Remarks
Density / molecular weight,
Flowrates of vapours, temperature and pressure
compensation shall be used for critical
gases, steam, liquids, kg/hr
flows (mass balance, reactor feed,
catalyst and solids furnace pass, fouling fluids, fuel to
furnace and similar)
System Pressure kg/cm2g
Vacuum mm Hg abs
Delta P mm Hg / kg/cm2
Temperature deg C
Non-linear level control shall be used

Level % vol
wherever applicable.

Table 6.2 – UoM for Datasheets, Specifications, Design Documents and Drawings
Parameter Unit of Measurement
SPACE AND TIME

m mm
Length
m2 mm2
Area
m3 l (litre) ml
Volume
s hr day
Time
m/s mm/s
Velocity
m/s2
Acceleration
m3/s l/s ml/s m3/h m3/d
Volume Flow
rad degree minute second
Plane angle
sr
Solid angle
rad/s
Angular velocity
PERIODICITY
MHz kHz Hz
Frequency
rev/s rpm
Rotational frequency
MECHANICS
t (tonne) kg
Mass


Mass Flow t/hr kg/hr
Molar Flow kgmol/hr kgmol/s
Volumetric Flow m3/hr
Normal Volumetric Gas Flow Nm3/hr (0oC and 1.033 kg/cm2a)
Standard Volumetric Liquid Flow Sm3/hr (15oC)
Density kg/m3
Liquid Absolute Density kg/m3 (15oC)
Momentum kgm/s
Moment of inertia kgm2
Force N
Moment of force Nm
Pressure (Absolute) kg/cm2a mmHgA

Energy, Work MJ kJ kcal
Power MW kW W
Dynamic Viscosity cP e) Pa s
(centipois
Kinematic Viscosity cSt (centistokes) m2/s
Surface Tension mN/m
Conductivity µS / cm
Sound Pressure dB
HEAT
Absolute temperature K
Customary temperature ºC
Heat Quantity kcal
Heat flow rate kcal/hr

Density of heat flow rate kcal/m2hr

Thermal conductivity kcal/mºChr
Coefficient of heat transfer kcal/hr m2 ºC
Specific heat capacity kcal/kg-K
Specific entropy kcal/kg
Calorific value (mass basis) kcal/kg
Specific energy, specific enthalpy, specific kcal/kg
latent heat
Calorific value (volume basis) kcal/Sm3

ELECTRICITY AND MAGNETISM
Electric current kA A mA
Electric charge, quantity of electricity kC C µC
Electric potential and electromotive force kV V mV µV
Electric field strength V/m

Capacitance F µF pF
Current density A/mm2 A/m2
Magnetic field strength A/m
Magnetic flux Wb mWb
Magnetic flux density T
Self inductance, mutual inductance H mH µH
Permeability H/m
Resistance, impedance, reactance MΩ kΩ Ω mΩ
Conductance kS S mS µS
Resistivity Ωm µΩm
Active power MW kW W
Reactive power MVAr kVAr VAr
Apparent Power MVA kVA VA
Electrical energy MWh Wh MJ kJ J
ILLUMINATION
Luminous intensity Cd
Luminous flux Lm
Illumination Lx
Luminance cd/m2

Notes:
Inch-pound units shall be used only for piping system sizing and rating
Standard conditions are 15oC and 1.033 kg/cm2a
Normal conditions are 0oC and 1.033 kg/cm2a
Conditions for specific gravity are ToC / 15oC

7. Site Information
Site Data
The site is located at latitude 22º 22' N, longitude 69º 51' E adjacent to the town
of Jamnagar in Gujarat State alongside the Gulf of Kutch approximately 480 km
north of Mumbai on India's west coast. The nearest major commercial airport
and port is Mumbai, however a dedicated Material Offloading Facility (MOF) is
operational.
Plant North is true North for the whole project except for the Marine Terminal
and Marine Tank Farm which have a plant north that is 16º to the West of true
North.
7.1.1. Plant site
Table 7.1 – Site Information and References for Plant and Facilities
Parameter Reference or Data

Geotechnical Data Refer 10080-1-ENGG-DBD-CS-006 Design Basis for
Foundation Design for geotechnical data and soil
investigation reports
Reference Northing and Easting shall be as per DTA and SEZ
Coordinates refineries
Datum Levels Shall be as per existing DTA and SEZ refineries
Topography Data Refer Area Specific / Project Specific topographic data
High Flood Levels Shall be as per existing DTA and SEZ refineries
7.1.2. Marine terminal (As applicable)

Table 7.2 – Site Information and References for Marine Facilities
Parameter Reference or Data
Geotechnical Data Refer 10020-GDB-NM800-1002 Design Premises for
Marine Structures for geotechnical data
Reference Northing and Easting shall be as per existing berths
Coordinates
Datum Levels Shall be as per existing marine facilities
Topography Data Refer 10020-DBD-NM800-1002 Design Premises for
Marine Structures for topography data
High Flood Levels Highest astronomical tide

Meteorological Data
7.2.1. Temperatures
Table 7.3 – Temperatures for use in design
Parameter Value
Recorded Dry Bulb Temperature (DBT), ºC 48 max,
3 min
Recorded Wet Bulb Temperature (WBT), ºC 28 max
Design DBT for Air Coolers, ºC 41
Design Temperature for Outdoor Electrical Equipment, ºC 43
Design Temperature for Indoor Electrical Equipment, ºC 40
Design Temperature for Electrical Lighting Fittings, ºC 40
Design Temperature for Surfaces exposed to Solar Radiation, ºC 65
Winterizing Temperature for pour point and freeze protection, 10

ºC
Low Ambient Design Temperature [*], ºC 7.5
[*] To be used for determining metal temperatures as required by ASME Pressure
Boiler Code, Section VIII, Division I
7.2.2. Atmospheric Pressure
Site elevation is close to mean sea level. Being a coastal location, there is no
significant seasonal variance in ambient conditions.
Table 7.4 – Atmospheric Pressure
Parameter Value
Minimum, kg/cm2a 1.003
Normal / Average, kg/cm2a 1.024
Maximum, kg/cm2a 1.034
7.2.3. Humidity
Minimum 27.0%, maximum 92.8%

7.2.4. Rainfall
Table 7.5 – Rainfall data for use in design
Parameter Value
Maximum hourly rainfall, mm 61

Maximum rainfall over 24 hours, mm 522
Rainfall Intensity Attachment 4
7.2.5. Intensity of storms

Refer 10090-1-DBD-GE-002 Drainage System Design Philosophy and
Coordination and RPMS-ENGG-DBD-CS-006 Engineering Design Basis for Storm
Water & Sewer System.
7.2.6. Wind Data
Table 7.6 – Wind Speeds for use in design
Parameter Value
Onshore (a): 50-year 3-second gust wind 10m from finished grade, m/s 50
Offshore (b): 5-year mean hourly wind speed 10m from finished grade, 15
m/s
Offshore (b): 500-year mean hourly wind speed 10m from finished 33
grade, m/s
Wind speed for determining flare heat radiation, m/s 11.5
Basic Wind Speed, Vb 10m from finished grade, m/s 50
Risk Coefficient K1 as per IS 875 part 3, Table-1 1.08

Topography factor K3 as per IS 875 1
Terrain Category 2
Wind Rose Attachment 1
a) Onshore includes J3 projects, J3 Tank Farm and Marine Tank Farm

b) Offshore includes Sea Island, Jetty Approach Trestle and Causeway

Seismic Data
All seismic design shall comply with the IS 1893 code.
Design Seismic Zone factor for JMD shall be taken as Z = 0.32
7.3.1. Categorization of structures / equipment for seismic design
Refer RPMS-ENGG-DBD-PS-005, Categorization of Structures/Equipment for
Seismic Design.
Metocean Data
7.4.1. Wind Data – Marine facilities
Refer 10020-DBD-NM800-1002 Design Premises for Marine Structures.
7.4.2. Tide Levels
Data in Table 7.7 is presented as per Admiralty Tide Tables with reference to
Chart Datum.
Table 7.7 – Tide Levels
Parameter Value
Highest astronomical tide, m +6.15
Mean high water spring, m +5.41
Mean high water neap, m +4.33
Mean sea level, m +3.10
Mean low water neap, m +1.87
Mean low water spring, m +0.79
Lowest astronomical tide, m -0.30
Coastal flood line, m +6.15
7.4.3. Surge Levels, Wave Heights, Current and Bathymetric data

Refer 10020-DBD-NM800-1002 Design Premises for Marine Structures.
8. Utility Information
General
Refer Attachment 2 for utility quality specifications and Attachment 3 for utility
battery limit conditions

8.1.1. Process Unit Design Basis

Refer respective Process Design Basis for feed, product, yield, conversion, critical
process parameters and other information for units and facilities designed by
Licensor or Basic Engineering Consultant.
8.1.2. Utilities systems design
Jamnagar site has integrated utility generation systems across DTA and SEZ
refineries. The major constraint is availability of river and treated water. It is an
imperative that unit designs minimize use of water, conserve available water and
be mindful of cooling water side fouling when using river water as makeup.
8.1.3. Utilities systems design input data
In order to take appropriate margins in the flow capacity of the OSBL lines, data
need to be furnished by ISBL plant DECs for three load conditions – Normal,
Maximum, and Peak.
Normal = Flows based on Name Plate Licensed Capacity for steady state plant
operation. This will be consistent with the PFD, HMB etc.
Maximum = Flows based on expected CONTINUOUS higher capacity operation.
This capacity will be different than Normal in plants where there is deliberate
increase of margin beyond standard design margins of 10%.
Peak = Peak flows required for abnormal, SHORT DURATION conditions during
emergencies, shut downs, start-ups, regenerations, decoking, tank to tank
transfers, loading / unloading etc.
It is suggested that above flows will be given with zero additional margin added
to the calculated flows.
Utilities Distribution Header Design Basis
All ISBL and OSBL utility distribution systems are to be sized for 10% greater
capacity than the estimated maximum requirement or 100% of peak
requirement, whichever is higher. However, for new projects, cooling water and
steam distribution system overdesign shall be reviewed in the context of future
expansion and a higher overdesign finalised with RIL on a case-to-case basis.
Utilities Battery Limit Conditions
Refer Attachment 2.
Sea Water System
Sea water is pumped from an intake system to a reverse osmosis unit located on
the coast near the marine terminal. Sea water supply lines are sized for maximum
flow rate of the sea water intake basin. Sea water is used as feed for desalination
units and as make-up for sea water cooling towers.
Desalinated Water System

Desalinated water is supplied from the RO unit at MTF in DTA refinery. It is used
for cooling tower make-up, demineralised water plant feed, potable water,
service water and as one of the sources of fire water makeup.
Cooling Water Systems
8.6.1. Approach to cooling tower circuit engineering
Jamnagar uses open recirculating type cooling towers for both sea water and
fresh water cooling water systems. Design contractors are required to remain
within cooling water side pressure drops recommended below:
Table 8.1 – Recommended Maximum Pressure Drops for Cooling Water System
Cooling Water System Section Value
From Cooling Tower Pumps to Unit Battery Limits, kg/cm 2 0.5
From Unit Battery Limits to CW consumer and back, kg/cm2 2.0 – 2.5
From Unit Battery Limits to Cooling Tower, kg/cm2 0.5
At base of Cooling Tower, kg/cm2g 1.5 – 1.8
Depending upon the type of cooling tower, height will be 15m to 18m from grade.
An integrated network analysis from Cooling Tower to consumers and back shall
be conducted during detailed engineering and piping and system design finalized
based on it.
8.6.2. Cooling tower design specifications
Cooling Towers are designed for 4 ºC approach over wet bulb temperature to
establish cooling water supply temperature for both fresh water and sea-water
based systems.
Process Water
DM Water will be used for process water consumers and as make up for Boiler
Feed Water.
Potable Water and Service Water
Narmada river water is restricted from being used for industrial purposes.
Desalinated water from RO plant will be used raw water and as potable water
after treatment in passivation and chlorination units. Safety showers and eye-
wash stations shall be supplied with potable water. Exposed piping in distribution
network shall be insulated to avoid heating of stagnant water by solar radiation.

Fire Water Systems

Jamnagar site has an integrated fire water system covering all facilities. Raw
water or desalinated water is used for initial fill and make-up during fire-fighting.
For marine tank farms, desalinated water is used for initial fill and seawater is
used during fire-fighting.
Steam and Condensate System
8.10.1. Steam system
Steam is available at four pressure levels – High High Pressure (HHP), High
Pressure (HP), Medium Pressure (MP) and Lower Pressure (LP). HHP and HP
steam will be used for turbine drives, letting down to HP, MP and LP levels and
distributed to other consumers.
8.10.2. Steam Conditions
Definitions:
 MINIMUM describes the lowest steam pressure and temperature
expected at the process battery limits during normal operation
 NORMAL describes the average or typical steam pressure and
temperature expected at the process battery limit during normal
operation.
 MAXIMUM describes the highest steam pressure and temperature
expected inside the process battery limits during normal (non-relieving)
operation.
 DESIGN describes pressures and temperatures used for the mechanical
design of piping and equipment - excluding steam generation equipment
designed under the provisions of the ASME Boiler and Pressure Vessel
Code, Section I. These conditions are particularly important if matching
existing equipment or design is done by others.
Methodology of how this information is to be used:
 Steam consuming equipment connected to a steam header will in general
be specified based upon the minimum steam conditions and reviewed for
satisfactory operation anywhere between the maximum and minimum
steam header conditions.
 Normal steam conditions will be used for utility estimates, heat and mass
balances, etc.
 Steam generating equipment connected to a steam header will in general
be specified based upon the maximum steam conditions and reviewed for

satisfactory operation anywhere between the maximum and minimum

steam header conditions.
 For steam turbines, design capacity will be based on minimum inlet and
maximum extraction pressure while rated capacity will be based on
normal inlet and normal extraction pressure
 Design conditions will be considered to establish relief valve set pressures
and mechanical design.
Steamout Conditions
 Hydrocarbon lines and vessels in the process area shall be checked for
steam-out conditions of at least 0.175 kg/cm2 external pressure at 150°C,
when specified for steam-out conditions in the vessel data sheet or line
list.
8.10.3. Steam Condensate system
Condensate return line hydraulics shall be checked to the final destination tank
or vessel, accounting for all joining condensate return streams, piping layout and
elevation, to ensure the battery limit pressure is adequate to avoid flashing in the
return line.
The lines from steam traps will carry condensate, incondensable gases, and flash
steam from the trap to the condensate return system. These lines should fall in
the direction of flow to maintain free flow of condensate. Condensate from more
than one temperature- controlled process at different pressure may join a
common line, as long as the common line is:
 Designed to slope in the direction of flow to a collection point.
 Sized to cater for the cumulative effects of any flash steam from each of
the branch lines at full-load.
 The lines should join at top of the common header
 Each part of the discharge piping system should be sized to carry any flash
steam present at acceptable steam velocities.
Condensate recovery shall be maximised from LP steam header and steam
tracing systems by either provision of pumping traps or flash drums and pumps.
Refer RPMS-ENGG-DBD-PS-003 Design Basis for Steam Condensate Handling
System
Fuel Gas System
Jamnagar site links fuel gas generation and consumption across DTA, SEZ and J3
complexes. Unsaturated process gas generated from FCC and Coker units

comprise feed to ROGC to recover Ethylene, C2 and heavier hydrocarbons,

returning Hydrogen and Methane to the fuel gas network. Saturated process gas
generated from Crude and Vacuum Distillation unit, Hydrotreaters and
Aromatics units are similarly routed to ROGC to recover C2 and heavier
hydrocarbons, returning Hydrogen and Methane to fuel gas network.
Syn Gas generated from Gasifiers is used as fuel to fire Gas Turbines, Steam
Generators and Auxiliary Boilers in J3, and for Gas Turbines in DTA and SEZ
refineries. Methane- rich synthetic natural gas from Gasifiers is used as fuel for
process furnaces where calorific value and Wobbe Index permit.
LPG vaporisers provide back up if fuel gas header pressures reach low pressure
set point. Natural gas import facilities are activated when needed.
Fuel Oil System
DTA and SEZ each have their own separate fuel oil systems, interconnected
through the blending header. Each system comprises of a blending and storage
facility, send-out pumps and a heated distribution circuit to process users. Fuel
oil is circulated through this system in excess of required consumption with
surplus returned to blending and storage area. Fuel oil temperature is maintained
to keep viscosity is below 43 cSt (200 SSU). A nominal fuel oil temperature drop
of 5 ºC is considered up to individual users.
Fuel oil is passed through a strainer of 0.03 inch screen size prior to delivery.
Typical limits maintained are sulphur 0.25 %wt and nitrogen 700 ppmw. Net
lower heating value of fuel may be considered as 9,444 kcal/kg.
Refer Attachment-2 and Attachment-3 for fuel oil quality and battery limit
conditions.
Power
The Main power source is captive power generation with primary distribution to
be preferably at 33 kV. The system may be connected to utility grid at 220 kV
voltage level. Further power distribution shall be at 6.6 kV and 415 V Voltage
level. Large motor of rated above 3500 kW shall be fed from unit transformer of
primary 33 kV to 11.5 kV secondary.
Table 8.2 – Power Levels
Frequency
Hz
Level Phase User
220,000 V 3 50 Main Incoming Substation

14,500 V
11,000 V 3 50 Generation Voltage
33,000 V 3 50 Main substation
11,000 V
6,600 V 3 50 Unit substation [Distribution]
415 V 3 50 LV Distribution
110 V 1 50 Instrumentation
415 V 3 50 Welding receptacles
415 V 3 50 High Mast and roadway lighting
240 V 1 50 Process Area Lighting and Essential Lighting
240 V 1 50 General indoor lighting
240 V 1 50 Convenience receptacles
110 V 1 50 Uninterruptible Power Supply (UPS)
415 V 1 50 Essential Power Supply
220 V - - DC Power Supply
8.13.1. Emergency power system

Emergency Diesel Generators at strategic locations support a distributed
emergency 3- phase power network at 415 V or 6.6 kV, depending on quantum
of emergency power requirements.
8.13.2. Uninterrupted power supply
AC UPS system shall generally be dual redundant, 115 V, 50 Hz, single phase
systems with dual load bus. Batteries for UPS shall be in accordance with project
specification RPMS-ENGG- SPC-EL-009.
Each Battery bank shall be rated for 6 hours backup for Fire and Gas System
(F&G), Public Address and General Alarm System (PAGA) / Telephone
/Security/Radio systems & IT Networks and 30 minutes backup for other loads
that include DCS/Process Monitoring & Control System, Emergency shutdown
and de-pressuring control system and flare ignition and shall be rated for 50% of
the total load.
Air System
All plants shall be provided oil free, water saturated plant air and oil free
instrument air with a water dew point of (-) 40ºC at atmospheric pressure.
For Instrument Air, volumetric capacity equal to minimum 20 minutes of normal
consumption of instrument air will be provided for safe shutdown on loss of
instrument.
air from source. This is achieved by use of high-pressure dry air storage vessel
with holdup volume of 20 minutes normal consumption between 40 kg/cm2g
and 6 kg/cm2g.
Nitrogen System
High purity nitrogen is dry, oil free and 99.998 vol% pure. Oxygen contamination
is kept below 5 ppmv for units like LDPE and LLDPE with source at Air Separation
Unit in EO/EG plant, and below 10 ppmv for other units with source at Air
Separation Units in DTA and SEZ refineries. Liquid nitrogen is stored for
vaporisation and use during intermittent high demand such as unit start up and
tank inbreathing. It is imperative that Contractors fully define duration and peak
demand of nitrogen to enable adequate sizing of generation and distribution
facilities.
Flushing Oil System
Oil refinery units processing distillate fuels or heavier require flushing oil for start-
ups and shut-downs, externally-flushed API seal plans and purging instruments in
congealing service. In addition, hydro-processing units may require low sulphur
flushing oil and heavy flushing oil for heavier fluid services where normal flushing
oil may cause vapour blowout in pump seals.
Closed Blowdown Systems
8.17.1. Non congealing hydrocarbons
 Connect equipment drain to CBD network leading to a closed blow down
drum (which shall be placed in RCC pit and sand packed by vibro compression.
Cathodic protection is required. Design CBD for 80ºC. CBD drum shall have
heating/cooling coil as applicable.
 Any hydrocarbon-hydrocarbon drains generated in polymer unit shall be
collected and reused, with suitable treatment within the unit. All facilities
required for this shall be considered within the unit scope.
 In general, CBD drum of 40 m3 for vessels and two pumps of 25 m3/hr should
be provided. However, it should be checked for adequacy to hold single
largest inventory of equipment of LLL, or single largest pipeline section, or
any other plant-specific requirement.
8.17.2. Congealing hydrocarbons

 Provide with combined cooling and heating coil
 Displace liquid inventory for liquid filled equipment like heat exchangers
with flushing oil to CBD /slop header for cool drains < 90 ºC or to an available
product rundown for compatible temperatures. Hot drains to be displaced
through an identified cooler.
8.17.3. Steam Generation blowdown drains
 Flash MP, HP and VHP for recovery of LP steam (if adequate steam
generation is feasible).
 Steam condensate will be routed to condensate polishing system
 Steam generation equipment intermittent blowdown shall be cooled to 50-
60 ºC and sent to ETP.
 The continuous blowdown from steam generation equipment shall be
flashed to LP steam level and will re-used after cool down in cooling water
system or sent to ETP.
8.17.4. Caustic Drains
 Separate caustic drain system shall be provided.
 All caustic drains shall be collected in a pit and pumped to ETP after
neutralization.
8.17.5. Acidic Drains
 Individual units handling amine will be provided with separate buried amine
closed blowdown system from where amine stream will be pumped to
regeneration unit.
 Process sour water shall be routed to identified sour water strippers.
Residual drains where unavoidable may be routed to oily water sewer. Sour
water drains within sour water stripper unit with large inventory of sour
water shall be provided with sour water blowdown drum for any drains.
 All acid drains shall be collected in a vessel and after neutralization pumped
to ETP. Depending on type of acid, proper fume handling system shall be
considered.
8.17.6. Spent Caustic Handling
Any process unit discharging spent caustic with light hydrocarbon shall degas the
stream in an atmospheric vessel floating with flare header and then pump this
out to ETP or spent caustic storage.

Hazardous Blowdown System

Refer Section 11.10.2.4

9. Equipment Design Considerations

Equipment Sparing
9.1.1. ISBL Static Equipment / ISBL Packages
Typically, static equipment in individual units are not spared. Exceptions would
be adsorption units / reactor units and similar installations that may require
periodic regeneration / catalyst replacement and the operating bed has a spare
that is regenerated and kept ready to maintain continuity of operation.
Owner strives for operational excellence through reliable designs that afford long
run lengths. However, it is mandatory to allow IBR inspection of steam generating
equipment every two years. Where such sparing of equipment requires
substantial capital, alternative solutions may entail leaving space for future spare
steam generator.
9.1.2. ISBL Continuous Rotary Equipment
All continuous running pumps and reciprocating compressors shall have installed
spare. For pumps, refer Table 9.1.
Table 9.1 – Recommended Installed Spare Pumps
Number of Operating Pumps Number of Spare Pumps
1 of 100% capacity 1 of 100%

2 of 50% capacity each 1 of 50% capacity
5 to 8 operating of specified capacity 2 spare of specified capacity
9 or more operating of specified capacity 3 spare of specified capacity
For critical compression applications, the complete package inclusive of

compressor, turbine, expander, motor, gearbox and auxiliary system shall be
spared in compliance with relevant project specification (referenced to relevant
API standards). In certain packages, vendor standard equipment may be accepted
on case to case basis.
In certain critical compression applications, machines with split capacity can be
explored. For critical agitators, warehouse spare rotor should be considered.
For Centrifugal compressors, spare rotor shall be considered. Kindly refer the
relevant Project Specification for detailed sparing philosophy.

9.1.3. Non-critical / Intermittent Service Rotary Equipment

For intermittent services, sparing philosophy shall be decided with Owner on case
to case basis.
9.1.4. OSBL Critical Packages
Common OSBL facilities may have installations that serve many units where
discontinuity or disruption can have economic repercussions and may also create
safety issues at other parts of the complex. Such packages, for example Power
and Steam Generation systems, Air Compression system and similar installations
are typically planned with one spare module to ensure continuity of supply during
outage or maintenance. Within other specific
packages, for example ETP and Nitrogen Generation system, sparing will be
provided at sub-assembly level rather than the entire unit.
Examples cited above are illustrative rather than being exhaustive. OSBL DEC is
responsible for evaluating and advising Owner of scenarios where sparing of
facilities are recommended for reliable and uninterrupted plant operation.
9.1.5. Hydrogen Service Definition
Hydrogen Service is defined as a process stream with a hydrogen partial pressure
of 100 psia (7 kg/cm2a) or greater, or service containing 90% mole hydrogen or
higher at any pressure level.
Equipment Overdesign
Equipment shall be sized for the highest of the following:
1. Percentage higher flow above controlling case steady state flow rate on PFD
or Heat and Material Balance recommended by Licensor for equipment sizing.
2. 10% higher flow above controlling case steady state flow rate on PFD or Heat
and Material Balance, where controlling case is for current operation.
3. 5% higher flow above controlling case steady state flow rate on PFD or Heat
and Material Balance, where controlling case is for future operation.
4. Percentage higher flow above controlling case steady state flow on PFD or
Heat and Material Balance recommended by empowered Owner
representative If this percentage is higher than alternatives above, the
justification shall be documented.

Equipment & Utility Header Isolation

9.3.1. Battery Limit Isolation
Battery limit isolation valves shall be provided at each ISBL interface at battery
limit. Arrangement of these valves shall permit safe isolation, depressurisation /
draining, inertisation of associated ISBL network without interrupting OSBL
network operation. Typically, these assemblies can include isolation valves at
either end, spectacle blind for positive isolation, and drain valve at plant end.
Number of valves at battery limit manifold will be rationalised depending on the
properties of fluid, availability of additional valve inside plant (for example for
meter isolation) and based on size of valve.
Table 9.2 – Battery Limit Isolation Valve manifold
SERVICE Block Vent Drain Warm-up Schematic
Valve Valve Valve Valve
Sea Water Single No Yes No B
Desalinated Water Single No Yes No B
Cooling Water Single No Yes No B
Cooling Tower Make-up Single No Yes No B
water
Demineralized Water Single No Yes No B
HHP Boiler Feed Water Double No Yes No A
HP Boiler Feed Water Double No Yes No A
MP Boiler Feed Water Single No Yes No B
LP Boiler Feed Water Single No Yes No B
Potable Water Single No Yes No B
Fire Water Single No Yes No B
HHP Steam Double No Yes Yes G
HP Steam Double No Yes Yes G
MP Steam Single No Yes Yes H
LP Steam Single No Yes Yes H
HP Condensate Double No Yes No A
MP Condensate Single No Yes No B

LP Condensate Single No Yes No B

Cold Condensate Single No Yes No B
Fuel Gas Double Yes No No E
Plant Air Single Yes No No F
Instrument Air Single Yes No No F
Nitrogen Single Yes No No F
Flare Singe Yes No No F
Lean Amine Single No Yes No B
Rich Amine Double No Yes No A
Sour Water Single No Yes No B
Hydrocarbon Double Yes Yes No C
Figure 9.2 – Battery Limit Isolation Valve manifold schematics
Note-1: See section 9.3.3 requiring provision of double valve on each side of a
blind for higher pressure piping (900# rating and above; and 600# and above for
Hydrogen and Steam).
Note-2: Minimum size of drain valve at plant battery limits shall be 1½”. Note-3:
Minimum size of warm-up valve at plant battery limits shall be 2”.

9.3.2. Flare Header Battery Limit Isolation

For battery limit isolations where multiple units are connected to a single flare
header, special high integrity butterfly valves shall be used. For smaller size flare
headers, if gate valves are used then the valve shall be installed in stem down
position so that in case of mechanical failure, valve plug does not close the valve.
This requirement shall be clearly marked on Piping & Instrumentation Diagrams
by Contractor.
9.3.3. Heat Exchanger Isolation
All fouling service heat exchangers shall have isolation and bypass facility with in-
situ cleaning arrangements appropriate for the hydrocarbon service and should
be provided with shell and tube side block and bypass valves and piping.
Bypass arrangements are not required on cooling water side or if spare heat
exchanger is provided to facilitate cleaning. Isolation valves shall be provided on
supply and return cooling water lines of heat exchangers and shall be gate or
butterfly type as per piping specifications.
Flow control of cooling water to an exchanger is not desired. However, if design
considerations make it a must, the velocity through the tubes must not be less
than 1 m/sec even under turndown conditions.
Positive Isolation
Table 9.3 – Equipment and Piping Positive Isolation
Serial # Service
1 Refer iRPMS-ENGG-GUD-PS-009 “Isolation and Blinding of Equipment for
Maintenance” for requirement of services where positive isolation is required
and to Reliance Piping Material Specification for details on blinds, spades and
spacers.
2 Spectacle blinds or spade and spacers shall be provided for all lines connected
to process vessels except PSV inlet lines and instrument nozzles. Spacers shall
be located at vessel trims and piping layout shall allow spacer to be inserted and
removed, for instance, at column overheads.
3 For 900# rating and above piping and other services, where specified, double
block valves shall be considered for isolation.
4 Isolation valves shall be provided on heat exchanger inlet and outlet lines where
maintenance can be performed on the exchanger with unit operating.
Provide spectacle blinds at inlet and outlets where maintenance valves have
been provided in process and steam services.

9.3.4. Automatic Remote Isolation

In an emergency, rapid isolation of vessels or process plant is an effective means
of preventing loss of containment or limiting its size. Refer RPMS-ENGG-GUD-PS-
023 “Remotely Operated Shut-off Valves” for guidance. Some stipulations are
reproduced below for reference:
1. Automatic remote isolation valves shall be provided between process vessels
and pumps with mechanical seals, in the following applications. The closure
of these valves shall result in the automatic shutdown of the corresponding
pumps.
 Upstream vessel/ tank inventory is 7.6 m3 or more of light hydrocarbons
(C5 and lighter)
 Upstream vessel/ tank inventory is 50 m3 or more of liquid hydrocarbons
(naphtha / C6 and heavier) in order to isolate large inventories where
pump seal failure could result in large uncontrollable releases.
 Suction and discharge of conventional centrifugal pumps in toxic service.
 Where vessel contents are at temperatures higher than the auto-ignition
temperature or at temperatures above 316ºC (600ºF).
Activation of these valves should be also possible from field by hand switch
located at safe distance (15 m) from the pump. Also, these valves should have
manual reset. For critical pumps DCS activation may be provided.
2. Automatic remote isolation valves are to be provided for non-pumped
systems where hydrocarbon inventories meet criteria specified above.
3. Automatic remote shutdown should also be considered in applications
identified below and decided on a case to case basis (over and above API 553).
Where equipment contain highly toxic material
At the battery limits for pipelines containing highly toxic materials
To reduce consequences of a fire in compressor area, ROSOVs are required to be
installed in the suction and discharge of any compressor with a power higher than
or equal 150 kW and handling flammable or toxic gases.
For compressor power ratings below 150 kW, provision of ROSOVs is to be
decided on a case-to-case basis with reference to Licensor recommendations.
At the inlet and outlet of highly exothermic reactors
Where risk of line failure is assessed to be higher than normal (judgment based
on experience)

Automatic Remote isolation valves should be specified as fire safe and with
leakage class VI (TSO). Refer RPMS-ENGG-SPC-CI-006 “Standard Specification for
Isolation / Shutdown Valves”.
Equipment Maintenance Facilities
Refer RPMS-ENGG-DBD-PP-003 “Design Basis for Plant Layout and Piping”,
Section
15.1.3.4 for requirement of davits, EOTs, lifting beam and hooks.
Determination of Design Temperature and Pressure
The design internal pressure is set such that relief devices will activate only in
emergency conditions and such that the relief devices will have adequate blow
down margin. The design external pressure is set such that vacuum breaking
devices are not required or such that vacuum relief devices will have adequate
pressure drop to provide protection.
9.5.1. Design Internal Pressure
Table 9.4 – Equipment Design Pressure
Service Design Pressure
Pressure Vessel
(General Service) As per Table 9.5
Pressure Vessel If not protected by relief valve at lower pressure, then

higher of the following:
(C3 and higher)
[1] Vapour pressure at maximum ambient temperature,
+ margin as per Table 9.5
[2] Vapour pressure at 55 ºC
Pump Discharge [1] Maximum Suction Pressure [A] + Maximum Differential
Pressure [B], where:
[A] = Suction Vessel PSV set point +
Suction Vessel Internals pressure drop +
Maximum Static Head pressure at HLL
[B] = Pump shutoff head @maximum specific gravity
Compressor Discharge At least 110% of maximum operating pressure or
maximum operating pressure + 1.8 kg/cm2 (25 psi).
However, this is often set as casing design pressure as
per vendor, exceeding minimum criteria stated.

Note-1: When vendor pump curves not available, consider 127% head rise to
shut-off (120% head rise to shut-off and 3% frequency variation) for motor driven
pumps, 140% for vertical sump pumps and 130% for turbine driven pumps
Table 9.5 – Systems Design Pressure
Operating Pressure Design Pressure
Vacuum to 1.8 kg/cm2g (25 psig) Typically 3.5 kg/cm2g (50 psig)
1.8 to 17.6 kg/cm2g (25 to 250 psig) Max. Operating Pressure + 1.8 kg/cm2 (25 psi)
17.6 to 35.2 kg/cm2g (250 to (500 psig) Max. Operating Pressure x 1.1
35.2 to 70.3 kg/cm2g (500 to 1000 psig) Max. Operating Pressure + 3.5 kg/cm2 (50 psi)
Over 70.3 kg/cm2g (1000 psig) Max. Operating Pressure x 1.05
Note-1: For column overheads systems, reflux drum relief valves shall be sized
for vessel fire case and design pressure set high enough so that relief valves
remain seated when column relief valves, protecting the entire system for other
cases, operate at full accumulation and impose additionally the full static head of
the flooded condenser from condenser relief valve to the reflux drum relief valve.
Note-2: Margins in Table 9.5 are based on typical relief valve blowdowns /
simmer. The design intent is to ensure that reseating pressure and simmer
pressure of the relief valve is higher than the vessel maximum pressure in its
normal operation mode. Some relief valves may have higher blowdowns and
require additional margin. On the other hand, pilot relief valves have small
blowdown and require lower margin.
It may be required to design with additional margin between operating and
design pressure to minimize the likelihood of a relief valve opening if the fluid
handled is toxic or produces a disposal problem when relieved.
Increasing equipment design pressure (for example to 5.3 kg/cm2g for low
pressure equipment), may involve incremental cost escalation for many
equipment, (controlling case may be wind load / earthquake), but can reduce the
size of the corresponding PSV and associated relief system.
This is especially important in cases where new plant PSVs will discharge into
existing flare network. Option of raising design pressure of low-pressure
equipment shall be compared against the option of running a separate low-

pressure header to the OSBL KOD or near the OSBL KOD. Judgment will be
exercised in these cases.
9.5.2. Design Temperature
Stipulations in this section shall apply where Licensor or Basic Engineering
Contractor criteria do not override. The maximum design temperature
determines the maximum allowable stress to be used for mechanical design of
equipment. For temperatures up to 343ºC (650ºF), the Design Temperature shall
be 28ºC (50ºF) plus the coincidental temperature at the Design Pressure. A lower
margin of, say 14ºC can be considered if the higher margin results in change in
material of construction.
For temperatures beyond 343ºC (650ºF), the Design Temperature shall be 14ºC
(25ºF) plus the coincidental temperature at the Design Pressure.
If temperature for a process upset scenario exceeds the maximum operating
temperature plus 28ºC (50ºF), additional margin on the upset temperature is not
required to set Design Temperature.
If tube skin temperature exceeds shell side design temperature, Design
Temperature must be specified considering tube skin temperature plus 28ºC.
For equipment under the purview of PESO, the minimum Design Temperature on
the positive side shall not be less than 65ºC.
9.5.3. Minimum Design Metal Temperature (MDMT)
Stipulations in this section shall apply where Licensor or Basic Engineering
Contractor criteria do not override. The minimum design metal temperature for
new design units is the most stringent of the following:
Minimum ambient design temperature
The minimum operating temperature less 5.6°C (10°F).
The minimum equipment temperature caused by upset condition/ depressuring
down to the constant superimposed back pressure of the flare header.
In many cases (e.g. systems containing light hydrocarbons) the MDMT will likely
be controlled by the depressuring criteria. The 5.6°C (10°F) margin is not applied
to the minimum design metal temperature for depressuring.
Under conditions of depressuring, equipment integrity needs to be ensured only
for the maximum superimposed back pressure under conditions of depressuring
without any reference to normal operating pressure inside the item of equipment
(refer API RP 579 – Fitness for service).

9.5.4. Vacuum design

Vacuum design is specified for equipment that normally operate under vacuum
conditions, or is subjected to vacuum during startup, shutdown and regeneration
operation, from loss of a heat source in condensing systems, or from failure of
blanket gas controls.
Vacuum design is also specified for vessels which normally operate liquid full at
elevated temperature, which can cool down while blocked in, and for
fractionators and associated equipment that can undergo vacuum condition
because of loss of heat input.
Steam condensers, steam reboilers or heaters, condensate pots, direct steam
injection equipment shall be designed for full vacuum.
Columns and vessels subjected to steam out shall be designed for 0.175 kg/cm2
external pressure at 150°C consistent with Owner standard operating practice.
Where it is impractical to design low pressure equipment to accommodate
vacuum conditions, (e.g. atmospheric tanks), equipment will be protected by
blanketing with air or nitrogen and providing vacuum relief.
Distillation columns and associated equipment for lighter hydrocarbons (upto
C4’s) should be designed for half vacuum condition instead of full vacuum.
Strippers containing water and light hydrocarbon to be designed for full vacuum.
Distillation column with partial condensation may be designed for half vacuum.
Material of Construction
Primary metallurgy for items of hardware exposed to process fluids shall be
advised by the Licensor / BEC through Material Selection Diagram (MSD) and
individual data sheets and P&IDs. These will be further elaborated and specified
in detail with exact material grades by Contractor. Metallurgy and corrosion
allowance will be specified considering equipment and piping system life
specified in Section 10.
9.6.1. Corrosion allowances
Licensor recommendations will serve as the starting point for fixing corrosion
allowances.
Static equipment

Table 9.6 – Equipment Corrosion Allowance (CA) for body and fixed internals
Material Minimum CA
Carbon Steel / LAS up to 2¼ % Cr 3.0 mm
Low Alloy Steel above 2¼ % Cr and up to 9 % Cr 3.0 mm
Stainless Steel (Non-Corrosive) (Austenitic & Duplex SS) Nil
Stainless Steel (Corrosive) (Ferritic, Martensitic, PH grades SS) 1.5 mm
Cladded equipment
Minimum cladding thickness is 3 mm. If equipment is overlaid, undiluted
thickness of weld overlay is considered as CA, minimum 3 mm. Strip lining clad is
not permitted.
Storage Tanks
For storage tanks corrosion allowance shall be considered as 1.5 mm for shell and
bottom. For roof, corrosion allowance shall be considered as 1 mm.
Process Piping
Table 9.7 – Piping Corrosion Allowance
Material Environment Minimum CA
Non-corrosive 1.6mm/0.063
inch
Mildly corrosive (Hydrocarbons, Steam) 1.6mm/0.063
inch
Carbon Steel Moderately corrosive (Amines, Caustic, Wet 3.175mm/0.125
Sour Gas, Sour Water) inch
Highly corrosive 6.35mm/0.250
inch
Mildly corrosive 1.6mm/0.063
inch
Low Alloy Steel
(up to 9% Cr) Moderately and highly corrosive 3.175mm/0.125
inch
Stainless Steel Non-corrosive (Austenitic & Duplex SS) 1.6mm/0.063

(11% Cr and Corrosive (Ferritic, Martensitic, PH grades SS) inch
1.6mm/0.063
above) inch
Equipment Design Guidelines

9.7.1. Vessels and Columns

Process requirements
Owner requirements for minimum residence time for vessel sizing are specified
in Table-
Normal residence times correspond to operating volume between high and low
liquid levels (HL and LL). Tripping residence times correspond to working volumes
between high and high-high (HL and HHL) and between low and low-low (LL and
LLL) liquid levels. Licensor or Contractor may adopt higher residence times, as
warranted by their own design and operational requirements. These values are
applicable for new design. For revamp case, due to increase in plant capacity,
actual residence time may decrease and will need to be reviewed on case to case
basis.
Table 9.8 – Vessel Residence Times
Service Residence time
Unit Feed Surge Drum [HL-LL] 15 minutes
Distillation Tower Feed [HL-LL] 10 minutes
Overhead Accumulators [HL-LL] 5 minutes
Pumped Product to Storage [HL-LL] 2 minutes
Low level trip [LL-LLL] 2 minutes
High level trip [HL-HHL] 2 minutes
Separators
For separators, review shall be done on a case by case basis for acceptable liquid
holdup and vapour / liquid disengaging space.
Sizing and rating
Proven rating calculation methods shall be used, that can include commercial
software like PV-Elite or Compress, and results documented and checked and
verified.
Vessel diameter shall be specified on ID basis.
Liquid drop legs (draw-off boots) on horizontal vessels will conform to the
following:
If vessel is lined and the drop leg diameter ≥ 30”, the drop leg will be internally
lined and welded to the vessel.

If vessel is unlined, the drop leg will be unlined and welded to the vessel
regardless of the drop leg diameter.
Mechanical design
The design and construction of pressure vessels, columns and reactors shall
follow ASME Section VIII Div I or Div 2.
PESO SMPV rules shall also be complied.
Boilers and other steam equipment shall be designed as per IBR.
Equipment foundations shall be typically designed for water filled condition
unless specifically stated otherwise in the datasheet or Civil / Structural design
basis / guideline.
Manways
On unlined horizontal vessels, a manway will be provided on the side of the vessel
at or below the horizontal centerline. Where there is one or more partition plates
/ baffles inside a vessel, multiple manways shall be provided.
If bottom half of the vessel is lined, the manway shall be located on the upper
side or top of the vessel unless specifically required.
On vertical vessels or horizontal vessels over 3m in tangential length, a blanked-
off 8” ventilation nozzle shall be provided on top of the vessel near the end
opposite the manway. On horizontal vessels over 6m in tangential length, two
manways will be considered, one manway on elliptical head and the other at the
top of vessel at the opposite end to the first manhole.
Manway sizes shall be as follows:
Vessel dia 900 mm to 1500 mm 20” NB [488 mm ID]
Vessel dia above 1500 mm 24” NB
Larger manway sizes shall be specified as required to accommodate internals.
If access is not required to the inside of a vessel of diameter < 900 mm, a hand
hole (8’’) may be provided instead of body flange. For column of diameter <
900mm, intermediate body flanges shall be provided.
Nozzles
Connections on pressure vessels shall be flanged, unless welded construction is
preferred for reasons of safety. Threaded connections are not permitted.
For cladded vessels, min nozzle ID for 2” nozzles shall be at least same as 2” Sch
160 and to achieve that, all nozzles of 2” size shall be LWN type. Nozzles of size
below 2” shall not be used for cladded vessels.

The minimum flange rating for instrument nozzles shall be 300#.

Minimum size of nozzles on equipment/vessels should be 1½”.
Vessels and columns should be provided with at least two level measuring
instruments. For reboiler condensate pots, single LT is adequate.
Column and vessels level transmitter to be provided with condensate pot on LP
tapping if operating temperature > ambient, to prevent vapor condensation in
the LP line. Alternately, diaphragm seal type transmitters can be used.
Below table specifies the recommended nozzle sizes. Licensor or Contractor may
adopt higher nozzle sizes, as warranted by their own design and operational
requirements.
Table 9.9 – Steam-out, vent and drain nozzles
Vessel Vol, m3 Drain Vent Steam-out Nozzle
Up to 6 m3 1½” NB 2” NB 2” NB
6.1 to 15 m3 2” NB 2” NB 2” NB
Above 15 m3 3” NB 2” NB 2” NB
Column > 2.5 m 3” NB 4” NB 2” NB
diameter
Column > 5 m 3” NB 6” NB 3” NB
9.7.2. Trays and packing

Fractionation specification will be agreed in design basis kick off meetings
Maximum jet flooding shall be ≤ 80% of flood. Downcomer clear liquid backup ≤
45% and choke flood ≤ 75%. These shall be reviewed on a case by case depending
on the type of trays / packings involved.
Type of trays specified for fractionation service: sieve trays, valve trays or packing
will be based on process considerations. Three pass and four pass trays are
specified where deemed appropriate. Where recommended by Licensor,
economics of installing MD (multi-downcomer trays) or other high capacity trays
may be studied for an application; but these are typically used for revamp
projects only.
Packed column shall have differential pressure indicator across each bed of
packing, feed and reflux lines to packed columns shall be provided with duplex
strainers.
All distillation columns shall have PDT indication either through separate
standard and properly calibrated PT at top and bottom of the column for practical
reasons or a DPT across the trayed sections / packing sections.

Sizing and rating

Proven rating calculations shall be used, documented and checked and verified.
Fractionator trays are generally designed for the same turndown as indicated
for the process unit. However, in some services, reflux rates and reboiler duties
may not be turned down in proportion to the unit turndown when tray loadings
are required to be kept higher to maintain desired mass transfer efficiency.
Trays are numbered from top to bottom.
Mechanical design
Trays of diameter less than 900 mm shall be of cartridge design.
Removable tower internals shall conform to minimum thicknesses and corrosion
allowances as per Table 9.10, superseding Table 9.6. MOC of removable column
internals shall be as specified by Licensor or BEC and may exceed values tabulated
based on design (for e.g. considering liquid loading, vapour up-thrust, or if the
self-weight of large diameter trays sections or internals cannot be adequately
supported with reinforcement pads with lower thickness trays). This will be
finalized based on input from tray supplier.
Table 9.10 – Removable Tower Internals Thicknesses and Corrosion Allowances

Min Min Thickness Min Total CA Min Total
Thickness * CA
*
Removable Sections Carbon Alloy Steel Carbon Steel Alloy Steel
Steel
*** ****
Decks & Downcomers 10 (3.57 14 (1.98 mm) 1/32” (0.8mm) None
mm)
Integral Beams & 10 (3.57 14 (1.98 mm) 1/32” (0.8mm) None
Separate Minor Beams mm)
Major Beams & Trusses 7 (4.76 10 (3.57 mm) 1 x Vessel CA None

mm)
Contacting Devices (Caps 14 (1.98 16 (1.59 mm) None None
& Valves) mm)
**
**
Piping & Pipe Std Weight 10S 1/32” (0.8mm) None
Distributors
* US Standard Gage

** Seller’s standard may be proposed for Owner / Buyer approval

*** CS trays are typically used in non-corrosive and non-fouling applications (eg
Naphtha Splitters). SS 410 valves are preferred with CS trays for durability
and operating range.
**** SS 410 trays and tray valves are typically used for corrosive and fouling
services such as amine and fluids containing H2S. Packings may be SS 316L,
PP/PTFE or ceramic, as suited.
All fasteners should be of SS. Trays should be designed for minimum uplift force
of 150 kg/m2.
Manways
In trayed columns manways will be provided above top tray, below bottom tray,
at feed tray, at any other tray at which removable feed distributor or similar are
located which need periodic inspection or maintenance. Size of removable parts
of internals should not exceed the ID of manhole.
The maximum spacing of column manhole shall not to exceed 10 meters (or does
not exceed 20 numbers of trays). One manway 500 X 450 mm size per pass shall
be provided. When manway is not feasible split-tray shall be considered. Five
trays above and below two-phase feed shall be provided with locknuts and shall
be capable of withstanding a net pressure of min 450 kg/m2 as specified in RPMS-
ENGG-SPC-MS-008 “Standard Specification for Trays and Packing (Random and
Structured) for Process Vessels”.

9.7.3. Tankage
Fixed roof tanks shall be designed considering specific gravity of fluid stored as
0.9 minimum, if the specific gravity is lower, and test fluid specific gravity as 1.0
to allow for water fill test. Floating roof tanks, however, shall be designed at
actual product specific gravity, with a check case at 0.9 specific gravity. Nitrogen
or Fuel Gas blanketing is provided when storage temperature is more than the
flash point of the liquid stored to prevent air ingress in vapor space and formation
of flammable atmosphere. Nitrogen blanketing is also used for utility storage
tanks, where required.
Mechanical design
The design and construction of storage tank will conform to API 650 for
atmospheric storage tanks and API 620 for low pressure storage tanks.
Modification of tank shall conform to API 653.
Inbreathing, outbreathing and emergency vent requirements shall be
determined as per API-2000.
Gas-blanketed fixed and Internal roof tanks will be designed for 300 mmwc
pressure and 50 mmwc vacuum at the roof as standard, unless there are
compelling reasons to do otherwise. A pilot-operated blanketing system will be
provided. Typical set-points are recommended as below, which allow adequate
overpressure range for each device:
Inbreathing regulator 50 mmwc (2”)
Outbreathing regulator 120 mmwc (5”)
Pressure relief vent 200 mmwc (6”)
Emergency vent or hatch 270 mmwc (11”)
Design pressure 300 mmwc (12”)
Vacuum relief vent (-) 20 mmwc (3/4”)
Vacuum design (-) 50 mmwc (2”)
Shell Manways
The minimum number and size for API 650 tanks shall be:
Nominal Tank Diameter (m) Minimum Number and Size of Manways per
Tank 12 and less 1-24 inch
Over 12 to 45 2-24 inch - spaced 180 degrees apart

Over 61 4-24 inch - spaced 90 degrees apart

The minimum number and size for API 620 tanks shall be:
Nominal Tank Diameter (m) Minimum Number and Size of Manways per Tank
12 and less 1-24 inch and 1-20 inch –spaced 180 degree apart
Over 25 4-24 inch - spaced 90 degrees apart
Lightning Protection –
To protect a storage tank having external floating roof from Lightning and
subsequent fire hazard , option to have provision of Aluminium dome over
External Floating roof tanks , which makes the design inherently safer , shall be
reviewed on case to case basis.
9.7.4. Double wall tanks
For design of double walled cryogenic tanks reference is to be made to Standard
for Storage and Handling of Liquefied Natural Gas (LNG) – OISD 194, API 625 and
API 620 Appendix Q (for low pressure storage tanks). Preference is for full
containment design. Membrane design may also be considered.
9.7.5. Spheres and Bullets
Flanges shall be minimum 300# rating for LPG storage
PSV installation shall conform with OISD 144 and OISD 158
Common outlet/Inlet line shall be provided with 1.5° slope away from vessel and
a Remote Operated Valve (ROV) shall be provided at least 3 m away from the
shadow of the vessel. There shall be no flanged connection till ROV.
Mechanical design
Design Code – ASME Sec-VIII Div 2
OISD / PESO guidelines shall prevail
For H2S bearing or sour application, only SA 516 Gr 60 shall be used. For other
cases, MOC may be SA 516 Gr 70 or SA 537.
On pressure vessels, minimum nozzle size shall be 1½”

9.7.6. Shell and Tube Heat Exchangers

Licensor or Basic Engineering Contractor process datasheets and specifications
will usually apply fully. In all other cases, guidelines in this section will prevail.
Owner preference is for horizontal exchangers, single pass shell, floating head
tube bundle arranged with two or more tube passes per shell. Refer Table 9.12.
Tube pitch will be square or rotated square for fouling service on the shell side.
Tube pitch can be triangular if shell side fluid is non-fouling.
Double pipe or multitube type exchangers can be used in services where the
surface area is less than 10 m2 and shall be of non-removable type. Hairpin
(multitube type) may be used up to 50 m2.
Design with high LMTD is to be avoided to minimize potential of leakage or
bowing. The exact magnitude will be a function of exchanger type and
mechanical design.
Vertical thermosiphon, horizontal thermosiphon, or kettle type reboilers are
used where appropriate. Vertical thermosiphon reboilers may be used where
there is a process advantage and there is suitable access. For vertical
thermosiphon reboilers, the top tube sheet elevation should be set such that
tubes maintain desired boiling regime from turndown to turnup operation and
eliminate risk of tubes running dry.
Individual heat transfer coefficient for exchangers shall be < 12,000 Kcal/hr/m2-
ºC
Generally, CW side of exchangers are designed for vacuum. This includes header.
However , if the headers are not designed for vacuum , for exchangers located at
elevation higher than the CW return header distribution pipe, VRV to be provided
on exchanger outlet pipe
Also, for such exchangers located at higher elevations CW return header for
vertical gravity lines should be designed by taking Froude no. in consideration (
Froude no. = 0.3)
Refer RPMS-ENGG-GUD-PS-025 “Design Requirements for Cooling Water Heat
Exchangers” for details on CW Heat exchangers
Sizing and rating issues
Proven rating calculations shall be used, documented and checked and verified.
Refer recommended values of fouling factors as per Table 9.11, exchanger types
as per Table 9.12 (unless superseded by Licensor or BEC specification), tube side
velocities as per Table 9.13 and tube diameters as per Table 9.14.

Table 9.11 – Recommended heat exchanger type

Shell side FF Tube side FF
hr-m2-ºC/kcal hr-m2-ºC/kcal Type of exchanger
> 0.0002 > 0.0002 Floating head

< 0.0002 > 0.0002 Fixed tube sheet, if fluid is not hazardous
> 0.0002 < 0.0002 U tube bundle
< 0.0002 < 0.0002 Fixed tube sheet / U-tube
Table 9.12 – Recommended fouling factors

Fluid Fouling Factor [FF] hr-m2-ºC/kcal
Cooling Water 0.0003 for desalinated water make-up
0.0004 for river water make-up
Sea Water 0.0006
Steam 0.0001
Steam Condensate 0.0002
Hydrocarbon 0.0003 or higher for refinery streams 0.0003 or lower for
petrochemical streams
Table 9.13 Recommended tube side velocities

Fluid Min Max
Cooling Water 1.3 m/s at normal flow # Based on MOC
Residues, Heavy Oil 1.0 m/s at turndown
Slurry oil 1.5 m/s at turndown 2.3 m/s at turnup
#
For exchangers having Cooling water on Shell side , velocity range shall be 0.6 m/sec to 1.5
m/sec, preferred minimum being 0.9 m/sec.
Table 9.14 – Tube diameter based on fouling factors
Tube side FF hr-m2-ºC/kcal Tube OD
≥ 0.0004 25 mm
< 0.0004 20 mm, 25 mm
Preferred tube length for fixed tube sheet, ‘U’ tube or floating head type
exchanger is 6.0m. If economically justified, alternate tube lengths that may be
used are 15m, 12m, 9 m,4.5 m, 3 m. ‘U’ tube exchangers are not required to
strictly follow standard tube length.

Heat Recovery
Pinch technology should be used in order to maximize heat integration. Steam
generation and heat recovery facilities shall be incorporated based on process
and economic considerations. Typical 3 years straight line payback period criteria
shall be used for deciding heat recovery.
Thermal design
Thermal Design and rating of shell & tube heat exchangers shall be performed
using HTRI. Exchanger type shall be selected based on fluid allocation, fluid
phase, specified fouling, cleaning requirements and its intended application. HTRI
will be used to check for vibration screening. The version shall be per approved
project standards.
Mechanical design
Design and construction of heat exchangers will conform to TEMA, ASME Section
VIII Div 1, API 660 (latest section) and IBR.
For U-tube construction, stationary head shall be TEMA type B or C except when
Tube side medium is water. When ‘B’ head is used, the tube-sheet shall be full
Diameter type, with threaded holes that permits testing of shell side after
removing the stationary head.
Low pressure side of shell and tube heat exchanger (including upstream and
downstream systems) should be designed for 10/13th of the design pressure of
high pressure side. Where 10/13 criteria is not adopted for technical or economic
reasons, pressure relief valves will be installed for tube rupture case. Corrosion
allowance should be 3 mm minimum for carbon steel / low alloy steel (except for
tubes). Tube to tube-sheet joint should generally follow TEMA stipulations.
Tube Specifications shall be as per Table 9.15:
Table 9.15 – Tube specifications for shell & tube exchangers
Tube Material Tube OD (mm) Tube Wall IBR
Thickness Tube Wall thickness
CS or LAS 19.05 14 BWG (min) 2.03 mm (min)

CS or LAS 25.4 or higher 12 BWG (min) 2.03 mm (min)
SS or HAS 19.05 or higher 16 BWG (avg) 2.03 mm (min)
Non-Ferrous Alloys 19.05 or higher 16 BWG (avg) 2.03 mm (min)
Titanium 19.05 or higher 18 BWG (avg) 1.245 mm
Note: For exchangers subject to IBR regulations, tube standard of latest IBR shall
apply. Values indicated above are current. For U-tube bundles, inner tubes may
need to be thicker to ensure bend thickness is adequate.

Nozzles
Miscellaneous nozzles shall be provided for heat exchangers as follows:
 Multipurpose connections 40 NB
 1½” vent and drain nozzles, located on shell side at the end opposite to
inlet and outlet nozzles, and on tube side on channel cover at opposite
end wherever applicable. Separate shell side vent and drain for vertical
exchangers through tapped threaded bore holes in tube sheet.
 Thermowells on connected piping at inlet and outlet of shell and tube
sides, and only at outlet for cooling water side.
 Drain valve on cooling water supply line downstream of isolation valve for
back- flushing or chemical cleaning.
Note 1: Drain valve same as line size up to 3”,

and of 3” size for higher.
Note 2: Valve will be butterfly type as per PMS

9.7.7. Air Cooled Heat Exchangers

Air Cooling shall be maximized.
Only air cooling shall be used when cooling a process stream to 55ºC or higher.
When cooling a process stream to below 55ºC, air cooling shall be followed by
water cooling with a break point of 55ºC. This shall be evaluated based on
economics.
Sizing and rating issues
Thermal design shall be carried out using HTRI or other software approved by
Owner or Buyer. Rating calculations shall be used, documented and verified.
Forced draft type fan to be provided for all applications except special
applications in corrosive environment or for cryogenic service. For example,
exhausting sour vapours from a tank, where induced draft type fan is preferred.
Draft type shall be indicated on datasheets.
Mechanical design
Tube specifications shall be as per API 661, reproduced in Table 9.16:
Table 9.16 – Tube specifications for air-cooled exchangers
Material Tube OD, mm Tube thk
CS or LAS (max 9% chromium) 25.4 (minimum)
2.11 mm
HAS (austenitic, ferritic and duplex 25. 1.65 mm
Non-ferrous material 25.4 1.65 mm
Titanium 25. 1.24 mm
Note: for embedded fin tubes, this thickness shall be measured from the bottom
of the groove to the inner wall
Fin material shall be Aluminium up to tube wall temperature 400ºC and welded
CS for tube wall temperature > 400ºC. Aluminium fins shall be (a) Extruded up to
288ºC (b) Embedded up to 400ºC.
Aluminium or FRP blades shall be used. Design to appropriately take into account
static electricity concerns.
If process temperature control is required or is critical, auto-variable pitch fans
or VFD driven motors or louvers may be specified. Electric motors for air cooled
heat exchangers may be direct-on-line type starters or VFD driven. For large air-
coolers typically one third of the fans (minimum 1 per bay) are fitted with VSDs.
These have good payouts as these make possible significant energy savings. VSDs

or dual speed motors can be considered for more number of fans individually on
merit. Variable pitch fans do not lead to energy savings though these may be
cheaper.
An economic evaluation may be carried out to make the final decision.
Noise limits and criteria shall be as per section 11.11.3.
Refer RPMS-ENGG-SPC-MS-001 “Mechanical Specification for Design and
Fabrication of Air-Cooled Heat Exchangers” for details.

9.7.8. Heaters
Process requirements and sizing and rating issues
Efficiency
Reasonably attainable heater efficiencies vary with service, size of heater and
quality of fuel. Based on the net heating value of fuel, the typical minimum target
fuel efficiency is 92%-93% with air preheat and 90%-91% with steam generation
for continuous operating heaters. The basis for this fuel efficiency is 15% excess
air for oil firing and 10% excess air for gas firing for the design case. Refer Table
9.17 for indicative hardware. Efficiency figures may vary based on several factors
and for a particular application, heater supplier will if efficiency improvement
measures suggested are not justified in specific cases.
Table 9.17 – Indicative hardware requirements for fired heaters
Sl # System Component >50 MMKcal/hr 5 – 50 < 5 MMKcal/hr
MMKcal/hr
ID fan Yes As per
economics
1 No
(Note-1)
FD fan Yes As per
economics
2 No
(Note-1)
3 VFD on FD fan (Note-2) Yes No No
4 VFD on ID fan No No No
5 Excess air (Note-3) 10%-15 % 10%-15% 15%-20%
6 O2 analyser at arch Yes Yes Yes
7 CO analyser at arch Yes Yes No
Automatic – acting Automatic – Manual – on

on stack damper acting on stack stack damper
8 Draft control
damper
Automatic – acting Automatic or
on VFD on FD fan Manual (Note-4)
9 O2 control Manual control

10 Air Preheater on Flue Gas Yes As per

economics
No
(Note-1)
11 Air Preheater on Flue Gas Yes No No
and u/s Steam
12 MOC for flue gas APH Usually Cast Iron As per design Not applicable
for all modules;
Optionally superior
MOC (eg. glass) for
acid corrosion
Note-1: ID / FD fans and APH may be uneconomical for heat duties < 10
MMKcal/hr
Note-2: Two fans, both on part load to avoid potential fuel rich condition in case
one fan trips
Note-3: For sizing of heater, associated fans, ducting and air preheaters, higher
level of excess air shall be considered (25% for oil firing and 15% for gas firing)
Note-4: Automatic for heater duties ≥ 10 MMKcal/hr, Manual for duties < 10
MMKcal/hr
Combustion monitoring at arch, Oxygen analyzer at stack (target minimum 1.7%
for gas firing and 2.5% for oil firing).
Steam Generation
Steam Generation in process heater convections is considered as indirect steam
generation, operating continuously for 2 years at a time.
Preheater type
Recuperative (stationary) type air preheater is normally used.
Combustion Air
Combustion air is to be supplied by a fan even when air preheater is bypassed.
Fan failure will result in shutdown of the heater.
A spare combustion air fan is specified (Refer Note-2 above).
Cold air bypass is provided for stack temperature control and for heater
operation at 100% of normal duty with air preheater bypassed.

Draft
A spare induced draft fan is not specified because the stack is considered to serve
the purpose of a spare. If the induced draft fan fails, the air preheater bypass will
open to divert flue gas to the stack.
NOx Emissions
Low NOx staged air burners are used for oil firing and Low NOx staged fuel
burners are used for gas firing. Maximum NOx emission shall be as per Indian
statutory regulations.
Soot Blowers
Retractable soot blowers are installed in convection coils wherever fuel oil firing
or dual firing facility is configured. MP Steam is used as the mobile carrier.
For gas fired heaters, space provisions may be kept for future installation of
methods to clean convection sections. Snuffing steam and emergency door shall
be provided for emergencies. A check shall be performed for design integrity of
convection section with dry process side conditions.
9.7.9. Rotating Equipment
9.7.9.1. Drives for critical rotary equipment
Critical service steam- or power-driven equipment is defined as equipment in a
service that must be maintained in the event of a power failure to protect
personnel, equipment, or catalyst.
Critical equipment should be motor-driven, with turbine-driven spare, unless
steam balance demands an extraction turbine for the main drive to avoid steam
let down.
Note– choice of power versus steam for large drives, or critical drives such as
shaft- mounted lube pumps – shall be determined for a site depending on
reliability of electric power versus steam.
Firewater pumps are 50% motor driven and 50% diesel engine driven.

9.7.10. Pumps
Shutoff Head: Shutoff head of pump will be at least 105 % of rated point for single
operation and 110 % of rated point for parallel operation, to the extent possible.
Shutoff head of centrifugal pump is to be preferably limited to 120 % of head at
rated point.
In general, following minimum overdesign margins are recommended, which
may be superseded by Licensor or BEC requirements, pre-investment decisions
or similar:
- 10% over maximum flow for transfer pumps
- 20% over maximum flow for reflux pumps
Minimum Continuous Flow: there are two definitions:
Min continuous stable flow: Lowest flow at which the pump can operate without
exceeding vibration limits imposed by the applicable specification.
Min continuous thermal flow: Lowest flow at which the pump can operate
without its operation being impaired by the temperature rise of the pumped
liquid due to internal recirculation of the liquid and /or energy from driver
converted to heat of the liquid inside the pump. This is generally experienced in
high energy pumps.
Pump circuit design shall account for satisfactory operation at both minimum
continuous flow cases.
NPSH: NPSHr shall be lower than NPSHa by at least 1m for normal service and 2m
for fluids with dissolved gases, throughout the range from minimum continuous
stable flow to rated capacity unless specified otherwise.
NPSHa shall be referenced to the bottom of the base frame for horizontal pumps,
the suction nozzle centre line for vertical pumps, and top of the foundation for
vertically suspended pumps.
Mechanical design requirements
In general, the centrifugal pumps should be selected from following four
categories:
A. API pumps
B. Non-API pumps
C. Specially engineered pumps
D. Seal-less pumps

A. API pumps:
API pumps should be selected for the following applications or conditions:
 All pumps in hydrocarbon processing plants. This would include pumps in
non-hazardous services such as phenolic water, wash water and similar.
 Pumps with high safety criticality. Failure or breakdown of the pump or its
components could result in serious hazard to personnel, plant or
environment. Examples of such service include concentrated acids, liquid
containing H2S, and liquids at and above auto ignition temperature.
 Pumps with high criticality with respect to reliability and availability. Failure
or breakdown of the pump would result in significant production loss.
Examples of such service are high pressure coke-cutting pumps, boiler feed
water pumps and coker charge pumps.
 API pumps shall conform to API 610 (latest edition) requirements.
B. Non-API pumps:
Non-API pumps should be selected for the following applications or
conditions:
 Centrifugal pumps in non-critical services in chemical plants
 Cooling tower pumps, firewater, seawater, wastewater treatment
applications, fresh water, reverse osmosis plant, Sodium Carbonate,
chemical effluents (mixture of alkaline and acidic liquids) or similar
C. Specially engineered pumps:
Specially engineered pumps should be selected for the following services or
conditions:
 Services which require additional engineering inputs beyond those in API
specifications. An example would be Coker Charge pumps with special
features like auger type coke crusher.
 Pumps in slurry applications. Pumps should be designed for slurry service
if the content of solid particles exceeds 20% by volume. These should be
selected from standard and proven designs of vendors who have designed
and developed these pumps for specific applications. Examples of such
services are PTA slurry, FCCU Column Bottoms, Coker plant Recirculation,
Coker maze pit, and similar.
D. Seal-less pumps
Seal-less centrifugal pumps are selected for services where, in view of safety
considerations, no leakage is permitted from the shaft-casing interface. Seal-

less pumps can be either “canned motor pumps” or “magnetic drive pumps”.
Canned motor pumps are used where safety of the highest level is required
and leakage has to be zero.
Typical seal-less pump services cover a broad range of fluids that include acids,
alkalis, salts, corrosive fluids, esters, hydrocarbons, monomers, polymers,
alcohols, ethers, halogens, nitrogen or sulfur compounds and some extreme
conditions for water.
Seal-less pumps should conform to API 685. Pumps will be normally unsheltered.
Start-upline: All pumps shall have start up bypass through restriction orifice for
testing. Refer Schematic-A and -B.
Suction line sizing: For continuous duty pumps, pump common suction line shall
be sized for flows corresponding to rated capacity of operating pumps plus
minimum flow capacity for standby pumps. This facilitates online testing of the
standby pump without disturbing the process flow.
Minimum recirculation line:
 If driver motor power is greater than 15 kW, control valve with controller
shall be used. Refer Schematic-A.
 If driver motor power is less than 15 kW, Restriction Orifice with Globe
valve shall be used. Refer Schematic-B.
 For low capacity pumps, this may be reviewed case to case basis.
 For reflux pumps, with FO type control valve in reflux line and FC type
control valve in product drawoff line, blocked discharge case does not
apply. In such cases, minimum recycle line through control valve need not
be provided, if either of the above-mentioned flows are higher than the
pump minimum circulation flow.

Minimum Flow Bypass – Schematic A Minimum Flow Bypass – Schematic B
Consider routing pump casing vent lines from pump casing or discharge piping,
whichever forms highest point, to the upstream suction vessel.
Motor Ratings: Motor power ratings will account for service factor, if any, as
below:
 For pumps with rated power < 22kW, motors shall be sized for at least
125% of the rated power requirement.
 For pumps with rated power ≥ 22 kW and for parallel operation or on
auto- start, motor power shall be at least equal to “end of curve” power
requirement of the pump at selected impeller size, or 115% of the pump
power at rated conditions, whichever is higher.
 For revamps, minimum motor margin should be as per API 610.
Pump Seals: The general practice is to provide:
 Double mechanical or tandem seal for flammable hydrocarbon and toxic
service as well as hazardous non-hydrocarbon services
 Single mechanical seal for non-hazardous non-hydrocarbon services
Refer RPMS-ENGG-SPC-MR-003 “Specification for shaft sealing systems for
Centrifugal and Rotary Pumps”.
9.7.11. Compressors
Design margin over highest operating flow shall be based on licensor
requirements, or pre investment decisions.

Mechanical design requirements

Centrifugal and axial compressors shall conform to API Standard 617. Driver
selection will be evaluated for each application based upon process
requirements, critical service, utilities, capital costs and appropriate shop test for
axial or centrifugal compressors.
Reciprocating compressor services in Process service shall conform to API
Standard 618. There will be sufficient spare capacity to permit maintenance of
one machine while the plant remains on-stream. Motor drivers will normally be
specified.
Screw compressors will be specified in special instances when determined to be
advantageous over alternate choices. Screw compressors shall conform to API
Standard 619. Driver selection will be as indicated for centrifugal and axial
compressors.
Refer RPMS-ENGG-SPC-MR-022 “Guidelines for online condition monitoring of
Rotating Equipment”.
Instrumentation
Instrumentation shall in general comply with RPMS-ENGG-DBD-CI-001
“Instrumentation Engineering Design Basis” and as per specifications enclosed
with a given material requisition.
Redundancy of trip sensors and actuators:
Requirement of trip sensors and final control element is determined in SIL level
assessment study conducted with HAZOP for any process unit. General guidelines
are:
Switches will not be used as sensors for any alarm or trip action. Transmitters will
be used for the same.
SIL1 : 1 sensor and 1 final control element
SIL2 : 3 sensors on 2oo3 and 1 final control element with or without PST
SIL3 : 3 sensors on 2oo3 and 2 final control element with PST
For machine related trips, the requirement of redundancy in trip sensors shall be
covered in accordance with RPMS-ENGG-SPC-MR-022.
Closed Couple hookups (CCH):
1. CCH shall be implemented for clean services up to design temperature of 200
ºC.
2. CCH shall be selected for installation of PG, PT, DP transmitters and DP type
flow transmitters

3. CCH shall not be used for toxic, cryogenic or steam services

4. MOC compatibility shall be checked for lined pipe classes during selection of
CCH
5. Requirement of CCH will be depicted in P&ID either at basic engineering stage
or the first revision at detailed engineering stage. Legend drawings to indicate
accordingly.
6. CCH shall not be used for services requiring double isolation valve
arrangement such as high-pressure systems ≥ 600#. Conventional root valves
to be used in such systems.
7. CCH root valves are in CCH vendor scope; no additional valves to be shown in
P&ID.
8. CCH shall be accessible by permanent platform
9. For orifice plates for flow measurement, conventional mounting assembly
will be used as a default, unless the model review confirms accessibility of the
isolation valve.
10. Refer RPMS-ENGG-DBD-CI-010 “Design Basis Document for Closed Hook-
ups”.
9.8.1. General Requirements for Instrumentation on Process P&IDs
 P&ID symbols shall be as per ISA and as specified for a project
 Sensor / transmitter for shutdowns are separate from control / indication
 Solenoid valve operation with interlock shutdown system only
 Hand switches and status indication shall not be only in DCS
 Emergency / bypass switches shall be hardwired only
 Shutdown signals shall be repeated in DCS
 Analog inputs for shutdown and interlocks shall be connected directly to
ESD without use of receiver switch or trip amplifier.
 Instruments shall have individual tappings from process lines except flow
measurement using orifice as a flow element, wherein two pair of tapping
shall be used for 4 transmitters (3 for shutdown and 1 for control).
 Remote stop push button shall be hard wired only
 Rotating equipment with auto start facility shall have local auto-manual
switch
 Indication of continuously running equipment on DCS

 Block and bypass valves to be provided for turbine meters, PD meters and
mass flow meters
 2oo3 voting is required for critical trip interlocks
 Minimum orifice plate hole size is 3mm
 PSV purge valves should be ¾’’ on inlet and outlet line
 Minimum size of control valve and pump drain and vent valves shall be 1’’
Fire and Gas Detection:
Gas detectors, linear heat detectors for floating roof tanks (Internal Floating Roof
and External Floating Roof), ROR heat detectors for clean agent system shall be
provided for process units and OSBL facilities as per provisions of OISD-116.
Interlock for operating Firewater or agent system shall be provided.
Refer RPMS-ENGG-DBD-CI-007 “Design Basis for Fire & Gas Detectors”
Instrument impulse lines shall be insulated or electrically heat traced wherever
required to avoid congealing and condensation. Cooling tower fans shall have
vibration monitoring system with control room indication. Cooling tower fans
shall have stop switch at grade.
For process plants Owner does not use gauge glass in design for flammable,
hazardous, toxic or corrosive fluids. Magnetic level gauges or equivalent are used
for process applications as per standard drawings.
Provisions in this section are applicable to only commercial plants. For pilot
plants, requirements shall be reviewed on case-to-case basis.

9.8.2. Standard Utility Line Instrumentation

Indicative requirements in Table 9.18 will be firmed up with Licensor or BEC.
Table 9.18 – Indicative utility line instrumentation requirements
Utility Local PI DCS PI PAL/PAH Local TI DCS TI TAL/TAH DCS FI FAL/FAH DCS FQ
MP Steam         
LP steam         
Condensat      
e
CW Supply        
CW Return      
Instrument      
Air
Plant Air    
Inert Gas      
Fuel gas         
Fuel Oil         
DM Water       
Service      
Water
Flare     
Fire Water   
9.8.3. Wireless Instrumentation

Refer RPMS-ENGG-GUI-CI-001 “Guideline for Wireless Instrumentation” and
RPMS- ENGG-DBD-CI-003 “Guideline for Foundation Fieldbus”.
Piping Related Guidelines
9.9.1. Engineering Design Basis
Design of piping systems shall comply with Piping Specifications and RPMS-
ENGG-DBD-PP-001 “Design Basis for Piping Engineering”, RPMS-ENGG-DBD-PP-
003” Design Basis for Plant Layout and Piping” and RPMS-ENGG-DBD-PP-010
“Design Basis for Piping Class”.
Sight Glasses: These are a source of hazard and should be avoided in process
plants. Sight glasses should not be used in piping in HC service or corrosive and/or
high temperature non-hydrocarbon services unless specifically mandated by
licensor for special application.
Except for lube oil return line inside a rotary equipment skid and viewing glass in
the fired heater, no sight glass is to be provided in process plants in HC service.

Non-Return Valves: All Small Bore check valves up to 1.5” size provided on the
lines having operating pressure <=1 kg/cm2g should be considered as Special
Piping item, with tag number marked in P&ID and a datasheet. If operating
pressure is >1 kg/cm2g, then it should be considered as piping bulk item.
Threaded plug in HC service: Threaded plugs are not used on Hydrocarbon lines
within process plants as per Owner practice. Hydrostatic test connections within
ISBL and in OSBL on Hydrocarbon lines are provided with butt-welded end cap.
Root Isolation valve provided on piping for Instrument connections can have
downstream end connection as threaded. Instrument drain valves can be
threaded connections after the first root isolation valve, as depicted in standard
J55 drawings of Owner.
Hose Connections details: Owner provides two NRVs in nitrogen line to the hose
station. Refer standard drawing RPMS-SD-P14-013 for piping arrangement.
Cryogenic service: If cavity relief valves are used in cryogenic service, flow
direction to be indicated on P&ID to depict HP and LP sides.
Line Spec. Break: In case of Utility lines connected to process equipment/process
line where Spec break shown on the check valve /Isolation valve, the piping class
towards process side portion of the line shall correspond to Process Piping class
and Process fluid code.
9.9.2. Control Valve Manifold
A typical control valve assembly will consist of isolation valves, bypass valve and
control valve. Isolation valve size is kept same as respective inlet and outlet line
size.
Bypass valve shall have their CVs equivalent to control valve CV. Bypass valves of
control valves up to 8” shall be globe valve and above 8” shall be gate valve,
except in defined critical services. Butterfly control valves shall have bypass valve
of the same type.
Control valves on vent and depressuring lines to flare shall be of Class VI leakage
class. If Class VI valve is not available for a given size and type, Class V will be
used. Normally control valves in process plants are specified for Class IV leakage.
Where tight shutoff is required and there is no on-off valve in the line upstream
or downstream of the control valve, then control valves are specified with Class
VI leakage class.
9.9.3. Overall Plot Plan and Equipment Layout
For Overall Plot Plan, minimum separations shall be higher of requirements of
insurance companies [XL-Catlin (GE-GAP)] or OISD, as applicable for a given site
and given facility. Special recommendations from Licensor, if any, are to be

incorporated. Depending on specific site and project requirement, a decision can

be taken to follow only OISD norms.
Refer RPMS-ENGG-DBD-PP-003 “Design Basis for Plant Layout and Piping” for
facilities/equipment separation distances.
9.9.4. Full Rated and De-rated Piping Classes
Owner does not desire higher pipe thicknesses for larger size lines/exotic
material unless absolutely warranted. Before finalizing pipe classes on P&IDs,
Contractor shall refer Standard Specification for Piping Material Class – Details
RPMS-ENGG-SPC-PP-038-Part-II to ascertain, for each piping class, fully rated
pipes and fittings and maximum pipe sizes that are specified. In case an
application requires larger pipe size, Contractor shall establish operating and
design pressures and temperatures for the particular pipe segment. These shall
be compared with the coincident pressure-temperature combinations that can
be withstood by de-rated pipe classes. The de-rated pipe classes shall be chosen
with adequate safety margin where required, for example margins for surge in a
long-distance pipeline.
Contractor shall select between owner’s specifications for full rated and de-rated
piping class with due diligence and care.
9.9.5. Insulation, Painting and Coating requirements
Refer RPMS-ENGG-SPC-PP-012/013 for Insulation and RPMS-ENGG-SPC-PP-014
for painting specifications.
9.9.6. Specific Technical Requirements for Piping
 Refer Design Basis for Piping Engineering RPMS-ENGG-DBD-PP-001 and
Design Basis for Plant Layout and Piping RPMS-ENGG-DBD-PP-003 for
technical requirements for Piping
 All process piping shall be as per ANSI B31.3. Steam, condensate and feed
water lines shall be as per IBR and ANSI B31.1 in CPP area, as applicable.
 Refer Design Basis for Piping Classes RPMS-ENGG-DBD-PP-010 for category of
valves which shall be considered as special valve and shall be shown as tagged
in P&ID
 Refer Standard Specification for Piping Components - Technical Supply
Conditions of Pipes / Fittings / Flanges / Valves / Fasteners and Gaskets RPMS-
ENGG-SPC-PP-004-Part-I to VI which provides technical requirements for
Piping components.
 In general, pipe of sizes 1¼”, 2½”, 3½”, 5” and 9” shall not be used. They may,
however, be used in specific applications if so dictated by process reasons.

 Licensor or BEC recommendations will be followed for spare headers in

fouling or choking service and for providing breakup flanges in piping headers
at certain distances. They will have minimum bends.
 Hydrocarbon process lines shall run above ground.
 All OSBL pipelines(within the complex) except firewater and cooling water >
24” OD shall be above ground.
 All drain valves in piping will have sufficient distance from grade to provide
temporary hose connection for decommissioning and flushing purposes.
 Blowdown lines can be underground or above ground depending on service.
For lighter hydrocarbon service where the line is pressurized, blowdown lines
can be above ground in OSBL.
 Root valves shall be provided in all ISBL utility distribution branch piping.
 Equalization bypass shall be provided on high pressure service (600# and
above) large bore piping isolation valves. The valve size will be 1” for line size
≤ 14” and 1½” for line sizes > 14”
 OWS piping shall be underground in ISBL and OSBL till collection pit;
thereafter it is pumped to ETP through above ground lines.
 Firewater hydrant riser will have isolation valve at grade.
 Drip Holes to be provided at Steam Relief valve discharge pipe and shall be
routed to OWS to avoid accidental high temperature exposure.
Refer RPMS-ENGG-DBD-PS-002 “Engineering Design Basis for Storm Water &
Sewer System”
Electrical system design related guidelines
Motor Reacceleration:
Licensor or Contractor shall recommend, based on operating experience and best
practice, the need to specify re-acceleration for electric motor drives of critical
pumps either for quicker start-up or for minimizing plant disruption during
momentary voltage dips. Re- acceleration will cover contingency of a 5-second
disruption in power supply. Reacceleration may be specified for critical service LV
motors and auxiliary drives such as lube oil pumps of HV motors. Process
considerations would dictate reacceleration requirement of HV motors.
Reacceleration facility is normally not provided for pump with intermittent duty.
In the event that a large number of drivers require re-acceleration, Licensor or
Contractor will recommend grouping of drivers and staging as determined by
permissible durations of disruption.

General requirements:
Refer RPMS-ENGG-DBD-EL-001 “Electrical System Design Basis”
10. Design Optimisation and Plant Life
Licensor or Contractor shall use a default criterion of a maximum of 3-year
straight-line payback for recovering increment investments, and assume default
plant operating life as 15 years with zero salvage value for economic calculation,
except for equipment and commodities per Table-10.1.
Table-10.1 Equipment and material design life
Item Design Life Remark
Heavy-walled reactors, separators, 20 years
towers and removable internals
Columns, vessels, heat exchanger 20 years
shells and similar static equipment
Pumps, compressors 20 years
Plant-piping, HAS tube bundles 15 years
Carbon, LAS tube bundles 10 years
11. Safety, Health and Environment Related Requirements

Hazardous Properties of Chemicals
Owner has standardised to a Globally Harmonized System of compiling and
reporting hazardous properties of chemicals. This shall be adopted for all
projects. Owner has a compiled database for common chemicals which can be
adopted by a project with requisite verification by Licensor or BEC.
Chemical-Chemical Interaction Matrix
Owner requires Licensor or BEC, and later Contractor, to compile and present
detailed chemical-chemical interaction matrix. The service list will include all
utilities, small quantity chemicals and atmospheric air. Standard risks associated
with fire, explosion, various chemical reactions, toxicity and others shall be
highlighted. Owner has matrices for all manufacturing installations covering most
chemical-chemical interactions foreseen.
Chemical-Metal Interaction Matrix
Licensor, BEC, Contractor and Suppliers shall take cognizance of all normal
operation Chemical-Metal Interactions. This information shall be compiled and
formalised in a matrix. Material Selection Diagram at basic design stage and

actual metallurgy selection by Contractor and Suppliers shall be guided by the

Chemical-Metal Interaction Matrix.
Management of Highly Toxic Materials
Licensor, BEC, Contractor and Suppliers shall be guided by Reliance Safety
Standards for management of highly toxic materials. This document provides
owner’s list of highly toxic materials and specific recommendations on their
handling and storage.
Ground level ppm sensors for Benzene ,Vinyl Chloride Monomer ,Ethylene Oxide:
Refer RPMS-ENGG-DBD-HS-001 HSE Engineering and Loss Prevention Philosophy.
Inherently Safer Process Design Approaches
Owner plans to progressively adopt inherently safer process design approaches.
These will follow principles of Elimination, Substitution, Inventory Reduction and
Process Intensification and Moderation. Licensor and BEC are required to actively
utilize such principles without compromising design objectives of the plant.
At the simplest level, this can be a check-list based audit that can identify safer
options. At a more comprehensive level, more formal tools can be used where
the risks justify use of detailed methodology.
Hazard Identification
Owner adopts semi-quantitative methods for identifying and categorizing
process hazards based on computation of various indices. Typical indices are Dow
Fire & Explosion Index, Chemical Exposure Index, Mond Index, Safety and Health
Index and others. It is required that Licensor, BEC, Contractor and Suppliers
conduct such analysis for the process plants.
Hazop
Hazop’s are required for all new facilities including all packages. All inter-
connections with existing facilities are to be studied critically, identifying the
potential impacts of incidents at either end of the interconnections.
Hazop shall take cognizance of GHS format data, Chemical-Chemical Interaction
Matrix data, Chemical Metal Interaction Matrix data, Hazard identification
studies. Hazop shall use a Risk Assessment Matrix advised by Owner. It is required
that this be uniform across all projects for a leadership team to moderate
recommendations conveniently and quickly.
For licensed technologies HAZID and HAZOPS shall be carried out during
evolution of basic engineering design. For standard processes using proven
technologies, pre-HAZOP- ed Basic engineering design are acceptable. This is in
addition to HAZOPS to be carried out during detail engineering. For other units,

one HAZOPS at Contractor’s premises, at 30% to 40% engineering progress shall

suffice.
Package Suppliers shall conduct HAZOPS following same guidelines, practices and
work instructions. The project team shall ensure compliance through respective
Contractors.
All HAZOPS recommendations shall be reviewed by a leadership team for
moderation and changes approved shall be tracked for implementation.
SIL Assessment Studies
HAZOPS at Licensor or BEC premises shall be followed by a SIL Assessment Study.
For such study, it is convenient to have the ESD systems defined. If this exercise
is not complete during basic engineering, the study shall be carried out at
Contractor’s premises once the first pass ESD definition is complete.
A leadership team shall moderate the SIL Assessment recommendations and
shortlist the ones to be implemented. These shall be tracked and liquidated by
respective Contractors and Suppliers. Project team shall ensure compliance.
Licensor or Contractor shall provide SRS (Safety Requirement Specifications) for
safety life cycle. Each step of safety lifecycle i.e. identification, verification,
validation shall be part of SIL study. Further, security level requirements are to
be established after SIL assessment is complete.
Refer RPMS-ENGG-DBD-CI-006 “Design Basis for Emergency Shutdown Systems
and Functional Safety Management”.
Risk Analysis
Quantitative Risk Analysis [QRA] shall be carried out for facility siting and
development of overall plot plan. PHAST, PHASTRISK and equivalent software
shall be utilized. Risk shall be analysed for major single events in isolation.
IR shall be calculated for most exposed (to process risk) employees and computed
IR shall be compared with Policy IR. Licensor or BEC shall advise failure data to be
utilized for QRA based on their experience. The ALARP principle shall be adopted
in making choices about risk mitigation measures.
Refer RPMS-ENGG-DBD-CI-011 “Design Basis for Cyber Security”
11.9.1. Baseline data for pollutants and dispersion modeling
The Ministry of Environment & Forests has stipulated maximum ground level
concentrations of various chemicals that can be allowed for a location. These
have been fixed based on the effect of these chemicals on health of human beings
and in some cases on flora and fauna.

For all new potential emissions, dispersion analysis shall be carried out initially
for project clearance. This study can have impact on location of individual stacks
and thus on the overall plot plan.
Typical Safety Features
This section describes key safety features typically utilized in linear installations.
11.10.1. For prevention
Safety facilities for prevention shall include the following:
 Basic Process Control System
 Design of DCS system with sufficient redundancies
 ESD systems for protection of process systems including packages
 Segregation between DCS and ESD systems, ideally no components are to be
shared for ESDs protecting high risk events
 Fault tolerant architecture for ESD system
 Reliability of power supply systems
 Reliability of UPS system
 SIL assignment and verification studies
 Provision of partial stroke testing devices on critical shut-down valves
 Designs with low potentials for spurious trips
 Close loop sampling for liquid and gaseous streams based on Licensor
philosophy
 Provision of back flow prevention devices as required.
 Standard Maintenance Procedures
 Standard Operating Procedures
 Operator intervention in contingencies
 Cyber Security requirements
11.10.2. For containment of incident impact

Safety facilities for incident containment shall normally include the following:
 Safe or closed loop discharge of relief and vent systems in plant (including
all hydrocarbon and ammonia systems) based on Licensor philosophy

 Provision of remote isolation valves with proximity switches that will display
the valve status in the control room
 Provision of PSVs and ruptures disks or combination of adequate capacity
 A complex-wide combined Fire & Gas (F&G) detection system
 All F&G alarms shall be available in the control room, fire stations, site Shift
Manager’s office and other strategic locations as specified by Owner
 A detailed F&G detection and provision matrix shall be prepared for the
complex. This will cover type of detectors and where those will be installed.
 F&G system will have integrations with systems below as a minimum:
o Deluge system
o Analyser shelter interface
o Large screen display or videowall interface, PA system interface
o Access control interface, beacon blackout interface, non-Process
building F&G interface
o Public Address system and CCTV
o Extinguishant skid (clean agent extinguishant gas)
o Fire hydrant / Fire water ring main header system / panel
o Gas Turbine system
o HVAC system
o ESD systems as per Licensor or SIL verification study recommendations
 Firewater network
 Fire extinguishers, fire monitors and deluge system
Fire and smoke detection and sprinkler system: Refer RPMS-ENGG-DBD-HS-001
“HSE Engineering and Loss Prevention Philosophy and RPMS-ENGG-DBD-HS-002
“Design Basis for Fire Water Protection System”.
Elevated Monitor: Refer RPMS-ENGG-SPC-HS-008 “Standard Specification for
Hydrants, Hose Reels and Monitors and RPMS-ENGG-DBD-HS-002 “Design Basis
for Fire Water Protection System”
Breathing Air: Quality of breathing air shall meet CGA Specification G-7.1 Grade
D breathing air quality. Mandatory air quality requirements for compressed
breathing air are:

Table-11.1 Quality of breathing air

Parameter Allowable Value
Oxygen (O2) 19.5% min to 23.5% max
Carbon Monoxide (CO) 10 ppm max
Carbon Dioxide (CO2) 1000 ppm max
Condensed Hydrocarbon 5 mg/m3
Water (H2O) Dew point (-) 5 ºC
Nitrogen (N2) Balance
Odour Free of pronounced odours

Options for generating Breathing Air

1. Add expected breathing air requirement in the Instrument Air system design
and provide humidifiers at each plant to convert instrument air to breathing
air. This option will avoid breathing air network across the plant site, but call
for individual humidifiers at each site, with redundancy.
2. Add expected breathing air requirement in the Instrument Air system design
with a common humidifier in OSBL and generate breathing air for the entire
complex at one location and distribute it through a piping network. This
option centralizes generation and avoids installation of multiple small
individual humidifiers inside each plant.
3. Add expected breathing air requirement in the Instrument air system design,
provide a separate high-pressure buffer storage of Instrument Air and
generate breathing air by mixing plant air and instrument air, let down from
the high-pressure buffer vessel. This is a simple system to control, but will call
for a separate high-pressure vessel. Existing high-pressure booster
Instrument Air compressors can be used for filling instrument air in the new
buffer vessel.
11.10.2.1. Provision of Pressure Relief Valves
PSVs will be installed on all vessels, columns, reactors and similar equipment or
connected piping. These PSVs can discharge to different headers depending on
process conditions. When combined single flare header size goes beyond the
window of 80-100 inches at a back-pressure of 1.75 kg/cm2g, it is generally
economical to segregate flare into more than one system. The cut-off between
HP and LP flare systems is typically 7 to 10 kg/cm2g, kept in a manner that keeps
the LP flare system in 150# flange class at design temperature.
Balanced PSV is to be used where the built-up backpressure is too high for
conventional PSVs or where the superimposed backpressure varies widely
compared to set pressure. Balanced valves are typically applied where total
backpressure does not exceed around 50% of set pressure.
¾” purge with isolation valve to be provided downstream of the PSV inlet and
upstream of PSV outlet isolation valves.
Accumulation limits recommended are as follows, while API 520 provides details:
 10% for process and operational failure cases
 21% for fire case
 25% for thermal case
 5% for IBR steam

For spheres and storage bullets under PESO approval, two independent relief
valves mounted on separate inlet nozzles shall be provided. Each safety valve
shall be sized to relieve full capacity.
Requirements for pressure relief valve installation are as follows:
 PSV for operational failures shall have at least one installed spare
 No installed spare for non-operational failures such as external fire, or for
thermal relief
 PSV in IBR steam service shall not have upstream or downstream isolation
 PSV in air service shall have only upstream isolation
 PSV on spare equipment shall have downstream isolation only if connected
to closed system
 Spared PSVs shall have upstream and downstream isolation
 Spared PSVs open to atmosphere shall have only upstream isolation (LO)
 Un-spared PSV shall have isolation valve (LC)
 For steam service, IBR shall be followed for safety valve sizing. IBR classifies
equipment in two categories with defined PSV isolation requirements:
Category 1: Upstream or downstream PSV isolation valves are not permitted
for steam generating equipment services (eg direct fired boilers, steam
drums, heat recovery systems generating steam)
Category 2: For equipment handling or consuming steam (eg process heat
exchanger, steam turbines, condensate collection drums and associated
piping), upstream and downstream PSV isolation valves are permitted,
provided they have 100% spare relief valves installed and those isolation
valves are either Car Sealed Open (CSO) or Car Sealed Close (CSC).
11.10.2.2. Prevention of back flow overpressure
A. Where reverse flow is not acceptable or is detrimental to upstream
process equipment safety, provide two dissimilar NRVs or check valves.
These check valves have to be identified, inspected and maintained
during turnarounds.
B. Where dissimilar NRV’s are installed for reverse flow protection, check
adequacy of relief system on upstream equipment.

C. Owner considers 1% cross sectional area basis for reverse flow estimation
in line with general industry practice. This may be superseded in cases
where Licensor recommends 10% cross sectional area for reverse flow
estimation as conservative approach.
D. Where the pressure differential between downstream reverse flow
pressure and upstream equipment design pressure is high, the design
should incorporate additional IPF or SIS for revere flow sensing and
prevention. This can be in the form of a DPT installed across the double
NRV to sense reverse flow and trip an XV on the line. For a pumped system
with low-low flow sensing and tripping of pump, the low flow signal can
trip an XV on the line in addition to pump trip. Incorporation of
instrumented reverse flow sensing system and trip of an XV on the line
gives additional safety for reverse flow condition, before the upstream
relief system operates. The trip system can be analysed further during
HAZOPS or SIL study to determine requirement of redundancy in sensing
and final control element.
E. API 521 does not mention pressure levels above which IPF or SIS are to be
considered. In general, owner considers pressure ratio of 5 between
downstream pressure and upstream equipment design pressure, for
implementing reverse flow protection.
F. Depending on criticality of reverse flow protection, Licensor or BEC can
select IPF or SIS for lower pressure ratios, eg connection of dome roof
tank breath out control valve to flare, continuous hard piped connection
of a utility line to process system, steam stripping application or to
mitigate issues of stream contamination.
11.10.2.3. Blow-down and Flare
PSV in hydrocarbon vapour and hydrocarbon liquid services shall discharge to a
close relief header routed to a knock out drum and flare. Knock out drum shall
be provided at the battery limit of each process unit.
Flare Header :
Half vacuum shall be used as design vacuum condition for flare headers and
equipment connected to the flare system.
The flare system within the plant is purged at each sub-header and header. Main
flares headers in OSBL are also continuously purged. Purging media is typically
fuel gas and nitrogen is used as a back-up source. A normal purge rate for the
headers will be based on minimum velocity of 0.01 m/sec. The purge rate will be
controlled by restriction orifices / PCVs as shown below.
Purge gas rate required for the flare stacks shall be advised by the flare vendor.

Typical arrangement for the purge gas injection points on the flare header
Emergency Flare Header Purging :
Provision should be made to introduce purge gas (typically fuel gas and nitrogen
as a back-up source) after a major release, to prevent air being drawn back into
the flare stack and header during cool down. On low pressure level detection (2
out of 3 voting) in the header, a signal shall be sent via the ESD system to open
the on-off valve on the purge gas supply to the header.
All hydrocarbon liquid drains from equipment shall have connection to CBD and
to OWS. Oily water drains shall not be combined with rain water collection
system. However, within the paved area of the unit, rain water is likely to be
contaminated with oil and can be discharged in the oil drains. The balance, rain
water shall drain off to the surface rain water system.
Cold Flaring (Open Venting): Cold flaring from new process plants should not be
allowed. Toxic releases like chlorine and bromine are routed through scrubbers
to atmosphere. Typical applications of cold flaring are:
 At jetty platforms, through local vent stack
 Cross country pipelines for small releases of light hydrocarbons. For large
releases during pipeline evacuation, mobile flare units are used.
 PSVs on storage vessels may have an alternate routing to atmosphere
with steam or nitrogen rings for dilution/dispersion where flare system is
not available
 Marketing terminals
Dispersion study is performed to determine the applicability of cold flare and
adequacy of the stack height.
Vegetation growth in the sterile area around the flare stack should be avoided.
Chlorine Scrubbers: By design, chlorine scrubbers are provided for large chlorine
storage systems and chlorine handling systems in process plants, (eg HIIR plant).
For small size chlorine tonner handling units, refer Scrubber system guidelines

RPMS-ENGG-GUD-PS-026 “Guidelines for Chlorine Scrubber for standalone

Chlorination Systems”.
Stack Monitoring: Refer S&OR GDP 7.1-0003 and RPMS-ENGG-SPC-CI-013
“Standard Specification for Continuous Emissions and Effluent Monitoring
System”
11.10.2.4. Aromatics Handling
Following are to be incorporated from the below-listed design and equipment
provisions in order to reduce emissions of benzene, a known carcinogen, and
other potentially hazardous aromatics.
1. The design requirements presented below are applicable for all process
streams containing 0.1% (weight) or more benzene or 25% (weight) or more C6
through C9 aromatics.
a. Closed, flow-through sample containers are used.
b. A closed, aromatics collection system is present, to which the following are to
be piped:
- Vessel drains;
- Control valve drains;
- Magnetic Gauge glass/level instrument drains;
- Pump drains;
- Other equipment where sparing and/or valving are provided for routine
maintenance and equipment removal.
c. Pumps are equipped with dual seals and suitable barrier fluid systems. Seals
are double or tandem depending upon process requirements. All seals to API
682 latest Edition for new and repeat pumps.
2. Water streams saturated with aromatics are directed to suitable locations

within the process whenever possible or to appropriate other processing or
treating facilities in order to minimize aromatic emissions to the environment.
3. Closed Sampling shall be followed. Refer RPMS-ENGG-DBD-PS-004

“Sampling System Selection Guidelines”
4. For piping, all streams containing benzene more than or equal to 50 wt%
shall be considered as toxic for selection of appropriate piping specification.
11.10.3. For emergency handling
 Adequate facilities shall be provided adjacent to the work areas to permit
reasonable access from all areas of potential hazards to the operator and
maintenance team

 Safety showers and eye wash

 Temporary Safe havens
 Emergency Lighting back up
 Exit from units shall be provided wherever necessary for emergency exit.
 Manual Call Points (MCP)
 Assembly point shall be marked for each unit
 Emergency light Coding ( Blue, Red Yellow)
 Public Announcement System (Emergency communication system) in plant
Environmental Compliance
A project-specific Environmental Design Guideline for projects shall be
established consistent with latest guidelines from the Ministry of Environment &
Forests.
11.11.1. Typical provisions for environmental monitoring
Project procedure shall be evolved and followed for fugitive emissions pertaining
to control valves and mechanical valves.
GC based Air ambient monitoring system for fugitive emission monitoring to be
provided as required by the statutory requirements and latest safety standards.
Monitoring of particulate matter on-line may require non-GC equipment.
11.11.2. Noise level limits
Unless otherwise specified in project procedures, purchased equipment and final
plant design are usually governed by noise level exposure limitations of OSHA.
Overall sound pressure level for any equipment shall not exceed 85 dBA for
continuous exposure at 1 meter distance from the equipment skid edge. For
short duration exposure, this level can be referred from site specific safety
document.
Refer 10080-1-SS-LP-020 for noise standard specification.
12. Documentation Requirements
Equipment Numbering
The Equipment numbering and component identification shall be as per RPMS-
ENGG- PRA-GE-028 “Drawings Documents Equipment Numbering”.
Documentation and Document Numbering

All documentation shall be prepared on International Standards Organization

(ISO) standard paper sizes (eg A0, A1, A3, A4). Drawing and document numbering
shall be as per RPMS-ENGG-PRA-GE-028 “Drawings Documents Equipment
Numbering”.

13. ANNEXURE 1 - Wind Roses at site

Annual (all months)
NORTH
20%
16%
12%
8%
4%
WEST EAST
WIND SPEED
(Knots)
>= 22
17 - 21
11 - 17
SOUTH
7 - 11
4-7
1-4
Calms: 10.44%
Summer (April – Jun)
NORTH
30%
24%
18%
12%
6%
WEST EAST
WIND SPEED
(Knots)
>= 22
17 - 21
11 - 17
SOUTH
7 - 11
4-7
1-4
Calms: 0.98%

Monsoon (July – August)
NORTH
35%
28%
21%
14%
7%
WEST EAST
WIND SPEED
(Knots)
>= 22
17 - 21
11 - 17
SOUTH
7 - 11
4-7
1-4
Calms: 1.01%
Post Monsoon (September – November)
NORTH
20%
16%
12%
8%
4%
WEST EAST
WIND SPEED
(Knots)
>= 22
17 - 21
11 - 17
SOUTH
7 - 11
4-7
1-4
Calms: 22.12%

Winter (December – March)
NORTH
15%
12%
9%
6%
3%
WEST EAST
WIND SPEED
(Knots)
>= 22
17 - 21
11 - 17
SOUTH
7 - 11
4-7
1-4
Calms: 13.61%

14. ANNEXURE 2 - Utilities Qualities and Test Methods

QUALITY OF TREATED SEA WATER
Sr.No Parameters Testing Method Unit Specification
1 pH IS 3025 P-11 –– 7.5 - 8.2
o
2 Normal Supply Temperature IS 3025 P-9 C 25 - 32
3 TDS IS 3025 P-16 ppm w/w 42000 (Max)
4 TSS IS 3025 P-17 ppm w/w 10 ( Max)
5 Calcium Hardness as CaCO3 IS 3025 P-21 ppm w/w 950 - 1100
6 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w 160 - 190
7 Magnesium Hardness as CaCO3 IS 3025 P-21 ppm w/w 5400 - 5700
8 Chlorides as Cl ppm w/w 21000 - 22000
9 Sulphate as SO4 IS 3025 P-24 ppm w/w 3050 - 3250
10 Sulphide IS 3025 P-29 ppm w/w < 0.1
11 Ammonia IS 3025 P-34 ppm w/w ND
12 Residual Chlorine 4500-Cl A ppm w/w 0. 1 - 0.3
Can be determined by O
13 Free Oil & G Analyser - APHA ppm w/w 0.015
5220B
14 Phenol ASTM D1783 ppm w/w Nil
APHA 5210 D / IS 3025 P-

15 BOD5 ppm w/w < 10
44
NOTES
1. To be confirmed from Jamnagar based on latest data ( seasonal variation in turbidity, design turbidity
for Desal unit).
2. Temperature at source varies from 21 degC to 32 degC.

QUALITY OF DSW FROM THERMAL DESAL UNITS IN DTA AND SEZ REFINERIES
1 pH IS 3025 P-11 –– 5.5 - 7
Normal Supply o
2 IS 3025 P-9 40 - 45
Temperature C
μS
3 Conductivity ASTM D1125 /cm <= 15
4 TDS IS 3025 P-16 ppm w/w < 10
5 TSS IS 3025 P-17 ppm w/w Nil
6 Silica as SiO2 ASTM D 859 ppm w/w < 0.02
AAS (PE Application

7 Sodium as Na ppm w/w <2
note)
8 p-Alkalinity APHA 2320B ppm w/w Nil
9 Iron APHA-3500 Fe B ppm w/w < 0.1
10 Copper IS 3025 P-42 ppm w/w < 0.005
11 Sulphate as SO4 IS 3025 P-24 ppm w/w <1
< 5 for TDS < 10 it is ok,

12 Chloride as Cl IS 3025 P-32 ppm w/w otherwise < 2
13 Residual Chlorine 4500-Cl A ppm w/w Nil
14 Total Hardness as CaCO3 IS 3025 P-21 ppm w/w <0.1
15 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w <2
16 Calcium as CaCO3 IS 3025 P-21 ppm w/w < 0.1
17 TOC APHA-5310 B ppm w/w -
NOTES
1. Preferentially routed to DM water system / process water system make-up use.

QUALITY OF DESALINATED WATER FROM RO UNITS IN J3 COMPLEX
1 pH IS 3025 P-11 –– 7.2 - 8.2
o
2 Normal Supply Temperature IS 3025 P-9 Ambient
C
μS
3 Conductivity ASTM D1125 /cm
4 TDS IS 3025 P-16 ppm w/w < 10
6 Silica ASTM D 859 ppm w/w < 0.01
7 Sodium as Na AAS (PE Application note) ppm w/w < 4.0
8 Iron APHA-3500 Fe B ppm w/w
9 Copper IS 3025 P-42 ppm w/w
10 Sulphate IS 3025 P-24 ppm w/w
11 Chloride as Cl IS 3025 P-32 ppm w/w Approx 5
12 Residual Chlorine 4500-Cl A ppm w/w
13 Total Hardness as CaCO3 IS 3025 P-21 ppm w/w
14 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w
15 Calcium as CaCO3 IS 3025 P-21 ppm w/w
16 TOC APHA-5310 B ppm w/w Nil
NOTES
1. To be further evolved during facility design.

QUALITY OF CIRCULATING COOLING WATER

1 pH IS 3025 P-11 –– 6.8 -7.8
2 Conductivity ASTM D1125 μS/cm < 2500
3 Calcium Hardness as CaCO3 IS 3025 P-21 ppm 75 - 125
4 M - Alkalinity as CaCO3 APHA-2320 B ppm < 100
5 Ortho Phosphate as PO4 U / F APHA-4500-P D ppm 8 - 12
6 Total Phosphate as PO4 APHA-4500-P D ppm 11 - 17
7 Delta Phosphate as PO4 APHA-4500-P D ppm <2
8 Zinc AAS (PE Application note) ppm 1.5 - 2.0
9 Iron APHA-3500 Fe B ppm <=2
10 Turbidity IS 3025 P-10 NTU <20
11 Free Residual Chlorine 4500-Cl A ppm 0.2 - 0.5
12 ORP mv 450 -550
13 TSS IS 3025 P-17 ppm <25
14 Chlorides as Cl IS 3025 P-32 ppm <500
15 Copper IS 3025 P-42 ppm <0.05
16 Active Dispersant polymer Chemical Specific ppm 4 -10
17 SRB Bactaslyde Org./100 ml 10
18 TBC col/ml < 10,000
19 TDS (Calculated) ppm < 1000
20 Nitrates ppm < 50
21 Sulphates ppm 50 - 200
NOTES
1. Cooling water quality specified is indicative only. It will be a function of design of cooling tower , make up water quality
and method of water treatment. Furnished figures are indicative and typical of DTA and SEZ refineries.

QUALITY OF COOLING TOWER MAKE-UP WATER
Specification
Sr.No Parameters Testing Method Unit High TDS
Low TDS Treated
Treated
Effluent
Effluent
1 pH IS 3025 P-11 –– 6.5 - 8 6.5 - 8.5
0
2 Normal supply Temperature IS 3025 P-9 C 20 - 40 20 - 40
<500 ( mainly
3 TDS IS 3025 P-16 ppm w/w 1000 - 2500
sodium chloride)
4 TSS IS 3025 P-17 ppm w/w < 15 < 10
5 Calcium as CaCO3 IS 3025 P-21 ppm w/w Low Low
6 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w 100 - 150 50 - 200
7 Magnesium IS 3025 P-21 ppm w/w Low Low
8 Sulphate as SO4 IS 3025 P-24 ppm w/w 50 - 200 Low
9 Sulphide IS 3025 P-29 ppm w/w 1 1
10 Ammonia IS 3025 P-34 ppm w/w < 15 < 15
11 Total Silica as SiO2 ASTM D 859 ppm w/w - -
12 Residual Chlorine 4500-Cl A ppm w/w 0.1 - 0.3 0.1 - 0.3
13 Total Iron APHA-3500 Fe B ppm w/w < 0.2 < 0.2
14 Copper IS 3025 P-42 ppm w/w - -

Can be determined by O & G
15 Free Oil ppm w/w <5 <5
Analyser - APHA 5220B
16 Phenol ASTM D1783 ppm w/w < 0.35 < 0.35
17 BOD3 APHA 5210 D / IS 3025 P-44 ppm w/w < 20 < 20
18 TOC ppm w/w < 20 < 20
19 COD ppm w/w < 50 < 50

NOTES
1. Make up water quality may vary for specific cooling Tower system ( Desalinated water / Sea water ).
2. Make up water can be Raw Water, Desalinated Water, Low TDS treated effluent or High TDS treated Effluent (depending on
the characteristics of J3 complex treated effluent - quality yet to evolve), and as such quality may vary. Low and High TDS water
qualities based on current experience. Project figures to be evolved by OSBL designer.

QUALITY OF DEMINERALISED WATER

1 pH IS 3025 P-11 –– 6.5 - 7.5
2 Conductivity ASTM D1125 μS/cm < 0.15
3 TDS IS 3025 P-16 ppm w/w < 0.1
5 Silica ICP ppm w/w < 0.01
6 Sodium as Na ICP ppm w/w < 0.01
7 Iron APHA-3500 Fe B / ICP ppm w/w < 0.02
8 Copper ICP ppm w/w 0.003
9 Sulphate IS 3025 P-24 ppm w/w Nil
10 Chloride as Cl IS 3025 P-32 ppm w/w < 0.05
11 Total Hardness as CaCO3 IS 3025 P-21 ppm w/w Nil
12 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w Nil
13 Calcium as CaCO3 IS 3025 P-21 ppm w/w Nil
14 TOC APHA-5310 B* ppm w/w ND
NOTES
1. To be verified during facility design basis finalization
* Method detection limit is 1.0 ppm

QUALITY OF HIGH HIGH PRESSURE (HHP) BOILER FEED WATER
1 pH IS 3025 P-11 –– 8.5 - 9.5

Conductivity
2 ASTM D1125 μS/cm < 10
(before cationic bed)
Conductivity
3 μS/cm < 2.5 (see Note 2)
(After Cation resin bed)
5 Sodium ICP ppm w/w < 0.01
6 Iron APHA-3500 Fe B / ICP ppm w/w <0.02
7 Copper ICP ppm w/w < 0.003
8 Chloride as Cl Ion-Chromatography ppm w/w < 0.05
10 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w < 5.0
12 Dissolved Oxygen (DO) ASTM D888 ppb w/w < 7.0
13 TOC APHA-5310 B* ppm w/w ≤1
14 Residual N2H4 ppm w/w Above traces
NOTES
1. To be verified during facility design basis finalization.
2. After cationic bed, TDS is maximum 1.5 ppm.

QUALITY OF BOILER FEED WATER ( HP,MP and LP)
1 pH IS 3025 P-11 –– 8.5 - 9.5
2 Conductivity ASTM D1125 μS/cm < 10

Conductivity
3 μS/cm < 2.5 (see Note 3)
(After Cation resin bed)
5 Sodium ICP ppm w/w < 0.01
6 Iron APHA-3500 Fe B / ICP ppm w/w <0.02
7 Copper ICP ppm w/w < 0.003
8 Chloride Ion-Chromatography ppm w/w < 0.1
10 Total Alkalinity as CaCO3 APHA-2320 B ppm w/w < 5.0
12 Dissolved Oxygen (DO) ASTM D888 ppb w/w < 7.0
13 TOC APHA-5310 B* ppm w/w ≤1
14 Residual N2H4 ppm w/w Above traces
NOTES
1. To be verified during facility design basis finalization.
2. CPP may require BFW at a pressure intermediate between HHP and HP
3. After Cationic exchanger TDS is maximum 1.5 ppm.

QUALITY OF POTABLE WATER

Specification
Sr.No Parameters Testing Method Unit
(as per IS 10500)
o
1 Normal Supply temperature IS 3025 P-9 C
2 pH IS 3025 P-11 –– 6.5 - 8
4 Turbidity IS 3025 P-10 NTU

500
5 TDS IS 3025 P-16 ppm
Maximum 2000
6 TSS IS 3025 P-17 ppm
7 Silica ASTM D 859 ppm
8 Total Silica as SiO2 ASTM D 859 ppm
9 Colloidal SiO2 ASTM D 859 ppm
10 Mercury ppm
11 Cadmium ppm
12 Selenium ppm
13 Arsenic ppm
14 Cyanide ppm
15 Lead ppm
16 Chromium ppm
17 Iron as Fe APHA-3500 Fe B ppm < 0.3
16 Alkalinity ppm < 200
18 Calcium as CaCO3 IS 3025 P-21 ppm 120 - 188
19 Chloride as Cl- IS 3025 P-32 ppm < 250
20 Magnesium IS 3025 P-21 ppm
20 Sulphates IS 3025 P-24 ppm < 150
21 Sulphide IS 3025 P-29 ppm
22 Ammonia IS 3025 P-34 ppm
23 Boron ppm < 0.5
24 Free Residual Chlorine 4500-Cl A ppm 0.2

Can be determined by
25 Free Oil O & G Analyser - APHA ppm
5220B
26 Phenol ASTM D1783 ppm
APHA 5210 D / IS 3025
27 BOD5 ppm
P-44
28 Dissolved Oxygen (DO) ASTM D888 ppm
29 O-PO4 APHA-4500-P D ppm
30 TOC APHA-5310 B ppm

NOTES

HHP STEAM QUALITY
1 pH IS 3025 P-11 –– 8.8 - 9.5
Conductivity
2 ASTM D1125 μS/cm < 10.0
(Before Cation Resin bed)
Conductivity
3 μS/cm < 2.5 (see Notes 3 & 4)
(After Cation Resin bed)
4 Silica,as SiO2 ASTM D 859 ppm < 0.02
5 Iron, as Fe APHA-3500 Fe B / ICP ppm < 0.02
6 Copper, as Cu ICP ppm <0.005
7 Sodium, as Na ICP ppm < 0.01
8 Chloride Ion-Chromatography ppm < 0.05
9 Total Alkalinity APHA 2320B ppm < 5.0
10 Phosphate , as PO4 ICP ppm < 0.01
11 TOC APHA-5310 B* ppm 0.5 Max
NOTES
1. Quality is Typical for HHP Steam. To be verified during facility design Basis.
2. Above Specifications may not be applicable for all levels of steam.
3. Method detection limit is 1.0 ppm
4. After Cationic resin bed the TDS is 1.5 ppm maximum.
5. Individual projects can obtain guaranteed parameters from boiler suppliers. Existing generator steam
quality is being further reviewed to explore possibility to improve the conductivity and TDS figures
after cationic resin bed .

CONDENSATE QUALITY
Sr.No Parameters Testing Method Unit Specification (Note-1)
1 pH IS 3025 P-11 –– 8.3 - 9.0

μ
2 Conductivity ASTM D1125 < 15
mhos/cm
3 TDS IS 3025 P-16 ppm w/w ≤ 5( For CPU design)
5 Silica ASTM D 859 ppm w/w 0.03
6 Sodium AAS (PE Application note) ppm w/w < 0.01
7 Total Alkalinity as CaCO3 APHA 2320B ppm w/w < 5.0
8 Iron APHA-3500 Fe B ppm w/w 0.03
9 Copper ICP ppm w/w 0.02
10 Sulphate IS 3025 P-24 ppm w/w Nil
11 Chloride IS 3025 P-32 ppm w/w 0.1
14 TOC APHA 5310 B* ppm w/ w < 10
NOTES
1. Typical condensate quality will depend upon the BFW quality and Condensate polishing facilities.
Values shall evolve as design progresses
2. The Quality indicated above may not apply to all pressure levels of condensate

QUALITY OF FUEL GAS IN DTA / SEZ REFINERIES (ROGC FEED)
Specification
Sr.No Parameters Testing Method Unit
Unsat gas Sat gas - 1 Sat gas -2
Composition
1 N2 UOP-539 wt % 12.34 1.43 1.06
2 Oxygen UOP-539 wt % 0.4 0.55 0.56
3 CO UOP-539 wt % 1.92 0 0
4 CO2 UOP-539 wt % 2.8 0.15 0.15
5 H2S ASTM D6228 wt % 0.018 0.001 0.001
6 NH3 wt %
7 H2 UOP-539 wt % 0.87 5.32 7.61
8 C1 UOP-539 wt % 29.09 8.31 12.13
9 C2= UOP-539 wt % 21.62 0.09 0.08
10 C2 UOP-539 wt % 22.28 44.17 46.23
11 C3= UOP-539 wt % 2.48 0.01 0.01
12 C3 UOP-539 wt % 1.46 22.58 20.63
13 iC4= UOP-539 wt %
14 iC4 UOP-539 wt % 0.67 4.08 3.35
15 nC4 UOP-539 wt % 0.87 5.56 2.85
16 Butene UOP-539 wt % 0.92 0 0
17 C5H12 UOP-539 wt % 1.1 4.28 2.08
18 C5H10 UOP-539 wt % 0.32 0 0
19 C6+ UOP-539 wt % 0.84 3.48 3.27
Total
20 LHV ASTM D3588 Kcal/kg
21 MW By Calculation kg/kmol 22.1 18.2 14.7
NOTES
1. The current qualities of Fuel gas in DTA and SEZ refineries as indicated as Unsaturated and Saturated Gases on this page, will
get routed to ROGC as feed after J3 implementation. Refinery fuel gases will become a composite of Synthetic natural gas,
ROGC return gas (nitrogen removal may be required), Imported Natural gas.
2. OSBL Designer responsible for overall integration will work out final numbers based on generated gas quality and quantity
numbers advised by process licensors / respective DECs.
3. The gas qualities in all the complexes will be functions of operating scenarios, normal and contingency cases; the hardware
suitability must be verified for the entire range of composition, Calorific values and Wobbe indices.
4. Method UOP 539 is currently used in the refineries.

QUALITY OF SYN GAS

Testing Method (Note
Sr.No Parameters 2) Unit Specification
Composition
Portable Dew Point Meter /

1 H20 mole %
Draegar tubes / GC
2 N2 UOP-539 mole % 0.84
3 Ar mole % 0.21
4 Oxygen UOP-539
5 CO UOP-539 mole % 50 - 53
6 CO2 UOP-539 mole % 12
7 H2S + COS ASTM D6228 < 20 ppmv
8 NH3
9 H2 UOP-539 mole % 32.74 - 34.85
10 C1 UOP-539 mole % 0.98 - 1.93
11 C2= UOP-539
12 C2 UOP-539
13 C3= UOP-539
14 C3 UOP-539
15 iC4= UOP-539
16 iC4 UOP-539
17 nC4 UOP-539
18 =N1C4 UOP-539
19 =T2C4 UOP-539
20 =C2C4 UOP-539
21 =1=4C5 UOP-539
22 3M=1C4 UOP-539

23 =1C5 UOP-539
24 2M=1C4 UOP-539
25 =T2C5 UOP-539
26 =C2C5 UOP-539
27 2M=2C4 UOP-539
28 iC5 UOP-539
29 nC5 UOP-539
30 C6+ UOP-539
31 Total 100
2,664 (Petcoke) to 2795

(Petcoke + Coal)
33 MW By Calculation
NOTES
1. Composition is indicative only. Detail composition to be furnished based on numbers advised by process licensor
for Gasification and OGBL DEC .
2. Test methods to be confirmed.

QUALITY OF SYNTHETIC NATURAL GAS FROM GASIFICATION
Composition
Portable Dew Point Meter
1 H20
/ Draegar tubes / GC
2 Oxygen UOP-539
3 CO UOP-539 mol% 0.01
4 CO2+N2+inerts UOP-539 mol% 5-7
5 H2S ASTM D6228
6 NH3
7 H2 UOP-539 mol% 8 -10
8 C1 UOP-539 mol% 80 -86
9 C2= UOP-539
10 C2 UOP-539
11 C3= UOP-539
12 C3 UOP-539
13 iC4= UOP-539
14 iC4 UOP-539
15 nC4 UOP-539
16 =N1C4 UOP-539
17 =T2C4 UOP-539
18 =C2C4 UOP-539
19 =1=4C5 UOP-539
20 3M=1C4 UOP-539
21 =1C5 UOP-539
22 2M=1C4 UOP-539

23 =T2C5 UOP-539
24 =C2C5 UOP-539
25 2M=2C4 UOP-539
26 iC5 UOP-539
27 nC5 UOP-539
28 C6+ UOP-539
Total 100
29 Calorific Value Kcal/ kg 10500 (Min)
30 Dew point o -40 (Min)

C
NOTES:
1. Quality is Typical for Synthetic Natural Gas. To be verified during facility design Basis.
2. Above figures are for Synthetic natural gas for internal consumption.
3. Synthetic natural gas, that may be put in the gas grid for supplying others will have minimum calorific
value of 30556 btu/scm. Corresponding composition will have higher levels of methane (to be
confirmed after design evolution).

INDICATIVE QUALITY OF RETURN GASES FROM ROGC
Composition

1 H20
Draegar tubes / GC
2 N2 UOP-539 Wt% 19.11
3 Oxygen UOP-539
4 CO UOP-539 Wt% 3.28
5 CO2 UOP-539
6 H2S ASTM D6228
7 NH3
8 H2 UOP-539 Wt% 3.5
9 C1 UOP-539 Wt% 72.62
10 C2= UOP-539 Wt% 1.14
11 C2 UOP-539 Wt% 0.35
12 C3= UOP-539
13 C3 UOP-539
14 iC4= UOP-539
15 iC4 UOP-539
16 nC4 UOP-539
17 =N1C4 UOP-539
18 =T2C4 UOP-539
19 =C2C4 UOP-539
20 =1=4C5 UOP-539
21 3M=1C4 UOP-539
22 =1C5 UOP-539

23 2M=1C4 UOP-539
24 =T2C5 UOP-539
25 =C2C5 UOP-539
26 2M=2C4 UOP-539
27 iC5
28 nC5 UOP-539
29 C6+ UOP-539
Total 100
30 LHV ASTM D3588 Kcal/kg 9,932
31 MW By Calculation 14
NOTES
1. Routing this stream with high % of Nitrogen in the fuel gas circuit will affect quality of fuel gas (CV , Wobbe index) at
the existing consumers. This issue will be addressed during design evolution.

QUALITIES OF HYDROGEN STREAMS
ROGC Gasification
1 Hydrogen Vol % 99.99 (min) 99.9 (min)
2 Oxygen Teledyne meter ppmv 5 max
3 CO2 UOP -603 ppmv 5 max

10 max
4 CO UOP -603 ppmv 5 max
5 Total Sulphur wt. ppb 500 max
6 Water wt. ppm 5 max
7 CH4 + C2 + Argon Balance
8 Acetylene ppmv 1 max
9 NH3 wt. ppm 1 max
Hydrogen Quality in DTA / SEZ
1 Hydrogen Vol % 99.9 (min)
2 CO + CO2 ppmv 10 max
3 CH4 + N2 Balance
NOTES
1. Typical Hydrogen quality specification.

QUALITY OF RETURN FUEL GAS FROM PX4

Composition Offgas From Off Gas From TA Off gas From TA Depentanizer
Xylene Stabilizer Reactor Purge Off Gas
Recovery
Column
Case 1 Case 2 Case 1 Case 2 Case 1 Case 2 Case 1 Case 2
1 H20 Portable Dew Point
Meter / Draeger
tubes / GC
2 N2 UOP-539 Mole % 0.5 0.4 0 0 0 0
3 Oxygen UOP-539
4 CO UOP-539
5 CO2 UOP-539
6 H2S ASTM D6228
7 NH3
8 H2 UOP-539 Mole % 28.3 25.9 18.3 18.3 80 80 1 1
9 C1 UOP-539 Mole % 0.1 0.1 0.4 0.4 0.4 0.4 0.1 0.1
10 C2= UOP-539
11 C2 UOP-539 Mole % 51.2 51.6 50.6 49.3 15 14.8 52 45
12 C3= UOP-539
13 C3 UOP-539 Mole % 11.6 12.2 25.5 26.3 3.6 3.7 23.8 24.9
14 iC4= UOP-539
15 iC4 UOP-539
16 nC4 UOP-539 Mole % 4.2 5.3 3.8 4.2 0.4 0.4 8.2 15.3
17 =N1C4 UOP-539
18 =T2C4 UOP-539
19 =C2C4 UOP-539
20 =1=4C5 UOP-539
21 3M=1C4 UOP-539
22 =1C5 UOP-539
23 2M=1C4 UOP-539
24 =T2C5 UOP-539
25 =C2C5 UOP-539
26 2M=2C4 UOP-539
27 iC5 UOP-539
28 nC5 UOP-539 Mole % 2.2 2.6 0.5 0.6 0 0.1 14.7 18.6
29 C6+ UOP-539 Mole % 1.9 1.9 0.9 0.9 0.6 0.6 0.2 -4.9
31 MW By Calculation Kg/Kgmole 26.8 28 30.2 30.4 8.5 8.5 42.1 43.2
NOTES:
1. Case 1: Design case feed, Case 2: Rating case feed
2. PX4 off gases will get routed to ROGC as feed.

QUALITY OF RETURN FUEL GAS FROM MEG

Composition
Portable Dew Point Meter

1 H20 mol frac 0.004
/ Draegar tubes / GC
2 N2 UOP-539 mol frac 0.033
3 Oxygen UOP-539 mol frac 0.078
4 CO UOP-539
5 CO2 UOP-539 mol frac 0.006
6 H2S ASTM D6228
7 NH3
8 H2 UOP-539
AR mol frac 0.051
9 C1 UOP-539 mol frac Balance
10 C2= UOP-539 mol frac 0.271
11 C2 UOP-539 mol frac 0.003
12 C3= UOP-539
13 C3 UOP-539
14 iC4= UOP-539
15 iC4 UOP-539
16 nC4 UOP-539
17 =N1C4 UOP-539
18 =T2C4 UOP-539
19 =C2C4 UOP-539
20 =1=4C5 UOP-539
21 3M=1C4 UOP-539
22 =1C5 UOP-539

23 2M=1C4 UOP-539
24 =T2C5 UOP-539
25 =C2C5 UOP-539
26 2M=2C4 UOP-539
27 iC5 UOP-539
28 nC5 UOP-539
29 C6+ UOP-539
30 EOX ppm 60
31 FORM mol frac Trace
32 ACET mol frac Trace
Total 100
33 LHV ASTM D3588 Kcal/kg 7000
NOTES:
1. Quality is Typical for Fuel Gas system. To be verified during facility design Basis.
2. Since there is Oxygen present in this gas stream, it will need to be routed to a dedicated set of burners.

QUALITY OF NATURAL GAS FROM GSPL
Composition
1 H20
Draegar tubes / GC
2 N2 UOP-539 mol % 0.2
3 Oxygen UOP-539
4 CO UOP-539
5 CO2 UOP-539 mol % 0.3
6 H2S ASTM D6228
7 NH3
8 H2 UOP-539
9 C1 UOP-539 mol % 98.2
10 C2= UOP-539
11 C2 UOP-539 mol % 1
12 C3= UOP-539
13 C3 UOP-539 mol % 0.3
14 iC4= UOP-539
15 iC4 UOP-539
16 nC4 UOP-539
17 =N1C4 UOP-539
18 =T2C4 UOP-539
19 =C2C4 UOP-539
20 =1=4C5 UOP-539
21 3M=1C4 UOP-539
22 =1C5 UOP-539
23 2M=1C4 UOP-539
24 =T2C5 UOP-539
25 =C2C5 UOP-539
26 2M=2C4 UOP-539

27 iC5 UOP-539
28 nC5 UOP-539
29 C6+ UOP-539
Total 100
30 LHV ASTM D3588 Kcal/kg 11,844
31 MW By Calculation 16.4
NOTES
1. The composition of Natural gas is typical.
2. Within a certain range of calorific value and Wobbe index, the composition can be allowed to vary.

ELECTRIC SUPPLY PARAMETERS
Sr.No Parameters Unit Specification
A Supply tolerances
I Steady State Limits
1 Non UPS
With internal generation and
Voltage +/- 10 %
grid connectivity
With internal generation and
Frequency +/- 3 %
grid connectivity
2 UPS
Voltage +6 / -3 % ( at equipment)
+/- 1 % feed via inverter
Frequency
+/- 3 % feed via bypass transformer
II Transient Limits
Non UPS
Voltage +10% /- 20 %
Frequency +/- 5 %
III DC Voltage Tolerance + 10 % , -15 %
NOTES
1 Indicative parameters. May further evolve as design progresses.

QUALITY OF PLANT AIR AND INSTRUMENT AIR
Testing Method
Sr.No Parameters Unit Specification
(Note 2)
1 Plant Air
Oil content - Oil Free
Water saturation - Water Saturated
2 Instrument Air
Oil content - Oil Free
0
Atmospheric Dew point Dew Point meter C -40
NOTES

QUALITY OF BREATHING AIR
Breathing Air
1 Oil content - Oil Free
2 Water saturation - Water Saturated
3 Oxygen (O2) 19.5% min to 23.5% max
4 Carbon Monoxide (CO) 10 ppm max
5 Carbon Dioxide (CO2) 1000 ppm max
6 Condensed Hydrocarbon 5 mg/m3
7 Water (H2O) Dew point (-) 5 ºC
8 Nitrogen (N2) Balance
9 Odour Free of pronounced odours
NOTES
1. For further details on breathing air quality - refer to - RIL Group Standard - Respiratory Protective Equipment.

QUALITIES OF NITROGEN
Testing Method
Sr.No Parameters (Note 2) Unit Specification
1 Nitrogen purity Vol % 99.99 (min)
2 Oxygen Teledyne meter ppmv < 3 (<10 for gasification)
3 CO2 UOP -603 ppmv 1 max
4 CO UOP -603 < 1.0 ppm
5 Oil Nil
Dew Point@atm. o
6 Dew point Meter C - 100
Pressure
NOTES
1. Typical Nitrogen quality specification.
2. To be confirmed.
3. The ASUs for gasification supply HP and LP nitrogen to gasification complex with 98% Nitrogen, 2%
Argon and <10 ppm Oxygen.
4. The ASUs for gasification supply NOx control nitrogen to the GTs, this stream will have maximum 2 %
of oxygen.

15. ANNEXURE 3 - Utilities Battery Limit Conditions

SERVICE WATER BATTERY LIMIT CONDITIONS
Pressure (kg/cm2g) Temperature (oC)
Description
Normal @ Process
Normal @ Source Normal @ User Design Min Normal Max Design
Battery limit
Utility Water 3.8 3.5 3 7 3 35 43 65
DTA 5.3 3.5 3 7 3 35 43 65
SEZ 3.8 3.5 3 7 3 35 43 65
NOTES :
1. Based on current Installation at Jamnagar. To be verified during facility design.

SEA WATER BATTERY LIMIT CONDITIONS
Pressure at User B.L (kg/cm2g) Temperature (oC)

Description
Min Normal Max Design Min Normal Max Design
Sea water to Desalination Plant
Sea Water to Sea water Cooling tower
Sea Water to MTF Fire water System
Sea water return from Desalination plant
Sea Water return / blowdown from SW CT
DTA
SEZ
NOTES : ( To be updated during Detail Engineering)
1. From sea water intake, sea water will be pumped, filtered and delivered to the consumers, Desalination plants, Sea water cooling tower (if any), and back-
up supply to Fire water (during actual fire-fighting only), at Marine Terminal.
2. The level of integration with existing facilities at DTA and SEZ refineries and will depend on the total water requirement. Where new facilities will need to
be installed, the operating and design conditions shall depend on requirements at destinations, geographic locations of intake system, line routings and any
specific system constraints. Exact numbers will evolve during progress of design.
3. The return header conditions will depend on the level of integration with existing facility, new outfall point location, depth of submergence at point of
discharge and design of diffuser.
4. SWRO plants will be located at MTF; however, if the choice is to go with Thermal units, the locations will be at Plant premises.

DESALINATED WATER BATTERY LIMIT CONDITIONS

Description
At Demineralised water system
At Utility / Potable Water System
At Fire Water System
At Cooling Tower
DTA
SEZ
NOTES : ( To be updated during Detail Engineering)

1. Desalinated Water from existing Desalination units and new RO units in the project will be stored in tanks and then pumped to the
consumers, Demineralised Plant (from existing Desalination units), Utility/Potable Water System, Cooling tower, and back-up supply to
Fire water.
2. The level of integration with existing facilities at DTA and SEZ refineries will depend on the total water requirement. Where new
facilities will need to be installed, the operating and design conditions shall depend on requirements at destinations, geographic
locations of new Desal units, Desal water tanks and final locations of consumers, line routings and any specific system constraints. Exact
numbers will evolve during progress of design.

COOLING WATER BATTERY LIMIT CONDITIONS

Water side
Description (Heat Max outlet Water side (Heat
Supply Return Return
Exchanger) Supply Temperature of Exchanger) Design
( Note 1) ( Note -1) ( Average)
Design Exchanger Temperature
Pressure
Fresh Cooling Water system 4.3 / 4.8 2.8 7 / F.V. 32 45 49 65
DTA 4.5 3.1 7 32 45 49 120
SEZ 4.1 / 4.6 2.7 7 / F.V. 32 45 49 120
NOTES :
1 Minimum at any process battery limit , grade level
2. If supply pressure required for a specific unit is essential to be different from usual values , then same shall be specified by Licensor / ISBL DEC and suitable
pumping arrangement shall be provisioned (separate high-pressure pumps / booster pumps) in co-ordination with concerned OSBL DEC.
3. Number of towers and the process units / utilities blocks these will serve will depend on overall plot plan and geographic spread.
Tower to tower, there can be small variations in terminal design conditions. Will be finalised by OSBL DEC as design progresses.
4. In DTA and SEZ refineries, the cooling water supply pressure at source is 5.1 kg/cm2g and temperature is 32 0C. Cooling water return Pressure and temperature
at Unit battery limit is 2.8 Kg/cm2g and 45 0C respectively. The Pressure at grade near cooling tower must be sufficient for water to rise to Cooling tower nozzle.
These are applicable to PX4 and HPIB plants.
5. See section 8.6.1 for new proposal on circuit supply and return pressures, as well as delta P. The OSBL DECs need to confirm that a) return pressure indicated
in section 8.6.1 is adequate for the type of tower arrangement selected; b) ISBL DECs to advise the optimum pressure drop in ISBL units considering life cycle
costs (including OSBL pumping costs).

COOLING TOWER MAKE-UP WATER

Description
Make up from Sea water for Sea water cooling tower

Make up from treated effluent
Low Total Dissolved Solids water (LTDS)
Make up from treated effluent
High Total Dissolved Water (HTDS)
Make up from return condensate
DTA
SEZ
NOTES : (To be updated during Detail Engineering)
1. The sources for make-up to each cooling tower will be firmed up during facility design. The make-up source can vary from tower to tower in each complex.
2. Low Total Dissolved Solids Water as possible make-up source is indicated based on experience in DTA and SEZ refinery complexes. The quality of effluent water
will evolve as process design progresses and water circuits are analysed and configured for zero discharge.
3. High Total Dissolved Solids Water as possible make-up source is indicated based on experience in DTA and SEZ refinery complexes. The quality of effluent water
will evolve as process design progresses and water circuits are analysed and configured for zero discharge.
4. See section 8.6.2 for general approach to cooling tower specification.

DEMINERALIZED WATER BATTERY LIMIT CONDITIONS

Description
Demineralised Water 4 4.5 7.5 10 Amb Amb Amb 65
DTA 6.5 7 7.5 10 Amb Amb Amb 65
SEZ 6.5 7 7.5 10 Amb Amb Amb 65
NOTES :

HHP BOILER FEED WATER BATTERY LIMIT CONDITIONS

Description
Normal Design
Normal Design
(Note 2 &3) (Note 3)
HHP BFW 127.7 (Note 3) 163.2 (Note 3) 121 150
DTA 127.7 163.2 121 150
NOTES :
2. Pressure at destination is dependent on distribution network.
3. The HHP BFW network operating and design pressure will depend on the distance from process HHP generators in Gasification and ROGC
Complex and mode of integration with DTA refinery HHP BFW network, if any.

HP BOILER FEED WATER BATTERY LIMIT CONDITIONS

Description
Normal
Design Normal Design
(Note 2 & 3 )
HP BFW 59.2 78 121 150
DTA 59.2 78 121 150
SEZ 59.2 78 121 150
NOTES :
2. In DTA refinery, the pressure at source for HP boiler feed water is 68 kg/cm2g at 121oC. Pressure at destination is dependent on
distribution network.
3. In SEZ refinery, the pressure at source for HP boiler feed water is 75 kg/cm2g at 124oC. Pressure at destination is dependent on distribution
network.

MP BOILER FEED WATER BATTERY LIMIT CONDITIONS

Description
Normal
(Note 2 & 3 )
MP BFW 23.9 33.8 121 150
DTA 23.9 33.8 121 150
SEZ 23.9 33.8 121 150
NOTES :
2. In DTA refinery, the pressure at source for MP boiler feed water is 28 kg/cm2g at 121oC. Pressure at destination is dependent on distribution
network.
3. In SEZ refinery, the pressure at source for HP boiler feed water is 30 kg/cm2g at 124oC. Pressure at destination is dependent on distribution
network.

LP BOILER FEED WATER BATTERY LIMIT CONDITIONS
Description
Normal
(Note 2 & 3)
LP BFW 10.9 17.6 121 150
DTA 10.9 17.6 121 150
SEZ 10.9 17.6 121 150
NOTES :
2. In DTA refinery, the pressure at source for MP boiler feed water is 14.7 kg/cm2g. Pressure at destination is dependent on distribution network.
3. In SEZ refinery, the pressure at source for HP boiler feed water is 14.7 kg/cm2g. Pressure at destination is dependent on distribution network.

POTABLE WATER BATTERY LIMIT CONDITIONS
Description
Normal @ Normal @ Process
Normal @ User Design Min Normal Max Design
Source Battery limit
38
Potable Water 3.8 3.5 3 7 3 35 65
Note -2
DTA 5.3 3.5 3 7 3 35 43 65
SEZ 3.8 3.5 3 7 3 35 43 65
NOTES :
2. As per ANSI standard Z 358.1 - 2009

HHP STEAM BATTERY LIMIT CONDITIONS
Conditions at Source B.L Pressure (kg/cm2g) Temperature (oC)

Description
Pressure Temperature
(kg/cm2g) (oC)
HHP Steam 109 515 101 106 109 116 490 510 515 520
DTA 105.7 524 105.7 106 106.3 117 516 520 524 548
NOTES :
1. For reference, from current installation at Jamnagar.
2. Steam drivers and ejectors must be able to operate at minimum conditions.
3. These pressure, temperature figures are for HHP distribution network. Within the steam generation system HHP pressure, temperatures are likely to be
higher. Exact figures at generation end shall depend on the supplier of steam system.
4. Interconnect design pressures and temperatures shall be decided taking full cognizance of provisions in ASME B 31.1 and B 31.3.

HP STEAM BATTERY LIMIT CONDITIONS
Description
(kg/cm2g) (oC)
HP Steam 43.2 399 40.1 42.2 43.2 47.6 381 383 399 426
Flash Steam from BFW /

See Note-2
Condensate Drum
DTA 43.2 399 41.1 42.2 43.2 47.6 371 391 399 426
SEZ 43.2 399 41.1 42.2 43.2 47.6 371 391 399 426
NOTES :
A. The pressure and temperature at user battery limit is to be met.
B. The pressure and temperature at user battery limit is dependent on distribution network, connected generators and Steam turbines.
2. As per conditions of BFW / Condensate type from which flash steam originates and the pressure in the flash drum.

MP STEAM BATTERY LIMIT CONDITIONS

Description
(kg/cm2g) (oC)
MP Steam 17.2 260 15 16 17.2 21.1 201 232 260 365

See Note-2
Condensate Drum
DTA 17.2 260 15 16 17.2 21.1 201 232 260 288
SEZ 17.2 260 15 16 17.2 21.1 201 232 260 288
NOTES :
B. The pressure and temperature at user battery limit is dependent on distribution network, connected generators and Steam turbines.
2. As per conditions of BFW / Condensate type from which flash steam originates and the pressure in the flash drum.

4. Incase new MP steam network is connected to the existing MP steam network, it is required to have concrete mechanism for isolation between high design
temperature and low design temperature sections of MP steam network.

LP STEAM BATTERY LIMIT CONDITIONS

Description
(kg/cm2g) (oC)
LP Steam 4.6 232 3.5 4.1 4.6 8.1 147 158 232 260

See Note-2
Condensate Drum
DTA 4.6 232 3.5 4.1 4.6 8.1 147 177 232 260
SEZ 4.6 232 3.5 4.1 4.6 8.1 147 177 232 260
NOTES :

B. The pressure and temperature at user battery limit is dependent on distribution network, connected generators and Steam
turbines.
2. As per conditions of BFW / Condensate type from which flash steam originates and the pressure in the flash
drum.

HP CONDENSATE BATTERY LIMIT CONDITIONS
Description
HP Condensate 41.1 42.2 43.2 47.6 252 254 255 261
DTA 41.1 42.2 43.2 47.6 252 254 255 261
SEZ 41.1 42.2 43.2 47.6 252 254 255 261
NOTES :
1. Based on current installation at Jamnagar. To be verified during facility design.
2. Condensate pressures represent the pressure at grade.

MP CONDENSATE BATTERY LIMIT CONDITIONS

Description
MP Condensate 15 16 17 21.1 201 203 206 217
DTA 15 16 17 21.1 201 203 206 217
SEZ 15 16 17 21.1 201 203 206 217
NOTES :

LP CONDENSATE BATTERY LIMIT CONDITIONS
Description
LP Condensate 3.5 4.1 4.6 8.1 147 152 154 175
DTA 3.5 4.1 4.6 8.1 147 152 154 175
SEZ 3.5 4.1 4.6 8.1 147 152 154 175
NOTES :


COLD CONDENSATE BATTERY LIMIT CONDITIONS

Description
Cold Condensate 5 10 11 15.4 35 90 100 150
DTA 3.5 4.75 40 95
SEZ 3.5 16 45 88
NOTES :

RETURN CONDENSATE BATTERY LIMIT CONDITIONS

Description
Cold Condensate 4 5 7 15.4 80 90 100 150
DTA
SEZ
NOTES :

FUEL GAS BATTERY LIMIT CONDITIONS AT DTA AND SEZ REFINERIES

Description
Fuel Gas (Note 1) 3.2 3.9 4.6 6.5 38 38 94 120
DTA 3.2 3.9 4.6 6.5 38 38 90 120
SEZ 3.2 3.9 4.6 6.5 38 38 94 120
NOTES :

SYN GAS BATTERY LIMIT CONDITIONS
Pressure (Kg/Cm2g) Temperature (oC)

Description
Syn gas from DTA gasification to DTA CPP 29.5 30
Syn gas from SEZ gasification to SEZ CPP 29.5 30
Syn gas to J3 CPP 29.5 30
NOTES :
1. Within J3 CPP's appropriate pressure reduction and heating arrangement shall be provisioned as required for the GTGs, HRSGs and Auxiliary boilers.
2. For the DTA and SEZ refineries CPPs, the performance and adequacy of existing hardware shall be verified by responsible DEC.
3. Information related to Syn Gas is furnished based on latest available information. The design conditions shall get firmed up as design evolves.

SYNTHETIC NATURAL GAS BATTERY LIMIT CONDITIONS

Description
SNG @ RFG DTA refinery (Note -2) 7.5 38
SNG @ RFG SEZ refinery (Note -3) 7.5 38
SNG @ Pipeline (Note -4) 73 38
NOTES :
1. Information related to Synthetic Natural Gas is furnished based on latest available information. The design conditions shall get firmed up as design evolves
2. SNG conditions at DTA gasification shall be maintained such that the pressure, temperature at existing burners in the refinery remain within range.
3. SNG conditions at SEZ gasification shall be maintained such that the pressure, temperature at existing burners in the refinery remain within range.
4. For SNG to be routed to gas grid contractual conditions shall need to be satisfied.

HYDROGEN SYSTEM BATTERY LIMIT CONDITIONS

Description
Return hydrogen from DTA gasification to DTA refinery
Return hydrogen from SEZ gasification to SEZ refinery
Return hydrogen from ROGC to DTA refinery
NOTES : (To be updated during Detail Engineering)

1. The battery limit conditions shall be adjusted based on the final intake system in DTA and SEZ refineries, where respective streams will be tied in.

RETURN FUEL GAS FROM PX4 BATTERY LIMIT CONDITIONS

Description
Off gas from Xylene recovery column 6.1 43
Off gas from TA stabilizer 6.5 15
Off gas from TA Reactor Purge 25 48.6
Depentanizer Off gas 5.3 36.6
NOTES :
1. The battery limit conditions shall be adjusted based on the final gas collection and despatch system to ROGC from DTA refinery, where respective streams will
be tied in.
3. Design conditions shall be furnished by ISBL DEC as design progresses.

RETURN FUEL GAS FROM MEG BATTERY LIMIT CONDITIONS

Description
Fuel gas from MEG 17.3 40
NOTES :
1. This stream has oxygen. Most likely this will need to be disposed of to a furnace through dedicated low pressure burner as in Merox offgas.

NATURAL GAS BATTERY LIMIT CONDITIONS

Description
Natural Gas intake to DTA

Gasification
Natural Gas intake to SEZ
Gasification
Natural Gas intake to ROGC
Natural gas to CPP's
DTA
SEZ NG to HMU 34.5 42.8 15 - 20 -20 to 60
SEZ NG to CPP 34.6 42.8 15 - 20 -18 to 60
NOTES :
1 NG system battery limit pressures will be worked out based on GSPCL skid outlet and line drops to J3 consumers.
2. NG line to SEZ gasification units may integrate with existing NG line to SEZ refinery.
3. NG line to DTA gasification and ROGC units may integrate with existing NG line to DTA refinery.
4. Performance and adequacy of the respective pressure reduction and metering skids of GSPCL shall need to be verified through GSPCL.

ELECTRICITY BATTERY LIMIT CONDITIONS
Description
Voltage Frequency(Hz) Phase Earthing
HHT Level 220 kV 50 3 neutral solid resistance earthed
HT Level 33kV 50 3 neutral solid resistance earthed
HT Level 6.6kV 50 3 neutral low resistance earthed
LT Level 415 V 50 3 neutral solidly earthed
Electrical Control Supply 240 V 50 single neutral solidly earthed
Small Power and lighting supply 240 V 50 single neutral solidly earthed
UPS Level 110 V 50 single one pole solidly earthed
Switchgear ( circuit Breaker control) 220 V DC
NOTES :
1. See also Electrical Design Basis RPMS-ENGG-DBD-EL-001.

PLANT AIR BATTERY LIMIT CONDITIONS
Pressure (kg/cm2g) ( Note 2 & 3) Temperature (oC)

Description
Min Normal Max Design Min Normal Design
Plant Air 5 7.7 8.5 10 40 40 65
DTA 5 7.7 8.5 10 10 55 65
SEZ 5 7.7 8.5 10 10 40 65
NOTES :
2 In DTA refinery, the Pressure and temperature at source are
Plant Air : 8.1 / 6.7 kg/cm2g and 32 0C .The Pressure at user battery limit is dependent on distribution network.
3. In SEZ refinery , the Pressure and temperature at source are
Plant Air : 7.8 kg/cm2g and 32 0C. The Pressure at user battery limit is dependent on distribution network.

INSTRUMENT AIR BATTERY LIMIT CONDITIONS
Pressure (kg/cm2g) ( Note 3 & 4) Temperature (oC) ( Note 3 & 4 )
Description
Instrument Air ( Note 3) 6 7 8 10 40 40 65
DTA 6 7 8 10 10 55 65
SEZ 6 7 8 10 10 40 65
NOTES :
2. For isolation valve actuator sizing use 4.5 Kg/cm2g.( See also RPMS-ENGG-DBD-CI-001)
3 . In DTA refinery, the Pressure and temperature at source are
Instrument Air : 8.7 kg/cm2g and 32 0C . The Pressure at user battery limit is dependent on distribution network.
4 . In SEZ refinery , the Pressure and temperature at source are
Instrument Air : 8.7 kg/cm2g and 32 0C. The Pressure at user battery limit is dependent on distribution network.

BREATHING AIR BATTERY LIMIT CONDITIONS

Description
Breathing Air 5 7.7 8.5 10 40 40 65
DTA
SEZ 6 9.1 10 10 40 65
NOTES :

NITROGEN SYSTEM BATTERY LIMIT CONDITIONS

Description
Normal
Min Max Design Min Normal Max Design
( note 5)
High Pressure Nitrogen( Note 2) 13 13.7 15.4 38 38 43 65
Low Pressure Nitrogen 6.5 7 8 10.5 38 43 65
LLP Nitrogen (Note 4) 4 Amb

NOx control Nitrogen
25 29.5 100
( Note 3 and 4)
DTA (HP Nitrogen) 13 13.7 15.4 38 43 65
DTA (LP Nitrogen) 6.5 7 8 10.5 38 43 65
SEZ (HP Nitrogen) 13 13.7 15.4 38 43 65
SEZ (LP Nitrogen) 6.5 7 8 10.5 38 43 65
NOTES :
1. Based on current installation at Jamnagar. To be ensured during facility design of J3 by OSBL Designer.
2. HP Nitrogen Battery Limit Conditions to be firmed up based on requirements for J3 Units.
3. Required for Both DTA and SEZ refineries
4. Gasification ASUs will be major sources of nitrogen. LLP and MPDGAN details are based on ASU data.
5. In DTA and SEZ refineries, pressure at source for LP nitrogen is 7.3 kg/cm2g and temperature is 32 0C

16. ANNEXURE 4 – Rainfall Intensity Chart


Design Basis For General Civil
RPMS-ENGG-DBD-CS-002
0 25.08.2020 Issued for Implementation SD PGN SPC/VKM

By By By
Reliance Project Management System RPMS-ENGG-DBD-CS-002
Design Basis For General Civil Date: 25.08.2020 Rev 0

(DD.MM.YYYY)
1 Kuddallur Seshadri ________________ ___________
S Sammaddar _________________ ___________

2
Sankar Chakraborty _________________ ___________

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
___________
10 _____________________________ _________________
RECORD OF REVISIONS

Number
Contents
1. Scope ......................................................................................................................... 5
2. Terms, Abbreviation and Definitions ......................................................................... 5
3. Dimensions and Units: .............................................................................................. 6
4. References ................................................................................................................. 6
5. Conflicts and Deviations .......................................................................................... 12
6. Site Grading / Earthwork and Plant Level Philosophy ............................................ 12
7. Fencing, Compound Wall & Gates .......................................................................... 14
8. Flexible Pavements (Asphalt), Rigid Pavements (Concrete) and Site Finishes ....... 16
9. Drainage Systems .................................................................................................... 24
10. Storage ponds/Reservoirs – Raw Water, Construction water, Storm Water, Fire
water and Evaporation Pond .................................................................................. 45
11. Guard rails and safety bollards ............................................................................... 46
12. Road / pavement marking and sign boards ............................................................ 46
13. Erosion Control & Slope Protection ........................................................................ 47
1. Scope
The scope of this document is to provide minimum design requirements to
establish a standard design engineering practice for General Civil activities such as
Site Grading/Earthwork, Plant Level philosophy, Fencing / Boundary Wall & Gates,
Asphalt Roads, Rigid Pavements (Concrete), Site Finishes, Drainage system
including Storm Water, Oily Water Sewer, Hydrocarbon Contaminated and Process
Waste Streams Drainage, Chemical Sewer, Sanitary Sewer Disposal system, Storage
Ponds/Reservoirs – Raw Water, Construction water, Storm Water and Firewater
including.
2. Terms, Abbreviation and Definitions
AG Above Ground
ARI Average Recurrence Interval
BEDD Basic Engineering Design Data
B/L Battery Limit
CBD Close Blow Down
CS Storm Water
CSA Civil, Structural and Architectural
CSWP Contaminated Storm Water Pit
ETP Effluent Treatment Plant
FGL Finished Grade Level
FOF Face of Flange
HAT Highest Astronomical Tide
HFL High Flood Level
HPP High Point of Paving
ISBL Inside Battery Limit (referred herein as Process Unit area)
LNG Liquefied Natural Gas
LPG Liquefied Petroleum Gas
LPP Low point of Paving
OSBL Outside Battery Limit (offsite areas)
OWS Oily Water Sewer

P&ID Piping & Instrument Diagram

PFD Process Flow Diagram
RGL Rough Grade Level
SOP Standard Operating Procedure
SER Site Engineering Request
SS Sanitary Sewer
UG Under Ground
Catch Basin Catch Basin is an open device used at a single point to collect
surface drainage with a liquid seal and sediment trap
Clean Out A piping connection in a sewer system that is located at grade
level for cleaning the system
Dry Box Dry boxes are located at the low point of drainage areas
containing fired equipment
Manhole An access or opening by which a man may enter or leave a sewer
for inspection, cleaning and other maintenance operations,
fitted with a suitable cover
3. Dimensions and Units:
The International System of Units (abbreviated SI) shall be used.
Dimensions Millimeter (mm)

Elevations meter (m)
Force: kiloNewton (kN)
Loadings kiloNewton/m² (kN/m²).
Mass kilogram (kg)
Moment kiloNewton meter (kNm)
Pressure kiloPascal (kPa)
Stress Newton/mm² (N/mm²) or Mega Pascal (MPa).
4. References
All work shall conform to the latest Indian Standards /code of practice as listed
below unless otherwise specially permitted by RIL to DEC. The revision of
standard/code with amendments, current “as on start date of the Project” shall be
applicable throughout the tenure of the project unless otherwise specifically
agreed between RIL and the DEC.

4.1. Reliance Standards
Standard Title
RPMS-ENGG-DBD- Design Basis for Civil, Structural & Architectural
CS-001
RPMS-HSEF-DBD- HSE Engineering and Loss Prevention Philosophy
HS-001
RPMS-HSEF-DBD- Design Basis for Fire Water Protection System
HS-002
RPMS-ENGG-DBD- Drainage System Design Philosophy and Coordination
PS-002
RPMS-ENGG-SPC- CSA Material Stock Code Index
CS-003
RPMS-ENGG-SPC- Specification for Earthwork
CS-004
RPMS-ENGG-SPC- Specifications for materials and workmanship for
CS-005 Bituminous Roadwork
RPMS-ENGG-SPC- Specification for Installation of Underground Piping
CS-020
RPMS-SD-C18-201 U/G Services Legend, Abbreviations and General Notes
RPMS-SD-C18-202 Typical Plan and Section of Oily Water Manhole
RPMS-SD-C18-203 Details of Vent Pipes (ISBL and OSBL Areas)
RPMS-SD-C18-204 Typical Plan & Section of Storm Water Manhole

(Flooded System)
RPMS-SD-C18-205 Typical Details of Catch Basin
RPMS-SD-C18-206 Typical Plan & Section of Sanitary Sewer Manhole
RPMS-SD-C18-207 Typical Details of Manhole & Catch Basin Cover Slab and
Manhole Cover Detail
RPMS-SD-C18-208 Typical Detail of Steel Ladder & MS Rungs for Manhole
and Catch basin

Standard Title
RPMS-SD-C18-209 Typical Details of Concrete Dry Box
RPMS-SD-C18-210 Typical Detail of Cleanout for OWS Drain
RPMS-SD-C18-211 Typical Details of Oily Water Sewer Drain Hub and

Closed Drain Riser
RPMS-SD-C18-212 Typical UG and AG Interface for Fire Water Hydrant,
Monitor and Hosereel
RPMS-SD-C18-213 Typical Format for Manhole and Catchbasin Schedule
RPMS-SD-C18-214 Fire Main Valve Pit 4”, 6” & 8” Dia Butterfly
RPMS-SD-C18-215 Fire Water Valve Pit and Spool Pieces for Hydrotesting
(10” and above) – Concrete Details (2 sheets)
RPMS-SD-C18-216 Typical Lifting Details of Precast Manhole and Catch
basin
RPMS-SD-C18-217 Typical Road Cross Section Details
RPMS-SD-C18-218 Typical Road Side Corridor Details
RPMS-SD-C18-219 Typical Details of RR Stone Masonry Head wall for Storm

Water Culvert
RPMS-SD-C18-220 Typical Trapezoidal Storm Water Ditch Details
RPMS-SD-C18-221 Typical Details of Crash Barrier
RPMS-SD-C18-222 Typical Details of Safety Bollard
RPMS-SD-C18-223 Typical Detail of Corner Embedded Angle
RPMS-SD-C18-224 Typical Detail of Grating
RPMS-SD-C18-225 Typical Details of Heavy Duty Perforated RCC Drain

Covers
RPMS-SD-C18-226 Details of Light, Medium and Heavy-Duty Pavement
RPMS-SD-C18-227 Typical Details of Cable Duct bank for Road Crossing
RPMS-SD-C18-228 Typical format for Cable Duct Bank Schedule

Standard Title
RPMS-SD-C18-229 Details of Precast Concrete Wall Cable Trench and
Electrical Trench Blockwork Side Walls
RPMS-SD-C18-230 Cable Route/Pipe Route Marker
RPMS-SD-C18-231 Typical Instrument / Electrical Cable Trench Crossing

Details
RPMS-SD-C18-232 Typical Cable Trench Crossing Under Preformed Ditch,
Buried Pipe line and Cable Trench
RPMS-SD-C18-234 Inlet Pipe Details
RPMS-SD-C18-235 GA & RC Detail for Channel Interceptor& Manhole Type-

II
RPMS-SD-C18-236 Fire Main Valve Pit Details (for Gate Valves)
RPMS-SD-C18-237 General Arrangement of Contaminated Storm Water Pit
RPMS-SD-C18-238 Pipe Bedding for Rigid Pipes in Trenches
RPMS-SD-C18-239 Pipe Bedding for Flexible Pipes in Trenches
RPMS-SD-C18-240 Typical Details of Steps in Road Side Embankments
RPMS-SD-C18-241 Cooling water manway details
RPMS-SD-C18-242 Typical Details of Precast Concrete Pipe Septic Tank

Details for Substation
RPMS-SD-C18-243 Typical Detail of Concrete Kerb Stone
RPMS-SD-C18-244 Typical Detail of Footpath
RPMS-SD-C18-245 Detail of Pipe Entry to ditch
RPMS-SD-C18-246 Drinking Water Valve Pit
RPMS-SD-C18-247 Typical Details of RCC Rectangular Storm Water Drain
RPMS-SD-C18-248 Typical Details of RCC Storm Water Box culvert
RPMS-SD-C18-249 Typical Details of Concrete Cross Over Slab for Storm

Water Drains

Standard Title
RPMS-SD-C18-261 Cleanout Detail for Closed Blow Down (CBD) System
RPMS-SD-C18-262 Typical Drain Hub Detail for Cluster of Drains
4.2. Industry Codes and Standards
Code Title
CPHEEO CPHEEO Manual on Sewerage and Sewage Treatment
(CPHEEO: Central Public Health and Environmental
Engineering Organization)
OISD-RP-108 Recommended Practices on Oil Storage and Handling
OISD-STD-109 Process Design and Operating Philosophies on Blow
Down and Sewer System
OISD-STD-116 Fire Protection Facilities for petroleum Refineries &
Oil/Gas processing Plants
OISD-STD-117 Fire Protection Facilities for petroleum Depots,
Terminals, Pipeline Installations and Lube oil
Installations.
OISD-STD-118 Layout for Oil and Gas Installations
OISD-STD-144 Liquefied Petroleum Gas (LPG) Installations
OISD-STD-173 Fire Prevention and Protection System for Electrical

Installations
IRC: 3 Dimensions and Weights of Road Design Vehicles
IRC: 6 Standard Specification and code of Practice for Road

bridges
IRC: 37 Guidelines for Design of Flexible Pavements
IRC: 56 Recommended practices for Treatment of Embankment

and Roadside Slopes for Erosion Control
IRC: 58 Guidelines for the Design of Plain Jointed Rigid
pavements for Highways.

Code Title
IRC: 86 Geometric Design Standards for Urban Roads
IRC: SP 63 Guidelines for use of interlocking concrete block

pavement
MORT&H Ministry of Road Transport and Highways Specification
for Road and Bridge works
NBC National Building Code
IS 456 Code of Practice for Plain and Reinforced Concrete.
IS 458 Precast Concrete Pipe with and without reinforcement
IS 783 Code of Practice for Laying of Concrete Pipes
IS 1172 Code of Basic Requirements for Water Supply, Drainage

and Sanitation
IS 1726 Cast Iron Manhole Covers and Frames
IS 1742 Code of Practice for Building Drainage
IS 1786 High Strength Deformed Steel Bars and Wires for

Concrete Reinforcement – Specification.
IS 2629 Recommended Practice for Hot-dip Galvanizing of Iron
and Steel
IS 4111 Code of Practice for Ancillary Structures for Sewerage
System
IS 4826 Specification for Hot-dipped Galvanized Coatings on
Round Steel Wires
IS 4984 Specification for HDPE Pipes for Potable Water, Sewage
and Industrial Effluents
IS 15328 uPVC Non-Pressured Pipes for Use in Underground
Drainage & Sewerage Systems
IS 15658 Precast concrete Block for Paving- Specifications

Code Title
BS 729 Specification for Hot Dip Galvanized Coatings on Iron
and Steel Articles
5. Conflicts and Deviations

In case of conflict between the regulations, codes and standards, the precedence
of requirements shall be as follows:
• National and/or Local Regulations
• This Design Basis
• Project Design Criteria
• Industry Codes and Standards
During the design, any conflict between the project documents and/or
national/local regulations that result in conflict with this design basis shall be
highlighted and submitted to RIL with the proposed action plan for resolution.
6. Site Grading / Earthwork and Plant Level Philosophy
6.1. Existing Site Conditions
Current site topographic survey conducted for the project or as approved by the
project shall be used to define existing site conditions. This topography shall form
the basis of all earthwork calculations.
For geotechnical recommendations and subsurface conditions, refer to the
Geotechnical report established for the work.
6.2. Site Preparation and Grading
The site preparation and grading activities including clearing, grubbing, stripping,
excavation and backfilling shall be in accordance with RIL specification no. RPMS-
ENGG-SPC-CS-004, Specification for Earthwork.
Site shall be graded to provide positive drainage and prevent ponding. Specific
attention shall be made to areas around at-grade or above-grade structures to
ensure structures do not block flow paths or trap water.
Surface Slope shall be as per Table-001, Slope in Graded Area.

Table-001 Slope in Graded Area
Item/Area Description Finished Grade/ Slope

General Site Grading (Rough Grading) 0.1% to 0.2%
Finished grading after completion of major 0.2% to 0.5%
construction
Finished Grading inside Tank Dikes 0.2% to 1.0%
Tank Farms (Flammable liquid) 1% for first 15m
Parking Areas 0.5% to 5.0%
Embankments shall be benched, if required, in accordance with the

Recommendations of Geotechnical Report established for the work and protected
to prevent erosion by wind and rain.
6.3. Plant Level Philosophy
Plant Rough Grade Level (RGL) should be minimum 300 mm above the High flood
level (HFL) established for the project, during a 100 year ARI storm and the Highest
Astronomical Tide Level (HAT) for marine facilities.
Finished Grade Level (FGL) in unpaved areas like tank farms/off sites/non-plant
shall be minimum 150mm above rough grade level.
Plant levels shall be as per Table-002, Plant Level Philosophy.
Table-002 Plant Level Philosophy
Item Description Level/Elevation

Offsite Area / Non Plant Area RGL/FGL
Open Area RGL/FGL
Tank farm
Operating Grade slab around Pump 150mm above FGL or 300 mm above
Skids (HPP) RGL
High Point of Paving (HPP) for Process 150mm above FGL or 300 mm above
unit RGL
Top of pipe sleeper, pipe support, Minimum 300 mm above FGL in
pedestal top unpaved areas and 150 mm above HPP
in paved areas
Truck Loading Area (Paved Area) (HPP) Min 150mm above FGL or 300 mm
above RGL

Item Description Level/Elevation

Buildings
Level Around Building Min 150 mm above FGL or 300 mm
above RGL
Min 450mm above FGL or 600 mm
Plinth Level of Building
above RGL
7. Fencing, Compound Wall & Gates

7.1. Fencing
Perimeter security fencing shall be chain link or welded mesh with galvanized pipe
or concrete posts with necessary stays as per the layout and standard drawings.
Fencing shall have a maximum mesh size of 50 mm for chain link fencing and 26 sq.
cm. for welded mesh fencing.
Fencing post and spacing shall be determined in accordance with the design wind
load established for the project.
Security barriers shall be provided at all locations where security fences must cross
culverts, drainage ditches, swales or other openings larger than 645 sq. cm.
Security fencing shall not be less than 2100 mm in height with additional minimum
300 mm high barb-wire for normal/standard industrial security fence wherever
required as per security requirements.
Fencing for utility areas, laydown areas, etc. shall not be less than 1800 mm in
height.
All posts, fixtures etc. shall be hot dip galvanized to IS:2629 and BS:729 with min.
coating weight of 610 gram/sqm.
Barb wire shall be galvanized with min. coating weight of 110 gm./sqm as per Table
2 of IS 4826.
7.2. Compound Wall
Compound wall shall be opaque type and shall be made of concrete / brick or
Random Rubble Masonry.
Compound wall design to be checked for wind forces.
The height of compound wall from the grade level shall be 2.4 m minimum. On the
perimeter (property) compound wall the minimum height of the compound wall
shall be 3.0 m. The height does not include concertina height.
The wall shall have anti-climbing design such that the wall itself should not act as a
ladder from inside / outside to help the intruder to climb-over.

Concertina coil (razor type) with proportionate size of ‘Y’ shape or ‘T’ Shape iron
angles atop the wall shall be provided. The height of concertina shall be 710 mm in
one loop as a minimum. In certain areas, as per security requirements, two coil
loops one over another of 710 mm each shall be provided.
The Concertina coil shall be 12 SWG, hot dip galvanized. The Concertina coil shall
be tied to horizontal barbed wire using 1.62 mm galvanized steel wire @400 mm
c/c. All barbed wire shall be properly strained.
7.3. Main Entrance Area
Main entrance gate shall be as per layout or standard drawing. Number of lanes
will be as per project requirement. Following are general requirement at main
entrance area.
• Security barrier arms
• Automatic bollards
• Denial lane for sending back the vehicle if entry is denied
• 1m median between lanes in case of more than one lane
• Shed for security guards at vehicle/pedestrian checking lanes
• Sufficient standard display board
7.3.1. Gates/Gate Houses
Main entrance gate and gate house shall be provided with separate segregated
movement space for pedestrian entry, space to keep door-frame metal detector,
space for physical screening (separate space for females), space to keep X-ray
baggage scanners, shelters for tripods / x-ray baggage scanners / turnstiles Waiting
area for visitors, registration, basic amenities like washroom, drinking water, pantry
etc., office space for duty officer / staff.
7.3.2. Contract Work Force Entry Gates
Contract work force entry gates shall be separate but provided with amenities as
like main entrance gate plus boarding/deboarding station for workforce.
7.3.3. Material Handling Gates
Material handling gates shall be provided with elevated checking platform, office
space for material logging/checking/crew registration depending upon the volume
handled, office space for duty officer/material gate in-charge/excise/custom
officials as per requirement. Following general requirements to be incorporated in
the layout:
• Sufficient parking space for entry and exit vehicles
• Truck Driver Rest shed and washroom facilities
• 50 m on both side of the gate to be concrete road
8. Flexible Pavements (Asphalt), Rigid Pavements (Concrete) and Site

Finishes
8.1. Definition of Terms
The following road classifications shall be used for the design of roads within the
plant site.
Road Type 1 - Main Plant Access Road:
Main traffic distributor road within the plant, and main vehicular access road
connecting the plant to the Public Highway.
Road Type 2 - Primary Road:
A main traffic route, for a tanker truck or semi-trailer truck route, including access
for heavy cranes. This type shall be used during construction phase and heavy lift
movement and during shut down period.
Road Type 2A - Primary Road:
A main traffic route, for man and material movement within the plant. Also used
for a tanker truck or semi-trailer truck route, including access for heavy cranes.
Road Type 3 - Primary Road:
A main traffic route, for man and material movement within the plant. Also used
for a tanker truck or semi-trailer truck route.
Road Type 3A - Primary Road:
A main traffic route, for a tanker truck or semi-trailer truck route including access
for medium to light cranes. This type shall be used for construction and shut down
period.
Road Type 4 - Secondary Road:
A road subject to regular operational or maintenance traffic but not subject to high
traffic volume and crane movement.
Road Type 5 - Firefighting Access way:
An access way specifically located to provide access for firefighting equipment.
Access ways:
A distinctly delineated travelled way within process units which provide access to
equipment in congested areas, which shall be paved as specified in the drawings.
8.2. Concrete Pavement
A rigid reinforced concrete slab, used as area paving within process units/operating
areas or as an alternative to flexible road pavements in areas subjected to heavy
traffic, e.g. warehouse areas, loading and unloading areas, weighbridge areas, areas
where heavy maintenance equipment is used or in high rainfall locations.

8.3. Geometric Design Basis – Roads

8.3.1. Carriageway and Shoulder Widths
Minimum carriageway and shoulder widths shall be as listed below. Shoulder
widths shall be added to the carriageway widths to obtain minimum roadway
widths.
On routes designated for the movement of the heavy lifting equipment for
maintenance purposes, a clear roadway of 16m shall be provided. This roadway
shall be clear of all signs, lighting columns, hydrants and ditches etc., all such items
being located beyond the edge of the roadway. The permanent road shall be
located centrally within the roadway.
Table-003: Carriageway and Shoulder Widths of Roads
Road Type Carriageway Width Shoulder Width Roadway Width
1 14.0 m 2.0 m 18.0 m

2 7.0 m 4.5 m 16.0 m
2A 14.0 m 1.0 m 16.0 m
3 7.0 m 1.5 m 10.0 m
3A 7.0 m 2.5 m 12.0 m
4 6.0 m 1.0 m 8.0 m
5 6.0 m - 6.0 m
6. As shown on plot plan
8.3.2. Turning Radius

Minimum radii for edge of carriageway for 90 degrees intersection shall be as per
below table.
Table-004: Turning Radius of Roads
Road Type Turning Radius

Road Type 1 15 m
Road Type 2 12 m
Road Type 2A 15 m
Road Type 3 12 m

Road Type 3A 12 m
Road Type 4 & 5 8 m (Min.)
Where junctions involve different road types, the radii shall be as for minor road
type.
8.3.3. Grade Limitations
Gradients on public roads shall conform to the requirements set out in IRC 86. The
gradients for all the roads within the complex shall be as per below table-005 Grade
Limitations of Roads:
Table-005: Grade Limitations of Roads
Longitudinal Grade Limitations Maximum % Minimum %

Road Type 1, 2, 2A, 3 and 3A 3.0 NA
Road Type 4 & 5 6.5 NA
Access ways (Ramps) 10.0 NA
Parking Areas 5.0 1.0
Roads carrying Super Over Dimensional 1.0 NA
Consignment (Long Vessels > 80m)
Cross fall/Camber Limitations
Cross fall for Road Types 1, 2, 2A & 3 and 3A 2 1.67
Cross fall for Road Types 4 & 5 3.33 1.67
Cross fall for Roads carrying Super Over 1 0.5
Dimensional Consignment (Long Vessels > 80m)
Note:
The super elevation (Cross slope) of plant roads shall be according to Table-005. In
special circumstances 4% gradient may be considered. In no case the gradient more
than 4% shall be provided which is required for convenience in construction and for
facilitating easy and safe movement of vehicles.
8.3.4. Horizontal and Vertical Alignment

In general, horizontal curves for public road and road Type 1 shall consist of a
circular portion with spiral transition curves at either end and shall conform to the
requirements of IRC 86.
Super elevation shall conform to the requirements of IRC 86, Table 9.

Vertical curves shall be designed in accordance with IRC 86 and shall be provided
at all grade changes exceeding those set out in Table 14 in IRC 86.
8.3.5. Horizontal and Vertical Clearance (Ref. IRC. 86)
At roads without raised kerbs, a horizontal clearance of 1.0 m shall be maintained
between the edge of the shoulder and any structure projecting above shoulder
grade. However, for guard rails and traffic signs the minimum horizontal clearance
shall be 0.5 m from the edge of the hard shoulder.
At roads with raised kerbs, the minimum horizontal clearance shall be 0.6m from
the face of kerb.
Horizontal clearances shall be maintained for the full required vertical clearance for
the road classification.
The vertical clearances shall be as defined in the plant design basis and as per traffic
and heavy lift requirements.
8.3.6. Access to Plant Site
The junction of the Main Plant Access Road and the public highway shall be
designed in compliance with IRC and MORT&H requirements and receive the
approval of the Local Authorities. Full construction details shall be provided on the
drawings.
8.3.7. Miscellaneous
8.3.7.1 Kerbs
Kerbs shall be pre-cast concrete or in-situ concrete as detailed on the drawings.
8.3.7.2 Culverts and Pipe track Crossings
At culvert and pipe track crossings the road width shall be continuous. The hard
shoulders shall generally be reduced to 0.5 m on each side of the culvert or pipe
crossing as details on the drawings. Crash barriers shall be provided.
8.3.7.3 Surface Drainage
All roads, except access ways, shall be crowned and storm water shall drain into
ditches provided on both sides of the roads, and as detailed on the drawings.
Only where specified, roads shall be edged with precast concrete kerbs with
150mm gap between each section of kerb.
8.4. Structural Design Basis
All roads shall be designed for the appropriate climatic conditions prevailing at the
particular project site.
The Design Life of roads shall be twenty (20) years.

8.4.1. Loadings
Loading for public roads shall conform to the requirements of IRC 3 and IRC 6.
Loadings for roads within the refinery shall be derived from the Operational and
Construction period Traffic Logistic Plan or IRC 3 and IRC 6 whichever is the most
severe loading condition.
8.4.2. Design of Flexible Roads
The roads shall be designed in compliance with IRC37 and MORT&H (Ministry of
Road Transport & Highways) requirements. For Materials and Workmanship of
bituminous roads, Specification No RPMS-ENGG-SPC-CS-005 shall be referred.
Suitable measures of soil stabilization, including use of geotextiles shall be
considered based on site specific geotechnical properties of subgrade.
8.4.3. Design of Concrete Roads
Reinforced and unreinforced concrete road pavements shall be designed in
accordance with IRC 58 and MORT&H requirements and constructed in accordance
with details provided on the drawings.
8.4.4. Parking Areas
Parking areas shall have bituminous paving of suitable design thickness as specified
on the drawings.
Concrete paving shall be used in
• Areas subject to excessive hydrocarbon spillage.
• Weigh bridge Areas.
• Warehouse Parking.
• Loading / Unloading Gantry Area.
8.4.5. Walkways
Walkways and footpaths at grade shall be a minimum of 0.9m wide. Construction
shall comprise of Pre-cast concrete interlocking paver block pavement. The paver
block shall conform to IS 15658 and installation shall be as per IRC SP-63. For heavy
traffic areas, the paver blocks shall be minimum 100 mm thick and M50 grade and
for non-traffic areas, it shall be 60 mm thick and M35 grade. Suitable curb wall on
all sides shall be provided for laterally restraining the paver block construction.
8.5. Area Paving
8.5.1. General
• Minimum Grade of Concrete for RCC Pavements and Grade Slab shall be M-
20.
• Paving shall be designed to suit the Unit operating requirements.

• In Process and Utilities units, paving shall be provided to achieve proper

access and operating space around the equipment.
• Paving for potentially contaminated Process Units shall be provided with
catch basins connected to the storm water sewer.
• The catch basins must be located so that the paving slopes away from
process equipment and pipe racks.
8.5.2. Culverts, Paving and Trench Cover Loads
Concrete pavement, culverts, manhole, catch basins and trenches including covers
subjected to vehicular traffic in main roadways or truck loading area shall be
designed for maximum wheel load. The wheel load shall be calculated in
accordance with IRC 6 Code of Practice for Road Bridges or actual traffic load data
obtained from traffic logistic plan.
Concrete pavement, manhole, catch basins and trenches including covers in
process area or other areas with access to vehicular traffic shall be designed for
maximum anticipated wheel loads. Concrete pavement, manhole, catch basins and
trenches including covers in process units shall be suitable for Hydra crane
movement as a minimum. For crane movement areas the design shall be checked
against the maximum crane loads.
Concrete pavement, manhole, catch basins and trenches including covers in off-site
and manhole, catch basins and trenches including covers in unpaved areas with no
vehicular access shall be designed for a uniform loading of 5 kN/m².
Hardstand suitable for actual crane capacity which is anticipated to be deployed for
erection shall be constructed to suit erection scheme.
Public highway structure shall be designed in accordance with the Government of
India Ministry of Road Transport & Highways Specification and Indian Road
Congress Specifications.
Manholes and catch basins shall be avoided as far as possible in the corridor
identified for vehicle movement.
8.5.3. In-Situ-Concrete Paving
All materials for concrete, reinforcement and cover requirement shall be in
accordance with Plain and Reinforced Concrete Specification No RPMS-ENGG-SPC-
CS-001.
Pavement shall be placed over a solid and compacted sub-base, free from loose
material. If sub-grade is a well compacted granular material achieving a minimum
CBR value of 25%, a sub-base will not normally be required. The slab shall be cast
onto a 75mm thick layer of blinding concrete (as per plain cement concrete
specification)

Where paving is to be placed on backfilled soil, backfilling shall be structural fill

compacted in layers of 200mm, each layer compacted to 98% standard proctor
density.
The pedestrian paving shall normally be 100mm thick (Light Duty Paving),
reinforced with one layer of high tensile square mesh fabric or rebar as defined on
the drawings, placed 50mm below top surface
In drop-out (maintenance area) and areas accessible to maintenance vehicles, the
paving shall be minimum 150mm thick (Medium Duty Paving), with one layer of
mesh fabric or rebar as defined on the drawings. However, each DEC shall evaluate
the functional requirement and design the RCC pavement, if loads anticipated on
the pavement are higher.
Foundation plinths penetrating the paving shall be isolated from the paving by pre-
moulded joint filler (non-extruded type), conforming to IS 1838 caulked with
elastomeric poly sulphide, hydrocarbon oil resistant sealant.
12mm thick compressible filler shall be used around foundation supporting
structures and static equipment.
25mm thick compressible filler shall be used around foundations supporting heavy
vibratory equipment. In areas subject to acid, caustic or chemical spills detrimental
to concrete, the concrete surface shall be adequately protected, i.e. by overlaying
with appropriate proprietary brand paint, tiles etc.
Control joint in paved surface shall be sawn within 8 to 24 hours after concrete
placement. Control joint shall at be at a spacing of 7M X 7M (Max)
The routes of buried cables through concrete paved areas shall be identified by red
colour concrete in-situ paving or precast concrete slabs, over the full width of the
trench.
8.5.4. Paving in Tank farm area
Based on the nature of chemicals stored in the tanks, process shall recommend the
requirement of the impervious lining within a particular tank dyke.
For tank dykes, which do not require impervious lining, the soil within tank farm
shall be compacted.
For tank farms requiring impervious lining, impervious lining in the form of either
HDPE membrane liner or concrete pavement with joint sealant inside dyke shall be
provided.
For those tank farms requiring impervious layer, having pipe supports occupying
less area (as a percentage of total area say less than 10%) then HDPE liner is
preferred. It shall be laid at a lower level with ends tucked in ring wall of tank and
foundation of pipe supports are provided over the liner.

For those tank farms requiring impervious layer having pipe supports occupy
significant part of tank farm (more than 10%) then the area shall be paved with
100mm thick concrete slab with increased thickness of at least 150mm at locations
of pipe supports.
Acid/alkali resistant chemical coating or acid/alkali resistant bricks shall be
provided in the tank dykes storing acid/alkali. Appropriate treatment to the joints
shall be provided in such situation.
8.6. Site Finishes
Table-006: Site Finishes
Area Finish
Process Unit Concrete Paving
Utility Area Concrete Paving
Transformer area/Switchyard Gravel
Truck Loading/Unloading Area Concrete Paving
Pipe Rack
Within Process Area Paving
Outside process area Compacted Earth. (Whenever compacted soil is
required, degree of compaction shall be to 95%
standard [proctor density compacted in layers
of 200mm.)
Footpath Interlocking Precast Concrete Paver blocks or
Plain Cement Concrete
Roads Bituminous (General)
Shoulder for roads Surface dressing over WMM course
Tank Farm (inside dyke) Refer section 8.5.4
Dyke walls RCC

Area between unit battery Compacted earth
limits and road shoulder edge
(except approach road)
Sphere area Concrete pavement
Open areas / future areas Compacted earth

Area Finish
Parking Area Bituminous or RCC
Offsite Pipe rack and sleeper Compacted earth
ways
9. Drainage Systems
Effluent generated from the plant areas shall be classified and directed to one of
the following segregated systems:
• Storm Water System (CS)
• Oily Water Sewer (OWS)
• Sanitary Sewer (SS)
• Process Sewers: Chemical Sewer and Closed Blow down System
Drainage systems shall be simple and direct, utilising natural ground slopes as far
as practicable to minimise sewer depths.
Pipes shall be laid between manholes in straight lines in the vertical and horizontal
planes.
Convenient access points shall be provided to all elements of the drainage system
to facilitate cleaning.
The design of drainage system shall be carried out in such a way that there shall not
be any back flow of water from peripheral OSBL system to ISBL system.
9.1. Storm Water System (CS)
The detailed design requirements for Storm water system are specified in section
9.5.1. The Strom Water System shall carry:
9.1.1. Clean Stormwater
Uncontaminated storm water such as runoff from plant roads, access areas, parking
lots and building roofs, diked tank farm areas, pipe tracks, depot and loading areas
and any other area outside process unit battery limits.
9.1.2. Potentially Contaminated System
Potentially contaminated surface storm water or spent firewater runoff from
process units and tank farms
9.1.3. Any other waste water stream if identified in P&ID and/or PFD.
9.2. Oily Water Sewer (OWS)
The Oily Water Sewer System shall collect:

• Oily water from process unit

• Oily waste water from hydrocarbon testing laboratory sinks and floor drains
where oily spills may occur.
• Oil contaminated Surface water diverted from the storm water system.
• Blow down from Process Equipment post decontamination
• Sample point drains
• Water draw-off from storage tanks.
• Oil Contaminated rain/spent fire water from tank bunds.
• Pipe trench drain
OWS shall not collect:
• Lighter hydrocarbons such as Class A materials (Naphtha and lighter than
Naphtha)
• Heavy viscous fluids such as asphalts
• Any fluid containing hazardous materials with concentrations more than
allowable figures set out by the environment and or biological treatment
restrictions.
• All hydrocarbons, chemicals and oil contaminated water while handover of
piping and equipment for maintenance/ inspection purpose during normal
/shutdown/ startup operations, shall be drained to Closed Blow Down. Only
leftover residual draining can be done in OWS.
The detailed design requirement for oily water sewer is specified in section 9.5.8.
9.3. Sanitary Sewer System
The sanitary sewer system shall collect waste from:
• All sanitary and toilet facilities.
• Kitchen sinks.
• Building floor drains (except where oily and chemical spills may occur).
• Laboratory non-hydrocarbon and non-chemical sink wastes.
The detailed design requirement for sanitary sewer is specified in section 9.6.
9.4. Process Sewers
9.4.1. Chemical Sewer System
The chemical sewer contains aqueous solutions of chemicals and may have small
quantities of hydrocarbons. The chemical sewer shall collect effluent from:
• Laboratory sinks

• Battery Rooms
• Acid and alkali storage and handling areas
• Specific chemical equipment drains or sampling points indicated on the
P&ID's.
Combined or multiple sewer system may be required, dependent on chemicals
discharged, to keep effluents separate for recycling or to simplify neutralisation.
Relevant P&ID shall be referred to develop the layout of chemical sewer.
Paved areas handling chemical such as acid, alkali shall be kerbed and lined or
coated where necessary for the protection of the concrete.
The paved areas shall be kept to a minimum to reduce the quantity of storm water
passing to the collection or neutralisation pit. Chemical storage area drains shall be
fitted with a removable manually operated stopper or plug valve at outlet and be
normally kept closed.
Acid sewers from Battery Charging facilities, in Substations and Plant Interface
Buildings, shall be discharged into a local Neutralisation pit designed to contain
spills.
The chemical sewer system shall normally be routed to a collection pit for recycling
or to a neutralisation pit before discharge into an oily water sewer, or for further
treatment as required by Codes or project specification. All chemical collection and
neutralisation pits shall be lined / coated for the protection of the concrete.
Reference shall be made to the relevant P& ID.
In the case where the quantity of chemical waste is small, it may be sufficient to
collect the waste locally in suitable containers for removal and disposal.
9.4.2. Closed Blow Down (CBD) Sewer System
This system shall collect hydrocarbon blow downs from plant vessels and
equipment as shown in P&IDs. The effluent is collected from equipment through
above ground drain points into underground sewer system through AG-UG flange
connections. Insulating gaskets shall be provided at all A/G-U/G flanged
connections to prevent current losses. The underground sewer shall consist of a
main header and laterals terminating to the blow down drum from where these
effluents are pumped out. Sewer shall be free draining with no traps or pockets.
CBD header shall be sloped towards the CBD drum (buried/placed in a pit) at one
corner of the unit and shall be located at the leeward side of the unit. In case the
CBD drum is kept in a pit, a system shall be installed to evacuate the liquid / HC
accumulated in the pit.
At the dead end of the CBD header, steam and/or inert gas connections (clean out)
shall be provided for proper purging and cleaning of the header.

Collection and disposal arrangement of blow down system shall be as per process
P&ID.
9.5. Design Guidelines
9.5.1. Storm Water System (CS)
The Storm water (CS) system shall be designed to be free flowing, to collect and
convey all surface run off to their final disposition and shall be arranged to impede
the spread of fire from one area to another. CS system is composed of area drains,
catch basins, manholes, ditches, underground piping, and Contaminated Storm
Water Pit (CSWP).
9.5.1.1 CS system in Process Unit (ISBL)
The CS system within process units shall be underground piped system designed to
collect storm water or spent fire water runoff from the concrete paved catchment
areas. The system shall be designed as a “Flooded” system and the pipes shall be
kept flooded by a weir at the downstream end of the system. The runoff shall be
collected within catchment areas served by catch basins or dry boxes connected to
buried Storm water system, which directs the runoff to a Contaminated Storm
Water Pit.
9.5.1.2 CS System for Offsite areas (OSBL)
Storm water runoff generated in offsite & utilities area shall be collected into lined
open ditches or swales. Drainage ditches in general shall be rectangular or
trapezoidal in cross-sections and shall be lined.
9.5.1.3 CS System for diked areas (Tank Farm)
The surface water run off within a tank dike shall be collected in interceptor
chambers or sumps inside the diked area. Uniform grading shall be provided with
slope away from the tanks toward interceptor chambers located at the farthest
practical distance from the tanks.
The final disposal of storm water collected shall be decided specifically for each
project during preliminary planning stage and accordingly detail design may take
place. One of the preferred ways (if feasible) of disposing the storm water is
through a storm water pond, which acts as a second line of defence before final
discharge outside the complex. A separate project specific design basis shall be
prepared for the storm water pond design, if applicable.
9.5.2. Design Flow Quantities
Storm Design flow quantities shall be larger of the following:
• Storm Water Runoff
• Spent Fire Water Runoff

9.5.2.1 Storm water Runoff

Q=CIA
Where:
Q = Peak runoff rate, m3/hr.
C = Coefficient of runoff for the catchment, (Refer Table - 007)
I = Rainfall intensity for the calculated time of concentration (tc), m/hr
A = Catchment area in sqm.
Rainfall Intensity ‘I’

Rainfall intensity data shall be in the form of local ‘intensity-duration-frequency’
(IDF) curve, which defines the rainfall intensities and durations for given storm
recurrence period. A project specific IDF curve shall be used.
Storm Return Period ‘T’

For all new grassroot projects, return period shall be adopted as Minimum 10 Years
return period for all areas.
For revamp projects, recurrence period as per existing design basis shall be
adopted.
Time of Concentration ‘tc’

Rainfall intensity shall be calculated corresponding to Time of concentration (tc) for
the actual site area under consideration.
The time of concentration is sum of time of entry & time of flow (tc = te + tf).
te=time required for rain water to enter a drain channel or sump in the drainage
network from remotest part of the catchment.
tf= time of flow which is the time required thorough drainage network and reach
the point of measurement.
Minimum time of concentration (tc) is assumed as 5 minutes for paved areas and
10 minutes for unpaved areas. These values shall be used as minimum values if the
calculated (tc) value is smaller.

Runoff Coefficient
Table - 007: Run-off Coefficients (C)
Type of Surface Runoff Coefficient “C”

Concrete paving, roofs: 1.00
Roads and Road shoulders: 0.90
Bare offsite areas (Clay soils), Compacted Crushed 0.70
Stone or Gravel Surface:
Bare offsite areas (Sandy soils): 0.60
Permanent Green Belt Areas /Grassy areas (Clay 0.50
soils),
Uncompacted Gravel Surface Area:
Permanent Green Belt Areas/Grassy areas (sandy 0.30
soils):
If more than one type of surface contributes to the drain system, then the
coefficient C shall be a weighted average of the run off factors of respective areas.
9.5.2.2 Spent Fire Water runoff
Spent fire water runoff for drainage design in process area, tank farms and LPG
storage areas shall be considered as 75% of the firewater usage.
Fire water (FW) shall be considered based on fire water demand calculations. In the
event of data is unavailable, firewater usage runoff shall be calculated as under and
verify with project specific loss prevention report.
Process Plant
Rate of FW discharge @1 lpm/m2 paved area (foot print) of the process plant. In
addition, FW requirement for supplementary hose stream of 372 m 3/hr (i.e. 4
hydrants @36 m3/hr + 1 monitor @228 m3/hr) shall also be considered.
Tank Farm Area
FW flow rate for tank farm shall be aggregate of the following:
FW flow calculated for cooling a tank-on-fire at a rate of 3 Ipm/m2 of tank shell area.
FW flow calculated for all other tanks falling within a radius of (R+30) M from centre
of the tank on fire at a rate of 3 Ipm/m2 of tank shell area.
FW flow calculated for all other tanks falling outside a radius of (R+30) M from
centre of the tank on fire and situated in the same dyke area at a rate of 1 Ipm/m2
of tank shell area.

Water flow required for applying foam into a single largest cone roof or floating
roof tank (after the roof has sunk) burning surface area of oil, by way of fixed foam
system, where provided or by use of water/foam monitors. (OISD 116 to be
referred)
Water flow for supplementary stream shall be considered as 372 m3/hr as indicated
under item 1.
LPG Storage Area
Fire water flow rate for LPG sphere storage area shall be aggregate of the following:
Water flow calculated for cooling LPG sphere on fire at a rate of 10.2 Ipm/ m 2 of
sphere surface area.
Water flow calculated for all other spheres falling within a radius of (R+30) metre
from centre of the sphere on fire at the rate of 10.2 Ipm/ m2 of surface area.
Water flow for supplementary stream shall be considered as 372 m3/hr as indicated
under item 1.
Water flow required for applying foam into a single largest cone roof or floating
roof tank (after the roof has sunk) burning surface area of oil, by way of fixed foam
system, where provided or by use of water/foam monitors. OISD 116 to be
referred)
9.5.3. CS system design considerations within Process Area:
The CS system within process unit shall be piped system designed to collect storm
water or fire water from the concrete paved catchment areas.
The system shall be designed as flooded system.
Pipe sizing shall be done in such a way that the total head loss in the system i.e.
friction loss, entry and exit loss and the weir losses shall not be more than the
available head in the system. The “Backwater Profile” for the system shall be
determined. The design shall be considered acceptable, if the high water level in
any catch basin for maximum discharge is not exceeding the level of 300mm below
High Point Paving (HPP). Further, the water level in the flooded system is
maintained at a minimum level of 150mm. above all pipe soffits by means of the
weir provided at the downstream most end of the respective system.
The pipe friction loss shall be calculated from the hydraulic gradient which shall be
determined using Colebrook-White equation. Colebrook-White equation the
roughness coefficient (k) shall be taken as 0.6 mm for the design of pipes. The
system shall be designed considering maximum velocity as 1.2 m/sec, as beyond
this velocity oil gets emulsified into water and it becomes difficult to physically
separate from water. A minimum velocity up to 0.3m/sec is allowable in case of
minimum flow condition (either spent fire water or rain water) in liquid filled pipes
(flooded systems) only.

Colebrook-White equation,
 k 2.5 
V = −2 ( 2 gDS ) log  
0.5
+
 3.7 D D ( 2 gDS )0.5 
 
k = Colebrook-White roughness coefficient, in metres
V = velocity, in metres per second
D = circular cross-section pipe, inside diameter, in metres
S = slope, in metres per metre
ν = kinematic viscosity of water, in square metres per second.
The paved process area shall be subdivided into rectangular catchments areas of
maximum 500 m2 in ISBL areas. All these catchment areas shall be segregated from
one another by peripheral high points of paving (HPP).
A Catch basin shall be located at the low point of paving (LPP) of each catchment
area. The difference in elevation between HPP and LPP (LPP = top of grating of the
catch basin), shall not be more than 150mm. The average slope to be considered in
paving shall be 1:100, with a minimum slope of 1:120 and a maximum slope of 1:30.
The HPP, LPP and slopes shall be oriented so that spills flow away from the
equipment. Diking in process area shall not be used in any case. However, small
diverting curbs can be used for specific purpose.
The inlet and outlet pipe size will be ranging from 300mm. to 900mm.
Catch basins and manholes shall be provided with a minimum clear depth of
250mm for sediment settlement separation. All manholes will be vented above
grade to a safe location.
Catch basin covers shall have heavy duty grating with 600 square opening. Top of
catch basins shall flush with the paving in paved area and the grating elevation shall
be 50mm above FGL in unpaved areas to prevent collection of washed soil. In the
flooded system, all the pipe’s soffit level shall be kept same for catch basin and
manhole in any particular area of any process unit.
No catch basins shall be located under the main pipe rack or within 16meters of a
heater shell or similar constant ignition sources Dry boxes shall be used at the low
point of drainage areas containing such fired equipment. No catch basin shall be in
front of the landing of the stair case. Building or sanitary drains shall be segregated
from the unit drainage system.
The extent of paving in ISBL to be optimised and kept to a minimum, limited to
process areas. If any peripheral area around the plant can be classified as non-
process area, the same can be sloped towards the open peripheral storm water
drain system thereby reducing the volume of contaminated storm water pit/pump
capacity.
Large or major spills which occur shall not be washed down the Storm water (CS)
system and then pumped to ETP. Instead the spill shall be cleaned either using a

vacuum truck or through absorbent material wherever feasible. Once most of the
spill is removed, the paving, catch basins and pipework shall be cleaned.
9.5.4. Contaminated Storm Water Pit (CSWP)
The contaminated storm water pit shall be located near the periphery of the ISBL
plant. Conceptually, the surface run off will be routed to inlet chamber of CSWP
from where contaminated water will be routed to the contaminated storm water
pit through an opening in the common wall between the inlet chamber and the
CSWP. The upstream storm sewer network shall be kept flooded by a weir which
can be either provided in the inlet chamber or a weir manhole upstream of the inlet
chamber. This weir will maintain a minimum 150mm liquid seal in the CS system.
Water shall be introduced into the flooded system during long periods of dry
weather to maintain this water seal. In the inlet chamber, there will be an overflow
weir with a sluice gate to divert the excess rain water, in case of heavy monsoon,
to peripheral storm water open channel after the contaminated storm water pit
becomes full. The sluice gate valve is to be kept closed during normal operation and
to be operated during rainy season only.
The contaminated storm water pit (CSWP) will be sized to contain a volume
equivalent to minimum
a) 15 mm of rainfall applied over the process paved area of the ISBL.
or
b) 10 minutes of peak spent fire water discharge.
There may be multiple contaminated storm water pits for a process unit depending
on the layout and area of the process unit. Also, maximum depth of pit shall be kept
limited to 6.0 meter from ground level, to avoid too deep excavation.
Under normal operations (during dry weather), the surface runoff which may
contain floor washes etc. will flow to the CSWP and get pumped to effluent
treatment plant. During rainy period, the first 15 mm rainfall over the contaminated
paved surface will be collected in the CSWP and after the CSWP becomes full,
excess rainfall will get diverted to the open peripheral channel / offsite storm sewer
drain system.
The CSWP will be provided with pumping arrangement to discharge the
contaminated water to central effluent treatment plant over a period of 3-5 hours
depending on the size of the pit and hydraulic load to the ETP. The pumping from
different CSWPs shall be carried out in a sequential manner to avoid overloading of
ETP. The pumps will start manually when it is required to transfer the contents of
CSWP to ETP. Pumps can discharge to the ETP directly or to nearest lift station
depending upon the system design and layout.

No skimming or physical separation of floating oil from the CSWP is envisaged. Any
such specific project specific requirement may be reviewed during detail
engineering and included in design.
The CSWP is to be provided with concrete cover slab and manhole openings in the
slab. The pumps are to be provided with emergency power supply.
One contaminated storm water pit pump can be in operation from each plant for
preliminary estimation of the total hydraulic load to the ETP.
For General Arrangement of Contaminated Storm Water Pit refer standard drawing
RPMS-SD-C18-237.
9.5.5. CS system design considerations for Offsite Areas
The offsite storm water drainage system shall be designed as a gravity system and
mainly comprises of swales and open ditches. The ditches shall normally be running
on either side of the main roads. Trapezoidal ditches shall have 1:1.5 to 1:1 side
slope for easy to moderately hard excavation material and 1:0.5 side slopes in hard
rock area.
The minimum width of rectangular channel shall be 300 mm, and the minimum
depth for all channels shall also be 300 mm. All open channels shall be designed
with minimum free board of 150 mm and seepage through joints shall be avoided.
For areas where the water table is in the freeboard range, measures shall be taken
to prevent soil erosion.
Open channels located at the toe of an embankment shall be provided with a
'walking strip' of minimum width 350 mm for cleaning and maintenance access.
The open drain channels/ditches shall be designed by using Manning’s
experimental formula. The coefficient of roughness (n) to be considered in
Manning’s Equation are shown in Table – 008.
Table – 008: Manning Roughness coefficient ‘n’
Ditch Surface / Pipe Material Typical Roughness Co-eff. ‘n’ value

Smooth Earthen ditches 0.020
Stone pitched ditches 0.025
Brick surface lined with cement mortar 0.015
Rubble masonry 0.020
Concrete lined ditch 0.015
Carbon Steel Pipe/CI / DI/ Concrete Pipe 0.013
FRP/HDPE/uPVC pipe 0.011

In some areas open storm water ditches may not be provided, such area may be
provided through underground piped drainage system such as parking lots etc.
Pipe culverts or box culvert(preferred) shall be used for road crossings. Minimum
size of pipe for culvert shall be 600 mm. Culverts shall be sized for 1.25 times the
design flow.
Maximum velocities in open ditches shall be such that no scouring of the bed and
sides occurs. Velocities in the range of 0.6 m/s and 2.4 m/s at maximum flow shall
be maintained.
No piping, cabling and/or pipe or cable supports shall be installed directly over or
across open channels without consideration being given to the access required for
the cleaning and repair of the channel.
Fire seals in manholes/catch basin are not required if it is located outside process
unit but may be required at certain points along the ditch routes. e.g.:
• to isolate unit or complex areas, i.e. culvert fire traps
• to impede the spread of spilled LPG or other denser than air entering lateral
ditches
Contaminated oily water should be not allowed to enter into the OSBL CS system.
However, following may be the possibilities wherein such case is expected:
• During spent firewater discharge after the CSWP is full.
• Hydrocarbon leakage/accidental contamination after the CSWP is full i.e.
after first flush.
• Residue oil back wash from CS flooded system, if not properly flushed
through after a large oil spill into CS system.
Oily water trap within the CS ditch system and oily water separators at high risk of
contamination area shall be installed. The detail locations and design shall be
carried out during detail engineering.
9.5.6. CS system design considerations for Tank Farm Areas
The surface water run off within a tank dike shall be collected in drain sump inside
the diked area. Uniform grading shall be provided with slope away from the tanks
toward drain sump located at the farthest practical distance from the tank. The
sump drain shall be connected to drain valve pit outside the dike. Drain valves
outside the dike to be located where they are accessible under fire condition. The
drain valves shall be kept closed normally and shall be opened only as needed,
because permanently opened drain valves will not retain discharged liquids if the
tank suddenly fails or leaks. A SOP to be established by operation team to schedule
checking the drain valves.

Tank Dyke Valves should be provided with position indicator (open or close) in
control room and necessary hardware and instrumentation should be provided for
this.
In a diked enclosure, where more than one tanks are located, separated by fire
wall(s), each part of the sub-divided area of the dike to be provided with individual
drain sump. There shall not be any drainage pipe or trench running from one tank
dike through the dike area of another tank.
The size of drainage pipe from dyked areas shall be sufficient to drain Rainwater
accumulated inside the tank farm within 6 hours after the rain storm event. The
design should ensure that the rain water does not rise above the bottom annular
plate level to avoid possibility of ingress of water between tank bottom and
foundation.
Refer standard drawing RPMS-SD-C18-235 GA & RCC details for Channel
interceptor & Manhole Type-II, which can be used as a standard detail for drain
sump.
9.5.7. Pressurised Storages (Sphere, Bullet & Vessels)
In Liquefied hydrocarbon gases storage areas, kerb wall shall be provided around
sites of the storage vessel with concrete flooring of the ground under vessel and
extending up to minimum distance of D/2 or 5M whichever is higher and at least 5
M(min.) from the edge of the Spheres with a slope of 1:100 (min.). Grading of the
ground underneath shall be provided such as to direct spillage away from the
storage vessel to a shallow sump. Kerb wall height shall be minimum 30 cm but
shall not exceed 60 cm otherwise evaporation of spilled LPG may get affected. DEC
must develop the detail concept as part of detail engineering based on OISD 118
and OISD 144 requirements. Spillage collection shallow sump shall be located at a
distance where the flames from sump will not impinge on the vessel. The distance
shall not be less than the diameter of nearest vessel or 15 m whichever is higher.
The capacity of the collection sump shall be as per OISD-STD-144. Water seal shall
be provided at outlet from shallow sump leading to storm sewer.
Storm water from theses area shall be controlled through a valve pit arrangement
at outlet of sump for further discharging to storm water drain system.
9.5.8. Oily Water Sewer (OWS) System
The oily water drains from various equipment and AG piping shall be collected in
the drain hubs as identified in P&ID/PFD. The OWS system shall be designed as free
flowing underground direct buried system, meant to collect and convey oily waste
water to their final disposition; care shall be taken to prevent fire hazards from
spreading from one area to other. The system shall be composed of drain hubs,
manholes, clean outs, lift stations and underground piping.
The transformer bay runoff shall be served through a standalone oil collection pit
which is to be periodically emptied using vacuum truck.

Oily water sewers in OSBL shall consist of a trunk sewer with branch connected to
process units, tank farm areas and other work areas. The main trunk sewer shall be
isolated from branch sewers by sealed manhole. The oily water trunk sewer in OSBL
area shall carry the flow by gravity (lift station may also be considered if depth of
sewer becomes prohibitive to Effluent Treatment Plant).
9.5.8.1 OWS System design considerations within Process Units
Carbon steel drain hubs in the form of concentric reducers will be used to collect
the effluent from the above ground sources like equipment’s, pump bases and
pump glands etc. Each drain hub shall be connected directly to a manhole and shall
be sealed at the manhole by submerging the inlet pipe a minimum of 150 mm
below the water level in the manhole.
Sometimes a number of individually sealed hubs may be connected to a lateral
which in turn shall discharge to a manhole using a dip seal inlet pipe.
Within process units, sealed manholes shall be provided in such locations so that
each sub-unit within the unit is isolated from other areas. Where such demarcation
is difficult, one sealed manhole for every 30 m length of unit sewer shall be
provided.
The P&ID will show the equipment’s requiring OWS drain. All OWS header, inlet
pipes and laterals shall be sealed by a minimum liquid depth of 150mm. The outlet
pipe invert of a manhole shall be a minimum of 25mm below the invert of the
lowest incoming pipe.
Drain hubs shall be one standard size larger than the equipment drain (minimum
size of 150 mm). Laterals serving a single drain hub shall have a minimum size of
100 mm. Laterals serving two or more drain hubs shall have a minimum size of 150
mm. No more than six drain hubs shall join with a lateral which in turn get
connected to a sealed manhole and not to another lateral. A drain hub or a lateral
joining a lateral or header shall be connected at an angle of 45 degrees or less using
“Y” type connection in the direction of flow. Refer standard drawing RPMS-SD-C18-
211 for typical OWS drain hub details.
Manholes shall have solid, heavy duty, double-sealed covers, and be vented. Refer
standard drawing RPMS-SD-C18-202 for typical section of oily water manhole and
RPMS-SD-C18-234 for typical inlet pipe details for oily water manhole.
Pipe shall be laid to gradients, and shall be coated, wrapped and/or cathodically
protected. Underground OWS headers shall preferably run either alongside the
pipe rack or at a location to suit distribution of equipment. All manholes within
process units shall be sealed manholes at 30m maximum spacing with 100mm dia.
vent pipe.

9.5.8.2 Water Draw-off from Tanks:

For tanks containing hydrocarbon based products from which water readily
separates, a sump/tundish shall be provided under each water draw-off valve. The
header connection from the sumps/tundishes shall pass to the oily water sewer
(OWS) system or be collected by road tanker.
The trunk sewer shall be provided with an emergency shut-off valve located outside
the diked area.
9.5.8.3 OWS System design considerations for Offsite Areas
The headers coming out of process area shall be connected with the offsite main
sewers at the process area battery limit. The connection manholes from Process
area branch sewers to main sewers shall be a sealed manhole. Offsite manholes
with single inlets shall be provided with fire seals at a maximum interval of 300 m.
Offsite manholes with more than one inlet shall be fire sealed on all the inlet lines.
The offsite Oily Water Main shall be constructed using carbon steel pipes, which
shall be coated, wrapped and cathodically protected. Each manhole shall be
provided with a 100 mm dia. vent pipe.
The OWS system may also receive primary treated effluent from the Sanitary Sewer
septic tank and from the neutralising tank pit. These streams shall discharge to
nearby OWS manholes, and the inlet pipes from each stream shall be sealed on
entry using dip seals.
For spacing of oily sewer manholes in offsite areas refer Table 010.
9.5.8.4 Pipe Gradients in OWS
The Pipe design philosophy for OWS sewers are common for offsite & process area,
it shall be free flowing gravity sewers. For sizing of pipes in oily sewers, Manning’s
formula shall be used. Gradients shall normally be based on a 1.0 metre/sec.
velocity. For light oils a velocity of 0.75 m/sec. is acceptable, if the preferred
gradients as per Table 009, give design problems.
Table – 009: Preferred Gradient
Pipe Size/Diameter (mm) Gradients
Preferred Maximum
100 1: 100 1 : 150
150 1 : 150 1 : 260
200 1 : 220 1 : 370
250 1 : 290 1 : 500
300 1 : 350 1 : 625

Pipe shall be designed for a maximum flow depth of 70% of the pipe diameter (i.e.
d/D =0.70). The minimum flow depth shall be 30 mm where solids are likely to be
present.
Minimum line size for any single sub lateral shall be 100 mm for ease of cleaning.
9.5.8.5 Cleanout
Cleanouts in OWS sewer to facilitate cleaning in the direction of flow shall be
provide as specified below:
At the upstream point of sewers unless a manhole is provided.
At the change in direction of sewers in excess of 135 degrees where it is preceded
by a straight run of 15 m or more.
Drain hubs may be considered as cleanouts if the run to the drain header is less
than 6 m.
Cleanouts shall be the same as the line size in case of sanitary sewer and shall not
exceed 150mm for all other sewer.
Refer standard drawing RPMS-SD-C18-210 for typical details of Clean out.
9.5.8.6 OWS Drainage Temperature
The temperature of the stream being drained to OWS should normally be in range
of 50o-60oC. In any case, OWS draining temperature shall not exceed 80◦C. A
suitable arrangement for cooling of hot liquid having temperature more than 80oC,
if being drained, shall be provided to cool the liquid before draining to OWS system.
The cooler system should be provided to bring down the temperature of liquid
being drained below 60oC.
9.5.9 Transformer Oil Collection Pit in substations
In order to prevent oil, whether from a small leakage or outflow from transformer
tank, from reaching and polluting the water bearing stratum, transformers shall
have following provisions, depending on the oil capacity of the transformer.
Oil Capacity up to 2,000 litres.
Transformer installed adjacent to substations/buildings shall, where oil capacity
does not exceed 2,000 litres, be provided with a layer of 100 mm deep stones of
about 40 mm granulation, all around the transformer.
Oil Capacity Exceeding 2,000 litres
Transformer installed adjacent to substations/buildings shall, where oil capacity
exceed 2,000 litres, be provided with containment storage.
The total volume of the containment required shall be equal to take a minimum of
10 minutes of deluge/fire water spray from the largest of transformer bays and
100% of the oil volume of the single largest transformer. For calculation of fire

water one single largest transformer shall be considered on fire at a time. Rate of
fire water spray system to be considered as 10.2 lpm/sqm on all the projected areas
of rectangular prism envelope for the transformer. When transformer is on fire the
deluge system will spray the water on all four sides and top of the transformer.
Hence, fire water volume (in litres) = (Total surface area of the transformer (all 4
sides) + top plan area of transformer) x 10.2 x 10.
This oil containment shall be provided in two forms:
• Oil Containment within transformer pen
• Waster Oil Tank
(i) Oil Containment within transformer pen
Oil containment within the transformer pen shall be provided in form of oil
containment pit all around the transformer. The whole pit around the transformer
shall be with gravels of about 40/60 mm granulation except that the top 150 mm
of the pit shall be devoid of gravels. A porosity factor of 40% shall be considered for
40/60 mm size gravel.
(ii) Waste Oil Tank
The oil containment pit within transformer pen, when of a smaller volume than
required, shall be connected by a draining pipe of carbon steel, not less than 150
mm diameter, to a waste oil tank situated at a suitable place. If the waste oil tank
collects the drainage of several transformer pens then, the outlet drainage pipe
from each of the transformer pen shall be connected to the main header through
a fire sealed manhole, the main header ultimately leading to the waster oil tank.
The capacity of this Waste Oil tank shall be such that the combined capacity of oil
containment pit and Waste Oil Tank shall be equivalent to containment storage
required as described above.
The Waste oil tank shall be constructed in RCC and provided with an air vent with
flame arrestor. The oil and/or contaminated fire water in case of oil spillage or
firefighting shall be emptied from the pit using gully sucker. An outlet pipe from the
pit is provided from the bottom portion since any oil collected in the pit will form a
layer at the top and the cleaner water at the bottom portion shall over flow from
the pipe. The outlet pipe shall be connected to nearest storm water drain/manhole.
A valve shall be provided on the outlet pipe downstream of the Waste Oil Tank. The
valve shall be kept normally closed and manually operated during rainy season to
divert excess rain water to storm water drain.
9.6. Sanitary Sewer System
The building sewer shall be designed based on the fixtures basis and maximum
discharge values of fixtures with diversity factors applied to the flow. The discharge

value for peak flow shall be in line with IS: 1742.The pipe shall have minimum
gradient of 2 % for the building sewer.
Venting on sanitary sewers will be provided at connections to buildings in
accordance with IS-5329 by means of ventilating pipes. In addition, the first and last
manhole in any sanitary system shall have provision of vents. Flow of sanitary waste
from buildings will be directed to the OSBL sanitary sewer system manhole by
gravity or by pumping.
The offsite sanitary pipe shall be designed considering daily volume of sewage
generated on 45 l/person/shift with due allowance for defined future development
of the area.
The pipe shall be designed considering minimum velocity of 0.6 m/s at peak flow.
The sanitary sewer header in OSBL area shall carry the flow by gravity (lift station
may also be considered if depth of the sewer becomes too prohibitive to
Effluent/Sewage Treatment Plant.
Independent septic tank can be used for remote areas with disposal to soak pit/sub-
soil irrigation or discharge into OWS system depending on availability of OWS
network nearby. If sub-soil condition at the disposal location is not favouring,
effluent shall be periodically collected by road tanker. However above mentioned
treatment method shall require prior approval from client.
The minimum pipe size for Sanitary Sewer shall be 100mm dia. within building and
200mm dia. in offsite area, manholes shall be provided at 30m maximum spacing.
Lift stations shall be provided as per design requirement.
The installation of sanitary sewers in the proximity of potable water lines shall
conform to the IS-1172 for lateral and vertical separation.
Trench design, bedding, backfilling and protection shall be selected to suit pipe
strength and applied loadings as set out in Indian Standards, or as manufacturers
recommendations.
Where it is feasible and economical, it is preferred to provide decentralised
Packaged Sewage Treatment Plant (PSTP) in the close vicinity of the building, to
treat the sanitary sewer. Two or more such buildings can be clubbed and a single
unit of PSTP may be provided to cater the combined sewage generated from such
building units. The treated water may be recycled to be used in horticulture.
Separate project specific design basis for PSTP to be prepared during detail
engineering, if applicable.
9.7. Manholes
Manholes on sewers and drains shall be provided as follows:
• At changes in pipe direction in vertical and horizontal planes.

• At a junction with incoming pipes that do not have cleaning access within
10m.
• At changes in main sewer diameter.
• The spacing between manholes for different pipe sizes shall be as per Table
– 010.
Table 010: Manhole Spacing
Maximum Spacing
Pipe Diameter (mm)
(m)
For 150 mm and 200 mm dia. 30
For 250 mm and 300 mm dia. 45
350- 600 mm dia. 75
Greater than 600 dia. 150
Sizes of manholes shall be such that it allows easy access for cleaning and
maintenance activities.
Manholes shall be constructed in precast concrete sections or cast in-situ concrete
as per project requirements. Manholes shall be of watertight construction.
Manhole covers shall be selected to suit the class of loading relevant to their
location as defined in IS-1726, IS 4111 (Part 1) and IS 12592.
The internals of manholes that could be attacked by corrosive effluents shall be
protected with two coats of Epoxy Paint, selected to provide adequate protection
against the chemical/combination of chemicals in the drainage system.
To minimise the risk of fracturing pipes at manholes and other structures when
differential settlement occurs, rocker pipes (spool pieces) shall be used, flexibly
jointed as indicated on the drawings. This section only applies to manholes not
directly bearing on rock where concrete pipes are connected.
9.8. Vent
9.8.1 General
Venting of manholes shall be provided as follows:
• At each manhole on oily water sewers (OWS)
• On each manhole of flooded(sealed) Storm Water (CS) system in process
units
• At each manhole on Chemical Sewers where gases are likely to be
developed

• On sanitary sewers venting will be provided at connections to buildings in

accordance with IS-5329 by means of ventilating pipes. In addition, the first
and last manhole in any sanitary system shall be vented.
• On all septic tanks, transformer oil collection pit, lift station sump and
CSWP.
• The minimum vent pipe shall be 100 mm dia. The underground horizontal
run of vent should be provided with minor slope towards manhole for
draining of any water ingress back to manhole.
• Vent shall not be provided in and near to furnace area.
9.8.2 Vents in ISBL
In ISBL, following guidelines shall be followed for vents:
• Vents will be provided with flame arrestors in ISBL. ISBL vent will be directed
vertically (for upward dispersion) along with canopy arrangement (for
protection against rain ingress).
• Vents which are located within 15 m of a Pipe rack, or a structure shall be
routed 3 m above such adjacent Pipe rack top tier level or nearest tallest
structure top operating platform located within 15 m.
• Vents which are located within 15-meter radius of a building, shall be routed
5.0 m above the building air intake or windows.
• Vents shall not be located within 15 m from any fired heater or any other
source of ignition.
• Vents within ISBL which does not have any Pipe rack, equipment, structure,
building or any fired heater or any source of ignition within 15 m radius shall
rise 3 m above grade only.
9.8.3 Vents in OSBL
In OSBL, following guidelines shall be followed for vents:
• Vents will be provided without flame arrestors in OSBL except tank farms.
In tank farms, OWS manholes shall be provided with vents with flame
arrestors. In OSBL, vent shall have 30 deg. bend from vertical so that any
hydrocarbon vapour shall get diverted in vertical direction.
• In areas where OWS network is not present for example Lube oil drain
sump, vent pipe shall be provided as per the guidelines provided for ISBL
with flame arrestor. Vent line for oil reservoir, shall be provided with a flame
arrestor.
• For substation oil collection pit, vent pipe shall be provided as per the
guidelines provided for ISBL with flame arrestor. Vent line for any oil
reservoir or lift station sump, shall be provided with a flame arrestor.

The underground part of vent pipe shall be provided with wrapping & coating as
per project specification and vents shall be constructed as shown on the standard
drawings.
9.9. Special Sewer
Effluent having high pour point, wax content, high viscosity and other fouling
characteristics e.g. asphalts, waxy lube/intermediates and other similar products,
shall not be routed to oily water sewers directly as there is danger of the entire
sewer system getting choked. Such product drains shall be handled separately.
Certain drain water containing Petcocks, Coal dust to be handled separately as per
Licensor recommendation or as defined in process PFD/ P&ID.
9.10. Material of Construction
Drainage networks and components shall be of leak-proof design. System tightness
shall be controllable and measurable, even after a long period of operation.
Trapezoidal drainage ditches shall preferably be lined with rip rap rubble/stone
pitching with flush pointing. RCC/PCC lining may be provided as per requirement.
Rectangular ditches shall be constructed with Brick/Block masonry/RCC. Weep Hole
shall be provided in the ditches.
MOC for flame arrestor – Body shall be of carbon steel and internal mesh shall be
of SS.
9.10.1. Underground Pipe Sewer
Piping materials shall be selected for each service as described in this Specification.
An indicative preferred list of pipe material & its service is given in table-011.
Table 011: Material of pipe for various UG services
Service Pipe Material
Storm Water System (Process Carbon Steel

Area)
Road Culvert Hume Pipe / Concrete Pipe (NP3)
Concrete Pipe (NP4)-Railway Crossing
Oily Water Sewer Carbon Steel
Sanitary Sewer (Gravity) uPVC / H.D.P.E / Carbon Steel
Sanitary Sewer (Force main) H.D.P.E / Carbon steel
Acidic / Chemical sewer HDPE /G.R.P/As defined in P&ID
Special Sewer As defined in P & ID.

All buried metallic piping shall be coated in accordance with project specification.
uPVC pipe and fittings conforming to IS-15328 shall be used for sanitary systems.
Installation shall be as per Manufacturer’s instructions.
Use of buried GRP pipes shall be avoided in high settlement prone areas/sites and
sites where deep deposits of expansive soils are found.
Carbon steel coated pipe shall be used for all oily water sewers and the flooded
sections of the storm water system.
Concrete pipe conforming to IS 458, NP4 class, complete with hydrocarbon
resistant neoprene jointing rings, shall be used, for non-flooded storm water
sewers, typically road crossings and gravity flow systems. Installation shall be as per
Manufacturer’s instructions.
Routing of drainage and service lines within the load bearing area of foundations,
structures, and buildings shall be avoided. In locations where this is unavoidable,
an adequate protection method is to be carried out to protect both the service and
the structure. This is to be constructed in accordance with the detail drawings. For
installation of Underground Gravity Sewers, specification no. RPMS-ENGG-SPC-020
shall be referred.
9.10.2. Fill
Selected fill shall be uniform readily compactable material free from all organic
matter, rubbish, clay lumps greater than 75mm size and stones greater than 40mm.
9.10.3. Cover to Pipe
All underground pipe lines shall have a minimum earth cover depending on their
location. Cover shall be measured from finished surface to top of pipe.
• Minimum earth cover in concrete paved area (where there is no traffic) shall
be 450 mm.
• Earth cover in unpaved areas not subjected to vehicular movement shall be
minimum 1000 mm.
• Earth cover for underground pipes in vehicle travelled areas shall be
minimum 1200 mm or pipe outside diameter whichever is more (except FW
Pipe).
• Earth cover for all underground fire water headers in vehicle travelled areas
shall be a minimum 1500 mm.
Following protection methods may be adopted for pipes buried under vehicle
travelled areas, wherever required:
• Pipe shall be encased in concrete or covered by a concrete slab
• Pipe shall run through sleeve

9.10.4. RCC -Manhole/Catch Basin/Valve Pits

The above shall be constructed Cast -in-situ from reinforced concrete or precast
units as per project specification. The structural load bearing capacity shall be
checked against vehicle wheel loadings from plant traffic.
All valves to be installed in valve chambers should have extended spindles to
facilitate operation from grade.
All concrete works shall conform to specification for Plain & Reinforcement
concrete material & Construction: RPMS-ENGG-SPC-CS-001.
9.11. Interfaces
DEC for ISBL process unit shall prepare the design basis, PFD, interface report for
Storm Water System (CS), OWS, sanitary sewer etc. for respective unit with
identification of discharge point location/quantities.
OSBL DEC shall develop overall PFD taking input from ISBL process unit, tankage
area and design UG sewer network for offsite area. OSBL DEC shall also prepare
storm water management plan including storm water pond design (if applicable)
and shall submit to client for approval.
Interface location for OSBL DEC for various services i.e. Storm water (CS), OWS,
sanitary, other UG connections at unit Battery Limit in the case of process area and
up to 4m distance from plinth face of building for PIB/Substation/Non-Plant
Building etc. Vendor/Unit DEC shall take-up the rest of job under their scope.
The storm drainage down pour pipe from the roof top and surrounding area shall
be routed properly to nearby storm water drain/sewer. In no case the down pour
line is to be left on grade as it may cause waterlogged condition around buildings
during rains. The HVAC condensate drain from inside building shall be routed
properly to nearby storm water drain/sewer or alternatively provided with a soak
pit if suit to local soil strata.
Tie-in summary for ISBL - OSBL & Above-ground / Under-Ground shall be prepared
by respective DEC and same shall be issued for construction. All the future
connections shall be identified at project early stage and provision shall be kept by
respective DEC, if required provision of valve with blind flange or puddle flange with
spool piece in manhole shall be provided.
10. Storage ponds/Reservoirs – Raw Water, Construction water, Storm
Water, Fire water and Evaporation Pond
The capacity of storage ponds/reservoirs shall be as per project design basis.
Open earthen reservoir lined with random rubble stone pitching / concrete / HDPE
lagoon liners or a combination of above as per project design basis and Layout
drawings shall be provided.

Slope of embankments and walls of reservoirs shall be as per recommendations

from Geotechnical report. Embankments shall be protected with Geotextiles
and/or geogrids as per recommendations of Geotechnical report.
Storage ponds/Reservoirs shall be protected with fencing or guard rail as per
project design basis. Anti-skid type steps at minimum two sides of the pond
(Preferably opposite to each other) shall be provided for maintenance
requirements.
11. Guard rails and safety bollards
Guard rails and/or safety bollards shall be provided to protect equipment and/or
structures that are not provided with the minimum horizontal clearances.
Horizontal clearance for guard rails or safety bollards shall be a minimum 600 mm
from the outer edge of the hard shoulder.
Special hazards that have the minimum clearance can still require protection with
guardrails or guard posts.
Guard rails shall be located on approaches to culverts, at locations where the
embankment height is more than 3 metres and at horizontal curves. The depth of
embankment shall be considered as the elevation difference between the Finished
road elevation and the grade elevation of the adjacent ground or the invert
elevation of the drainage ditch.
Guard rail shall be provided in form of metal beam crash barrier and shall conform
to the MORT&H Specification Cl. 811.3.
Safety bollards shall be provided as per the standard drawing.
12. Road / pavement marking and sign boards
Road/Pavement marking within plant boundaries shall include centre lines, traffic
lanes, border or edge lines, no passing zones, traffic lanes, warning lines, bus lane
marking, cycle lane markings, marking on rotaries and intersections, markings on
hazardous locations, markings for parking and bus stops etc. The details of the
road/pavement markings shall be as shown on the drawings and in conformity with
Code of Practice for Road Markings, IRC 35. Road marking shall be of ordinary road
marking paint, hot applied thermoplastic paint, reflectorized paint or cold applied
reflective paint as specified in the project specifications and shall conform to
MORT&H Specification Cl. 803.
Road signages within plant boundaries shall include road names, speed limits, stop
signs, clearance signs, railroad crossings, facility names, assembly points and
evacuation routes or any other project specific signboard requirement. The details
of the signboards shall be as shown on the drawings and in conformity with Code
of Practice for the road Signs, IRC 67.

13. Erosion Control & Slope Protection

Geosynthetic Materials are widely used in applications such as soil stabilization, turf
reinforcement, erosion and sedimentation control, separation, filtration and
drainage.
Using geosynthetic is recommended because these are less weather dependent,
controls rockfall and debris, reduces earthwork, allows usage of lower quality fill
materials (which are less expensive), better aesthetics and environment
considerations to reduce noise and dust.
It includes geotextiles, geogrids, geomembranes, geocells and geosynthetic mats
etc. Applications of different geosynthetic materials as below.
• Geotextile: used for separation, filtration, drainage, reinforcement or
combination thereof.
• Geogrids: used as reinforcement in pavements and soil slopes.
• Geomembranes: used to control fluid migration.
• Geocells and Geosynthetic mats: used in erosion control of slopes.
Selection of suitable erosion control method shall be done according to section 9
and Table 2 of IRC-56 depending upon the situation (soil type, cut or fill), Height of
embankment, Rainfall etc. and Project specific Geo-Technical recommendations.
Installation and testing of geosynthetics shall be performed as per MORT&H
(Specifications for Road and Bridge works).

Design Basis for Fireproofing

RPMS-ENGG-DBD-HS-003
0 25.08.2020 Issued for Implementation SG/LT MS AKS/GDG

By By By
Reliance Project Management System RPMS-ENGG-DBD-HS-003
Design Basis for Fireproofing Date:25/08/2020, Rev. 0

(DD.MM.YYYY)
Atul K Srivastava
1 (Sub-Committee Chairman)
_____________________________ _________________ ___________
Umesh Khandalkar
_____________________________ _________________ ___________
2
Anand C Haridas
_____________________________ _________________ ___________
3
Tushar Mukherjee
_____________________________ _________________ ___________
4
Shashank Singh
_____________________________ _________________ ___________
5
Kuddallur Seshadri
_____________________________ _________________ ___________
6
RECORD OF REVISIONS

Number
25.08.2020 First Issue – Based on Bechtel Review 0
Contents
1. Purpose...................................................................................................................... 5
2. Scope ......................................................................................................................... 5
3. Application ................................................................................................................ 5
4. Abbreviations & Definitions ...................................................................................... 5
5. Introduction............................................................................................................... 7
6. Fireproofing Philosophy ............................................................................................ 8
7. Evaluating Fire Hazards (Fire-Potential Equipment) ............................................... 10
8. Developing Fire-Scenarios ....................................................................................... 11
9. Defining the Fire-Scenario Envelope (FSE) .............................................................. 11
10. Fire-Resistance Rating Selection ............................................................................. 13
11. Rating of Fireproofing Material ............................................................................... 14
12. Deviations ................................................................................................................ 14
13. References ............................................................................................................... 14
14. Annexures................................................................................................................ 15
1. Purpose
To outline the design basis for fireproofing requirements that will limit the extent
of fire-related loss from pool fire and/or jet fire. This document will help Reliance
Project Management Team to review deliverables (fireproofing Schedule and fire-
proofed layout/s) which DEC/EPC Contractor would develop for implementing on a
Project.
2. Scope
This design basis provides minimum design criteria for development of the
fireproofing schedule and layout for RIL onshore hydrocarbon facilities (except
exploration and production facilities), for both new projects and to modifications
and expansion of existing plants.
This document does not address selection of fire-resisting materials, application
procedures for such materials. Users are advised to refer to the assigned Subject
Matter Experts in civil engineering, coating, insulation, and materials within RPMG
(Reliance Project Management Group)/RIL and the associated PMT representative
for all materials-related matters, as the case may be.
3. Application
Contractor should refer to this document to prepare project-specific fireproofing
design basis for the assigned Project.
C&I Control and Instrumentation.
DEC Design Engineering Consultant
EPC Engineering, Procurement, Construction Contractor
FHA Fire Hazard Analysis
FSE Fire-Scenario Envelope
GDP Group Defined Practice
HAZOP Hazard and Operability
MOC Management of Change
PFP Passive Fire Protection
PHA Process Hazard Analysis
PMT Project Management Team
PSL Potential Source of Leakage
REG Reliance Engineering Group
RIL Reliance industry Limited

Active Protection: Fire protection systems that require either human or mechanical
intervention to activate automatically or manually during a fire. Examples include
fire sprinkler, water spray and hose reels.
Buyer: Owner (Reliance) or Owner-appointed DEC or EPC who specifies equipment
and services for purchase from Supplier.
Char: A carbonaceous residue formed during pyrolysis that can provide heat
protection.
Contractor: DEC or EPC
Endothermic Fire Protection: Heat-activated chemical or physical phase-change
reaction resulting in heat absorption by a non-insulating heat barrier.
Extinguishing Agent: Any substance used for the purpose of controlling or
extinguishing a fire.
Fire: Rapid oxidation of combustible materials accompanied by a release of energy
in the form of heat and light.
Fire Hazard Area: Any area where the potential for fire is possible.
Fire Performance: Laboratory tested results of the response of a fire-resisting
material, product or assembly to a realistic fire scenario.
Fireproofing: A systematic process, including materials and the application of
materials that provides a degree of fire resistance for the protected substrates and
assemblies.
Fire Resistance Rating: The number of minutes in a standardized fire test without
failing based on a set of predetermined failure criteria.
Fire scenario areas: Areas where a potential fire is premised.
Functionally Equivalent Performance: The ability to perform a given function
under specific conditions in a manner equivalent to other methods under the same
conditions.
Hazard: An inherent chemical or physical property with the potential to do harm.
Incipient Fire: First phase of the burning process where the substance being
oxidized is producing some heat, but the heat has not spread to other objects
nearby. The oxygen content of the air has just begun to be reduced. This is often
the only phase of a fire that untrained personnel should attempt to attack
themselves.
Intumescent Fire Protection: A chemical reaction, occurring in passive materials
when exposed to high heat or direct flame impingement, that protects by
expanding into an insulating layer of carbonaceous char material.
Jet Fire: A turbulent diffusion flame resulting from the combustion of a pressurized
fuel, continuously released with some significant momentum in a particular

direction or directions. Jet fires (sometimes called torch fires) can arise from
pressurized releases of gaseous, flashing liquid (two phase) and pure liquid
inventories.
Owner: Reliance Industries Limited or specified Reliance Group Company
Passive Fire Protection (PFP): A physical barrier, coating or other safeguard that
protects equipment, structure, architecture against heat from a fire without the
need for additional human or mechanical intervention.
Pool Fire: A buoyant diffusion flame in which the fuel (liquid) is configured
horizontally.
Pyrolysis: Process of simultaneous change in phase and chemical species caused by
heat.
Qualitative Risk Assessment: An experience-based evaluation of risk.
Quantitative Risk Assessment: The systematic development of numerical
estimates of the expected frequency and consequence of potential accidents based
on engineering evaluation and mathematical techniques.
Risk: The probability of exposure to a hazard that results in harm.
Risk Assessment: The identification and analysis, either qualitative or quantitative,
of the likelihood and outcome of specific events or scenarios with judgments of
probability and consequences.
Risk-based Analysis: A review of potential needs based on a risk assessment.
Supplier: Party which manufactures or supplies equipment and services to perform
the function as specified by Buyer
5. Introduction
Fireproofing is applied to resist a rise in the temperature of protected components
and materials when structures and equipment are exposed to fire. The primary
purpose of fireproofing is to ensure that critical load-bearing and pressure-
containing components retain their structural strength in event of fire and to
prevent the collapse of equipment carrying fire potential chemical/material which
may lead to the spread of burning liquid and substantial loss of property/
environment/ reputation, thus reducing the fire escalation. Under some
circumstances, a secondary purpose may be to limit the load on the pressure-relief
and flare system when fire exposure results in the opening of pressure-relief valves.
The term fireproofing within this document is used to describe a measure of fire
protection through passive fire protection to control the rate of temperature rise
in supporting structures and other fire-exposed critical parts of process plants and
offsites.
However, the term "fireproofing" may also broadly refer to fire-resisting materials,
application of such materials or assemblies which are intended to provide a degree
of fire resistance to the protected structures or equipment.

This design basis is broadly based on engineering aspects of OISD-164 “Fire Proofing
in Oil & Gas Industry” and API 2218 “Fireproofing Practices in Petroleum and
Petrochemical Processing Plants”. Wherever deemed necessary by RIL, more
stringent requirements have been added based on of RIL experience or perspective.
6. Fireproofing Philosophy
Fireproofing is a form of Passive Fire Protection (PFP). Its principal value is realised
during the early stages of a fire, where it improves the capacity of equipment and
their support structures to maintain their structural integrity. The main objectives
of fireproofing are:
• To prevent escalation of the fire due to the progressive collapse of structures/
supports, thereby causing consequential release of flammable inventories.
• To protect essential safety systems.
• To protect critical components, such as vessels, pumps, etc., if required.
• To provide escape routes integrity.
Determining fireproofing for any project will involve mainly experience-based
evaluation for the repeat/similar units. The evaluation will include developing fire
scenarios from which the Needs Analysis evolves.
A proposed route/methodology for fireproofing selection is:
1. Fire Hazard Requires knowledge of materials present,

Evaluation: conditions and quantification of inventories of
potential fuels.
2. Development of Requires analysing possible incidents by identifying
Fire-Scenarios: what might happen (e.g. by a fire), in order to
subsequently develop a scenario (e.g. how long
might the fire burn if unabated, what damage could
it cause etc.)
3. Definition of Fire- A three-dimensional space into which fire-potential
Scenario Envelope equipment can release flammable or combustible
(FSE): fluids, which can burn for long enough and with
enough intensity in order to cause substantial
property damage
4. Needs Analysis: Determines the level of protection (if any) which is

needed to protect equipment. The result should
include definition of which equipment to fireproof,
and for what duration and heat-exposure intensity
the fireproofing should provide protection.

5. Fire-Resistance Specifically defines the desired protection time-

Rating Selection: scale. It also takes into account the most
economical and practical fire-resistant rating that is
available within the requirements.
Note: If layout of an existing Plant is subjected to Management of Change (MOC)
or undergoes revamp due to which there is addition, deletion and modification of
equipment in the same layout, then the following should be implemented:
1. Contractor shall review and repeat all the above-mentioned steps in order to
check the extent of fire scenario envelope and the requirement of fireproofing.
2. Contractor shall check additional requirement of fireproofing of the existing fire
potential/non-fire potential equipment, structures, ESD & depressurizing valves,
critical instrument control/electrical/power cables etc, since they may fall in the
FSE of new fire potential equipment.
3. Contractor shall check additional requirement of fireproofing of new fire
potential/non-fire potential equipment, structure, ESD & depressurizing valves,
critical instrument control/electrical/power cables etc, since they may fall in the
FSE of existing fire potential equipment.
Protection is specified for the following categories of equipment, which will be
located within FSEs inside and outside process areas:
 Equipment structures and supports (including pipe racks, flangeless valves,
vessels and vessel skirts).
 Electrical and instrumentation systems, including cabling.
 Emergency valves which are considered critical for the safe shutdown of
the process unit, or which are otherwise designed to operate during a fire.
 Radioactive sources used for instruments.
Passive Fire Protection systems, such as fireproofing, are generally preferred over
active systems, such as firewater spray/deluge systems. However, it should be
recognised that applying insulating fireproofing materials to steel surfaces may
introduce additional problems, primary amongst which are:
 Corrosion underneath fireproofing (difficult to detect). Wherever
possibility exists, the designer shall consider using thermal Aluminium
spray as primary corrosion protection underneath fireproofing. Painting
of steel structures is covered in Piping Specification RPMS-ENGG-SPC-PP-
014 and Civil Structural Drgs and Spec. Please refer to it for surface
preparation, primer and paint for structural steel.
 Absorption of leaked hazardous fluids (difficult to detect and an additional
fire risk).

Therefore, whenever the above concerns are present, careful consideration still
needs to be paid to the alternative of installing active fire protection systems with
RIL approval.
7. Evaluating Fire Hazards (Fire-Potential Equipment)
In order to evaluate fire hazards, it is necessary to identify the location and types
of fire hazard areas. The factors which need to be considered are quantities,
pressures, temperatures and the chemical composition of potential fuel sources.
The equipment, located where there is a reasonable possibility that hydrocarbon
could be released and subsequently ignited, are defined as Fire-Potential
Equipment. Fire-Potential Equipment includes:
 Fired equipment, including process heaters and steam boilers, which
handle flammable materials.
 Pumps which handle liquids above or within 80C of their flash point
temperatures and with rated capacity greater than 45M3/Hr.
 Gas compressors, together with related lube-oil systems. While
compressors do not have a high liquid‐fire potential, they can generate a
fire scenario envelope if there is a prolonged release of gas and an intense
fire in the vicinity of important structural supports. The Compressor shall
be equipped with remote shut down by ESD valve and shall be isolated
from gas supplies or depressurized during an emergency, hence it need
not be considered as high fire potential equipment.
 Heat exchangers (including air cooled exchangers), and other equipment
containing flammable or combustible liquids over 315 °C or over their
auto-ignition temperature, whichever is less.
 Pressure vessels handling light hydrocarbons with an inventory of more
than 5 m3.
 Other pressure vessels handling heavy hydrocarbons over 315 °C or their
auto-ignition temperature, whichever is less, with an inventory more than
5 m3. Reactors which operate at high pressure or might produce runaway
exothermic reactions.
 Complex peripheral equipment such as combustion air preheaters.
 Process piping containing flammable materials.
 Spheres and bullets containing liquefied petroleum gases (LPGs), including
their drainage and impounding basin.
 Pressure relief valves which vent to atmosphere, and which could produce
a torch fire.
 Any equipment (including towers) with a history of bearing failure/s,
fatigue failure/s, instrumentation failure/s or seal leakage.

8. Developing Fire-Scenarios
A fire scenario seeks to define sequence of events that might release materials to
fuel a fire and evaluates the nature of a fire if it occurred. Basically, it is a risk
assessment (also known as Fire Hazard Analysis) by stakeholders from various
disciplines.
For each scenario the following should be considered:
 Potential fuel-release scenarios
 Potential of released materials to cause a fire
 Quantities of material/s which could be released
 Flow rate of release
 Potential of fuel being impounded by diking or berms
 Capacity of drainage system to remove a spill of hazardous material/s
Also, in case of ignition:
 Potential extent of the fire
 Burning rate of the hazardous material/s
 Heat of combustion and heat released
 Physical properties of hazardous materials
 Potential time of fire burn if unabated
The above steps can be used as an aid in developing fire scenarios for the areas
with equipment in potential need of fireproofing.
Note: Assess the impact of fire on an equipment containing HTM (Highly Toxic
Material) while planning fire proofing, and also to recommendations of the
technology licensor.
Examples of Risk Assessment: (i) Fire of the flammable combustion product (e.g.
syn gas) of solid material (e.g. coke) may lead to disintegration of structural
members. (ii) carburization/carbide precipitation may cause micro-fissures to open
up, thereby releasing flammables in open to the surrounding equipment.
9. Defining the Fire-Scenario Envelope (FSE)

The locations and dimensions of the FSE shall be established using experience-
based approach.
The experience-based boundaries of the FSE are defined in Annexure A.
In case of a potential small-scale pool fire, a risk assessment may justify smaller
horizontal boundaries which should not be less than 6 m.

To determine the boundaries of the FSEs, the following procedure shall be used:
1. Identify items of fire-hazardous equipment on a plot plan of the plant area.
2. For each piece of fire-hazardous equipment, draw a line 9 m away from the
outer edge of the equipment.
3. Identify drainage patterns from fire-hazardous equipment on the plot plan,
especially areas where liquid hydrocarbons can pool.
4. Draw a line 9 m from the outer edges of the drainage patterns and pools.
5. “Square off” the circles or shapes developed in steps 2 and 4. This will result
in a petal diagram of the FSE on the plot plan which will usually encompass all
equipment items, apart from the exclusions listed above.
6. Determine the height to which equipment/supports in the area must be
protected. Usually this is 9m above grade, with the following exceptions:
 When a fire can be started above grade, equipment located between it
and grade is also considered to be within the FSE.
 When fire-hazardous equipment is located above grade, and is installed on
a platform which could accumulate hydrocarbon liquids, or there is a
reasonable probability of a pressurized torch fire, the FSE shall be
extended 9m above the level at which the fire-hazardous equipment is
located (as the base, where liquid will accumulate, is shifted)
The Fireproofing requirements for equipment, its supports and system components
are shown in ANNEXURE A and ANNEXURE B and shall be chosen to provide the
level of protection stated in the design basis. Any additional requirement shall be
arrived based on the severity and criticality of process fluid (w.r.t. to temperature,
pressure, flash point, etc.) and will be discussed between DEC/EPC and RIL. Decision
of RIL will be final.
Supporting steel structures, critical installation etc should be protected from torch
fires by proper location selection and orientation of the supporting structure with
regard to potential source of leakage (PSL) and/or by providing fire shields near the
PSLs or the surfaces of the structures to avoid direct impingement. If protection of
the supporting structures against torch fires is not possible or practicable, then
fireproofing of these structures should be done.
It is impractical and not cost-effective to fire-proof each and every load bearing
member exposed to jet fire potential. While optimum inspection, maintenance and
operating practices are the answer, risk-based review and assessment should be
done for selected critical equipment having high damage and toxic potential in jet
fire scenarios. RIL stakeholders should finally communicate to the DEC/EPC
contractor to carry out selective Fire Hazard analysis (FHA) and a focused CA and
/or risk-based study for the scenarios identified in the FHA and accordingly decide
on the type of protection (active and /or passive) required. Recommended release
size for above study is 10 mm. Study for any other leak hole-size will be decided on

case-to case basis as per approval from RIL. Licensors requirement shall also be
considered for fire proofing requirements.
Note: Please pay special attention to the impact of fire on an equipment containing
HTM (Highly Toxic Material) while planning fire proofing.
10. Fire-Resistance Rating Selection

Following the Needs Analysis which quantified the risk factors related to severity
and duration, it is necessary to determine a suitable Fire-Resistance Rating. To do
so, it requires determination of the length of time the fireproofing is intended to
provide protection.
The following Table lists the minimum requirements which shall apply for
fireproofing of equipment supports, and categories of equipment identified while
evaluating fire hazards, unless modified elsewhere in this specification:
Table A: Temperature Limits and Fire Exposure Times
Max Exposure
Substrate or Component Temperature Limit
Time
Carbon steel structures, vertical vessel
legs or vessels skirts, equipment and 538oC (1000oF) 2 hours
pipe supports
Fireproofed pressure vessels
427oC (800oF) 2 hours
(including LPG storage vessels)
Critical electrical components, 15 to 30
150oC (300oF)
instrumentation and valve operators minutes
Note: Fireproofing in excess of the above requirements may be required by RIL
for high-valued equipment (such as reactors), or equipment handling large
quantities of flammable and toxic material in congested areas which are
impacted by fire scenarios. This must be agreed and communicated by Project
Manager to the Contractor in coordination with stakeholders.
The requirements of the above specification presuppose an adequate drainage
system, so that the spread of a spill of flammable liquid is minimised. Where
drainage does not meet the design criteria, additional fireproofing may be justified.
The level of fireproofing required shall be such which is necessary to prevent the
temperature of the protected equipment from reaching its temperature limits
whilst exposed to a gasoline/flammable fire of about 1100oC (2000oF).

11. Rating of Fireproofing Material

All steel support structures provided with fireproofing shall protect the steel from
exceeding a temperature of 538oC for a duration of 2 hours when exposed to
hydrocarbon fire.
12. Deviations
The requirement of the DBD are essentially to be met. However, if there is any
deviation, approval has to be obtained from RIL on a standard RIL deviation Form.
Decision of the RIL will be final.
13. References
Document ID Document Title
National & International codes:
API RP 2218 Fireproofing Practices in Petroleum
and Petrochemical Processing
plants, Third edition, July 2013.
ASTM E119 Methods for Fire Tests of Building
Construction and Materials.
OISD-STD-164 Fireproofing in Oil & Gas Industry
OISD-STD-144 Liquified Petroleum Gas (LPG)
Installations
RPMS HSE Design Documents:
RPMS-ENGG-DBD-HS-001 Overall Requirements for HSE and
Loss Prevention Engineering
iRPMS-ENGG-PRA-HS-001 HSE & LP Engineering Management
System
RPMS C&I Document:
RPMS-ENGG-SPC-CI-006 Standard specifications for
Isolation/Shut down valves
RIL Group Defined Practices (One Reliance):

GDP 3.1-0001 Assessment, Prioritization and
Management of Risk
GDP 3.3-0003 Process Hazard Analysis (PHA)

14. Annexures
ANNEXURE A: Typical Dimensions of Fire-Scenario Envelope (FSE)
Hazard Concern Horizontal Vertical
A fire scenario source of 9m 9m

liquid fuel release - general
Fire potential equipment 9m Up to highest level
supporting equipment
Non-fire potential equipment 9m Up to level nearest 9 m
above fire potential above grade
equipment
LPG vessels as potential Pipe supports within Up to level nearest 9 m
source of exposure 15 m or within spill above grade
containment area
Air coolers on pipe racks 9m All support members
within fire-scenario envelope up to cooler
Rotating equipment 9 m from the expected 9m
source of leakage
Tanks, spheres, and spheroids The area shall extend 9m
containing liquid flammable to the dike wall, or 6m
material other than LPG from the storage
vessel, whichever is
greater
Marine docks where 30 m horizontally from From the water
flammable materials are the manifolds or surface up to and
handled loading connections including the dock
surface

ANNEXURE B: Tables of Typical Fireproofing Requirements

Table 1: Fireproofing for Structures
SR. DESCRIPTION EXTENT OF FIREPROOFING DO NOT FIREPROOF
NO.
1 General • Up to 9 m above grade (a) Support steelwork for
supporting non-fire stairways and access
potential equipment platforms, or steelwork
used exclusively for
• Up to point of attachment
maintenance.
of equipment supporting
fire potential equipment (b) Bracing provided for wind
and earthquake loads only.
(c) Intermediate supports
provided for branch take-offs
or to reduce the span of small
lines,
(d) Concrete structure.
2 Overhead pipe- • Main structures, or bents, (a) Upper surface of top flange
racks, without air- up to and including lowest of lowest main transverse
coolers installed main transverse pipe- pipe support beam.
above or pumps support beam. (b) Refer Sr. No. 1
installed below.
• Up to the level that is
nearest to 9 m elevation if
levels above the first
horizontal beam carries
hydrocarbon piping greater
than 6 inches.
• Longitudinal members
connecting main bents,
when they also act as
supports for large lines to
pumps, exchangers,
columns, etc.
• Columns, brackets and
stanchions for auxiliary
pipe supports outside pipe
rack carrying hydrocarbon
piping greater than 6
inches.


NO.
3 Overhead pipe- All supporting elements, to a (a) Upper surfaces of top
racks, without air- minimum height of 9 m. flanges of transverse pipe
coolers installed support beams.
above, but with (b) Refer Sr. No. 1
pumps installed
below.
4 Pipe-racks with air- Fireproof elements contributing (a) Upper surface of pipe or
coolers installed to the air-cooler support, equipment supporting
above or elevated including transverse and beams.
air-coolers. longitudinal beams (as (b) Horizontal beams which do
applicable) up to the point of not contribute to the
support of the bundles. air-cooler support.
(c) Refer Sr. No. 1
5 Individual pipe Fireproof up to point of pipe Pipe supports located no more
support columns or support. than 1m above grade.
stanchions.
6 Heater transfer line Fireproof up to point of Refer Sr. No. 1
support where a attachment of pipe support.
major support
structure is
required
7 Supports for flue Fireproofing up to point of duct (a) Refer Sr. No. 1
gas ducting attachment.
connecting two or
more heaters to a
common stack.
Note: Piping which is supported from spring hangers or rods shall be protected against
failure of a hanger or rod by a bracket beam located beneath the pipe.

Table 2: Fireproofing for Air-coolers

NO.
8 Grade-mounted air- Fireproofing up to point of Refer Sr. No. 1
coolers support of tube bundle.
Table 3: Fireproofing for Boilers and Fired Heaters

NO.
9 Boilers and fired Fireproof vertical columns and (a) Main frame and side plates.
heaters horizontal beam supports up (b) Refer Sr. No.1
to furnace floor level.
Table 4: Fireproofing for Vessel Skirts

NO.
10 Grade-mounted Fireproof outside of skirt only Vessels with a diameter of less
vessels with: than 1200 mm (4ft)
(a) not more than
one access
opening, max
600 mm
opening, and
(b) annular
openings of
less than 25
mm (1 in)
around
entering lines,
and
(c) no skirt vents,
(d) no flanged
joints or pumps
within skirt.
11 Grade-mounted Fireproof outside and inside of Same as Sr. No. 10
vessels with: skirt.
(a) two or more Special consideration is to be
access given to cases where the skirt
openings, or operating temperature
gradient is a significant factor

(b) one access
in vessel design or where an
opening and
air gap is required, i.e. vessel-
annular
to-skirt joint.
openings
exceeding 25
mm (1 in)
around,
entering lines,
or
(c) skirt vents,
(d) flanged joints
or pumps
within skirt.
12 Elevated vessels Refer Sr. No. 11 Same as Sr. No. 10
where the skirt is
not closed off at
the bottom.
Note: Special consideration shall be given to the details of fireproofing skirts on hot vessels
that require fireproofing (to ensure that installation of the fireproofing will not result in
possible structural problems caused by heat build-up within the skirt). Where the skirt
temperature gradient is critical, a "hot box" shall be provided at the shell-to-skirt joint.
Table 5: Fireproofing for Vessel Legs

NO.
13 Vessels having Fireproof support legs up to (a) Same as Sr. No. 10
support legs point of attachment. (b) Support legs for vessels
attached to the containing non-combustible
shell. material where total height
above grade is 3 m or less and
diameter is 1.2 m or less.

Table 6: Fireproofing for Horizontal Vessels and S&T Heat Exchangers

NO.
14 Pier or column Use concrete piers, or (a) Intermediate saddles
supported fireproof supporting steel up between stacked exchangers.
to point of support For vessels
that have a diameter greater
than 30 inches (0.76 m) if the
vertical distance between the
concrete pier and the shell of
the vessel exceeds 12 inches
(0.30 m).
15 Structure As Sr. No. 1 Refer Sr. No. 1
supported
Table 7: Aboveground Power and Control Cables

NO.
16 Grouped electric Fireproofing not required.
power and lighting
cables.
17 Individual power (See Notes 1 and 2 below) (a) Fire-resistant electrical and
and control cables control cables capable of
for those items providing at least 20 minutes
essential for safe protection under "High Rise"
shutdown or fuel time/temperature curve test
isolation conditions. (Such as IEC
331/332 types).
Cables of critical
systems like escape (b) Individual tubing for non-
routes illumination, essential instruments.
smoke extraction (c) Types 304/316/321 SS
package, etc shall tubing are highly resistant to
be check for failure during a hydrocarbon
fireproofing. fire and need not be
fireproofed.
Note 1: Cables to be protected by applying a proprietary fireproofing system on cables or
by putting them in a fire-resistant enclosure.
Note 2: Junction boxes handling essential cables to be covered externally with approved
lightweight fireproofing materials capable of providing 30 minutes of protection under
"High Rise" time/temperature curve test conditions.

Table 8: Emergency and Critical Valves

SR. DESCRIPTION EXTENT OF FIREPROOFING
NO.
18 Emergency valves (air or electric (a) Air or electric motor actuator
motor operator) – are defined as (b) Pneumatic Power and Signal lines to the
any valve which is required to act in valve including lines on double-acting
an emergency and includes all ESD valves required to move the valve to the
valves, emergency blow-down or “safe” position
depressurizing valves, and remote
operated emergency pump (c) Solenoid on solenoid operated valves
isolation valves. (d) Diaphragm Housing on diaphragm
operated valves
Air filter and lubricator if installed on Air
operated valves. Other accessories like
volume boosters, air operated relays,
volume tank, and local/remote panels.
Notes:
• Stainless steel tubing does not require fireproofing
• Electrical cabling which is specified as fire-resistant does not require fireproofing
• Accessories and valve controls which are located outside the fire exposed
envelope/FSE do not require fireproofing – Pl refer to Loss Prevention/HSE Engg for
further guidance.
EXCEPTIONS
1. Fail Safe Spring return for emergency shutdown (ESD) valves and emergency
depressuring valves (EDV) can be provided with suitable fusible plugs in the
instrument airline instead of fireproofing the actuators. In this case when the valve
is involved in a fire, the plug will fuse and release air activating the spring return
piston and closing the emergency shutdown valve or opening the emergency
depressuring valve. See API RP 553, Section 7.5.2.2.
2. All Fail Last ESD valves and EDVs, will be provided with fireproofing for actuators.
Particularly some ESD Valves (including EDVs and Pump Suction ROVs) may need to
be stroked once or multiple times even in the presence of fire and this is due to
process requirements. For these ESD valves, all the components related to the
operation of the valve (including the cables, the body of the valve, the valve panels
and the Volume Tanks) need to be fire proofed when they are within a fire
envelope.

Table 9: Flangeless Valves

NO.
19 Flangeless Valves Valves with lug-less bodies The hand wheel, if provided on
which have exposed bolts the valve, shall not be
longer than 75 mm (3 in). fireproofed and shall be
accessible from outside the
Refer Note.
fireproofing.
Table 10: LPG Storage Vessels

SR. DESCRIPTION EXTENT OF FIREPROOFING
NO.
20 LPG storage vessels • When the Project Specifications specify passive fire
(spheres and protection, the entire shell and vessel supports shall be
bullets). fireproofed
• The legs of spherical storage tanks shall be fireproofed up to
the point of attachment to the shell.
• Horizontal pressurized LPG storage vessel supports which
have a height of more than 300 mm (12 in) between the
concrete pier and the shell of the vessel shall be fireproofed.
Table 11: Radioactive Sources

NO.
21 Enclosures 4-hour protection per ASTM E Enclosures when the source
containing 119 for outer surface of the holder will not release
radioactive sources enclosure. radioactive material when
exposed to a constant
temperature of 980oC (1800oF)
for a period of two hours.

Table 12: Flare Line Supports

NO.
22 Supports for flare Refer Sr. No. 1 Refer Sr. No. 1
lines which pass
through a FSE, or
are located within 9
m of open ditches
or drainage
channels.
Table 13: Fire Water Pipe

NO.
23 Fire water pipe Up to 9 m on FW Line from the
(ring-main), if laid subject flange on the
above-ground hydrocarbon line
within 5 m of any
flange-joint on
hydrocarbon line.

Design Basis for Wind and Seismic Analysis of

Static Equipment
RPMS-ENGG-DBD-MS-001

By By By
Reliance Project Management System RPMS-ENGG-DBD-MS-001
Design Basis for Wind and Seismic Analysis of Static Date: 17.08.2020, Rev. 0
Equipment

Sr.
No.
1 _____________________________ _________________ ___________
_____________________________ _________________ ___________

2
_____________________________ _________________ ___________

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
Design Basis for Wind and Seismic Analysis of Static Date: 17/08/2020, Rev. 0
Equipment
RECORD OF REVISIONS

Number

Equipment
Contents
1. Scope............................................................................................................................ 5
2. References ................................................................................................................... 5
4. Abbreviations ............................................................................................................... 5
5.1. Wind Design and Analysis ............................................................................................ 6
5.1.1. Allowance Factor for Wind Load ................................................................................. 6
5.1.2. Wind Design Parameters ............................................................................................. 7
5.2. Seismic Design and Analysis ........................................................................................ 8
5.2.1. Seismic Design Parameter ........................................................................................... 8
5.2.2. Methodology/Guideline .............................................................................................. 8
5.2.3. Equipment Supported on Structure ............................................................................ 9
Equipment
1. Scope
The purpose of this design basis is to provide guide lines for wind and seismic
analysis of static equipment.
2. References
IS-875: Part 3 Code of Practice Part 3 Wind Loads
ASCE 7 Minimum Design Loads and Associated Criteria for Buildings
and Other Structures
IS 1893: Part 1 Criteria for Earthquake Resistant Design of Structures - Part 1
2016 Edition General Provisions and Buildings
IS 1893: Part 4 Criteria for Earthquake Resistant Design of Structures Part 4
2015 Edition Industrial Structures Including Stack - Like Structures
Addendum 2018

In case of conflict between requirements, the SELLER shall notify the BUYER for
review and resolution at pre-order stage. Deviations (if any) shall be approved, in
writing by the BUYER.
4. Abbreviations
BEDD Basic Engineering Design Data
MCE Maximum Considered Earthquake
DBE Design Basis Earthquake
Unit of Measurement:
The International System of Units (abbreviated SI) shall be used as follows:
ITEM UOM
Area m2 or mm2
Elevations m
Force N
Length or Size m or mm
Equipment
Loadings N/m²
Mass kg
Moment Nm
Pressure N/m² or MPa
Stress N/mm² or MPa
Volume m3 or mm3
5. Technical and Design Requirements

5.1. Wind Design and Analysis
5.1.1. Allowance Factor for Wind Load
DM = Bare Dia (OD) of the Column (m)
DI* = Insulated Dia (m)
DK = Insulated Dia of Piping (m)
DL = 0.33 (for Ladders)
FB = 𝐷𝐼 ∗ + 𝐷𝐾 + 1.2 𝐷𝐿
𝐷𝐼 ∗
Extent of Platforms for design purpose shall be as follows:

Platforms covering 180 deg circumference at every 6 meters and one 360 deg
platform 600 mm above top of top dished end.

Equipment
5.1.2. Wind Design Parameters

a) Static Wind Load (As per IS-875 part 3 Section 10)
Terrain Category = 2,
As per Site Data. (Basic Wind
Vb =
Speed)
k1 x k2 x k3 x k4 x Vb (Design
Vz = Wind Speed at height z, in
m/s)
Risk Coefficient, k1 = 1.08
Terrain Height Factor, k2 = As per code
Topography Factor, k3 = 1
Importance Factor for Cyclonic Region, k4 = As per Code
Wind Pressure (N/m2) based at height z: Pz = 0.6 Vz²
Design Wind Pressure, P̅d = As per Code IS-875 part 3
Static Wind Load at given height Fz = Cf * FB * Ae * P̅d
Where,
Cf = 0.7
Ae = Effective Projected Area, as
applicable (Effective Dia X
Height).
Note:
Total Wind Force, F = Σ Fz
Total Wind Moment, M = Σ Fz * hz
Where,
Height of the Section from
hz = Base
For Columns H/D < 15, the same Wind Load is used for Structural Design (combined
stresses), foundation design and anchor design.
b) Dynamic Wind Load (Gust Factor Method as per IS-875 part 3 Section 10)
This shall be used for columns with H/D > 15 for calculating wind loads and
moments for structural design (combined stresses in the shell and skirt), foundation
design & anchor bolts design.
Fz = Cf * FB * Ae * P̅d * G
Where,
Cf = 0.7
FB = Same as in clause 5.1.1
Ae = Same as in clause 5.1.2 a)
Equipment
Design Wind Pressure

calculated as per Section
P̅ d = 10.2 of IS 875 part 3
Gust Factor, to be
calculated as per Section
G = 10.2 of IS 875 part 3
Note:
Total Wind Force, F = Σ Fz
Total Wind Moment, M = Σ Fz * hz
Where,
Height of the Section from
hz = Base
However, if static wind loads are higher than that with gust factor method, then
the higher loads shall be used.
Also, for vertical vessels with height to diameter ratio >15 the effects of wind
induced vibration shall be checked.
5.2. Seismic Design and Analysis

5.2.1. Seismic Design Parameter
Seismic Zone Factor Z = As per IS 1893 or site spectra
Importance Factor I = 2 for category 1 equipment and for all other category the
factor shall be as per code (Part 4, Section-2).
Seismic Category of equipment: This shall be based on BEDD of the project or
Mechanical Datasheet. Table 6 of IS 1893 part 4 shall not be used.
Response Reduction factor, R = As per Code IS 1893
Soil Type = As per site data.
% Damping = 2 % for equipment (As per the Code IS 1893)
5.2.2. Methodology/Guideline
5.2.2.1. Equipment Category 1:
a. Design Basis Earthquake (DBE) as per IS 1893 shall be used.
b. Response Spectrum Method shall be used.
c. Project specific Seismic Spectra are arrived at for various time values, using the
formula below:
Spectra ordinate Ah (as a fraction of g) = (Z/2)*(I/R)*(Sa/g)

Equipment
(Sa/g) = Spectral acceleration Co-efficient
The other values in the equation shall be considered as follows:

Importance Factor I =2.0
d. A detailed analysis shall be carried out as per IS 1893 Part 4. Sufficiently large
number of modes shall be used to include the influence of at least 90% of total
seismic mass.
e. Use the seismic loads and moments thus calculated, for sizing the equipment,
its support, anchoring etc.
5.2.2.2. Equipment category 2:

a. Design Basis Earthquake (DBE) as per IS 1893 shall be used.
b. Use the same methodology, as for category 1.
c. I = As per Code IS 1893
5.2.2.3. Spheres and Bullets:

Seismic Category of Spheres and Bullets shall be taken as 1 unless specified
otherwise in the data sheet.
Response Reduction Factor R = 2.0
5.2.3. Equipment Supported on Structure

The following additional requirement is applicable,
a. For equipment with weight more than 25% of the combined weight of
equipment and supporting structure, then the equipment shall be analysed
along with the structure.
b. When equipment weight is less than 25% of the combined weight of supporting
structure, then seismic force shall be multiplied by the following factor:
0.4 ap (1+ (2z/h))

ap = 1 for all equipment which are not supported on skirt support.
ap = 2.5 for equipment which are supported on skirt support.
z= height in structure up to point where equipment is mounted on
structure from the base.
h= average roof height of the structure with respect to the base.
This multiplication factor shall not be less than 1.
Above requirement is applicable to Equipment Mounted on Non‐Standard
Increased Height Concrete Plinths.

Design Basis
Indian Boiler Regulations
Approval Procedure for Static Equipment
RPMS-ENGG-DBD-MS-002
0 17.08.2020 Issued for Implementation ND / ADB LS TNR / VKM

By By By
Design Basis - Indian Boiler Regulations Date: 17.08.2020, Rev. 0

Sr.
No.
1 _____________________________ _________________ ___________
_____________________________ _________________ ___________

2
_____________________________ _________________ ___________

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
Design Basis - Indian Boiler Regulations Date: 17/08/2020, Rev. 0
RECORD OF REVISIONS

Number

Contents
1. Scope ......................................................................................................................... 5
2. Conflicts and Deviations ............................................................................................ 5
3. Abbreviations ............................................................................................................ 5
4. Codes and Standards ................................................................................................. 5
5. Documentation Requirements: ................................................................................. 5
1. Scope
This document defines standard formats and numbering for documentation related
to IBR submissions and states more clearly the responsibilities of various project
roles, in order to ensure compliance with the regulations.
This design basis provides uniform approach to collating the documentation
required to form a design, fabrication and installation approval package of
equipment under the jurisdiction of Indian Boiler Regulations (IBR)

In case of conflict between requirements, the Supplier shall notify the BUYER for
review and resolution at pre-order stage. Deviations (if any) shall be approved, in
writing by the BUYER.
3. Abbreviations
CBB Central Boiler Board
CIB Chief Inspector of Boilers
DOB Director of Boilers
TEMA Tubular Exchanger Manufacturers Association
GA General Arrangement
TPIA Third Party Inspection Agency (IBR Approved)
4. Codes and Standards

IBR Indian Boiler Regulations, 1950 with latest amendments
5. Documentation Requirements:
5.1. General
In addition to the normal design codes (ASME/TEMA), IBR equipment has to meet
the design, fabrication and testing requirements of either IBR or IBR Recognized
Codes. The manufacturing drawing shall bear “IBR” as the design code.
Design calculations including safety valve calculations have to be carried out as per
IBR.
Value of design pressure (not the operating pressure) shall be entered against WP
in Form II. All other documents shall be modified accordingly
5.2. Vendor Submissions for Manufacturing Approval:

The following sections define the scope and quantities of the Vendor document
submissions to the CIB/DOB and Reliance in order to obtain IBR approval.
For IBR equipment manufactured in India, design calculations/drawings have to be
approved by IBR. Such equipment shall be manufactured and tested under the
inspection of IBR. Such Supplier’s shop should have been IBR-approved
For Equipment supplied from outside India the IBR design calculations/drawings
have to be approved by one of the IBR Approved Third Party Inspection Agencies
listed below (refer latest IBR for updates): -
1. The Hartford Steam Boiler Inspection and Inspection and Insurance Company
2. Engineers India Ltd
3. RWTUV ev
4. Royal and Sunalliance Engineering
5. Japan Inspection Company Ltd
6. Intertek Testing Services ( Japan ) k.k
7. S.G.S.Korea Company Ltd
8. Bureau Veritas
9. Det Norske Veritas
10. Lloyds Register of Shipping
11. Technischer Uberwachungs Verein (TUV)
12. Velosi Certification Bureau Ltd
13. ABSG Consulting Incl
14. Moody International Ltd
All drawings and calculations shall be approved by one of the above IBR approved
Third Party Inspection agency prior to direct submission of the documents to
Reliance for submission to the CIB/DOB.
Note: Where Vendors are responsible for process design, confirmation of the scope
of IBR is to be obtained by submission of a 1st Submission (Equipment) Package in
accordance with RPMS-ENGG-DBD-ST-005.
Manufacturing of equipment under the purview of IBR shall not commence until
approval of the design has been obtained from the CIB/DOB.

5.2.1. Steam Generators (IBR Reg. 393) Design Approval:

1. Manufactured in India:
For Steam Generators manufactured in India, documentation requires approval
by the Local State IBR Inspector. Vendor shall supply this IBR Package to Reliance
and shall contain all the Original IBR approved manufacturing drawings (in
triplicate), the design calculations including safety valve sizing calculations as per
IBR, all the original certificates and the additional documents.
2. Manufactured outside India:
Direct Fired Steam Generators of a generating capacity of 100TPH or more and
Waste Heat Steam Generators of a generating capacity of 20TPH or more, require
that one (1) copy of all the Manufacturing drawings, design calculations including
safety valve sizing calculations as per IBR and Specifications of the materials, shall
initially be Approved by an IBR approved Third Party Inspection Agency.
Then, these documents, along with P&ID’s, plan & elevation drawing of the heat-
body and the steam drum shall be submitted to the technical adviser (Boilers),
Central Boiler Board, New Delhi and to the Director Boilers of the State in which
it is to be erected for Approval through Reliance.
Three (3) sets of these drawings, Bill of material, IBR calculation approved by the
IBR approved Third Party Inspector & Design appraisal document from third party
in the country of manufacture, shall be issued to Reliance to obtain the necessary
approvals.
Reliance shall submit drawings for approval as below: -

a) To IBR Technical Advisor, New Delhi:
The original copy of all Manufacturing Design Documents comprising:-
1. General Arrangement for the Steam Generator system. This is an elevation drawing
of the system indicating their relative elevations and locations.
2. Drawings of IBR vessels (steam generating and non-steam generating) which clearly
show side / end views, nozzle schedule, service, design data, materials of
construction and weld seam location of longitudinal and circumferential joints in
side and end view of drum.
3. Manufacturing Drawings, Material Specifications and Calculations: -
a. Tube wall thickness calculations (IBR Reg. 338 or proprietary thickness calculation
as per TEMA).
b. Tube sheet thickness calculations.
c. Piping wall thickness for Risers / Down-comers, piping connections between vessels
of the system (anything between feed water inlet to boiler and steam outlet) ʹ
piping outside of this is subject to submission at a later stage.

d. Shell thickness calculations.

e. P&ID for the Steam Generation system.
b) To Local State CIB/DOB
Reliance, will submit 1 photocopy of the drawings to the local State CIB/DOB for his
review and discussions with the Technical Advisor, New Delhi during the process of
approval.
After review and approval, the Technical Advisor, New Delhi will send the approved
documents to the local State CIB/DOB for his approval to permit manufacturing
under the Quality Surveillance of the approved IBR Third Party Inspection Agency in
the vendors works.
Drawings for Registration purpose subsequent to approval from New Delhi:
1 Original +1 Copy of Drawings & Design Calculations as per IBR code. No
modifications are to be made to the drawings already approved by the Technical
Advisor New Delhi.
The above requirements are for drawings & design calculations only. For certificates
& Rub - Off only one set of originals is required.
On completion of the fabrication of the equipment the vendor shall submit all final
documentation to Reliance, who shall in turn submit the same to the CIB/DOB of
the State where it is to be installed.
5.2.2. Non-Steam Generating IBR Vessels and Exchangers

1. Manufactured inside India
Three (3) copies of all original IBR approved design calculations including safety
valve sizing calculations, manufacturing drawings along with all other original
certificates and documents as detailed above , shall be submitted by the Vendor to
Reliance, who shall in turn submit the same to the CIB/DOB in the State where the
equipment is to be installed.
2. Manufactured outside India
One (1) copy of all design calculations including safety valve sizing calculations,
manufacturing drawings along with all other original certificates and documents
shall be submitted to the selected IBR Third Party Inspector for review and approval.
Three (3) copies of all original IBR approved Third Party Inspection Agency along
with all other original certificates and documents as detailed above, shall be
submitted by the Vendor to Reliance, who shall in turn submit the same to the
CIB/DOB in the State where the equipment is to be installed.

5.2.3. Site Documentation

Subsequent to completion of Manufacture / Supply the following documentation is
required to be submitted for Site use.
In addition to all original manufacturing drawings and calculations being submitted
to the CIB/DOB for his approval, the following original documents are required at
the site for inspection by the Divisional Boiler Inspector for all equipment under his
purview, prior to erection and subsequent hydrostatic testing:
1. FORM II: Inspecting Authorities Certificate of Inspection during Construction
2. FORM II-B: Inspecting Authorities Certificate of Inspection during Construction of
Boilers for which variations from Standard Conditions Have Been Permitted
3. FORM III: Constructors certificate of manufacture and test.
4. FORM III-A: Certificate of Manufacture and Test for Pipes.
5. FORM III-B: Certificate of Manufacture and Test for tubes.
6. FORM III-C: Certificate of Manufacture and Test for Boiler Mountings and Fittings.
7. FORM IV: Certificate from the maker of Steel.
8. FORM IV-A: Certificate of Manufacture and Results of Tests in Lieu of Form IV
9. GA Drawing + detail drawing: Approved by CIB/DOB/TPIA of the place of
manufacture with original stamp and wet signatures. Drawing should be
submitted equipment TAG number wise separately. Drawings for combine
equipment is not acceptable. E.g. MV-XXX-VXXXA/B/C shall have separate drawing
for MV-XXX-VXXXA, MV-XXX-VXXXB & MV-XXX-VXXXC
10. Weld Map: Weld map showing orientation of longitudinal weld seams & distance
between the circumferential seams.
11. Design Calculations: Approved by CIB/DOB/TPIA of the place of manufacture with
original stamp and wet signatures.
12. Original rub-off: While the equipment is in the vendor’s works as per Form II/IIB,
Form III, Form IV-A, GA Drawings, Weld map, Rub-off must be with original
stamp & wet signature of IBR CIB/DOB/TPIA of the place of manufacture. Rub-off
should be visible clearly. Supplier to ensure that HARD punch must be visible
(readable) and same as Form II. IBR rub-off location shall be marked on GA
drawing.
13. Positive material identification must be done for all alloy steel material
used in IBR circuit. Report for the same is required to be submitted before
heat treatment of the circuit.
Note: - IBR stamp must be same as what is punched on equipment (rub-off).

Stamping to be done on Form II/ II-B. Typing is not acceptable.

Supplier Documents Requirement

RPMS-ENGG-PRA-GE-041
0 17.03.22 Issued for Implementation VS BB/JT/SP/ TNR/VKM

PG/LS

By By By
Reliance Project Management System RPMS-ENGG-PRA-GE-041
Supplier Documents Requirement Date: 17/03/2022, Rev. 0
RECORD OF REVISIONS

Number
17-03-2022 Issued for Implementation 0
Contents
1. Purpose...................................................................................................................... 4
2. Scope & Application .................................................................................................. 4
3. References ................................................................................................................. 4
4. Abbreviations ............................................................................................................ 4
5. Supplier Documentation ........................................................................................... 5
6. Document Format Requirements ............................................................................. 5
7. Document Submission Procedure ............................................................................. 6
8. Document Content Requirements ............................................................................ 9
9. Attachments: ........................................................................................................... 40
1. Purpose
The purpose of this procedure is to identify and define the contents of
documentation to be submitted by the supplier as part of his contract. The
document also establishes the standard numbering structure to be followed by the
suppliers. The instructions laid down in the subsequent sections shall be read in
conjunction with form VDR-001 i.e. Supplier Drawings & Data Requirement,
attached in this document.
2. Scope & Application
This procedure covers all work processes associated with supplier documents
developed during various phases of the project.
This document shall be applicable to all projects (Greenfield and Brownfield)
executed by RPMG.
3. References
RPMS-PMMD-PRA-MM-001 MR Numbering System
RPMS-PMMD-PRA-MM-002 MR Categorization listing for Material
Requisition
RPMS-DCCC-MAN-GE-001 eRoom user Guide
RPMS-DCCC-PRA-GE-006 Contractor Document Exchange
RPMS-ENGG-PRA-GE-028 Numbering Systems for Drawings, Documents &
Equipment and Component Identification codes
4. Abbreviations
DCC Document Control Centre
DECAL Electronic Sticker showing approval status by Engineering assigned
status code (Attachment-3)
EDMS Electronic Data Management System
eRoom Internet based web application that provides a secure
collaborative environment to the authorized users across the
world enabling them to share information.
REIMS Reliance Enterprise Information Management System
Submittal Documents submitted by Supplier
VDR-001 Supplier Drawings & Data Requirements Form (Attachment-1)
VDS-001 Supplier Drawing & Documentation Schedule Format (Attachment-2)
MRP Material Requisition for Purchase
WBS Work Breakdown Structure
Confidential Page 4 of 43
5. Supplier Documentation
The documentation required to be submitted by Supplier is shown on the “Supplier
Drawings & Data Requirements" form VDR-001. Supplier shall submit for review the
documents indicated on the VDR-001 form at the time stated. Any submissions to
third parties e.g. Process Licensors, will also be defined on this form.
All vendor documents have to be classified as per the category coding system
provided in this procedure i.e. Attachment-1, VDR-001. All the
drawings/documents to be submitted by the Supplier shall be included in the
Drawing & Documentation schedule (Refer VDS-001 format).
The documents under different category codes shall not be clubbed into on single
category.
6. Document Format Requirements
6.1. Template/Format
Submission of documents shall be on Buyer standard forms unless otherwise
agreed. Supplier will be responsible for provision and support of both hardware and
software required to interface with and use Buyer’s preferred format.
6.2. Electronic Format
Buyer requires to submit the documents for review electronically, in Adobe Acrobat
Portable Document Format. To enable the integration of the Supplier’s documents
into the Buyer’s EDMS, the Electronic Document Submittal Guidelines are given in
attachment-4 (RPMS-DCCC-PRA-GE-006) of this document. The Buyer’s EDMS shall
facilitate the review of the Supplier’s documents.
6.3. Language
All documents are to be legible and shall be submitted in English language or shall
have translation in English.
6.4. Documentation Quality
All submittals of documentation shall meet the following quality requirements
• All drawings and document submitted shall be legible and clear. Legibility and
contrast of the documents shall be such that every line, number, letter and
character shall be crisp and clear.
• All images must be in colour, legible and properly orientated for viewing.
• All documents supplied, shall be rejected if information thereon is incomplete,
incorrect or illegible.
• Drawings and Documents shall be in PDF files and must be text searchable.
• Documents not generated by vendor can be scanned to pdf files. However, the
reproduction quality shall be of such clarity that a third generation (printed)
copy will meet the legibility requirements as stated in this section.
• Documentation shall be typed and arranged in a neat professional manner.

• Wherever applicable documents shall contain a table of contents, list of
figures, and tables of applicable, reference or complementary documents.
Adobe Acrobat Portable Documents Format (pdf file extension) files will be
book marked per table of contents of by sections where applicable.
• Clearly mark all additions, deletions, changes, and other revisions on
documents with revision marks and “clouding”.
 By a vertical line in the right-hand margin against the revised text.
 By a triangle for drawings with the Rev. No. denoted inside the triangle.
The area affected by the revision and the triangle shall be enclosed within
a ‘cloud’.
• Clouding and revision mark from the previous submission shall be removed.
Documents/Drawings that are submitted with previous revision number
and/or revision date will be REJECTED.
• Any verification of drawings and document by PMC/Buyer representative, will
only be limited to the changes identified above.
7. Document Submission Procedure

7.1. Submission
Suppliers shall attach a DECAL sticker/sheet on/to each document submitted. For
drawings larger than A3, DECAL sticker shall be inserted above the title block in the
drawing. For A3 and A4 size documents, a separate A4 size decal sheet shall be
appended as coversheets. Native file for the DECAL sheet/sticker in “excel”, “.dgn”
and “.dwg” shall be as per format in attachment-3.
The DECAL shall be duly filled with all relevant information. The document number
shall be as per clause 7.3.
Vendor Document Schedule - VDS (Category A01) shall be generated as per format
VDS-001 ahead of preparation of all other applicable documents/drawings. This
shall be a dynamic document and be revises periodically for any changes.
Prime package vendor shall include references of all VDS of the next level of sub-
suppliers in the VDS of the package.
The first submission of a document will be designated REV 00 on the decal against the
document number. Subsequent submissions of the same document retain the original
document number, but will reflect the next revision, i.e. Rev 01 for the second
submission, Rev 02 for the third, and so on.
A document resubmitted by the Supplier shall retain the original document number. If
the drawing number has to be changed under any inevitable circumstances, the new
drawing must clearly state the reason and shall also refer the old drawing number at a
conspicuous place for easy reference. The new drawing should always start with Rev
00, as per the standard procedure. Please refer to the Buyer’s Electronic Document
Submittal Guidelines as given in Attachment-4 RPMS-DCCC-PRA-GE-006.
7.2. Review
Documents shall be returned to the Supplier coded as below: -
1 - Approved
2 - Approved with comments. Work may proceed
3 - Revise and resubmit. Work shall not proceed.
4 – Retained For information.
5 - Cancelled/Superseded.
F – Final Certified
For documents coded 2 or 3, Supplier is required to incorporate comments made
by Engineering Contractor/Buyer into his drawings and data. Documents shall be
revised and resubmitted within two weeks of receipt or within agreed time span.
The vendor shall submit the Change Resolution Sheet (CRS) while resubmitting the
documents after incorporating comments from Buyer/Contractor. The change
resolution sheet shall capture the comments and response from the supplier
against each line item.
If Supplier feels that the comments change his contractual obligation with respect
to cost and/or schedule, supplier must notify the Engineering Contractor/Buyer
shown on page one of the Purchase Order. If Engineering Contractor/Buyer is not
notified it is assumed that comments will be incorporated with no change to cost
or schedule.
The review - return - revise and resubmit cycle shall be repeated until the
documents are returned under code 1 or 4 by Engineering Contractor /Buyer.
Documents coded 1 which would be subsequently modified by Supplier shall be
resubmitted for re-approval. If the document is revised to reflect the actual as
manufactured conditions, then, Supplier shall mark these drawings "As
Manufactured". In cases where drawings are requested to be submitted as part of
manuals only copies of drawings that are coded 1 or 4, shall be used in the final
issue of the manual.
7.3. Document Numbering
All Document required to be submitted by the Supplier shall be numbered by the
Supplier as follows:
MRP number (without discipline and type) – Common Unit WBS for Bulk or Semi
Bulk (D000 for DTA & Z000 for SEZ) / Unit Number for tagged items – Category
Code as per this procedure – Sequence No
Note: For detailed description of the MRP numbering reference shall be made to
document RPMS-PMMD-PRA-MM-001 (MR Numbering System).
Please see below examples:

a) For tag item: The number shall be as follow:
Vendor Document Number
Discipline Rev
MRP Number Excluding Discipline & Type Unit WBS Cat No. Seq No.
& Type No.
M T J 1 8 0 0 1 D 1 J C R - M C C 0 0 1 - R E G - P - 0 0 - A C 3 0 1 - B 0 2 - 0 0 1 0 0
b) For Common Documents:

Documents which are common within the project can use WBS as Complex code /
Project code and then D000 for DTA & Z000 for SEZ.
Discipline Rev
& Type No.
M T J 1 8 0 0 1 - D 1 J C R - M C C 0 0 1 - R E G - P - 0 0 - A - D 0 0 0 - B 0 2 - 0 0 1 0 0
c) For Bulk / Semi Bulk (Single Supplier Order):

Discipline Rev
& Type No.
P B J 1 8 0 0 1 - Z 1 J G G - P V 0 0 0 1 - P M T - P - 0 0 - Z 0 0 0 - B 0 2 - 0 0 1 0 0
d) For Bulk MRP’s that is split into multiple PO’s:

Discipline Vend Rev

& Type Code No.
P B J 1 8 0 0 1 - D 1 J C G - P V 0 0 0 1 - P M T - P - 0 0 - 0 0 - D 0 0 0 - B 0 2 - 0 0 1 0 0
Note: The supplier code is added after the MRP number to avoid duplication of
document numbers submitted by multiple suppliers for the same material. This
supplier code shall be created and maintained by procurement/expediting team
post order.
e) For each Category code the documents shall start at sequence 001.
Example:
• J18001-D1JCH-MES001-JPP-P-00-A-C501-B02-001 then 002 etc.
• J18001-D1JCH-MES001-JPP-P-00-A-C501-A05-001 then 002 etc.
• J18001-D1JCH-MES001-JPP-P-00-A-C501-C02-001 then 002 etc.
• J18001-D1JCH-MES001-JPP-P-00-A-C501-F01-001 then 002 etc.

7.4. Rejection of Documents:
The Engineering Contractor / Buyer reserves the right to reject any document that
does not meet with the requirements laid down in this procedure.
7.5. Manuals
First issue of the Operating and Maintenance Manual (N02) for review should
consist of one manual for each generic type.
8. Document Content Requirements
8.1. Minimum Content
Each document called for on the VDR-001 form is given a document category code, e.g.
A01, A02, B01, etc. The documents shall have information as described in Attachment-
4 for respective category codes.
8.2. Clubbing of document categories
Information related to different category shall not be clubbed into a single document,
unless agreed with PMC upfront. Any information that cannot be categorised under
defined category codes shall be highlighted separately and discussed with PMC prior
to issue.
8.2.1. CATEGORY A - CONTROL DOCUMENTS

A01: DRAWINGS AND DOCUMENTATION SCHEDULE
• Buyer standard project form VDS-001 to be completed.
A02: FABRICATION/PRODUCTION SCHEDULE

• Schedule in bar chart form, showing design, manufacture, inspection, testing
and delivery of all equipment, materials and components to be delivered by
Supplier and his sub suppliers.
• Start date of shop floor manufacturing shall be clearly shown.
• Earliest and latest completion dates shall be shown for each activity with float
indicated.
• Fabrication/Production schedule to be updated showing progress achieved
and submitted to Buyer every 4 weeks until completion.
• Procurement and delivery of sub-Supplier items with names and references.
• Schedule to show calendar dates.
A03: SUB-ORDER SCHEDULE/COPIES SUB ORDERS
• Supplier shall list all materials to be purchased showing quantities required and
planned and latest date by which sub- order must be awarded to meet the
overall schedule. As sub-orders are placed sub-order schedule to be updated
to show sub-order number, sub-Supplier, dates of award, contractual delivery
and current promise. Sub-order schedule to be updated and submitted to
buyer every 4 weeks until all materials are received.
• Supplier shall submit 4 un-priced copies of major sub-orders at the time of
order placement.
A04: WEEKLY PROGRESS REPORT

The weekly interval may be extended or decreased at the discretion of Buyer. Email
/ Fax report to be submitted each week giving:
• Activities % completed this week.
• Any problems encountered, with corrective actions proposed.
• Major problems are to be notified immediately.
• Notification of any delays being caused by EP/ Buyer to Supplier’ program.
• Confirmation that contracted delivery date(s) will be maintained.
• List of sub-orders placed.
A05: JOB SPECIFIC INSPECTION & TEST PLAN

A document which:
• Sequentially identifies and describes, briefly, the activities performed to meet
all requirements.
• References all procedures, specifications and instructions used to control these
activities.
• Identifies all tests and inspections as well as their associated hold, witness and
review points, for all parties.
• Identifies all documents which verify the results of tests and inspections.
• Identifies all acceptance criteria.
• Identifies all inspection and test plans from sub-Suppliers.
• This document shall be subject to revisions, as necessary, during the Contract
period.
A06: CERTIFICATE OF APPROVAL
• A valid Certificate of Approval for the Quality Management System issued by

an organization accredited by a recognized accreditation body, e.g. the
National Accreditation Council for Certification Bodies (NACCB).
A07: QUALITY MANUAL
• A document that fully defines the Quality Management System in accordance
with the requirements of ISO 9001, ISO 9002, ISO 9003, (latest editions) or
similar national or international standard, as specified in the Material
Requisition.
A08: CONTRACT SPECIFIC QUALITY PLAN
A document which sets out the specific quality practices, resources and sequence
of activities for the described scope of work shall contain the following:
• Identify all technical and quality requirements and how they will be satisfied.
• Identify all quality activities relevant to the work as well as the associated
procedures to control these activities.
• Include all inspection and test plans.
• Define all interfaces between Client, contractors, Suppliers, sub-Suppliers, and
third parties such as certifying authorities.
• Identify the quality system requirements to be placed on contractors, Suppliers
and sub-tiers thereof.
• Make reference to applicable procedures and manuals.
• Give organization details and identify the quality related responsibilities of
named holders of key positions.
• This document shall be subject to revisions, as necessary, during the Contract
period.
8.2.2. CATEGORY B- ARRANGEMENTS

B01: KEY DESIGN SKETCH
• Blank Key Design Sketches issued with the Material Requisition shall be
completed. In the event of the blank sketch formats not being suitable, for the
as purchased arrangement, then Supplier shall develop a Key Design Sketch
containing the same information as defined in the blank forms.
B02: GENERAL ARRANGEMENTS

• Envelope dimensions and data expanding on the information provided in the
"Key Design Sketch” shall be shown, where applicable.
• Access, withdrawal and laydown requirements for maintenance to be shown.
• Termination and interface points for Supplier's connections to process and

utilities etc. shall be dimensioned and include number, size, rating and type,
preferably in tabular format. This shall include instruments and skid edge
junction boxes requiring connection by Supplier.
• Identification of all major on skid components with Buyer's tag numbers.
• Overall weights and maintenance weights for major components.
• Lifting points and C of G of skid and components and overall C of G with skid
and components assembled to be shown.
• Acceptance nozzle loads based on relevant design standard or Buyer’s standard
criteria provided separately.
• Foundation bolt details (quantity, size, type and location).
• Static and dynamic forces acting on the foundation during all operating
conditions.
• For control valves and similar, envelope drawings and/or tables showing flange
sizes and ratings, face to face dimensions and maximum envelope sizes shall
be provided.
• Earthing lugs, electrical trace heating, and cathodic protection anodes if any.
• In the case of packages with several different types of equipment, the above
information shall be supplied for each individual item or skid as appropriate.
• Each item or skid shall be separately identified and an overall GA showing the
interconnections between each individual item of package provided. In these
situations, Suppliers shall group the required drawings as a set. Electrical
layouts shall be provided showing on skid electrical equipment and cabling
arrangements.
B03: INTERFACE AND CONNECTION SCHEDULE

• List by number of all Suppliers’ termination points, including piping, electrical,
instrument cable terminations and all junction boxes.
• Size, rating and specification of all connections.
• Identification of corresponding connection point on another system.
• Identification of corresponding connection point on another system.
• Identification of supply at each connection point e.g. pressure, temperature,
flow rate, voltage etc.
• Entry size and type of all electrical and instrument cable glands.
• This document shall always be submitted together with and cross related to
General Arrangement Drawings.
B04: UTILITY REQUIREMENTS

• List of utility consumptions required to start, operate (all conditions) and
maintain the equipment. The list shall show duty, utility, quantities, pressures,
temperature, flow, voltage levels and power consumptions (normal and peak)
at each level.
B05: FOUNDATION DRAWINGS
• Separate foundation layout drawings shall normally be submitted may be
combined with B2 if the equipment is simple and foundations can be clearly
shown on the general arrangement drawings.
B06: PLATFORM & LADDER
8.2.3. CATEGORY C - SCHEMATICS
C01: PFDs AND HEAT AND MASS BALANCE

• These shall be provided for all process and utility systems and shall indicate
major control functions.
• Each stream shall be clearly labelled with a tag number.
• PFD will indicate the duty performed by all items of equipment.
• Accompanying the PFD shall be a Heat and Mass Balance Sheet relating to the
stream tag numbers on the PFD.
C02: P&ID
• P&IDs shall be drawn by Supplier for all process and utility systems.
• P&IDs shall include the following (depending on scope):
▪ Drawing title.
▪ Equipment names and tag numbers.
▪ Insulation and trace heating requirements.
▪ Venting and draining requirements.
▪ Relief valve location, tag numbers, sizes and set pressure.
▪ PSV interlock valves and interlocking sequence and set pressure.
▪ Positive isolation requirements.
▪ Block and check valves, with type identified.
▪ Valves and actuators and solenoids. Failure mode to be stated.
▪ Nozzles of vessels, sizes, man ways, and other inspection provisions.

▪ Slope of vessels.
▪ Levels in vessels, NLL, LSL, LSH, LSLL, LSHH, etc.
▪ Elevations of major equipment.
▪ Process and utility flow lines with directional arrows.
▪ Continuation boxes plus references.
▪ Line sizes, numbers, pipe specifications, specification breaks and
product designation.
▪ Piping special items.
▪ Piping notes.
▪ Switches and instruments with tag numbers, and alarm trip set points.
▪ Emergency shutdown valves.
▪ Interfaces with other P&IDs including Buyer's P&IDs.
▪ All interface equipment, instruments, valves etc. shall be tagged, with
Buyer's tag numbering system requirements. All others are to be
tagged in accordance with ISA S5.1 and Buyer's specifications.
▪ Major items of equipment shall have duties and design conditions
stated.
▪ Motor control station START/STOP etc.
C03: CAUSE AND EFFECT CHART

• Cause and Effect Chart shall be in a matrix format.
C04: CONTROL PHILOSOPHY AND BLOCK LOGIC DIAGRAM

• Shall be in the form of a simplified block logic diagram relating to the system
tag numbers and shall consider the following:
• Start-up, shut-down, abnormal operating condition and special maintenance
operations.
• Input, output, permissive signals, including internal logic signals to accomplish
start-up, shut-down etc.
• Information displayed and operator interface.
• Listing of pre-alarm and shut-down alarm trip requirements and the failure
mode of all valves and equipment must be clearly indicated.
• It shall clearly show switch room equipment, control room equipment and
types of signal to and from, with interface information clearly stated.
C05: OPERATING PHILOSOPHY

• Shall be applied for all packaged equipment in support of C3 and C4 and shall
include: -
• Modes of operation
• Basis for selection of the mode of operation
• Operator dependent actions
• Health and Safety responsibilities
C06: FUNCTIONAL DESIGN SPECIFICATION

• Shall be supplied for all packaged equipment in support of C1 and C2 and shall
include: -
• Basis of design.
• Operating parameters with allowable deviations
• Process guarantees
• Basis of process and utility mass balances.
• List of all consumables and rate of consumption
• Identification of all environmental interfaces.
8.2.4. CATEGORY D - DATA SHEETS

D01: DATA SHEETS
• Where Equipment Data Sheets are issued by Buyer as part of Purchase Order,
Supplier shall fully complete.
D02: MOTOR DATA SHEET

• Where Motor Data Sheets are issued by Buyer as part of Purchase Order,
D03: INSTRUMENT DATA SHEETS

• Each and every instrument shall have a data sheet completed to the project
format, provided by Buyer, for Supplier to complete. Where the same
instrument data applies to several tag numbers, then those tag numbers may
be listed on the one data sheet.
D04: WEIGHT DATA SHEET

• Where Weight Data Sheets are issued by Buyer as part of Purchase Order,
D05: NOISE DATA SHEET

• Where Noise Data Sheets are issued by Buyer as part of Purchase Order,
D06: COUPLING DATA SHEET

• Where Coupling Data Sheets are issued by Buyer as part of Purchase Order,
8.2.5. CATEGORY E – CALCULATIONS
E01: DESIGN/CODE CALCULATION

• Stress calculations shall be in accordance with relevant code requirements and
demonstrate that design (including nozzles) is adequate for operation within
the parameters specified for the item, in terms of pressure, temperature,
nozzle loadings etc.
• Also to include calculations for lifting lugs, brackets, support brackets, support
skirts, support legs and saddles, platform, pipe clip loadings, and
foundation/anchor bolts.
• All calculations should show formulae used and assumptions.
E02: PROCESS/UTILITY CALCULATION

Process Criteria:
• Calculations demonstrating the selection and/or sizing of equipment and the
associated utilities.
Heat Emission Calculations:
• Shall determine heat emitted to atmosphere including radiation and
convection for various loadings, versus the extremes of environmental
temperatures specified by Buyer. Discharge temperatures of exhaust gases

from both equipment and exhaust stack/pipe to be substantiated.
System Head Loss Calculations:
• Calculations to indicate basis on which equipment is sized, including pipe
friction losses, equipment elevations, and terminal point static pressures.
Calculations shall also include acceleration head loss for reciprocating pumps.
Lube and Seal Oil System Sizing Calculations:
• Calculations to substantiate the oil system design in accordance with project
requirements including:
• Oil flow
• Reservoir and overhead tank sizing including retention capacities
• Component sizing for coolers, pumps, filters, control valves, motors etc.
• Line sizing
• To be accompanied by a sketch of the system (or P&ID), and/or adequate
details included on the Key Design Sketch, or the GA.
Exchanger Thermal Rating Calculations:
• Calculations to show basis of thermal sizing of heat exchangers, including
checks for flow induced vibrations.
Acoustic Enclosure Ventilation System Calculations:
• Calculation of air flow requirements and power requirements to substantiate
system design and sizing criteria, taking into account:
• Air mass flows
• Inlet and exhaust pressure drops
• Temperature rise, heat loads and temperature gradients
• Filtration requirements
• Back pressure at worst wind conditions
• Motor sizing and rating.
• Sketch of system shall be provided. Full details of all assumptions shall be
stated.
E03: STRUCTURAL FOUNDATION AND SUPPORT CALCULATIONS

Lifting Aid Calculations:
• Lifting Aid calculations shall determine that any lifting aid is suitable for all
phases of lifting, transportation, installation and operation without over
stressing any component.
Foundation Support Calculations:
• Calculations of foundation support loads and base plate deflections under
normal, fault, transportation and installation conditions taking into account
static and dynamic loads, and as defined in Supplier's specifications.
• Effect of base plate deflection on shaft alignment.
• Anchor/foundation bolt calculations:
• Tolerances required on leveling.
Support Structures:
• Calculations to substantiate the design, and defining forces and moments
acting on the support structure including:
Thermal expansion:
• Support location temperature gradients and heat transmitted to the structure
• Static and dynamic loads including wind loads and snow and ice loads
• Temperature and mass flow profiles
E04: ROTATING ELEMENT CALCULATION

Bearing Life Calculations:
• Calculations for Rolling Element bearings shall determine anticipated B10 life
with bearing identification in accordance with ANSI B3.15 or B3.16 for radial,
axial or combined loading, considering methods of lubrication, dimensions,
and load variation determined from performance envelope.
Thrust Bearing Sizing Calculations:
• Calculations and curves taking into account static and dynamic forces over full
range of operating conditions including:
• Aerodynamic or hydrodynamic thrust load and balance position compensating
load to be shown.
• Variation in balance piston compensating load with increased leakage rate to
be shown.
• A comparison with the manufacturers design data shall be included.
Lateral Critical Speed Calculations:
• Calculations shall determine the natural frequency of the shaft assembly and
identify forcing frequencies and harmonic components thereof, relative to
operating speed range. Results shall be presented in graphical and narrative

form, and shall include:
Rotor drawings showing each shaft segment clearly numbered:
• Table of masses stiffness values for each segment.
• Plot of critical speed against support stiffness with stiffness both in vertical
plane and horizontal plane to be shown for each support point.
• Plot of speed against vibration amplitudes (Campbell Diagrams) to
demonstrate the specifications of operating modes from harmonic regions.
Torsional Critical Speed Calculations:
• Calculations shall determine the Torsional critical speeds for
driver/transmission/driven equipment trains. Calculation shall clearly indicate
number and details of finite elements that the system has been divided into
for the calculation and a table of stiffness’s and inertia's for each element shall
be included. Results shall be presented in graphical and narrative form.
Coupling Selection Calculations:
• To show speed range, torque, power, lock up axial stiffness, Torsional stiffness,
service factors, etc., to substantiate coupling selection.
Rotor/Shaft System Imbalance Response Analysis:
• Demonstration of the sensitivity of the rotor/shaft design to imbalance at
various locations by plotting amplitude against shaft speed for both vertical
and horizontal vibration.
• Plot of shaft vibration mode, shape, showing displacement against axial length
and bearing locations with the rotor excited at its critical speeds.
Reciprocating Elements:
• Primary and secondary unbalance forces and moments with information on
component weights and counter balance weights as appropriate.
• Flywheel sizing calculations with information on moments of inertia of all
components and the expected torque curves for all conditions of unloading
and operation.
• Expected resulting speed and current variations.
• Rod load calculations in accordance with API 618 for all stages and specified
conditions of operation and all available load steps.
E05: INSTRUMENT SIZING CALCULATION

Calculations to be presented for the following items:
• Hydraulic line sizing
• Orifice plates and restriction orifices (sizing)

• Control valves and regulators (sizing and noise)
• Bursting discs
• Safety relief valves (sizing)
• Thermowells (natural and vortex shedding frequency)
• Ball valve operating torque and actuator torque
For control valves this shall include:
• CV figures for minimum, normal and maximum flow conditions
• % open figures for above
• Pressure drop for above
• Noise calculations
• Actuator sizing
• Inlet/outlet body velocities
ESD Valve:
• Flow capacity calculations; break out, running and resetting torque figures for
valve versus actuator torque figures at minimum supply pressure.
Relief Valve and Burst Disc Calculations:
• Orifice size calculation to API 520 for all relief valves including maximum relief
temperature.
• Anti-Surge Valve Sizing
System calculations to substantiate valve sizing selection and noise data.
Pulsation Damper Sizing Calculations:
• Sizing calculations and holding down locations.
E06: PIPING STRESS ANALYSIS

• Piping stress isometric drawing showing the extent of calculations
• Calculations of piping stress of line defined as critical.
• Wall thickness calculations
• Piping stress calculations
E07: PRIME MOVER PERFORMANCE CURVE
• Curves to indicate power developed at output shaft, fuel and air mass flow over
the operating range and ambient temperatures, with specified inlet and
exhaust pressure loss at varying speeds. Correction curves for variations in inlet
and exhaust pressure drops shall be provided.
• Guarantee points shall be clearly identified.
• Speed/Torque Starting Curves:
• Curves shall indicate torque versus speed characteristics of both driver and
driven equipment on the same graph from zero to rated speed, and a
statement as to the process condition prevailing at the driven equipment for
the curve shown. This shall be carried out for 80% and 100% volts.
• Combustion Gas Turbine Performance Curves:
• Curves for turbines for specified site conditions of atmospheric temperature
and pressure plus, where appropriate, inlet and exhaust pressure loss, shall
indicate firing temperature, exhaust temperature, combustion air flow,
exhaust gas mass flow, constant heat rate lines and efficiency against power
developed for output shaft speeds between 70 and 105% rated speed.
Correction curves shall be provided for variations of inlet and exhaust pressure
drops. Guarantee points shall be clearly identified.
E08: DRIVEN EQUIPMENT PERFORMANCE CURVE

• Centrifugal Pump Performance Curves:
▪ As designed performance curves to indicate differential head,
efficiency, NPSHR and absorbed power (basis product SG), versus
flow, at rated impeller, maximum and minimum. Units driven by
variable speed drivers shall show these performance curves to
indicate performance form minimum to maximum operating speeds.
Curves shall indicate performance from zero to at least 120% BEP flow,
with minimum mechanical continuous flow clearly indicated. For fire
pumps a shop test curve identified by pump serial number is required
showing head to rated and 150% capacities. All curves shall be plotted
back to zero flow. These curves will be superseded by test curves.
▪ Guarantee points shall be clearly identified.
• Rotary Pump Curves:
▪ Curves shall indicate discharge pressure, NPSHR and absorbed power,
versus inlet flow including velocity corrections.
▪ Centrifugal Compressor Performance Curves:
▪ Curves to indicate the discharge pressure, coupling shaft power,
polytrophic head and efficiency versus inlet capacity for specified inlet
pressure temperature and molecular weight for each section (casing)
and overall unit. Curves shall indicate performance from surge

through to 115% rated capacity. Units driven by variable speed drivers
shall be provided with curves for the full range of speed operation.
Curves of Mu versus Q/N and quadrant curves will also be provided.
▪ Guarantee points shall be cleanly identified.
• Fan Performance Curves:
▪ Curves shall indicate pressure rise, efficiency, and power absorbed,
versus inlet flow for specified inlet pressure, temperature and
molecular weight. Curves shall also indicate performance from surge
to 115% rated capacity. Fans with variable pitch screws shall indicate
performance for five settings between maximum and minimum.
▪ Guarantee points shall be clearly identified.
• Reciprocating Pump Performance Curves:
▪ Differential pressure, shaft input power, efficiency and NPSHR over
the range of operation with stroke length, for variable stroke pumps.
▪ Reciprocating Compressor Performance:
▪ Expected capacity and horsepower showing the effects due to each
stage of unloading.
E09: ELECTRICAL CURVES

• Electrical Protection Curves:
▪ Curve to indicate fuse I2t characteristics and current fusing points
versus time. Operating characteristic curves and setting ranges of
protective relays, discrimination curves and calculations to illustrate
the correct selection and discrimination of fuses, relays, MCB etc.
▪ Calculations to show sensitivity and stability of restricted earth fault
and differential protection relays.
• Current, Potential and Power Transformer Curves:
▪ Performance and design data and saturation curves.
• Motor Performance Curves:

▪ Torque against Speed for both 80% and 100% voltage conditions.
Driven equipment torque shall also be plotted over the same graph
to confirm that there is adequate torque for acceleration.
▪ Current against Speed for both 80% and 100% voltage conditions.
For motors 2500 HP and larger chart recordings of the actual starting
currents and voltages are required.
• Overload heating curve:

▪ Locked rotor withstand curve for both 80% and 100% voltage
conditions and also for hot and cold winding conditions.
▪ Lighting Performance Data
• Polar Diagrams:
▪ General performance data for specific luminaries’ types.
E10: RELIABILITY AND AVAILABILITY

• Supplier to present data to demonstrate starting and operating
reliability/availability of purchase equipment (for example, mean time
between failure data).
E11: PULSATION STUDIES

• Calculations shall be provided to demonstrate compliance with the nominated
design approach in compliance with API 618. Results of acoustical simulation
studies shall be provided where specified.
E13: HEAT DISSIPATION AND POWER CALCULATIONS
8.2.6. CATEGORY F - DETAIL MECHANICAL DRAWINGS
F01: EQUIPMENT DETAIL DRAWINGS

• Detail drawings to indicate method of construction, plus all features which are
omitted from the GA drawing for clarity.
F02: ANCILLARY PIPING DRAWING

• This should preferably be shown on the General Arrangement drawing B2.
Ancillary piping drawings should only be produced when their inclusion in B2
would give unacceptable levels of clarity.
F03: CROSS SECTION

Cross section drawings of major items of equipment shall be produced to allow:
• Design to be reviewed
• Parts to be identified for material identification in conjunction with F06.
• Parts to be identified for spares identification in conjunction with N01.
F04: PARTS LIST/BILL OF MATERIAL

To be used in conjunction with F05 and N01. It shall identify:
• All materials of construction.
• Manufacturers/Supplier's part numbers.
• Quantity per item and total quantity supplied against the Purchase Order.
F05: SEAL & SEAL SYSTEM / ROD PACKING SYSTEM

Information to be shown on document as a minimum:
• Dimensions including clearances
• Parts list, defining materials (see F03 &F04)
• Identification of fluid connection points
• Seal system description (if required)
• Description of operation (if required)
• Piping system indicating all components and materials
F06: INSULATION/LINING DETAIL

• Drawings to indicate thicknesses, specification and limit of application. To
include anchoring and expansion joint details.
8.2.7. CATEGORY G - DETAIL INSTRUMENT DRAWINGS
G01: INSTRUMENT LOCATION DRAWING

• These drawings will show location and elevation of all instruments, control
valves, control panels etc. and Buyer free issue equipment where applicable.
In addition, the drawing will show the routing of all instrument air distribution,
pneumatic tubing, signal/power supply cables, and the location of all
instrument junction boxes. Location drawings will also be required to show fire
detection instrumentation.
G02: INSTRUMENT SCHEDULE

The following is the minimum information required:
• Tag number (in alpha-numeric sequence)

• Instrument description (pressure switch, control valve, level gauge etc.)
• Service description (e.g., vessel low level, etc.)
• Location or line (size/number/spec)
• P&ID number
• Data sheet number
• Hook-up drawing reference
• Set point and range
• Gland sizes
Vendor shall submit finally, the instrument schedule as per Buyer's requirement in
an excel format
G03: WIRING SCHEMATIC DIAGRAM

• These drawings will show the wiring details in ladder or other simplified
format. The wiring for all the instrumentation, including relay numbers,
terminal numbers etc.
G04: TERMINATION DETAILS

• Diagrams shall show each of the terminal blocks which are to be individually
numbered, with each terminal numbered and the cores of connecting cables
clearly identified. The core identifiers shall be those as ferruled onto the
conductors and shall follow the Suppliers numbering system. Drawings shall
show segregation between IS and Non-IS signals together with cable and/or
core screen terminations Inputs and outputs shall be identified using their tag
numbers. For ease of identification cable destinations shall be shown with any
cross reference drawing numbers. The diagrams shall also show all earthing
requirements along with suggested conductor sizes.
G05: PANEL/CABINET LAYOUT

Drawings required as follows:
• Front of panel layout clearly showing overall size and layout, with a table of
instruments showing duty/label engraving/model number.
• Back of panel arrangement clearly showing same data as front of panel.
• Construction drawing showing main dimensions hinging/opening of doors,
door restraints, method of locking, plinths, stiffeners, hold down details (fully
dimensioned) anti-vibration methods, materials, panel finish procedure and

colors.
• Mimic/annunciator drawing where applicable.
• Internal layout of panel showing:
▪ lighting
▪ Cable entries and terminal strip locations
▪ wiring trays
▪ Segregation of voltage level, IS and non-IS equipment
▪ Hydraulic, pneumatic layouts (where applicable)
▪ Grounding points
▪ Power Isolation
G06: LOGIC DIAGRAMS/DESCRIPTION

• These will give full details of all interlocks, permissive, overrides and
automatic/manual trip requirements along with a functional description
allowing a full understanding of the system operation.
G07: HOOK UP DIAGRAM

• Process and pneumatic hook-up drawings shall be prepared for each tagged
instrument that required a process impulse line for sensing purpose. Similarly,
a pneumatic hook-up drawing shall be prepared for each tagged instrument air
transmission/control signal. Both types of drawings shall include all the
necessary mounting details and a schedule of all installation materials used.
G08: LOOP DIAGRAMS

• For each loop, the diagrams shall show all details of wiring, termination and
inter-connections from primary element to final, including numbering of JB's,
cables, cable cores, terminal color coding of wires and locations and ferruling
details, etc. Each loop shall be shown on a separate sheet.
G09: CABLE BLOCK DIAGRAM

• The diagram shall show schematically (in single line form) interconnections
between package instruments/junction boxes and marshaling/control panels.
The diagram shall clearly identify junction box, cable and marshaling/control
panel numbers.
G10: INSTRUMENT OUTLINE DRAWING

A drawing shall be provided for each tagged instrument, which will contain the
following information where appropriate:
• Manufacturer
• Tag number
• Overall height width and depth
• Weight
• Process connection size(s) and ratings
• Inlet and outlet configuration
• Face-to-face dimensions
• Electrical connection size(s)
• Instrument mounting details
• Instrument accessories (positioner, hand wheel, air set, etc.)
G11: SERIAL LINK

Provide details of PLC type, device address, all jumper settings, cable and connector
types with port pin definitions, interface type, protocol, baud rate and parity bit
and data bit. All alarms, analogue variables, diagnostic and status registers,
permitted remote commands and timer accumulators shall be stored in contiguous
registers and be available for transmission to the DCS. For this data the following
details shall be supplied as a minimum for each signal:
• Tag number
• Service descriptor
• Engineering units for analogue signals
• Engineering high scale for analogue signals
• Engineering low scale for analogue signals
• For binary signals, 0 and 1 descriptors and operator alarm requirements.
• PLC registers
G12: GRAPHICS
• Graphic layouts with all the details of dynamic data, etc., shall be provided
based on typical graphic layouts supplied by the DCS Supplier.
G13: SOFTWARE LISTING
8.2.8. CATEGORY H - DETAIL ELECTRICAL DRAWINGS
H01: ELECTRICAL SINGLE LINE DIAGRAM

Representation of electrical power, and/or control circuits, electrical major
components and their function or instrument control circuits, defining the
relationships, to include (as appropriate):
• Control systems.
• Consumer ratings.
• Switchgear/control gear ratings.
• Bus bar ratings.
• Equipment descriptions and tag numbers.
• Protection devices.
• Metering and indication
• Interlocks
H02: ELECTRICAL LAYOUT DRAWING
H03: SCHEDULE OF ELECTRICAL EQUIPMENT
H04: CABLE SCHEDULE

All electrical, instrument and telecom cables shall be listed, both internal to
Supplier's package and identification of Buyer installed cables between
components of Supplier's package, listing:
• Number of cores.
• Cable size and type
• Cable number
• Gland size and type
• To and from location
• Inter-connection diagram cross reference
• Cable length, in meters (inter-connecting cables only)
• Voltage grade
Cable numbering shall be to project standards unless otherwise agreed with the
buyer.
H05: INTERCONNECTION DIAGRAM

• Diagrams shall display, in block form, the items of electrical equipment and
the cables connecting them. The terminal block reference for each item
shall be stated, along with the number of size of the conductors in the
cables.
H06: TERMINAL BOX BLOCK DIAGRAMS

• Diagrams shall show each terminal block, which is to be individually
numbered, with the terminals numbered and the cores of the connecting
cables identified. The cores identifiers given shall be those ferruled onto the
conductors and shall follow any numbering system advised by Buyer.
Terminal block diagrams may be incorporated with interconnection
diagrams - if the complexity of the system permits.
• Drawings must show AC/DC segregation, IS and non-IS segregation (where
applicable) and cable screen termination's, together with duty
description/tag against input and output. For ease of identification,
destination 'to and from' is to be shown, with cross-referenced drawing
numbers and earthing requirements clearly shown.
• Electrical cable termination details shall show gland plate size and location,
together with its distance from associated terminals. Motor terminal boxes
shall be shown, particularly HV motors, which shall be full dimensioned and
sectioned so that HV cable termination can be designed by others.
H07: DISTRIBUTION BOARD SCHEDULE

• Schedule shall list the lighting and small power loads connected to a
distribution board. Description shall include fuse sizes, terminal sizes and
switching arrangements, cable size and number.
H09: WIRING DIAGRAMS
8.2.9. CATEGORY J - MANUFACTURING PROCEDURES
J01: WELD PROCEDURES (WPS AND PQR)

• Provide all shop, field and repair welding procedures (WPS) together with cross
referenced Weld Maps in accordance with Buyer's requirements. WPS shall be
cross referenced to the applicable weld procedure qualification record (PQR).
Qualification records describe parameters used in qualification of weld
procedure specifications (WPS) together with mechanical testing and results in
accordance with Buyer's requirements. PQR test records are to be cross
referenced to the WPS's and when applicable stamped by the third party
inspection authority. Fabrication shall not commence before the appropriate
weld procedure has been reviewed and accepted by Buyer.
Note: WPS's to be submitted with associated PQR's unless PQR previously
submitted.
J02: NDE PROCEDURES

• Define all proposed NDE procedures to be utilized in accordance with Buyer's
requirements. Provide detailed technique sheets with procedure and cross
reference with Weld Map to determine procedures to be used.
J03: HEAT TREATMENT PROCEDURES (INC PWHT)

Detailed procedures for compliance with Buyer's specification including:
• Drawing number, diameters, thickness, materials
• Heat soak and cooling parameters, temperature ranges, type of heat source
e.g. furnaces or electric resistance heaters, temperature control procedures
• Number & spacing of thermocouples, type of thermocouple & cable, method
of attachment & removal
• Protection of machined surfaces
• Indication of NDE(PT) upon removal of thermocouples
• Equipment calibration, Production tests where appropriate.
J04: SURFACE PREPARATION, PAINTING AND COATING SPECIFICATION

This shall be supplied for equipment, especially where exception to Buyer
specification has been agreed (in writing), and shall include:
• Surface cleaning
• Preparation
• Shop or field painting
• Linings (where applicable)

• Repairs to damaged finishes
• Quality System in place.
J05: MATERIAL SPECIFICATION

• Cathodic protection anodes: - Detailed procedure for compliance with Buyers
specification including control and calibration of electrochemical parameters,
temperature preparation, and method of data analysis, metallographic
evaluation, and acceptance criteria.
J06: OPERATOR QUALIFICATIONS
• Operator qualifications for both NDE and welding to the level required by the
respective operation and Buyers requirements including RT Film Interpretation
e.g. ASNT Level II 'Film Interpreter' where appropriate.
8.2.10. CATEGORY K - TEST PROCEDURES
K01: FUNCTIONAL AND PERFORMANCE TEST PROCEDURES

Procedures for both works and site testing shall include the following:
• Purpose of the test.
• P&ID or diagram with written description of test set-up.
• Definition of all equipment to be used for testing, including tag numbers for
Buyers equipment.
• Description of the method of testing, readings to be taken and instruments to
be used.
• Acceptance criteria for the test.
• Sample log for the readings to be taken.
• Full description of the method of calculating the results and their accuracy.
K02: HYDROSTATIC/ PNEUMATIC TEST PROCEDURES

Detailed procedures for compliance with Buyers specifications and shall include:
• Details of test medium (temp, chloride content etc.)
• Procedure shall include or reference acceptance criteria.
• Rejection procedure
• Procedure shall include sample copy of certificate.
• Drying procedure
• Calibration of instruments
K03: MATERIAL TEST PROCEDURES
K04: WEIGHT CONTROL/WEIGHING PROCEDURE
K05: FACTORY ACCEPTANCE TEST PROCEDURE
K06: SITE ACCEPTANCE TEST PROCEDURE
K07: PMI TEST PROCEDURE

• Supplier to submit his method for compliance with the vessel specification
requirements for verification of chemical composition (if applicable).
8.2.11. CATEGORY L – CERTIFICATION
L01: MANUFACTURING RECORD BOOK INDEX

• Index /List of Contents shall be submitted to Buyer for review prior to
compilation of the Manufacturing Record Book.
L02: MANUFACTURING RECORD BOOK

• The record book shall include documentation indicated on the VDR-001 form
in the column "REQ'D IN MANUAL" where identified by the reference to L02.
L03: MATERIAL CERTIFICATES

Material certificates as identified by the relevant attachments to the material
requisition shall be provided. Certificate types are as follows.
• Material Test Certificate Type 3.1.C.:

▪ Certificates in compliance with DIN 50049-3.1.C shall include as a
minimum chemical analysis, specification range analysis, mechanical
test results, and heat treated condition for the product supplied to
the Buyer. Certificates must be fully traceable to each component by
means of a unique numbering system. Each certificate shall state

that it is to DIN 50049- 3.1.C.
• Material Test Certificate Type 3.1.B:
▪ Certificates in compliance with DIN 50049- 3.1.B shall include as a
minimum chemical analysis, specification range analysis, mechanical
test results, and heat treated condition for the product supplied to
the Buyer. Certificates must be fully traceable to each component by
means of a unique numbering system. Each certificate shall state
that it is to DIN 50049 - 3.1.B.
• Material Test Certificate – Other:
▪ Material Test Certificates to be in accordance with requirements
stated in Buyer’s specifications.
NACE Requirements
• Certificate of conformance (hardness results etc.,) to confirm that NACE MR
/01/ 75 (latest edition) requirements.
Material Traceability Records
• Locations plans/records with an identification system cross referring to the
individual material certificates. When applicable, material placement drawings
shall be verified by the Buyer and/or third party inspection authority.
Heat Treatment Records
• Pyrometric charts and certificates confirming the heat treatment cycles that
have been conducted to Buyer's requirements. Charts and Certificates to state
Buyer’s purchase order number, item number, and identification to permit
traceability to the heat treated component or materials.
L04: HAZARDOUS AREA CERTIFICATES

• Certificate issued by a recognized independent authority indicating that a type
test has satisfied the specified standards, e.g., BASEEFA, INTRINSIC SAFETY,
FIRESAFE. Certification not in English language shall be supplied with a verified
translation. With each Certificate submitted, the Supplier shall include a
statement identifying to which items of equipment the Certificate applies.
L05: CODE/STANDARD/COMPLIANCE CERTIFICATES

• Certificate issued by a recognized independent authority indicating that the
item/equipment has been manufactured in accordance with code/standard.
For fire test certification the certificates are to be complete and as issued by
the testing authority. Certificates are to state Buyer's purchase order number,
item number and identification to permit traceability to the fire tested item or
material. Certificates not in the English language shall be supplied with a

verified translation. Type approval certificates are normally acceptable for
proprietary items.
L06: TEST RESULTS

• Performance Test Results Report
• Description of how test was conducted and procedures used.
• Method of calculating results.
• Acceptance criteria.
• Log of test readings signed by Buyer's representative and third party inspection
authority (where applicable).
• Calculations of results, taking into account the accuracy of the results.
• Problems encountered during the test, and corrective actions taken.
• Tested performance curves as detailed earlier.
Factory Acceptance Test Report:

• Report on performance/functional tests carried out in the factory to
demonstrate the equipment suitability to fulfill the duty specified. This report
to include certificates as appropriate, tests for over speed, balancing, shaft
mechanical and electrical run out, and vibration. Reports on electrical and
instrument control equipment shall include high voltage pressure tests and
insulation resistance certificates.
Electrical Machinery Type Tests:

• Test report to include temperature rise on full rated load, resistance of
windings, no load losses, locked rotor current/torque momentary overload,
high voltage tests, power factor and any tests to establish efficiency. Alternator
reports will include wave form and magnetization curves.
Routine Test Certificate Electrical Machinery:
• Certificate of routine tests carried out, e.g., no load losses, high voltage,
insulation resistance etc., when type tests have been carried out.
High Voltage Flash Test:
• High Voltage Flash Test Certificate as appropriate.
Insulation Resistance Check:
• Insulation Resistance check certificate as appropriate.
Measurement of Resistance:
• Measurement of Resistance certificate as appropriate.
Proof Load Certification:
• Test certificates for all lifting equipment, i.e., hoists, cranes, wire ropes,
shackles, hooks, pulleys and lifting beams. Certification to be to Buyer's
requirements and approved by the third party inspection authority, when
applicable.
Pressure Test Certificate:

• Certificate and/or chart of hydrostatic and/or pneumatic tests carried out,
stating specification/standard procedures, actual pressure and duration of
test. When applicable, low temperature test results and/or leak test results
shall be included. Instrument calibration certificates also to be included.
Dimensional Report:
• Report to verify all critical dimensions, including Buyer interconnection points
are in accordance with Supplier's approved drawings.
Painting/Insulation Inspection Report:
• Certificate to state Buyer's Purchase Order number; item number, tag number,
and shall verify that painting and/or insulation is in accordance with Buyer's
specifications or Buyer approved specifications, as applicable, showing anchor
pattern measurements, temperatures, humidity, intermediate coat checks,
final DFT and signed by the painting/ insulation coating operatives and
inspector.
Production Test Results (Inc. Welding):
• Results of tensile, ductility, hardness, bend and impact tests etc. carried out on
production and qualification tests.
• Includes production weld test results.
• Procedure qualification results.
Visual inspection results:
• Certificates to state Buyer's purchase order number, tag number (or other
unique identification) to permit traceability of tested equipment, item or
piping system. Supplementary marked-up piping isometrics shall be included
when necessary to define extent of testing, those being verified by the Buyer,
when required.
NDE Records:
• All NDE for final acceptance shall be performed after PWHT where applicable.
Radiography:
• Results of radiography tests interpreted and signed by a qualified technician.
Detailed reports are to state Buyer's order number, and to include the
procedure used, acceptance level and results obtained in accordance with
Buyer's specified standard. Reference shall be made to applicable operator
qualification and RT film Interpretator certificates, and approvals by third party
inspection authority shall be gained when necessary.
Ultrasonic Examination:
• Certificate confirming that acceptable results have been obtained on
examinations carried out to the specified standard and stating the equipment
used, calibration standard and procedure adopted. The certificate shall be
signed by a qualified operator. Reference shall be made to applicable NDE
operator qualification certificates, and approvals by third party inspection
authority shall be obtained when necessary.
Magnetic Particle Inspection:
• Details as in Ultrasound Examination as given above.
Dye Penetrant Inspection:
• Details as in Ultrasound Examination as given above.
Note: When applicable, NDE Records shall be supplemented with weld history
drawings verified by Buyer (and the third party inspection authority, when
necessary).
L07: SPECIFICATION WAIVERS

• Supplier shall include in the Manufacturing Record Book details of specification
waivers granted by the Buyer. These shall be in the form of the original written
approval.
Buyer's Release Notes/Waivers
• Buyer's Release Notes/Waivers to state Buyer's purchase order number, item
number, and other unique identifications when necessary (e.g., cast numbers,
serial numbers etc.).
Certifying Authority Release Note/Waivers
• Documents shall state Buyer's purchase order number; item number and tag
number, with other unique identification when necessary (e.g. cast numbers,
serial numbers, etc.). Copies of Non-Acceptance Notes issued by the Certifying
Authority shall also be included.
L08: TYPE TEST CERTIFICATE
L09: INSPECTION RELEASE NOTE

• For inspected items standard form PSQ-231 will be completed by the Buyer’s
Representative and a copy handed to the Supplier. For non-inspected items a
release note shall be raised by PSQR or the Project Expediter and transmitted
to the Supplier.
8.2.12. CATEGORY M - HANDLING & SITE INSTALLATION
M01: DOCUMENTS TRAVELLING WITH GOODS

Packing and Shipping Schedule
• For equipment shipped in more than one piece, a schedule is to be submitted
which identifies all the major components of the package for use as a Check
List at the receiving point to ensure all items have been received and the copy
of document to accompany shipment.
Erection Fastener Schedule
• Schedule to indicate number off, type, size and material of all fixing
bolts/fastener required. Where temporary bolts are required to withstand
transportation forces, these shall also be indicated with suitable note of
explanation.
M02: PACKING, SHIPPING, HANDLING AND STORAGE PROCEDURES.

• Supplier to detail techniques to be used to meet the Buyer's requirements as
specified in the P.O. Indicate size of container, number off, weight,
identification and contents, include details preservation procedure detailing
inspection periods, materials required, etc., both prior to installation and post
installation but prior to commissioning. Any special unpacking/handling
requirements shall be stated.
M03: PRESERVATION PROCEDURE

• Supplier to submit recommendations for extended storage and preservation
prior to installation and for preservation activities after installation and prior
to start-up.
M04: INSTALLATION INSTRUCTIONS
Detailed description and procedures shall be provided, for installation of

equipment, to be used at the fabrication site. The following information shall be
included:
• Lifting points
• Lifting weights
• Shipping break points for panels and switchboard assemblies
• Erection match markings
• Fixing points
• Leveling procedures
• Alignment procedures
• Erection fasteners summary list
• Details of any special unpacking/handling requirements shall be stated
• Provision of all rigging drawings/studies to be used for loading/ unloading,
erection and transportation.
• Provision of all lifting frames, lifting beams, shackles, slings etc. required for all
lifting operations at the fabrication facility, for transportation to and at the site
and for installation operations.
• Provision of all design calculations for all lifting frames beams etc.
M05: FIELD FABRICATION ITEMS
8.2.13. CATEGORY N - OPERATING INSTRUCTIONS
N01: SPARE PARTS LIST OR DATA PACKAGES.

• Spare Parts Data Packages to be submitted in accordance with Spare Parts
Interchangeability List.
N02: OPERATING AND MAINTENANCE MANUAL

• Manuals shall be provided in WHITE 4 ring A4 sized binders with a 40mm or
larger spine, clear plastic sheeting on the spine and front cover. Artwork for
the spine and cover will be provided by Buyer for Supplier to add Purchase
order no., title and Supplier name and insert into covers.
• Manual shall include description of equipment, operating procedures for start-
up, steady state, shutdown, emergency and fault conditions, operating
parameters, function of protective devices and controls, copies of all relevant

cause and effect charts and block diagrams, and fault finding guidelines.
▪ Manuals must include the following as appropriate: -
▪ Data sheet for Equipment
▪ Data sheet for driver
▪ data sheet for oil system
▪ Performance Curves
▪ General Arrangement drawings
▪ Outline and cross section drawings including base plate
▪ Drawings of ancillary equipment such as fans, gearboxes and filters
etc.
▪ Details of lube and seal oil systems
▪ Complete Parts lists
▪ Schedule of Packing
▪ Purchasing specifications
▪ Process and Instrumentation Diagrams
▪ Instructions for Operation, maintenance, disassembly, repair,
overhaul and assembly
▪ System of trouble detection and remedy
▪ Electrical drawing and details
▪ Control schematics
▪ Details on sub Suppliers equipment with information on the specific
model utilized
▪ Final certified drawings as specified in the Supplier Document
Requirements schedule VDR-001.
▪ Configuration manuals for PLCs.
Special Tools List

• List shall indicate those tools necessary for removing equipment from
transport at site, plus those necessary for installation, calibration and
maintenance equipment. Against each entry, a brief description shall be given
and where necessary for clarity, a drawing shall be provided.
Computer System Documentation
• To include full documentation related to both hardware and software as

required by the purchase order.
N03: SUPPLIER'S CATALOGUE
N04: LUBRICATION SCHEDULE
9. Attachments:
Attachment - 1: VDR-001 (refer page 41 -43)
Attachment - 2: VDS‐001 Supplier Drawings & Documentation Schedule.xls
Attachment - 3: Supplier Document Review Sheet (DECAL).xls
Supplier Document Review Sheet (DECAL).dgn
Supplier Document Review Sheet (DECAL).dwg
Attachment - 4: Electronic Document Transfer Procedure
(RPMS-DCCC-PRA-GE-006)
Attachment – 1: VDR-001
SUPPLIER DOCUMENT REQUIREMENTS
WITH BID
FOR REVIEW
All documents Shall be submitted electronically FOR INFORMATION
through E-Room created in REIMS System.
WEEKS AFTER AWARD
REMARKS
CAT
CODE
A CONTROL DOCUMENTS
A01 VDS- 001 SUPPLIER DRAWINGS AND
DOCUMENTATION SCHEDULE.
A02 FABRICATION / PRODUCTION SCHEDULE
A03 SUB-ORDER SCHEDULE/COPIES SUB ORDERS
A04 WEEKLY PROGRESS REPORT
A05 JOB SPECIFIC INSP. AND TEST PLAN ( ITP)
A06 CERTIFICATE OF QUALITY SYSTEM
APPROVAL*
A07 QUALITY MANUAL*
A08 CONTRACT SPECIFIC QUALITY PLAN
A09 CONTRACT SPECIFIC QUALITY PLAN*
B ARRANGEMENT DRAWINGS /DOCUMENTS

B01 KEY DESIGN SKETCH
B02 GENERAL ARRANGEMENTS
B03 INTERFACE AND CONNECTION SCHEDULE
B04 UTILITY REQUIREMENTS
B05 FOUNDATION DRAWINGS
B06 PLATFORM & LADDER
C SCHEMATICS
C01 PFDs AND HEAT MASS BALANCE
C02 P&IDs
C03 CAUSE AND EFFECT
C04 CONTROL PHIL. AND BLOCK LOGIC DIAG.
C05 OPERATING PHILOSOPHY
C06 FUNCTIONAL DESIGN SPECIFICATION
D DATA SHEETS
D01 DATA SHEETS
D02 MOTOR DATA SHEET
D03 INSTRUMENT DATA SHEETS
D04 WEIGHT DATA SHEET
D05 NOISE DATA SHEET
D06 COUPLING DATASHEET
E CALCULATIONS
E01 DESIGN/CODE CALCULATION
E02 PROCESS/UTILITY CALCULATION
E03 STRUCTURAL FOUNDN. AND SUPPORT CALCS.
E04 ROTATING ELEMENT CALCULATION
E05 INSTRUMENT SIZING CALCULATION
E06 PIPING STRESS ANALYSIS
E07 PRIME MOVER PERFORMANCE CURVE

WITH BID
FOR REVIEW
WEEKS AFTER AWARD
REMARKS
CAT
CODE
E08 DRIVEN EQUIPMENT PERFORMANCE CURVE
E09 ELECTRICAL CURVES
E10 RELIABILITY AND AVAILABILITY
E11 PULSATION STUDIES
E13 HEAT DISSIPATION AND POWER
CALCULATIONS

F01 EQUIPMENT DETAIL DRAWINGS
F02 ANCILLARY PIPING DRAWING
F03 CROSS SECTION
F04 PARTS LIST/BILL OF MATERIAL
F05 SEAL & SEAL SYSTEM/ROD PACKING SYSTEM
F06 INSULATION/LINING DETAIL

G01 NSTRUMENT LOCATION DRAWING
G02 INSTRUMENT SCHEDULE
G03 WIRING SCHEMATIC DIAGRAM
G04 TERMINATION DETAILS
G05 PANEL / CABINET LAYOUT
G06 LOGIC DIAGRAM
G07 HOOK UP DIAGRAM
G08 LOOP DIAGRAMS
G09 CABLE BLOCK DIAGRAM
G10 INSTRUMENT OUTLINE DRAWING
G11 SERIAL LINK
G12 GRAPHICS
G13 SOFTWARE LISTING

H01 ELECTRICAL SINGLE LINE DIAGRAM
H02 ELECTRICAL LAYOUT DRAWING
H03 SCHEDULE OF ELECTRICAL EQUIPMENT
H04 CABLE SCHEDULE
H05 INTERCONNECTION DIAGRAM
H06 TERMINAL BOX BLOCK DIAGRAM
H07 DISTRIBUTION BOARD SCHEDULE
H09 WIRING DIAGRAMS
J01 WELD PROCEDURES (WPS AND PQR)
J02 NDE PROCEDURES
J03 HEAT TREATMENT PROCEDURES (INC. PWHT)
J04 SURFACE PREP., PAINTG. AND COATG. SPEC.
J06 OPERATOR QUALIFICATIONS

WITH BID
FOR REVIEW
WEEKS AFTER AWARD
REMARKS
CAT
CODE
K TEST PROCEDURES
K01 FUNCNL. AND PERF. TEST PROCEDURES
K02 HYDRO./PNEUM TEST PROCEDURES
K03 MATERIAL TEST PROCEDURES
K04 WEIGHT CONTROL/WEIGHING PROCEDURE
K05 FACTORY ACCEPTANCE TEST PROCEDURE
K06 SITE ACCEPTANCE TEST PROCEDURE
K07 PMI TEST PROCEDURE
L CERTIFICATION
L01 MANUFACTURING RECORD BOOK INDEX
L02 MANUFACTURING RECORD BOOK
L03 MATERIALS CERTIFICATES
L04 HAZARDOUS AREA CERTIFICATES
L05 CODE/STANDARD/COMPLIANCE CERTS.
L06 TEST RESULTS
L07 SPECIFICATION WAIVERS
L08 TYPE TEST CERTIFICATE
L09 INSPECTION RELEASE NOTE
M HANDLING AND SITE INSTALLATION

M01 DOCUMENTS TRAVELLING WITH GOODS
M02 PACKG., SHIPG., HANDLG. & STORAGE PROCS
M03 PRESERVATION PROCEDURE
M04 INSTALLATION INSTRUCTIONS
M05 FIELD FABRICATION ITEMS
N OPERATING INSTRUCTIONS
N01 SPARE PARTS LIST OR DATA PACKAGES
N02 OPERATING AND MAINTENANCE MANUAL
N03 SUPPLIERS CATALOGUE
N04 LUBRICATION SCHEDULE
Procedure for
Technical Queries (TQ) and Concession Requests (CR)
0 10-03-2021 Issued for Implementation PGN BB TNR/VKM
Prepared Checked Approved

Rev Date Revision Details
By By By
Procedure for Technical Queries (TQ) and Concession Date: 10.03.2021 Rev. 0
Requests (CR)
RECORD OF REVISIONS

Number
Requests (CR)
Contents
1. Purpose...................................................................................................................... 4
2. Scope ......................................................................................................................... 4
3. Application ................................................................................................................ 4
4. Abbreviations ............................................................................................................ 4
5. Definitions ................................................................................................................. 4
6. General Requirements .............................................................................................. 5
7. Attachments .............................................................................................................. 9
Requests (CR)
1. Purpose
The purpose of this procedure is to cover the process of raising Technical Queries
and Concession Requests.
2. Scope
The scope of this procedure is to describe the sequence of activities required to
answer or clarify a technical (or engineering) issue raised by the CONTRACTOR or
by a manufacturer through the CONTRACTOR. The issue is termed as a “Technical
Query” (TQ). If it is determined during the process of addressing the TQ, that the
answer will lead to a deviation from the Owner specifications or standards or
procedures, the TQ shall be followed by a Concession Request. The Concession
Request work process will also be addressed as part of the scope of this procedure.
3. Application
This procedure is applicable to Green field / Brown field projects executed by
RELIANCE.
4. Abbreviations
• CR = Concession Request
• DCC = Document Control Coordinator – Manages development of Tracking
Logs and Distribution Matrices for all TQ’s and Concession Requests as well as
controlling distribution to designated parties.
• TQ = Technical Query
5. Definitions
• CONTRACTOR– Reliance appointed EPC contractor executing E,P,Cworks in an
integrated way or a DEC responsible for Engineering and or Procurement
services.
• PEM = Project Engineering Manager – Review TQ for validity and
completeness and establish requirements for distribution. In the event a PEM
has not been assigned, an assigned Project Manager or Project Engineer will be
nominated to address this function.
• PMC = Project Management Consultant – This entity could be a Reliance
appointed 3rd Party Project Management Consultant or RPMG or combination
of 3rd Party Consultant and RPMG acting as PMC.

Requests (CR)
• RELIANCE- Reliance Industries Limited, and its AFFILIATES, legal successors in

title and assigns for whom all the GOODS and other item of activities are
provided by the CONTRACTOR and its SUB-CONTRACTOR under the ORDER.
• SUPPLIER- an entity directly or indirectly engaged by the CONTRACTOR for
supply of GOODS in connection with the ORDER.
6. General Requirements
Initiate Technical Query (TQ)
The CONTRACTOR shall comply with RIL specifications and standards. In the event
the CONTRACTOR encounters a technical issue which requires further clarification,
the CONTRACTOR shall generate a TQ.
CONTRACTOR or Supplier may initiate TQ process under the following
circumstances, but not limited to:
 Ambiguity in the specifications.
 Conflicting requirements specified among the various RIL specifications.
 Conflicting requirements between RIL specifications and Licensor technical
requirements.
 Conflict with statutory requirements or codes and standards.
 The specification requirements are outdated and does not match with
current industry practice.
The TQ shall clearly describe question / concern with specific reference to the issue
or equipment in question, and request clarification. Where applicable, the
CONTRACTOR shall also offer a proposed solution.
The technical issue is described by the CONTRACTOR by completing the Project
specific Technical Query form as per Attachment-1.
Numbering of TQ
The TQ form will be numbered as follows:
X X X X X X - T Q - Y Y Y - D - NNNN
Where
XXXXXX - Job Identifier.
TQ – Technical Query (Constant).
YYY – CONTRACTOR Code. This code will be communicated to the CONTRACTOR at
the start during Kick-Off Meeting.

Requests (CR)
D – Discipline Code as per Clause 7.1 of RPMS-ENGG-PRA-GE-028. In-case the TQ is

not specific to any discipline CONTRACTOR shall use “Z” for general category.
NNNN is a four-digit sequence number starting at 0001 for each CONTRACTOR
which shall be a unique number, refer example below.
Examples:
J18P01-TQ-FWH-M-0001
J18P01-TQ-FWH-M-0002
J18P01-TQ-FWH-P-0001
J18P01-TQ-TCM-P-0001
Transmit TQ to PMC
Once a TQ is ready to be submitted to PMC DCC, the same shall be submitted via
eRoom only.
TQ is transmitted via the CONTRACTOR document control system to the PMT DCC
who will log and route to the specific PEM.
NOTE: The PEM will review TQ’s for completeness. If it is determined that
additional information / details are required, the submittal will be rejected and
returned to the CONTRACTOR for further action.
Resolution of TQ
PMC will review the TQ considering the merit and involving all the internal stake
holders and will revert within five (5) working days.
The CONTRACTOR shall maintain status of all TQs initiated, covering all important
dates till closure.
The CONTRACTOR shall also maintain an Index of all the TQs with the following
details:
 TQ Number
 Date of TQ initiation
 Discipline
 Status (Open or Close)
 Date of TQ Closure
The CONTRACTOR shall issue the TQ index along with the TQ bi-weekly and the
document shall have a revision number and shall be uploaded by the DCC in REIMS.
The format of the TQ index shall be as per Attachment-5.

Requests (CR)
Based on the outcome of TQ, to avoid repetition; RIL reserve the right, exercising
discretion, to communicate the resolution with all other stakeholders including
other Contractors and Manufacturers.
An overview of the work processes for development, submittal and approval of
Technical Queries is outlined in Attachment-3 (Flowchart – Technical Queries).
Initiate Concession Request (CR)
CONTRACTOR is required to follow specifications, standard drawings, procedures
attached as part of Contract. In exceptional circumstances, wherein the
CONTRACTOR is unable to meet the project specifications, standard drawings or
procedures, the CONTRACTOR shall initiate concession request along with their
proposal for execution by alternate method and submit for PMC approval. In some
cases, Technical Queries may create the need for an application for Concession to
address / obtain approval for deviation to Project specifications /
standards/procedures. The CONTRACTOR shall not proceed with implementation
of proposed changes /modifications pending approval of such concession request
by PMC. Concession request can be pertaining to
a) Engineering
b) Construction
c) Bought out items/materials/Equipment.
For Bought out items/material or equipment, respective SUPPLIER shall initiate
concession request through CONTRACTOR as per prescribed format in
Attachment-2 along with all necessary marked-up documents. CONTRACTOR shall
ensure that all such concession requests are reviewed and approved internally
before its submission to PMC.
The following steps outline requirements for development, submittal and approval
of Concessions:
Post resolution of TQ and based on the clarifications provided by PMC, the
CONTRACTOR or Supplier may raise a concession to
specifications/standards/procedures for any alternate solutions or suggestions
which shall not compromise on the design intent of the specifications &
standards/procedures.
The Concession is described by the CONTRACTOR by completing the Project specific
Concession Application form as outlined in Attachment-2.
The form shall be completed by the CONTRACTOR/Supplier and shall include proper
justification as per the matrix given in Section 6.9
Numbering of CR
The CR form will be numbered as follows:
X X X X X X - C R - Y Y Y - D - NNNN

Requests (CR)
Where
XXXXXX - Job Identifier.
CR – Concession Request (Constant).
YYY – CONTRACTOR Code. This code will be communicated to the CONTRACTOR at
the start during Kick-Off Meeting.
D – Discipline Code as per Clause 7.1 of RPMS-ENGG-PRA-GE-028. In-case the CR is
not specific to any discipline, CONTRACTOR shall use “Z” in this place.
NNNN is a four digit sequential number starting at 0001 for each CONTRACTOR
which shall be a unique number.
Examples:
J18P01-CR-FWH-M-0001
J18P01-CR-FWH-M-0002
J18P01-CR-FWH-P-0001
J18P01-CR-TCM-P-0001
Transmit CR to PMC
Once a Concession is ready to be submitted to PMC DCC, the same shall be
submitted via eRoom only.
The CONTRACTOR’s DCC shall transmit the completed CR form to PMT DCC who
will distribute it in accordance with approved Distribution Matrix.
Resolution of CR
The PEM will review form for completeness and solicit discipline engineering input
and concurrence as needed, and sign Section B (box marked “OTHER”). This is then
transmitted to the PMC for approval via DCC. Once approved, the CR will be
returned to the CONTRACTOR via DCC.
PMC will review the CR considering the merit and involving all the internal stake
holders and will revert within ten (10) working days as far as possible. In case, the
concessions involve Process Licensors and outside stake holders, a mutually agreed
date with the Project team shall be decided upon.
The CONTRACTOR shall maintain a register for concession requests. This register
shall list all the concession requests and indicate its approval, cancellation or
rejection status. Summary of concession/deviation requests shall be included in in
the progress report.
Where the implementation of a Concession creates scope change, the Project
Change Management procedure iRPMS-PLNG-PRA-GE-039 will be invoked.

Requests (CR)
An overview of the work processes for development, submittal and approval of

Requests is outlined in Attachment-4 (Flowchart – Concession Requests).
CR Format Field: Responsibility Matrix ( Refer Attachment-2)

Field CR Responsibility Matrix
No CR by CONTRACTOR CR by Supplier
A1 CONTRACTOR* Supplier*
A2 CONTRACTORr * Supplier *
A3 CONTRACTOR(In-case of Supplier (In-case of
regularization of mistake) regularization of mistake)
A4 CONTRACTOR* Supplier*
B1 CONTRACTOR* CONTRACTOR* (Note 2 )
B2 Inspection Team (RIL) Inspection Team (RIL)
B3 PMC Engineering* PMC Engineering
B4 PMC Engineering PMC Engineering
C1 Specification/Process Owner* Specification/Process Owner*
(Discipline Head ) (Discipline Head)
C2 Specification/Process Owner Specification/Process Owner
D1 Project Manager* Project Manager*
Note 1: Fields marked with * are to be mandatorily filled otherwise the CR will be
rejected.
Note 2: In case of Bulk Items procured by RIL, these will not be applicable for the
CONTRACTOR.
7. Attachments
• Attachment 1 - Technical Query form
• Attachment 2 - Concession Application form
• Attachment 3 – Flowchart – Technical Queries
• Attachment 4 – Flowchart – Concession Request
• Attachment 5 – TQ Index form

Procedure for Compilation of

Manufacturing Record Book [MRB]
&
Operations & Maintenance Manual [OMM]
0 18-02-2021 Issued for Implementation VS LS TNR/VKM

By By By
Procedure for Compilation of MRB and OMM Date: 18/02/2021, Rev. 0
RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 4
2. Scope ......................................................................................................................... 4
3. Application ................................................................................................................ 4
4. Abbreviations ............................................................................................................ 4
5. Definition ................................................................................................................... 5
6. General Requirements .............................................................................................. 5
7. References ................................................................................................................. 8
8. Attachments .............................................................................................................. 9
1. Purpose
Manufacturer Record Book (MRB) and Operation & Maintenance Manual (OMM) are
the documents which provide vital information to the Owner during the life cycle of
the asset. It is important to have the information properly organized and verified
for quick retrieval of information by all stake holders.
The purpose of this procedure is to describe the process of compilation and
submission of Manufacturing Record Book (MRB) and Operations Maintenance
Manual (OMM) by vendors.
2. Scope
This procedure covers the requirements for formatting and compiling the
Manufacturing Record Book (MRB) and Operation & Maintenance Manuals (OMM)
for all equipment and material supplied for all projects.
The detailed requirements for each category of vendor document in MRB and OMM
are listed in the Supplier Document Requirements (VDR) – RPMS-ENGG-PRA-GE-041,
which shall be part of Material Requisition for the Equipment and Materials
purchased.
3. Application
This document shall be applicable to all projects (Greenfield and Brownfield)
executed by RIL.
4. Abbreviations
DEC - Detailed Engineering Contractor
IBR - Indian Boiler Regulations
MRP - Material Requisition for Purchase
TPIA - Third Party Inspection Agency
QA - Quality Audit
QC - Quality Control
CTS - Reliance – Central Technical Services
JEC - Jamnagar Execution Centre (JEC)All quoted
P&IDs - Piping & Instrument Diagrams
IFC - Issued for Construction
IFD - Issued for Design
DCC - Document Control Centre
MDR - Master Document Register

TPIA - Third Party Inspection Agency

VDR - Vendor Document Requirement
EPC - Engineering, Procurement & Construction
Contractor
5. Definition
PMC- This entity could be a Reliance appointed 3rd Party Project Management
Consultant or RPMG or combination of 3rd Party consultant and RPMG acting as
PMC.
CONTRACTOR- Reliance appointed EPC executing E, P, C works in an integrated way
or a Contractor responsible for Engineering and or Procurement services.
e-Room- Internet based application that provides secure collaborative
environment to the authorized users across the world enabling them to share
information.
Supplier- Party which manufactures or supplies equipment and services to
perform the function as specified by Buyer.
Buyer- Owner (Reliance) or Owner-appointed contractor who specifies equipment
Owner- Reliance Industries Limited or specified Reliance Group Company.
6. General Requirements
MRB and OMM Compilation

Compilation of MRB shall always be a live activity right from the commencement of
engineering through readiness for dispatch of the equipment. The MRB shall be
compiled on regular basis during the fabrication, manufacture or supply period and
shall be kept up to date at any point of time. It shall be presented to the authorized
RIL approved TPIA / vendors QC manager for review. QA audits may be performed
on MRB by Owner or by authorized representative without any prior intimation to
ensure compliance with Project technical specifications and that progressive
compilation.
6.1.1. Documents for inclusion in the MRB and OMM shall be written in English. Documents
in other languages shall have English translation written along with.
6.1.2. Once checking by TPIA is completed original or certified original of MRB and an
electronic file to be uploaded in e-Room as described in Section 6.3
6.1.3. The MRB and OMM shall contain all the information and documentation requested
and defined in the Purchase Order, Material Requisition for Purchase and project
procedure.

6.1.4. Vendor is required to follow the standard index for MRB and OMM as defined in
Attachment 3 to this procedure. However, documents listed in VDR shall take
precedence. The MRB shall contain the MRB Index duly reviewed by DEC.
6.1.5. All documentation to be included in the MRB and OMM should already have been
approved under Code 1, 4 as defined in the vendor document approval procedure.
Vendor shall ensure timely approval of the documents by Contractor to ensure
release of MRB and OMM. Request last minute approval of documents pending
dispatch of equipment will not be entertained.
30-Day Status Note [30-DSN]: One month prior to the dispatch of the equipment, a
formal note shall be issued to Contractor along with a copy to PMC indicating the
preparedness and constraints towards submission of MDR & OMM as per the
schedule. Identified corrective actions shall be swiftly implemented to ensure timely
release of MDR & OMM.
6.1.6. In addition to above documentation, vendor shall include all Third-Party Inspection
Reports required as per VDR in the MRB in the section for Test Reports.
6.1.7. For Items/equipment subjected to IBR regulations, copies of all the documentation
stamped by IBR inspector (or nominated inspector by IBR) shall be included in a
separate volume of MRB clearly marked “IBR Documents”. All above copies shall be
stamped by TPIA Inspector or Vendor QC Manager to indicate that they are Certified
Originals. In addition, the copies of these documents or its updated/latest revisions
shall also be included in their original sections as per index.
6.1.8. All Electrical devices, Electronic devices, Cable Glands, Switches, blind plugs, Junction
Boxes etc. which are to be placed in Hazardous area ( Zone 1 and Zone 2) vendor shall
submit PESO (CCOE) certification as minimum. Devices manufactured outside India,
shall also carry ATEX / IEC Ex approvals (as per latest IEC 60079 Standard) as
additional apart from PESO (CCOE) Certification.
6.1.9. All the documents of the MRB & OMM shall be legible and color scanned with
minimum resolution of 300 to 600 dpi. Documents generated in electronic format
shall be converted to .pdf in color and for scanning requirement content should be
in Optical Character Recognition (OCR) to have search facility in .pdf file. Compilation
of the documents shall also be professional offering text book feel.
MRB and OMM Details

6.2.1. Each MRB and OMM shall have an A4 size cover as per Attachment 1 and 2 of this
Procedure for MRB and OMM respectively and a list of contents approved by
Contractor.
6.2.2. For package items, the Seller shall provide a ‘User Guide’ detailing how the
traceability and identification system works, how to locate the documentation
applicable to a particular item with an assembly or equipment package.

6.2.3. For all the Tagged items Vendor shall submit unit wise MRB.
6.2.4. For Packaged equipment, or where there are number of repeated items, a General
File can be compiled to contain the documentation relevant to the whole order
rather than repeating these documents in each individual file.
6.2.5. Further, For Package items and for the equipment which are sourced from various
sub vendors and integrated by the Vendor, sub vendor list along with index for
locating the equipment in the MRB shall be indicated. Vendor shall create separate
section for each equipment in the package.
6.2.6. For packaged items main package vendor shall submit individual MRB / OMM for that
respective item.
6.2.7. The MRB and OMM shall consist of sections as specified in MRP. Only those
documents that are applicable to the material/equipment being supplied shall be
included in these sections.
6.2.8. For sections of the MRB and OMM that are not applicable state “Not Applicable” on
the list of contents, but do not delete sections from the list of contents.
6.2.9. Sections of the report shall be divided by separator tab sheets. All of the separator
sheets shall carry the following information:
6.2.10. Section letter designation and the title of the section, e.g. ‘Section D – Data Sheets’.
Tab shall be identified by the section letter.
6.2.11. Separator sheets shall not be included in the MRB and OMM for those sections that
are marked as “Not Applicable” on the list of contents.
6.2.12. The contents of each report section (Section A, Section B, etc.) shall be inserted
directly behind the relevant separator sheet and each document shall be marked
with the following:
• Purchase Order Number
• MR Number
• Equipment / Material description
• Item Number (Tag Number - Each applicable Tag No. shall be explicitly indicated).
• Relevant Volume Number (if there is more than one volume)
• Page Number – every sheet shall be numbered sequentially within its relevant
section (i.e. A1 to A6, B1 to B25, etc.).
6.2.13. Documents to be included in each Category from A to N are described in VDR.
The MRB shall include the following as a minimum:
• General documents
• Discipline specific documents

• Test and Inspection procedures

• Quality Assurance Plan
• Test certificates
• Test reports verified by third party inspector
6.2.14. The MRB is to be reviewed and stamped by the authorized TPIA on an ongoing basis.
If TPIA has not been appointed by the RELIANCE / Vendor in the case of certain
package vendors, QA/QC Manager of the vendor may sign and stamp the content of
the MRB.
6.2.15. All certification not requiring submittal for approval must be reviewed and stamped
by TPIA.
Submission of Soft copies for MRB and OMMs

6.3.1. Vendor shall submit the MRB & OMM documents for review through e-Room – For
Approval.
6.3.2. Contractor shall review the entire documentation and technical contents of the MRB
and OMM. The document shall be assigned appropriate review code as per
procedure “RPMS-ENGG-PRA-GE-041” and send comments back, if any; to Supplier
through e-Room.
Final submission of approved MRB and OMM – which have achieved code 1 or 4.
6.4.1. Vendor shall submit only approved MRB & OMM to RIL DCC through e-Room as final
submission.
Documents which are required to be submitted certified originals only, which shall
bear the original red/blue stamp of the TPIA inspector. In the event of non-
involvement of TPIA, Vendor QC Manager may certify the originals. The original
books shall be submitted to the designated authority in RIL which will be
communicated upon request.
Note: For few catalogue items such as Datasheets, GA, Calculation verified by TPIA
however not available with original RED/BLUE stamp, for such documents vendor can
submit DEC approved copy in MRB.
7. References
Document No. Document Name
RPMS-ENGG-PRA-GE-041 Supplier Document Requirement

IBR 1950 Indian Boiler Regulations 1950
8. Attachments
Attachment ‐ 1: MRB cover sheet
Attachment ‐ 2: OMM cover sheet
Attachment ‐ 3: Standard Index for MRB & OMM for:
Mechanical ‐ Static Package Equipment
Electrical
Instrumentation – Instrument System
Piping
Rotary
Attachment ‐ 4: Validation statement for MRB & OMM
Attachment - 5: Certification Requirements

Attachment 1- MRB Cover Sheet
Manufacturing Record Book [DEC Logo]
------------------------------------
(Client Name)
------------------------------------
(Client Project Location)
Project: ____________________ Job Identifier Number: ________
Program Number: ________ Unit Number: ________
Plant Name: ____________
Vendor Name
Detail Engineering Consultant (DEC)
Equipment Tag No
MR Number
PO Number
Document Number
Volume
Issue date

Attachment 2- OMM Cover Sheet
Operations & Maintenance Manual [DEC Logo]
------------------------------------
(Client Name)
------------------------------------
(Client Project Location)
Project: ____________________ Job Identifier Number: ________
Program Number: ________ Unit Number: ________
Plant Name: ____________
Vendor Name
Detail Engineering Consultant (DEC)
Equipment Tag No
MR Number
PO Number
Document Number
Volume
Issue date

Attachment-3: Standard Index –
1. Standard Index of MRB For Static Equipment
SECTION CATEGORY CODE DESCRIPTION

1 A01 Drawing and Documentation Schedule
2 A03 Copies Sub-Orders
3 A04 Job Specific Inspection & Test Plan
4 A07 Contract Specific Quality Plan
5 B02 General Arrangement
6 D01 Data Sheets
7 D04 Weight Data Sheet
8 E01 Design/ Code Calculation
9 F01 Equipment Detail Drawings
10 F04 Parts list/ Bill Of Material
11 F06 Insulation/ Lining Detail
12 J01 Weld Procedures (WPS and PQR)
13 J02 NDE Procedures
14 J03 Heat Treatment Procedures (Including PWHT)
15 J04 Surface Preparation, Painting and coating
Specification
16 J06 Operator Qualifications
17 K02 Hydrostatic/pneumatic Test Procedure
18 K03 Material Test Procedure
19 K07 PMI Test Procedure
20 L01 Manufacturing Record Book Index
21 L03 Material Certificates
22 L05 Code/ Standard / Compliance Certificate
23 L06 Test Results

24 L07 Specification Waivers

25 L09 Inspection Release Note
26 M01 Documents Travelling with Goods
27 M02 Packing/ Shipping/ Handling and Storage
Procedure
28 M03 Preservation Procedure
29 M04 Installation Instruction
30 N01 Spare parts list or Data Packages
2. Standard Index of MRB for Package Mechanical Equipment

1 A05 Job Specific Insp. And Test Plan (ITP)
2 A09 Contract Specific Quality Plan
3 B01 Key Design Sketch
4 B02 General Arrangements
5 B03 Interface and connection Schedule
6 B04 Utility Requirements
7 C01 PFDs and Heat Mass Balance
8 C02 P & IDs
9 C03 Cause And Effect
10 C04 Control Philosophy and Block Logic Diagram
11 C05 Operating Philosophy
12 D01 Data Sheets
13 D03 Instrument Data Sheets
14 D04 Weight Data Sheet
15 D05 Noise Data Sheet
16 D06 Coupling Data Sheet
17 E01 Design/ Code Calculation
18 E02 Process/ Utility Calculation

19 E03 Structural Foundation and Support Calculations

20 E06 Piping Stress Analysis
21 E07 Prime Mover Performance Curve
22 E08 Driven Equipment Performance Curve
23 E09 Electrical Curves
24 E10 Reliability and Availability
25 F01 Equipment Detail Drawing
26 F02 Ancillary Piping Drawing
27 F04 Parts List/Bill of Material
28 F05 Seal & Seal System / ROD Packing System
29 J02 NDE Procedure
30 J03 Heat Treatment Procedures (INC. PWHT)
31 J04 Surface Preparation, Painting and coating
Specification
32 J05 Material Specification
33 K02 Hydrostatic / Pneumatic Test Procedure
34 K03 Material Test Procedure
35 K05 Factory Acceptance Test Procedure
36 K07 PMI Test Procedure
37 L03 Materials Certificates
38 L04 Hazardous Area Certificates
39 L05 Code/ Standard/ Compliance Certificates
40 L06 Test Results
41 L07 Specification Waivers
42 L08 Type Test Certificate
43 L09 Inspection Release Note
44 M02 Packing., Shipping ,Handling , & storage Process
45 M03 Preservation Procedure

46 M04 Installation Instructions
47 M05 Field Fabrication Items

48 M06 Detailed Packing List
3. Standard Index of O&M for Mechanical Package Equipment

1 N-Series Operating & Maintenance Manual
4. Standard Index of MRB for Electrical

1 A04 Job specific Inspection Test Plan (ITP)
2 A07 Contract Specific Project Quality Plan
3 B01 Name Plate Facsimiles
4 B02 General Arrangement Drawings incl. Terminal
Boxes
5 H01 Single Line Diagram
6 H09 Wiring Diagrams including interconnection
diagram
7 D01 / D02(for motors) Data Sheets
8 J - SERIES Manufacturing Procedures
9 K - SERIES Testing Procedures
10 L - SERIES Certifications
5. Standard Index of O&M for Electrical

1 N-Series Operating & Maintenance Manuals

6. Standard Index of MRB for Instruments
CATEGORY DESCRIPTION
SECTION CODE
1 A05 Job specific Inspection Test Plan (ITP)
2 A07 Contract Specific Project Quality Plan
3 B01 Name Plate Facsimiles
4 B02 General Arrangement Drawings incl. Terminal
Boxes
5 B03 Interface and connection schedule
6 B04 Utility requirements
7 D03 Instrument Data Sheets
8 E05 Instrument sizing calculation
9 G03 Wiring schematic diagram
10 G04 Termination details
11 G05 Panel/cabinet layout e.g. LCP in case of valve
12 G07 Hook up diagram
13 J – SERIES Manufacturing Procedures
14 K – SERIES Testing Procedures
15 L – SERIES Certifications

7. Standard Index of O&M for INSTRUMENTS

1. B02 General Arrangement Drawings
2. B03 Interface and connection schedule
3. C05 Operating philosophy
4. D03 Instrument Data Sheets
5. E05 Instrument sizing calculation e.g. FT in case of
CTM
6. G03 Wiring schematic diagram
7. G04 Termination details
8. G05 Panel/cabinet layout e.g. LCP in case of valve
9. G07 Hook up diagram
10. G08 Loop diagram e.g. Analysers
11. M - SERIES Handling and site installation
12. N-SERIES Operating and maintenance manual

8. Standard Index of MRB for Systems

A05 Job specific Inspection Test Plan (ITP)
1.
A07 Contract Specific Project Quality Plan
2.
B02 General Arrangement Drawings
3.
B03 Interface and connection schedule
4.
B04 Utility requirements
5.
B05 Foundation drawings (e.g. Shelter)
6.
C06 Functional design specification
7.
D03 Instrument Data Sheets
8.
E05 Instrument sizing calculation
9.
E10 Reliability and availability calculations
10.
E12 Heat dissipation and power calculation.
11.
G03 Wiring schematic diagram
12.
G04 Termination details
13.
G05 Panel/cabinet layout
14.
G06 Logic diagrams/description
15.
G07 Hook up diagram
16.
G08 Loop diagrams
17.
G09 Cable block diagram
18.
G11 Serial link
19.
G12 Graphics
20.
G13 Software listing
21.

J - SERIES Manufacturing Procedures

22.
K - SERIES Testing Procedures
23
L - SERIES Certifications
24.
9. Standard Index of O&M for Systems

1. C02 P&ID
2. C04 Control philosophy and block logic diagram
3. C05 Operating philosophy
4. D03 Instrument Data Sheets
5. E05 Instrument sizing calculation
6. M-SERIES Handling and site installation
7. N-SERIES Operating and maintenance manual
10. Standard Index of MRB for Piping Items

1. A05 JOB SPECIFIC INSPECTION & TEST PLAN
2. A07 CONTRACT SPECIFIC QUALITY PLAN
3. F-SERIES DETAIL MECHANICAL DRAWING
4. J-SERIES MANUFACTURING PROCEDURES
5. K-SERIES TEST PROCEDURES
6. L-SERIES CERTIFICATES
7. M-SERIES HANDLING & SITE INSTALLATION

11. Standard Index of O&M for Piping

1. N-Series Operating & Maintenance Manuals
12. Standard Index of MRB for Rotary

A05 JOB SPECIFIC INSPECTION AND TEST PLAN(ITP)
1.
D01 DATA SHEETS
2.
J01 WELD PROCEDURES (WPS AND PQR)
3.
J02 NDE PROCEDURE
4.
J03 HEAT TREATMENT PROCEDURES (INC. PWHT)
5.
J04 SURFACE PREP. , PAINTG.,AND COATG. , SPEC.
6.
7.
J06 OPERATOR QALIFICATIONS
8.
K01 FUNCNL. AND PREF. TEST PROCEDURES
9.
K02 HYDRO. / PNEUM TEST PROCEDURES
10.
K03 MATERIAL TEST PROCEDURES
11.
K04 WEIGHT CONTROL/ WEIGHING PROCEDURE
12.
K05 FACTORY ACCEPTANCE TEST PROCEDURE
13.
K06 SITE ACCEPTANCE TEST PROCEDURE
14.
K07 PMI TEST PROCEDURE
15.
L01 MANUFACTURING RECORD BOOK INDEX
16.
L03 MATERIAL CERTIFICATES
17.

L05 CODE/ STANDARD/COMPLIANCE CERTIFICATES

18.
L06 TEST RESULTS
19.
L07 SPECIFICATION WAIVERS
20.
L08 TYPE TEST CERIFICATES
21.
L09 INSPECTION RELAESE NOTE
22.
13. Standard Index of O&M for Rotary

1 N - SERIES OPERATING & MAINTENANCE MANUAL

Attachment 4 - Validation Statements for MRB & OMM
Validation Statement
Date :
I hereby certify/acknowledge/declare to the best of my knowledge that the MRB
that has been submitted by me complies with this procedure.
I certify that all documents in the MRB have been reviewed by Contractor
(Name of DEC: ) and necessary approvals have been taken before
furnishing information in this MRB. No document has been modified after
receiving the approval from Contractor / RELIANCE.
The MRB has been thoroughly checked for errors and has been certified by TPIA/
QC manager. For any non-compliance I am liable to resubmit the MRB.
Signature & Name of Authorized

Stamp of vendor
representative of Vendor
Stamp of TPIA
N.B. This statement must be certified by TPIA or by QC manager wherever TPIA is not involved.

Validation Statement
Date :
It is certified that the OMM No _______________________________________
Contains all documents represented by the index.
The OMM contains all required documents, as stipulated in the relevant Material
Requisition.
All documents requiring Contractor review have been assigned either code 1
(Work may proceed) or Code 4 (For Information Only) or F (Final Certified).
QA/QC Manager
Name:
Signature:
Date:
Stamp:

Attachment 5: Certification Requirements

Code
CAT Certification Requirement
CODE Description
Requirement at Final
Stage
A CONTROL DOCUMENTS
VDS- 001 VENDOR DRAWINGS AND DOCUMENTATION
A01
SCHEDULE.
N Code 1 / 4
A02 FABRICATION / PRODUCTION SCHEDULE N Code 1 / 4
A03 SUB-ORDER SCHEDULE/COPIES SUB ORDERS N Code 1 / 4
A04 WEEKLY PROGRESS REPORT N Code 1 / 4
A05 JOB SPECIFIC INSP. AND TEST PLAN ( ITP) N Code 1 / 4
A06 CERTIFICATE OF QUALITY SYSTEM APPROVAL* Y Code 1
A07 QUALITY MANUAL* Y Code 1
A09 CONTRACT SPECIFIC QUALITY PLAN* Y Code 1
B ARRANGEMENT DRAWINGS /DOCUMENTS
B01 KEY DESIGN SKETCH Y Code 1

B02 GENERAL ARRANGEMENTS Y Code 1
B03 INTERFACE AND CONNECTION SCHEDULE Y Code 1
B04 UTILITY REQUIREMENTS Y Code 1
B05 FOUNDATION DRAWINGS Y Code 1
B06 PLATFORM & LADDER Y Code 1
C SCHEMATICS
C01 PFDs AND HEAT MASS BALANCE Y Code 1

C02 P&IDs Y Code 1
C03 CAUSE AND EFFECT Y Code 1
CO4 CONTROL PHIL. AND BLOCK LOGIC DIAG. Y Code 1
C05 OPERATING PHILOSOPHY Y Code 1
C06 FUNCTIONAL DESIGN SPECIFICATION Y Code 1
D DATA SHEETS
D01 DATA SHEETS Y Code 1

D02 MOTOR DATA SHEET Y Code 1
D03 INSTRUMENT DATA SHEETS Y Code 1

D04 WEIGHT DATA SHEET Y Code 1

D05 NOISE DATA SHEET Y Code 1
D06 COUPLING DATASHEET Y Code 1
E CALCULATIONS
E01 DESIGN/CODE CALCULATION Y Code 1

E02 PROCESS/UTILITY CALCULATION Y Code 1
E03 STRUCTURAL FOUNDN. AND SUPPORT CALCS. Y Code 1
E04 ROTATING ELEMENT CALCULATION Y Code 1
E05 INSTRUMENT SIZING CALCULATION Y Code 1
E06 PIPING STRESS ANALYSIS Y Code 1
E07 PRIME MOVER PERFORMANCE CURVE Y Code 1
E08 DRIVEN EQUIPMENT PERFORMANCE CURVE Y Code 1
E09 ELECTRICAL CURVES Y Code 1
E10 RELIABILITY AND AVAILABILITY Y Code 1
E11 PULSATION STUDIES Y Code 1
E13 HEAT DISSIPATION AND POWER CALCULATIONS Y Code 1
F01 EQUIPMENT DETAIL DRAWINGS Y Code 1

F02 ANCILLARY PIPING DRAWING Y Code 1
F03 CROSS SECTION Y Code 1
F04 PARTS LIST/BILL OF MATERIAL Y Code 1
F05 SEAL & SEAL SYSTEM/ROD PACKING SYSTEM Y Code 1
F06 INSULATION/LINING DETAIL Y Code 1
G01 NSTRUMENT LOCATION DRAWING Y Code 1

G02 INSTRUMENT SCHEDULE Y Code 1
G03 WIRING SCHEMATIC DIAGRAM Y Code 1
G04 TERMINATION DETAILS Y Code 1
G05 PANEL / CABINET LAYOUT Y Code 1
G06 LOGIC DIAGRAM Y Code 1
G07 HOOK UP DIAGRAM Y Code 1

G08 LOOP DIAGRAMS Y Code 1

G09 CABLE BLOCK DIAGRAM Y Code 1
G10 INSTRUMENT OUTLINE DRAWING Y Code 1
G11 SERIAL LINK Y Code 1
G12 GRAPHICS Y Code 1
G13 SOFTWARE LISTING Y Code 1
H01 ELECTRICAL SINGLE LINE DIAGRAM Y Code 1

H02 ELECTRICAL LAYOUT DRAWING Y Code 1
H03 SCHEDULE OF ELECTRICAL EQUIPMENT Y Code 1
H04 CABLE SCHEDULE Y Code 1
H05 INTERCONNECTION DIAGRAM Y Code 1
H06 TERMINAL BOX BLOCK DIAGRAM Y Code 1
H07 DISTRIBUTION BOARD SCHEDULE Y Code 1
H09 WIRING DIAGRAMS Y Code 1
J01 WELD PROCEDURES (WPS AND PQR) Y Code 1

J02 NDE PROCEDURES Y Code 1
J03 HEAT TREATMENT PROCEDURES (INC. PWHT) Y Code 1
J04 SURFACE PREP., PAINTG. AND COATG. SPEC. Y Code 1
J05 MATERIAL SPECIFICATION Y Code 1
J06 OPERATOR QUALIFICATIONS Y Code 1
K TEST PROCEDURES
K01 FUNCNL. AND PERF. TEST PROCEDURES Y Code 1

K02 HYDRO./PNEUM TEST PROCEDURES Y Code 1
K03 MATERIAL TEST PROCEDURES Y Code 1
K04 WEIGHT CONTROL/WEIGHING PROCEDURE Y Code 1
K05 FACTORY ACCEPTANCE TEST PROCEDURE Y Code 1
K06 SITE ACCEPTANCE TEST PROCEDURE Y Code 1
K07 PMI TEST PROCEDURE Y Code 1

L CERTIFICATION
L01 MANUFACTURING RECORD BOOK INDEX N Code 1 / 4

L02 MANUFACTURING RECORD BOOK Y Code 1
L03 MATERIALS CERTIFICATES Y Code 1
L04 HAZARDOUS AREA CERTIFICATES Y Code 1
L05 CODE/STANDARD/COMPLIANCE CERTS. Y Code 1
L06 TEST RESULTS Y Code 1
L07 SPECIFICATION WAIVERS N Code 1 / 4
L08 TYPE TEST CERTIFICATE Y Code 1
L09 INSPECTION RELEASE NOTE N Code 1 / 4
M HANDLING AND SITE INSTALLATION
M01 DOCUMENTS TRAVELLING WITH GOODS N Code 1 / 4

M02 PACKG., SHIPG., HANDLG. & STORAGE PROCS Y Code 1
M03 PRESERVATION PROCEDURE Y Code 1
M04 INSTALLATION INSTRUCTIONS Y Code 1
M05 FIELD FABRICATION ITEMS Y Code 1
M06 DETAILED PACKING LIST Y Code 1/4
N OPERATING INSTRUCTIONS
N01 SPARE PARTS LIST OR DATA PACKAGES N Code 1 / 4

N02 OPERATING AND MAINTENANCE MANUAL Y Code 1
N03 SUPPLIERS CATALOGUE N Code 1 / 4
N04 LUBRICATION SCHEDULE N Code 1 / 4
Note – Contractor reviewer shall mark responsible to mark final coding (Code 1/4) on
document.

for
Hot and Acoustic Insulation
RPMS-ENGG-SPC-PP-012
0 25.08.2020 Issued for Implementation MD RS AS/VKM

By By By
Reliance Project Management System RPMS-ENGG-SPC-PP-012
Standard Specification for Hot and Acoustic Insulation Date: 25/08/2020, Rev. 0
Ajay Shrivastava
_____________________________ _________________ ___________
Anand Umakanthan
_____________________________ _________________ ___________
2
A. Srinagesh
_____________________________ _________________ ___________
3
S. Sammadar
_____________________________ _________________ ___________
4
Kuddallur Seshadri
_____________________________ _________________ ___________
5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
4. Abbreviations and Definitions................................................................................... 7
5. Technical and Design Requirements ......................................................................... 9
6. Basic Properties of insulation material ................................................................... 18
7. Application procedure............................................................................................. 22
8. Inspection and Testing ............................................................................................ 43
9. Vendor Data ............................................................................................................ 43
10. Packing, Preservation, shipment and Storage ........................................................ 44
11. Measurement Wastages Norms. ............................................................................ 44
12. Attachment.............................................................................................................. 46
1. Purpose
This Standard Specification is to ensure uniform and sound approach to the hot &
acoustic Insulation for Piping, Equipment and Storage Tanks etc. for all projects of
Reliance.
All tanks, vessels, columns, equipment and piping containing hot fluids or vapours
are to be insulated to meet one of the below requirements.
a) Conserve heat energy/Minimize heat loss.
b) Maintain temperature for process control or product
c) Provide personnel protection.
d) Maintain noise level within specified limit <85 db.
e) Fire protection
This Standard Specification covers minimum requirement for the manufacturing,
supply, application & quality control of thermal insulation for Tanks, Vessels,
Columns, Equipment and Piping operating in the temperature range from ambient
to 600 °C.
This specification is not applicable for cold service insulation. Refer RPMS-ENGG-
SPC-PP-013 for cold insulation.
2. References
The latest edition of following Codes and Standards are referenced in this standard
specification and all relevant provisions of these reference codes and standards
shall be applicable. Any deviation with respect to below mentioned codes and
standards shall be brought to the notice of Buyer for approval.
Standard Standard Description
ASTM B209 Standard Specification for Aluminum and Aluminum-Alloy
Sheet and Plate
ASTM C165 Test Method for Measuring Compressive Properties of
Thermal Insulations.
ASTMC168 Terminology Relating to Thermal Insulating Materials
ASTMC177 Test Method for Steady-State Heat Flux Measurements
and Thermal Transmission Properties by means of the
Guarded Hot-Plate Apparatus
ASTMC303 Test Method for Density and Dimensions of Preformed
Block-Type Thermal Insulation
ASTMC356 Test Method for Linear Shrinkage of Preformed High-
Temperature Thermal Insulation subjected to Soaking
Heat


ASTMC411 Test Method for Hot-Surface Performance of High-
Temperature Thermal Insulation
ASTMC447 Practice for Estimating the Maximum Use Temperature of
Thermal Insulations
ASTMC585 Practice for Inner and Outer Diameters of Rigid Thermal
Insulation for Nominal Sizes of Pipe and Tubing (NPS
System)
ASTMC680 Practice for Determination of Heat Gain or Loss and the
Surface Temperatures of Insulated Pipe and Equipment
Systems by the Use of a Computer Program
ASTMC692 Test Method for Evaluating the Influence of Thermal
Insulations on the External Stress Corrosion Cracking
Tendency of Austenitic Stainless Steel
ASTMC795 Standard Specification for Thermal Insulation for Use in
Contact with Austenitic Stainless Steel
ASTMC871 Test Methods for Chemical Analysis of Thermal Insulation
Materials for Leachable Chloride, Fluoride, Silicate, and
Sodium Ions
ASTMC930 Materials and Accessories Classification of Potential
Health and Safety Concerns Associated with Thermal
Insulation
ASTMC1338 Test Method for Determining Fungi Resistance of
Insulation Materials and Facings
ASTMC1728 Standard Specification for Flexible Aerogel Insulation
ASTMC1729 Standard Specification for Aluminium Jacketing for
Insulation
EN 13472 Thermal insulating products for building equipment and
industrial installations. Determination of short-term water
absorption by partial immersion of preformed pipe
insulation
AGI Q- 132 Specification for test methods of classification
temperature for mineral wool insulation for industrial use.
IS 8183 Bonded mineral wool specification
IS3144 Mineral wool thermal insulations –method of test
IS9842 Preformed Fibrous pipe insulation- specification


ISO 15665 Acoustics – Acoustic Insulation for Pipes, Valves and
Flanges
RPMS-ENGG-SPC-PP- Standard Specification for Protective Coatings (Shop &
014 Field)
RPMS-ENGG-SPC-PP- Standard Specification for Cold Service Insulation
013
RPMS-ENGG-PRA-PP- Engineering and Procurement strategy for Hot, Cold and
040 Acoustic Insulation

shall govern:
1. Line designation Table (LDT) & Equipment GA Drawings
of enquiry, shall be applicable. In case of any conflict, the decision of owners
1. “Data Sheets and Drawings” represent those attached to the Material
Requisition – Equipment Datasheets, Stock Code Item Description, Piping &
Instrumentation Diagram.
2. “Material Requisition” represents Material Requisition for Quotation,
Order
4. Abbreviations and Definitions

Abbreviations
AHA : Acoustic Hot Insulation Class A
AHB : Acoustic Hot insulation class B
AHC : Acoustic Hot Insulation Class C
AIA : Acoustic Insulation Class A

AIB : Acoustic Insulation Class B

AIC : Acoustic Insulation Class C
ASTM : American society for testing and materials
BIS : Bureau of Indian standard
BS : British Standard
C/C : Centre to Centre
CUI : Corrosion Under Insulation
DEC : Design Engineering Contractor
ET : Electric Traced
FI : Fire safe insulation
FSI : Flame Spread Index
HC : Heat Conservation
HCET : Heat Conservation with Electric tracer
HCHT : Heat Conservation with High pressure steam tracer
HCLT : Heat Conservation with Low pressure steam tracer
HCMT : Heat Conservation with Medium pressure steam tracer
HCWT : Heat Conservation with warm water tracer
ISO : International Organization for Standardization
LDT : Line Designation Table
LRB : Lightly Resin bonded
MW : Mineral Wool
NI : No Insulation
O&M Operations and Maintenance
PG : Personnel guards
PP : Personnel Protection
PS : Pipe Section
SDI : Smoke Development Index
SP : Solar Protection
SS : Stainless Steel
ST : Steam Traced
WFT : Wet Film Thickness

Definitions
Supplier/Vendor: Party which manufactures or supplies materials and services to
perform the function as specified by Buyer
Buyer: Owner (Reliance or Owner-appointed licensor, DEC or EPC who specifies
Owner: Reliance Industries Limited or specified Reliance Group Company
DEC: Detailed Engineering Contractor
EPC: Engineering, Procurement and Construction Contractor
Insulation Contractor: Supplier of insulation services
Applicator: The party contracted to install the insulation systems
Insulation Material Supplier: Supplier / Manufacturer of insulation materials
Standard Terminology Relating to Thermal Insulating Materials is defined in ASTM
C168.
5.1. Basic Design and Engineering of an insulation system shall be governed by
following parameters.
▪ Heat conservation with economical thickness
▪ Avoiding of corrosion under Insulation (CUI).
▪ Compliance with safety requirements for personnel protection
(PP/PG).
▪ Compliance with process conditions / requirements.
▪ Acoustic requirements
▪ Fire safe requirements (FI)
5.2. Based on above criteria following are the type of insulation covered in this
• These Insulation codes to be used by all stake holder, DEC or Process licensors
for P&ID, ISO and PDS CAD modelling.

Insulation type Insulation material

HC Heat conservation
HCLT Heat Conservation with Low pressure steam tracer
Heat Conservation with Medium pressure steam
HCMT
tracer
HCHT Heat Conservation with High pressure steam trace
HCWT Heat Conservation with warm water tracer
HCET Heat Conservation with Electric tracer
SP Solar protection (potable water ,Breathing air etc.)
AIA/AIB/AIC Acoustic insulation Class A/ Class B/ Class C
Heat conservation + Acoustic insulation Class A/Class
AHA/AHB/AHC
B/ Class C
PP Personnel protection
PG Perforated guard
NI No insulation
DC Dual Condition (hot and cold service)
Note:1: For all other details of "DC" type insulation refer RPMS-ENGG-SPC-PP-013.
Note:2:Details of Insulation and material required against each type of insulation
shall be as per Table 1.
Note:3:Inside and outside diameters of pipe insulation shall comply with ASTM
C585.

Table 1: Insulation and materials requirements

Type of insulation & Applicable insulation and Cladding material
Insulation type Insulation material Cladding material
0.9 mm aluminium cladding with
polysurlyn moisture barrier ,
Silica aerogel +Mineral wool
HC 0.8 mm thick corrugated
Slab or Pipe section
cladding for Equipment and
tanks >900 mm diameter
Silica aerogel +Mineral wool
HCLT, HCMT, polysurlyn moisture barrier
Slab or Pipe section
HCHT, HCWT & 0.8 mm thick corrugated
HCET (Insulation thickness as for
HC. Type insulation).
polysurlyn moisture barrier
Mineral wool Slab or Pipe
SP 0.8 mm thick corrugated
section
Mineral wool slab or pipe 0.7/0.8/1.2 mm thick Aluzinc
AIA/AIB/AIC
section. cladding as per acoustic class
Silica aerogel +Mineral wool 0.7/0.8/1.2 mm thick Aluzinc
AHA/AHB/AHC
Slab or Pipe section cladding as per acoustic class
0.9 mm AL. cladding with
polysurlyn moisture barrier
Mineral wool slab or pipe
PP 0.8 mm thick corrugated
section.
1.2 mm Aluminum perforated
PG NA
guard
NI No insulation
As per Table 5-2 of As per Table 5-2 of
DC
RPMS-ENGG-SPC-PP-013 RPMS-ENGG-SPC-PP-013

5.3. Extent of insulation

5.3.1. Extent of insulation for Vessel, equipment and exchanger
5.3.1.1. All Equipments, Exchangers and Vessel within the scope of this specification shall
be completely insulated including all hand hold covers, Manholes, support ring
stiffeners, lifting lug, etc.
5.3.1.2. For tank insulation, anchor chairs shall be insulated fully by insulation contractor.
5.3.1.3. All instrument assemblies requiring insulation and attached to insulated equipment
shall be insulated for the operating temperature of equipment.
5.3.1.4. All the protrusion shall be insulated minimum 300 mm or 4 times the insulation
thickness, whichever is the more stringent.
5.3.1.5. Bottom dish ends of insulated vessel secured in skirt, shall be cladded with hard set
cement and Reinforcement glass cloth in lieu of Cladding material.
5.3.1.6. Vessel trims of insulated vessel or equipments, shall be insulated as per vessel
insulation thickness up the extent to 300 mm or 4 times the insulation thickness.
5.3.2. Extent of insulation for piping
5.3.2.1. Straight Pipes, elbows, tees and all other welded fittings shall be insulated as
defined in LDT.
5.3.2.2. Lines with Tracers and Jacketing shall be completely insulated, valves and flanges
shall be insulated as per guidelines provided in section 5.3.3.
5.3.2.3. All protrusions, Vent, Drains, by pass & support attached to parent piping shall be
insulated with the same insulation thickness as of parent pipe and extent of
insulation shall be 4 times the thickness of insulation or 300 mm, whichever is
greater.
5.3.2.4. For steam trap insulation, steam trap manufactures guidelines shall be followed
5.3.2.5. For closed recovery system, outlet piping of steam trap shall be insulated.
5.3.2.6. Condensate lines down stream of steam trap, discharging to drainage system, shall
not be insulated unless otherwise specified. If insulation is required for safety
purpose, perforated guard shall be provided.
5.3.2.7. Relief valves, flare and blow down piping system shall not be insulated unless
otherwise specified.
5.3.3. Extent of insulation for valves and flanges
5.3.3.1. Unless otherwise specified, all valves & flanges shall be insulated in steam and
condensate lines.
5.3.3.2. Flanges and valves shall not be insulated in system containing
 Hydrogen service.
 Hydrocarbon /Process lines.

 Hydrocarbons above their auto-ignition temperature.

 Flange joints where 80% rule for bolting has been applied as per ASME B
31.3.
5.3.3.3. Valves and flanges for the lines categorized in clause 5.3.3.2, shall be insulated if
specifically required by Process Licensors. In addition to Process Licensor’s
requirement, below guidelines shall be strictly followed.
5.3.3.4. All such valves and flanges shall be clearly identified/ defined in LDT and Marked in
Isometrics.
5.3.3.5. Valve body only to be insulated excluding bonnet and valve flanges, leaving the
flange joint open for inspection.
5.3.3.6. Bolts of flange joints shall not be covered with insulation.
5.3.3.7. Wherever conventional lagging and cladding is not feasible for valve size up to 6”,
same shall be insulated with removable box type Pad Insulation with suitable silicon
impregnated fiber glass cloth or high silica cloth for higher temperature.
5.3.3.8. Where ever Fire safe insulation is specified, valve and flanges shall be insulated with
boxes using cellular glass material with thickness as per Process Licensors /DEC
specification. In case of non-availability of Process licensors /DEC guidelines,
insulation shall be carried out as per “Attachment No 8” of this specification.
5.4. Insulation Thickness Table
5.4.1. Thickness of insulation for Heat Conservation (HC)
• Heat conservation thicknesses calculated using NAIMA (North American
Insulation Manufacturers Association) 3E PLUS surface temperature computer
analysis.
Table 2:Thickness calculation Basis
Inner Wrap Silica Aerogel
Outer Layer Mineral wool
Bare Surface Emittance 0.8
Cladding Emittance 0.3
Average Ambient Temperature 35 °C
Maximum Outer Temperature 55 °C
Wind Speed 0 m/s

Table 3- Thickness Table for Heat conservation (HC)

Silica Aerogel /Mineral wool combination thickness Table (mm / mm)
NPS
(IN) Operating Temperature (°C)
151- 201- 251- 301- 351- 401- 451- 501- 551-
55-150 200 250 300 350 400 450 500 550 600
0.5 0 / 40 0 / 40 0 / 50 0 / 65 0 / 65 0 / 80 0 / 100 0 / 115 0 / 125 0 / 165
0.75 0 / 40 0 / 40 0 / 50 0 / 65 0 / 80 0 / 90 0 / 100 0 / 125 0 / 150 0 / 175
1 0 / 40 0 / 40 0 / 50 0 / 65 0 / 80 0 / 90 0 / 115 0 / 125 0 / 165 0 / 175
1.5 0 / 40 0 / 40 0 / 50 0 / 80 0 / 80 0 / 100 0 / 115 0 / 150 0 / 175 0 / 200
2 10 / 40 20 / 25 25 / 25 20 / 65 25 / 65 25 / 90 30 / 75 35 / 75 35 / 75 45 / 75
3 10 / 40 20 / 40 15 / 50 15 / 65 25 / 75 15 /115 30 /115 35 /140 50 / 75 50 / 75
4 10 / 40 20 / 40 25 / 40 25 / 65 25 / 75 25 /100 25 /125 35 /140 60 / 75 60 / 75
6 10 / 40 20 / 40 20 / 65 25 / 65 25 / 90 25 /115 35 / 75 50 / 75 60 / 75 70 / 75
8 10 / 40 20 / 50 20 / 65 25 / 65 25 / 90 25 /125 40 / 75 60 / 75 60 / 75 70 / 75
10 10 / 40 20 / 50 20 / 65 25 / 75 25 /100 30 /125 50 / 75 60 / 75 60 / 75 70 / 75
12 10 / 40 20 / 50 15 / 65 25 / 75 30 /100 40 /125 50 / 75 70 / 75 70 / 75 70 / 75
14 10 / 40 20 / 50 20 / 75 25 / 75 25 /115 25 /140 50 / 75 70 / 75 70 / 75 80 / 75
16 10 / 40 20 / 50 20 / 75 25 / 75 25 /115 25 /140 50 / 75 70 / 75 70 / 75 80 / 75
18 15 / 50 10 / 65 20 / 75 25 / 90 25 /115 25 /150 50 / 75 70 / 75 70 / 75 80 / 75
20 15 / 50 10 / 65 20 / 75 25 / 90 25 /115 25 /150 60 / 75 70 / 75 70 / 75 80 / 75
24 15 / 50 10 / 65 20 / 75 25 / 90 25 /125 25 /150 60 / 75 70 / 75 70 / 75 80 / 75
30 15 / 50 10 / 65 20 / 75 20 /105 20 /140 50 / 75 60 / 75 70 / 75 70 / 75 80 / 75
36 15 / 50 10 / 65 20 / 75 20 /105 20 /140 50 / 75 60 / 75 70 / 75 80 / 75 80 / 75
Pipe>36”
and all
equipments 15 / 50 10 / 65 20 / 75 20 /105 20 /150 40 /125 70 / 75 80 / 75 80 / 75 90 / 75
Insulation thickness for piping and equipment shall be selected from above Table 3
and same shall be specified in equipment data sheet and piping isometric.
Thickness shown in Table 3, 10/40 means, combination of
• 10 mm Silica Aerogel
• 40 mm mineral wool
When operating temperature exceed 600°C, additional layer of ceramic fibre
blanket shall be provided on the hot face (Inner most layer) of piping or equipment
as per thickness mentioned below,

• Operating temperature between 601°C and 700°C - 13 mm

• Operating temperature between 701°C and 800°C - 38 mm
• DEC to calculate the temperature at outer most layer of ceramic fiber blanket
and shall specify the thickness of “HC” insulation as per Table 3 provided above.
5.4.1.1. Thickness Break up for Mineral wool insulation (Pipe section /Slab)
• Mineral wool insulation shall be applied in single layer for all piping and
equipments up to thickness 75mm.
• When mineral wool insulation thickness is more than 75 mm, required
thickness shall be build up in multiple layer as per Table 4.
Table 4: Thickness Break-up for multilayer mineral wool insulation
Sr no Total thickness of mineral wool material Thickness break up
1 80 40+40
2 90 40+50
3 100 50+50
4 105 40+65
5 115 40+75
6 125 50+75
7 140 65+75
8 150 75+75
9 165 40+50+75
10 175 50+50+75
11 180 40+65+75
12 190 40+75+75
13 200 50+75+75
5.4.1.2. Provision of foil at interface of Silica aerogel and Mineral wool material.
• Foil shall be provided at Silica aerogel and Mineral wool Interface as per table
below.
Sr No Operating Temperature Type of Foil
1 300°C to 400 °C 0.19 mm Aluminum foil
2 Above 400 °C 0.1 mm SS foil

• Securement of foils for piping & equipments,
Pipe diameter 8” & below 1 mm diameter wire (SS304) @200 CC

Pipe diameter above 8” and all 0.2 mm thick X 10 mm wide SS304
equipment bands @200 CC
• All insulation penetrations and terminations (valve bonnets, supports,
trunnion’s, instrument tubing, etc.), the foil shall be folded over the exposed
end of the Silica aerogel and compressed around the penetration to form a
tight fit cover.
• To improve air sealing at pipe supports, wrap foil over the Silica aerogel such
that the foil drapes onto the web of the support by 50mm.
5.4.2. Thickness of insulation for Personnel Protection (PG/PP)
5.4.2.1. Thickness of insulation for PP & PG for piping and equipment shall be as per Table
5.
Table 5- Thickness Table for Personnel Protection (PP)
Operating
Insulation Type Remarks
Temperature
Refer “Attachment No.9
& 11” for piping &
Perforated Guard 1.2 mm all along
equipment respectively
56°C to 200°C the line / equipment for
(refer clause 7.2.5 for
approachable area. (refer 7.2).
S=distance of Perforated
guard)
201 °C to 400 °C 65 mm thick mineral wool Slab or pipe section
401 °C to 600 °C 90 mm thick mineral wool Slab or pipe section
5.4.3. Thickness of insulation for Solar Protection (SP)

5.4.3.1. Thickness of insulation for solar protection shall be calculated by DEC. If not
specified, 40 mm mineral wool thickness shall be used.
5.4.4. Thickness of insulation for Impulse line
5.4.4.1. Impulse line shall be insulated sing fiber glass braided ceramic rope. Thickness &
layers of fiber glass braided ceramic rope shall be as per below Table 6.
Table 6- Thickness Table for impulse lines
Size of No. of insulation
impulse Operating Temperature. Thickness of each layer
Layer
line
½” Up to 150 °C 2 13 mm
¾” Up to 150 °C 2 19 mm
½” 151°C to 250 °C 2 19 mm
Size of No. of insulation

impulse Operating Temperature. Thickness of each layer
Layer
line
¾” 151°C to 250 °C 2 19 mm
5.4.4.2. For lines operating above 250 °C, thickness of insulation shall be calculated by DEC.
5.5. Acoustic Insulation Engineering Requirement
5.5.1. General requirement
5.5.1.1. The performance of Acoustic Insulation is defined as Class A, Class B or Class C.
Minimum insertion loss shall be as specified in ISO 15665 for the defined Class of
Acoustic Insulation, for piping equipment and tanks
5.5.1.2. Acoustic Insulation shall be provided to all piping operating with sound pressure
level greater than 85 dB (A) at 1.0-meter distance.
5.5.1.3. Class A provides the lowest level of acoustical benefit. Where a section of pipe is
designated with class A insulation, the associated flanges and valves need not be
insulated.
5.5.1.4. Class B &C insulation shall be applied in 2 x 50mm layers of mineral wool with
staggered joints. All flanges and valves shall be insulated to the same class as the
pipe except where insulation of such devices is not allowed for safety reasons (for
example in hydrogen service). Pipe supports when necessary shall be insulated
down to the concrete or steel base, or alternatively to the vibration isolator. (Refer
“Attachment No. 26”)
5.5.1.5. Process Licenser’s / Manufacturer’s requirements of Acoustic Insulation for
Equipment and /or piping shall be in accordance with the relevant specifications
furnished by them.
5.5.2. Acoustic Insulation Thickness Requirements
5.5.2.1. Wherever the Hot and Acoustic (AHA, AHB, AHC) Insulation is required for piping /
Equipments, silica aerogel + mineral wool insulation material shall be used.
5.5.2.2. Thickness of insulation system shall be as per Table 3 (Clause 5.4.1). The thickness
of Insulation shall be more stringent of the two requirements.
5.5.2.3. Wherever insulation is required for Acoustic reasons only the insulation material
shall be Mineral wool material and thickness of insulation shall be as per Table 7
(Insulation type AIA, AIB, AIC).
Table 7- Insulation requirements for acoustic insulation
Acoustic class Insulation thickness with only mineral
wool
AIA 50 mm
AIB 100 mm (50 mm + 50 mm)

AIC 100 mm (50 mm + 50 mm)
5.5.3. Cladding for Acoustic Insulation

5.5.3.1. The Table below shows the recommended thickness of the cladding materials.
Table 8- Cladding requirement based on acoustic insulation type
CLASS Min. mass of cladding. (kg/m²) Cladding Type & Thickness. (mm).
A 4.5 0.7 Aluzinc
B 6.0 0.8 Aluzinc
C 7.8. 1.2 Aluzinc
5.5.3.2. In case correct gauge of Aluzinc cladding is not available to achieve the required
mass as per Table 8, then the cladding may be composed of an outer layer of metal
for weather jacketing and an inner damping layer. The inner layer may be made of
PVC foil weighted with barium oxide to provide the additional mass or a high mass-
per-unit-area limp rubber or plastic sheet.
5.5.3.3. The total weight for the vinyl sheet and cladding shall comply with Table 8. The
material should be suitable for service between -29°C and 82°C and have the ability
to self-extinguish. Adhesive for laps shall be phenolic-based nitrile material,
compatible with the sheet and approved by the loaded vinyl manufacturer. The
loaded vinyl may be bonded to the insulation-facing side of the cladding.
6. Basic Properties of insulation material
Unless otherwise specified, materials shall be selected from those described in
Table 9. All materials shall comply with the relevant BS / ASTM or Indian standards.
Insulation materials can affect personal health. Guidance on the classification of
health and safety concerns associated with insulation materials and accessories is
defined in ASTM C930.
6.1.1. Properties of mineral wool material
Table 9- Insulation materials
Sr.
Properties Standard Acceptable values
no
1 Density
1.1 Mineral wool IS 8183 / IS-
144 kg/m³ ±10% Tolerance
mattress 3144
1.2 Mineral wool pipe IS 9842/ IS- 160 kg/m³ ±10% Tolerance
section 3144

Sr.
Properties Standard Acceptable values
no
1.3 IS 8183 / IS- 150 kg/m³ ±10% Tolerance
Mineral wool slab 3144
2 Dimensions
2.1 Length 1.5 meter +/-0.5%, width 0.6
Mineral wool meter +/-0.5%, Thickness -2/+5mm
mattress
2.2 Mineral wool pipe Length 1 meter (+/-0.5%), ID(+/-1.6mm),

section Thickness -2/+5 mm, OD(+/-1 mm)
2.3 Length 1-meter (+/-0.5%) X Width 0.6
Mineral wool slab (+/-0.5%), Thickness-2/+3mm
3 pH Content & IS 8183 / IS- 7 to 8

Chloride content 3144 14 mg/Kg Max
4 Fire resistance ASTM E 84 FSI<5, SDI<10
5 No flammable material attached to insulation
6 Insulation material shall be asbestos free
For approved supplier for Mineral wool material refer RPMS-ENGG-PRA-PP-040,

No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.2. Properties required for Silica Aerogel insulation material
6.1.2.1. Silica aerogel material shall confirmed to ASTM C1728 Type III, Grade 1, Category
A. The material going to be used shall be Pyrogel XTE from Aspen Aerogel. No other
equivalent material may be used without prior approval from Core Engineering.
Sr no Properties Standard Acceptable value

1 ASTM C
Density 176 kg/m3 (-0/+5% Tolerance)
1728
6.1.2.2. Higher version of Silica aerogel -Pyrogel HPS from Aspen Aerogel may be used for
high temperature lines operating above 350°C, however higher version of silica
aerogel may be used on stand-alone basis (i.e. without Mineral wool combination)
with Core Engineering approval.

6.1.3. Properties for Cellular Glass material

6.1.3.1. Cellular Glass material shall confirm to requirement of ASTMC 552 Grade 6, with
additional requirement as Table 10.
Table 10- Cellular glass insulation materials
1 Density ASTM C 303 115 kg/m³ ± 10% Tolerance
2 Water vapour ASTM E 96 0.00 ng/pa.s.m
permeance
3 FSI/SDI ASTM E 84 0/0
6.1.3.2. Gypsum Cement (Hydrocal B 11) shall be used as a bore coating. Thickness of
gypsum cement shall be ≥ 1.2 mm.
For approved supplier for Cellular glass & Ancillaries material refer RPMS-ENGG-
PRA-PP-040, No other equivalent material Shall be used without prior approval
from Core Engineering.
6.1.4. Properties for Aluminum Cladding material
• Insulation shall be protected from weather, oil spillage, mechanical wear or
other damage by Aluminum cladding with factory applied 75 microns thick
Polysurlyn moisture barrier heat laminated to inner surface of cladding.
Properties as Table 11.
Table 11- Aluminium cladding materials
1 Plain Aluminium ASTM C Thickness 0.9 mm/ 1.2mm, Aluminum
Cladding 1729 shall be 5005, 3105, 3103 or 1100 alloys
with H14 tempered in accordance with
ASTM B209 or 19000 H2 as IS 737.
2 Corrugated ASTM C Thickness 0.8 mm, Pitch of corrugation

Aluminium 1729 30 mm, Corrugation depth shall be 6 mm
Cladding
3 Polysurlyn ASTM C 75µm thick (over and above cladding
1729 thickness)
For approved supplier for Aluminum Cladding material refer RPMS-ENGG-PRA-PP-

040, No other equivalent material Shall be used without prior approval from Core
Engineering.

6.1.5. Properties of Aluminized steel cladding.

6.1.5.1. Aluminized Steel shall be type T2-100 as designated in ASTM A463 or approved
equal.
6.1.6. Properties of Aluzinc Cladding
6.1.6.1. Aluzinc cladding shall be as Table 12.
Table 12- Aluzinc cladding materials
Sr no Material Standard Requirement
1 0.7/0.8/1.2mm Properties shall be Material shall be CS
Aluzinc as per ASTM type B, with
A792/792M minimum coating
weight as per Table
2 of ASTM A792 and
coating grade
AZM210
For approved supplier for Aluzinc Cladding material refer RPMS-ENGG-PRA-PP-040,

No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.7. Ceramic Fiber Blanket properties.
6.1.7.1. Ceramic fiber blanket shall be used for Insulation where surface temperature is
above 600 °C. Ceramic fiber shall confirm to ASTM C 892 Grade III, Type 8. Materials
shall be as Table 13.
Table 13- Ceramic Fibre Blanket
Density 128kg/m³ ± 10%
Maximum Service Temperature 1260°C
Thermal Conductivity @ 800°C 0.15 W/m K
For approved supplier for Ceramic fiber blanket material refer RPMS-ENGG-PRA-
PP-040, No other equivalent material Shall be used without prior approval from
Core Engineering.
6.1.8. Ceramic Fiber rope properties
6.1.8.1. Ceramic fiber rope shall be used for impulse piping insulation purpose. Properties
shall be as Table 14

Table 14-Ceramic fibre rope

Density 250 kg/m³± 10% with fibre glass braiding
Maximum Service Temperature 500°C for Impulse lines
6.1.8.2. All other properties shall be as per ASTM C 892 Grade III, Type 8.
For approved supplier for Ceramic fiber rope material refer RPMS-ENGG-PRA-PP-
040, No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.9. Cladding for Fire Safe Services
6.1.9.1. For fire safe services the cladding shall be as specified by DEC/Process Licensors.
6.1.9.2. Generally, for Fire safe requirement Polysurlyn moisture barrier sheet is not
recommended as per standard practice.
6.1.10. Anti-Vibration Seal for Acoustic Insulation
The following materials are suitable for use in anti-vibration seals: -
1. Synthetic rubber.
2. Natural rubber.
3. Non-flammable felt.
4. Strip and Stick AR 300
5. Silica Aerogel material Strip
Where these materials are not compatible with the operating temperature, the seal
shall be made from suitable compressed porous-layer material.
6.1.11. Cladding Sealing Strip for Acoustic Insulation
6.1.11.1. All cladding joints shall be sealed with an elastomeric sealant. The material shall be
fiberglass reinforced sponge silicone tape such as “STRIP-N-STICK AR 300”
manufactured by Saint Gobain Performance Plastics or an approved equivalent.
Each strip shall be 13mm wide x 1.5mm thick minimum.
7. Application procedure
7.1. Surface Preparation prior to Insulation of tanks, equipment and piping.
7.1.1. All surface preparation, materials, and other work shall comply with all applicable
environmental and safety provisions, laws, regulations, ordinances, etc., of the
city, county, state, province, or nation pertaining to the work being performed
and the materials being used.

7.1.2. The surface to be insulated shall be cleaned free of oil, grease and all other
foreign matter and moisture prior to the application of any insulation. No
insulation shall be installed until completion of any stress-relieving, chemical
cleaning, coating application, pressure testing, tracer installation, and release of
the surfaces in writing by RMPG’s site representative.
7.1.3. Painting shall be as per RPMS-ENGG-SPC-PP-014 prior to the start of insulation.
7.1.4. Damaged painting, rusted surface shall be immediately reported to concern Buyer
representative for rectification.
7.1.5. Selection of foil over the hot surface (over pipe/Equipments) prior to insulation.
MOC Operating Temperature Foil Description
CS Above 400°C 0.19 mm Aluminum Foil
SS & Alloy Steel 201°C to 400°C 0.19 mm Aluminum Foil
SS & Alloy Steel Above 400°C 0.1 mm SS foil
• Securement of foils for Piping & equipments,
Pipe diameter 8” & below 1 mm diameter wire (SS304) @200 CC
Pipe diameter above 8” and all 0.2 mm thick X 10 mm wide SS304 bands @200
equipment CC
7.2. Application procedure for Personnel Protection (PP)/Standoff guard (PG)
7.2.1. Personnel Guards or “PG” insulation shall be applied for protection of O&M
personnel. Protection shall be provided for all exposed surfaces with operating
temperatures 56°C to 200℃ that are located.
▪ within 600 mm horizontally or 2000 mm vertically of normal access
areas
▪ around operating platforms, along the grade & walkway
7.2.2. Perforated guard shall be installed all along the pipeline / Equipment for all
normal accessible areas.
7.2.3. 5 mm thick Silica aerogel material strip shall be provided at each support location
for perforated guard beneath the support clip, to avoid galvanic corrosion. (Refer
Attachment No 9 & 11)
7.2.4. Flanges shall not be insulated. Perforated plate or expanded metal of 1.2 mm
thick shall be used for insulation of flanges. The perforated area shall be at least
35%, with a hole diameter max. 5mm in triangular pattern.
7.2.5. Distance between Hot surface and Perforated plate shall be as per Table 15.

Table 15- Distance between Hot surface and perforated guard

Nominal Pipe Diameter Distance between uninsulated flanges or equipment
(inches) and perforated plate (mm)
1” – 8” 50
10” – 16” 100
18”-24” 150
Equipment and piping > 24” DEC to calculate the distance of perforated plate to
maintain the temperature maximum 55 °C at the
surface of perforated plate .
7.2.6. Application procedure for “PP” type insulation is similar as mentioned in Section
7.3 for Piping and Section 7.5 for equipment. Thickness for mineral wool shall be
according to 5.4.2.1.
7.3. Application of Insulation to Piping in Hot Service (HC type insulation)
7.3.1. General Requirements
7.3.1.1. Wet, oil soaked, and damaged insulation shall not be used. Due Care shall be taken
that no flammable material is attached to the insulation material. All insulation and
necessary materials shall be protected from moisture during Storage & installation.
Suitable protection shall protect insulation in wet weather conditions until the final
application of the permanent cladding or weather barrier. Wet insulation is
unacceptable and must be replaced with dry materials. foil
7.3.1.2. Expanded perlite and cellular glass which has been exposed to the rain or other
moisture shall be dried to the Buyer's satisfaction. Mineral wool and calcium silicate
that becomes wet shall be removed from the site and not used.
7.3.1.3. All piping in hot service (HC) shall be insulated with Silica aerogel blanket as inner
wrap, with all longitudinal and circumferential joints butted tightly. Outer layer
shall be rigid slabs or preformed mineral wool half sections. (Refer “Attachment No.
15”)
7.3.1.4. Insulation adjacent to flanges in piping and equipment shall be terminated to allow
removal of bolts without damage to insulation. Bolt clearance from the flange to
the insulation cladding shall be at least the bolt length +25 mm. For certain flange
bolts, hydraulic bolt tension or torqueing equipment may be used which requires
greater bolt clearance. Mechanical/piping specifications should be consulted for
these clearances. (Refer “Attachment No. 7”).
7.3.1.5. Insulation contractor to prepare detailed sketch and submit for approvals from
buyer prior to application.
7.3.1.6. For supply of bolted type insulation support, insulation contractor shall prepare and
submit sketch showing the support details and obtain approval from Buyer prior to
the supply. The same shall be installed by Insulation Applicator. If welded types of
insulation supports are used, these shall be installed by the Piping contractor.

7.3.1.7. All pipe insulation shall be provided with an aluminum metal cladding with a factory
applied Polysurlyn Moisture barrier, unless otherwise specified.
7.3.1.8. For hydrocarbon & process lines, ends of pipe runs at flanges shall be sealed with
Hard Set Cements (BD6 or CAT 9 Cement or approved equivalent) to prevent the
product from entering in to the insulations in case of leakages. (“Refer Attachment
No. 7”)
7.3.1.9. For utility lines which are insulated except for valves and flanges, ends of pipe runs
at flanges shall be sealed as above. (Refer “Attachment No. 7”)
7.3.1.10. Small bore Insulated utility lines (Except Hydrocarbon /process lines less than 2”),
end of pipe runs shall be sealed as per “Attachment No 27 A”.
7.3.1.11. Insulation contractor shall be aware of the health and safety issues associated with
insulation materials and shall follow the guidance provided in ASTM C930.
7.3.2. Installation of silica aerogel and mineral wool
7.3.2.1. Inner wrap shall be Silica aerogel blanket over hot face. The outer layer over silica
aerogel shall be mineral wool pipe section up to 24” OD of insulation and above 24”
OD of insulation, mineral wool slab shall be used.
7.3.2.2. Silica aerogel insulation shall be applied by “cigarette wrapping” around the pipe,
as illustrated in “Attachment No.15”. Insulation shall be applied square to the
longitudinal axis of the pipe / equipment and pulled tight around the
circumference.
7.3.2.3. For pipe sizes <4”, 5 mm thick Silica aerogel material shall be used, while for pipe
sizes ≥4” both 5 mm and 10 mm thick Silica aerogel can be used.
7.3.2.4. Where ever combination of 5 mm and 10 mm thick silica aerogel is specified, 5 mm
thick layer shall be installed first.
7.3.2.5. Circumferential & longitudinal joints of silica aerogel shall be tightly butted with no
visible gaps. For multi-layer installations, circumferential and longitudinal joints
shall be staggered by a minimum of 75 mm (3”) with respect to previous layer.
7.3.2.6. The Mineral wool insulation over silica aerogel shall be snugly fitted, with all joints
tightly butted with no visible gaps. All circumferential and longitudinal joints shall
be staggered as per “Attachment No. 15”. Before Application of Mineral wool
applicability of foil shall be check as per clause 5.4.1.2.
7.3.2.7. The insulation shall be secured firmly with tie-wire or band as mentioned in this
specification. Twisted ends of the wire shall be bent flush with the surface of the
insulation. When bands are used, it shall be secured with conventional wing seals.
7.3.2.8. For bends up to 24” OD of insulation, miter segments for insulation shall be cut
from mineral wool pipe section. Above 24” OD of insulation, elbows shall be
insulated with Mineral wool mattresses as shown on “Attachment No. 14”.
7.3.3. Securement for basic insulation will be as follows

7.3.3.1. Silica aerogel layer shall be secured layer wise. Initial and subsequent layers of silica
aerogel shall be secured with 1 mm SS 304 wire at C/C 225 mm . Final silica aerogel
layer shall be secured with 0.6 X20 mm SS bands at C/C 225 mm C/C.
7.3.3.2. Securement method for mineral wool over silica aerogel.
OD of insulated surface Securement method for mineral wool
up to 900 mm. 0.6 mm x 20 mm aluminium bands at C/C 225 mm.
> 900 mm. 0.6 mm x 20 mm SS 304 bands at C/C 225 mm.
7.3.4. Application of Metal Cladding

7.3.4.1. The final weather cover for the insulation shall be 0.9 mm Aluminum cladding with
factory bonded Polysurlyn moisture barrier as specified for HC insulation.
7.3.4.2. Cladding shall be provided with minimum 75 mm overlap at the longitudinal seam
and circumferential seam, with double groove on both ends.
7.3.4.3. The cladding shall be applied to ensure a tight fit over the insulation and to prevent
any lifting of the lapping edge at the longitudinal seam. All longitudinal seams shall
be staggered on alternative sides (4 o’clock and 8 o’clock) of the pipe and laps shall
be located to give maximum protection from wind and rain. A bead of Metal Sealant
shall be sandwiched between overlap to prevent rain water penetration, bead
thickness shall be 3.2 mm.
7.3.4.4. Securement of cladding shall be by means of SS self-tapping pan head screws 12
mm long (No. 10) with maximum gap of 100 mm C/C at the longitudinal seam.
7.3.4.5. Screws are not required at the circumferential seam, except for vertical piping,
where a maximum of 4 screws per lap are required for line with OD of insulation up
to 200 mm. Beyond 200 mm OD of insulation screws shall be provided at 45 degrees
along the circumference at equal spacing around the pipe.
7.3.4.6. Any penetrations of the metal cladding by pipe supports, nipples etc., shall be
weatherproofed by a tight fit metal flashing, with minimum overlap 75 mm. Any
voids between the cladding and weatherproofed flashing shall be filled with Metal
Sealant to prevent the ingress of moisture, water and foreign contaminants.
7.3.4.7. The metal cladding at the elbow shall be of lobster back construction or two piece
formed covers secured at seams by SS self-tapped pan head screws 12 mm long
(No. 10). Screws shall be placed at maximum 75 mm C/C.
7.4. Insulation of Valves and Flanges
7.4.1. Application of insulation of valves and flanges for Steam and condensate lines
(HC)

7.4.1.1. Wherever insulation is specified in steam & condensate lines the insulation material
shall be silica aerogel + mineral wool mattress material.
7.4.1.2. Thickness of silica aerogel and mineral wool material shall be same as specified on
Piping as per Table 3.
7.4.1.3. The inner wrap shall be silica aerogel blanket over valves & flanges with 50 mm
overlap.
7.4.1.4. After application of Silica aerogel material, Mineral wool mattress application to be
completed as mentioned above with basic securement procedure as per clause
7.3.3. Application of foil shall be ensure as per Clause 5.4.1.2.
7.4.1.5. The insulation of valves and flanges where specified for steam and condensate
services shall be carried out by means of flexible, reusable, weather proofed covers
or insulation lined boxes in accordance with the valve and flange box details refer
“Attachment No. 8”.
7.4.2. Insulation of valves and flanges in Hydrocarbon / Process lines. (HC)
7.4.2.1. Process Licensors/DEC shall identify valves and flanges to be insulated for
hydrocarbon and process lines. The same shall be marked in LDT and Isometrics by
DECs.
7.4.2.2. For valve size ≥ 8” valve body shall be insulated with silica aerogel and mineral wool
mattress as per 7.4. Valve and bonnet flanges shall not be insulated, bolts shall be
left un insulated. (Refer “Attachment 19 Sheet 4 of 4”). Application of foil shall be
ensure as per Clause 5.4.1.2.
7.4.2.3. For valve size <8”, valve shall be insulated with removable pad type insulation as
per section 7.6. (Refer “Attachment 19 Sheet 3 of 4”)
7.4.2.4. Flanges of all sizes in hydrocarbon and process lines shall be insulated with
removable pad type insulation as per section 7.6.
7.4.3. Expansion Joints (HC)
7.4.3.1. Due to the difference in expansion coefficients of metals and insulating materials,
necessary allowance should be provided for differential movements between the
hot surface, the insulation material and the cladding. DEC to calculate the
differential expansion and provide the distance at which expansion joint shall be
provided.
7.4.3.2. If no guideline is provided by DEC, expansion joints shall be provided on insulated
lines operating at ≥400°C, at every 6 meters centers on horizontal lines and at each
insulation support ring on vertical lines/Equipments as per attachment No. 22.
7.4.3.3. Expansion joints shall be formed by 25 mm space between pipe insulation sections,
this space shall be filled with loose mineral rock fibers. Expansion joints in each
layer shall be offset at least 150 mm from each other in case of multilayer
insulation.

7.4.4. Traced Piping (HC)

7.4.4.1. The inner wrap shall be silica aerogel blanket over traced pipe (electric traced or
steam traced) and outer layer shall be mineral wool.
7.4.4.2. Insulation of steam traced lines shall be in accordance with the requirements for
untraced piping as per section 7.3 with the following exceptions:
7.4.4.3. Where the insulation can be carried out with preformed half sections, they shall be
of sufficient bore size (One size Higher Pipe section shall be specified by DEC to
accommodate the tracers). (Refer “Attachment No.12”). The pipe and tracer shall
be wrapped in 0.19 mm thick Aluminum foil and heat transfer cement shall be
applied at contact point of tracer and core pipe.
7.4.4.4. If the mineral wool pipe section is of equal or smaller diameter as compared to the
required size of pipe section, then the gap formed between the two halves of pipe
sections shall be filled up with makeup piece as shown in “Attachment No. 12”.
7.4.4.5. Weather protection with metal cladding shall be as per clause no 7.3.4.
7.4.5. Impulse Lines
7.4.5.1. Wrap the impulse lines tightly with Ceramic rope braided with fiberglass threads of
250 kg/m³ density. A 3 mm thick coating of mastic (Foster 60-38 or approved
Equivalent) shall be applied to ceramic fiber rope insulation. While this coat is still
wet, glass cloth shall be laid over the surface and embedded in the mastic. Care
shall be taken to ensure that the 10X10 glass cloth is laid smooth and free from
wrinkles and that no air pockets are trapped beneath the surface. At junctions in
the glass cloth, the overlap shall not be less than 75 mm. A second layer of 3 mm
thick mastic coat shall be applied after approximately 12 hours. When dry, this
coating shall be a minimum of 6 mm thick. Apply a coat of aluminum paint (Type 3
refer RPMS-ENGG-SPC-PP-014) of DFT 25 microns over the mastic, after it has dried
completely. A suitable sealant (BD 6 / CAT 9 / Equivalent) shall be applied to stop
the water ingress at the termination points of insulation.
7.4.5.2. Impulse line insulation details shall be as Table 16
Table 16:Table Details of insulation thickness for impulse Line
Size of impulse Operating No. of insulation Thickness of each

line(Ø) Temperature. Layer layer
½” 150 °C 2 13 mm
¾” 150 °C 2 19 mm
½” 250 °C 2 19 mm
¾” 250 °C 2 19 mm
7.4.5.3. Beyond 250 °C operating temperature, impulse lines insulation thickness shall be
specified by DEC, considering touch temperature requirement as per this standard
specification.

7.5. Application of Insulation to Equipment / Vessels (HC)

7.5.1. General Requirements (HC type insulation)
7.5.1.1. Wet and damaged insulation shall not be used.
7.5.1.2. All equipments and vessel in hot service (HC) shall be insulated with Silica aerogel
blanket as inner wrap, with all longitudinal and circumferential joints butted tightly.
Outer layer shall be mineral wool rigid slabs for shell and mineral wool mattress for
dished ends.
7.5.1.3. Supplier to prepare detailed procedure along with sketches and submit for
approvals from Buyer, prior to application.
7.5.1.4. Protected heads of vessels within a skirt shall be insulated with LRB Mattresses and
shall be weatherproofed with hard setting cement (BD6/CAT9), & with
reinforcement of wire mesh.
7.5.1.5. All horizontal equipments & exchangers etc. irrespective of dimensions, shall be
weatherproofed with 0.9 mm flat Aluminum cladding.
7.5.1.6. All vertical equipments, of diameter ≤ 900 mm, shall be cladded with 0.9 mm flat
Aluminum cladding .
7.5.1.7. All vertical equipments > 900 mm in diameter shall be cladded with 0.8mm
corrugated Aluminum cladding . Conical /Tapered portion of vertical vessel shall be
cladded with 0.9 mm flat Aluminum cladding .
7.5.1.8. Insulation supports for equipment shall be as per “Attachment No. 23 & 24”. The
parts of the insulation support to be welded on the equipment shall be welded by
equipment supplier.
7.5.1.9. Where “standoff guards” or shields are used for personnel protection insulation
they shall be fabricated from perforated aluminized plates or aluminum plate,
1.2mm thick. The perforated area shall be at least 35%, with a hole diameter max.
5mm in triangular pattern.
7.5.2. Application of Insulation & cladding to all Horizontal Vessels (All sizes) & Vertical
Vessels (up to 900 mm Diameter)
7.5.2.1. Inner wrap shall be silica aerogel blanket & outer layers shall be of mineral wool
rigid slabs. Thickness of insulation system shall be as per operating temperature of
the equipment.
7.5.2.2. Application procedure for applying insulation on part of equipment between vessel
tangent line shall be same as that of piping (Section 7.3.2).
7.5.2.3. The insulation material securement of silica aerogel & mineral wool shall be with
SS 304 bands 0.6 mm x 20 mm at 300 mm C/C.
7.5.2.4. Stainless steel “Childers” type flat expansion springs shall be provided at every
3mtr C/C.
1. Up to 1800 mm dia. – No spring required

2. >1800 mm to 6000 mm dia. – 2” long expansion springs.

3. > 6000 mm dia. – 4” long expansion springs.
7.5.2.5. Heads of vessels shall be insulated with silica aerogel & mineral wool wired
mattress, cut to conform to the contours of the vessel’s heads. (Refer “Attachment
17”)
7.5.2.6. The segments shall be snugly fitted by stitching with S.S. wires.
7.5.2.7. Securement for the head insulation shall be with 0.6 mm x 20 mm stainless steel
bands fastened to the tangent line support ring at maximum 300 mm C/C and
secured at the support ring at the center of the head. The bands shall be passed
across the head and secured at the opposite point of the tangent line support ring.
7.5.2.8. Metal cladding application requirements between tangent lines on horizontal
vessels for all diameter and on vertical vessels up to 900 mm diameter shall be the
same as for straight pipe (Clause 7.3.4) with the additional requirement of one 0.6
mm x 20 mm S.S. band at each circumferential seam.
7.5.2.9. Horizontal vessels exceeding 1800mm in diameter shall have the tangent to
tangent cladding secured by 0.6mm x 20mm stainless steel bands fitted with
breather springs which shall be tensioned to allow a maximum compression of 1-
1/2” for each 6000mm of the insulation circumference. The bands shall be placed
on maximum 450mm centers. Screws shall not be used. Bands shall be secured with
conventional closed seals.
7.5.2.10. All laps shall be of minimum 75mm; longitudinal laps shall be staggered to give the
maximum spacing between laps while still providing protection from wind and rain.
7.5.2.11. Paragraph 7.3.4 shall apply to all Vessel weatherproofing of cladding penetrations
& for the sealing of all overlaps.
7.5.2.12. Exposed heads of vessel shall be clad with petal construction segmental cladding,
which shall be overlapped to prevent moisture& water penetration. Self-tapping
screws shall be used for fastening cladding. (Refer “Attachment 17”)
7.5.2.13. Heads of vertical vessels contained within a skirt shall be weatherproofed as
follows:
• After application of insulation hairpins made up of 20 SWG. SS. tie wire shall
be attached to the banding.
• This shall be followed by a 3 mm thick skim coat of hydraulic cement armouring
compound with the hairpins being allowed to protrude.
• A layer of 20 SWG. X 25mm mesh SS wire netting shall then be applied over the
entire head and secured to the insulation support ring and to the insulation
support wires by means of the 20 SWG SS hairpins. All butting edges of the
mesh shall be laced using 20 SWG SS tie wire to form a tight cover.
• A final layer with 9 mm WFT hydraulic cement shall be applied and shall be
trowelled smooth and true.
7.5.3. Application of Insulation to Columns and Vertical Vessels > 900 mm Dia.
• For surface preparation refer clause 7.1.
7.5.3.1. The insulation shall be mineral wool beveled slabs applied over an inner wrap of
silica aerogel blanket. Applicability of foil at interface of Silica Aerogel and Mineral
wool Shall be according to Clause 5.4.1.2.
7.5.3.2. The slabs shall be snugly fitted with all joints firmly butted and circumferential
joints staggered.
7.5.3.3. Securement shall be provided by 0.6 x 20 mm SS bands at 300 mm C/C.
7.5.3.4. Exposed heads of vessels shall be insulated with mineral wool blanket faced with
expanded metal cut and shaped to conform to the contours of the head. All butting
edges of the expanded metal shall be tightly laced with 20 SWG SS wire. (Refer
“Attachment 16”)
7.5.3.5. The metal cladding to protect the shell insulation shall be of 0.8 mm corrugated
Aluminum cladding . Overlap at the longitudinal seam shall be one corrugation;
overlap at the circumferential seam shall be 75 mm. (Refer “Attachment 16”)
7.5.3.6. The sheets shall be supported at the circumferential lap by 0.6 mm x 25 mm S.S. ‘S’
clips spaced at 2 per sheet, to allow for vertical expansion. Screws are not required
on circumferential seams. (Refer “Attachment No. 10 Sheet 1& 2”).
7.5.3.7. The cladding shall be secured by 0.6 mm x 25 mm S.S. bands. On vessels exceeding
1800mm diameter the bands shall be fitted with compression springs to allow for
circumferential tensioning of cladding . The bands shall be spaced on maximum 450
mm centers. All bands will be supported on joggle clips at 1800mm centers. Bands
shall be secured with conventional wing seals.
7.5.3.8. Stainless steel “Childers” type flat expansion springs at 3mtr. C/C shall be provided
as mentioned below for securement of insulation.
1. <1800 mm dia. – No springs required
3. Above to 6000 mm dia. – 4” long expansion springs.
7.5.3.9. Vertical seams shall be secured by self-tapping pan head SS screws 12 mm long
(No.10) at 100 mm C/C. All screws on corrugated sheets shall be located at the
crown of the corrugation. Care shall be taken not to locate screws at any place
where they may pierce the circumferential lap.
7.5.3.10. Exposed heads of vessel shall be clad with petal construction segmental cladding,
which shall be overlapped to prevent moisture & water penetration. Self-tapping
screws shall be used for fastening cladding. Overlaps shall be sealed as noted in
clause 7.3.4.
7.5.3.11. Protected heads within a skirt shall be insulated in accordance with paragraphs
7.5.2.13.

7.5.3.12. For vessels operating at a temperature over 400°C, air space shall be provided at
the junction of the skirt to vessel head, where the following criteria are satisfied.
7.5.3.13. Distance of Air Space “Z” Shall ne as per Table 17.

Table 17:Air space distance for vessel shell to skirt connection
Vessel Diameter (mm) Z (mm)
Up to 1800 150
1801 to 3000 200
3001 to 4250 250
4251 & above 300
NOTE:
“Z”- Air space shall under no circumstances be less than Z = Rt.
7.5.3.14. Paragraphs 7.3.4 shall be applied to for weather proofing of all penetration from
cladding.
7.5.4. Man way, Exchanger Shell Cover and Flange Boxes
7.5.4.1. The Insulation system and thickness shall be as that of equipment, with exception
that outer layer over silica aerogel insulation with mineral wool mattress in place
of MW slab.
7.5.4.2. Vessel Manways and their associated flanges, exchanger shell covers shall be
fabricated from minimum 0.9mm thick flat Aluminum cladding with factory bonded
polysurlyn moisture barrier and shall be made in sections (removable) of suitable
size to permit inspection.
7.5.4.3. All box construction seams shall be lock-formed, and individual erection joints shall
be located and arranged to give maximum protection from wind and rain.
7.5.4.4. The boxes shall be positioned on the vessel in conjunction with the vessel cladding
to prevent any ingress of moisture at the location of the box/cladding joint.

7.6. Insulation of Irregular surfaces (Pad Type insulation)

7.6.1. General requirement for Equipment
7.6.1.1. Wherever pumps, turbines and other similar irregular shaped equipment are
required to be insulated, use weatherproof flexible, easily removable, insulated
“tea cozy” type cover made up of silicon impregnated fiber glass cloth and high
silica a cloth.
7.6.1.2. Insulation shall not be applied on pumps handling Hydrocarbon products.
7.6.1.3. Thickness of insulation shall be designed by DEC or Process licensors for all
equipments.
7.6.1.4. The manufacturer shall field measure the irregular surface to ensure that the
fabricated cover conforms to the configuration being insulated, including all
openings and protrusions, etc.
7.6.1.5. Supplier to prepare and submit the pad insulation procedure with all the details to
core engineering for review and approval before proceeding with the job.
7.6.1.6. No force folding or bending of the cover will be acceptable, and no “one size fits
all” cover design will be allowed.
7.6.1.7. The tailor-made cover will be pre-fabricated with a minimum number of joint to
minimize ingress of water.
7.6.1.8. Supplier shall use Buyer approved product for these types of insulation.
7.6.2. Procedure of pad fabrication for equipments
7.6.2.1. At upward facing terminal points the design shall allow for S.S. bands to be passed
through “belt type loops” to positively secure the cover to the assembly. (Refer
“Attachment 19 Sheet 1 & 2”)
7.6.2.2. At horizontal and downward facing penetrations, drawstrings shall be inserted in a
double stitched “tunnel” to effect positive securement.
7.6.2.3. All cover outer jacketing fabric seams shall be machine stitched. No gaps or holidays
will be allowed in any seam. All cover fabric seams shall be turned in or under and
stitched to prevent any raw edges from being exposed on any surface. No pinched
seams shall be allowed.
7.6.2.4. Cover parting faces, terminal ends or splits in covers shall utilize flaps closed off
with Velcro to seal against entrance by wind or water.
7.6.2.5. The cover shall have a waterproof fabric tag (3" x 2") sewn on its outer surface. The
tag shall identify the equipment name and its identification number.
7.6.2.6. The hot and cold face encapsulating cover material shall be silicon impregnated
fiberglass cloth for operating temperature up to 200°C.
7.6.2.7. For operating temperature above 200°C, the inner cover in contact with hot face
shall be high silica cloth and outer cover shall be made up of silicon impregnated
fiber glass cloth.
7.6.3. Procedure of pad fabrication for Valves size up to 6” and Flanges in Hydrocarbon
/Process lines
7.6.3.1. Inner cloth in contact with hot surface shall be High temperature silica cloth.
7.6.3.2. Outer cloth for weather protection shall be Silicon impregnated fiber glass cloth.
7.6.3.3. Thickness of ceramic wool/Silica aerogel shall be as per parent line insulation
thickness. Ceramic wool to be filled in bag prepared with above mentioned two
cloths’ and stitched properly with High temperature fiber glass thread to protect
ceramic wool. Density of loose ceramic wool shall be 128kg/m3.
7.6.3.4. Pad shall be fabricated in two parts with Box type construction and finally covered
with one more layer of Silicon impregnated fiber glass cloth to make it water tight.
7.6.3.5. All the mating surfaces with Pad shall be sealed with High temperature silicon
sealant up to 200°C to avoid any water ingress. Above 200°C no sealant shall be
applied.
7.6.3.6. These pads shall be fixed over valve body with fiber glass bands or any other
suitable removable type attachment. SS band shall not be used for fixation of pad
insulation.
7.6.3.7. Separate set of pads shall be prepared for insulating flanges in such a manner that
the bolts are not covered in insulation.
7.7. Application of Insulation for Tanks (HC, SP)
7.7.1. General requirement
7.7.1.1. Before application of insulation, bottom 400 mm of the external surface of tank
shell shall be painted as per RPMS-ENGG-SPC-PP-014.
7.7.1.2. Bottom 400 mm height from tank base plate shall be insulated with cellular glass.
Thickness of cellular glass material shall be calculated by DEC or Process Licensors
to maintain heat loss equivalent to silica aerogel +mineral wool combination.
7.7.1.3. The tank roofs will be insulated with cellular glass in two-layer construction. The
first layer thickness shall be such that the interface temperature does not exceed
80°C.Thicknes shall be provided by DEC.
7.7.1.4. Material used for insulation work shall be from the approved vendor Insulation
Material Supplier.
7.7.1.5. Thickness of insulation shall be as per thickness table provided in this specification
for heat conservation. The thickness of insulation shall be detailed in Project Tanks
Schedule.
7.7.1.6. Wet insulation shall not be used in any case. Installed Insulation materials over
tanks shall be protected from rain and any contaminants by suitable covering till
permanent cladding is provided.

7.7.1.7. Insulation Contractors are invited to propose either proprietary system such as
“Kitsons Kalzip”, Tyco – “Trac-Loc”, or Conventional Systems, such as detailed
herein. Regardless of system, the insulation contractor shall submit a full design
and detailed drawings for review and approval prior to application. Application of
Insulation with Tyco – “Trac Loc” system do not require any supports on the Tank
shell. Whereas for conventional application, support arrangements to the shell to
be provided (as shown in “Attachment No. 2 and 3”) by Tank Manufacturing
Contractor prior to release the tank for Insulation work.
7.7.1.8. Due regard shall be paid to the effects of wind loading. Calculations for strength of
banding and cladding shall be in accordance with BSI CP3 Chapter V, Part 2.
7.7.1.9. Roof insulation is not designed to support pedestrians. Access to all fittings shall be
via designated walkways only.
7.7.1.10. The insulation contractor shall keep his working locations in a tidy condition.
7.7.2. Surface preparation
• Refer clause number 7.1 for surface preparation.
• Any non-conformities found in painting application shall be reported by
insulation contractor to concern Buyer representative prior to start insulation
work.
7.7.3. Application of insulation over shell portion of tank
7.7.3.1. Inner wrap shall be of Silica aerogel blanket with 50 mm overlap for longitudinal
joints and outer layers shall be of mineral wool slabs.
7.7.3.2. Bottom 400 mm height from tank base plate shall be insulated with cellular glass in
two layers.
7.7.3.3. Insulation material shall be secured over the shell with 0.6 mm x 40 mm SS 304
bands. The bands shall be installed in such a way, that there is a minimum of 2
bands per slab, positioned 150 mm from each slab joint. (Refer attachment No.1).
7.7.3.4. Maximum band length shall be 15 meters. Stainless steel “Childers” type flat
expansion springs at 3mtr. C/C shall be provided on each 15-meter length of band
as mentioned below.
2. Above 6000 mm dia. – 4” long expansion springs.
7.7.3.5. This is to ensure equal tensioning and expansion over the entire tank. Ends of the
bands shall be anchored with 12 mm Ø vertical rod. (Refer “Attachment No.2”).
7.7.3.6. The cladding shall be secured to the vessel by means of 1.2 mm x 50 mm SS 304
bands, with minimum of 4 number of bands per 2-meter sheet. The top outer band
of each lift shall coincide with the horizontal sheet lap.

7.7.3.7. The bands will be supported by joggle clips riveted to the cladding. Material and
width of the clips shall be same as that of bands. Distance between two adjacent
clips shall be 1.8 meters.
7.7.3.8. The thermal movements of the tank will be transmitted through the bands to
suitable breather spring units (Mity spring).
7.7.3.9. The maximum circumferential pitch of the breather springs (Compression Spring)
will be 4.5 meters for cladding securement.
7.7.3.10. Horizontal end laps shall be arranged weather-wise and each sheet shall overlap
the lower sheet by 75 mm. Each lift will be supported by minimum three numbers
0.6 mm x 20 mm SS ‘S’ clips to allow vertical expansion. Screws are not required on
circumferential seams. (Refer “Attachment No.10”).
7.7.3.11. The vertical overlap per sheet shall be one corrugation, and each joint shall be
sealed with approved adhesive/sealer and secured with self-tapping screws or
rivets at 100 mm pitch.
Note: Each “lift” of cladding shall be independent of the one above and one below.
7.7.3.12. Each lift of cladding shall span a maximum circumferential distance of 15 meters.
At the junction of each span the cladding will be secured to the vertical support
anchor plates by “Cromp Arc” studs and nuts (supplied and fitted by the Insulation
Contractor) (Refer “Attachment No.3 and 4”).
7.7.3.13. A molded profile filler strip shall be used to seal the roof to shell junction.
7.7.3.14. All projections shall be cut around locally with close fit to protrusion, maximum gap
around protrusion shall be 3mm, all protrusion shall be neatly finished with flashing
overlapping 75 mm minimum to adjacent surface and sealed with metal sealant to
avoid any moisture or water ingress (Refer “Attachment No.6”).
7.7.4. Roof
7.7.4.1. The tank roofs will be insulated with cellular glass in two-layer construction.
7.7.4.2. If any undulation observed over tank roof, the same shall be filled with Hydrocal
B11 and Cellular glass dust to make the surface smooth.
7.7.4.3. The first layer shall be laid on to the dry and smooth roof plates. The second layer
shall be bonded to the first with PC 88 adhesive. All joints and edges in the second
layer shall be staggered relative to the first and shall be fully sealed with adhesive.
7.7.4.4. At the junction of roof to shell, loose mineral wool shall be used to tightly packed
the space between kerb plate and Cellular glass.
7.7.4.5. The whole system will be secured by means of 0.6 mm x 20 mm SS 304 bands tied
to a floating ring at the center of the tank and an outer ring at the kerb junction.
The bands shall be pitched at 300 mm C/C.

7.7.4.6. The insulation shall be finished with two coats of PC 404 acrylic coating reinforced
with PC 79 polyester cloth, applied in accordance with Pittsburgh Corning’s data
sheets (Refer “Attachment No.5”).
7.8. Application for Solar protection insulation (SP)
7.8.1. Wherever solar protection type insulation is required for Piping or equipments,
insulation material shall be mineral wool pipe section or slab material only.
7.8.2. Thickness of insulation material shall be calculated by DEC.
7.8.3. If no details are available 40 mm insulation thickness shall be considered for solar
protection insulation.
7.8.4. Application procedure is similar as mentioned in Section 7.3 for Piping and Section
7.5 for equipment.
7.9. Inspection Windows / Pockets
A. Piping
Plug type inspection windows of ellipsoidal shape shall be provided on all of the
insulated pipelines having diameter 2” and above. One inspection window shall be
provided at a distance of every 20 meters of straight length of pipe. It should be
provided at the bottom i.e. at 4-6-8 clock position whichever is convenient. There
must be at least one inspection window between two bends which are minimum
10 meters apart. At least alternate bends shall be provided with inspection
windows. The size of the inspection windows shall be as Table 18.
Table 18: Inspection window details for Pipelines
Pipe diameter 2” 35mm x 120mm
Pipe diameter 6” 100mm x120mm
Pipe diameter 8” 100mm x120mm
Pipe diameter >8” 120mm x120mm
B. Exchangers
All the heads shall be provided with four (4) inspection windows one in each
quadrant. Minimum four (4) inspection windows shall be provided on the shell side.
(Refer “Attachment No. 21” for Inspection window details).
C. Columns & Vessels
Heads shall be provided with four (4) inspection windows one in each quadrant.
Four (4) inspection windows shall be provided at 1.5m above every platform.
Minimum two inspection windows shall be provided on shell portion on either side

of the ladder wherever platforms are not available. (Refer “Attachment No. 21” for
Inspection window details).
D. Tanks
One inspection window shall be provided at each course of the tank and at the top.
(Refer “Attachment No. 21” for Inspection window details).
7.10. Application procedure of Acoustic Insulation
7.10.1. Surface preparation shall be as per Clause no 7.1 for Piping and equipment in
conjunction with RPMS-ENGG-SPC-PP-014.
7.10.2. Any non-conformities found in painting, insulation contractor to consult concern
Buyer representative.
7.10.3. Wherever insulation for only acoustic reason is specified (AIA/AIB/AIC) shall be
provided with only mineral wool material, basic application procedure for
insulation shall be same as per clause 7.3.
7.10.4. Insulation for AHA/AHB/AHC shall be provided with silica aerogel and mineral
wool material, basic application procedure for insulation shall be same as per
clause 7.3.
7.10.5. Voids and cracks in mineral wool insulation, which are larger than 2.3 mm, shall
be corrected by re-fitting the insulation unless filling with loose mineral wool has
been accepted in writing by Buyer.
7.10.6. In case correct gauge of cladding is not available to achieve the required mass for
particular acoustic class then alternatively Loaded vinyl sheet shall be applied
between the insulation and metal cladding. Circumferential and longitudinal
joints shall be overlapped a minimum of 50 mm. The loaded vinyl sheet shall be
cemented on both surfaces of the area overlapped.
7.10.7. All longitudinal seams shall be staggered on alternative sides (4 o’clock and 8
o’clock) of the pipe and laps shall be located to give maximum protection from
wind and rain. (Attachment no 15).
7.10.8. On vertical pipe insulation, metal cladding shall overlap 50 mm for circumferential
seams and 75 mm for longitudinal seams. Cladding shall be supported from
insulation support rings or from cladding below using 3 or more stainless steel "S"
clips. Circumferential joints shall be lapped to shed water. The longitudinal seam
shall be located on the leeward side from the prevailing storm wind direction if
possible. In any case, the joints shall be located so they are easily accessible for
caulking.
7.10.9. Cladding shall be held in place using banding placed on the circumferential
overlaps and by screws on 75mm centers along the longitudinal over-laps.
Longitudinal seams of vertical pipe cladding shall be caulked with Fiberglass
reinforced sponge silicone tape as clause 7.11.2.2.

7.10.10. Fiberglass reinforced sponge silicone tape as clause 7.11.2.2. shall be used to
caulk around all protrusions through the cladding. Protrusions with metal
temperatures above 360°C must rely on flashing to keep water out. Other
cladding to cladding seams not waterproof by virtue of their design shall be
caulked with silicone rubber sealant.
7.10.11. Expansion springs shall be fitted to bands that secure cladding on piping larger
than 710 mm. Bands shall not be located adjacent to cladding laps. Springs shall
be extended 1.3 times their original length when tensioned.
7.10.12. Joints in preformed Aluzinc covers shall be fastened with screws on 100 mm
maximum centers. Joints shall include an overlap of at least 50 mm. Bands shall
secure each end of the cover to the pipe cladding.
7.10.13. The acoustic insulation cladding shall not be in direct or indirect metal to metal
contact with the pipe or equipment surface. Any such contact will allow a
transmission of vibrations to the cladding which will reduce or nullify the noise
reduction by the insulation. It may even enhance the noise radiation because of
the greater surface area of the cladding. It is also important that there should be
no gaps in the insulation. Joints in the porous layer shall therefore be staggered at
least 200mm and the cladding shall overlap at all joint (Refer “Attachment No.27
&29”).
7.10.14. The length of pipe to be insulated and the class of insulation shall be as specified
by the Noise Control Engineer / Consultant/ Manufacturer responsible for the
acoustic design. The requirements shall be identified on the P&ID’s, LDT’s and
Isometric drawings. With vertical pipes, any supports which carry the weight of
the cladding shall contain resilient elements to reduce the transmission of
vibrations from the pipe. (Refer “Attachment No. 28”). Where necessary, these
resilient elements should contain mechanical stops to limit excess movement.
Resilient elements shall not be loaded to such an extent that their operational
range of deflection is exceeded.
7.10.15. Insulation of pipe supports; flanges and valves shall be in accordance with the
requirements of the noted class. (Ref. section 5.5.3). Otherwise, the specified
length of pipe or equipment shall be insulated to cover the whole of the noise
radiating area without gaps or voids.
7.10.16. At locations where metal to metal contact would normally occur, anti-vibration
seals shall be applied (Refer “Attachment No. 29, 30 and 31”). They shall have a
minimum thickness of 3mm and a minimum width of 50mm.
7.10.17. At all exposed flanges the acoustic insulation shall be terminated with an end cap.
(Refer “Attachment No. 27 & 29”). This shall be located as close to the flange as
possible and shall not interfere with the requirements for bolt removal. The end
cap shall be isolated from the pipe by means of an anti-vibration seal.

7.10.18. When the noise radiated from a valve has to be reduced, the equipment shall be
surrounded by an acoustic enclosure. Flanges may be surrounded by an acoustic
enclosure or by removable insulation. Acoustic enclosures shall be easily
demountable to provide access to the flange or valve. Joints shall be sealed to
prevent noise leakage (Refer “Attachment No. 25”). If it is required that a flange
should be ventilated for safety reasons, a special construction such as that shown
in “Attachment No. 25" sht. 2 of 2 shall be used. Demountable parts of acoustic
enclosures heavier than 25kg shall have lifting lugs.
7.10.19. The acoustic enclosure shall have an outer surface of metal sheet with a mass per
unit area at least equal to that of the cladding.
7.10.20. The porous layer shall be similar in material to that used on the piping cladding
and shall be retained by an inner surface layer with an open area of about 30 %,
For example, perforated metal sheet. The inner surface layer shall be at least
10mm away from the flange or valve.
7.10.21. Where acoustic enclosures are installed around flanged joints, they shall be of
sufficient length to overlap the end caps on the pipe cladding by at least 100mm
for class B and 200mm for class C.
7.10.22. Cladding shall be continuously bonded and earthed to prevent electrostatic
charging. Where the earth connection is made via pipe it shall be made with
braided wire and not rigid bar.
7.10.23. Special provisions shall be made to protect the acoustic insulation at locations
where it could be susceptible to mechanical damages. For example, separate
supported steps should be provided where insulation may be stepped on. Where
mechanical load cannot be avoided, the cladding should be reinforced by using
stiffer plate and additional distance rings.
7.11. Ancillaries
• There are several ancillary materials, which shall be used to ensure that the
insulation system forms an effective seal to prevent ingress of fluids, or for
other special applications. Approved Ancillaries are listed in Table 19.

Table 19: Ancillaries Items for insulation
Adhesive - PC 88 / Pitt seal 444N or Pittsburgh Corning or approved equivalent

approved equivalent
Sealer Coat - PC 404 or approved Pittsburgh Corning or equivalent
equivalent
Anti-vibration seal- Silica aerogel /Strip Aspen Aerogel /Saint Gobain /Mahavir Corporation
and stick AR 300/MC SRF 400 or approved equivalent
Adhesive sealer strip for cladding in Saint Gobain /Mahavir Corporation or approved
acoustic insulation - Strip and stick AR equivalent
300/ MCSRF 400
Expansion / Compression springs Stainless Steel “Childers” type flat expansion/
compression springs to suit banding width.
Reinforcing cloth PC 79 Owens Corning or equivalent
High Silica cloth Ch-84 AVX Corporation/Urja Industries /Harsh deep
industries/Mahavir Corporation or approved
equivalent
Silicon impregnated cloth Alpha Maritex / Urja Industries /Harsh deep
industries/Mahavir Corporation or approved
equivalent
Profile filler strip B.S.R. Type. Grade S.E. (Internal and External) to suit cladding profile
Metal sealant 95-44/TIC 7030/ Loid Seal Fosters / TIC/ Capricorn Coating and Colours or
94A Approved equivalent.
Hard Set cement - BD6/CAT9 Limpet/ Newkem or approved equivalent
7.11.1. Hard Set Cements, (BD6 or CAT 9 Cement or Approved Equivalent).
7.11.1.1. An asbestos free composition consisting of Approved Portland Cement reinforced
with long, graded, glass silk fibers.
7.11.1.2. It provides a low cost protective coating with a hydraulic set and gives a high degree
of mechanical protection. It should be used for sealing ends of pipe runs at flanges
in hydrocarbon service even where the flanges are being insulated. It can also be
used over mattresses on heat exchanger end covers, pumps etc.
7.11.2. Sheeting Sealants.
7.11.2.1. For sealing joints in metal sheeting, mastic sealants such as Foster Elastomeric 95-
44, TIC 7030, Loidseal 94A or approved equivalent shall be used.
7.11.2.2. Fiberglass reinforced sponge silicone tape 13mm wide x 1.5mm thick minimum
manufactured by from Saint Gobain/Mahavir Corporation or approved equivalent.

7.11.3. Silicon impregnated fiber glass cloth and High silica cloth.
7.11.3.1. This material shall be particularly used for Pad type removable insulation.
Minimum properties requirements for Silicon impregnated glass cloth

Sr no Properties Acceptable value
1 Maximum temperature resistance 210 °C
2 Water vapor permeance 0.00perms
3 Fire resistivity criteria FSI/SDI<25
Minimum properties required for High silica cloth

Sr no Properties Acceptable value
1 Maximum temperature resistance 750 °C
2 Fire resistivity criteria FSI/SDI<25
7.12. Fastening Materials
Fastening material.
Wire 1 mm and 1.6 mm austenitic stainless steel, Type 304.

SS 304 wire shall be soft annealed as per ASTM A 580 /
A 580M.
Banding (over Insulation 0.2 mm x 10 mm stainless steel bands, type SS 304.(for
materials) Securement of foil only )
0.6 mm x 20 mm stainless steel bands, type SS 304.
0.6 mm x 25 mm S.S. bands, type SS 304.
0.6 mm x 40 mm S.S. bands, type SS 304
Banding (over cladding) 0.6 mm x 20 mm,0.6 mm x 25 mm &

1.2 mm x 50 mm S.S. bands type SS 304 as applicable.
Sheet metal screws shall be No. 10 x 12 mm 18-8 SS

self-tapping screws with elastomeric gaskets. Self-
tapping screws for covers and boxes shall be No. 14 x
Self-Tapping Screws 20 mm. with elastomeric gaskets

8. Inspection and Testing

8.1. Insulation Material Supplier
8.1.1. Insulation Material Supplier shall be responsible for the quality of the finished
product regardless of any inspection activity carried out by the Buyer or it’s
appointed representative. TPI shall put their stamp and signed on any box of
batch, material of that box is checked by them. This is to arrest rejection of TPIA
cleared material received at site.
8.1.2. Insulation Material Supplier shall have their own quality control and inspection
staff who are independent of the production departments and who report directly
to the head of the quality control department.
8.1.3. Insulation Material Supplier shall have their own quality plans and procedures for
Inspection and Testing. These procedures shall refer to the relevant sections in
the project specification. The quality plan / ITP shall include the parameters for
acceptance / rejection, the levels of inspection required, and the hold points.
8.1.4. The Inspection and Testing Procedure (ITP) shall be available to the Buyer or it’s
representative for approval prior to commencement of the production. Where
the order has a requirement for a prequalification test, a separate prequalification
Testing and Inspection Procedure shall be required.
8.1.5. Insulation Material Supplier shall have available all inspection instruments and
calibration equipment required to comply with the relevant project specification
inspection requirements and shall ensure the competence of the inspection staff
in the use of such equipment.
8.1.6. Insulation Material Supplier shall investigate process and sign off Non-
conformance Reports (NCR) produced by Buyer or it’s representative.
8.1.7. Insulation Material Supplier shall complete daily inspection report sheets
referenced in the relevant specifications. These reports shall be reviewed and
approved by the Buyer or it’s representative.
8.2. Inspection & Testing criteria during application
8.2.1. Inspection and Testing checkpoint with Frequency shall be as per attachment 36
& 37.
8.2.2. Applicator to prepare detailed ITP and submit to owner for approval before
starting the work.
9. Vendor Data
9.1. The supplier data requirement shall cover the documents to be submitted by a
supplier during the following stages:
• Along with the bid :- Material Catalogues.
• With the supplied material :- Test Certificates & Storage Instructions.

• During training and site services-procedure & supervision.

9.2. Insulation applicator to prepare detailed application procedure with sketches &
ITP and submit to Buyer for review and approval.
10. Packing, Preservation, shipment and Storage
10.1. All hot insulation & related materials shall be packed in damage free containers
suitably marked with the following minimum information for identification:
Marking requirement for dispatch
a. Name of the manufacturer.
b. Type of material and product designation.
c. Batch Number
d. Date of Manufacture
e. Shelf Life / Expiry Date
f. Storage Conditions
g. Material stock code & sap code / material code as mentioned in purchase
10.2. Any materials
order. found without above identification markings shall be rejected by
Buyer. Rejected materials shall be promptly removed and replaced by the
Insulation contractor. Batch number shall segregate insulation materials during
shipment, storage and handling.
10.3. Insulation materials shall be stored, handled and transported in accordance with
the Insulation Materials Manufacturer’s recommendations. Storage time of
materials shall not exceed the shelf life recommended by the insulation materials
manufacturer.
11. Measurement Wastages Norms.
11.1. Mode of Measurement
11.1.1. Measurement of work will be made on UOM (Unit of Measurement) mentioned in
the SOR (Schedule of Rates) and as per specification.
11.2. Mode of Measurement for Piping
11.2.1. All measurements will be as per IS 14164:2008; however, the following will be the
deviations from IS codes.
11.2.2. All measurements for piping shall be taken along the center line of piping as
shown in piping isometrics & GA drawings, through all fittings, such as valves,
flanges, elbows, bends, tees & reducers (Valves and flanges shall be included in
the measurement only for small bore lines up to and incl.2 Inch NB size).
• Other than valves and flanges, fittings like elbows, bends, tees & reducers etc.
will not be measured separately for payment.
• If the valves, flanges, venturi, steam traps/ strainers including flanges and body
and pair of flanges including orifice plate needs to be insulated, all such valves
/ flanges shall be measured in linear measurement in addition to below
measurement.

• For each insulated valve/venturi /steam traps/ strainers including flanges and
body, up to 300 mm line size 1.5 linear meter of piping of the connected parent
line and 2.00 linear meters for Line size above 300 mm shall be taken in to
account.
• For each pair of insulated flanges including orifice plate & flanges, 0.80 linear
meters of parent piping shall be considered.
11.3. Mode of measurement for Equipment
11.3.1. For insulation of equipment, measurement shall be taken in square meter over
the insulated equipment surface. The surface area for the nozzles, manholes,
projections will be derived as per relevant code of IS 14164:2008.
11.3.2. Surface area for ancillaries if indicated separately for payment viz., SS foil
wrapping shall be measured over the actual surface of application.
11.4. Wastage norms for hot insulation
SR No Insulation Commodity Wastage
1 MW pipe section, MW slab, MW 3%
Mattresses
2 Cladding material + Overlap 75 MM 2.5%
3 Silica Aerogel material 5 MM thick and 10 2.5 %
MM thick
4 Cladding Metal sealant 5% over actual
consumption

12. Attachment
Typical Tank shell Bottom insulation with
Attachment 1
Cellular glass
Attachment 2 Typical Tank Shell insulation Installation
Attachment 3 Typical Tank Shell, insulation vertical support

and anchor plate details
Attachment 4 Typical Tank Shell attachment
Attachment 5 Typical Tank shell and roof connection
Attachment 6 Typical Tank shell flash plate detail
Attachment 7 Typical Pipe insulation end closure for

hydrocarbon and process lines
Attachment 8 Sheet 1 Typical Flange box insulation arrangement
Attachment 8 Sheet 2 Typical Valve box insulation arrangement
Typical arrangement for Personnel protection of
Attachment 9 valves, flanges and equipment with perforated
guard
Attachment 10 Sheet 1 Typical vessel insulation arrangement
Attachment 10 Sheet 2 Typical vessel insulation arrangement
Attachment 11 Typical stand off guard/Perforated guard for

personnel protection for piping
Attachment 12 Sheet 1 Typical arrangement for traced line insulation

with pipe section
Attachment 12 Sheet 2 Typical arrangement for traced line insulation

with mineral wool slab
Attachment 13 Typical arrangement for beveled lag slab

configuration
Attachment 14 Typical Pipe elbow insulation
Attachment 15 Sheet 1 Typical pipe insulation method
Attachment 15 Sheet 2 Typical pipe cladding method
Attachment 16 Typical vessel head insulation vertical
Attachment 17 Typical vessel head insulation horizontal
Attachment 18 Typical pipe support insulation
Attachment 19 Sheet 1 Typical arrangement of pad type insulation for

irregular surface
Attachment 19 Sheet 2 Typical arrangement of pad type insulation for

irregular surface
Typical arrangement for insulation of
Attachment 19 Sheet 3 Hydrocarbon process line valves with removable
pad
Typical arrangement for Insulation of
Attachment 19 Sheet 4 Hydrocarbon process line valves>6” with
conventional method
Attachment 20 Typical arrangement of insulation support (Site)

for vessel bottom
Attachment 21 Typical inspection window details
Attachment 22 Typical expansion joint detail
Attachment 23 Typical insulations support detail for vertical

vessel
Attachment 24 Typical insulations support detail for Horizontal

vessel
Attachment 25 Sheet 1 Typical acoustic insulation for flanges and valves
Attachment 25 sheet 2 Typical acoustic insulation for flanges and valves

for venting requirement
Attachment 26 Typical acoustic insulation of support for vertical

pipes
Attachment 27 Typical arrangement of acoustic insulation

cladding end cap
Attachment 27 A Typical arrangement for 2” and below insulation

ends cap for utility lines
Attachment 28 Typical arrangement for cladding support for

vibration isolated
Attachment 29 Typical arrangement for cladding end caps
Attachment 30 Typical arrangement for tees and branches for

acoustic insulation
Attachment 31 Sheet 1 Typical arrangement of cladding support for

acoustic insulation where welding
Attachment 31 Sheet 2 Typical arrangement for cladding support where

welding allowed
Attachment 32 Inspection test plan for Silica aerogel[i]

Attachment 33 Inspection test plan for Mineral wool pipe

section [*]
Attachment 34 Inspection test plan for Mineral wool Slabs [*]
Attachment 35 Inspection test plan for Mineral wool Mattress

[*]
Attachment 36 Check list for Hot & acoustic insulation

application for Piping [*]
Attachment 37 Check list for Hot & Acoustic insulation

application for Equipment [*]
[*] ITP / Check List defines minimum requirements to be included in Supplier's ITP.
Supplier shall develop ITP specific to manufacturing/Application process

for
Protective Coatings (Field and Shop Painting)
0 25.08.2020 Issued for Implementation MD RS AS/VKM

By By By
RPMG Project Management System RPMS-ENGG-SPC-PP-014
Standard Specification for Protective Coatings (Field and Shop Date: 25/08/2020, Rev. 0
Painting)
Ajay Shrivastava
_____________________________ _________________ ___________
Anand Umakanthan
_____________________________ _________________ ___________
2
A. Srinagesh
_____________________________ _________________ ___________
3
S. Sammadar
_____________________________ _________________ ___________
4
Kuddallur Seshadri
_____________________________ _________________ ___________
5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
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RECORD OF REVISIONS

Number
25.08.2020 First Issue - Based on Bechtel Review 0
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Contents
1. Scope ......................................................................................................................... 5
2. References ................................................................................................................. 5
4. Abbreviations and Definitions:................................................................................ 10
5. Technical and Design Requirements ....................................................................... 12
6. Surface Preparation................................................................................................. 15
7. Coating Application ................................................................................................. 19
8. Inspection and testing ............................................................................................. 29
9. Vendor Data ............................................................................................................ 33
10. Preparation, Preservation, Shipment and Storage ................................................. 35
11. Attachments: ........................................................................................................... 36
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1. Scope
1.1. This standard specification defines
 Minimum standard requirements for protective coating applied at supplier
shops and RIL sites.
 Minimum requirements for surface preparation, materials, application, and
inspection of protective coatings for carbon steel, low alloy steel, and stainless
steel for new construction and maintenance.
1.2. This specification applies to lining of interior surfaces of tanks , protective coating
for structural steel, pipe and valves, pipe supports, tanks, vessels, columns and
mechanical equipment that is above ground, indoors and outdoors, onshore
marine service (i.e. above the splash zone & immersion zone) operating at
temperatures between -45°C and +600°C.
This Specification is also applicable for maintenance of already applied painting
system for existing facility.
1.3. This standard is not applicable to the following:
1. Internal lining of pipes.
2. Fusion bonded epoxy coating of pipes.
3. Buried pipe lines.
4. Equipment & piping operating below -45°C or above 600 °C
5. Items which require temporary construction primer application.
6. Coating of steel stair treads, open grid flooring and steel gratings (these shall
be protected by galvanizing as per RPMS-ENGG-SPC-PP-042).
7. Concrete structures & buildings.
8. Machined parts & Internals of rotary machines items.
2. References
The latest edition of Codes and Standards listed in Table 1 are referenced in this
standard specification and all relevant provisions of these reference codes and
standards shall be applicable.
Table 1: Codes and Standards
Standard Description
Preparation of steel substrates before application of paints
and related products - Visual assessment of surface - Part 1:
ISO 8501 -1 Rust grades and preparation grades of uncoated steel
substrates and steel substrates after overall removal of
previous coatings.

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and related products - Visual assessment of surface cleanliness
ISO 8501-4
- Part 4: Initial surface conditions, preparation grades and flash
rust grades in connection with high pressure water jetting.
ISO 11124 -2 and related products - Specifications for metallic blast-cleaning
abrasives - Part 2: Chilled-Iron grit
ISO 11124-3 and related products - Specifications for metallic blast-cleaning
abrasives- Part 3: High-Carbon cast-steel shot and grit
ISO 11125 -3 and related products - Test methods for metallic blast-cleaning
abrasives - Part 3: Determination of hardness
ISO 11126-4 and related products - Specifications for non-metallic blast-
cleaning abrasives. Part 4: Coal furnace slag
cleaning abrasives - Part 7: Fused aluminium oxide
cleaning abrasives - Part 9: Staurolite
cleaning abrasives - Part 10: Almandite garnet
Paints and Varnishes - Corrosion Protection of Steel Structures
ISO 12944-1
by Protective Paint Systems - Part 1: General introduction
ISO 12944-2 by Protective Paint Systems - Part 2: Classification of
environments
ISO 12944-5
by Protective Paint Systems - Part 5: Protective paint systems
by Protective Paint Systems - Part 9: Protective paint systems
ISO 12944-9
and laboratory performance test methods for offshore and
related structures

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Paints and varnishes — Evaluation of degradation of coatings
— Designation of quantity and size of defects, and of intensity
ISO 4628-3
of uniform changes in appearance — Part 3: Assessment of
degree of rusting
Protective clothing for abrasive blasting operations using

ISO 14877
granular abrasives
Procedure for Determining Conformance to Dry Coating

SSPC PA 2
Thickness Requirements
SSPC-SP1 Solvent Cleaning
SSPC-SP2 Surface Preparation Specification No.2: Hand Tool Cleaning
SSPC-SP3 Power Tool Cleaning
SSPC-SP5 White Metal Blast Clean
SSPC-SP7 Brush-Off Blast Clean
SSPC-SP10 Near-White Metal Blast Cleaning
SSPC-SP11 Power-Tool Cleaning to Bare Metal
Surface Preparation and Cleaning of Metals by Water jetting
SSPC-SP12
Prior to Recoating
Brush-Off Blast Cleaning of Coated and Uncoated Galvanized
SSPC-SP16
Steel, Stainless Steels, and Non-Ferrous Metals
SSPC-AB1 Mineral and Slag Abrasives
SSPC-AB2 Cleanliness of Recycled Ferrous Metallic Abrasives
SSPC-AB3 Ferrous Metallic Abrasives
Guide for Reference Photographs for Steel Surfaces Prepared
SSPC VIS 1
by Dry Abrasive Blast Cleaning
Guide and Reference Photographs for Steel Surfaces Prepared
SSPC VIS 3
by Power- and Hand-Tool Cleaning
ISO 8504 -2 and related products - Surface preparation methods - Part 2:
Abrasive blast cleaning
Design, Fabrication, and Surface Finish Practices for Tanks and
NACE SP0178
Vessels to Be Lined for Immersion Service

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and related products - Test methods for non-metallic blast-
ISO 11127-2
cleaning abrasives - Part 2: Determination of particle size
distribution
Standard Test Method for Total Evaporable Moisture Content
ASTM C566
of Aggregate by Drying
ASTM D520 Standard Specification for Zinc Dust Pigment
ASTM D3359 Standard Test Methods for Rating Adhesion by Tape Test
Standard Practice for Qualification of Coating Applicators for
ASTM D4228
Application of Coatings to Steel Surfaces.
Standard Test Method for Indicating Oil or Water in
ASTM D4285
Compressed Air
Standard Practice for Measurement of Wet Film Thickness by
ASTM D4414
Notch Gages
Standard Test Methods for Field Measurement of Surface
ASTM D4417
Profile of Blast Cleaned Steel
Standard Test Method for Pull-Off Strength of Coatings Using
ASTM D4541
Portable Adhesion Testers.
Standard Practice for Measuring MEK Resistance of Ethyl
ASTM D4752
Silicate (Inorganic) Zinc-Rich Primers by Solvent Rub.
Standard Test Method for Conductimetric Analysis of Water-
ASTM D4940
Soluble Ionic Contamination of Blast Cleaning Abrasive
Standard Test Method for Measurement of Surface Roughness
ASTM D7127 of Abrasive Blast Cleaned Metal Surfaces Using a Portable
Stylus Instrument
Standard Test Method for Measuring Humidity with a
ASTM E337 Psychrometer (the Measurement of Wet- and Dry-Bulb
Temperatures)
and related products - Tests for the assessment of surface
ISO 8502-6
cleanliness - Part 6: Extraction of soluble contaminants for
analysis - The Bressler Method
ISO 8502-9 Preparation of steel substrates before application of paints

and related products - Tests for the assessment of surface

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cleanliness - Part 9: Field method for conductometric
determination of water-soluble salts
ISO 8504-2 and related products - Surface preparation methods - Part 2:
Abrasive blast-cleaning
OSHA-29CFR1910.
Hazard Communications Standard
1200
RPMS-ENGG-SPC- Standard Specification for Field Joint Coating for Underground
PP-020 Piping
RPMS-ENGG-SPC- Standard Specification for External Glass Flake Coating for
PP-032 Underground Piping
RPMS-ENGG-DBD-
Design Basis for Pipe Supports Standard Drawings
ST-004

shall govern:
1. Line designation table, equipment data sheets and GA drawings
5. Other National and International Standards as Referenced.
Notes
• Data Sheets and Drawings represent those attached to the Material
Requisition – Equipment Datasheets, Stock Code Item Description, and Piping &
Instrumentation Diagram.
• Material Requisition represents Material Requisition for Quotation,
superseded by Material Requisition for Purchase on execution of a Purchase Order.

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4. Abbreviations and Definitions:

Abbreviations
ASTM : American Society of Testing & Materials
DFT : Dry Film Thickness
DSS : Duplex Stainless Steel
ESCC : External Stress Corrosion Cracking
FTIR : Fourier Transform Infrared (Spectroscopy)
IOZ : Inorganic Zinc Silicate
ISO : International Organization for Standardization
ITP : Inspection and Test Plan
CS : Carbon Steel
LAS : Low Alloy Steel
LTCS : Low Temperature Carbon Steel
LAT : Lowest Astronomical Tide
LDT : Line Designation Table
MEK : Methyl Ethyl Ketone
MIO : Micaceous Iron Oxide
MOC : Materials of Construction
MSDS : Materials Safety Data Sheet
MTC : Materials Test Certificate
NACE : National Association of Corrosion Engineers
NNF : Normal No Flow
OSHA : Occupational Safety and Health Administration
QC : Quality Control
Ri : Rust Index
SS : Stainless Steel
SSPC : Society for Protective Coatings
TPI : Third Party Inspector
WFT : Wet Film Thickness

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Definitions:
Buyer: Owner (Reliance) or Owner-appointed DEC or EPC who specifies equipment
Supplier/Vendor: Party which manufactures or supplies equipment and services to
perform the function as specified by Buyer.
Owner: Reliance Industries Limited or specified Reliance Group Company.
Contractor: DEC, EPC.
Coating materials manufacturer: The party that manufactures the coating
materials comprising the coating system.
Coating Applicator: The party that is responsible for the coating operation, whose
scope may include supply of coating materials, application of the coating and
transport of uncoated and coated items as specified in the relevant contract. The
term Coating Applicator includes the contractor performing work in any location
(shop, field, in the plants or any other manufacturer’s premises)
Additional definitions referred to within body of Engineering Standard
Batch: The amount of materials produced within one uninterrupted production run
of maximum 10 hours under constant production conditions in a shift.
Coating System: The specific combination of surface preparation and coating
meant to have the corrosion protection properties as described in this standard
specification.
Shift: A set of pipes/spools coated in one production run of which the beginning
and end coincide with a change in personnel. In the context of the quality control
procedures of this standard specification, the maximum duration of a shift is 10
hours.
Holiday: A defect penetrating through the coating to the steel surface, of such
dimensions that it is detectable by means of the specified procedures.
Submerged Zone: That part of a fixed offshore or marine structure below the splash
zone or that permanently wetted area below the water line of a floating vessel.
Splash Zone/Tidal Zone: That part of a fixed offshore or marine structure between
+2m above mean high water spring tide and the lowest level at which the

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preparation for, and application of, repair coatings is possible without recourse to
underwater techniques.
5.1. General Design Requirements (Projects and Marine)
5.1.1. All temperatures mentioned in this specification are actual operating conditions,
not design conditions. Coating materials and systems shall be suitable for the
minimum and maximum operating temperatures they will experience in service,
not design temperatures. Operating temperature in this specification means
highest or lowest temperature during operation to include upset, beginning of
run, end of run or catalyst regeneration.
5.1.2. Coating materials and systems for normal no flow (NNF) operation shall be
suitable for the highest and lowest operating temperature known to occur more
than once during the planned service life of the coating system. Coating materials
and systems for normal no flow (NNF) operation, where possible extreme
temperatures could only occur once during an unplanned event, such as a fire,
shall be suitable for the highest and lowest operating temperature experienced in
normal service (see 5.1.1).
5.1.3. Coating materials and systems shall be for industrial use and capable of providing
effective, long term corrosion protection in harsh service environments in
accordance with ISO 12944-2 corrosivity categories C5-M for industrial areas with
high humidity and coastal areas with high salinity.
5.1.4. Coating materials shall be suitable for carbon steel, low temperature carbon steel
(LTCS), low alloy steel (up through 9 chrome), austenitic stainless steel, and
duplex stainless steel as specified.
5.1.5. Exotic alloys shall not be coated unless otherwise required in project procurement
documents.
5.1.6. All special supports like spring supports, hangers, snubber and tie rods etc. shall
be coated as per RPMS-ENGG-DBD-ST-004.
5.1.7. Refractory lined items such as heaters and stacks shall be coated in accordance
with calculated cold face temperatures.
5.1.8. Apart from Services /fluid listed in Tank Coating schedule RPS12 to RPS14 for
internal lining, Project in consultation with Process or Licensors should provide
recommendation for internal lining system suited to fluid corrosivity.
 All carbon steel substrate which are insulated, operating from -45°C to +400°C
shall be painted.
 All carbon steel substrate which are un insulated and operating from ambient
to+ 600°C shall be painted.

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 All insulated LAS and SS substrate operating from -45°C to +200°C shall be
painted.
 All uninsulated SS & DSS shall be painted from operating temperature range
+50°C to +175°C to provide protection against ESCC.
 Uninsulated stainless steel operating continuously below +50°C or
continuously above +175°C shall not be coated unless otherwise required in
project procurement documents.
5.1.9. Lines or equipments located within 50 meter radius of cooling tower periphery
shall be coated as per coat code RPS11 of Annexure C/I.
5.1.10. The areas covered under marine coating are as below.
 Splash zone
 Submerged zone
 Atmospheric zone
5.1.11. For marine protective coating system refer “Annexure I”.
5.1.12. “Annexure J” is typical drawings showing for marine facilities.
5.1.13. All SS and DSS substrate at marine facilities, shall be coated for operating
temperature in the range from ambient to +175°C for reducing risk of ESCC.
5.1.14. Coating materials used in direct contact with austenitic stainless steels, shall meet
the following requirements:
 The inorganic halogen content shall be less than 200 ppm by weight.
 The total halogen (inorganic and organic) content shall be less than 1% by
weight.
 The sulfur content shall not exceed 1% by weight.
 Low melting point metals (lead, bismuth, zinc, mercury, antimony, cadmium,
and tin) shall not be intentionally added to the coating material. This includes
inorganic zinc and zinc rich epoxy coatings.
5.1.15. Superimposed primers and coatings shall be compatible with the surfaces. In the
event of conflicts, differences shall be bought to the notice of Owner for
resolution.
5.1.16. Coating material and products are specified in “Annexure A and B”. Coating
systems are specified in “Annexure C, G or I”.
5.1.17. Coating materials used at site in conjunction with each other in a system shall be
from the same coating material manufacturer.
 All shop fabricated equipment and components shall be strictly painted with
all the coats of paint system from same paint manufacturer.

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5.1.18. Coating system defined in this specification are consistent with 15 years minimum
designed life
5.1.19. Coating Applicator in conjunction with Paint manufacturer, shall warrant the
coating for a life to first maintenance of 07 years for all RIL site application work.
 For all fabricated equipments and components supplied by vendor the paint
system warranty shall be as per the warranty period specified in respective
contract document.
5.1.20. Degradation criteria for warranty of coating are defined in Table 2.
Table 2:Criteria for degradation of coating before maintenance
Material Criteria (after 07 years life)
Carbon Steel and Alloy steel Visual standard - Ri 3 per ISO 4628 -3
Galvanized Steel Visual standard - Ri 3 per ISO 4628 -3
Stainless Steel Adhesion drop - Maximum drop in adhesion
50%
5.1.21. Paint codes shall be marked in LDT
perand
ISO Isometric
12944-9 drawings by DEC.
5.1.22. Any other coating system not covered in this specification, but identified by
DEC/Licensor, shall be used subjected to Owner approval.
5.1.23. Wherever Instruments, Machineries and drivers, Control panels or Tag Items are
to be coated as per manufacturer’s standard coating system at manufacturer's
facility, Painting system proposed by manufacturer shall meet the requirements
as per category C5-M specified in ISO 12944-5.
5.1.24. The manufacturer shall provide a detailed description of the proposed coating
system to include as a minimum the following:
1. The method and degree of surface preparation.
2. Identity of all coating products by coating material manufacturer, name and
catalogue number.
3. Application sequence of all coats.
4. Dry film thickness of each coat.
5. The Coating material manufacturer’s latest published product data sheets
and application instructions for all coating products.
6. Daily inspection record and verification forms the seller will use.
5.1.25. Note that the volume solids figure given in the product data sheets of coats is the
percentage of the film obtained from a given wet film thickness under specified
application conditions. The theoretical coverage can be determined from the
formula
𝑚2 𝑉𝑜𝑙𝑢𝑚𝑒 𝑆𝑜𝑙𝑖𝑑𝑠 (%) .10
𝐶𝑜𝑣𝑒𝑟𝑎𝑔𝑒 [𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙] ( )=
𝐿 𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝐷𝐹𝑇 (µ𝑚)

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5.2. Safety and Environmental

5.2.1. All surface preparation, materials, and coatings work shall comply with all
applicable environmental and safety provisions, laws, regulations, ordinances,
etc., of the city, county, state, province, or nation pertaining to the work being
performed and the coating materials being used.
5.2.2. Coating Applicator shall comply fully with OSHA Hazard Communication Standard
29 CFR 1910.1200 or the applicable country code. MSDS shall be available for
review at the jobsite.
5.2.3. Chromium or chromate pigments or other compounds shall not be intentionally
added to coating materials, abrasives and other consumables.
5.2.4. Asbestos or asbestos-containing products and compounds shall not be used or
employed in any way in the surface preparation, coating application, or curing
processes.
5.2.5. Only ASTM D520 Type II (total lead content 0.01% maximum) zinc powder shall be
used in zinc rich coating materials.
5.2.6. Coatings shall contain a maximum of 0.1 % (by mass) monomeric iso-cyanate at
the time of coating.
5.2.7. Handling and disposal of hazardous waste resulting from the Coating Applicator's
coating activities should be in accordance with local government regulations and
specific contract requirement.
6. Surface Preparation
6.1. Abrasive Blast cleaning
6.1.1. Prior to the start of work, the Coating Applicator shall examine all surfaces to be
coated to determine their acceptability for the specified work. If the surfaces are
found to be unacceptable, the Coating Applicator shall either return the surface to
an acceptable condition or immediately notify the Buyer in writing if the repairs
are outside the scope of work. Work shall not commence until corrective action
has been taken. Commencement of work prior to the taking of corrective action
shall preclude any subsequent claim by the Coating Applicator.
6.1.2. Internal surfaces of tanks, vessels, etc. that are to be lined shall be designed and
fabricated in strict accordance with NACE SP0178, Standard Practice, design,
Fabrication, and Surface Finish Practices for Tanks and Vessels to be Lined for
Immersion Service. Welds shall be full seal welds, ground smooth as NACE SP0178
weld preparation designation “C”.
6.1.3. Surfaces which may become inaccessible during fabrication, shall be prepared and
coated before assembly, tagging, fitting, or welding.

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6.1.4. Precautions shall be taken to protect surfaces that are not to be coated, (flange
faces, bolt threads, machined sealing surfaces, name plates etc.) from damage
resulting from abrasive blasting and coating application. Any such damage on
substrate caused during blasting shall be repaired by Coating Applicator to the
satisfaction of owner at his own cost.
6.1.5. Weld spatter shall be removed, sharp or rough welds shall be rounded off and
contoured, prior to start of surface preparation.
6.1.6. Grease, oil, and heavy dirt shall be removed by solvent cleaning in accordance
with SSPC-SP-1 prior to conducting further surface preparation. The solvent
cleaning procedure shall include the following steps:
 Washing with 2% emulsifying liquid by volume of water, giving special
attention to weld areas, bolt holes, mouse holes, to remove galvanic salts and
alkali deposits from welding flux. Washing may be supplemented by scrubbing
with stiff bristle brush.
 High pressure water washing the whole area with fresh water.
6.1.7. Zinc salts, rust stains, and other stubborn contaminants shall be removed from
galvanized surfaces that require coating, by scrubbing with fresh water and a stiff
bristle brush, followed by a fresh water flush.
6.1.8. Surfaces shall be dry and the steel temperature a minimum of 3°C above the dew
point prior to abrasive blast cleaning.
6.1.9. Abrasive blast cleaning shall produce the surface profile and cleanliness specified
in “Annexures C, G& I" unless otherwise required by the coating material
manufacturer's latest published application instructions.
6.1.10. Compressed air used for abrasive blasting and coating shall be demonstrated
suitable for use by testing in accordance with ASTM D4285 at the beginning of
each shift, every 4 hours thereafter and after every interruption of compressor
operation. Test results shall be recorded.
6.1.11. Abrasives used for blast cleaning of substrate shall be in accordance with ISO
8504-2. Test methods shall be in accordance with ISO 11125 and ISO 11127 for
metallic and non- metallic abrasives, respectively.
6.1.12. Abrasives containing more than 1% crystalline silica shall not be used.
6.1.13. Copper slag abrasive shall not be used.

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Table 3:Selection of abrasives

Type Standard Description
Chilled Iron grit /
Metallic ISO 11124 – 2 / ISO 11124 - 3 /SSPC AB3
shots
Metallic Natural Staurolite /
ISO 11126 – 9 / ISO 11126 - 10 /SSPC AB1
Mineral Garnet
Synthetic Coal slag /
ISO 11126 – 4/ ISO 11126 – 7 /SSPC AB1
Mineral Aluminum oxide
Recycled Recycled Chilled
SSPC AB2
Metallic Iron grit / shots
6.1.14. Abrasives used for blast cleaning shall be free from oil, grease, moisture, chloride
contamination etc. Maximum moisture content in abrasives shall be 0.5% by
weight when tested in accordance with ASTM C566.
6.1.15. Abrasive for CS and LAS surface shall be tested for water-soluble salts content and
conductivity measured according to standard ASTM D4940. Conductivity shall not
exceed 1000 µS/cm at 25°C.
6.1.16. When stainless steel, galvanized or non-ferrous metal surfaces are to be coated,
then blast cleaning shall be carried out by smooth sweep blasting, using a fine
mineral or slag abrasives meeting the requirements for Metallic Natural Mineral
defined in Table 3. No defects such as break through or crisping of the zinc layer
shall occur on galvanized surfaces. The surface roughness shall be in the range of
20 μm to 30 μm (0.75 to 1.2 mils) or as recommended by the coating material
manufacturer.
6.1.17. The conductivity of abrasives for use on stainless steels shall be a maximum of
150 μS/cm.
6.1.18. Ferrous abrasive used in automated blast equipment shall be a mix of steel shot
and steel grit with a shot to grit ratio not greater than 2:1.
6.1.19. Prior to application of first coat, after blast cleaning, dust shall be removed with
compressed air, free of oil and moisture. Vacuum cleaning shall be used if the
surface cannot be made dust free using compressed air, as determined by the
Owner’s Representative.
6.1.20. The abrasive blast cleaned surface shall not exceed the maximum allowable level
of “Total” soluble salt contamination defined in Table 4 :Maximum “Total”
soluble salts.

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Table 4 :Maximum “Total” soluble salts

Surfaces New Construction Repair/ Maintenance
External C.S surfaces 25 mg/ m2 50 mg/ m2
Stainless Steels 20 mg/ m2 20 mg/ m2
Internal surfaces of
25 mg/ m2 25 mg/ m2
Vessels and Tanks
Surfaces that exceed the allowable level of soluble salt contamination shall be high
pressure water washed or steam cleaned to reduce soluble salt contamination to
allowable limits. The degree of cleanliness required of abrasive blast cleaning shall
be restored by dry abrasive blast cleaning after salt contamination has been
removed. Quality of water used for cleaning shall be of minimum potable water.
6.1.21. Inspection of the blast equipment (i.e. hogger lines, bull lines, blast nozzles,
helmet and lines, dead man handles, air reservoirs etc.), will be carried out by the
operators supervisor to ensure safe and sound working conditions with no danger
to life.
6.2. Power tool cleaning
6.2.1. Power tool cleaning may be substituted in very limited areas (maintenance & Field
welds) with prior written Owner acceptance. Power tool cleaning of carbon steel
shall be conducted in accordance with approved procedure compliant with SSPC-
SP 11 (Power Tool Clean to Bare Metal).
6.2.2. Power tool components for stainless steel, (including needles, wires, flapper
wheels, pads, disc, etc.) shall be stainless steel or non-metallic material. Carbon
steel tools shall not come into direct contact with stainless steel. Power tools used
for carbon steel substrate shall not be used on SS substrate.
6.3. Surfaces prepared for coating shall meet the specified cleanliness requirements
immediately prior to coating and shall have the first coat applied not more than 4
hours after completing blast cleaning. Surfaces that are not coated within 4 hours
of the completion of blast cleaning shall be abrasive blast cleaned again to the
specified requirements. Surfaces that are not in strict accordance with the
conditions specified for a prepared surface immediately before coating shall not
be coated until the specified conditions are restored.
6.4. The substrate shall be demonstrated free from contamination by visual
examination.
6.5. Surface preparation and coating inspection shall be documented using the
“Surface Preparation and Coatings Inspection form” as per “Annexure E”.
6.6. The standards of surface preparation as defined in Table 5 are considered
equivalent.

Painting)
Table 5: Equivalence of surface cleanliness grades

SSPC DESCRIPTION ISO 8501-1
SP-1 Solvent cleaning ---
SP-2 Hand tool cleaning St 2
SP-3 Power tool cleaning St 3
SP-5 / SP- White metal / Near white metal Sa 3 / Sa 2.5
10
SP-7 Sweep blast cleaning Sa1
SP-11 Power tool cleaning to bare metal ---
SP-12 Water jetting (ISO 8501-4) Wa 2.5
SP-16 Brush-Off blast cleaning of coated and uncoated ---
galvanized steel, stainless steels & non-ferrous
metals.
7. Coating Application
7.1. General
7.1.1. Coating shall be applied as per annexures mentioned below.
 “Annexure A” - Generic name and basic properties of paints and coatings
 “Annexure B” - List of approved coatings with manufacturers
 “Annexure C” - Project coating schedule
 “Annexure G” - Maintenance coating schedule
 “Annexure I” - Marine coating schedule
7.1.2. All equipment, prefabricated spools and structures fabricated at manufacturers
shop shall be brought to site in coated condition for erection. Field coating shall
be limited to field welds and repairs of damaged areas only.
 Painting/Coating shall be performed in Dust free environment.
7.1.3. Coating material manufacturer's latest, approved and published instructions for
application shall be followed.
7.1.4. Owner shall have free access at all times to the work being performed by the
coating contractor.
7.1.5. Only approved blaster and painters shall be allowed to carry out blasting and
painting activity, blasters and coaters working on the coating job shall be certified
in accordance with a scheme approved by Owner (e.g., ASTM D4228).

Painting)
7.1.6. Coating Applicator to prepare report for each day testing performed & certified by
Owner.
7.1.7. Defective work shall be rectified as per manufacturer’s recommendation & as per
Owner’s instruction, by the Coating Applicator at his sole expense.
7.1.8. Coating material Storage and Mixing
7.1.8.1. Coating materials shall be delivered to the place of application in the coating
material manufacturer's unopened, original containers bearing a legible product
designation, batch number, and date of manufacture, shelf life, storage condition,
material stock, SAP code /Material mentioned in Purchase order. Containers,
which are damaged, shall not be used.
7.1.8.2. The coating material shall be handled and stored in accordance with the coating
material manufacturer's latest published instructions and shall be protected from
damage, moisture, direct sunlight, and temperatures below 5°C (40°F) or above
32°C (90°F).
7.1.8.3. Material shall be used on a first-in, first-out basis. Material that has exceeded the
coating material manufacturer's latest published shelf life shall not be used.
7.1.8.4. Storing, mixing, applying, and curing of the coating material shall be in strict
accordance with the coating material manufacturer's latest published instructions
and the requirements specified herein.
7.1.9. Containers of coating, catalyst, and thinners shall only be opened for immediate
use.
7.1.10. When multiple component units are mixed, each component shall be mixed
separately prior to the mixing of the combined materials. Mixing shall be carried
out by power agitator. Hand mixing is not allowed. Only complete kits, as
originally packaged by the coating material manufacturer, shall be mixed. No
partial kits will be allowed at any time. Improper ratio leads to problems like soft /
non-dried film, poor performance, etc.
7.1.11. Mixing, application and curing of coatings shall be performed only when: the
steel surface is at least 3°C (5° F) above the dew point; the relative humidity does
not exceed 85 percent (except for inorganic zinc); both the ambient and surface
temperature are in accordance with the coating material manufacturer’s latest
published application instructions. The substrate temperature shall be a minimum
of 5°C and a maximum of 60°C during coating application.
7.1.12. Coating materials shall be thoroughly mixed until they are smooth and free from
lumps, and then strained through a 30 mesh or finer screen. Material shall be
agitated to keep the solids in suspension. Coatings containing solid phases (e.g.
Zinc rich coatings, MIO coatings, glass flake coatings) must be mechanically
agitated at all times.

Painting)
7.1.13. Minimum “Dwell Time” or “Sweat-In Time” for multi-component coating products
shall be strictly observed, after components are combined and before application
begins, when required by the coating material manufacturer’s latest published
application instructions.
7.1.14. Thinner shall only be added when necessary for proper application. The thinner
used shall be in strict accordance with the coating material manufacturer’s
published instructions. The amount of thinner shall be the minimum needed for
application and shall not exceed the maximum amount in the coating
manufacturer’s published instructions.
7.1.15. Mixed materials shall be used within the coating material manufacturer’s
published pot life. Material that has exceeded its pot life shall be discarded.
7.2. Coating application (Projects and Marine)
7.2.1. Items shall be coated using products and systems in “Annexure C/I”. All coats on
the interior surfaces of tanks and vessels shall be applied as a continuous process,
at the same location. Shop priming and field top coating of tank and vessel
internal surfaces is not allowed.
7.2.2. Coating application shall be by spray unless otherwise specified or accepted in
writing by Owner prior to use. Coating application equipment shall be in
accordance with the coating material manufacturer’s latest published application
instructions.
7.2.3. Zinc Rich Coating shall not be applied by brush.
7.2.4. All edges, corners, webs and inaccessible areas, shall be stripe coated with primer
by brush (other than zinc rich primers). The full coat of primer/intermediate coat
shall be spray applied over the stripe coat.
7.2.5. No coating shall be applied closer than 150 mm from an end that will be welded in
the field.
7.2.6. During coating application, while coat is wet, WFT shall be checked with Comb
gauge, in accordance with ASTM D4414.
7.2.7. Each coat in a system shall be applied to at least the minimum dry film thickness
and not more than the maximum dry film thickness specified in the applicable
Annexure.
7.2.8. Wherever top coat is applied over inorganic zinc silicate primer / MIO or any other
coat, the surface shall be checked for soluble salt contamination as per clause
8.3.2, if salt concentration exceeds permissible limit, then necessary correction
shall be done as mentioned in clause 6.1.20.

Painting)
7.2.9. Coatings shall be cured in strict accordance with the coating material
manufacturer’s published instructions. Applied coats in a system shall be cured
for at least the minimum published recoat time before over coating with the next
coat in the system, and the next coat shall be applied before the maximum
published recoat time for the previously applied coat has been exceeded.
7.2.10. For proper curing of inorganic zinc silicate primer, the humidity requirement is
55% minimum. If humidity falls below 55%, then water misting/Steaming shall be
carried out repeatedly after 30 minutes of application till the complete curing of
IOZ. Potable water shall be used for misting.
7.2.11. Time required for curing of IOZ with 55% humidity shall be as per coating material
manufacturer’s data sheet.
7.2.12. Inorganic zinc primers shall not be over coated before solvent (MEK) rub testing
achieves a rating of 4 or more. Test shall be performed in accordance with ASTM
D4752.
7.2.13. When zinc rich epoxy is used as a primer, then substrate shall not be left without
overcoat.
7.2.14. The dry film thickness of each coat shall be measured in accordance with SSPC
PA2 for compliance with Clause 7.2.7. The number of measurements shall be as
per Table 6.
Table 6: Test sampling plan
Inspection area (m2)
Number of measurements
length (m)
Up to 1 5
Above 1 to 3 10
Above 3 to 10 15
Above 10 to 30 20
Above 30 to 100 30
Corresponding number of
Above 100
measurements as mentioned above.
7.2.15. Each coat shall be visually inspected for defects such as over spray, runs, sags,
voids, blistering, peeling, rusting, mud cracking, inadequate cure, and lack of
adhesion. Mud cracking must be removed by re-blasting. The Coating Applicator
shall repair all defects per Owner approved touch-up and repair procedures.
Areas where defective coatings have been repaired or replaced shall be re-
inspected to the original requirements.

Painting)
7.2.16. Coated surfaces shall be protected from damage during lifting, handling, shipment
and storage. All surfaces that come into direct contact with the coated item
during shipping, handling and storage shall be of non-abrasive material. Lifting
forks and dunnage shall be effectively padded to prevent coating damage.
7.2.17. Work performed by the Coating Applicator shall be supervised by NACE certified
coating inspector.
7.3. Color Code and Schedules
7.3.1. General Color Code and Schedules, Method of Color Code Application and
Contents Code / Tag Indication are defined in “Annexure K”.
7.4. Field joint coating and touch up for new construction.
7.4.1. Coating system for field joint & touch up shall be as per “Annexure C/I”.
7.4.2. Coated surfaces that are damaged during assembly, handling or shipment shall be
repaired in strict accordance with this specification and approved procedures.
7.4.3. Coating systems, materials and products applied in the field shall be as specified
and application and inspection shall be conducted in accordance with this
specification and procedures accepted by Owner. Internal surfaces of field
erected tanks shall be prepared and lined after erection is complete, in a
continuous operation.
7.4.4. Prior to field coating, all oil and grease shall first be removed in accordance with
SSPC-SP 1.
7.4.5. Precautions shall be taken to protect sound coating adjacent to the damaged area
from further damage during touch-up and repair.
7.4.6. Coating systems, materials and products used for touch-up and repair shall be the
same as specified in this specification.
7.4.7. Uncoated surfaces greater than 0.1 m2 in area (other than field welds) and steel
exposed by coating damage greater than 0.1 m2 in area, shall be prepared and
coated as originally specified.
7.4.8. Surface preparation shall be carried out as per Section 6 of this specification.
7.4.9. Damaged and loosely adhering coating shall be removed and the sound coating at
the periphery of the damaged area shall be abraded to provide a smooth
transition between the original and the repair coating.
7.4.10. Localized repair of inorganic zinc primer, or galvanizing, shall be made using zinc
rich epoxy primer when the maximum operating temperature is ≤120°C.
7.4.11. Localized repair of inorganic zinc primer, or galvanizing, shall be made using Coat
type 23 (a high temperature, high build, multi-polymeric coating) when the
operating temperature is >120°C.

Painting)
7.4.12. Damaged areas of galvanized structures shall be feathered to remove loose

coating as per SSPC-SP3. The damaged area shall be coated with a high zinc dust
content coating such as “META FLUX” or Equivalent approved.
7.4.13. After complete application of coating system, adhesion testing as per ASTM
D3359 shall be carried out, minimum rating shall be 4A or 5A, as applicable (see
Table 9: ).
7.5. Responsibilities of Coating Applicator
7.5.1. Coating Applicator shall depute NACE/SSPC/BGAS/FROSIO certified
supervisor/Inspector at site/shop.
7.5.2. Coating Applicator should read and understand the relevant standard and
specification as mentioned in section 2.
7.5.3. Coating Applicator shall submit application procedure and Inspection test plan as
per guidelines provided in this specification as per as per Annexure E and
Annexure F and submit to Owner for review and approval prior to start of the
work.
7.5.4. Work described shall be performed by the Coating Applicator. All required tools,
equipment, solvents etc. necessary to complete the work, shall be mobilized by
coating contractor.
7.5.5. Work shall be protected against damages during all stages of application by the
Coating Applicator.
7.5.6. The Coating Applicator shall be responsible for damages caused by windblown
overspray or spatter. The Field Coating Applicator shall take adequate precautions
to prevent spattering and overspray on adjacent equipment, paving, structures,
vessels etc., by the use of drop cloths and shields.
7.5.7. The Coating Applicator shall protect surfaces like flange faces, bolt threads,
machines surfaces, name plates, nametags, glasses on temperature indicators,
pressure gauges, level instruments, etc., by masking or applying a heavy coat of
lubricant. Operating mechanisms, such as valve stems and valve positioners must
also be protected. Masking and lubricant applied by the Coating Applicator shall
be removed by him after completion of all work.
7.5.8. Coating Applicator shall clean all spatter and overspray from equipment, vessels,
tanks, piping, insulation, structures. For work performed in the field, daily clean-
up of the work area shall be done by the Coating Applicator to remove empty
cartons, cans and other discarded containers or equipment at designated area
advised by Owner.
7.5.9. For personnel working in the field, Coating Applicator shall give class room and
field training to all his manpower. Training shall be given by NACE or equivalent
certified inspector. Coating Applicator shall submit the record of training given to
workers and supervisors.

Painting)
7.5.10. Minimum accessories to be mobilized by coating contractor for work to be

performed in the field.
Blasting Equipment
Stylus gauge
Testex press-o-film and other profile measuring accessories.
SCM 400 Meter.
Hygrometer.
MEK KIT.
Pneumatic Pull-off adhesion tester ASTM D4541.
Tape adhesion tester as per ASTM D3359.
Single Component Airless Sprayer.
Plural Component Airless Sprayer.
WFT Gauge.
DFT Gauge.
Dust assessment Kit.
Holiday Tester.
MBX Bristle Blaster
7.5.11. The Coating Applicator shall comply with all applicable laws, regulations,
ordinances, etc., of the city, county, state, province or nation pertaining to his
work and coating materials.
7.5.12. All personnel should be provided with approved personnel protection, e.g.,
protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators,
earplugs, fresh-air-fed hood and any other necessary safety equipment.
7.5.13. Protective clothing for abrasive blasters should comply with ISO 14877.
7.5.14. Handling and disposal of hazardous waste resulting from the coating activities
should be in accordance with regulations and specific contract requirements.
7.5.15. Coating Applicator shall submit calibration report of all testing & measuring
instruments for review to Owner. Calibration report shall be authorized by TPI.
7.6. Coating application for maintenance (Steady state)
7.6.1. General requirements
 Coating material and approved products are as per “Annexure A & B”.
 For surface preparation, coating application, Inspection and testing
requirement, Coating Applicator’s responsibility and safety & environmental
requirements, refer to the applicable clauses mentioned in this specification.
Painting)
 Refer “Annexure G” for maintenance coating schedule.

 Refer “Annexure H” for guidelines for ITP - maintenance coating.
7.6.2. Prior to start of maintenance coating activity, operating parameters of lines or
equipments shall be confirmed and recorded (i.e. MOC, Operating
temperature/Upset condition, with insulation or without insulation).
7.6.3. Performance requirements
7.6.3.1. All coating systems shall be supplied with a manufacturer's & applicator’s warranty,
with any conditions or exclusions agreed with Owner, prior to award of contract,
for the minimum lifetime given below.
 5 years minimum life with atmospheric exposure & with hand tool/power tools
surface preparation to the standard St 2/St 3.
 7 years life with atmospheric exposure with abrasive blasting, surface
preparation to the standard Sa 2½.
 The degree of rusting shall be in accordance with ISO 4628-3 as given below,
for the specified minimum lifetime.
 not worse than Ri 2 (0.5 % rusting);
 Only in localized isolated locations and not scattered over the total surface
area coated.
 For fabricated equipment and components supplied by vendor the warranty
period shall be according to period mentioned in contract.
7.6.3.2. Surfaces that are not meeting clause 7.6.3.1 shall be repaired by the Coating
Applicator. The Coating Applicator shall bear the cost of total repair if above
mentioned performance criteria is not met.
7.6.3.3. Initial acceptance of any applied coating does not relieve Coating Applicator from
his liability for performance warranty.
7.6.4. Prior to commencement of maintenance of coating system, Coating Applicator
shall submit all the details as per Clause 9.2 .
7.6.5. Coating application and inspection shall be according to this specification and
procedure approved by Owner.
7.6.6. High pressure water washing shall be performed as per SSPC SP 12 before surface
preparation to remove all the soluble salts and other impurities adhered to
surface. Subject to Owner approval, fresh water mopping in accordance with SSPC
SP 1, may be performed in lieu of high pressure water washing. Soluble salt
contamination test shall be performed as per ISO 8502-6 after high pressure
water washing or / fresh water mopping and the value shall be as mentioned
below in Table 7.

Painting)
7.6.7. Wherever surface preparation is possible with blast cleaning during maintenance
activity, it is preferred to re blast the surface before primer coat application.
7.6.8. Uncoated surfaces greater than 0.1 m2 in area (other than field welds) and steel
exposed by coating damage greater than 0.1 m2 in area, shall be prepared and
coated as originally specified.
7.6.9. Surfaces for coating with Inorganic zinc silicate shall be prepared by abrasive blast
cleaning. For other coatings, surface preparation by power tool cleaning per SSPC
SP 11 may be used as an alternative to abrasive blast cleaning for the following:
 field welds,
 uncoated surfaces less than 0.1 m2 in area,
 Steel exposed by coating damage less than 0.1 m2 in area.
Table 7: Maximum acceptable values for soluble salt contamination
New Construction Repair/Maintenance
Surfaces
(Sa2-1/2) (St2/St3)
External C.S surfaces 25 mg/ m2 50 mg/ m2

Stainless Steels 20 mg/ m2 20 mg/ m2
Internal surfaces of
25 mg/ m2 25 mg/ m2
Vessels and Tanks
7.6.10. Prior to the start of maintenance coating, the condition of the surface and the
existing coating shall be assessed by:
Removing existing coating from a 25 cm2 area with a coat scraper to expose the
metal surface and examine the exposed metal surface for the presence of mill scale,
corrosion, contamination, undercutting and an abrasive blast cleaning profile. The
absence of a blast pattern indicates insufficient surface preparation prior to
applying the primer. In both cases, the old coating should be completely removed,
and the surface shall be carefully prepared before application of new coating.
Testing adhesion of current /existing system as per ASTM D3359 by tape adhesion
test. Minimum rating of adhesion shall be 3A.
7.6.11. Surfaces which fail to meet the criteria defined in clause 7.6.3 shall be prepared
by completely removing existing coating and applying a completely new coating
system applied per maintenance coating schedule as per “Annexure G”.
7.6.12. Maintenance coating activity shall be performed under strict supervision of NACE
or equivalent certified inspector from coating material manufacturer.
7.6.13. Owner to verify the test report of coating material supplied by coating material
manufacturer as per the requirement mentioned in clause 10.

Painting)
7.6.14. Additives intended to increase the effectiveness of the wash water in the removal
of chlorides are not required. If such solutions are used, a final flush of the
surface with fresh water shall be done.
7.6.15. Coating Applicator to submit procedure for High pressure water washing /wet
abrasive blasting /vacuum blasting /Power tool cleaning, if used as an alternative
method of surface cleaning.
7.7. Coating application for Bulk purchased valves
7.7.1. Coating Applicator shall submit detailed painting procedure covering all
requirement of this specification.
7.7.2. Small bore forged valves of size ½” to 1½” shall be supplied with Zinc
phosphate/Manganese phosphate coating. Coating Applicator shall submit the
procedure for Zinc phosphate/Manganese phosphate coating to Owner for review
and approval. Zinc phosphate/Manganese phosphate coating shall be performed
by valve manufacturer at Owner approved facility. Wherever small bore valves of
size ½” to 1½” are supplied in casting, below mentioned painting Table 8 shall be
followed.
7.7.3. Coating Applicator shall submit the procedure for zinc phosphate/Manganese
Phosphate coating to Owner for review and approval. Zinc
Phosphate/Manganese phosphate coating shall be performed by Valve
manufacturer at Owner approved Facility
7.7.4. Coating of valves >1½” shall be as Table 8: .
Table 8: Valve Coating system at Manufacturer’s Shop
INTERMEDIA DFT
SURFAC FIRST COAT FINISH
Valve MOC TE COAT (Micro
E PREP (DFT) COAT (DFT)
(DFT) n)
CS, CSIBR, LAS,
Type1 Type3 Type3 100 to
LAS IBR, LTCS, Sa2 ½
(60 to 90) (20 to 25) (20to 25) 140
NACE
SSPC Type 3 Type 3 Type 3 60 to
SS, SS IBR
SP16 (20 to 25) (20 to 25) (20 to 25) 75
Note: For all other requirements like surface Preparation, Coating application,
Inspection and testing requirement, approved coating materials manufacturer list,
shall be as per this document.
7.7.5. Coating Applicator shall use only approved product as per “Annexure B” of this
specification.

Painting)
8. Inspection and testing

8.1. General
8.1.1. Inspection shall be carried out by NACE/SSPC/BGAS/FROSIO certified inspector
deputed by vendor unless otherwise accepted by Owner in writing. Owner
inspection is not a substitute for Coating Applicator inspection and does not
relieve the Coating Applicator of responsibility for conducting testing and
inspection required by the specification.
8.1.2. Surface preparation and coating application inspection shall be done as per this
specification & approved ITP. ITP shall be prepared by Coating Applicator using
“Annexure F” & “Annexure H”- (Minimum guidelines for Inspection check list and
frequency) & same shall be documented by Coating Applicator using Inspection
record & verification form, attached in “Annexure E”.
8.1.3. The Coating Applicator shall furnish the testing and inspection instruments
needed to fully comply with the specification and see that they are properly
calibrated and maintained.
8.1.4. Surface preparation and coating application is subject to inspection by Owner at
the following stages:
 Following surface preparation and immediately prior to coating application
 Following the application and curing of each coat
 Final inspection
8.1.5. The Coating Applicator shall make the testing and inspection instruments needed
available to Owner for inspection of the work.
8.1.6. Coating activity at RIL site or manufacturer’s shop shall be inspected as per
minimum guidelines provided in “Annexure F” (Minimum guidelines for inspection
check points & frequency) of specification.
Maintenance painting activity for steady state shall be inspected as per “Annexure
H”.
8.2. Pre Blasting Inspection
8.2.1. Surfaces shall be visually examined for weld spatter and sharp welds, for
compliance with Clause 6.1.5.
8.2.2. Prior to surface preparation and coating application, dew point, relative humidity,
ambient air temperature, and surface temperature shall be determined every four
hours or at other time intervals approved in writing by the Owner.
8.2.3. Dew point, relative humidity, and air temperature shall be determined using a
sling Psychrometer, or an accepted equal, following procedures in ASTM E337.
Surface temperature shall be determined using a surface temperature
thermometer on the surface being prepared/coated.

Painting)
8.2.4. Surfaces shall be examined for the traces of oil, grease, other contamination, for
compliance with Clause 6.1.6. If oil and grease contamination is found to be
present, the surface shall be washed with 2% emulsifying liquid by volume of
water, giving special attention to weld areas, bolt holes, mouse holes, to remove
galvanic salts and alkali deposits from welding flux. Following on above the whole
area shall be high pressure water washed and if necessary scrub with a stiff bristle
brush. Alternatively, continuous monitoring of these parameters may be
performed using systems established and/or accepted by Buyer.
8.2.5. The work shall not proceed if environmental conditions are outside the
requirements of Clause 6.1.8 or 7.1.11 of this specification, as applicable.
8.2.6. Compressed air used for abrasive blasting and coating shall be demonstrated
suitable for use by testing in accordance with ASTM D4285 at the beginning of
each shift, every 4 hours thereafter and after every interruption of compressor
operation. Test results shall be recorded.
8.3. Post Blasting Surface Preparation Inspection
8.3.1. Immediately prior to application of the first coat the prepared surface shall be
inspected for cleanliness, surface profile and soluble salt contamination.
8.3.2. Soluble salt contamination shall be determined on 10% blasted surface of each
day in accordance with ISO 8502-6 and chlorides shall be as per ISO 8502-9, for
compliance with Clause 6.1.20.
8.3.3. Blast cleaned surfaces shall be visually inspected for the degree of cleanliness
using the SSPC VIS 1 visual comparison standard, for compliance with clause 6.1.9.
8.3.4. Power Tool Cleaned surfaces shall be visually inspected for the degree of
cleanliness using the SSPC VIS 3 visual comparison standard, for compliance with
Clause 6.2.
8.3.5. The anchor pattern profile depth shall be verified in for compliance with Clause
6.1.9. Profile measurements for abrasive blast cleaned surface shall be initially
made with a Stylus Probe according to ASTM D7127. Further anchor pattern
profile depth shall be verified with method B & C of ASTM D4417, for compliance
with Clause 6.1.9, the quantum shall be 25% of each day’s production.
8.3.6. Prepared surfaces shall be visually inspected for dust, spent abrasive, and loose
contamination, for compliance with Clause 6.3.
The dust level shall not exceed quantity-rating 2 and class 1 in accordance with ISO
8502-3 over the blast-cleaned surface at the time of coating. Frequency of the
checks shall be at least once on each component and once per 100 m2 of prepared
surface with a minimum of three checks per day

Painting)
8.4. Coating Application Inspection

8.4.1. Unopened containers of coating materials shall be visually inspected for damage
and labelling for compliance with Clause 7.1.8.1 and Clause 7.1.8.3 for shelf life.
Coating storage conditions shall be inspected for compliance with Clause 7.1.8.2.
8.4.2. Mixing coatings shall be inspected for compliance with Clauses 7.1.10, 7.1.11, and
7.1.12.
8.4.3. Stripe coating shall be inspected for compliance with Clause 7.2.4.
8.4.4. Curing for each coat shall be inspected for compliance with Clause 7.2.9. The cure
of inorganic zinc primers shall be tested by solvent rub in accordance with ASTM
D4752 for compliance with Clause 7.2.12.
8.4.5. Coated items shall be inspected for the extent of coating in compliance with
clause 7.2.15.
8.4.6. When Zinc rich epoxy used as primer then Adhesion test as per ASTM D3359 shall
be carried out to ensure proper adhesion and curing of Zinc rich system. The
rating shall be minimum 4B.
8.4.7. Coating Applicator to perform tape adhesion test for complete coat system on
10% of coated pipes, spools, equipments and structure as per ASTM D3359.
Minimum rating shall be as per Table 9: . This shall be witnessed by TPI or Owner
representative. After testing the affected area shall be rectified as per repair
guidelines.
8.4.8. Coating Applicator with the help of coating material manufacturer shall perform
Pull off adhesion test according to ASTM D4541 on fully cured total applied
painting system and at least once per 100 Sq. meter area painted.
 The test shall be performed on reference plate of 100X100X6 mm thick
dimensions, 3 plates shall be prepared in the same manner during production
painting of piping system /structures or equipment. This has to be witnessed
by TPI or Owner. Minimum adhesion shall be as per Table 9:
Table 9: Criteria for Pull of Adhesion and X cut Adhesion test
Pull off adhesion as X cut as
Sr.
Coat system per ASTM D4541 per ASTM
no
(MPa) D3359
Type 1+Type 5(or 22) +Type 6
1 & >5 5A
Type 4 +Type 5+ Type 6
Type1+Type3+Type3
2 & >2 4A
Type 1+Type 2+Type 2
3 Type 20+Type 20 >7 5A
4 Type 23 +Type 23 >2 4A

Painting)
Tank Internal Lining

5 >10 5A
(All system)
6 Type 25+Type 25 >10 5A
8.4.9. Coating systems in immersion or the splash zone shall be 100% holiday tested for
pinholes, voids and other holidays using equipment as defined in the coating
material manufacturer’s written instructions. High voltage testing shall be
conducted using 400 volts per mm of dry film thickness, unless otherwise defined
in the coating material manufacturer’s latest published instructions. All findings
shall be repaired and retested until there are no holidays in the film.
8.5. Quality Control Requirements at Fabricator’s shop/Equipment manufacturer’s
Shop
8.5.1. Supplier/Coating applicator shall be responsible for the quality of the finished
product regardless of any inspection activity carried out by the Owner or his
appointed representative.
8.5.2. Suppliers/Coating applicator shall have their own NACE/SSPC/BGAS/FROSIO
certified or RIL approved quality control and inspection staff who are independent
of the production / construction departments and who report directly to the head
of the quality control department.
8.5.3. Supplier/Coating applicator shall have their own quality plans and procedures
including repair procedures for Inspection and Testing as per this specification.
These procedures shall refer to the relevant sections in the project specification
and include the parameters for acceptance / rejection, the levels of inspection
required and the hold points for Owner or TPI.
8.5.4. The Inspection and Testing Procedure shall be made available to the Owner for
approval, prior to commencement of the contract / purchase order. Where the
order has a requirement for a prequalification test, a separate prequalification
Inspection and testing Procedure shall be produced for owner approval.
8.5.5. Supplier shall have a minimum inspection instruments and calibration equipment
required to comply with this project specification & inspection requirements.
8.5.6. Supplier shall investigate, process and sign off Non-conformance Reports (NCR)
produced by Owner.
8.5.7. Supplier shall complete daily inspection report sheets as attached in this
specifications. Supplier’s own daily inspection report sheets may be used in lieu of
Owner Reports, provided these have been reviewed and approved by the Owner.
8.5.8. The inspection reports shall be signed off by the Owner.
8.6. TPI responsibility

Painting)
8.6.1. TPI shall have certification from NACE or RIL approved equivalent and shall be
fully experienced in inspection of coating activity. Such certification shall be
reviewed by Owner.
8.6.2. TPI shall verify compliance and perform inspections as per approved Procedure &
ITP by RIL/DEC.
8.6.3. Where, in the opinion of the inspector, there is a deviation from the specification
or the testing reveals failure to meet the parameters of the specification, the
inspector shall immediately inform the Coating Applicator and Coating Applicator
shall ensure that non-conforming items are quarantined.
8.6.4. Only after remedial action and re-inspection has established concurrence with the
specification, Inspector shall accept previously nonconforming materials.
8.6.5. NCR raised by owner or TPI shall be duly closed by Coating Applicator to the
satisfaction of owner/TPI.
8.6.6. TPI should maintain QC Check List as per “Annexure F”. Same to be followed by
Coating Applicator.
9. Vendor Data
9.1. Coating Material supplier’s responsibilities
9.1.1. The coating materials supplier’s data requirement shall cover the documents to
be submitted along with the bid and with supplied material. These shall include
the following:
 Coating material supplier’s stamped data sheet & application guide
 Test certificates
 Storage instructions
9.1.2. Coating material supplier to provide FTIR (fingerprint check) as per ISO 12944-9
Clause 6.5 and Annex C (both main and optional parameters) for the supplied
coating. The same shall be compared with original approved FTIR of that coating
material.
9.1.3. Validity of test certificate of coating materials shall be limited for 5 years from
date of testing.
9.1.4. Coating material supplier shall depute NACE or RIL approved Equivalent certified
representative at site with all inspection accessories during application as per the
requirement mentioned in Purchase order for inspection and submit the report to
Owner.
9.1.5. Coating material supplier shall provide one-time assistance in training for field
coating application to workers and supervisors.

Painting)
9.1.6. Coating material supplier shall perform testing for each paint type for given PO for
confirmation of chemical and physical parameters at NABL or Owner authorized
lab or at coating materials manufacturers test lab with TPI certification before
dispatch from factory. TPI shall select the random sample and witness the testing.
9.1.7. For above testing one sample shall be selected from each batch of one lot.
9.1.8. Batch test certificate, for Parameters decided by Owner and agreed by Coating
material supplier with TPI witness.
9.1.9. Coating material supplier shall perform Surveillance test decided by Owner at TPI
lab or Coating material supplier’s lab and witness by TPI or Owner authorized
person from randomly selected sample after receipt of paint at site.
9.2. Coating Applicators Submittals
9.2.1. Coating Applicator shall submit detailed written procedures for surface
preparation and coating application for Owner review and acceptance prior to the
start or work. Acceptable procedures shall demonstrate strict compliance with
this specification and the coating material manufacturer’s latest published
application instructions. Conflicts, if any, between the coating material
manufacturer’s instructions and this specification shall be reported in writing by
the Coating Applicator for review and disposition by Owner prior to the start of
work.
9.2.2. Coating Applicator’s procedures shall, as a minimum, address the items listed
below and include the coating material manufacturer’s latest published product
data sheets and application instructions for all coating products, and daily
inspection record and verification forms the Coating Applicator will use.
 Storage of coating materials and thinners.
 Method of surface preparation, degree of cleanliness and profile of the
prepared surface.
 Type of abrasive to be used for surface preparation.
 Identity of all coating materials, thinners and cleaners by specific
manufacturer, name and product number.
 Coating application sequence.
 Dry film thickness of each coat
 Mixing and thinning of each coat.
 Application equipment and method to be used.
 Environmental restrictions to be observed during surface preparation, coating
application and curing.
 In-process inspection activities, methods and equipment.

Painting)
 Touch-up and repair procedures

10. Preparation, Preservation, Shipment and Storage
10.1. All coating & related materials to be used shall be packed in damage free
containers suitably marked with the following minimum information for
identification:
a. Name of the coating material manufacturer.
b. Type of material and product designation.
c. Batch Number
d. Date of Manufacture
e. Shelf Life / Expiry Date
f. Storage Conditions
Material stock code & SAP code / material code as mentioned in
g.
purchase order.
10.2. Any materials found without above identification markings shall be rejected by
Owner. Rejected materials shall be promptly removed and replaced by the
coating contractor. Coating materials shall be segregated by Batch number during
shipment, storage and handling.

Painting)
11. Attachments:
Sr.no Annexure Description
1 Annexure A Generic Name and Basic Properties of Paints and
Coatings
2 Annexure B List of Approved coatings with Manufacturers
3 Annexure C Project Coating Schedule
4 Annexure D Color Equivalent Standards
5 Annexure E Surface Preparation and Coating Inspection Form
6 Annexure F Minimum Guidelines for Inspection Check points &
frequency for Coating Application (Projects &
Marine
7 Annexure G Maintenance Coating Schedule
8 Annexure H Minimum Guidelines for inspection Check points -
Manual & Mechanical Cleaning and Painting
application for maintenance
9 Annexure I Marine coating schedule
10 Annexure J Typical coating system for Marine structure
Color Code and Schedules
11 Annexure K

for
Positive Material Identification at Supplier’s Works
0 25.08.20 Issued for Implementation MS IGK AS / VKM

By By By
Standard Specification for Positive Material Identification Date: 25/08/2020, Rev. 0
at Supplier’s Works
Sr. Name Signature Date

No.
Ajay Shrivastava
1 (Sub-committee Chairman)
_____________________________ _________________ ___________
2 Anand Umakanthan
_____________________________ _________________ ___________
3 A. Srinagesh
_____________________________ _________________ ___________
4 S. Sammadar
_____________________________ _________________ ___________
5 Kuddallur Sheshadri
_____________________________ _________________ ___________
6 _____________________________ _________________ ___________
7 _____________________________ _________________ ___________
8 _____________________________ _________________ ___________
9 _____________________________ _________________ ___________

RECORD OF REVISIONS

Number
Contents
1. Purpose.................................................................................................................. 5
2. References ............................................................................................................. 5
3. Conflicts and Deviations ......................................................................................... 5
4. Abbreviations and Definitions ................................................................................ 6
5. Technical Requirements ......................................................................................... 7
6. Inspection and Testing ........................................................................................... 8
7. Extent of PMI examination ..................................................................................... 9
8. Elements to be checked in PMI ............................................................................ 11
9. Acceptance, Rejection and Retest criteria ............................................................ 11
10. Vendor Data ......................................................................................................... 12
11. Sample Format ..................................................................................................... 13
1. Purpose
1.1. This specification defines minimum requirements for Positive Material
Identification (PMI). The purpose of this specification is to verify chemical
composition of materials being supplied by the manufacturers / suppliers are
consistent with the material specifications as specified in purchase documents by
using Alloy analyser and thus preventing any mix up of materials/welds.
1.2. This specification for positive material identification (henceforth will be termed as
PMI) covers piping bulk/tagged items (including piping spools), mechanical
(Static/Rotary) equipment (including internals) and instrumentation bulk/tagged
items.
1.3. This specification is applicable for the manufacturers as well as suppliers.
1.4. PMI shall be applicable for all SS/LAS/NF metals and their alloys and all the welds
including weld overlay and clad materials.
1.5. All grades of materials are liable for PMI test at site by Owner. In case of any
discrepancies found at site, Supplier shall be liable for immediate replacement of
such materials without any cost implications.
1.6. Identification of materials by PMI shall not be considered as a substitution for
identification by mill markings, or any required Mill Test report (MTR) or other
required Materials Test Certificate included in the quality assurance program.
MTRs shall not be considered a substitute for PMI testing either.
2. References
Codes and Standards: -
API RP 578: Guidelines for Material Verification Program (MVP) for New and
Existing Assets.

shall govern:
1. Data Sheets and Drawings /Stock Code Purchase Description
RIL Confidential
Page 5 of 13
Notes:
Requisition
• “Material Requisition” represents Material Requisition for Quotation

Abbreviations: -
LAS: Low Alloy Steel
MTR: Mill Test Report
MTC: Material Test Certificate
NF: Non-Ferrous
OES: Optical Emission Spectroscopy
PMI: Positive Material Identification
SPWD: Spiral Wound Gasket
SS: Stainless Steel
XRF: X-Ray Fluorescence
Definitions: -
Supplier/Vendor: Party which manufactures or supplies equipment and services
to perform the function as specified by Buyer.
Buyer: Owner (Reliance) or Owner-appointed DEC or EPC who specifies
equipment and services for purchase from Supplier.
Owner: Reliance Industries Limited or specified Reliance Group Company.
RIL Confidential
Page 6 of 13

Other definitions: -
Alloy materials: Any metallic materials that contains alloying elements such as
Chromium (Cr), Nickel (Ni), Molybdenum (Mo), Vanadium (V), Titanium (Ti),
Niobium (Nb), Tantalum (Ta) etc which are intentionally added to enhance
mechanical and/or corrosion resistance properties.
5. Technical Requirements
5.1. PMI shall be performed for identification & confirmation of alloying elements of
pressure retaining and wetted components of each assembly including equipment
and each individual segment of piping components (including forgings, fittings
etc), plates, welds (including weld overlay). Refer Table 1 in paragraph 8 for the
extent of testing.
5.2. Supplier shall submit a PMI procedure to Owner prior to fabrication for approval
which shall contain as a minimum:
1. Detail of PMI instrument (brand and model) and its calibration requirements.
2. Alloying elements to be verified and acceptance criteria.
3. Marking on the PMI tested items.
4. Timing of PMI.
5. Operator minimum qualifications.
6. Process for managing non-conformance.
7. Record keeping including report forms.
5.3. The Supplier/Contractor shall ensure that all the alloy/non-ferrous materials are
segregated and stored in separately identified locations to prevent mix up of
materials of different alloy specifications.
5.4. PMI examination is subject to surveillance inspection by Owner or Owner’s
representative.
RIL Confidential
Page 7 of 13

6.1. PMI instrument can either be portable X-ray fluorescence (XRF) analyzer or
portable optical emission (OES) analyzer type. Reliable equipment from leading
brands are preferred such as Bruker, Olympus, Niton, Thermo Fisher, Hitachi (X-
met). Buyer/Owner’s approval is required if other equipment is used.
6.2. Instruments used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of alloying
elements present.
6.3. Chemical spot testing, alloy sorters, magnets, eddy current etc methods are not
acceptable for PMI examinations.
6.4. All PMI instruments shall be serviced periodically, and the same report shall be
available for review whenever sought.
6.5. PMI shall be performed by qualified operators. Qualification of the personnel
performing PMI shall be the responsibility of the Supplier. As a minimum, the
operator must have completed a training course provided by the Supplier or the
PMI equipment manufacturer. Review of the qualifications shall be provided to
the Buyer/Owner if requested.
6.6. All PMI instruments need to be calibrated according to manufacturer’s
specification at the beginning and end of each shift. The calibration checks shall
be performed prior to the examination of each batch of components using
certified standards of the same alloy family.
6.7. In case of verification by optical emission analyzer, the surface to be examined
shall be prepared by light grinding or using abrasive paper and solvent cleaner.
The arc burn resulting of the test shall be removed by either light grinding or by
abrasive paper leaving no permanent mark on the surface.
6.8. PMI test of Ring type joint, Metal gaskets and heat exchanger tubes shall be
performed by XRF analyzer only. Optical emission analyzer shall never be used.
RIL Confidential
Page 8 of 13
7. Extent of PMI examination

Table 1 summarizes the components to be tested and the extent of PMI.
Table 1: Components to be tested
Item Extent of PMI

Piping bulk (forging, flanges, fittings, 100%
valves, pipes, Ring type & Metal
gaskets), Piping tagged (strainers,
exhaust heads, flame arresters,
metallic hoses, traps etc) and Plates
Piping weld overlays & clad plates 100% (Note 1)
Piping spools including welds 100%
Valve trims, Valve Stelliting/overlays & 10%
Valve fasteners
SPWD gasket internal ring or other 10%
semi-metallic gaskets
Fasteners 10% for equipment and as per
sampling plan for bulk order (Note 2).
Heat exchanger tubes 100%
Instrumentation tubes ½ inch and NIL for austenitic SS

below 100% for other material (e.g. Ti, Ni-
alloys, other NF)
Instrumentation items, pressure 100%
chambers
Rotating equipment (casing, shafts, 100%
impellers, blades, stator, rotor, piston,
sleeves, cylinder, pulsation dampers,
diaphragm, Pressure retaining bolting,
Process and auxiliary piping including
welds, Internals exposed to process
media etc) (Note 3)
Static equipment including internals 100% (each component, weld and
(vessel, reactor, tank, heat exchanger weld overlay, clad restoration)
etc)
Weld consumables Refer clause 7.3
Sacrificial anodes for Cathodic 100% (Refer clause 7.4)
Protection
Note 1: For each pipe, two PMI spots shall be performed, one near each end.
Note 2: For Fasteners bulk orders
RIL Confidential
Page 9 of 13
Up to 100 = 10% with a minimum of 5 per heat

101 to 500 = 5% with a minimum of 10 per heat
501 and above = 2% with a minimum of 20 per heat
Note 3: Rotating equipment includes compressors, pumps, agitators, centrifuge
etc.
Unless and otherwise specified in purchase order, PMI for lube oil system
components is not required.
7.1. For equipment, bulk / tagged piping and instrumentation items, PMI shall be
performed for base materials as well as for weldments. For welds, PMI shall be
performed from outside as well as from inside (wherever accessible).
7.2. PMI shall be performed for each weld seam less than 5 m in length, two spots
shall be tested for length greater than 5 m in length.
7.3. For welding consumable verification, whenever a new lot of welding electrodes is
to be used, a sample “button” of material shall be deposited and analyzed. It is
not necessary to deposit and analyze samples from solid metal electrodes which
do not rely on flux to achieve the final weld composition. For such electrodes, the
metal consumable may be analyzed directly using XRF or OES techniques in lieu of
analysis of a deposited “button”. It shall be noted that weld dilution may affect
the reading and sufficient passes have to be made for analysis of sample “button”
to be valid.
7.4. PMI shall be performed for sacrificial anodes used in Cathodic Protection.
Constituents of elements shall be verified with MTC / lab test report of anode.
RIL Confidential
Page 10 of 13
8. Elements to be checked in PMI

Table 2: Elements to be checked
Material Elements to be checked
All SS materials Cr and Ni in addition Mo, Ti, Nb, Ta etc

whenever present as per material
specification (Refer to para. 8.3)
Duplex and Super Duplex SS Cr, Ni, Mo and any other elements
present as per material specification.
Alloy steel Cr and Mo in addition V, Ti, Nb, W, Ni
etc whenever present as per material
specification.
Nonferrous alloys Ni, Cr, Mo in addition Ti, Zr, Cu etc as
(e.g. Titanium & its alloys, Zirconium & applicable whenever present as per
its alloys, Incoloy, Inconel, Monel, material specification
Alloy 20, Hastelloy, etc.)
8.1. For all other non-ferrous alloys, all alloying elements need to be checked that are
present as per the material specification (ASTM, ASME, JIS, CEN, DIN, AWS etc).
8.2. For final acceptance, all PMI shall be done on the materials and welds after
completion of all fabrication activities. However, Supplier shall ensure correct
materials are being used in every stage with their internal material control
system.
8.3. Inclusion of carbon verification in the PMI program shall be on a case-by-case
basis as specifically noted on the purchase order/ datasheet.
9. Acceptance, Rejection and Retest criteria

9.1. Acceptable Range
9.1.1. Base Metal
PMI test results showing elements up to 10% less than the specified minimum value
in the respective material specification and up to 10% more than the maximum
specified value in the material specification shall be acceptable.
9.1.2. Deposited weld metal
For deposited weld metal, PMI test results showing elements up to 12.5% less than
the minimum specified value in the welding consumable specification and up to
RIL Confidential
Page 11 of 13
12.5% more than the maximum specified value in the welding consumable
specification shall be acceptable
9.2. Rejection and Retest Criteria
Items or components containing materials which have not passed PMI i.e. falling
outside the acceptable range shall be clearly marked as "DO NOT USE - PMI FAILED"
and segregated from the remainder of the stock. Buyer shall be notified
immediately for the failure.
Supplier will then have the following options with Buyer concurrence.
9.2.1. All the material, components represented by sample (same heat, lot, or identical
welds) shall be scrapped or grinded out and replaced by new material,
components, welds.
9.2.1.1. 100% of the remainder lot shall be tested for PMI.
9.2.1.2. 100% of the next lot of the same component shall be tested for PMI.
9.2.1.3. If next lot in above case does not identify any similar non – conformance, sampling
plan shall be returned to originally specified level.
9.2.2. Correct chemistry of failed components shall be verified by laboratory chemical
analysis.
9.3. Buyer/Owner shall not be responsible for cost bearing for Rejected items.
9.4. Substitution
If PMI examination identifies a material substitution with apparently a minor
chemical element addition and at least identical or superior properties (e.g. 2.25Cr-
1Mo-0.25V instead of 2.25Cr-1Mo) it shall not be accepted, and the test result shall
be considered as PMI FAILED.
10. Vendor Data

10.1. Records
The result of PMI examination shall be recorded and reported in a "Sample Format"
refer Clause no.11 of this specification.
10.2. Marking
All material tested by PMI shall be identified using either of the following methods
by indicating PMI OK.
i) Bar code/Hologram sticker
ii) A low stress stamp punching.
RIL Confidential
Page 12 of 13
11. Sample Format

Positive material identification Report (Sample format)
Project: Client:
Purchase order No: Supplier/sub supplier:
Material requisition no: Testing agency:
Item type/description: Procedure:
Material specification/Grade: Heat number:
Alloy analyser Type/make: Analyser Serial Number
Chemical Composition - Weight % Accept Reject

Nb
Cr Ni Mo V Ti Cu Other
(Cb)
Material Min.
Specification
Max.
Range
Stockcode / Item
Tag No.
Component
Date : Tested By : Witnessed by:
RIL Confidential
Page 13 of 13
Standard Nozzle Loads

RPMS-SD-M15-010
0 10.04.2020 Issued for Implementation ADB LS TNR / VM

By By By
Reliance Project Management System RPMS-SD-M15-010
Standard Nozzle Loads Date: 10/04/2020, Rev. 0
Contents
1. Scope ......................................................................................................................... 3
2. Definitions: ................................................................................................................ 3
3. Codes and Standards: ................................................................................................ 3
4. Externally Applied Nozzle Loads for Equipment ....................................................... 3

1. Scope
This standard covers the externally applied minimum nozzle loading for equipment
of Reliance Projects.
2. Definitions:
The definitions of key terms used in this specification are as follows:
BUYER Reliance Industries Ltd (RIL)
SELLER The firm contracted to supply the equipment to BUYER.
3. Codes and Standards:

3.1. Unless otherwise specified the editions of codes and standards which apply shall
be those current at the date stated in the Material Requisition, including all
revisions and addenda up to and including that date.
Welding Research Council - Bulletin Local Stresses in Spherical and Cylindrical
No. 107/297 Shells due to External Loadings
British Standards Institution PD 5500 Specification for Unfired Fusion Welded
Pressure Vessels
4. Externally Applied Nozzle Loads for Equipment

1. Each nozzle, including those designated “spare” but with the exception of
manways and instrument nozzles shall be designed to withstand the forces and
moments specified herein.
The indicated loads are to be considered to act at the shell/head to nozzle
intersection and to be true normal and tangential to the shell at that point.
The effect on the shell/head shall be analyzed per WRC107/297 (It is preferable
to use WRC 297 for cylindrical shells with nozzles) or PD 5500 - Appendix G.
WRC 107 is not preferred for nozzles on cylindrical shells.
2. Nozzles are to be designed to withstand the forces and moments as computed
from the formulae below, where “D” is the nominal nozzle diameter in inches
and “β” is the value listed against the nozzle flange rating in the table given
below.

3. Externally Applied Nozzle Loadings for Pressure Vessels

METRIC UNITS
Longitudinal Bending Moment ML =β x 0.13 x D2 kNm
Circumferential Bending Moment Mφ= βx 0.10 x D2 kNm
Resultant Bending Moment MR = (ML2 + Mφ2)0.5 = βx 0.164 x D2 kNm
Torsional Moment MT =β x 0.15 x D2 kNm
Axial Tension or Compression Load FA =β x 2.00 x D kN
Longitudinal shear Load FL =β x 2.00 x D kN
Circumferential shear Load Fφ =β x 1.5 x D kN
Flange Rating, Class 150 300 600 900 1500 2500

β Value 0.6 0.7 0.8 0.9 1.0 1.1
Externally Applied Nozzle Loadings for Heat Exchangers

Longitudinal Bending Moment ML = β × 0.13 × D² × B kNm
Circumferential Bending Moment Mφ = β × 0.10 × D² × B kNm
Torsional Moment MT = β × 0.15 × D² × B kNm
Axial Tension or Compression Load FA = β × 2.00 × D × B kN
Longitudinal Shear FL = β × 2.00 × D × B kNm
Circumferential Shear Fφ = β × 1.5 × D × B kNm
Flange Rating, Class 150 300 600 900 1500 2500

β Value 0.6 0.7 0.8 0.9 1.0 1.1
B Value 0.75 0.75 0.75 0.75 0.75 0.75
4. With regards to the radial load (FA), calculations shall be made first with the force
acting radially outwards in conjunction with the internal pressure and then with
the force acting inwards. In the second instance, the internal pressure shall not
be used to oppose the compressive stresses due to the force acting radially
inwards; for this load condition a null pressure condition is to be considered to
exist.
5. Under “vacuum” conditions, deflections (δ) shall be derived at locations
adjacent to the nozzle to shell junction and shall be limited to: -

δ ≤0.0025 R
Where R is the shell or head radius.
In case of Sphere, R is the sphere shell radius and the basic stress intensity limits
shall be as per ASME Section VIII, Division 2.
6. The loadings computed from these equations shall be considered as being
caused by 67% thermal and 33% dead weight load.
7. If the application of the loadings, to a nozzle assembly that is fully reinforced for
pressure considerations, result in stresses that exceed the allowable, then the
SELLER shall apply adequate reinforcement and/or increased thickness of shell
and/or nozzle locally, over that required for pressure and support loadings.
8. However, the SELLER is to inform the BUYER, in writing, of instances where the
tabulated nozzle loads would require the pressure envelope shell or head
thickness to be increased. Additionally, the SELLER is to advise the maximum
loadings that can be applied to that reinforced nozzle assembly, without having
to increase the shell or head thickness over that required for pressure and
support loadings. The SELLER will be advised of “actual” piping loads should they
exceed the values as computed by the above formulas.
9. Loadings for nozzles above 24” NB will be advised to the CONTRACTOR by DEC.


NAME PLATE HEAT EXCHANGER
RPMS-SD-M15-002
Design Basis for Structural Engineering

RPMS-ENGG-DBD-CS-001
0 25.08.2020 Issued for Implementation VSK PGN SPC/VKM

By By By
Design Basis for Structural Engineering Date: 25/08/2020 Rev. 0

(DD.MM.YYYY)
1 Kuddallur Seshadri _________________ ___________
S Sammaddar _________________ ___________

2

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number
Contents
1. Scope ......................................................................................................................... 5
2. Abbreviations ............................................................................................................ 5
3. Dimensions and Units ............................................................................................... 5
4. References ................................................................................................................. 5
5. Loads ....................................................................................................................... 15
6. Load Combinations.................................................................................................. 23
7. Structural Analysis ................................................................................................... 27
8. Structural Design – Steel ......................................................................................... 29
9. Structural Design – Concrete .................................................................................. 41
10. Structural Design – Masonry ................................................................................... 49
11. Structural Serviceability Considerations ................................................................. 50
12. Foundation Design Requirements ........................................................................... 50
13. Existing Structures and Foundations ....................................................................... 55
14. Materials ................................................................................................................. 56
15. Applicable Software ................................................................................................ 61
16. Work Responsibility................................................................................................. 62
Annexure 1 - Seismic Design Criteria for Steel Members and Base Plate (4 Pages)
Annexure 2 – Locknut Detail for Expansion Joints and Sliding Support (4 Pages)
Annexure 3 - Guidelines for the Design of Piperack (38 Pages)
Annexure 4 – Sample Design Calculation of Anchor Bolts (13 Pages)
1. Scope
This document defines the basis for carrying out the structural engineering work
for all RIL projects. This document is issued to DECs to facilitate the preparation of
project specific design criteria, design calculations and detailed drawings.
2. Abbreviations
EPC: Engineering, Procurement, Construction
C&S: Civil and Structural
DEC: Detailed Engineering Consultant
SER: Site Engineering Request
BEDD: Basic Engineering Design Data
3. Dimensions and Units

The International System of Units (abbreviated SI) shall be used.
Elevations: meter (m).
Dimensions: millimeter (mm).
Force: kiloNewton (kN).
Mass: kilogram (kg).
Moment: kiloNewton meter (kNm).
Stress: Newton/mm² (N/mm²) or Mega Pascal (MPa).
Pressure: kiloPascal (kPa).
Loadings: kiloNewton/m² (kN/m²).
4. References
All work shall conform to the latest Indian and International standards / code of
practice as listed below unless otherwise specially permitted by RIL to DEC. The
revision of standard/code with amendments, current “as on start date of the Pro-
ject” shall be applicable throughout the tenure of the project unless otherwise spe-
cifically agreed between RIL and the DEC.

4.1. List of Basic Design Data, Design Basis and Specifications
Sr. No. Document Number Title of the Document
1 RPMS-ENGG-DBD-GE-001 Basic Engineering Design Data

2 - Geotechnical Report
3 RPMS-ENGG-DBD-CS-002 Design Basis for Civil Work
4 RPMS-ENGG-DBD-CS-003 Design Basis for Architectural Work
5 RPMS-ENGG-DBD-CS-004 Design Basis for Blast Resistant Buildings
6 RPMS-ENGG-DBD-CS-010 Design Basis for Concrete Framed Struc-
tures Supporting Rotating Equipment
7 RPMS-ENGG-DBD-CS-011 Design Basis for Rigid Block Foundations

for Rotating Equipment
8 RPMS-ENGG-SPC-CS-001 Specification for Plain and Reinforced Con-

crete Materials and Construction
9 RPMS-ENGG-SPC-CS-002 Specification for Structural Steelwork –
Fabrication and Erection
10 RPMS-ENGG-SPC-CS-003 CSA Stock Code Index
11 RPMS-ENGG-SPC-CS-007 Standard Specification for Waterproofing

of Concrete Structures
12 RPMS-ENGG-SPC-CS-009 Standard Specifications for Masonry and

Plastering
13 RPMS-ENGG-SPC-CS-012 Technical Specification for Supply of Rein-
forcement Bars
14 RPMS-ENGG-SPC-CS-013 Technical Specification for Supply of Rein-

forcement Bar Couplers
15 RPMS-ENGG-SPC-CS-014 Technical Specification for Supply of Steel
Sections, Plates, Flats, Bars and Any Other
Solid Shape Used for Structural Work

Sr. No. Document Number Title of the Document
16 RPMS-ENGG-SPC-CS-015 Technical Specification for Supply of Bolts,

Studs, Nuts and Washers Used for Struc-
tural Work
17 RPMS-ENGG-SPC-PP-014 Standard Specification for Field and Shop
Painting
18 RPMS-ENGG-SPC-PP-042 Standard Specification for Galvanising
19 RPMS-SD-C15-303 Standard Anchor Bolt Detail - 4 Sheets
20 RPMS-SD-C17-503 Insert Plate Details
21 RPMS-SD-P14-004 Cross Section Typical Process Unit
4.2. List of Codes, Standards, Specifications and Publications

4.2.1. Loading
Sr. No. Code Number Title of the Code

Indian
1 IS 875 (Part 1) Code of Practice for Design Loads (Other than Earth-
quake) for Buildings and Structures, Part 1 : Dead
Loads – Unit Weights of Building Materials and
Stored Material
quake) for Buildings and Structures, Part 2 : Imposed
Loads
quake) for Buildings and Structures, Part 3 : Wind
Loads
quake) for Buildings and Structures, Part 5 : Special
Loads and Combinations


5 IS 1893 (Part 1) Criteria for Earthquake Resistant Design of Struc-
tures, Part 1 : General Provision and Buildings

tures, Part 2 : Liquid Retaining Tanks
tures, Part 3 : Bridges and Retaining Walls
tures, Part 4 : Industrial Structures Including Stack-
Like structures
International
9 ASCE 7 Minimum Design Loads and Associated Criteria for

Buildings and Other Structures
10 ASCE Publica- Wind Loads for Petrochemical and Other Industrial
tion Facilities
11 ASCE Publica- Guidelines for Seismic Evaluation and Design of Pet-
tion rochemical Facilities
4.2.2. Steel

Indian
1 IS 800 General Construction in Steel - Code of Practice
2 IS 801 Code of Practice for Use of Cold-Formed Light Gauge
Steel Structural Members in General Building Con-
struction
3 IS 808 Dimensions for Hot Rolled Steel Beam, Column,
Channel and Angle Sections
4 IS 1363 (Part 3) Hexagon Head Bolts, Screws and Nuts of Product
Grade C, Part 3 : Hexagon Nuts (Size Range M5 to
M64)

5 IS 1367 (Part 2) Technical Supply of Conditions for Threaded Steel

Fasteners, Part 2 : Tolerances for Fasteners – Bolts,
Screws, Studs and Nuts – Product Grades A, B, and C
6 IS 1367 (Part 3) Technical Supply of Conditions for Threaded Steel
Fasteners, Part 3 : Mechanical Properties of Fasten-
ers Made of Carbon Steel and Alloy Steel – Bolts,
Screws and Studs
7 IS 1367 (Part Technical Supply of Conditions for Threaded Steel
13) Fasteners, Part 13 : Hot-Dip Galvanized Coatings on
Threaded Fasteners
8 IS 1852 Specification for Rolling and Cutting Tolerances for
Hot Rolled Steel Products
9 IS 2016 Specification for Plain Washers
10 IS 2062 Hot Rolled Medium and High Tensile Structural Steel
– Specification
11 IS 3757 Specification for High Strength Bolts
12 IS 4000 High Strength Bolts in Steel Structures
13 IS 4759 Hot-Dip Zinc Coatings on Structural Steel and Other
Allied Products-Specification
14 IS 5372 Taper Washers for Channels (ISMC)
15 IS 5374 Taper Washers for I Beams (ISMB)
16 IS 6610 Specification for Heavy Washers for Steel Structures
17 IS 6623 High Strength Structural Nuts - Specification
18 IS 6649 Specification for Hardened and Tempered Washers
for High Strength Structural Bolts and Nuts
19 IS 7215 Tolerances for Fabrication of Steel Structures
20 IS 1161 Steel Tubes for Structural Purposes – Specification
21 IS 1730 Steel Plates, Sheets, Strips and Flats for Structural

and General Engineering Purposes – Dimensions

22 IS 4923 Hollow Steel Sections for Structural Use - Specifica-

tions
23 IS 6639 Hexagon Head Bolts for General Steel Structures –
Specifications
International
24 AWS D1.1 / Structural Welding Code - Steel

D1.1M
25 ASTM Standard Specification for Pipe, Steel, Black and Hot-
A53/A53M Dipped, Zinc-Coated, Welded and Seamless
26 ASTM Standard Specification for Seamless Carbon Steel

A106/A106M Pipe for High Temperature Service
27 ANSI / AISC 341 Seismic Provisions for Structural Steel Buildings
28 ANSI / AISC 358 Prequalified Connections for Special and Intermedi-

ate Steel Moment Frames for Seismic Applications
29 AISC – DG1 Base Plate and Anchor Rod Design
30 AISC - DG16 Flush and Extended Multiple Row Moment End Plate
Connections
31 BSEN 10025-2 Hot Rolled Products of Structural Steel: Technical De-
livery Conditions for Non-Alloy Structural Steel
32 BS 4-1 Structural Steel Sections - Specification for Hot-
Rolled Sections
33 BS EN ISO 1461 Hot-Dip Galvanized Coatings on Fabricated Iron and
Steel Articles - Specifications and Test Methods
34 BS EN 10210-2 Hot Finished Steel Structural Hollow Sections - Toler-
ances, Dimensions and Sectional Properties
35 AISC Journal, El-Tayem; Adel A.; Goel, Subhash C. (1986). "Effec-
Vol. 23, pp. 41- tive Length Factor for the Design of X-bracing Sys-
45 tems"

4.2.3. Concrete
Indian
1 SP 16 Design Aids for Reinforced Concrete
2 SP 34 Handbook of Concrete Reinforcement and Detailing
3 IS 456 Code of Practice for Plain and Reinforced Concrete
4 IS 3370 (Part 1) Code of Practice for Concrete Structures for Storage
of Liquids, Part 1 : General Requirements
of Liquids, Part 2 : Reinforced Concrete Structures
of Liquids, Part 4 : Design Tables
7 IS 4326 Code of Practice for Earthquake Resistant Design and
Construction of Buildings
8 IS 4995 Criteria for Design of Reinforced Concrete Bins
9 IS 4998 Criteria for Design of RCC Chimneys
10 IS 6313 Code of Practice for Anti-Termite Measures in Build-
ings
11 IS 13920 Ductile Detailing of Reinforced Concrete Structures
Subjected to Seismic Forces
International
12 ACI 318M Building Code Requirements for Structural Concrete
13 NIST GCR 8- Seismic Design of Reinforced Concrete Special Mo-
917-1 ment Frames: A Guide for Practicing Engineers
14 PD CEN/TR Design and Use of Inserts for Lifting and Handling of
15728 Precast Concrete Elements

4.2.4. Foundation

Indian
1 IS 1080 Code of Practice for Design and Construction of Shal-
low Foundation in Soils (Other than Raft, Ring and
Shell)
2 IS 1904 Code of Practice for Design and Construction of Foun-
dation in Soils – General Requirements
3 IS 2502 Code of Practice for Bending and Fixing of Bars for
Concrete Reinforcement
4 IS 2911 (Part 1) Design and Construction of Pile Foundations – Code
of Practice, Part 1 : Concrete Piles
5 IS 2911 (Part 3) Code of Practice for Design and Construction of Pile
Foundations, Part 3 : Under-Reamed Piles
6 IS 2911 (Part 4) Code of Practice for Design and Construction of Pile
Foundations, Part 4 : Load Test on Piles
7 IS 2950 (Part 1) Code of Practice for Design and Construction of Raft
Foundation, Part 1 : Design.
8 IS 2974 (Part 1) Code of Practice for Design and Construction for Ma-
chine Foundations, Part 1 : Foundation for Recipro-
cating Type Machines.
chine Foundations, Part 2 : Foundation for Impact
Type Machines (Hammer foundations)
chine Foundations, Part 3 : Foundations for Rotary
Type Machines (Medium and High Frequency)
chine Foundations, Part 4 : Foundations for Rotary
Type Machines of Low Frequency.


chine Foundations, Part 5 : Foundation for Impact
Machines Other Than Hammers
13 IS 4091 Code of Practice for Design and Construction of Foun-
dations for Transmission Line Towers and Poles
14 IS 6403 Code of Practice for Determination of Bearing Capac-
ity of Shallow Foundations
15 IS 8009 (Part 1) Code of Practice for Calculation of Settlements of
Foundations, Part 1 : Shallow Foundations Subjected
to Symmetrical Static Vertical Loads
16 IS 8009 (Part 2) Code of Practice for Calculation of Settlements of
Foundations, Part 2 : Deep Foundations Subjected to
Symmetrical Static Vertical Loading
17 IS 11089 Code of Practice for Design and Construction of Ring
Foundation
18 IS 12070 Code of Practice for Design and Construction of Shal-
low Foundation on Rocks
19 IS 13063 Code of Practice for Structural Safety of Building on
Shallow Foundations on Rocks
20 IS 13301 Vibration Isolation for Machine Foundations - Guide-
lines
International
21 API 650 Welded Tanks for Oil Storage
22 AS 5216 Design of Post Installed and Cast-in Fastenings in Con-
crete

4.2.5. Reinforcement

1 IS 432 (Part 1) Specification for Mild Steel and Medium Tensile Steel
Bars and Hard-Drawn Steel Wire for Concrete Rein-
forcement, Part 1 : Mild Steel and Medium Tensile
Steel Bars
2 IS 1566 Specification for Hard-Drawn Steel Wire Fabric for
3 IS 1786 High Strength Deformed Steel Bars and Wires for
Concrete Reinforcement – Specification
4 IS 2502 Code of Practice for Bending and Fixing of Bars for
4.2.6. Masonry

1 IS: 1597 Code of Practice for Construction of Stone Masonry
2 IS 1905 Code of Practice for Structural Use of Unreinforced
Masonry
3 IS 2185 (Part 3) Specification for Concrete Masonry Units – Auto-
claved Cellular (Aerated) Concrete Blocks
4 IS 2212 Code of Practice for Brickworks
5 IS 6041 Code of Practice for Construction of Autoclaved Cel-
lular Concrete Block Masonry
4.2.7. Safety and General Guidelines

1 SP 7 National Building Code of India
2 IS 1642 Code of Practice for Fire Safety of Buildings (Gen-
eral) : Details of Construction


3 OISD STD 163 Safety of Control Room for Hydrocarbon Industry
4 OISD STD 164 Fireproofing in Oil and Gas Industry
5 OISD STD 173 Fire Protection System for Electrical Installations
5. Loads
5.1. Dead Loads
5.1.1. Dead loads shall be calculated as per IS 875 (Part 1). For self-weight of materials
(Dsw) not available in this code, American / British codes, specific literature, or ven-
dor data shall be referred.
5.1.2. Structural loads of components / members (Ds) those are not modelled in analysis,
such as grating, roofing, siding, handrail, ladder, wall, partitions, soil above the
foundation resisting uplift (overburden), etc. shall be considered.
5.1.3. Fireproofing loads (Dfp) that consist of weight of fireproofing material applied on
structural members shall be considered.
5.2. Live Loads
5.2.1. Live loads for buildings shall be in accordance with IS 875 (Part 2) as a minimum.
5.2.2. The following floor live loads (Lf) are applicable to plant buildings:
Specific Use UDL Concentrated Load (kN)

(kN/m2)
Storage areas for heavy 10.0 4.5
goods and battery rooms
Storage areas, light 5.0 4.5
Operating platforms / floors 5.0 4.5
/ stairs (including exit stairs)
Maintenance platforms 5.0 Weight of the heaviest piece of equip-
ment being dismantled or transmitted
across

Specific Use UDL Concentrated Load (kN)

(kN/m2)
Access platforms / walkways 2.5 4.5
(without equipment)
Switchgear rooms 7.0 4.5
Compressor / Generator op- 7.5 4.5
erating level floors including
platforms
Fixed ladders NA At least one 1.4 kN load for every 3 m
of ladder height; each load shall be
applied at any point to produce the
maximum load effect on the element
being considered
Handrails and guardrails NA 0.9 kN shall be applied in any direc-
tion on the top rail
(Note: The floor slab of switchgear rooms (where MCC panels are fixed) shall be
designed for actual location and loading of panel. However, the foundation shall be
designed for the live load as 10kN/m2).
5.2.3. Uniform and concentrated live loads listed in the table above shall not be applied
simultaneously. Position of concentrated load shall be such that it produces the
maximum stress.
5.2.4. Where the actual load is known to be greater than the above values, it shall be used
in the design.
5.2.5. Platforms and operating floors which are likely to be subjected to higher loads due
to erection/removal of equipment during installation/shutdown stage shall be de-
signed for higher loads.
5.2.6. For building structures, design-imposed loads for seismic load calculation shall be
in accordance with Cl. 7.3 of IS 1893 (Part 1).
5.2.7. For industrial structures, design-imposed loads for seismic load calculation shall be
in accordance with Cl. 9.1 of IS 1893 (Part 4).

5.3. Piping Loads

5.3.1. Piping loads shall be considered as dead loads. It shall be subdivided into,
a. Empty load of pipe (Dpe),
b. Operating load of pipe (Fpo),
c. Hydro test load of pipe (Fpt)
5.3.2. Piping loads on racks shall be provided by Plant Design & Piping group, based on
detailed piping analysis.
5.3.3. Piping Vertical Loads
a. Pipe Loads for Pipe Nominal Diameter < 300 mm (Dp)
i. For pipe levels in pipe racks and for members supporting multiple
pipes, in the absence of defined loads and locations, an assumed mini-
mum uniform pipe load of 1.7 kPa shall be used, for piping, contents
and insulation. 1.7 kPa corresponds to an equivalent load of 150 mm
lines full of water covered with 50 mm thick insulation and spaced on
300 mm centers. This assumption should be verified based on coordi-
nation with the Plant Design & Piping Group, and concentrated loads
should also be applied for any anticipated large pipes. For fast track
projects a uniform pipe load of 1.9 kPa may be used, with project man-
agement concurrence. When the actual loads and locations become
known, as the project develops, the structural design should be
checked against these assumed initial load parameters and revised as
required.
ii. Where consideration of uplift or system stability due to wind or seismic
load is required, 60 % of the design gravity loads as an "all pipes empty"
load condition shall be considered.
b. Pipe Loads for Pipe Nominal Diameter >= 300 mm
i. Pipe loads shall be considered as point loads at their actual location.
The point load is defined as P = s(w - pd), where,
s = Pipe support spacing, m
w = Weight of pipe including contents, kg/m
p = Uniform loading, kPa
d = Diameter of pipe (including insulation), mm

ii. Pipe empty loads consist of the weight of piping, valves, fittings, insu-
lation, etc.
iii. Pipe operating loads consist of the pipe empty loads and content
weight. In the absence of actual content weight for vapour / gas lines,
10% of the line in general and 30% of the flare line, shall be considered
as filled with liquid for content weight to account for condensation.
iv. Pipe hydrotest loads consist of the pipe empty loads and weight of the
hydrostatic test fluid. Consultations shall be made with Pipe Stress &
Support group and Project Engineering group for determination of lines
requiring hydrostatic testing.
5.3.4. Piping Horizontal Loads
a. Frictional / Thermal loads (Tf)
Friction loads caused by hot lines sliding across the pipe support during
startup and shutdown are assumed to be partially resisted through friction
by nearby cold lines. Therefore, in order to provide for a nominal imbalance
of friction loads acting on a pipe support, a resultant longitudinal friction
load is applied at each level, the magnitude of which shall be larger of the
following:
i. 10% of the total pipe weight or
ii. 30% of the operating pipe load of pipes known to be moving simulta-
neously in the same direction.
b. Anchor and Guide Loads (Ta)
The Anchor loads on pipe rack at anchor bays shall be given by Plant Design
& Piping group from pipe stress analysis. For pipe racks, in the absence of
loads provided by Pipe Stress & Support group, 7.5% and 10% of the pipe
total weight shall be used as anchor load and guide load respectively acting
at midspan of each bent.
c. Pipe rack designs shall be rechecked, when actual pipe loads, friction and
anchor loads are known from Plant Design & Piping group.
5.3.5. Piping Load on Longitudinal Beam Struts
a. For off-plot pipe racks, at expansion bays, the longitudinal beam struts shall
be designed for vertical and horizontal loads imposed by expansion loops,
located by Plant Design & Piping group.

b. The longitudinal beam struts that support piping or raceway should be de-
signed for 50% of the gravity loading assumed for the transverse pipe or
raceway support beams, unless unusual loading is encountered. This 50%
gravity loading will account for the usual piping and raceway take-offs. Nor-
mally, the gravity loading carried by the beam struts should not be added to
the design loads for the columns or footings since pipes or raceway contrib-
uting to the load on the beam struts would be relieving an equivalent load
on the transverse beams.
For any continuous piperack system where the anticipated piping and race-
way take-offs are minimal or none, the 50% loading criteria does not apply.
In such cases, the beam struts should be designed primarily as axially loaded
members supporting only the gravity loads. All longitudinal beam struts, in-
cluding connections, should be designed to resist the axial loads produced
by the longitudinal forces.
5.3.6. Water Hammer Loads (WH)
Structures supporting pipe shall be designed to resist water hammer loads from
piping, particularly for product loading / unloading lines. These loads shall not be
considered to act concurrently with thermal loads, wind loads, earthquake loads,
and slug / pressure relief valve loads.
5.3.7. Slug Loads / Pressure Relief Valve Loads (Psl)
Structures supporting pipe shall be designed to resist slug loads from piping or tran-
sient loads generated from pressure relief valves. These loads shall not be consid-
ered to act concurrently with thermal loads, wind loads, earthquake loads, and wa-
ter hammer loads.
5.4. Fluid Loads (F)
5.4.1. Fluid loads are loads due to internal and external fluids, with well-defined densities
and maximum heights. An example of fluid load is the load due to ground water on
structures and foundations.
5.5. Cable Tray Loads (Del)
5.5.1. A minimum vertical cable tray load of 1.0 kN/m2 per tray layer shall be used for
electrical/instrument trays.

5.6. Wind Loads (Wx, Wz)

5.6.1. Wind load shall be calculated in accordance with IS 875 (Part 3). The specific site
related information shall be obtained from BEDD (Spec No RPMS-ENGG-DBD-GE-
001).
5.6.2. For diagonal wind effects, Cl. 29.4 and Cl. C27.3.5 of ASCE 7 shall be referred along
with IS 875 (Part 3).
5.6.3. Wind Load on Piping
The transverse wind load on piping shall be applied on a projected area equal to
the diameter of the largest pipe including insulation where applicable plus 10% of
the useable width of the pipe rack, where the useable width of the pipe rack is
defined as the distance between inside faces of pipe rack columns minus clearances
required between column faces and piping.
5.6.4. Wind Load on Cable Tray
The transverse wind load on cable trays shall be applied on a projected area equal
to the height of the tray plus 10% of the net width of cable way dedicated to trays.
5.7. Seismic Loads (Sx, Sy, Sz)
5.7.1. Seismic loads shall be calculated in accordance with the following codes:
Building structures - IS 1893 (Part 1)
Liquid retaining structures - IS 1893 (Part 2)
Bridge and retaining walls - IS 1893 (Part 3)
Industrial structures including stack-like structures - IS 1893 (Part 4)
The specific site related information shall be obtained from BEDD (Spec No RPMS-
ENGG-DBD-GE-001).
5.7.2. Categorization of structures and equipment shall be based on the guidance given
in BEDD in consultation with project process engineers. Table 6 of IS 1893 (Part 4)
shall not be used.
5.7.3. For buildings and structures within plant, importance factor shall be based on re-
spective categorization of the buildings.
5.7.4. Seismic Load from Pile-Cap
An additional seismic load based on the pile-cap’s mass, need to be considered for
pile supported structures. The pile-cap shall be treated as a “rigid element” (refer

Section 5.3.5.5 of ASCE publication entitled “Guidelines for Seismic Evaluation and
Design of Petrochemical Facilities”) and consequently the seismic acceleration shall
be considered at EPGA (Section 3.10 of IS I893 – Part 4) level for the calculation of
seismic load in the pile-cap. Total seismic load resisted by pile group shall be the
combination of seismic base shear from superstructure (which is based on “fixed
base” assumption) and the additional seismic shear in the pile-cap. These two load
components shall be combined by SRSS method because of their differing
modal/phasing characteristics such that their individual response maxima do not
occur concurrently (refer Section 5.3.5.5 of the above mentioned ASCE publica-
tion). In some cases, however, where the superstructure and foundation are both
relatively stiff, such as a turbine or compressor on a heavy block foundation, the
seismic load on the piles should be the algebraic sum of the component loads.
• The load from pile-cap shall be calculated as per Cl. 6.4.2 of IS 1893 (Part 1):
where, Sa/g =1.0 and R =1.
• The seismic shear due to the foundation should not affect the vertical distribu-
tion of the seismic shear in the superstructure.
5.8. Blast Loads
For design basis for Blast Resistant Buildings refer Doc No RPMS-ENGG-DBD-CS-
004.
5.9. Cranes and Lifting Appliances Loads (CR)
5.9.1. The crane live load shall be the rated capacity of the crane. Design loads on crane-
ways include the maximum wheel loads of the crane and the vertical impact, lateral
and longitudinal loads induced by the moving crane. Impact and surge factors shall
be applied to vertical and horizontal loads in accordance to IS 875 (Part 2) depend-
ing upon the class and type of crane. Possibility of overloading from operations
point of view shall be evaluated and added to the design loads.
5.9.2. Particular attention must be given to the effect of crane stop loads on support
structures such as stoppers. However, bracing and foundation system shall not be
designed for this force.
5.9.3. Impact load due to elevators shall be applied to structures and foundations in ac-
cordance with Section 4.6 of ASCE 7.
5.10. Equipment Loads
Equipment loads shall be considered for the following conditions:

5.10.1. Empty Load (De)

Empty load shall consist of the empty weight of equipment including all attach-
ments, trays, internals, insulation, packing, agitators, ladders, platforms, etc. Based
on the equipment size, empty weight, and number of attachments, the empty
weight of equipment may be increased by 10 % to account for weight of attach-
ments.
5.10.2. Operating Load (Feo)
Operating loads shall consist of the equipment empty loads and the weight of op-
erating liquid, catalyst, or product to be contained in the equipment.
5.10.3. Hydro test Load (Fet)
Hydro test load shall consist of the equipment empty loads and the weight of test
medium, usually water, contained in the system to be considered under test. It is
required to verify the type of testing (hydrostatic or pneumatic) to be performed
in-situ, including the sequencing and locations with the Construction, Project Man-
agement, Project Engineering and/or the Plant Design & Piping Groups.
5.10.4. Dynamic Load (Fdyn)
Design of structures and foundations supporting equipment shall be carried out on
the basis of Manufacturer's information on loads, their mode of action and vibra-
tion characteristics. DEC shall ensure that, manufacturer's information shall include
all the requirements as specified in RPMS-ENGG-DBD-CS-010 and RPMS-ENGG-
DBD-CS-011.
5.11. Bundle Pull on Heat Exchanger (BP)
5.11.1. Horizontal load shall be taken as the weight of bundles if loosening devices are sup-
plied and used. (Min value = 10 kN).
5.11.2. Horizontal load shall be taken as 150% of weight of bundle for area other than crude
and 200 % (in the crude area), if no loosening devices are provided. (Min value =
10 kN).
5.11.3. If the total weight of the exchanger is less than 1000 Kg, the bundle pull design load
need not exceed the total weight of the exchanger.
5.11.4. The load evaluated from above shall be applied to supporting member at the fixed
end and the structure as a whole shall be checked for stability.

5.12. Thermal Expansion Loads (Te)

5.12.1. All equipment support structures and elements thereof shall be designed to accom-
modate the loads or effects produced by thermal expansion.
5.12.2. Thermal loads and displacements caused by operating conditions shall be based on
the difference between ambient or equipment design temperature and installed
temperature. Refer to BEDD (Spec No RPMS-ENGG-DBD-GE-001) for the ambient
temperature range.
5.12.3. Thermal expansion loads include loads due to expansion (or contraction) of hori-
zontal exchangers and vessels.
5.12.4. The static coefficient of friction for commonly used bearing surfaces shall be as fol-
lows:
Sr. No. Surfaces Friction Factor

1 Steel/Steel (un-corroded) 0.3
2 Steel/Concrete 0.45
3 Steel/Steel(lubricated) 0.15
4 ‘Lubrite’/Steel 0.15
5 PTFE/Stainless Steel 0.08 or as per
Manufacturer's
(Mating surfaces of Stainless Steel to be mirror pol-
data sheets
ished. Contact pressure to be between 10-25
N/mm²) whichever, is
more stringent
6 PTFE/PTFE 0.08
7 Concrete/Concrete 0.8
5.13. Culverts, Paving and Trench Cover Loads

Refer to RPMS-ENGG-DBD-CS-002.
6. Load Combinations
6.1. Basic load cases that are to be considered in structural design are listed in the ta-
ble below:

LC# Load Load Description Remarks

Case Type
1 Dsw Dead Structure Load – S/W of analyzed com-
ponents
2 Ds Dead Structure Load – S/W of non-structural
components
3 DFP Dead Structure Load – Fireproofing
4 DP Dead Piping Load for Pipe Diameter < 300 mm
5 DPE Dead Piping Empty Load for Pipe Diameter >=
300mm
6 De Dead Equipment Empty Load
7 FPO Dead Piping Operating Load for Pipe Diameter
>= 300mm
8 FEO Dead Equipment Operating Load
9 F Dead Fluid Load
10 Del Dead Cable Tray Load
11 Fpt Test Piping Test Load for Pipe Diameter >=
300 mm
12 Fet Test Equipment Test Load
13 LF Live Floor Live Load
14 WH Live Water Hammer Load
15 Psl Live Slug / Pressure Relief Valve Load
16 ML Live Maintenance Load
17 BP Live Bundle Pull Load
18 CR Live Crane and Lifting Appliances Load
19 Ta Thermal Piping Anchor & Guide Loads
20 Tf Thermal Piping Thermal / Friction Loads
21 Te Thermal Thermal Expansion Load

LC# Load Load Description Remarks

Case Type
22 WX Wind Wind in the X Direction See note
2
23 WZ Wind Wind in the Z Direction See note
2
24 SX Seismic Seismic Operating Load in X Direction See note
2
25 Sy Seismic Seismic Operating Load in Y Direction See note
2
25 SZ Seismic Seismic Operating Load in Z Direction See note
2
Notes:
Project may include additional load cases, if required.
X, Y & Z coordinate axis for the wind and seismic load cases listed above align with
coordinate axis orientation in STAAD (positive Y axis = vertical). If a different coor-
dinate axis orientation is chosen for a project, it is the responsibility of the Engineer
to modify the basic load cases and combinations as required.
6.2. The basic load combinations provided in IS 875 (Part 5) shall be used for the design
of buildings, structures, and foundations.
6.3. The load conditions shown in the following table of Load Combination Matrix, shall
be considered in the design of buildings, structures, and foundations. They do not
limit the Engineer's responsibility to check the most severe load combinations that
may exist.

Conditions
Primary Operation Test Erec- Mainte- Water Slug Blast Uplift

tion nance Ham- /
Loads Nor- With With With With
mer PRV
mal Wind Seis- Wind Seis-
mic mic
Weight of struc-
ture, empty X X X X X X X X X X X+
equipment, pip-
ing and electri-
cal
Weight of con-
tents (operating X X X X X X X
– empty) during
operation in
equipment and
piping
Weight of Hy-
dro-static test X
media (hydro
test – empty)
Piping Anchor
and Guide Loads X X X X X X
Piping Friction X
Load
Water Hammer X
Slug / PRV X
Live Loads X X X X^ X^^ X^^ X X X
Wind Loads# X X* X* X** X
Seismic Loads# X X
Thermal Loads X X X X X X
Bundle Pull X
Fluid Loads X X X X X X X
Equipment X X X
Dynamic Loads
Blast Loads X
Crane and Ele- X** X** X**

vator Loads
Maintenance X
Loads
+ Seismic load shall correspond to dead load considered

^ 75% of live load shall be considered under test condition
^^ Live loads may be reduced under erection and maintenance conditions after dis-
cussion with the concerned groups

# For any load combination, wind and seismic need not be considered acting
together.
* For short test and erection periods, 50% wind load shall be considered.
** Crane and elevator loads should be considered for operating load conditions
only when they occur frequently during the normal operation of the plant. If the
crane is provided for maintenance purposes only, then crane load should be con-
sidered as maintenance load. In such cases crane loads need to be combined with
50% wind load but need not be combined with seismic loads.
7. Structural Analysis
7.1. Analysis Method
7.1.1. First-order elastic analysis shall be carried out for all structures and structural com-
ponents.
7.1.2. Second-order elastic analysis shall be carried out for structures and structural com-
ponents wherever appropriate.
7.1.3. Structural stability must be ensured in all cases. Software analysis output files
should not contain any “Warning” message related to structural stability.
7.2. Lateral Load Transfer
7.2.1. Structures with Flexible Diaphragms
a. For structures with flexible diaphragms or without diaphragms, the lateral
loads shall be distributed to the column lines based on the tributary area of
each lateral-load-resisting system.
b. Structural framing at the locations of large pipe supports and equipment
supports shall be checked and designed for the large seismic loads that act
locally.
7.2.2. Structures with Rigid Diaphragms
For structures with rigid diaphragms, the lateral loads and lateral torsional moment
shall be distributed to the column lines based on the relative lateral stiffness of the
vertical resisting elements and diaphragm.
7.3. Moment of Inertia
7.3.1. For structural analysis involving seismic loads, moment of inertia, shall be taken as:
a. In RC and masonry structures (per Section 4.2 of NIST GCR-08-917-1)

I. For moment frame beams with large gravity loads, use 0.35 x Igross
(otherwise use 0.5 x Igross)
II. For moment frame columns, use 0.7 x Igross for zone 2 and 0.5 x Igross
for zone 3, 4 and 5
b. In steel structures: Igross for both columns and beams
7.3.2. For all other cases
In concrete and steel structures: Igross for both columns and beams
7.4. Damping
7.4.1. 5% damping shall be considered for bolted steel structures
7.4.2. 5% damping shall be considered for concrete structures
7.5. Modal mass participation and cut-off frequency
7.5.1. For most types of loadings, the displacement contributions generally are greatest
for the lower modes and tend to decrease for the higher modes. However, higher
modes are of greater significance in defining the forces in the structure. Base shear
for buildings with T1 (fundamental time period) within acceleration-sensitive re-
gion of the spectrum is essentially due to first mode. However, for structures with
T1 in the velocity or displacement-sensitive regions of the spectrum, the higher-
mode responses can be significant, increasing with increasing T1 and with decreas-
ing  (beam to column stiffness ratio).
7.5.2. In case of Response Spectrum analysis, sufficiently large number of modes shall be
used to satisfy one of the following criteria:
a. Capture influence of modes with at least 90% of the total seismic mass for
each direction of seismic excitation
b. Include modes up to cut-off frequency of at least 33 Hz, if 90% mass partic-
ipation is not achieved
7.5.3. Depending on how the mode frequencies compare with the deemed 33 Hz ZPA fre-
quency threshold, seismic response contribution of mode shapes shall be ac-
counted as follows:
a. Use the CQC modal combination for modes with frequencies smaller than
33Hz;
b. Use the missing mass correction procedure for all modes with frequencies
greater than 33 Hz.

7.5.4. The scenario as envisaged in Section 7.5.2.b is more likely for vertical seismic re-
sponse because structures tend to be stiffer in the vertical direction, and therefore
the missing mass correction procedure per Section 7.5.3.b will need to be exercised
for computing the total vertical seismic response.
7.6. Combination of Modes
7.6.1. CQC method of modal combination in general shall be followed, as it degenerates
into the SRSS method for systems with well-separated natural frequencies.
7.6.2. SRSS method of modal combination works well when modes are well separated
(10% or more of the lower frequency).
7.7. Interaction effects between structure and equipment shall be considered as per Cl.
9.2 of IS 1893 (Part 4).
8. Structural Design – Steel

8.1. Specific Design Data
8.1.1. The design of structural steelwork shall incorporate loading conditions applicable
to the specified equipment being supported. Temporary loading conditions that
may occur during equipment erection shall also be considered.
8.1.2. The final design shall consider the facilities available for transportation, handling
and erection of fabricated components.
8.1.3. Field or shop changes to steel structures including member substitutions and fabri-
cation / construction requirements shall be referred to DEC for approval.
8.1.4. Category of structures based on Risk Category in Table 1-5-1 of ASCE 7 shall be in-
dicated on the Design Drawing of each structure in order to determine weld inspec-
tion requirement as per clause 5.3.5 of Technical Specification RPMS-ENGG-SPC-
CS-002.
8.2. Types of Construction
8.2.1. This design basis is directed mainly to the use in structures of hot rolled steel sec-
tions, plates and tubular shapes.
8.2.2. The selected design shall take account of ease of erection, accessibility for painting
and general maintenance. Lattice type structures, other than roof trusses, should
therefore be minimized.
8.2.3. Fabrication of structural steelwork by shop welding is preferred. Field connections
shall be bolted as far as possible.

8.3. Structural Design

8.3.1. The structural design shall be in accordance with IS 800 by limit state design. While
designing the structure, attention should be given to Section 12 of the IS 800 deal-
ing with design and detailing for earthquake loads.
8.3.2. The structural column and connections shall be checked for additional load combi-
nations with seismic load as given in Cl. 12.2.3 of IS 800.
8.3.3. For special concentrically braced frames (SCBF) the compressive and tensile
strength of bracing member should comply with Cl. 12.8.2.3 and Cl. 12.8.2.4 of IS
800. For more details refer to Section 2 of Annex 1.
8.3.4. Top support beams of pipe rack frames shall be framed into the columns, with the
columns extended above the top of the beam so that stubs are provided where
future expansion is required. The length of the stub shall not be less than 250 mm.
8.3.5. Anchor and guide support shall be designed to meet the stiffness and deflection
criteria wherever optimization is required for large loads. Structural group shall pro-
vide stiffness value to Pipe Stress & Support group for stress analysis.
8.3.6. Vertical and horizontal bracings working points shall be as specified on the standard
drawings. If design working point location needs to be different from that specified
on the standard drawings, then it shall be shown on design drawings. Additional
loads due to the working point eccentricity shall be considered in design.
8.3.7. Whenever water hammer, pressure relief valves and slug loads occur in a structure,
framing shall be adequate to resist the lateral loads and minimize twisting of the
supporting steel. Local checks to be carried out for members subjected to above
loading shall be by doubling the load to check lateral bending capacity and keep the
interaction ratio less than 0.9.
8.3.8. Sliding Support – Width of the Beam supporting vessel sliding saddle shall be wide
enough to accommodate vessel thermal movement. The location of the vessel slid-
ing support, bolt tightening requirement and other special installation require-
ments shall be shown on design drawings. Special installation requirements as per
the vendor drawings shall be considered.
8.3.9. Clearance from Piping and Equipment: Framing members, including column and
bracing, should clear vessels, piping, and / or related attachments, insulation and
supports by a minimum 75 mm both vertically and horizontally.

8.3.10. Construction shall coordinate with the Engineering-in-Charge for the lifting or jack-
ing points and the type of the lift (straight lift, dual lift or single point lift) with Rig-
ging and Construction Groups. Lifting or jacking points and type of lift shall be indi-
cated on design drawings. Lifting lugs and associated column cap plates shall be
designed considering an impact factor of 1.5.
8.3.11. Plan bracing members which are part of seismic load resisting system (SLRS) shall
be plastic sections. Tee section (or cut Tee section from I-section) shall be preferred
for plan bracings. Bracings which are not part of SLRS need not be plastic sections.
For definition and details of SLRS refer to Section 1 of Annexure 1. Tee section In-
teraction ratio shall be limited to 0.7 to accommodate the effect of additional mo-
ment due to eccentricity.
8.3.12. A-Bracings or inverted A-Bracings are to be avoided. When A-bracings or inverted
A-bracings are provided, they shall be designed as per AISC 341. As per code, when
these bracings are provided, zipper columns or strengthening of horizontal beam
will be required.
8.3.13. Unbraced length of the X-brace in each orthogonal direction may be taken as half
the entire length of the brace provided the two segments of each diagonal are col-
linear and there is flexural continuity at the bracing intersection. (Reference no. 35
of Section 4.2.2)
8.3.14. The selection of members shall be based on following guidelines:
a. UC sections should be selected for columns and UB/ISMB sections for
beams.
b. Where UC/UB sections are not adequate, flange plates can be used to in-
crease stiffness of members. Alternatively, for columns compound sections
using UB/ISMB sections with lacing or star I-sections may be used. Only, in
exceptional cases, built-up/plated sections shall be provided.
c. In sheds, ideally, compound UB/ISMB section with lacing may be provided
as column up to gantry level. Beyond gantry level, single UC section can be
used.
d. Bracing members shall be plastic sections for seismic governing structures.
8.4. Design of Connections
8.4.1. Connections shall be designed as per IS 800. Design of connections of column
splices, bracings, beam column connections which are resisting seismic loads shall
be designed for enhanced forces as per Section 12 of IS 800.
8.4.2. Moment connections shall be designed as per the prequalified connections detailed
in AISC 358. In case there is a restriction on providing stiffeners as required for 8-
bolt extended stiffened end plate, then bolts may be provided as per AISC-DG16.
8.4.3. Column Base
a. Column bases shall be designed following the recommendations given in
AISC-DG1.
b. Pinned column bases are preferred over fixed column bases
c. Where vertical braces are at or near the bottom of column base, the same
shall be defined as pinned base.
d. Pinned bases preferably shall have anchor bolts located inside the column
flanges
e. Horizontal shear transfer from column base plates to the foundation shall
be developed by shear in the anchor bolts or by other mechanical means,
such as shear keys.
f. The base plate and shear key shall be designed for load combinations in-
cluding those given in Cl. 12.2.3 of IS 800. However, column bases and shear
keys need not be designed as per Cl. 12.12.2 of IS 800. Design method as
described in Section 3 of Annexure 1 may be followed for ductile design of
base plate and its associated attachments.
8.4.4. For columns which have a net compressive load, shear shall be resisted by friction.
Shear key shall be provided only for balance shear if applicable.
8.4.5. Design of shear keys shall be largely based on AISC DG - 1. Based on this guide,
shear shall be resisted by only one face of shear key in any direction. However,
shear resistance within concrete pedestal may be achieved using links.
8.4.6. For shear key design the grout thickness shall not be considered.
8.4.7. Shear keys need not be provided in columns which are not resisting shear.
8.4.8. The shape of shear key can be I-sections for columns requiring shear key in one
direction and ‘+’ shape made of plates for columns requiring shear key in both di-
rections. The design shall be such that sufficient space is available for welding and
sufficient clearance is kept from grout holes in the base plate.
8.4.9. The base plates shall be sized in such a way that they have sufficient bearing on
concrete beyond pockets for shear key.

8.4.10. Minimum thickness of gusset plates shall be of 10 mm for main steel.

8.4.11. Welding electrodes shall conform to AWS D1.1 and have minimum tensile strength
of 480 MPA.
8.4.12. The acceptance criteria for structural welding shall be in accordance with AWS
D1.1. Different acceptance criteria apply to joints of statically and cyclically loaded
structural members. Static equipment can be classified as follows: vertical vessels,
horizontal vessels, shell and tube exchangers and reboilers, air cooler exchangers,
free standing stacks/chimneys, guyed stacks, furnaces / fired heaters and cooling
towers. Cyclically loaded structures are designed to support rotating and recipro-
cating equipment. The following equipment fall into this category: pumps and com-
pressors weighing over 22.5 kN, vertical pumps weighing over 24.5 kN, centrifugal
compressors and turbo generators, and the reciprocating compressors. Based on
the above guideline the steelwork GA drawings shall contain proper references to
equipment number, mechanical specifications, as well as statements of specific
testing requirements with respect to cyclic type of loading. In absence of such state-
ment the structure shall be considered statically loaded. Drawings or cut sheets
which have cyclically loaded non-tubular connections shall be marked with auto
generated stamp - CYCLICALLY LOADED PARTS. In absence of such stamp/marking
on detail drawing (cut sheet), respective non-tubular shall be considered as stati-
cally loaded.
8.5. Detailing of Connection
8.5.1. High strength structural bolts shall be property class 8.8 or property class 10.9. High
strength structural bolts and their associated nuts and washers shall be in accord-
ance with RPMS-ENGG-SPC-CS-015. Structural bolts shall be 20 mm diameter min-
imum.
8.5.2. Ordinary bolts shall be property class 4.6. Ordinary bolts and their associated nuts
and washers shall be in accordance with RPMS-ENGG-SPC-CS-015. Use of ordinary
bolts shall be as noted on the drawings. Maximum size of ordinary bolts shall be
16mm diameter.
8.5.3. Bolts of property class 4.6 and 8.8 along with corresponding nuts and washers shall
be furnished hot-dip galvanized in accordance with IS 1367 (Part 13). Bolts of prop-
erty class 10.9 along with corresponding nuts and washers shall be PTFE coated or
alternatively with ASTM F2833 applied in accordance with SPC-CS-015. Nuts shall
be property class 10 for property class 8.8 galvanized bolts.

8.5.4. Washers shall conform to IS 2016, IS 5372, IS 5374, IS 6610 for ordinary bolts and
IS 6649 for high strength bolts.
8.5.5. Bolts shall be designed as bearing bolts unless otherwise specifically noted.
8.5.6. The following connections shall have pretensioned bolts. The pre-tensioning loads
shall be as given in RPMS-ENGG-SPC-CS-002.
a. Seismic load resisting system such as moment resisting frame, braced frame
– bracing and beams, etc.
b. Column splices.
c. Collector members and plan bracings acting as horizontal diaphragms
which are transferring load to the vertical bracing system.
d. Structures carrying cranes of over 50 kN capacity: roof truss splices and con-
nections of trusses to columns, column splices, column bracing, knee
braces, and crane supports. Other connections need not be pre-tensioned.
e. Connections for the support of equipment, moving loads (example Crane)
and other live loads that produce impact or reversal of loads.
f. Property class 10.9 bolts.
8.5.7. The bolted connections of cable tray structures supporting cable trays above pipe
support levels in pipe racks need not be pre-tensioned, if such structures are wind
governing.
8.5.8. Welds used in frames designed to resist earthquake loads shall be complete joint
penetration (CJP) butt welds, except as follows:
a. Welds to stiffeners can be fillet welded.
b. Vertical bracing gusset plates connected to the web of columns having
depth less than 275 mm can be PJP / fillet welded due to access considera-
tions.
c. Splices of sections with depths less than 275 mm can have fillet welded
splices with plates at flanges and web designed for full strength. This is for
splices for building up sections from cut lengths.
d. Plan bracings gussets can be fillet welded.
8.5.9. For non-critical structures (non-seismic load resisting structure) ductile design re-
quirements as per Section 12 of IS 800 may not be followed if Response Reduction
Factor (R) is considered as 1 for seismic design.

8.5.10. All main bolted connections shall be provided with a minimum of two 20 mm bolts
of property class 8.8.
8.5.11. Column bases shall be designed with a minimum of four anchor bolts. Posts weigh-
ing less than 125 kg are excluded from this requirement.
8.5.12. Washers shall be parallel or tapered to suit rolled steel Sections being connected
and shall be provided under the nut.
8.5.13. Lock nuts shall be provided for bolts securing crane runway beams to main framing,
members supporting vibrating equipment, equipment with sliding supports and
guide supports for ladders and for expansion or isolation joints in pipe racks or
structures. See Annexure 2 for typical details.
8.5.14. Schedule CT1 of RPMS-ENGG-SPC-PP-014 specifies special painting requirements
for structures in the splash zone as opposed to the general steel structures and
same must be mentioned in the design drawings. The splash zone shall cover struc-
tural steel members within 50 m radius from the periphery of the cooling tower.
The concerned structures shall be separately identified and mentioned in the draw-
ings. Cut sheets of structures near splash zone shall be notified for special painting
purpose as per Schedule CT1 mentioned in the painting specification.
8.6. GA Drawings
8.6.1. The General Arrangement (GA) drawings shall consist of plans and elevations
clearly showing all the members constituting the structure.
8.6.2. Wherever PDS / SP3D model is made, GA drawing should preferably be extracted
from the model after ensuring that all structural members are clear of obstructions.
DEC shall ensure integration of TEKLA Model, with connection / gusset plates into
final PDS / SP3D model to ensure that it is clash free with other interface elements
like piping / cable trays, equipment nozzles, etc.
8.6.3. The GA drawings should clearly show the type of connections welded or bolted and
details of each of the connections should be covered either in standard connection
drawings or by means of specific details shown on the drawings.
8.6.4. The elevation drawings should clearly show the bolted connections that need to be
pretensioned and pipe rack expansion joints or likewise in structures.

8.6.5. The GA drawings shall show Opening for Erection (OFE) to be left in place for the
erection of critical equipment. The engineer needs to check the stability of the
structure with OFE and temporary bracings / beams needs to be provided if re-
quired to keep structure safe with OFE. These temporary beams/bracings shall be
removable with bolted connections. OFE should be later closed by members shown
on design drawings with bolted connections.
8.6.6. The GA drawings shall show extent of fireproofing based on Hazop study.
8.7. Flooring
8.7.1. Open grid flooring shall be serrated rectangular open grid type with load bearing
bars 30 mm deep x 5 mm thick at 30 mm centres with cross members at 100 mm
centres, hot dip galvanized after fabrication.
8.7.2. Open grid flooring shall be attached to the supporting steelwork with clips or other
effective means. Welding of galvanised open grid flooring and drilling holes through
supporting members should be preferably avoided. Holes or cut-outs in panels shall
be made by the flooring manufacturer and have perimeter stiffening strips welded
in. This work is to be carried out before galvanizing. However, openings less than
150 mm diameter shall be made at site as shown on steel GA drawings.
8.7.3. Chequered plates shall have a raised pattern affording a non-slip surface and shall
be minimum 6mm thick exclusive of pattern.
8.7.4. Chequered plates shall be attached to the supporting steelwork with proprietary
connectors, unless otherwise noted on the layout drawings. Unsupported edges
shall have a 60 x 10 mm butt-strap. A 13 mm diameter drainage hole shall be pro-
vided for every 1.5 m2 of floor plate, with a minimum of one hole per panel, unless
shown otherwise on design drawings.
8.7.5. Deflections for floor panel must not exceed span/200 or 6 mm whichever is the
smaller.
8.7.6. Galvanizing shall be in accordance with IS 4759 or BS EN ISO 1461 with minimum
weight coating of 610 g/m2.
8.7.7. The weight of removable flooring sections shall not exceed 75 kgs for ease of han-
dling.

8.8. Stairways
8.8.1. Stairways shall be provided for access to platforms serving equipment which re-
quires regular and frequent operational attendance or rapid escape or access in the
event of an emergency.
8.8.2. Stairs shall have a minimum clear width between stringers of 750 mm.
8.8.3. Main access and escape stairs shall have a minimum clear width of 1000 mm.
8.8.4. All stairs in the same building or structure shall, if possible, have the same slope,
and stair handrails shall be continuous with platform handrails. Stairs shall be ar-
ranged to have a slope between 35° and 38° to the horizontal.
8.8.5. Stairs shall have maximum riser height of 190mm and minimum width of tread
250mm.
8.8.6. The vertical distance between landings shall be such that no more than 16 risers
occur in a single flight of stairs and not more than 32 risers without change of di-
rection.
8.8.7. Landings shall be 1200mm minimum width. Clearance over stairs shall be such that
a minimum vertical clearance of 2100 mm measured at the nose of a tread shall be
maintained.
8.8.8. Treads shall be serrated rectangular pattern open grid type, (30 mm x 5 mm bearing
bars at 30 mm centers with cross members at 100 mm cross centers) with non-skid
abrasive nosing, hot dip galvanized after manufacture.
8.8.9. Entrance and exits from stairways shall always be from a landing. Doors shall not
open directly onto stairways.
8.8.10. The above parameters shall also conform to local area statutory requirements.
8.9. Ladders
8.9.1. Ladders shall be provided when:
a. Access to platforms do not have staircase.
b. As an emergency escape from a platform which is already served by a stair-
way.
c. For access to locations where no platform is necessary but where observa-
tion of a process condition is required, which will not create a hazardous
safety situation.

8.9.2. Ladders shall have a width of 450 mm inside stringers. In general, ladders shall be
vertical.
8.9.3. If inclined ladders are used, the slope shall be not less than 75 degrees to the hori-
zontal and shall only be used where the vertical off-setting of ladders is not practi-
cal.
8.9.4. Side access ladders shall be given preference to front access. Ladders shall be ar-
ranged to prevent access to the back or non-climbing sides.
8.9.5. Ladder rungs shall be 20mm diameter round steel bar. Spacing between ladder
rungs shall not exceed 300 mm. The first rung from the base of pedestal / cheq-
uered plate / grating shall be minimum 150 mm and maximum 300 mm.
8.9.6. Ladder rungs shall be positioned such that the top of the rung is at the same eleva-
tion as the platform served.
8.9.7. Ladders serving platforms and landings 1200 mm or more above grade shall be
equipped with a safety gate.
8.9.8. Ladders serving platforms or landings from 1500 mm to 2500 mm above grade shall
be provided with a single top hoop only at handrail level.
8.9.9. Ladders serving platforms or landings 2500 mm above grade shall be equipped with
safety cages. Safety cages shall start at 2500 mm above grade or landing.
8.9.10. Permanent ladders starting from grade shall have a maximum vertical run of 9000
mm between rest platforms.
8.9.11. Changes in inclination of ladders shall be avoided as far as possible but if this is
impractical, intermediate platforms shall be provided to avoid a change of inclina-
tion within a flight.
8.9.12. Where the bottom of a ladder stands at a platform 5000 mm or more above grade
and the horizontal distance between the face or edge of the ladder and the handrail
of the platform is less than 1200 mm, the vertical cage bars shall be extended to
the handrail of the platform unless they thereby impede access. An additional bar
or bars shall be extended from the bottom cage band to the handrail at the side of
the ladder when the handrail is within 1200 mm of the edge of the ladder.
8.9.13. Ladders shall be 230 mm clear of obstructions including insulation.

8.10. Handrails and Toe Plates

8.10.1. Handrails shall be extended around edges of platforms, landings, walkways and
stairs at a height of 1100 mm except as noted in Section 8.10.3.
8.10.2. Platforms and walkways located at 1200 mm or more above grade shall be provided
with handrails on all sides.
8.10.3. Platforms and walkways at less than 1200 mm above grade shall be provided with
handrails on one side only.
8.10.4. Platforms and walkways 1800 mm or more above grade shall be provided with toe
plates. Toe plates shall also be provided around pipe penetrations through plat-
forms.
8.10.5. Toe plates shall be 100 mm high x 6 mm thick unless shown otherwise on design
drawings.
8.10.6. Maximum centers of handrail posts shall be 1500 mm.
8.10.7. Toe Plates shall extend continuously around edges of platforms, landings, walkways
and openings except at stair and ladder accesses
8.10.8. In side entry ladder, the ladder with rungs shall extend up to the top of handrail
and the cage of ladder shall be connected to top of handrail. In front entry ladder,
the topmost rung (top of rung) shall be at the level of platform and stringers shall
extend up to the top of handrail and connect to the handrail.
8.11. Shelters
8.11.1. The structure of shelters shall be designed preferably as portal frames with a mini-
mum of bracing to facilitate maintenance access.
8.11.2. Metal clad roof shall have minimum slope of 5⁰.
8.11.3. Metal siding and roofing products shall be from a single manufacturer/ contractor,
unless noted otherwise in this specification, to ensure a compatible weather tight
system.
8.11.4. Roof and side cladding shall be profiled sheeting terminating at a suitable height
above ground. Glazing or translucent sheeting shall be kept to a minimum. The
profile of translucent sheeting must match with wall and roof sheeting profile.
8.11.5. At high pressure zones at the eaves, apex and gable ends as defined in Cl. 7.3 of IS
875 (Part 3), a reduced purlin / girt spacing shall be adopted.

8.11.6. In shelters where overhead cranes are installed, suitable access shall be provided
for maintenance and operation of the crane. Crane stops shall be designed in ac-
cordance with crane manufacturer's requirements.
8.11.7. In other respects, the structures must comply with this specification and local reg-
ulations.
8.12. Fireproofing
8.12.1. DEC is to identify and mark the extent of fireproofing in the GA drawings.
8.12.2. Knee and diagonal braces that contribute to the support of gravity loads shall be
fireproofed. Bracing that is used only to resist wind or earthquake loading need not
be fireproofed.
8.12.3. CPS: Pipe Supports (e.g T-posts, Hangers, etc) located within the fire hazard area
supporting pipes equal to or larger than 150 mm in diameter or important piping
(such as relief lines, blowdown lines or pump suction lines from accumulators or
towers) shall be fireproofed. Pipe supports for lines less than 150 mm but carrying
hydrocarbons shall be fireproofed.
8.12.4. The fire proofing material may be vermiculite cement, concrete or intumescent
paint which should be able to withstand 2 hours fire.
8.12.5. Vermiculite cement is preferred as it is easy to apply, giving smooth finish and cost
effective.
8.12.6. Intumescent paint is an expensive option and shall be used only where other op-
tions are not feasible.
8.12.7. The thickness and fireproofing material (vermiculite) shall be confirmed by fire-
proofing contractor based on UL certificate for 2-hours fire rating.
8.12.8. The structural fabricator shall provide primer coat as specified in SPC-CS-026 on the
surface to be fireproofed to ensure protection from corrosion/handling till it is fire-
proofed.
8.12.9. If required, the final painting compatible to the fireproofing material shall be sup-
plied and applied by the fireproofing contractor.
8.12.10. The fireproofing contractor is responsible for the supply and installation of fire-
proofing material and associated reinforcing mesh and studs.
8.12.11. The fireproofing contractor shall furnish the necessary UL certificate for the fire-
proofing material used.

9. Structural Design – Concrete

9.1. Codes / General
9.1.1. Limit state method shall be used in accordance with IS 456 for the design of build-
ings and IS 3370 for the design of liquid retaining structures.
9.1.2. Ductility requirements for applicable members shall be in accordance with IS
13920.
9.1.3. ACI 318M shall be used for the design of following structural components:
a. Corbel
b. Anchor Bolts
9.1.4. Annexure 3 provides guidelines for material of construction, types of construction,
design philosophy and joint details for precast concrete piperack.
9.2. Cover to Reinforcement
Concrete cover to reinforcement, including links or ties shall not be less than the
following:
Concrete cast against / in contact with soil 75 mm

(without formwork)
Footing sides, bottom and top 50 mm
Marine Substructures 75 mm
Columns Beams and pedestal 50 mm
Slabs 30 mm
Walls 50 mm
9.3. Anchor Bolts, Sleeves, Embedded Items and Anchor Fasteners

9.3.1. Cast-In Anchors
a. Cast-in anchor bolts shall be designed per guidance provided in Chapter 17
of ACI 318M.
b. The loads and load combination used for anchorage design shall be normal-
ized with respect to load combinations specified in Cl. 5.3 of ACI 318M. Al-
ternatively, the strength reduction factors of Cl. 17.3.3 of ACI 318M shall be

normalized by an additional factor of 0.9 for wind load combinations to be

consistent with load combinations of IS 800 / IS 456.
c. The 28-day characteristic concrete cube strength shall be multiplied with a
factor of 0.8 for use as characteristic concrete cylinder strength in ACI 318M
strength calculations.
d. The “nominal strength” of anchors/ group of anchors in various failure
modes shall be as per following table:
Failure Mode ACI 318M Single Anchor group

Anchor
Cl. No. Single An- Anchors
chor in a as a
Group Group
Steel strength in Tension 17.4.1 X X -
Concrete breakout 17.4.2 X - X

strength in Tension
Concrete pullout strength 17.4.3 X X -
in Tension
Concrete side face blow- 17.4.4 X - X
out strength in Tension
Steel strength in Shear 17.5.1 X X -
Concrete breakout 17.5.2 X - X

strength in Shear
Concrete pryout strength 17.5.3 X - X
in Shear
The “design strength” of anchors for non-seismic case shall be determined by
applying appropriate “strength reduction factor” to “nominal strength”.
e. The “design tensile strength” of anchors for seismic design shall be deter-
mined by multiplying an additional factor of 0.75 over and above “strength
reduction factor” for concrete failure modes viz. concrete breakout, pullout

and side face blowout per Cl. 17.2.3.4.4 of ACI 318M, unless it can be
demonstrated that concrete remains uncracked. However, no such reduc-
tion is required for computation of “design shear strength”.
f. Transfer of tensile and shear loads shall preferably be thru provision of “an-
chor reinforcement” provided in accordance with Cl. 17.4.2.9 and Cl.
17.5.2.9 respectively instead of relying on concrete breakout strength. A
strength reduction factor of 0.75 is to be applied over nominal reinforcing
bar strength in computation of design strength irrespective of seismic/ non-
seismic design condition.
Anchor reinforcement shall be developed in accordance with Cl. 25.4.2 of
ACI 318M for straight bars and Cl 18.8.5.1 of ACI 318M for standard hooks
on both sides of potential breakout cone. No further reduction in design
tensile or shear strength of anchor bars is required for seismic load case per
Cl. 17.2.3.4.5 or Cl. 17.2.3.5.4 of ACI 318M, if developed as above.
g. The diameter of rebar used as anchor reinforcement in shear is recom-
mended to be limited to 16 mm for constructability consideration.
h. The anchor reinforcement shall be located within a confined core.
i. Anchor bolts shall satisfy the additional ductility requirement of Cl. 17.2.3
of ACI 318M for seismic load case in moderate and high seismic zones only
if seismic load component of tensile or shear load is more than 20 % in a
load combination.
I. For tensile load in anchor bolts (Cl. 17.2.3.4 of ACI 318M)
▪ Concrete-governed nominal strength (including anchor reinforce-
ment nominal strength if provided) shall be greater than 1.2 times
the nominal steel strength of bolt. The bolt shall be provided with
a stretch length of at least eight times bolt diameter.
▪ Alternatively, the anchor bolt / bolt group shall be designed for ten-
sion load obtained from load combinations with earthquake loads
increased by a factor of 2.50 per Cl. 12.2.3 of IS 800. The concrete
design strength shall be factored with 0.75 as required in Cl.
17.2.3.4.4 of ACI 318M. However, in case of anchor bolts for rigid /
non ductile equipment such as tanks and horizontal vessel, this al-
ternative shall not be utilized due to absence any ductile mecha-
nism in superstructure.

II. For shear loads in anchor bolts (Cl. 17.2.3.5 of ACI 318M)
▪ Anchor bolt / bolt group shall be designed for maximum shear
transmitted through development of ductile yield mechanism in at-
tachment. In absence of such information such as in case of equip-
ment, the concrete-governed design strength (including anchor re-
inforcement design strength if provided) shall be greater than de-
sign steel strength of anchor bolts.
▪ Alternatively, the anchor bolt / bolt group shall be designed for
shear load obtained from load combinations with earthquake loads
increased by a factor of 2.5 as per Cl. 12.2.3 of IS 800. The concrete
design strength shall be as per Cl. 17.3.1.1 of ACI 318M (no multi-
plication with seismic factor i.e. 0.75 is required in this case).
j. Two closely spaced ties shall be provided near bolt head as a precaution
against side face blowout in pedestals. Supplemental reinforcement may
be provided in the form of regular transverse ties or hairpins to restrain the
side face blowout load using ties near anchor plate as indicated in sketch
below.
Design ties for a force F =  x T

Where,
 = max {0.1*√(p/fc’), 0.037*(p/fc’)} but > 0.25 and < 0.50
p = bearing pressure at bolt head
k. Anchor bolts subjected to both tension and shear shall be checked for inter-
action as per Cl. 17.6 of ACI 318M.
l. If shear key is provided, bolts do not participate in shear load transfer.

m. For non-seismic load combinations, jobsites in low seismic zones or if seis-

mic loads do not govern (20% criteria as mentioned above), shear transfer
may be considered thru friction between base plate and concrete if ade-
quate vertical load is present corresponding to shear load in load combina-
tions.
n. If shear key is not provided and bolts are designed to resist shear,
i. All bolts/anchors are considered to resist shear equally if base plate is
provided with standard bolt holes or if anchors are rigidly connected to
plate (such as in studs welded to embed plate).
ii. For base plates with oversized bolts holes, only 50% of bolts shall be
considered for determination of steel strength in shear of the bolt
group. However, if the washers with standard holes are welded to such
base plate post installation, all bolts shall be considered to resist shear
equally.
iii. Note that it is preferable to provide higher bolt size or a shear key if
loads are considerably high to avoid additional site work of welding
washers to base plate and field touch up to coating system.
iv. Shear force transfer to concrete from the bolt group is considered in
such a way that shear is transferred at rear anchor bolt location in the
direction of shear for formation of breakout cone.
o. Where anchor plate is provided at head of anchor bolt, it shall be permitted
to calculate projected area of failure surface from an effective perimeter.
The effective perimeter shall not exceed the value at a section more than
the thickness of plate from edge of nut at head.
p. The steel strength of bolts shall be reduced by a factor of 0.8, if thickness of
grout is between 0.5 x bolt diameter and 5.0 x bolt diameter subject to a
maximum of 40 mm. For grout thickness more than limit indicated, the bolt
shall be checked for bending action per Cl. 4.2.2.4 of AS 5216.
q. Minimum center to center distance of cast-in anchor bolts shall be 4 x bolt
diameter for non-torqued bolts and 6 x bolt diameter for torqued bolts.
r. Edge distance from nearest concrete edge to center of bolt shall be such
that it avoids interference of bolt / sleeves / anchor plates with reinforcing
bars while maintain the minimum concrete cover requirement for bolts /

sleeves / anchor plates. For torqued bolts, the bolt center to nearest edge
shall be minimum 6 x bolt diameter.
s. Anchor bolts shall be provided with double nuts except for bolts used for
minor foundations such as stairs, handrails, ladder, pipe supports, electrical
supports, small skids, electrical panels etc.
t. Standard drawing RPMS-SD-C15-303 shall be referred to for standard de-
tails of cast-in type anchor bolts.
9.3.2. Post Installed Anchors
In general, embed plates shall be used to connect to steel members. Only in excep-
tional cases, anchor fasteners shall be used where embed plates are not provided.
DEC shall refer to anchor fastener vendor’s technical documentation, such as Euro-
pean Technical Approval Guidelines (ETAG) by the European Organisation of Tech-
nical Approvals or ICC-ES evaluation reports (ESR), for strength determination and
usage limitations of the anchor fasteners. Following types of anchor fasteners shall
be used:
a. Undercut Mechanical Anchors shall be used in critical pipe supports and ro-
tary equipment supports. It may also be used when anchoring is required
in overhead position.
b. HSL Mechanical Anchors shall be used in non-critical supports like utility
pipe supports, cable tray supports, false ceiling hangers etc.
c. Chemical Anchors can be used in both critical and non-critical applications.
9.4. Bearing Plates
9.4.1. Bearing plates shall be provided between top of foundations or piers and equip-
ment base plates for equipment subject to movement due to thermal expansion or
contraction. Specific applications are horizontal exchangers and vessels, heaters,
and furnaces. Bearing plates should conform to IS 2062 and painted per project
specification.
9.4.2. The slide end bearing plate shall be lubricated with “MolykoteR G-n Metal Assem-
bly Paste by Dow Corning” or have Teflon pads. Refer to Section 5.11.4 for static
coefficients of friction for the usual types of bearing surfaces.
9.4.3. Bearing plates shall be provided for slide end piers only.

9.5. Grout
9.5.1. Grout materials and methods employed for installation shall conform to the re-
quirements of RPMS-ENGG-SPC-CS-001.
9.5.2. Equipment base plate operating temperatures shall be obtained to ensure pro-
posed grout materials can withstand expected temperatures as per manufacturer’s
recommendations.
9.5.3. Differences in thermal coefficients of expansion between epoxy grout and concrete
shall be considered during design so as to prevent excessive stresses and cracking
at grout edges. Proper grout details shall allow for expansion joints, grout cut backs,
corner reinforcing or added epoxy depth at corners to prevent cracks.
9.5.4. Grout Thickness
a. For grout pad area smaller than 600 x 600 mm, minimum grout thickness
should be 25 mm.
b. For grout pad area between 600 x 600 mm and 1200 x 1200 mm, grout
thickness should be 50 mm.
c. For each 600 mm increase in grout pad area dimensions, grout thickness
should be increased by 25 mm up to a maximum thickness of 100 mm.
9.5.5. Areas to be grouted shall be shown clearly on the design drawings. Design details
for grout shall be in accordance with the grout manufacturer’s recommendations.
9.5.6. Where grout is provided along the full perimeter of equipment baseplates / skids /
vessels, provide suitable drain holes within the thickness of grout by using half-cut
PVC sleeves.
9.5.7. Vent holes (25 mm in diameter) should be located in structural base plates near the
intersection of all crossing stiffeners and at each point where air may be trapped
during a grout pour. The design drawings shall show the location of grout vent
holes.
9.5.8. Grout placement holes (75 to 150 mm in diameter) should be located in large struc-
tural base plates so that grout does not have to travel more than 1200 mm. The
design drawings shall show the location of grout placement holes.

9.6. Coating Systems

9.6.1. Where the necessity for coating systems to protect concrete against aggressive
chemicals (e.g. acid, caustic, etc.) has been determined by project criteria, selection
and design of the coating system shall be performed in consultation with the coat-
ing specialist.
9.7. Constructability Considerations
9.7.1. Considering ease of concrete placement, beam reinforcement shall be designed in
such a way that a minimum 50 mm clear gap shall be maintained between the bars
in the same layer and higher diameter of bar between any 2 layers.
9.7.2. Where embed plates are provided on top of columns / piers, the minimum clear-
ance for concrete placement can be provided by increasing the dimensions of the
columns / piers or detailing a hole in the embed plate.
Note: The location and dimensions of the hole in the embed plate shall be coordi-
nated with Pipe Stress & Support Group for pipe movement and support connec-
tion requirements.
9.7.3. Where a high-density of reinforcement is present in concrete members, clearances

for anchor bolts or embedded items should be checked.
9.7.4. Mechanical splices (couplers) should be considered instead of lap splices in areas
with congestion of reinforcement. For column bar diameter 25 mm and above,
splicing shall be done using mechanical couplers of type 2 as per ACI 318M.
9.7.5. Where there are large openings /pockets/through embedment in precast/cast-in-
situ RCC sections, proper analysis shall be done for checking the adequacy of the
remaining sections and minimum 75 mm concrete cover should be available around
the openings.
9.7.6. Constructability Considerations for Anchor Bolts:
a. Anchor bolts should not be extended into footings / mats if possible.
b. Shear lugs at column bases should be used only where required.
c. If projecting anchor bolts can interfere with construction or maintenance
activities, use of split bolt with coupling nut should be considered.

10. Structural Design – Masonry

10.1.1. Design procedures for masonry building components and related masonry criteria
shall be in accordance with IS 1905. For autoclaved cellular concrete (AAC) block
masonry, IS 2185 (Part 3) and IS 6041 need to be followed.
10.2. Design Requirements
10.2.1. Masonry buildings shall be one of the two following types:
a. Load bearing exterior masonry walls; joists and metal roof deck supported
by exterior walls and interior columns, as required.
b. Non-load bearing exterior masonry walls; joists and metal roof deck sup-
ported by steel column and beam frame system.
10.2.2. Lateral stability of buildings shall normally be accomplished through utilization of
one of the two following systems:
a. Shear wall / diaphragm system consisting of:
i. Exterior and/or interior masonry walls parallel to wind direction acting
to resist total horizontal wind load. Walls must be structurally inte-
grated with foundation and roof system.
ii. Roof deck acting as a diaphragm transmitting the horizontal load from
wind or seismic effect to the shear walls.
b. Column and beam frame system comprised of:
i. A steel column and beam frame employed for support of roof deck or
multiple floor levels.
ii. Braced frames or rigid frames utilized to resist total horizontal load
from wind or seismic effect.
iii. Masonry walls tied structurally to the steel frame and to the foundation
may also be utilized in a shear resisting capacity.
10.2.3. Mullions / Runner Beams / Lintels shall be provided as structural elements in ma-
sonry structures as per the requirements given in the corresponding masonry code.

11. Structural Serviceability Considerations

11.1. Horizontal Deflections of Structures (Drift)
11.1.1. Maximum horizontal deflections due to load combinations including wind shall not
exceed the following limits, where h is the height of the structure:
a. Pipe racks supporting piping and cable tray raceways only: h/100.
b. Equipment structures: h/200, unless a more stringent requirement is pro-
vided by manufacturer of the equipment.
c. Occupied buildings: h/200
d. Reinforced masonry buildings: h/200
e. Unreinforced masonry buildings: h/400
f. Structure with elevator: h/500 (or as recommended by elevator vendor)
g. Shelters with bridge cranes: h/140 limited to a maximum of 50 mm at bridge
crane level.
h. Structures shall be limited to a differential deflection between portal frames
of B/250 where B = distance between frames.
11.1.2. Maximum horizontal deflection due to load combination with seismic effect shall
be per Cl. 11.1 of IS 1893 (Part4).
11.2. Vertical Deflections of Structural Members
11.2.1. The vertical deflection in steel structures shall as per table 6 of IS 800.
11.2.2. The vertical deflection in concrete structures shall be as per Cl. 23.2 of IS 456.
12. Foundation Design Requirements

12.1.1. Design of foundations shall include appropriate considerations regarding design
loading conditions and load combinations, and shall take into account strength, sta-
bility, serviceability, durability, and other design requirements as specified in appli-
cable standards.
12.1.2. The following design parameters shall be in accordance with Geotechnical Report:
a. Soil density

b. Buoyant density
a. Design water table elevation
b. Coefficient of friction or base adhesion for sliding resistance
c. Coefficient of active earth pressure, Ka
d. Coefficient of passive earth pressure, Kp
e. Coefficient of earth pressure at rest, Ko
12.1.3. Mats, footings, and pile caps can be assumed to act as rigid bodies for design if the
larger horizontal dimension is smaller than eight times the foundation thickness.
Foundations with larger length to depth ratios may be considered to act as rigid
bodies if demonstrated by calculation.
12.1.4. Mats, footings, and pile caps that cannot be classified to act as rigid bodies (as de-
scribed above) should be analyzed and designed considering the flexibility of the
system. The following parameters are required from Geotechnical Report / Special-
ist:
a. Vertical and horizontal static spring constants to be used to represent soil /
piles in finite element analysis of foundations.
b. Dynamic stiffness and damping coefficients to be used to represent soil /
piles in finite element analysis of foundations supporting vibrating equip-
ment.
12.1.5. Interconnected equipment sensitive to differential settlement shall be placed on a
common foundation. Depending on soil conditions, piles may also be required. This
requirement shall apply to foundations for:
a. Bottle supports near compressor cylinder or suction connections
b. Drivers connected to rotating equipment
c. Heater support columns
d. Re-boilers directly connected to vessels
e. Combinations of equipment and piping where differential settlement will
cause excessive piping, nozzle or flange stress
12.2. Foundation Systems
12.2.1. The foundation systems shall be designed in accordance with the Geotechnical Re-
port.

12.2.2. Soil-Supported Foundations

a. For footings, minimum depth to bottom of footing below finished grade
shall be 900 mm.
b. For mats, minimum depth to bottom of mat below finished grade shall be
600 mm.
c. Minimum depths to bottom of footing / mat below finished grade specified
above may be relaxed for minor foundations that can accommodate the an-
ticipated foundation movements (e.g. settlement).
d. Allowable net uniform bearing pressure varies based on foundation location
and size. For design requirements for soil-supported foundations, refer to
Geotechnical Report.
e. Refer to applicable codes and Geotechnical Report to consider the increase
in allowable bearing pressure of soil under transient loading conditions.
f. All founding level shown in the drawing shall be such that the foundation
will rest on virgin soil. In case, the required strata is not available at the
founding level shown in the drawing, extra excavation shall be carried out
till the required strata is reached and the difference in level shall be built up
with plum concrete. In no case shall any foundation rest on backfilled soil.
12.2.3. Pile-Supported Foundations
a. Geotechnical and structural capacities of piles shall be considered in design.
b. Refer to Geotechnical Report for compression, uplift and lateral capacities
of piles to be considered in design.
c. The lateral load capacity of a pile or pile group is essentially based on per-
missible horizontal deflections. Geotechnical group often sets lateral load
capacity based on a pile deflection at ground level. The structural engineer
should determine from the geotechnical group, whether lateral pile load ca-
pacity is based on deflection or soil strength. If deflection is the governing
criterion, the engineer should then evaluate whether a larger horizontal de-
flection is acceptable for the particular facility being designed, to avoid un-
necessary conservatism.
d. Refer to applicable codes and Geotechnical Report to consider the increase
in pile capacities under transient loading conditions.

e. Refer to Geotechnical Report for reductions in pile allowable compression

and lateral capacities due to group effects.
f. Portions of piles in air, water, or soils not capable of providing adequate
restraint throughout the member length to prevent buckling shall be de-
signed as columns.
g. Minimum embedment of pile into the pile-cap shall be as per IS 2911.
12.3. Stability Ratios
12.3.1. The minimum stability ratios that shall be applied in the design of the structure as
a whole and on its components are listed in the table below. Allowance shall be
made for buoyancy where foundations or structures or parts of the structures are
submerged in ground water. The factor of safety for stability shall be considered as
per following table:
Service Condition Overturning Sliding Flotation

(Uplift)
*Dead Load + Wind load 1.2 1.4 1.1
*Dead Load + Live Load + 1.4 1.4 1.1

Wind/Seismic
Maintenance / Bundle Pull- 1.4 1.4 1.1
ing, Operational Upset
Other than above 1.4 1.4 1.1
(Note: Passive soil resistance shall not be considered while calculating the stability
against sliding)
*90% of dead load needs to be considered where stability is dependent on dead
load.
12.4. Foundation Design – Special Requirements

12.4.1. Pipe Sleepers
a. Pipe sleepers shall have a minimum width of 300 mm and a minimum top
of concrete elevation of 300 mm above finished grade.

b. An embedded steel plate or channel shall be provided at the top of concrete

sleepers.
12.4.2. Tank Foundation
a. When internal diameter of tank is less than or equal to 8 m, raft foundation
shall be provided. When the internal diameter of tank exceeds 8 m, then
ring-wall foundation shall be provided.
b. Soil inside the ring-wall shall be well compacted to at least 98% of Standard
Proctor density. However, for 500 mm depth below tank bottom, with sand
filling, the same shall be compacted up to 85% relative density.
c. Pile-supported foundations for tanks shall be utilized only where otherwise
impractical to satisfy bearing and settlement criteria using soil-supported
foundations.
d. Unless shown otherwise on tank manufacturer’s drawings, the finished sur-
face (concrete slab or earth fill) under a flat-bottom tank shall be crowned
from the periphery to the center. A minimum slope of 1:120 should be pro-
vided.
e. Foundations for tanks containing hydrocarbons or chemicals shall include
under-tank leak detection and subgrade protection details in accordance
with API Standard 650, Annex I, or approved tank manufacturer details.
f. Tanks on ring-wall foundations normally require cathodic protection sys-
tems. Structural engineer shall coordinate with other groups for embedded
conduit details to be shown on foundation drawings.
g. Geotechnical group shall be consulted for evaluation of settlement, dishing
effects, tilts etc. during testing and operating conditions. Coordinate with
stress group and tank manufacturer for the expected settlement. Attach-
ments or connections to tanks shall be designed as flexible members to ac-
commodate differential settlement.
12.4.3. Vertical Vessels and Towers
A foundation for a vertical vessel or tower shall consist of a pedestal supported on
footing. The footing may need to be supported on piles, if dictated by soil condi-
tions.

12.4.4. Horizontal Vessels and Exchangers

A foundation for a horizontal vessel or exchanger shall consist of a pier under each
saddle support. The piers may be supported on a combined footing or on individual
footings as required by vessel size and soil conditions. Soil conditions may require
the use of piles.
12.4.5. Underground Pits for Blowdown Collection Vessel
In underground sand filled pits with vessels, the wall shall be designed as a retaining
wall for submerged soil assuming no soil inside the pit. Crack width shall be re-
stricted to 0.3 mm.
12.4.6. Rotating and Reciprocating Equipment Foundations
Refer to RPMS-ENGG-DBD-CS-010 and RPMS-ENGG-DBD-CS-011.
12.4.7. Anti Termite Treatment
Buildings such as substations, PIBs, control centers, laboratory etc. shall be given
anti termite treatment by a specialized agency at plinth level around the building.
13. Existing Structures and Foundations

13.1. General
13.1.1. Existing structures and foundations may receive additional loads where piping,
electrical cable and/or tray is added to them. The structural design of existing struc-
tures may have been performed based on codes, regulations and criteria different
than those of the current project.
13.1.2. The DEC Engineer shall identify any existing structures that are to receive additional
loads and submit a written request to RIL to furnish any existing and relevant design
criteria, calculations and drawings for the structures identified. The DEC Engineer
or representative shall then conduct a walk-down of the structure to:
a. Verify that the information provided conforms to the existing site condition,
and
b. Assess the current condition of the structure and its suitability to support
the additional loads proposed.
13.2. Basis
13.2.1. RIL furnished drawings, once verified by a walk-down, shall be the basis for existing

layout. In the absence of existing design drawings, sketches prepared by the DEC
Engineer shall be the basis of existing layout. The sketches shall be generated based
on the information from a laser-scan survey, the walk-down and any additional sur-
veys as required. A reduction in a member’s section properties shall be required
where corrosion has impaired the load carrying capacity of the member. If the cur-
rent condition of the existing structure cannot be assessed for deterioration, then
the existing structure shall not be used to support the new loads and an alternate
support framing shall be considered.
13.2.2. RIL furnished drawings, design criteria and/or calculations shall be the basis of de-
termining material of existing structure. RIL furnished design criteria and/or calcu-
lations shall be the basis of existing design loads on the structure. In the absence of
this data, loads shall be assumed based on walk-down, auxiliary information from
RIL and this design basis.
13.2.3. The DEC Engineer shall compare the new loads added to the structure to the exist-
ing loads ensuring they are consistent to the same code (i.e., both calculated to the
current codes, or both to the old codes used for the original design). The design
wind and seismic loads on the structure shall be considered based on the original
codes and regulations, unless specifically instructed otherwise by RIL.
14. Materials
DEC shall use materials from “Civil Material Stock Code Index” (RPMS-ENGG-SPC-
CS-003) as far as possible. Deviations from this list shall be only with prior approval
of CSA core engineering.
14.1. Steel
14.1.1. Material shall be of new stock.
14.1.2. Structural steel shall comply with the requirements as follows:
For ISMB, ISMC, ISA (angles) : IS 2062 Grade E250BR
For Flats : IS 2062 Grade E250A
For plates : IS 2062 Grade E250BR/E350BR/ B0/E350C
Universal Columns / Beams : BSEN 10025 S275JR/S275J0/S355J0/ S355JR
14.1.3. Dimensions of Rolled sections shall conform to:
Equal angles / Unequal angles, ISMB, ISMC sections to IS 808
UB and UC sections to BS4

Cold Rolled sections to IS 801

Flats to IS 1730
Hot formed steel hollow sections to IS 4923 / BS EN 10210-2
Cold formed steel hollow sections to IS 4923 / BS EN 10219-2
Steel tubes for structural purposes shall conform to IS 1161
Seamless carbon steel pipes shall conform to ASTM A106 or A53
14.2. Concrete
14.2.1. Concrete Cube tests
Normally, concrete cubes shall be tested for 28 days' strength as per IS 456. How-
ever, in case of concrete which has substantial quantity of supplementary cementi-
tious material such as fly ash or GGBS, concrete cubes shall be tested up to 56 days
to ascertain the strength of concrete.
14.2.2. Minimum Grade of Concrete shall be as follows:
All Cast in Place Structural Members except Marine Structures M30

Blinding Concrete (Strength of concrete need not be tested) M10 or 1:4:8
Precast Members M35
Marine Structures (Island Jetty) and all MTF work M40
Note:
a) For Marine structures, MTF and Desalination Plant, for cement type refer Spec
No RPMS-ENGG-SPC-CS-001.
b) For all other areas, OPC cement of Grade 53 shall be used.
14.2.3. Mass Concrete

For definition of what constitutes mass concrete and what are the precautions to
be taken for it, concrete spec No RPMS-ENGG-SPC-CS-001 shall be referred.
14.3. Concrete Reinforcement
14.3.1. Grades of reinforcement bars shall be as follow:

Diameter (mm) Grade (As per IS 1786)

8, 10, 12 Fe 500
16,20, 25, 28, 32,36,40 Fe 500D/Fe500S/Fe550D
Either Fe550D, Fe500D or Fe500S shall be
procured.
14.4. Materials other than those specified above shall be in accordance with respective
material specifications.
14.5. Material Control / Tracking
14.5.1. DEC shall raise material requisitions for all bulk items to enable procurement at the
commencement of the project. List of bulks shall be in accordance with the Scope
Matrix given in the table below:
SCOPE MATRIX FOR MTO AND REQUISITIONING
Sr. Descrip- Requisitioning MTO by Remarks

No. tion DEC
Mat. Con- Construc- Bulk IFC
trol-H.O. tion
1 Structural  ̶   Cut sheet prepa-
sections, ration is in the
plates etc scope of DEC and
delta MTO to be
topped in IFC GA
drg MTO by con-
struction.
2 Reinforce-  ̶  
ment
3 Cement ̶   
4 Holding  ̶  
Down Bolts
5 Grout  ̶  Given in the
drawing.


No. tion DEC
trol-H.O. tion
6 Structural  ̶ ̶  a) Early procure-
Fasteners ment quantity to
be furnished by
HO-PMT.
b) Construction
to update quan-
tity in respective
IFC GA MTO.
7 Grouted ̶  ̶ 
(Lenton)
Couplers
8 Mechanical ̶  ̶
Couplers
9 Stud Bolts  ̶ 
10 Anchor ̶  
Fasteners
11 UPVC pipes  ̶ 
12 Concrete  ̶ 
Pipes
13 Gratings  ̶  a) Bulk require-

and Stair ment shall be
Treads given by DEC for
finalisation of
supply contract.
B) Shop drawing
and Bill of Materi-
als shall be given


No. tion DEC
trol-H.O. tion
by Grating ven-
dor.
14 Manhole  ̶ ̶ 
Covers
15 Roof  ̶  a) DEC to furnish
Sheeting, area requirement
Side Clad- of sheeting /gut-
ding and ter with GA draw-
Gutter ing.
b) Supply con-
tractor shall make
sheeting drawing
with BOM.
16 Steel Deck  ̶ ̶ 
Sheets
17 Nelson  ̶ 
Studs
18 Blast Proof  ̶  
Doors
19 Metal  ̶ ̶ 
Doors
20 Rolling ̶  ̶
Shutters
21 Other ̶  ̶ IFC drawings shall
Doors and furnish MTO.
Windows


No. tion DEC
trol-H.O. tion
22 Geotech- ̶  ̶ 
nical Mem-
brane
23 Rolling ̶   Will be centrally
Shutters procured by con-
struction.
Note:
These are engineered quantities. Quantities raised in the system by Requisitioning
or Construction shall be through project specific system (Rworks or others) as de-
cided at start of the project.
14.5.2. Civil and structural drawings shall contain MTO of the items mentioned in the Scope
Matrix.
14.5.3. As far as possible, precast and cast in situ concrete members shall be detailed in
separate drawings. MTOs for precast and cast in situ members shall be given sepa-
rately even if it is detailed in the same drawing.
14.5.4. DEC shall use the material control system of RIL for the bulk items. DEC shall moni-
tor material consumption with release of drawings and issue revised MTO from
time to time.
14.5.5. Bar bending schedules shall be prepared by civil works contractor.
14.5.6. Drawings for fabrication of structural steel including handrail, ladders, stairs and
gratings shall be prepared by fabricator and checked by DEC before IFF /IFC. Fabri-
cation drawings shall include actual MTO of members and connections with stock-
code and coating details. Quantity of bolts (permanent, shop and erection) also
needs to be furnished.
15. Applicable Software

The following software shall be used by DEC for preparing design calculations,
drawings and 3-D Model works. The latest version shall be used by DEC.
STAAD–Pro For Structural Analysis and Design.

GTStrudl/SAP For Time History Analysis of Table Top Compressor foun-
dations
STAAD-Foundation For Foundation Design (optional)
ETABS For Concrete Buildings (Optional)
Microstation For preparation of 2-D drawings
AutoCad For preparation of shop drawings using Tekla
PDS/SP3D/PDMS For preparation of 3-D Modelling
SPR For review of 3-D Model
Mathcad/Excel/Word For preparation of design calculations / reports
16. Work Responsibility

The DEC’s responsibility for preparation and issue of civil documents shall include
but not be limited to the requirement as specified in the Contract Documents. RIL
shall audit design of structures/ facilities which they consider are critical. DEC shall
make available all documents and models prepared for the same and shall incorpo-
rate the comments of RIL after due discussions.

Annexure 1
Seismic Design Criteria for Steel Members and Base
Plate

1. Seismic load resistance system (SLRS)

The seismic load resistance system (SLRS) includes those elements which are essen-
tial to transferring seismic internal forces from their point of origin to the ground.
This generally includes (See Figure 1 and 2):
Vertical braced frames – Columns, associated bracings, beams and ties Shear walls
Moment frames - Columns, associated beams and ties
Diaphragms - Plan bracings which transmit seismic forces to vertical elements)
Diaphragm chords and drag strut.
Figure 1
Figure 2

2. Required strength of braces

Within a single line of framing, at least 30% but not more than 70% of the total
lateral load resisted by the frame at any level must be resisted by tension bracing.
Figure 3
3. Column Bases
The following is guideline to determine the required strength of column bases, ex-
cluding those that are not designated as part of the SLRS. This applies to the steel
elements at the column base, including base plates, anchor rods, stiffening plates,
and shear lug elements.
Required Axial Strength
The required axial strength of column bases that are designated as part of the
SLRS, including their attachment to the foundation, shall be the summation of the

vertical components of the required connection strengths of the steel elements

that are connected to the column base.
The column axial loads calculated using the load combination prescribed in Cl.
12.2.3 of IS 800. The vertical components can include both the axial load from col-
umns and the vertical component of the axial load from diagonal members framing
into the column base. Where diagonal braces frame to both sides of a column, the
effects of compression brace buckling should be considered as given in Cl. 12.8.2.3
of IS 800 and tensile force shall be as given in Cl. 12.8.3.1 of IS 800.
Required Shear Strength
The required shear strength of column bases, excluding those not designated as
part of the SLRS, and their attachments to the foundations, shall be the summation
of the horizontal component of the required connection strengths of the steel ele-
ments that are connected to the column base.
a. For diagonal braces, the horizontal component shall be determined from
the required strength of diagonal brace connections for the SLRS in accord-
ance with Cl. 12.8.2.3 and 12.8.3.1 of IS 800.
b. For columns, the horizontal component shall be equal to the lesser of the
following:
i. 1.2FyZ/(H) of the column, H is the height of the storey (Refer – AISC
341, D2.5 Connections)
ii. The column end shear calculated using load combination of Cl. 12.2.3
of IS 800
Note: For braced frames the shear from column shall be small compared to that
from the diagonal braces.
Single storey columns with simple connections at both ends need not comply with
the design procedure given above.

Annexure 2
Locknut Detail for Expansion Joints and Sliding Support

EXPANSION JOINT DETAIL WITH LOCK NUT

(REPRESENTATIVE SKETCH)

RUNWAY / MONORAIL BEAM


LOCKNUT DETAIL FOR SLIDING SUPPORT


Annexure 3
Guidelines for the Design of Piperack

Section A: Material of Construction, Types of Construction, Design Philosophy

This section provides guidelines for the design of piperack in RIL projects. The scope
includes specifying material of construction, various types of construction, design
philosophy and joint details for precast concrete members.
1. Selection of Material
1.1. For piperacks having width 6m and above:
a) Up to beams carrying pipes – reinforced concrete. Grade of concrete shall be
per Section 14 of this document.
b) Beams supporting cable trays – structural steel
c) Beams supporting flare lines – structural steel
1.2. For piperacks having width less than 6m: Structural Steel
2. Geometry of Piperack
Geometry of piperack, location of anchor bay, number of tiers, spacing of expansion
joint shall be per project plant design model/drawings.
3. Method of Construction
RIL’s objective is to have as much precast concrete as possible for piperack. However,
construction shall decide extent of precast based on accessibility, constructability, and
the feasibility of erection.
3.1. Precast Piperack:
a) Foundations: Cast-in-place
b) Pedestal from top of foundation up to 1.0m above FGL/High point of paving
(HPP): Cast-in-place
Columns above 1.0 m from FGL/HPP: Precast column along with precast trans-
verse beams to form ‘H frame’, based on convenience of construction.
Longitudinal Beams except at anchor Bays: Precast.
c) The precast elements of pipe rack shall be lifted from casting bed only after
concrete attains 67% of its nominal strength or seven days whichever is later.

d) DEC shall perform lifting analysis and design checks per PD CEN/TR 15728.
Drawings shall show dimensions, camber, tolerances, embedment, inserts,
anchor bolts, welding details, surface finishes, lifting points, support points,
additional reinforcement, concrete strength and concrete cover
3.2. Cast in-place Piperack:
a) All foundations, columns, transverse beams: Cast in-place
b) Longitudinal beams except at anchor bays: Precast
3.3. Anchor Bay in Precast Piperack:
a) Ref, Section B of this Annexure for typical anchor bay details
b) Generally, anchor bay shall be cast in place.
c) DEC shall explore if transverse frame of anchor bay can be precast, based
on number of main bars in the column (maximum 20 bars).
d) Longitudinal beams of anchor bay shall be cast in place.
e) If the sizes of columns & beams are more than 50% of the size of precast
sections in other bays, additional anchor bay may be provided.
f) Steel bracing shall not be provided in anchor bay.
3.4. Pipe Bridges
Geometry and clearance shall be as per piping input / requirement. Material
of construction for pipe bridges shall be structural steel.
3.5. Insert Plate on Concrete Piperack
Insert plate on concrete piperack to be referred from RPMS-SD-C17-503 for
typical arrangement. Specific additional requirement to be detailed by DEC af-
ter validation of standard insert plates.
4. Loads and Load Combinations

Loads shall be per Section 5 and load combinations shall be as per Section 6 of this
document.
5. Joints in Concrete
5.1. Column to Column:

The column to column joint shall have rebar continuous across the joint by means
of Lenton Interlok Gravity Flow type (or equivalent) splicing system for connection
of precast elements. The location or the absence of this joint does not affect the
analysis and design part of the piperack. The location of the joint shall be purely
from construction feasibility point of view. The construction has the option of ei-
ther a single H frame having one transverse beam or a double H frame having two
transverse beams as shown in Section C of this Annexure. To make this connection
feasible, the column bars should be in one layer preferably not more than 16 Nos.
– For Lenton Interlok information & Sketches refer Section C of this Annexure.
Site shall seek approval by DEC for use of alternate equivalent couplers, if Lenton
Interloks are not available.
5.2. Longitudinal Beam to Column Corbel:
The column shall have a corbel jutting out to support the longitudinal beam. The
joint shall ensure transfer of lateral forces from column to the beam. Both longi-
tudinal beam and the joint shall be designed with an overstrength factor of 2.0.
The ends of precast longitudinal beam shall not transfer moments. The mecha-
nism for transfer of lateral loads and design of anchors shall be as shown in Sec-
tion D of this Annexure.
Summary of Longitudinal Beam & Corbel Design:
Dowel Information Connection

Sr. No. Embed. Depth In Capacity (kN)
Size (mm)
Corbel (mm)
1 2-20 Dia. 300 55.0
2 2-25 Dia. 400 86.0
3 2-32 Dia. 450 141.0
4 2-40 Dia. 500 221.0
Notes:
a) 25 mm thick grout between longitudinal beam and corbel shall be considered
for design
b) Overstrength factor of 2.0 shall be considered for the design of collector ele-
ment and its connection

c) Values indicated in the table above are for M30 grade of concrete. DEC may
use higher grade for piperack.
Corbel shall be designed as per ACI 318, for the forces transferred by longitudinal
beam. Reinforcement shown in Section D of this Annexure is minimum required
for connection purpose.
Longitudinal beams with 40 mm diameter dowels, requiring higher width at the
support location, shall have same cross section maintained for the entire length.
5.3. Steel Column to Concrete Column:
This connection shall be by means of anchor bolts.
6. Erection Methodology
See Section E of this Annexure for Erection methodology

Section B: Anchor Bay Typical Arrangement

• Pipe Rack Longitudinal View for Cast-In Place Anchor Bay ---- Sheet 8
• Pipe Rack Longitudinal View for Precast Anchor Bay-------------Sheet 9
• Cast-In-Place Longitudinal Beam for Anchor Bay -----------------Sheet 10

Pipe Rack Longitudinal View for Cast-In Place Anchor Bay

SKETCH – 1

Pipe Rack Longitudinal View for Precast Anchor Bay

SKETCH – 1


Section C: Column to Column Connection

• Lenton Interlocak Rebar Splicing System Instruction Manual ----Sheet 12
• Precast Joint Location for 4.0 m High Tiers of Piperack ------------Sheet 16
• Precast Joint Location for 3.0 m High Tiers of Piperack -----------Sheet 17
• Typical Detail at Precast Joint --------------------------------------------Sheet 18




NOT USED




Section D: Longitudinal Beam and Corbel Connection - Typical Calculation and

Details
• Longitudinal Beam Connection with Corbel 2-40 Diameter Dowels --- Sheet 20
• Longitudinal Beam Connection with Corbel 2-32 Diameter Dowels ----Sheet 28
















Section E: Erection Methodology of Concrete Precast Piperacks

Erection Methodology:
The sequence of erection of the Precast Pipe rack shall be as follows:
Step 1: Construction / Erection of the Anchor Bays

• Option 1: Cast in-situ Anchor Bay:
When Anchor Bay is cast-in-situ then entire bay including longitudinal beams
within Anchor Bay shall be constructed as cast-in-situ.
Entire block construction shall be carried simultaneously. At outer end, Corbels
with dowel bars shall be constructed with precise dimensions as shown to re-
ceive Precast longitudinal Beams from the non-anchor bays.
OR
• Option 2: Precast Anchor Bay:
The two Precast Anchor bay Transverse frames shall be erected and shall be held
in position by crane and proper lateral guy rope arrangement for stability shall be
provided before grouting the couplers.
Crane shall hold the H Frames in position throughout the time required for the
initial setting time of the grout.
The guy rope arrangement shall be maintained till the complete construction of
the cast-in-situ longitudinal beams of Anchor Bay, to ensure the stability of the
erected frames.
Step 2: Construction / Erection of the Bays other than Anchor Bays

• Erection of precast transverse frames shall only be commenced after the con-
struction / erection of anchor bay and backfilling of excavation for the cast-in-situ
foundations is completed.

• The precast transverse frame shall be erected with the help of crane and held in
position till the guy rope arrangement (as shown in the sketch overleaf) is in-
stalled and subsequent grouting of the couplers is completed.
• The precast longitudinal beam shall be erected on the corbels and holes for the
dowels grouted. During the erection, precaution shall be taken to protect pro-
jected dowel bars from the corbels. It shall be ensured that grout is set prior to
release of guy rope arrangement.
• The above step shall be repeated till the complete erection of the entire desig-
nated Piperack module.
• Grouting and setting of all the grouted connections in the module shall be en-
sured before release of lateral tying arrangement.
• The guy rope (Lateral Tying) arrangement shall be used repeatedly along with the
required Pin’s for tying with already constructed elements for the further seg-
ments.


Annexure 4
Sample Design Calculation of Anchor Bolts













Technical Specification for Structural Steelwork -

Fabrication
RPMS-ENGG-SPC-CS-002
0 25.08.2020 Issued for Implementation RBS PGN SPC/VKM

By By By
Reliance Project Management System RPMS- ENGG-SPC-CS-002
Date: 25.08.2020, Rev. 0
Technical Specification for Structural Steelwork - Fabrication

(DD.MM.YYYY)
2 S Sammaddar _________________ ___________
3 Sankar Chakraborty _________________ ___________
4 _____________________________ _________________ ___________
5 _____________________________ _________________ ___________
6 _____________________________ _________________ ___________
7 _____________________________ _________________ ___________
8 _____________________________ _________________ ___________
9 _____________________________ _________________ ___________
10 _____________________________ _________________ ___________

Date: 25.08.2020, Rev. 0
RECORD OF REVISIONS

Number
Date: 25.08.2020, Rev. 0
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
4. Abbreviations and Definitions ................................................................................... 8
7. Vendor data ............................................................................................................. 20
8. Packing, Preservation, Shipment and Storage ........................................................ 20
Date: 25.08.2020, Rev. 0
1. Purpose
This specification defines the minimum technical requirements for materials,
manufacture, inspection, testing, packaging, and shipment of steel framed
structures, buildings and platforms. It includes submission requirements of
compliance documentation by FABRICATOR.
2. References
The products and workmanship shall adhere to the requirements laid down in the
codes and publications referenced below, OWNER specifications and related local
statutory requirements and construction safety procedures. The documents shall
be current edition or revision including amendments and errata as applicable at the
time of enquiry, unless expressed otherwise. Revisions, amendments or errata
published afterwards shall be incorporated by FABRICATOR only at direction of
Engineer in Charge after approval from OWNER.
2.1. Indian Codes:
Code No Title
IS 800 General Construction in Steel – Code of Practice
IS 801 Code of Practice for use of Cold-Formed Light Gauge
Steel Structural Members in General Building
Construction
IS 808 Dimensions for Hot-Rolled Steel Beam, Column,
Channel and Angle Sections
IS 1852 Rolling and Cutting Tolerances for Hot Rolled Steel
Products
IS 2062 Hot Rolled Medium and High Tensile Structural Steel -
Specification
IS 4000 Code of Practice for High Strength Bolts in Steel
Structures
IS 7205 Safety Code for Erection of Structural Steel Work
IS 7215 Specification for Tolerances for Fabrication of Steel

Structures
2.2. American Codes:
Code No Title
AWS D1.1/1.1M Structural Welding Code – Steel

Date: 25.08.2020, Rev. 0
Code No Title
AWS D14.1/14.1M Specification for Welding of Industrial and Mill Cranes
and Other Material Handling Equipment
ASTM A435/A435M Standard Specification for Straight-Beam Ultrasonic
Examination of Steel Plates
ASTM A578/A578M Standard Specification for Straight-Beam Ultrasonic
Examination of Rolled Steel Plates for Special
Applications
ASME/BPVC Specifications for Welding Rods, Electrodes and Filler
Metals – Materials
Sec II Part C
ASME/BPVC Qualification Standard for Welding, Brazing and
Sec IX Fusing Procedures; Welders; Brazers and Welding,
Brazing and Fusing operators – Welding, Brazing and
Fusing Qualifications
ASME B46.1 Surface Texture (Surface Roughness, Waviness, and
Lay)
ASME Sec V ASME Boiler and Pressure Vessel Code-
Nondestructive Examination
ANSI/AISC 360 Specification for Structural Steel Buildings
PIP STS05120 Process Industry Practice – Structural and
Miscellaneous Steel Fabrication Specification
ASCE/SEI 7 Minimum Design Loads and Associated Criteria for
Buildings and Other Structures
2.3. Euro Codes:
Code No Title
EN 1090 (Part 2) Execution of Steel Structures and Aluminium Structures -
Technical Requirements for Steel Structures
2.4. Specifications
Specification No Title
RPMS-ENGG-SPC-CS-003 CSA Material Stock Code Index

Date: 25.08.2020, Rev. 0
Specification No Title
RPMS-ENGG-SPC-CS-014 Technical Specification for Supply of Structural
Sections, Plates, Flats, Bars and Other Solid Shapes
used for Structural Works
RPMS-ENGG-SPC-CS-015 Technical Specification for Supply of Bolts, Studs, Nuts
and Washers used for Structural Works
RPMS-ENGG-SPC-CS-023 Technical Specification for Structural Steelwork –
Erection
Detailing
RPMS-ENGG-SPC-PP-014 Standard Specification for Field and Shop Painting
RPMS-ENGG-SPC-PP-042 Standard Specification for Hot Dip Galvanizing of
Equipment, Piping and Structural Steel
RPMS-ENGG-SPC-CS-026 Standard Specification for Fireproofing Materials

3.1. Conflicts
In the event of conflict between requirements stipulated in this specification and
other applicable documents, the following order of precedence shall govern:
a. Drawings
b. The purchase order
c. This specification
d. Codes and standards specifically referred
e. Other national and international standards as referenced
of enquiry, shall be applicable. In case of any conflict, the decision of owner’s
engineer in charge shall be final and FABRICATOR shall implement that without any
3.2. Deviations
Deviations to specified technical condition would require specific approval from
OWNER.

Date: 25.08.2020, Rev. 0

0C Degree Centigrade
ASNT American Society for Nondestructive Testing
ASTM American Society for Testing and Materials
AWS American Welding Society
DPT Dye Penetrant Test
IS Indian Standard
ISNT Indian Society for Non-Destructive Testing
MPT Magnetic Particle Test
NDT Non-Destructive Testing
PCN Certification by British Institute of Non-Destructive Testing
RT Radiographic Testing
TPIA Third Party Inspection Agency
UT Ultrasonic Testing
WPS Weld Procedure Specification
BUYER OWNER or OWNER Appointed EPC Contractor who specifies
equipment, product and services for purchase from
FABRICATOR
Engineer in Charge BUYER’s authorised representative with overall authority
and responsibility for engineering design, quality, and
performance of civil/ structural works
FABRICATOR Party responsible for furnishing fabricated Structural &
Miscellaneous steel
MANUFACTURER Party which manufactures and supplies a product to perform
the function as specified by BUYER
OWNER Reliance Industries Limited (RIL) or specified Reliance Group
Companies

Date: 25.08.2020, Rev. 0

5.1. Material
5.1.1. Rolled sections, plates, hollow and pipe sections, crane rails, flats, bars, grating/
chequered plate floor panels, steel decking, and other solid shapes used for
structural work shall be as per Technical Specification RPMS-ENGG-SPC-CS-014.
5.1.2. Structural bolting products shall be as per Technical Specification RPMS-ENGG-SPC-
CS-015.
5.1.3. Headed studs shall be ASTM A108 Grade 1010 through 1020, AWS D1.1/1.M
Section 7, Type B.
5.1.4. Weld filler material shall be AWS D1.1/D1.1M Section 3.3 (including Table 3.1), low
hydrogen, electrode strength of 400 MPa minimum yield strength and 480 MPa
minimum tensile strength and shall be procured with Mill Test certificates.
5.1.5. Material procured by FABRICATOR shall meet requirements of Technical
Specification RPMS-ENGG-SPC-CS-014. FABRICATOR shall perform supplementary
material verification testing on profiles and plate material as per RPMS-ENGG-SPC-
CS-014 on a sampling basis, if procured by FABRICATOR from sources other than
OWNER approved MANUFACTURER, irrespective of availability of material test
certificate from MANUFACTURER. Material failing supplementary test shall not be
utilised for fabrication.
FABRICATOR shall submit material test certificate and supplementary test reports
to BUYER for record.
5.1.6. All proprietary items shall be used in accordance with the MANUFACTURER's
recommendations and instructions.
5.1.7. Material shall be visually inspected for surface defects and/or damages, cracks,
surface scabs, corrosion, extent of rusting and pitting prior to use for fabrication.
Rolled sections and plates shall be clean, free from kinks, bends or twists, and shall
conform to the tolerances allowed by IS 1852.
5.1.8. Where straightening is necessary, corrective procedure shall be submitted for
approval of Engineer in Charge. Correction/ straightening may be carried out by
mechanical means or by the application of localised controlled heat. The
temperature of the heated area shall not exceed 600°C and shall be frequently
monitored by methods approved by the Engineer in Charge such as thermal crayon/
non-contact thermometer.
To avoid brittle zones, the heated area shall not be actively cooled till the steel
surface temperature is less than 315°C. Additional heat shall not be applied until
the entire member has cooled below 120°C and the straightening movement has
been verified.
5.1.9. Rolled sections and plates with major defects shall be returned to MANUFACTURER
for replacement.

Date: 25.08.2020, Rev. 0
5.2. Fabrication of Steelwork

5.2.1. Structural and miscellaneous steel shall be fabricated as per approved shop
drawings and shall comply with the requirements of IS 800, IS 7215, AWS
D1.1/1.1M and this specification. Fabrication works shall be performed in
compliance to clause 17.13.4 of IS 800 and IS 7205 as applicable to fabrication of
material and other applicable national, state or local regulations.
5.2.2. Shop splices other than indicated on shop drawings, substitution of member
profiles or change in details or dimensions shall not be permitted.
No more than one welded shop splice shall be provided in any rolled shape or in
any component of a built-up member. For non-critical members, more than one
shop splice may be permitted by written approval of Engineer in Charge, provided
each piece is not less than 2.0 m in length.
In case offcuts are to be utilised, shop splices can be used for building up of
member. For Primary members there will no more than one such splice in a
member. For non-critical members like secondary/tertiary member which are not
supporting any equipment or piping, more than one shop splice may be permitted
by written approval of Engineer in Charge, provided each piece is not less than 2.0
m in length.
Built up members shall not be substituted for rolled profiles without approval from
Engineer in Charge.
5.2.3. Ends of columns at column base plates and splices that depend on contact bearing
identified as "Finished" on shop drawings shall be sawn square and prepared to
have a roughness height equal to or less than 12.7 micron per ASME B46.1 by use
of any fabrication technique such as sawing, milling or any other. (Note that most
cutting processes, including friction sawing, cold sawing and milling processes meet
a roughness limitation of 12.7 micron.)
5.2.4. For on-site fabrication, ends of columns shall be permitted to be gas flame cut and
ground.
5.2.5. Steel bearing surface of base plate at column bases shall be straightened by
pressing or milling to a roughness height equal to or less than 12.7 micron per ASME
B46.1, if specified on shop drawings.
5.2.6. All re-entrant corners shall be shaped, notched-free, to a radius. The radius of re-
entrant flame cuts/ corners shall not be less than 20mm, except for small members
up to 150 mm size where this is impracticable, a radius of 13 mm per clause M2.2
of ANSI/AISC 360 is permissible.
5.2.7. Weld access holes shall be detailed and finished as per AWS D1.1/1.1M Section
5.16.1.2. Beam copes and weld access holes in profiles with flange thickness not
exceeding 50 mm shall have surface roughness not greater than 50 micron.

Date: 25.08.2020, Rev. 0
5.2.8. In case assemblies are to be hot dip galvanised, beam copes and weld access holes
shall be ground to bright metal to prevent web cracking. 100% of copes of
galvanised steel shall be visually inspected and in case of doubt magnetic particle
testing may be used to examine.
5.2.9. Structural members shall be preheated to a minimum 650C for following conditions:
a. For beam copes and weld access holes thermally cut in beams with flange
thickness greater than 50 mm
b. All parts that are thicker than 38 mm before welding as per Table 3.3 of AWS
D1.1/1.1M or as per approved WPS
c. All base plates thicker than 38 mm before thermal cutting of holes
5.2.10. Holes for structural bolts shall be drilled, punched or combination of punching and
drilling to required size. Thermal cutting shall not be permitted except for slotted
holes or anchor rod/ grout hole in base plates. Thermal cutting shall be by
mechanical means only.
Anchor rod and grout holes in column base plates may be thermally machine flame
cut if greater than 50 mm in diameter. The slotted holes may be cut using NC flame
or plasma or may be formed with punching/ drilling of two holes completed with
NC flame/ plasma.
The holes shall meet the requirement of AWS D1.1/1.1M clause 5.14.8.3 & clause
5.14.8.4 as referred in Section M2.2 of ANSI/AISC 360.
5.2.11. Machining
The thickness of elements shown on the shop drawings that require machining shall
mean the minimum thickness after the machining operations. The original element
thickness as furnished, prior to machining, shall be as stated on the shop drawings.
5.2.12. Dressing
Connection joint surfaces shall be free of burrs, dirt, or other foreign material that
may prevent the solid seating and proper fit up of parts. Sharp edges on parts and
holes shall be dressed as required to remove foreign matter, burrs, protruding
edges and irregularities. A 900 rolled, cut, or sheared edge is acceptable without
further treatment.
5.2.13. Before surface preparation for coating, steel damaged during fabrication (arc
strikes, chain damage during handling etc.) shall be restored to its original condition
by welding and grinding. Sharp corners, burrs (including bolt hole burrs), weld
splatter, slag, weld flux, loose mill scale and other foreign matter shall be removed.
5.2.14. Lifting Lugs
a. The pinholes shall be drilled, reamed, or otherwise finished to provide a
maximum surface roughness of 12.5 micron around the inside surface of hole.
Flame cutting of pinholes is not permitted.

Date: 25.08.2020, Rev. 0
b. In case doubler plates (cheek plates/donuts) are required, the assembly shall
be line bored only after welding the doubler plates to the main plate.
c. Plates 16mm and more used for fabricating lugs and corresponding cap plates
shall be inspected by UT test per ASTM A578/A578M, acceptance level C, prior
to use. Acceptance shall be per clause 10.1 of ASTM A578/A578M.
d. Rated/ allowable load (tonnage) shall be hard stamped or stenciled on the lugs.
For lifting lugs welded to structural members, the lug identification and the
rated load may be stenciled on the structure close to lug location additionally.
e. Prior to initial use, new or modified/repaired lifting lugs shall be load tested to
minimum 1.25 times the rated load and inspected as required in this
specification. Refer Clause 5.3.5.6 for NDT of lifting lug welds
f. FABRICATOR shall submit following documentation to BUYER prior to shipment
of the lugs
 Documents providing material traceability of plate materials used in
fabrication of lifting lugs and associated column cap plates (if applicable)
to the corresponding material test reports
 Material test reports
 Weld NDT reports, NDT record must identify the specific lugs
 UT records or evaluation of plates for through thickness defects
 Fabrication inspection records including visual inspection of welding
 Load test records
5.2.15. All beams, except cantilevers, shall be fabricated with natural mill camber in the up
position.
5.2.16. Traceability
5.2.16.1. Individual parts/ pieces shall be marked for positive identification at all stages of
fabrication and records shall be maintained so that each can be traced back to
individual heat number from MANUFACTURER.
5.2.16.2. Offcuts/ remnant shall be tracked using a method preapproved and agreed with
BUYER that ensures positive traceability of such pieces.
5.2.17. Alignment Holes
All matching holes for loose plates with large number of bolts such as splice plates
shall be trail assembled using fasteners or pins with members to be connected to
ensure they register with corresponding holes, and fasteners can be inserted
without undue force. Drifts may be used but holes shall not be distorted.

Date: 25.08.2020, Rev. 0
5.2.18. Assembly
5.2.18.1. All components shall be assembled within tolerances specified in IS 800 and IS
7215 and in a manner such that they are not bent, twisted or otherwise damaged.
The dimensional tolerance of fabricated components shall be as per IS 7215
class B, unless note otherwise on shop drawings.
5.2.18.2. Drifting of holes to align the components shall be permitted, but must not cause
damage or distortion to the final assembly.
5.2.18.3. Components shall be checked for dimensional accuracy and conformity to shop
drawings.
5.2.18.4. Structures and platforms shall be trial assembled in the fabrication shop prior to
transportation, where called for on the shop drawings.
5.2.18.5. Frames, platforms, stairs, guard and handrails shall be shop assembled in largest
units suitable for handling and transportation. Ladder cages when required shall
be shop assembled on ladder. Fabricated frames shall be suitably braced to prevent
distortion during transit.
5.2.18.6. Where shown on the shop drawings, assemblies shall be shipped as one assembled
piece (e.g. handrail shipped with toe plate bolted on post).
5.2.18.7. Loose connection plates or angles shall be assembled as indicated on shop drawings
using a minimum of two temporary bolts (not ship wired). Temporary bolts shall
be ordinary black bolts with diameter same as permanent bolts. The heads of
temporary bolt and nut shall be painted “white” for ease of identification.
5.3. Welding
5.3.1. General
5.3.1.1. Welding shall be in accordance with AWS D 1.1/1.1M or ASME IX, unless noted
otherwise. For lifting lugs, monorails, transport beams and other below the hook
devices (lifting beam) required for lifting / rigging, welding shall conform to
AWS D14.1/14.1M.
5.3.1.2. The following sections of AWS D14.1/14.1M mentioned above shall be referred to
a. Workmanship - Section 7.2 thru section 7.4
b. Welder qualification - Part C, Section 9.15 thru 9.31
c. Visual examination - Section 10.6
d. UT examination - Section 10.15
e. Weld repair - Section 12.1
f. Base metal repair - Section 12.2
5.3.1.3. All welding shall be protected from rain, wind, air-borne dust and sand. Before
welding, the weld joint shall be free from oil, grease, rust, scale etc.

Date: 25.08.2020, Rev. 0
Welding is not permitted on coated steel surface per standard practice. However,
if necessary, suitable welding procedure shall be established for specific primer
type, paint thickness and paint MANUFACTURER. Approval of welding procedure
from a material specialist and Engineer in Charge is required to be obtained prior
to proceeding in each case.
5.3.1.4. Parts to be welded shall be carefully prepared. Alignment, jigging and welding
sequence shall be planned in such a manner to minimise distortion and residual
stress.
5.3.1.5. Butt welds shall be made in at least two passes such that filler metal is deposited
over the whole thickness of the joint. Back gouging shall be done by carbon arc
electrode for members having depth 300 mm and less and where it is difficult to
carry out back chipping in web to produce sound.
5.3.1.6. Prepared weld profiles shall be checked by gauges before welding.
5.3.1.7. Seal welds shall be provided for galvanized steel joints, if specified on shop
drawings. Seal welds shall be 3 mm minimum fillet weld, unless noted otherwise.
5.3.1.8. All run-off bars and extension tabs shall be removed.
5.3.1.9. Weld tabs or weld backing strips shall be removed after fabrication to prevent crack
formation and propagation during seismic event for certain connections as noted
on drawings:
a. Column to base plate groove weld connection: Weld tabs and weld backing
shall be removed except for:
i. Weld backing inside of flanges (note fillet weld of backing to column flange
is prohibited)
ii. Weld backing on web of I shaped sections unless backing is attached to
base plate using minimum 8 mm continuous fillet weld
iii. Weld backing located inside of Hollow Square Section (HSS)/ Box sections
b. Welded splice in columns made with groove weld: Weld tabs for groove welds
shall be removed. However, steel backing of groove welds is permitted
5.3.2. Welding Procedures
5.3.2.1. WPS shall be prepared and tested in accordance with AWS D1.1/D1.1M by the
FABRICATOR. However, WPS prepared in accordance with ASME Sec IX are also
acceptable provided the welders using the WPS are qualified for ASME Sec IX.
5.3.2.2. The procedure shall identify material, weld geometry, tolerances, welding process,
pre-heat temperature and welding position to be used.
5.3.2.3. WPS shall be qualified by procedure qualification and shall be approved by an
independent TPIA or an Authorized Representative of BUYER.

Date: 25.08.2020, Rev. 0
5.3.2.4. Welding Procedure Specification (WPS) shall be made available to the welder prior
to the commencement of the work and shall be available to the Engineer in Charge
or Inspection Authority on request.
5.3.3. Welder Qualification
5.3.3.1. Individual welders shall be generally qualified in accordance with requirement of
AWS D1.1/ D1.1M and specifically for AWS D14.1/14.1M when welding the lifting
lugs. ASME Sec IX qualified welders may be permitted with approval from OWNER.
5.3.3.2. Welder testing shall be witnessed, and certificates endorsed by a TPIA or an
Authorized Representative of BUYER.
5.3.3.3. The certificate shall be updated at six monthly intervals, subject to the welder
having been engaged on appropriate work in the intervening period.
5.3.4. Welding Inspection

5.3.4.1. Welding shall be inspected in accordance with AWS D1.1/D1.1M and when
applicable ASME Sec IX.
5.3.4.2. Welding of rigging and under the hook lifting devices shall be inspected in
accordance with AWS D14.1/D14.1M.
5.3.4.3. Fabricator’s Inspector shall be qualified and certified as per AWS / CSWIP/IWE or
equivalent. Third party inspectors for inspection on behalf of OWNER shall be
approved by the OWNER.
5.3.4.4. Welds shall be free from spatters, Slag, Incomplete fusion, Arc strikes etc.
5.3.5. Scope and Frequency of Inspection
5.3.5.1. All welds shall be visually inspected along 100% of their length in accordance with
AWS D1.1/1.1M, unless noted otherwise.
5.3.5.2. Minimum frequency of NDT inspection for ASCE/SEI 7 Risk Category III/ IV
structures as per Table 1.5-1, with potential of substantial risk to human life or
substantial economic impact, shall be in accordance with the following:
a. Fillet welds - DPT/ MPT for 10% of welds with leg length > 10 mm or where the
connecting material is greater than 20mm
b. Partial joint penetration weld - DPT/ MPT for 20% of welds
c. Complete joint penetration weld subject to transverse tensile stress - DPT/
MPT for 50% of welds & UT for 100% of welds for components with thickness
8 mm or more (refer Section N5.5b of ANSI/AISC 360)
d. Complete joint penetration weld not subject to tensile stress - DPT/ MPT for
20% of welds
e. Reduction in the rate of UT from 100% to 25% is permitted for individual
welders who have demonstrated a high level of skills (failure rate less than 5%),

Date: 25.08.2020, Rev. 0
proven after a significant number of their welds (40 minimum) have been
tested (refer Section N5.5e of ANSI/AISC 360)
f. For evaluating UT failure rate of continuous welds over 1.0 m in length (refer
Section N5.5d of ANSI/AISC 360)
 Each 300 mm increment or fraction shall be considered as one weld where
effective throat is 25 mm or less
 Each 150 mm increment or fraction shall be considered as one weld where
effective throat is more than 25 mm
g. NDT shall be performed over the entire length of the selected welds. Joints
chosen for NDT shall be selected on a random basis ensuring the sampling
covers each welder’s work and joint type (fillet, partial joint penetration,
complete joint penetration). In case of defects, two additional welds of same
type by same welder shall be examined additionally. If additional welds are
also found to be defective, 100% of welds made by specific welder shall be
100% examined and welder shall be re-qualified.
5.3.5.3. Frequency of NDT inspection for ASCE/SEI 7 Risk Category II structures shall be in
accordance with the following:
a. Fillet welds - DPT/ MPT for 5% of welds with leg length > 10 mm or where the
connecting material is greater than 20mm
b. Partial joint penetration weld - DPT/ MPT for 10% of welds
c. Complete joint penetration weld subject to transverse tensile stress - DPT/
MPT for 10% of welds & UT for 10% of welds for components with thickness 8
mm or more (refer Section N5.5f of ANSI/AISC 360)
d. Complete joint penetration weld not subject to tensile stress - DPT/ MPT for
10% of welds
e. In case more than 5% of welds for an individual welder in a sample of 20 welds
fail in UT, the UT rate shall be increased to 100% till welder achieves less than
5% failure rate after a significant number of their welds (40 minimum) have
been tested (refer Section N5.5f of ANSI/AISC 360). NDT shall be performed as
per 5.3.5.2.g.
5.3.5.4. The Risk Category of the structure shall generally be mentioned in the design
drawings and the shop drawings.
5.3.5.5. In absence of direction on shop drawings, structures shall be considered
ASCE/SEI 7 Risk Category III and CJP shall be considered as transversely applied
tension loaded. (refer clause 4.1.15 PIP STS05120)
5.3.5.6. NDT for lifting lug welds
Lifting lugs and associated column caps as applicable shall be subject to following
NDT:

Date: 25.08.2020, Rev. 0
a. Fillet weld - MPT for 100% of welds

b. Partial joint penetration weld - MPT for 100% of welds
c. Complete joint penetration weld - DPT/ MPT for 100% of welds & UT for 100%
of welds. No reduction in UT test rate is permitted for lifting lug.
d. 100% UT of localized area ( 50mm all around of welded lifting lug or thickness
of connected member/plate whichever is greater) of structural members
where Lifting Lugs will be welded
The lifting lug welds shall be tested both prior to initial load test and post initial load
test.
5.3.5.7. For purpose of NDT on weld joints, IS 2062 (E250/ E350) shall be considered under
same family of BS Grades S275/ S355 respectively.
5.3.6. Non-Destructive Testing of Welds - Personnel
5.3.6.1. NDT shall be performed by personnel qualified to a recognised national or
international standard (e.g. PCN, ISNT/ASNT Level II, etc.). NDT technicians shall be
validated by TPIA/ OWNER Authorised Representative prior to deployment on the
job.
5.3.7. Non-Destructive Testing of Welds - Procedure
5.3.7.1. Magnetic particle test (MPT), Dye penetrant test (DPT) and Ultrasonic Testing (UT)
shall be performed in accordance with the recommendations given in AWS
D1.1/D1.1M and ASME Sec V.
5.3.7.2. Radiographic testing (RT) may be used as an alternate to UT and shall be done in
accordance with the recommendations given in AWS D1.1/D1.1M.
5.3.7.3. The test results shall be recorded and be available for inspection by the Engineer in
Charge/ BUYER or Inspection Authority.
Whenever a weld joint is detected as defective using an NDT technique, same NDT
shall be performed for reassessing the joint quality after repair. The weld or joint
repair plan shall be submitted for Engineer in Charge approval.
5.3.8. Non-Destructive Testing of Welds - Acceptance Criteria
5.3.8.1. Acceptance criteria for visual examination of welds shall be as per AWS
D1.1/D1.1M Table 6.1, “Cyclically Loaded Non-Tubular Connections” for crane
girders or those identified on shop drawings and “Statically Loaded Non-tubular
Connections” for other fabrications.
5.3.8.2. Acceptance criteria for dye penetrant testing (DPT) shall be as per AWS
D1.1/D1.1M, Section 6, Part C.
5.3.8.3. Acceptance criteria for magnetic particle testing (MPT) shall be as per AWS
D1.1/D1.1M, Section 6, Part C.

Date: 25.08.2020, Rev. 0
5.3.8.4. Acceptance criteria for ultrasonic testing (UT) shall be as per AWS D1.1/D1.1M,
Section 6.13 “Cyclically Loaded Non-Tubular Connections” or “Statically Loaded
Non-Tubular Connections” as identified on shop drawings.
5.3.8.5. In absence of specific “Cyclically Loaded Parts” stamp/marking on shop drawing,
members shall be considered as statically loaded.
5.3.9. Site welding shall be permitted only when specifically called for on the drawings, or
with prior approval of Engineer in Charge. Type and frequency of NDE for site
welding shall be as per this specification. However, for UT the frequency for site
welds should be 100% without any reduction.
5.4. Painting
5.4.1. Steelwork shall be prepared, primed and painted as indicated on shop drawings in
accordance with the Technical Specification RPMS-ENGG-SPC-PP-014.
5.4.2. Steelwork to be galvanized shall be prepared in accordance with Technical
Specification RPMS-ENGG-SPC-PP-042.
5.4.3. Paint shall be excluded from areas within 50mm of joints to be field welded as
identified on shop drawings.
5.4.4. Top and/ or intermediate coat of paint shall be masked at specific locations on
assembly, if required on shop drawings.
5.4.5. In order to minimize coating damage reasonable care shall be taken when handling
steelwork between stages in painting, especially when slinging and loading
steelwork which has received its final coat.
5.4.6. No material shall be shipped until the final shop coat of paint including touch-ups
is thoroughly dry and only after it is clearly colour coded as per this specification.
5.4.7. Adequate packing, crating, blocking and/or bracing shall be provided to prevent
damage to the fabricated material while loading, in transit and while unloading.
5.5. Erection Marking
5.5.1. Assemblies shall be marked with a durable and distinguishing erection mark in such
a way as not to damage the material. Method and location of marking shall be
proven by past performance to survive painting, galvanizing, shipping and outdoor
storage and be pre-approved by BUYER. Assemblies shall be marked by a minimum
of two of the following methods:
a. Hard stamping at location indicated on shop drawings
b. Aluminum/ Galvanized metal tags wired to assembly at same end as hard
stamp
c. Numeric bar codes/ QR codes
d. Erection markings corresponding to erection drawings painted in letters a
minimum of 40mm high on members.

Date: 25.08.2020, Rev. 0
e. The locations of markings shall be such that at least one marking shall be visible
at any position. For e.g., for beams and columns, marking shall be both on
flange and web.
5.5.2. Where areas of steelwork are indicated on the drawings as being unmarked, they
shall be left free of any markings and hard stamping.
5.5.3. Bundles shall be tagged with non-destructible labels.
5.6. Colour Coding
5.6.1. Fabricated structural steel including galvanised steel, shall be identified by a band
of coloured paint on each separate piece. Colour Bands shall be used to identify
different plants in a Complex, as decided in Project specific procedure.
5.6.2. Each band of paint shall be 40mm minimum width. The bands shall be placed at the
north or west ends of beams and the bottom end for columns and bracing. The
band shall completely encircle each member.
5.6.3. Chequered plate and assembled handrails shall have stripes of 75mm in length
painted on one side.
5.6.4. The location and colour of band shall be as indicated on shop drawings.
5.7. Fire Proofing
5.7.1. Steelwork to be fireproofed shall be prepared and primed in accordance with
Technical Specification RPMS-ENGG-SPC-CS-026. No further painting on primed
surface needs to be done.
5.7.2. Fireproofing materials shall be applied in accordance with Technical Specification
RPMS-ENGG-SPC-CS-026.
5.7.3. Extent and type of fireproofing shall be as specified on the shop drawings.
6.1. FABRICATOR shall record testing of materials, weld equipment and consumables,
dimensional checks, surface checks, weld inspections and protective treatment
inspections.
6.2. FABRICATOR shall perform minimum shop inspections and NDT on product and
finishes as required by this specification and provide inspectors meeting the
requirements of this specification to inspect material and workmanship in the
fabrication shop.
6.3. Positive marking shall be provided on fabricated parts. Parts shall be marked to
identify that visual examination and NDT have been completed and the product is
satisfactory for additional manufacturing processes.
6.4. Mock up assembly of structures shall be done where required.

Date: 25.08.2020, Rev. 0
7. Vendor data
Vendor in title of this section to be read as FABRICATOR for purpose of this
specification.
7.1. Written records of material receiving, material testing, material traceability,
fabrication, fabrication tolerance dimensional checks, welding inspections, NDT,
cleaning and coating, and galvanizing shall be prepared by the FABRICATOR and
shall be available for review by the BUYER. Records shall be legible and duly signed
by FABRICATOR’s authorized personnel (electronic signatures shall be acceptable).
7.2. If required in purchase order, the inspection records and non-destructive
examination reports as required by this specification shall be maintained at the
FABRICATOR’s facility for a period as defined in purchase order and shall be made
available to the OWNER/ BUYER upon request during this period.
8. Packing, Preservation, Shipment and Storage
8.1. FABRICATOR shall establish and maintain controls for material handling and
storage during fabrication and preparation for shipment to prevent damage and
deterioration.
8.2. Delivery of steel shall be in the order needed for erection and shall be in erectable
lots. The delivery sequence for the fabricated steel, unless otherwise noted in
purchase order or directed by BUYER, shall be as follows:
a. Loose base plates
b. Steel embedded in concrete
c. First tier columns and framing for all its levels (including stairs, grating, and
handrail)
d. Second tier columns and its framing, etc.
8.3. All steel and its coatings shall be protected from any damage caused by handling,
storage, or shipping before receipt by BUYER. Damage to steel surface finish,
painted or galvanied, during handling or delivery shall be repaired in accordance
with Technical Specification RPMS-ENGG-SPC-PP-014 or Technical Specification
RPMS-ENGG-SPC-PP-042 as applicable.
8.4. Fabricated components which are stored prior to being transported shall be
stacked clear of the ground and arranged so that water cannot accumulate and rust
the components. They shall be kept clean and supported in such a manner as to
avoid permanent distortion.
8.5. Individual components or bundles shall be stacked and marked in such a way as to
ensure that they can be easily identified and accessible.
8.6. Packing/ bundling/ loading of steel shall be in accordance with the following:
a) No steel to steel contact is ensured
b) Bundles shall contain steel from a single release.
Date: 25.08.2020, Rev. 0
8.7. Bundles shall be loaded and cribbed so they can be readily unloaded by others.
Assemblies/ bundles shall be placed in a manner which ensures no ponding/
accumulation of water on steel during transportation.
8.8. Adequate protection shall be provided for threads on sag rods and any other
threaded components to prevent damage during shipping and handling.
8.9. All materials and documentation shall be delivered to the job site in good condition.
All materials and documentation shall be inspected by BUYER upon receipt to
determine that all items included in the bill of materials have been supplied, to
ensure that all documentation has been received, and to check for any damage.
8.10. BUYER reserves the right to reject all damaged or below quality material or
documentation.

Technical Specification for Supply of Steel Sections,

Plates, Flats, Bars and Other Solid Shapes Used for
Structural Steelwork

By By By
Reliance Project Management System RPMS-ENGG-SPC-CS-014
Technical Specification for Supply of Steel Sections, Plates, Flats, Date:25/08/2020, Rev. 0
Bars and Other Solid Shapes Used for Structural Steelworks

(DD.MM.YYYY)
S Sammaddar _________________ ___________

2

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
3. Conflicts & Deviations ............................................................................................... 8
4. Abbreviations and Definition .................................................................................... 9
7. Vendor Data ............................................................................................................ 16
1. Purpose
This specification defines the minimum technical requirements for supply,
manufacture, inspection and testing and packaging of rolled solid steel products
like sections (beams, column, angles, tees), plates, flats, strips, bars, rods etc.;
tubular steel products such as structural pipes and square/ rectangular hollow
sections; cold formed C and Z sections for purlins and girts; flooring products such
as gratings and chequered plates; and steel deck profile for use in structural steel
construction.
[This specification shall be used as the standard minimum requirements by the
Detailed Engineering Contractor/ Engineering, Procurement & Construction
Contractor and for In-House purchases on Reliance Projects by Reliance Group
companies to achieve maximum technical and economic benefits of
standardization.]
2. References
The products shall adhere to the requirements laid down in the codes and
publications referenced below. The documents shall be current edition or
revision including amendments and errata as applicable at the Time of Enquiry,
unless expressed otherwise. Revisions, amendments or errata published
afterwards date shall be incorporated only at the direction of the Engineer in
Charge after approval from BUYER.
2.1. Codes and Standards
Indian Codes
Code Title
IS 228 Methods of Chemical Analysis of Steels (Part 1 to Part 14)
IS 432 (Part 1) Specification for Mild Steel and Medium Tensile Steel Bars
and Hard-Drawn Steel Wire for Concrete Reinforcement,
Part 1: Mild Steel and Medium Tensile Steel Bars
IS 808 Dimensions for Hot Rolled Steel Beam, Column, Channel
and Angle Sections
IS 811 Specification for Cold Formed Light Gauge Structural Steel
Sections
IS 1161 Steel Tubes for Structural Purposes – Specification
IS 1173 Specification for Hot Rolled and Slit Steel Tee Bars
IS 1239 (Part 1) Steel Tubes, Tubulars and Other Wrought Steel Fittings –
Specification, Part 1: Steel Tubes

Code Title
IS 1387 General Requirements for the Supply of Metallurgical
Materials
IS 1608 Metallic Materials – Tensile Testing at Ambient
Temperature
IS 1730 Steel Plates, Sheets, Strips and Flats for Structural and
General Engineering Purposes – Dimensions
IS 1732 Steel Bars, Round and Square for Structural and General
Engineering Purposes – Dimensions
IS 1757 (Part 1) Metallic Materials Charpy Pendulum Impact Test Charpy
Pendulum Impact Test, Part 1: Test Method
IS 1852 Specification for Rolling and Cutting Tolerances for Hot-
Rolled Steel Products
IS 1977 Low Tensile Structural Steels – Specification
IS 2062 Hot Rolled Medium and High Tensile Structural Steel –
Specification
IS 2314 Specification for Steel Sheet Piling Sections
IS 3502 Steel Chequered Plates
IS 3803 (Part1) Steel – Conversion of Elongation Values,
Part 1: Carbon and Low Alloy Steels
IS 4225 Recommended Practice for Straight Beam Ultrasonic
Testing of Steel Plates.
IS 4923 Hollow Steel Sections for Structural Use – Specification
IS 8500 Structural Steel - Micro-Alloyed (Medium and High Strength
Qualities) – Specification
IS 8910 General Technical Delivery Requirements for Steel and Steel
Products
IS 10842 Evaluation Procedure for Y-Groove Weld Crackability Test in
Structural Steel

British Codes
Code Title
BS 4 Structural Steel Sections - Specification for Hot-Rolled
Sections
BS EN 1330-4 Non-Destructive Testing Terminology – Terms Used in
Ultrasonic Testing
BS EN 10024 Hot Rolled Taper Flange I Sections - Tolerances on Shape
and Dimensions
BS EN 10025-1 Hot Rolled Products of Structural Steels - General Technical
Delivery Conditions
BS EN 10025-2 Hot Rolled Products of Structural Steels - Technical Delivery
Conditions for Non-Alloy Structural Steels
BS EN 10027 Designation System of Steel
BS EN 10034 Structural Steel I and H Sections - Tolerances on Shape and
Dimensions
BS EN 10051 Continuously Hot-Rolled Strip and Plate/ Sheet Cut from
Wide Strip of Non-Alloy and Alloy Steels - Tolerances on
Dimensions and Shape.
BS EN 10055 Hot Rolled Steel Equal Flange Tees with Radiused Root and
Toes - Dimensions and Tolerances on Shape and
Dimensions
BS EN 10056-1 Specification for Structural Steel Equal and Unequal Angles
– Dimensions
BS EN 10056-2 Specification for Structural Steel Equal and Unequal Angles -
Tolerances on Shape and Dimensions
BS EN 10058 Hot Rolled Flat Steel Bars for General Purposes -
Dimensions and Tolerances on Shape and Dimensions
BS EN 10164 Steel Products with Improved Deformation Properties
Perpendicular to the Surface of the Product,
Technical Delivery Conditions
BS EN 10204 Metallic Materials - Types of Inspection Documents
BS EN 10279 Hot Rolled Steel Channels -
Tolerances on Shape, Dimension and Mass

Code Title
BS EN 10365 Hot Rolled Steel Channels, I and H Sections –
Dimensions and Masses (replaces BS4-1)
American Codes
Code Title
ASTM Standard Specification for Straight-Beam Ultrasonic
A435/A435M Examination of Steel Plates
ASTM Standard Specification for Through-Thickness Tension
A770/A770M Testing of Steel Plates for Special Applications
Specification
Specification Title
RPMS-ENGG- Standard Specification for Hot Dip Galvanizing of
SPC-PP-042 Equipment, Piping and Structural Steel
3. Conflicts & Deviations

3.1. Conflicts
a. The purchase order
b. This specification
c. Codes and standards specifically referred
d. Other national and international standards as referenced
time of enquiry, shall be applicable. In case of any conflict, the decision of
owner’s engineer in charge shall be final and SUPPLIER shall implement that
without any commercial implications. All “local and statutory requirements as
applicable shall be complied to without any deviation”.
3.2. Deviations
Deviations to specified technical condition would require a specific approval from
OWNER.

4. Abbreviations and Definition

BS British Standard
EN European Norms
IS Indian Standard
ISO International Standards Organization
TPIA Third party inspection agency
BUYER OWNER or OWNER appointed EPC Contractor who specifies
equipment, product and services for purchase from SUPPLIER
Engineer in Charge BUYER’s authorised representative with overall authority and
responsibility for engineering design, quality, and
MANUFACTURER Party which manufactures a product to perform the function
as specified by BUYER
Company
SUPPLIER Party which manufactures or supplies equipment, product
and services to perform the function as specified by BUYER
5.1. Manufacturing
Steel shall be manufactured per section 6.2 of IS 2062 for Indian steel grades and
section 6 of BS EN 10025-2 for British steel grades. The raw material may be in
the form of billets, bars, slabs or coils with well documented metallurgy
conforming to industry standard and codes.
5.1.1. Material shall be of new stock and shall comply with the requirements of the
referenced IS or BS EN standards in this specification. Alternate proposed
materials shall contain the minimum IS or BS EN requirements for chemical
composition. Scrap or other steel material or elements extracted from such
materials shall not be added at any stage of manufacture. The finished product
shall have clear and documented traceability.

5.1.2. Material produced by re-rolling of finished products, even if from new stock, is
not acceptable.
5.1.3. Material manufactured from billets produced from Induction Melting furnace
shall require prior approval of RIL.
5.2. Material
Material of products shall be non-alloy (ordinary) or micro-alloyed structural steel
supplied in As-Rolled (AR) condition unless specified otherwise in the purchase
order for additional treatment such as normalizing rolling (N), accelerated cooling
or heat treatment.
Steel with copper bearing weathering grades are excluded from this specification.
5.2.1. Total micro-alloying elements shall not be more than 0.25 percent. Steel may be
treated with rare earth elements to achieve better formability.
5.2.2. Steel for hot rolled shapes, sections, plates, flats, bars shall be supplied as Semi-
Killed or Killed and shall be de-oxidised as per Table 1 of IS 2062 for Indian steel
grades and as per Table 2 of BS EN 10025-2 for British steel grades.
5.2.3. Structural steel shall comply with the requirements of IS 2062 Grade E250 BR or
BSEN 10025 Grade S275 JR for sections up to 25mm thickness. Steel shall comply
with IS 2062 Grade E250 B0 or BSEN 10025 Grade S275 JO for sections greater
than 25mm. Where high yield steel is required it shall comply to IS 2062 Grade
E350 BR or BSEN 10025 Grade S355 JR for section up to 25mm thickness, IS 2062
Grade E350 B0 or BSEN 10025 Grade S355 JO for section greater than 25mm but
less than 50mm and IS 2062 Grade E350 C or BSEN 10025 Grade S355 J2 for
section thickness 50mm or greater.
5.3. Profiles
The material grade of structural steel rolled sections, plates and other items shall
be as specified in purchase order.
5.3.1. Indian Material Grades
The minimum material grades, nominal dimensions and tolerance of rolled
products shall be as follows:
Shape Material Grade Dimensions &

Tolerances
Hot Rolled Structural Long IS 2062: Grade E250 BR or IS 808
Products - Beams & Columns Grade E350 BR/B0

Shape Material Grade Dimensions &

Tolerances
Structural Steel Plates IS 2062: Grade E250 BR/B0 IS 1730
or E350 BR/B0/C
Channels IS 2062: Grade E250 BR IS 808
Angles IS 2062: Grade E250 BR IS 808
Square/ Rectangular Hollow IS 4923: Grade YSt 310 IS 4923
Structural Sections (SHS/RHS)
Circular Hollow Structural IS 1161: Grade YSt 310 IS 1161
Sections (CHS)
Pipe (for Handrails) IS 1161: Grade YSt 240 IS 1161
if specified on purchase IS 1239
order, IS 1239 (medium
grade pipe)
Cold formed C and Z Sections IS 811 IS 811
Round Bars (for Sag Rods) IS 432 (Part 1): Grade 1 IS 1732
material
Square Bars IS 2062: Grade E250 A IS 1732
Mild Steel Flats IS 2062: Grade E250 A IS 1730
Steel Sheet Pile IS 2062: Grade E250 A IS 2314
a. The rolling and cutting tolerances of hot rolled steel products shall be as
specified in IS 1852.
b. Substitution of material with higher quality (BR, B0, C) within the same
material grade (E250, E350) as in purchase order is permissible with BUYER’s
consent. Substitution of material with a higher material grade (E350, E450,
E550) for plates and profiles requires formal approval from Engineer in
Charge.
5.3.2. British Material
The minimum material grades, nominal dimensions and tolerance of rolled
products shall be as follows:

Shape Material Grades Dimensions &

Tolerances
Hot Rolled Structural Long BS EN-10025-2: BS EN 10365
Products - Universal Beams and Grade S275 JR or (Tolerances
Universal Columns Grade S355 J0 BS EN 10034)
Structural Steel Plates BS EN-10025-2: BS EN 10051
Grade S275 JR or
Grade S355 JR/J0/J2
Parallel Flange Channels BS EN-10025-2: BS EN 10365
Grade S275 JR (Tolerances
BS EN 10279
Angles BS EN-10025-2: BS EN 10056-
Grade S275 JR 1 (Tolerances
BS EN 10056-
2)
Tee (WT) shapes BS EN-10025-2: BS -4-1
Grade S275 JR or (Tolerances
Grade S355 J0 BS EN 10034)
Substitution of material with higher quality (J0, J2) within the same material grade
(S275, S355) as in purchase order is permissible with BUYER’s consent.
Substitution of material with a higher material grade (S355, S450) for plates and
profiles requires formal approval from Engineer in Charge.
5.3.3. If SUPPLIER proposes plate or profile material of lower quality because of non-
availability; for example, quality A in lieu of quality BR, quality BR in lieu of quality
B0 or quality JR in lieu of quality J0; the chemical and mechanical properties shall
be checked as per material test certificate to confirm that they meet the
requirements of the proposed material. In addition, relevant Charpy Impact test
shall be compulsorily done at requisite temperature to satisfy the impact energy
requirement of originally ordered quality. This is to ascertain the ductile behavior
of the ordered material. This shall be followed even if the substituted material is
of higher material grade but is lower on the quality.
Substitution of Indian material grade with British material grade and vice versa
shall be permitted with dual certification.

5.3.4. Chequered floor plates shall conform to IS 3502 with raised patterns on top of
surface pattern type 1D and shall be supplied hot dip galvanised. The plates shall
be manufactured from a base material as per requirements of grade E250 A of
IS 2062 as a minimum. Hot Dip Galvanizing & Testing shall be performed as per
specification RPMS-ENGG-SPC-PP-042.
5.3.5. Welded floor grating (grid flooring) shall be manufactured from material
conforming to grade E250 A of IS 2062 as a minimum. Gratings shall be open grid
type with rectangular pattern and hot dip galvanised. Top surface of bearing bars
shall be serrated unless plain is specified in purchase order. Grating shall be
supplied with hot dip galvanised clips and other appurtenances including bolt and
nut. Hot Dip Galvanizing & Testing shall be performed as per specification RPMS-
ENGG-SPC-PP-042. Gratings shall be Load tested as per BS4592 Part 1. Gratings
shall be manufactured by fusion welding.
SUPPLIER shall submit catalogue providing grating and clip details and load
capacity information to Engineer in Charge for approval.
5.3.6. Stair treads shall be manufactured from material conforming to grade E250 A of
IS 2062 as a minimum. Stair treads shall be hot dip galvanised serrated
rectangular pattern open grid type. Stair treads shall be provided with slip
resistant nosing strip and carrier plates. Treads shall be supplied with hot dip
galvanized fixing bolts. Hot Dip Galvanizing & Testing shall be performed as per
specification RPMS-ENGG-SPC-PP-042.
5.3.7. Steel deck sheet for use as form decks or composite decks shall be manufactured
from cold formed steel sheets with a minimum yield strength of 250 MPa. The
deck sheets shall be hot dip galvanised with zinc coating of minimum 275
gram/square metre (including both sides) unless specified otherwise. SUPPLIER
shall submit catalogue providing deck sheet details and load capacity information
to Engineer in Charge for approval.
5.3.8. This specification does not cover supply of built-up/ welded girders or bought out
items such as open web fabricated trusses, tapered beams, castellated beams,
built-up or welded girders. For such items, material supply shall confirm to this
specification and fabrication shall comply to fabrication specification.
5.4. Properties and Testing
5.4.1. Sampling Frequency
The sampling frequency shall be as per IS 2062 or relevant IS code for Indian
material grades and BS EN 10025-2 or relevant code for British material grades.
For mechanical properties, the number of test samples shall be min 2 per cast/
heat and at least 2 per type of section or grade of steel. For impact test, the
number of samples shall be one per cast, unless specified otherwise. The impact

test shall be done for Grade BR /JR material supplied as per IS 2062 / BS EN
10025.
5.4.2. Samples
The test samples shall be cut lengthwise for sections, flats and bars. For plates
and strips the samples shall be cut crosswise.
a. Samples for Mechanical Tests
b. Sampling and preparation of samples for mechanical tests shall be as per
Section 9 of IS:2062 for Indian structural steel sections, plates, bars and flats.
For British sections, sampling and preparation of samples shall be as per
Section 9.2 of BS EN 10025-1.
c. Samples for Chemical/ Product Analysis
d. Samples for ladle analysis shall be taken during casting/ teeming of the heat.
5.4.3. Chemical Properties
The chemical composition shall be checked by ladle analysis during manufacturing
and by product analysis of the finished product.
a. For Indian structural steel sections, plates, bars, flats, the chemical
composition shall be determined by ladle analysis during manufacturing and
product analysis of the finished product shall be carried out as per Section 8 of
IS 2062. The results of ladle analysis shall conform to Table 1 of IS 2062. The
results of product analysis shall not vary more than the limits specified in
Table 3 of IS 2062.
b. For British sections, chemical composition tests shall be carried out by a
suitable method in accordance to Section 10.1 of BS EN 10025-1. The results
of ladle analysis shall conform to Table 2 of BS EN 10025-2. The results of
product analysis shall be in conformation to values given in Table 4 of BS EN
10025-2.
c. For profile and plate materials to be hot dip galvanised, the "silica" content
should be limited preferably as per Section 7.2.5 and Section 7.4.3 of
BS EN 10025-2 to achieve better surface finish of final product, if specified on
purchase order.
5.4.4. Physical Properties
a. Mechanical Tests
MANUFACTURER shall perform tests to determine tensile, bending, and
impact properties for Indian structural steel sections, plates, bars, flats as per
IS 2062. The results shall comply to Table 2 of IS 2062.
Other material shall follow requirement as per respective codes in Section 5.2.

For British structural steel sections, tests shall be carried out in accordance to
BS EN 10025-1. The results shall follow Table 7 of BS EN 10025-2.
b. Y Groove Crackability Test
Grade E250 C plate and sections with material thickness 12 mm or above shall
be compliant to Y-Groove crackability test carried out in accordance with
IS 10842.
c. Ultrasonic Test
Plates shall be tested for internal soundness by straight-beam, pulse-echo
ultrasonic examination as per ASTM A435/A435M.
Discontinuity indication which is unacceptable shall be brought to the notice
of BUYER.
UT examination shall be conducted by rolling mill or by the SUPPLIER.
d. Through Thickness Test
SUPPLIER shall perform through thickness ductility test to ensure quality class
"Z15" of BS EN 10164 (or conforming to ASTM A770/A770M alternatively) for
plates greater than 25 mm, if such plates are manufactured by rolling mills
which are not approved by OWNER.
Material test reports shall note that this test was performed indicating results.
6.1. Supply Condition
6.1.1. The supply of Indian steel products shall conform to the requirements of IS 8910
and IS 1387. Supply of British section shall comply with BS EN 10025-1.
6.1.2. The dimensions, shape, weight, tolerances and testing shall conform to respective
IS or BS EN codes and requirements specified in this document. The finished
product shall be free from surface defects, laminations, rough and imperfect
edges, piping and other harmful defects. The surface condition of material
supplied shall be as per BS EN 10025-2.
6.1.3. A defect which is not detrimental to the performance of the product may be
allowed to be rectified before dispatch. The surface defects may be repaired by
grinding as permitted by BS EN 10163/ BS EN 10221. Repair welding shall not be
allowed without prior approval of RIL.
6.1.4. The product or lot shall not be cleared for dispatch, unless inspected and cleared
by BUYER or its appointed TPIA.
6.1.5. Material purchased from mills shall be subjected to inspection and testing by
BUYER or BUYER authorized TPIA at site as per relevant IS Codes on a random
basis. Final acceptance will be based on Inspection and testing at site.

7. Vendor Data
7.1. Vendor in title of this section to be read as SUPPLIER for purpose of this
specification.
SUPPLIER shall submit material test certificate duly signed and stamped along
with each order. The test certificate shall carry results of the tests mentioned
herein for each product, as per frequency of sampling mentioned in Section 5.
The test certificate shall typically have results of following material tests:
a. Ladle analysis results
b. Product analysis results
c. Tensile test results giving yield strength, tensile strength and percentage
elongation values
d. Bend test results
e. Impact test results
f. Y groove crackability test results where applicable
g. Dimensions and weights of product.
h. UT test for plates 25mm and greater
i. Through thickness test for plates 25mm and greater
Steel rolled sections, plates and other miscellaneous steel materials shall be free
of loose mill scales, rust, oil, mud, paint or other coatings.
Each product other than bars, flats or flooring product shall carry a tag or a
permanent mark, with the MANUFACTURER’s name and/ or trade mark, steel
grade designation and the cast/ heat number. BIS certification, if available shall
also be marked on steel products. The marking shall be at two locations for the
products mentioned, so that the same is visible at any position. For instance: for
plates on opposite surfaces and for beams columns etc., both on flange & web.
Bars, flats and flooring products shall carry a tag bearing MANUFACTURER’s name
and/ or trademark.
The end of rolled products shall be painted with a colour code as per purchase
order.
It is permissible to supply products such as bars, flats, pipe for handrails, flooring
products, steel deck profiles and sheet piling in securely tied bundles. Product
marking shall be as a label attached to bundle or on the top product of the
bundle.

Technical specification for supply of bolts, studs, nuts

and washers used for structural works

By By By
Technical specification for supply of bolts, studs, nuts and Date: 25/08/2020, Rev. 0
washers used for structural works

(DD.MM.YYYY)
S Sammaddar _________________ ___________

2

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
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10
RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
7. Vendor Data ............................................................................................................ 13
8. Packing, Preservation, Shipment & Storage ........................................................... 13
1. Purpose
This specification defines the minimum technical requirements for design,
manufacture, inspection & testing, packaging and shipment of Hexagonal Bolts,
double end/ fully threaded Studs, Nuts and Washers for use in structural steel
construction. The property class, surface treatment, length of bolt and quantity
shall be as specified in the Purchase Order.
This specification shall be used as standard minimum requirement by DEC/ EPC
Contractor and for all In-House purchases for all Reliance Projects and by all
Reliance Group companies to achieve maximum technical and economic benefits
of standardization.
2. References
The products shall adhere to the requirements laid down in the codes and
publications referenced below. The documents shall be current edition or revision
including all amendments and errata as applicable on the date of enquiry (OR
CONTRACT AWARD), unless expressed otherwise. Any revision, amendment or
errata published after contract award date shall be incorporated only at direction
of Engineer in Charge after approval from RIL/ OWNER/ BUYER.

Common Codes and standards specific to Bolts:
Code Title
IS 1363 (Part 1) Hexagon Head Bolts, Screws and Nuts of Product Grade `C' -
Hexagon Head Bolts (Size Range M 5 to M 64)
IS 1367 Technical Supply Conditions for Threaded Steel Fasteners:
(Part 1): General Requirements for Bolts, Screws & Nuts
(Part 2): Tolerances for Fasteners - Bolts, Screws, Studs and Nuts -
Product Grades A, B and C
(Part 3): Mechanical Properties of Fasteners Made of Carbon Steel
and Alloy Steel - Bolts, Screws and Studs
(Part 9): Surface discontinuities: Section 1 - Bolts, screws and studs
for general applications
(Part 13): Hot-dip galvanized coatings on threaded fasteners
(Part 16): Designation System for Fasteners
(Part 17): Inspection, Sampling and Acceptance Procedure
(Part 18): Packaging

Code Title
(Part 19) Axial Load Fatigue testing of Bolts, Screws & Studs
(Part 20) Torsional Test and Minimum Torques for Bolts and Screws
with Nominal Diameters 1 mm to 10 mm
IS 1499 Method for Charpy Impact Test (U-notch) for Metals
IS 1500 Metallic Materials - Brinell Hardness Test
(Part 1): Test Method
(Part 2): Verification and Calibration of Testing Machines
(Part 3): Calibration of Reference Blocks
(Part 4): Table of Hardness Values
IS 1501 Metallic Materials - Vickers Hardness Test
(Part 2): Verification and Calibration of Testing Machines
(Part 4): Table of Hardness Values
IS 1586 Metallic Materials - Rockwell Hardness Test
(Part 2): Verification and Calibration of Testing Machines and
Indenters
IS 1608 Metallic Materials - Tensile Testing
(Part 1): Method of test at Room Temperature
IS 1862 Specification for Studs
IS 3757 Specification for High Strength Structural Bolts
IS 6639 Hexagon Head Bolts for General Steel Structures –
Specification
IS 8535 Bolts, Screws, Nuts and Accessories - Terminology and
Nomenclature

Codes for Threads:
Code Title
IS 2334 ISO General Purpose Metric Screw Threads- Gauges and

Gauging
IS 4218 ISO General Purpose Metric Screw Threads
(Part 1): Basic Profile
(Part 2): General Plan
(Part 3): Basic Dimensions
(Part 4): Selected Sizes for Screws, Bolts and Nuts
IS 14962 ISO General Purpose Metric Screw Threads – Tolerances
(Part 1): Principles and Basic Data
(Part 2): Limits of Sizes for General Purpose External and Internal
Screw Threads - Medium Quality
(Part 3): Deviations for Constructional Screw Threads
(Part 4): Limits of Sizes for Hot-dip Galvanized External Screw

Threads to Mate with Internal Screw Threads Tapped with
Tolerance Position H or G after Galvanizing
(Part 5): Limits of Sizes for Internal Screw Threads to Mate with Hot-
Dip Galvanized External Screw Threads with Maximum Size
of Tolerance Position h Before Galvanizing
Codes for Nuts:
Code Title
IS 1363 (Part 3) Hexagon Head Bolts, Screws and Nuts of Product Grade C -
Hexagon Nuts (Size Range M 5 to M 64)
IS 1367 Technical Supply Conditions for Threaded Steel Fasteners
(Part 6): Mechanical Properties and Test Methods for Nuts with
Specified Proof Loads
(Part 10): Surface Discontinuities – Nuts
IS 6623 High Strength Structural Nuts – Specifications

Codes for Washers
Code Title
IS 2016 Specification for Plain Washers
IS 5369 General Requirements for Plain Washers and Lock Washers
IS 5372 Taper washers for channels (ISMC)
IS 5374 Taper washers for I-beams (ISMB)
IS 6610 Specification for Heavy Washers for Steel Structures
IS 6649 Specification for Hardened and Tempered Washers for
High Strength Structural Bolts and Nuts
Codes for Corrosion Protective Coatings
Code Title
ASTM F2833 Standard Specification for Corrosion Protective Fastener
Coatings with Zinc Rich Base Coat and Aluminum Organic/
Inorganic Type
ISO 10683 Fasteners – Non-electrolytically applied zinc flake coating
systems

3.1. Conflicts
a. The Material Requisition
b. This Specification
c. Codes and Standards specifically referred
d. Other National and International as referenced
time of enquiry, shall be applicable. In case of any conflict, the decision of
owner’s engineer in charge shall be final and SELLER shall implement that
without any commercial implications. All “local and statutory requirements as
applicable shall be complied to without any deviation”.

3.2. Deviations
Deviations to specified technical condition would require a specific approval from
RIL/ OWNER/ BUYER.
For purchase identified as packages, involving components as part of package,
suitable deviations may be granted, if these are standard supply conditions and
have demonstrated past references.
DEC Design Engineering Contractor
PTFE Poly Tetra Flouro Ethylene
OWNER Reliance Industries Limited (RIL) or specified Reliance Group Company
BUYER OWNER or OWNER-appointed EPC Contractor who specifies material
and services for purchase from SELLER
SELLER Party which manufactures or supplies material and services to perform
TPIA Third party inspection agency
5.1. Material
The material of bolts, studs, nuts and washer for structural application shall be
carbon steel or low / medium alloy steel.
Bolts and studs of property class 8.8S and class 10.9S shall be quenched and
tempered at 425oC in accordance with IS 1367 (Part 3). Property class 10.9S bolts
and studs shall have sufficient hardenability in the as-hardened condition before
tempering as per IS 1367 (Part 3).
Nuts of property class 8S and 10S shall be hardened and then tempered at a
temperature of at least 425oC as per IS 6623.
5.2. Plain circular Washers for use with bolts of property class 4.6 shall be as per IS 2016.
Washers for use with bolts of property class 8.8S and 10.9S shall be hardened and
tempered as per IS 6649. Dimensions and Tolerances
5.2.1. Bolts & Studs
The dimensions of hexagon bolts of property class 4.6 shall be as given in Table 1
of IS 6639. All the other characteristics shall be as per IS 1363 (Part 1).

Dimensions of high strength bolts of property class 8.8S and 10.9S shall be as per
IS 3757.
The length-size combination and grip range for property class 4.6 bolts shall be as
given in Table 2 of IS 6639 and as per IS 3757 for property class 8.8S and 10.9S bolts.
Dimensions and length-size combinations of double end studs shall be as per
IS 1862, unless noted otherwise in the Purchase Order.
Tolerances shall be of grade C for all bolts and studs in accordance with IS 1367
(Part 2).
5.2.2. Nuts
The characteristics of nuts shall be as per IS 1363 (Part 3). However, dimensions of
nuts of property class 8S and 10S shall be as specified in Table 1 of IS 6623.
Tolerances shall be of product grade B in accordance with IS 1367 (Part 2) for all
nuts of property class 8S and 10S. Tolerances for nuts for property class 5 shall be
of product grade C.
5.2.3. Threads
The threads of fasteners shall be in accordance with IS 4218 (Parts 1, 2, 3 and 4)
and shall conform to threaded ring gauges in accordance with IS 2334 prior to hot
dip galvanization. The tolerances on the threads shall be 8g for property class 4.6
and 6g for property class 8.8S and 10.9S bolts/ studs as per IS 14962 (Parts 1, 2 and
3). The tolerances on the threads for nut shall conform to tolerance 6H of IS 14962
(Parts 1, 2, and 3).
All dimensions apply before hot-dip galvanizing.
In case of hot-dip galvanized fasteners, the tolerance shall be in accordance with IS
14962 (Part 4 and 5).
5.2.4. Washers
Dimensions and tolerances of ordinary grade circular washers for use with property
class 4.6 bolts shall be as per IS 2016. Dimensions of ordinary grade taper washers
for use with ISMC shall be as per IS 5372 and that for use with ISMB shall be as per
IS 5374.
Dimensions of plain washers for use with high strength bolts/ studs of property
class 8.8S and 10.9S shall be as per IS 6649 Type A. Dimensions of tapered washers
for use with high strength bolts and studs shall be IS 6649 Type B or Type C for use
with ISMC or ISMB structural sections respectively.
All other requirements for washers shall be as per IS 5369.
5.3. Properties and Testing
5.3.1. Chemical Properties

The chemical composition for bolts and studs of carbon & alloy steels shall conform
to the values given in Table 2 of IS 1367 (Part 3). Chemical composition of nuts shall
be as per Table 4 of IS 1367 (Part 6). The chemical properties of steel used for
manufacture of hardened and tempered washer for high strength bolts shall be
consistent with clause 5 of IS 6649.
5.3.2. Mechanical and Physical Properties
Bolts and studs shall, at ambient temperature, conform to mechanical and physical
properties set out in Table 3 of IS 1367 (Part 3), when tested by the methods
described in clause 8 of IS 1367 (Part 3).
The bolts of property class 4.6 shall withstand a minimum shear stress of 260 Mpa
as given in IS 6639.
If specified on Purchase Order, the bolts or studs shall be tested additionally for
axial load fatigue as per IS 1367 (Part 19).
Test Program B as per Table 5 of IS 1367 (Part 3) shall be followed for acceptance
of the bolts and studs.
For nuts of property class 5, the mechanical properties shall be as per Table 6 of IS
1367 (Part 6) and Hardness shall be as per Table 5 of IS1367 (Part 6). For nuts of
property class 8S and 10S, the values of proof loads and hardness shall be as
specified in Table 2 of IS 6623.
Permissible surface discontinuities for the bolts and studs of property class 8.8S and
10.9S shall conform to IS 1367 (Part 9) and shall be as per IS 1367 (Part 10) for nuts
of property class 8S and 10S.
Unless indicated otherwise in the Purchase Order, the property class of nuts shall
be as per Table 2 of IS 1367 (Part 6), corresponding to the property class of bolts
specified. . For high strength bolts property class of nuts should be as per IS 3757
clause 6.3.
The hardness of hardened and tempered washer for high strength bolts shall be as
per with clause 7 of IS 6649.
5.4. Surface treatment
The finish (surface) of the products not subjected to any surface treatment shall be:
a. As processed, for steel products not quenched and tempered;
b. In general, black oxide for quenched and tempered steel products;
c. All bolts and studs shall be supplied lightly oiled.
5.4.1. Galvanization
If specified on Purchase Order, the bolts/ studs of property class 4.6 & 8.8S and and
nuts of property class 5 & 10S shall be hot-dip galvanized as per IS 1367 (Part 13).

Internal threads of galvanized nuts shall be re-tapped per tolerance limits in IS

14962 (Part 5). Washer for use with property class 4.6 & 8.8S galvanized bolt or
stud shall be hot dip galvanized as per clause 8.1 of IS 6649, minimum 300 gram /
square metre.
Bolts/ studs of property class 10.9S & nuts of property class 10S when used in
assembly (10S/10.9S) shall not be hot-dip galvanized.
Hot dip galvanized bolts & nuts shall be provided with suitable lubricant to ensure
that seizure shall not take place in assembly. The coated surface shall be clean and
dry to touch. Hot dip galvanized nuts for high-strength bolts of property class 8S
and 10S shall be provided with blue coloured wax-lubricant as per ASTM A563.Hot
dip galvanized bolts and nuts of property class 8.8S/10S shall be subjected to anti-
seizing test as per Appendix A of IS 3757 and IS 6623, to test the effectiveness of
lubricating coating and shall be tested by manufacturer to ensure adequate
rotational capacity.
5.4.2. Corrosion Protection Coatings
If specified on Purchase Order, bolts and studs property class 10.9S and
corresponding nuts of property class 10S shall be furnished with PTFE coating. The
PTFE coating shall have a Dry film thickness of 25 – 30 microns.
The PTFE Coating shall satisfy the following:
a. Coating Thickness (DFT) as per ASTM D1186
b. Salt Spray Test as per ASTM B117 : Min 1000 hours
c. Adhesion Test as per ASTM D3359 Method B
Alternatively, chrome free Zinc Aluminium duplex corrosion protective coating
system shall be applied on bolts/ studs, nuts and washers in accordance with ISO
10683 and shall be consistent with ASTM F2833 Grade 1. The coating system shall
be applied as dip-spin method and not the spray method.
All requirements such as mass, uniformity and adhesion of coating shall be tested
and shall comply with the codal requirements.
Before applying any coating, the manufacturer shall verify that the coating
thickness allows nuts to be rotated smoothly onto the bolts by hand for each
diameter. Nuts shall be suitably tapped before application of coating system.
The product shall have intact surfaces and edges and shall be free of burrs and pits
consistent with the manufacturing methods used. Any burr which influences the
performance of the product or would be a safety hazard when handled shall be
removed. Trimming burrs beyond the bearing face of bolts and studs is not
permissible.

The inspection and testing of each sample representing a particular lot shall be
carried out in accordance to IS 1367 (Part 17).
Pre-delivery inspection of products by RIL/ OWNER/ BUYER or its authorized
representative does not relieve the manufacturer the responsibility of delivering
the product in good condition. If an individual fastener is found deteriorated or not
complying with the requirements upon delivery, the lot or the complete package is
liable for rejection.
7. Vendor Data
Vendor in title of this section to be read as SELLER for purpose of this specification.
SELLER shall submit to RIL/ OWNER/ BUYER the manufacturer’s certificates of
compliance of product including protective coating system, mill test reports and
component/ assembly test certificates for each lot of bolts, studs, nuts and
washers.
All packages of fasteners shall be accompanied with test certificates giving details
of tests carried out and its conformance to the required codes. The test certificates
shall be duly endorsed and stamped by RIL/ OWNER/ BUYER appointed TPIA, if
specified on Purchase Order. RIL/ OWNER/ BUYER also reserves its right to perform
secondary verification testing of selected random samples.
8. Packing, Preservation, Shipment & Storage
Each component of fastener assembly shall be marked with the manufacturer’s
identification mark and with the marking symbol of the property class as per Table
14 of IS 1367 (Part 3). The marking may be induced during manufacturing or by
indenting or embossing.
Bolts and studs shall be shipped fully assembled (bolt/ stud with nut and washer).
All bolts, studs, nuts and washers shall be delivered in clean condition.
The packaging of bolts shall be weatherproof and in accordance with IS 1367 (Part
18).
Special care to be taken to ensure that the PTFE coated bolts are properly packed
in plastic kegs before dispatch.
The package shall be marked clearly and legibly with following information
a. Name and/or identification mark of the manufacturer
b. Product designation as per IS 1367 (Part 16) indicating among other things
required by code, the diameter, grade and property class of the product.
c. A pictorial representation of product if possible
d. Total number of pieces in package
e. Net weight of the package
f. Lot number of fasteners in package

Each package shall carry a tag and distinctive colour coding as per IS 1367 (Part 18)
for proper identification.
The package may also be marked with the Standard BIS Mark, along with the
corresponding Indian Standard number to which the packaged product conforms.
The package shall comply with standards of weights and measures (packaged
commodities) rule 197, issued by Government of India.

Technical Specification for Structural Steelwork-

Erection

By By By
Technical Specification for Structural Steelwork - Erection Date: 25.08.2020, Rev. 0

(DD.MM.YYYY)
2 S Sammaddar _________________ ___________
4 _____________________________ _________________ ___________
5 _____________________________ _________________ ___________
6 _____________________________ _________________ ___________
7 _____________________________ _________________ ___________
8 _____________________________ _________________ ___________
9 _____________________________ _________________ ___________
10 _____________________________ _________________ ___________

RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
4. Abbreviations & Definitions ...................................................................................... 7
7. Vendor data ............................................................................................................. 20
1. Purpose
This specification defines the minimum technical requirements for materials,
handling, assembly, inspection, and testing for erection of steel framed structures,
buildings and platforms including submission requirements of compliance
documentation by the ERECTOR.
2. References
The products and workmanship shall adhere to the requirements laid down in the
codes and publications referenced below, OWNER specifications and related local
statutory requirements and construction safety procedures. The documents shall
be current edition or revision including amendments and errata as applicable at the
Time of Enquiry, unless expressed otherwise. Revision, amendment or errata
published afterwards shall be incorporated only at direction of Engineer in Charge
after approval from BUYER.
2.1. Indian Codes:
Code No Title
IS 800 General Construction in Steel - Code for Practice
IS 801 Code of Practice for use of Cold-Formed Light Gauge Steel
Structural Members in General Building Construction
Specification
IS 4000 High Strength Bolts in Steel Structures

Structures
Code No Title
ASME/BPVC Sec IX Qualification Standard for Welding, Brazing and Fusing
Procedures; Welders; Brazers and Welding, Brazing and
Fusing Operators – Welding, Brazing and Fusing
Qualifications
ASTM A108 Standard Specification for Steel Bar, Carbon and Alloy,
Cold-Finished
AWS D1.1/D1.1M Structural Welding Code - Steel
AWS D14.1/D14.1M Specification for Welding of Industrial and Mill Cranes and
Other Material Handling Equipment
Code No Title
OSHA Occupational Safety and Health Administration -
29 CFR Part 1926
2.3. Euro Codes:
Code No Title
EN 1090-2 Execution of Steel and Aluminium Structures – Part 2:
Technical Requirements for Steel Structures (Part 2)
ISO 6789-2 Assembly Tools for Screws and Nuts – Hand Torque Tools,
Part 2: – Requirement for Calibration and Determination
of Measurement Uncertainty
2.4. Specifications:
Spec No Title
RPMS-ENGG-SPC-CS-002 Technical Specification for Structural Steelwork -
Fabrication
Sections, Plates, Flats, Bars and Other Solid Shapes
Used for Structural Works
RPMS-ENGG-SPC-CS-016 Technical Specification for Supply of Roofing and Side
Cladding Material
Detailing
RPMS-ENGG-SPC-PP-042 Standard Specification for Hot Dip Galvanising of
RPMS-SD-C15-303 Standard Drawing for Cast-In Anchor Bolt


3.1. Conflicts
a. Drawings
engineer in charge shall be final and ERECTOR shall implement that without any
3.2. Deviations
Deviations to specified technical condition shall require a specific approval from
OWNER.
IS Indian Standard
TPIA Third Party Inspection Agency
BUYER OWNER or OWNER Appointed EPC Contractor who specifies

equipment, product or services for purchase from ERECTOR
Engineer in Charge BUYER’s authorised representative with overall authority and
responsibility for engineering design, quality, and
ERECTOR Party responsible for installation of fabricated structural &
miscellaneous steel on site

MANUFACTURER Party which manufactures and supplies a product to perform

the function as specified by BUYER
Companies
5.1. Material
5.1.1. Rolled sections, plates, hollow and pipe sections, crane rails, flats, bars, grating/
chequered plate floor panels, steel decking and other solid shapes used for
structural work shall be as per Technical Specification RPMS-ENGG-SPC-CS-014.
5.1.2. Structural bolting products shall be as per Technical Specification RPMS-ENGG-SPC-
CS-015.
5.1.3. Headed studs shall be ASTM A108 Grade 1010 through 1020, AWS D1.1/D1.1M
Section 7, Type B.
5.1.4. Material procured by ERECTOR shall meet the requirements of and shall be
subjected to third party inspection per Technical Specification RPMS-ENGG-SPC-CS-
014.
5.1.5. Weld filler material shall be AWS D1.1/D1.1M Section 3.3 (including Table 3.1), low
hydrogen, electrode strength of 400 MPa minimum yield strength and 480 MPa
minimum tensile strength.
5.1.6. Proprietary items purchased by ERECTOR shall be used in accordance with the
MANUFACTURER’s recommendations and instructions.
5.1.7. Shim plates for setting base plates shall conform to IS 2062, grade E250A minimum.
5.2. Erection of Steelwork
5.2.1. General
a. Structural and miscellaneous steel shall be erected in in accordance with the
erection drawings, this specification, IS 800, IS 7205 and applicable state,
municipal, or local regulations or codes.
b. Erection of bought out items such as open web fabricated trusses, tapered
beams, castellated beams etc. shall follow MANUFACTURER’s written
instructions and may refer to safety requirements of OSHA 29 CFR 1926
Subpart R as required.
c. Steel decks shall be installed in accordance with deck MANUFACTURER’s
written instructions and may refer to safety requirements of OSHA 29 CFR 1926
Subpart R as required.
d. Fit-up bolts, drift pins, shim plates and other tools or equipment as required
for erection of structural and miscellaneous steel shall be provided by the
ERECTOR.

5.2.2. During construction, ERECTOR shall be responsible for maintaining structure in a

stable condition; ensuring that no part is overstressed or deflect/ deform
excessively during construction activities. It shall be ERECTOR’s responsibility to
specify, install and locate temporary bracing and/or guy cables to maintain the
partly-assembled structure in a stable condition, under a combination of probable
construction and wind loads. This responsibility shall also extend to temporary
bracing required to ensure safe and stable conditions of partially completed
structural assemblies.
5.2.3. Erection Method Statement
a. A method statement, giving details of the erection sequence and techniques,
crane requirement, laydown area, etc., shall be submitted 30 (thirty) days prior
to the commencement of field erection for approval.
b. Method statement shall address safety measures adopted that will be used
during steel erection work. Safety program shall be in accordance with the
purchase order, clause 17.13 of IS 800, IS 7205, this specification, and other
applicable national, state, or local requirements.
c. Vertical bracing members which are required to maintain stability/ strength of
structures/ preassemblies during erection/ lifting such as diagonal elements of
preassembled pipe bridge/ truss, vertical bracing for crane transfer girders,
plan bracing system acting as a floor diaphragm, elements which provide
stability to the four column structure supporting the pipe bridge girders etc.
shall be erected before proceeding with the erection of the supported
members. This sequence of construction shall also be explicitly marked in the
method statement.
d. ERECTOR shall submit a written assembly lift plan for preassemblies to
Engineer in Charge for approval. Assembly lift plan shall contain detailed data
on extent of lifted assembly, its weights, verification of capacity/ capabilities of
cranes utilised for the lift, location and positioning of cranes, and a description
of rigging to be utilized.
ERECTOR shall be responsible for assuring that preassemblies not specifically
shown or noted in erection drawings, will maintain structural integrity during
lifting. For such preassemblies, ERECTOR shall submit structural calculations
that prove structural stability of assembled components during lifting
operations to Engineer in Charge for approval as part of assembly lift plan.
5.2.4. Structure shall be plumbed, leveled, and braced before final bolted or welded
connections are made and before grouting of base plates.
5.2.5. Equipment
a. Erection equipment shall be suitable, of sufficient capacity and available in
adequate number to complete erection of the steelwork within the contract
schedule.

b. Construction equipment shall conform to the requirements of statutory

regulations applicable to construction lifting devices. Test certificates for items
such as slings, etc. shall be available for inspection.
5.2.6. Provision of Setting-Out Lines
The ERECTOR shall provide setting-out lines and datum levels within, or
immediately adjacent to, the works prior to the commencement of erection.
Datum and setting-out lines shall be transferred from the site survey monuments.
5.2.7. Foundations and Other Interfaces
a. ERECTOR shall report immediately to BUYER in writing discrepancies in OTHER
CONTRACTOR's work or circumstances discovered that affect progress,
performance, or completion of work activities. These may include, but are not
limited to, discrepancies between the erection/shop drawings and the
delivered steel members, incorrectly fabricated steel members, or incomplete
or unacceptable work of OTHER CONTRACTORS affecting the work.
b. Before commencing work, ERECTOR shall inspect the foundations, anchor bolts
and other connection points to confirm their location, orientation, elevation,
and condition not less than 7 (seven) days before erection of steelwork starts.
Discrepancies which are beyond permissible deviations specified in Standard
Drawing RPMS-SD-C15-303 shall be corrected by OTHERS before erection is
commenced.
5.2.8. Receipt, Handling and Storage
a. Materials shall be received, unloaded, stored, and otherwise handled in a
manner that prevents distortion, deterioration, damage, or staining.
b. Materials shall be stored well clear of the ground, on skids or timbers. Supports
shall be spaced so that no damage results from deflection. Materials shall be
kept free of dirt, grease, and other foreign matter.
c. Material shall be stacked in a safe manner to prevent toppling over. Stacking
of components more than three pieces high is not permitted. Stacking of
bundled material is not permitted. Individual accessibility of stored materials/
bundles shall be maintained.
d. Steelwork components/ bundles shall be handled and stored in such a manner
as to avoid steel to steel contact minimising the risk of surface abrasion and
damage. Painted or galvanised structural members shall be lifted with a
nonabrasive choker.
e. Fasteners and small fittings shall be stored in dry conditions. Storage of bolt
assemblies shall be as per clause 4.2 of IS 4000. Bolts which are not used shall
be returned to store after shift is over.

f. Particular attention shall be given to storing by colour codes, structures, areas,

erection sequence, etc. The steelwork shall be arranged so that the colour
codes and the member marks are clearly visible. Additional member marks
shall be provided if stacking arrangement renders the original colour code and
member mark invisible.
g. Materials shall be inspected immediately after receipt to ensure that the
materials are not damaged, that all items on the packing list have been
supplied, and that all documentation has been received.
h. If damage is discovered, or parts, components, or documentation are missing
or otherwise defective, the occurrence shall be immediately reported in
writing to the BUYER.
5.2.9. Receipt of Damaged Steelwork
In case free issued fabricated items are received damaged, ERECTOR shall take
corrective measures to restore damage on received material as per direction of
BUYER /Engineer in Charge.
5.2.10. Damage to Steelwork During Erection
Steelwork damaged during off-loading, on site transportation, lifting, storage or
erection shall be reported to BUYER/ Engineer in Charge in writing and shall be
restored to conform to the standards of manufacture given in other related
specifications such as RPMS-ENGG-SPC-CS-002 at no extra cost/ schedule.
5.2.11. Column Base Plates
a. Steel packing shall be supplied by ERECTOR to allow the structure to be
properly lined and levelled. These packing shall be of sufficient size to avoid
local crushing of the concrete.
b. Where ever Equipment/Structure bases rest on structural steel, Packing plate
width should be set as at least fifty percent (50%) of the bearing area or the
base plate should be fully in contact with Packing plate.
c. Thickness of the individual packing plate should not be less than 6 mm. Any
plate below 6 mm shall be considered as shim plates and shall be of SS and not
CS.
d. Length of the Packing plate should be inline with the size of
Equipment/Structure base plate and should project min. 50 mm beyond the
base plate on both sides.
e. If the number of packing plate is more than one at each location, it has to be
tack welded with each other.
f. Base packing shall be placed so that they do not prevent subsequent grouting
to completely fill all spaces directly under the base plates.
g. Base packs may be left permanently in place only when agreed by the Engineer
in Charge.

5.2.12. Temporary Members

a. The ERECTOR shall install temporary elements or restraints at positions on the
structure as called on erection drawings and shall retain them in place until
walls, floors or other non-steel structures are built and works are completed,
unless directed otherwise. These members however may be “left in place” but
only after formal approval from Engineer in Charge.
b. Other temporary restraints used by ERECTOR during erection, which do not
substitute for permanent features, may be removed after the structure has
been lined, levelled and plumbed provided that sufficient steelwork and/or
permanent bracing has been installed to ensure the stability of the structure.
Stage at which these members are to be removed shall be provided in method
statement.
5.2.13. Erection Loads
a. ERECTOR shall ensure that no temporary erection loads, stacking of material
or permanent loads are placed on incomplete portions of structure being
erected.
b. No other Sub-Contractor shall place loads on the partly erected structure
without the permission of the ERECTOR.
5.2.14. Lining and Levelling
a. Each part of the structure shall be aligned as soon as practicable after it has
been erected. Permanent connections shall not be made between members
until sufficient sections of the structure have been aligned, levelled, plumbed
and temporarily connected to ensure that members shall not be displaced
during subsequent erection or alignment of the remainder of the structure.
b. No equipment shall be supported from the frame until correct position and
alignment has been obtained and the structure is securely connected and
grouted to its foundations.
5.2.15. Field Holes
Holes required in the field shall be made by drilling and no burning or punching
shall be permitted unless authorised by the Engineer in Charge.
5.2.16. Welding
Unless directed otherwise, no site welding shall be permitted on structural
steelwork which has received a special surface preparation or painting. Steelwork
shall only be welded when specifically called for on the erection drawings, or with
prior approval of the Engineer in Charge.
Site welds shall be performed in accordance with AWS D1.1/D1.1M or ASME IX and
shall generally follow Section 5.3 of Technical Specification RPMS-ENGG-SPC-CS-
002 unless specified otherwise in this specification.

ERECTOR shall submit site welding procedures for BUYER’s approval. 10% of site
fillet weld and 20% of site partial joint penetration weld shall be examined with dye
penetrant (DPI) or magnetic particle (MPI) method along with full visual inspection.
Complete joint penetration welds shall undergo 100% dye penetrant (DPI)/
magnetic particle (MPI) and 100% ultrasonic (UT) non-destructive examination
along with full visual inspection. Acceptance criteria of non-destructive
examination shall be as per AWS D1.1/D1.1M.
Site welding of rigging, lifting devices, lifting lugs and associated column cap plates
shall be in accordance with AWS D14.1/D14.1M.
5.3. Bolting
5.3.1. Bolt/Nut Combinations
Erector shall ensure that the specifications of bolts/nuts and washer assembly shall
be as follows:
a. Galvanised property class 4.6 bolts with galvanised property class 5 nut &
galvanised ordinary grade washer
b. Galvanised property class 8.8S bolts with galvanised property class 10S nut &
galvanised hardened and tempered washer
c. Coated property class 10.9S bolts with coated property class 10S nut & coated
hardened and tempered washer
Bolts of different property class shall not be used for bolt assemblies of same
diameter on a project.
5.3.2. Bolt Tightening
a. Bolts for connections marked for pre-tensioning in erection drawings, shall be
brought together to a snug-tight condition before commencement of
subsequent steps. “Snug tight” is defined as tightness attained by a few
impacts of an impact wrench or the full effort of a man using an ordinary spud
wrench.
b. Bolts shall be tightened using Torque (Calibrated Wrench) Method. Part Turn
(Turn of Nut) Method is permitted to be used for hard to access areas only.
c. Bolts and nuts shall be tightened in a staggered pattern and procedure shall be
carried out progressively from the most rigid part of the joint to the least rigid
part. When a bolt group comprises more than four bolts, tightening shall be
from the middle of the joint outwards and ensuring that the plies are properly
pulled together in full contact. Residual gaps at the edges should not exceed 2
mm at this stage. .Washer shall be placed under the bolt head, when bolt head
is rotated for tightening the bolts to protect the surface protective treatment.
d. Bolts tightened by means of a power or hand operated torque wrench shall
achieve a minimum tensile load given in the Table 19 of EN 1090-2 and as
tabulated below:

MINIMUM BOLT TENSION
Nominal Size of Bolt Property class 8.8S Property class 10.9S

(kN) (kN)
M20 137 172
M24 198 247
M30 314 393
M36 458 572
e. Bolt tightening by means of Part Turn Method shall be as per clause 7.2.2 of IS
4000.
f. Tightening shall be performed preferably by rotation of the nut, except where
the access to the nut side of the assembly is inadequate. Special precautions,
depending on the tightening method adopted, shall be taken when bolts are
tightened by rotation of the bolt head.
g. To achieve uniform pre-tensioning, more than one cycle of tightening may be
necessary.
h. Bolt assemblies which seize when being tightened shall be replaced.
i. Bolts that have been pre-tensioned shall be color coded, die punched, or
otherwise marked on the ends indicating that bolts have been properly
tensioned and are ready for inspection.
j. Pre-tensioned property class 8.8S and 10.9S bolts shall not be reused.
5.3.3. Property class 8.8S bolts not marked for pre-tensioning, shall be tightened to a
“snug tight” fit. Snug-tightening shall be carried out progressively from the most
rigid part of the joint to the least rigid part
5.3.4. Property class 4.6 bolts used for connecting miscellaneous steel (i.e., guard and
handrails, fixed ladders and cages, etc.) to structural steel members shall also be
tightened to a snug-tight condition.
5.3.5. Torque wrench calibration
a. Torque wrenches shall be calibrated periodically once in a year to an accuracy
level +/- 10% and shall be recalibrated after impact, fall or mishandling.
b. The torque wrench used for final tightening in torque method is required by
EN 1090-2 to have an accuracy of ± 4 % according to ISO 6789-2. Each wrench
also must be checked for accuracy at least weekly, and in the case of pneumatic
wrenches, every time the hose length is changed.

5.3.6. Pre-installation Verification of Bolts

a. A representative sample of three bolt assemblies shall be checked daily for
each combination of diameter, length, and grade and lot to be used on that
particular day on-site using a tension calibrator to confirm that pre-tensioning
method develops minimum pre-tension.
b. For Part Turn Method, there is no daily test requirement.
5.3.7. Post Installation Inspection of Bolts
Pre-tensioned and non-pre-tensioned bolts shall be inspected as per IS 4000 after
completion of joint and before release of structure for loading.
5.4. Erection Fit-Up
5.4.1. Fit-Up
Connected parts shall be firmly drawn together. Fit-up bolts and drift pins shall not
be used to bring improperly fabricated members and parts into place (springing).
Drift pins shall not be driven with such a force as to damage adjacent metal areas.
Permanent bolts shall not be used as drift pins.
If there is a gap remaining which may affect the integrity of the joint, the joint shall
be remade after insertion of a suitable packing or shimming. One filler plate up to
3 mm thickness may be used in spaces between members to be bolted. Approval
from Engineer in Charge shall be required for filler plate requirements greater than
3 mm. Filling or wedging shall not be permitted otherwise to correct faulty work.
5.4.2. Reaming
Where parts cannot be brought together by drifting without distorting the
steelwork, enlargement of holes shall be made by reaming or drilling, provided the
design of the connection allows for larger diameter holes and bolts. Flame cutting,
burning, gouging, chipping, or drift punching shall not be permitted.
5.4.3. Miscellaneous Steel Erection
a. Field cut floor plate or grating openings requiring toe plate protection or
banding shall be in accordance with standard details. Grating and floor plate
shall be fastened using a minimum of four fasteners per panel.
b. Floor and roof metal deck shall be installed in accordance with deck
MANUFACTURER’s written installation instructions. Sags, deformations, holes,
and other irregularities observed during installation shall be repaired. Field
touch-up to damage to shop-applied coatings on metal decking shall be in
accordance with decking MANUFACTURER’s recommendations.
c. Shear stud or shear connector shall be welded in strict accordance with
MANUFACTURER’s recommendations for welding procedure and welding
equipment. Ensure that the steel surface to which studs or connectors are
welded are clean and free from paint or other material which may affect quality
of weld.

If two or more stud welding guns are operated from the same power source,
interlock guns so that only one gun can be operated at a time to ensure that
the power source has fully recovered from making one weld before another
weld is started.
Ceramic insulators from base of studs shall be removed after welding.
5.4.4. Lifting Lugs
Bolted on lifting lugs, which are to be reused, shall be inspected and load tested
before reuse in each lift.
Property class 10.9S bolts and property class 8.8S bolts shall not be reused after the
bolts have been loosened to remove the lugs.
5.4.5. Permissible Deviations
The erection of steel framed structures shall be to the tolerance limits as per EN
1090-2 Deviation Class 1 or as specified otherwise in this document. Erection shall
be controlled in such a way that the following permissible deviations requirements
as tabulated below are met for the completed structure, unless noted otherwise
on erection drawings:
a) Position
i) Design and actual position of erected columns at base ±10mm

ii) Design and actual position of a pair of adjacent
erected columns at base:
Column spacing, L < 5m centres ±10mm
Column spacing, L > 5m centres ±0.2*(L+45)mm
iii) Design and actual position of pair of end columns in
each column line measured at base
End column spacing, L < 30m centres ±20mm
End column spacing, 30m < L < 250m centres ±0.25*(L+50)mm
End column spacing, L > 250m centres ±0.1*(L+500)mm
iv) Permissible non-intended column to column ±5mm
eccentricity in plan (about either axis) at column
splice
v) Permissible deviation from design distance between ±10mm
adjacent beams measured at corresponding ends
vi) Permissible deviation from design location of a beam ±5mm
to column connection measured relative to column

b) Plumb (Verticality)
i) Permissible inclination of “H” m high columns of ±1/300

“single-storey” buildings
ii) Permissible inclination of “H” m high columns of a

“single-storey portal frame” building
Inclination of individual columns ±1/300
Mean inclination of columns in same frame ±1/500
iii) Permissible inclination of “columns that support Minimum of ±25
crane gantry” measured from floor level to bearing of mm or as per
crane runway beam erection drawings
iv) Permissible deviation of columns of “H” m high

“multi-storey” building/ structure “n” storeys with
“hi” m heights:
Actual position of column centre in plan relative to a ±hi/500 mm
vertical line through its centre at next lower level
Actual position of column centre in plan at “i”th level
±hi/[300*sqrt(n)]
relative to a vertical line through its design position
mm subject to a
at base
minm of ±hi/500
mm
v) Straightness of column between adjacent storey ±hi/1000mm
levels
c) Levels
i) Permissible deviation between the design and actual ±5mm

base elevation of the columns
ii) Storey height relative to adjacent levels ±10mm
iii) Permissible deviation between design and actual top ±10mm
of steel elevation of beams at the junction with the
column
iv) Permissible deviation between design and actual top ±L/500mm
of steel elevation of “L” m long beams at the junction subject to a
with the column relative to the other end of beam maximum of
10mm

v) Permissible deviation between top of steel elevation ±10mm

of adjacent beams measured at corresponding ends
d) Crane Runway Girder

Permissible deviation after the erection of crane girders and rails shall be as follows
unless indicated otherwise on erection drawings. In case, the crane
MANUFACTURER’s requirements are more stringent, the same shall be followed.
i) Actual location of rail in plan on runway girder ±10mm

relative to design location (shift in overall alignment
with respect to intended axis)
ii) Variation of local alignment of rail in plan measured ±1.5mm
over a 2m gauge length
iii) Actual overall level of rail relative to design level ±15mm
iv) Variation in level of rail over span “L” m of crane ±L/500mm
runway beam subject to
maximum of
10mm
v) Variation in local level of rail measured over a 2m ±3mm
gauge length
Actual spacing between centres of crane rails relative
to design spacing “S” in metres
Spacing between rails, S < 16m ±10mm
Spacing between rails, S > 16m ±[10+(S-
16)/4]mm
vi) Relative level of rails on two sides of a runway

measured at corresponding location
Spacing between rails, S < 10m ±20mm
Spacing between rails, S > 10m ±S/500mm
e) Trusses and Pipe Bridges

Permissible deviation for the erection of trusses and pipe bridges shall be as follows
unless indicated otherwise on erection drawings.
i) Lateral shift for top chord member at midspan ±Height of

relative to vertical plane at centre of bottom chord truss/250 subject

to maximum of
15mm
ii) Lateral shift for top chord member at midspan ±Span of
relative to vertical plane at supports truss/1500
subject to
maximum of
10mm
iii) Difference of bearing levels of truss from design ±Span of
levels truss/1200
subject to
maximum of
20mm
f) Purlins & Girts
i) Actual location of fixing relative to design line of ±Flange width /10

fixing or 5mm,
whichever is
greater
g) "Design position” or "design level" is that position or level given by the

dimensions and coordinates on erection drawings.
h) "Actual position” or "actual level" is the final erection position and shall be
determined from agreed survey monuments
i) Actual levels at a floor or equipment level (including ground level) within a
structure shall be measured from single transferred bench mark.
j) In structures where movements due to temperature change are considerable,
the permissible deviations listed above shall apply at the mean position of the
member being checked.
5.5. Fireproofing
Fireproofing block-outs shall be patched on site to match with fireproofing material
and thickness in accordance with Technical Specification RPMS-ENGG-SPC-CS-026.
5.6. Touch-Up Painting
After complete erection, surfaces areas with damaged paints shall be repaired in
accordance with the Technical Specification RPMS-ENGG-SPC-PP-014.
Damage caused during delivery and/or erection to galvanised steel surfaces shall
be repaired in accordance with Technical Specification RPMS-ENGG-SPC-PP-042.


Inspectors shall inspect materials, installations and workmanship to ensure
conformance with requirements of this specification. Quality control, inspection
and testing by the ERECTOR shall be as specified in this document.
Rejected material, installations and workmanship shall be repaired or replaced as
per BUYER’s instruction at no cost or schedule impact to BUYER.
7. Vendor data
Vendor in title of this section to be read as ERECTOR for purpose of this
specification.
ERECTOR shall submit documents such as erection method statement, safety
program, quality control program, inspection procedures and site welding
procedures for BUYER’s approval.
ERECTOR shall maintain records of inspection tool calibration and shall submit to
BUYER on request.
Not Applicable

Guide Specification for Structural Steelwork -

Detailing

By By By
Guide Specification for Structural Steelwork – Detailing Date: 25.08.2020, Rev. 0

(DD.MM.YYYY)
2 S Sammaddar _________________ ___________
4 _____________________________ _________________ ___________
5 _____________________________ _________________ ___________
6 _____________________________ _________________ ___________
7 _____________________________ _________________ ___________
8 _____________________________ _________________ ___________
9 _____________________________ _________________ ___________
10 _____________________________ _________________ ___________

RECORD OF REVISIONS

Number
25.08.2020 First Issue- Based on Bechtel Review 0
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
7. Vendor data ............................................................................................................. 20
Annexure A : Guidelines for Preparation of Fabrication Drawings…………….. (18 pgs)

1. Purpose
This specification defines the minimum technical requirements and provides
guidance for detailing of structural & miscellaneous steel and preparation of
detailing deliverables including design required to complete works.
2. References
The products (detailing deliverables) shall adhere to the requirements laid down in
the codes, publications and OWNER specifications referenced below. The
documents shall be current edition or revision including amendments and errata as
applicable at the Time of Enquiry, unless expressed otherwise. Revision,
amendment or errata published afterwards shall be incorporated at the direction
of the Engineer in Charge after approval from the OWNER.
2.1. Indian Codes:
Code No Title
IS 800 General Construction in Steel - Code for Practice
IS 801 Code of Practice for use of Cold-Formed Light Gauge Steel
Structural Members in General Building Construction
IS 808 Dimensions for Hot Rolled Steel Beam, Column, Channel
and Angle Sections
IS 1852 Rolling and Cutting Tolerances for Hot Rolled Steel
Products
Specification
IS 4000 Code of Practice for High Strength Bolts in Steel Structures
Structures
Code No Title
AWS D1.1/D1.1M Structural Welding Code

2.3. Euro Codes:
Code No Title
EN 1090 (Part 2) Execution of Steel Structures and Aluminium Structures -
Technical Requirements for Steel Structures
2.4. Specifications:
Spec No Title
Fabrication
Sections, Plates, Flats, Bars and Other Solid Shape
used for Structural Works
Erection
3.1. Conflicts
a. Drawings
engineer in charge shall be final and DETAILER shall implement that without any

3.2. Deviations
OWNER.
IS Indian Standard
REIMS Reliance engineering information management system
RFI Request for Information

SUPPLIER
DETAILER Party responsible for detailing and preparation of Structural
and Miscellaneous steel detailing deliverables [DETAILER
can be a third-party structural detailing agency or detailing
team of DEC/ EPC Contractor, for a project]
Engineer in Charge BUYER’s authorized representative with overall authority
and responsibility for engineering design, quality, and
Detailing Coordinator Buyer’s authorized representative with overall
responsibility of coordinating structural steel detailing and
fabrication related activities
FABRICATOR Party responsible for furnishing fabricated structural &
miscellaneous steel
Companies
This section describes the practice with all the details as required.
5.1. Units of Measure
Units of measure shall be in SI units. Dimensions shall be ‘MM’-millimetres and
elevations shall be in ‘M’-metres with a precision of 1 mm. Weights shall be in
“KG”- kilograms or “MT”- metric tons.

5.2. Materials
Unless noted otherwise on the design drawings, materials shall conform to the
specifications listed in Section 2.1 of this document.
5.3. Design Drawings
Detailing shall be performed as per the design drawings prepared by DEC/ EPC
Contractor. The design drawings will have adequate information and dimensions
required to perform steel detailing such as:
• Notes and references
• Size of the members
• Material grade (if required)
• Location of members
• Floor elevation
• Work points and offsets
• Transport/temporary steel
• Interface structure shown in phantom
• Fireproofing type and limits
• Flooring limits and span direction
• Metal deck details for composite floors
• Floor penetrations for pipe supports, pipes and cable tray penetrations
• Limits and type of guardrail (Ex. removable guardrail, guardrail cut-outs)
• Ladder locations
• Stair elevations
• Special instructions (Ex. coating requirements, head knocker cope, load limits
for davits, lift beams)
• Standard connections
• Non-standard connection details
DETAILER shall review the design drawings in detail for completeness, adequacy
and appropriateness of information provided prior to start of work. DETAILER shall
raise numbered RFI’s in case of conflicting or missing information.
5.4. Design of Connections
The scope of connection design shall be “Option A”, “Option B” or “Option C” as
mentioned in the purchase order.

• Option A
Design of connections shall be excluded from DETAILER’s scope. Connections shall
be modelled in Tekla by DETAILER based on design drawings and standard
tabulations provided by DEC.
• Option B
DETAILER’s scope of connection design shall be as follows:
a. DETAILER shall prepare the standard tabulations for “DETAILER selected
connections (simple shear connection with limited bending moments)” based
on design basis/ minimum load criteria provided on design drawings. Checked
tabulations for these connections shall be submitted for DEC approval.
DEC does not provide force mark-up for these connections on design drawings.
DETAILER shall model these connections in Tekla based on geometry and size
of members on design drawings (with no load information) by selecting from
standard tabulations.
b. “DETAILER designed connections (plan brace, vertical brace connections and
main frame beam connections with large axial loads typically)” shall be
designed by DETAILER for design forces shown on design drawings by DEC.
Checked engineering calculations for each fabricator designed connection shall
be submitted for DEC approval.
c. “DEC designed connections (Base plate, Splice, Moment Connection)” shall be
fully designed by Engineer and details provided on design drawings. Fabricator
shall incorporate these connection details as provided on design drawings in
Tekla Model.
• Option C
However, if DEC is responsible for detailing activity, connections design shall be
performed by Design Engineering team of DEC.
5.5. Detailing Requirements
General detailing requirements shall be as follows:
5.5.1. Detailed 3D Model
a. DETAILER shall use Tekla Structures for detailing. The version shall be as per
Software List in Work Order.
b. The detailed model shall contain primary structural members (major beams,
columns, bracings) and secondary steel (girts and purlins), miscellaneous steel
(guardrails, handrails, ladders, stairs and flooring with penetrations),
connection material (plates, gussets, stiffeners), bolts and welds.
c. Aspects of fabrication (including splices, welds, notches, copes and cut-outs),
fireproofing and erection shall be modelled and shall reflect on the erection
and fabrication drawings.

d. Work points shall be maintained as shown on the design drawings. Modelling

shall be to true plant coordinates and orientation.
5.5.2. Detailing:
a. Detailing shall be in accordance to the codes, standards and specifications
referenced in Section 2.0 of this document. The fabrication details shall be as
per connection details shown on the design drawings.
b. Field connections shall be bolted, and shop connections shall be welded unless
noted otherwise on the design drawings.
c. Fabrication drawings shall identify the “Cyclically Loaded Non-Tubular
Connections” which require different weld ultrasonic test acceptance criteria
such as crane girders or those identified on design drawings.
d. Bolted connections requiring bolts to be pretensioned shall be identified on
erection drawings.
e. Fabrication drawings shall detail notches, copes and cut-outs as per project
standards and codes.
f. Surface finish/ coating system/ fireproofing information and/or specific
fabrication requirements identified on the design drawings shall be shown on
the fabrication drawings.
g. Connections for fireproofed members shall be detailed using the guidelines
provided on design drawing with suitable block-outs.
h. Bolts of different property class shall not be used for bolt assemblies of same
diameter on a project
i. Bolt length shall be chosen such that the thread run-out shall be clear between
the nut and the unthreaded shank of the bolt after tightening and at least one
clear thread shall show above the nut.
j. Structural bolts for fixing equipment supported on steel shall be modelled in
Tekla and bolts included in bolt report.
k. When the bolt head or nut is in contact with a surface which is inclined at more
than 3° from a plane at right angles to the bolt axis, taper washer shall be
provided to achieve satisfactory bearing.
l. Washer shall be placed under the bolt head, when bolt head is rotated for
tightening the bolts to protect the surface protective treatment. DETAILER to
identify such connections and provide a suitable note on erection drawings.
m. Suitable plate washer shall be used under the head and nut when bolts are
used to assemble components with oversize or slotted holes.
n. Assemblies shall be sized for transportation limits.
o. Hollow structural sections and pipe sections shall be closed with cover plates
at open ends.

p. Where galvanization is indicated on design drawings, individual assemblies

shall be sized for hot dip galvanization vats size as well. Double dipping of
assemblies for galvanization shall be avoided.
q. For galvanized assemblies, following shall be detailed
 Seal welds shall be provided on parts to prohibit pickling acids and/or
liquid zinc from entering pockets formed between two parts and as a
measure of corrosion protection. Seal welds shall be a fillet weld 3 mm
minimum.
 Drainage holes in gusset, stiffener and cap plates
 DETAILER shall provide standard drawings or standard details on
fabrication drawing as guidance to the FABRICATOR to indicate the
requirements and suggested location of drainage/ vent holes in enclosed/
semi enclosed structural assemblies or tubular assemblies such as pipe
handrail. Vent holes need not be detailed by DETAILER on assemblies.
r. DETAILER shall check the adequacy of bolt tightening clearance and adequacy
of access for welding and painting especially in pockets formed by stiffeners
and gussets. Welded assemblies to be coated with paint shall be detailed with
adequate clearances for cleaning and grinding the welds to produce acceptable
surface finish for painting. Discrepancies shall be notified to Engineer in Charge
for a resolution.
5.6. Erection Marking
Every component which is individually assembled or erected at the site shall be
allocated an erection mark. Members which are identical in all respects may have
the same erection mark.
5.7. Products
5.7.1. List of Deliverables
DETAILER shall submit following detailing deliverables in the formats specified
hereinafter.
a. Erection drawings / marking plans & elevations – PDF format
b. Fabrication drawings / cut-sheets – PDF format
c. Flooring marking plans & floor panel drawings – PDF format & DXF format
d. Handrail/ ladder detail drawings – PDF Format
e. MTO files/ Report files – XLXS/ CSV format
f. CNC machine input files- NC format
g. DXF files for plates
h. Standard welded splice detail for splicing offcuts – PDF format.
i. Drawing Index/ Information File - XLXS/ CSV format

j. Tekla 3D model – IFC format

k. Connection design calculations – PDF format along with native files
l. For compressed file – ZIP format
The above deliverables shall be accompanied with a transmittal. Samples of the
same are enclosed in the Attachment- A.
5.7.2. Erection Drawings / Marking Plans and Elevations
Erection drawings shall be generated from the 3D Tekla model and shall not be
manually drafted/ edited. Erection drawings shall have relevant plans, elevations,
sections, dimensions, details and instructions required for erection of structural
steel.
Erection drawings shall indicate following:
a. The first erection drawing shall contain an isometric view of the structure,
general and installation notes, legends used, list of design drawings with
revision number included in the model
b. Individual piece marks for assemblies and identification for preassemblies/
shop assemblies/ modules/ stick-built and their location in structure along with
profile sizes, surface finish/ fireproofing requirement for each piece
c. Construction Work Package (CWP) numbers
d. Orientation mark and colour banding information for main assemblies along
with their location
e. Site welding or hole drilling shall be detailed in the erection drawing
f. Extent of fireproofing for structure as well as type ( FP/FPX)
g. Splice locations
h. Ladder details like location, bottom / top elevation, type of entry to be
provided in erection drawing.
i. Temporary/ transport steel shall be identified on erection drawings
5.7.3. Fabrication Drawing / Cut-Sheet
Fabrication drawings shall be generated from the 3D Tekla model and shall not be
manually drafted.
a. Fabrication drawings shall have a unique assembly per drawing. Parts for the
assembly shall be detailed on the same drawing. If all details cannot be
accommodated in one sheet, then more than one sheet may be used with
extension of sheet number as suffix of drawing number.
b. Fabrication drawings shall indicate Construction Work Package (CWP)
numbers.
c. Fabrication drawings shall indicate piece/ part marks, profile sizes, material
grade, orientation marks, surface finish and identification if piece is
fireproofed, size and location of bolt holes, weld callouts and running
dimensions required for fit up and shall have relevant sections, details and
instructions required for fabrication of an individual assembly.
d. Drawings shall indicate individual part profiles/ grades, dimensions, hole
location and sizes.
e. Fireproofing requirements shall be displayed in the fabrication drawing.
Fabrication drawings shall indicate fireproofing block-outs sizes and paint
masking areas if required.
f. Fabrication drawings shall have cleat or other provision as indicated on design
drawings for bolting handrails/ ladders at site. Pitch and size of the holes shall
be kept the same in the cleats / provisions.
g. Fabrication drawings shall contain information on bolted loose parts, assembly
temporarily bolted for shipping and sub-assembly.
h. Running dimensions shall be provided in the fabrication drawing from zero end
in addition to hole to hole dimension and part to part dimension
i. Hole sizes shall be clearly mentioned in the fabrication detail of each part
j. Weld size shall be clearly mentioned in case of fillet weld/ partial joint
penetration welds. Welding symbol and details shall be consistent with AWS
D1.1/D1.1M.
k. Dimension of the holes of the bottom flange gussets shall be from the top
flange of the beam, not from the bottom flange of the beam. Bottom flange
shall not be considered for dimensioning purpose unless it is unavoidable.
l. Fabrication drawing shall contain a bill of material list which indicates the parts
required to fabricate a single assembly mark.
m. In bill of material, unique part numbers shall appear once with required
quantity in quantity column.
n. Weight shown on the bill of material shall be the weight of the fabricated part.
The pay weight shall be the “gross” weight of the sum of parts required to
create one assembly.
o. Fabrication drawing shall clearly indicate quantity to be produced for the
specific assembly mark number.
p. Member location shall be indicated below the bill of material list.
q. Risk category of structures, if provided on design drawings, shall be indicated
on fabrication drawings to determine weld inspection requirement as per
clause 5.3.5 of Technical Specification RPMS-ENGG-SPC-CS-002.
r. Site welding, shall be displayed in the fabrication drawings. If any site welded
part needs edge preparation, the same shall be shown in fabrication drawing.

5.7.4. Handrail/ Ladder Detail Drawing

Length of the handrails/ ladders shall be such that these can be easily transported
in standard trailer. The handrails/ ladder shall be detailed as per points mentioned
in above sections, whichever are applicable.
5.7.5. Floor Marking Plans and Panel Drawings
Structural steel floor general arrangement drawings developed by the DEC/ EPC
Contractor indicating limits of flooring and designed span directions including floor
cut-outs and penetrations more than 75 mm through the floor required for the
equipment, piping, cables or other purposes, shall be provided in “pdf” format to
the DETAILER and flooring (grating, chequered plate or steel deck) vendors,
selected for fabrication & supply of the floor panels for each project.
These drawings do not indicate notches in the grating required to accommodate
gussets, bracing etc. It is the responsibility of DETAILER to provide this information
for sharing with flooring vendor.
DETAILER shall model floor in TEKLA model and shall extract floor plans additionally
indicating dimensions, penetrations and cut-outs resulting from detailing (at
bracing, gusset plates, columns etc.). Native files of the floor plans extracted from
TEKLA, developed by the DETAILER shall be reviewed by the DEC/ EPC Contractor
and provided to the flooring vendor(s).
The flooring vendor(s) shall utilize the native file mentioned above provided by the
DEC/ EPC Contractor to develop the floor panel drawings incorporating the floor
cut-outs provided on the GA drawings and additional notches provided in floor by
DETAILER.
For vessel supported platforms, whether they are detailed by the DEC/ EPC
Contractor or by the mechanical vendor, the native file of plan drawings indicating
exact dimensions of cut-outs and notches required for the floor detailing shall be
provided to the flooring vendor by the DEC/ EPC Contractor.
The DEC/ EPC Contractor shall review the floor panel drawings and ensure that they
accurately reflect the latest information provided. The flooring vendor shall then
proceed with preparation of cut sheets and fabrication of the floor panels.
DEC/EPC Contractor shall provide DETAILER with information on additional steel/
detail required to support floor panels around cut-outs and penetrations for
incorporation in Tekla model.
5.7.6. MTO Files/ Report Files
5.7.6.1. Following report files shall be submitted along with detail drawings (erection &
fabrication drawings). Reports shall clearly indicate project name, report number,
revision status, Construction Work Package (CWP) Number. Reports shall be
extracted from model and shall not be edited manually.
a. Hot rolled material list (profiles)
b. Plates MTO if required
c. Cut list
d. Shop assembly list
e. Site bolt location list
f. Site bolt summary list
g. Shop bolt location list
h. Shop bolt summary list
i. Steel material management system (SMMS) input file
j. Horizontal member elevation list
k. Vertical member elevation list
l. Fireproofing list
m. Field weld list
Samples of above report files are enclosed in Annexure A.
5.7.6.2. DETAILER shall provide bulks list for bought out items such as safety gate report,
stair tread report, crane rail clip report, flooring penetration collar (site welded)
etc. as required on a project.
5.7.7. Drawing Index / Information File
Each release shall contain drawing index with it. This is applicable for both fresh
and revised release and is independent of number of detail drawings getting
released. Drawing index shall contain the following details :
a. List of design drawings with revision number, included or referred in the
release.
b. Erection drawing list with revision number, included or referred in the release.
c. List of fabrication drawings indicating latest revision of the same.
Drawing index lists shall clearly indicate project name, report number, revision
status and Construction Work Package Number (CWP).
Sample drawing index is enclosed in the Annexure A.
5.7.8. CNC Machine Input Files
CNC input files shall be provided for all components. As and when drawings are
revised CNC files shall be provided for the revision affected part numbers only. The
CNC files shall have the same name as the assembly mark and part mark number
except for the extension.
5.7.9. DXF Files for Plates
DXF files shall be provided for fabricated plates on a scale of 1:1. File shall contain
outline of the plate, bolt hole details, plate mark, plate size and plate material as a

minimum. The DXF files shall have the same name as the part mark number except
for the extension.
5.7.10. Standard Welded Splice Detail for Splicing Offcuts
Standard welded splice details shall be provided for steel sections getting used in
the project along with NDE requirement.
5.7.11. Tekla Model
DETAILER shall prepare two separate “*.IFC” model files consisting of primary/
secondary steel and other consisting of miscellaneous steel/ connection material
for submission from the single Tekla model for a structure. These files shall be
submitted with each submission of detailing package. DETAILER shall submit the
fully connected Tekla model along with the submission of last release of detailing
package for a structure. Tekla model shall contain the related files and folders and
shall not be limited to *.db files only. Model components and plugins shall not be
exploded and maintain relationships to macros and drawings.
• Control files for custom component definition files and saved attribute files for
components, macros and plugins used in generating the model shall be
provided with the model
• Profile, material and bolt catalogs shall be provided
In case of revisions, revised and updated Tekla model shall be submitted by
DETAILER.
5.8. Numbering System
The document numbers for detailing deliverables shall have correlation with design
drawing number of first sheet for a structure.
5.8.1. The model name for a set of design drawings with first sheet numbered as
C63-RDZ311-653 shall be : RDZ311-653
5.8.2. Erection Drawing/ Marking Plan Numbers
REIMS code for erection drawings shall be C65. Erection drawing number shall be
based on drawing number on first sheet of design drawings for a structure. The
erection drawings for a set of design drawings with first sheet numbered as C63-
RDZ311-653 shall be numbered as : C65-RDZ311-653-001 to nnn
Erection drawings shall be issued as “Issued for Construction”
5.8.3. Fabrication Drawing/ Cut Sheet Number
REIMS code for fabrication drawings shall be C65. The fabrication drawing number
shall be correlated to erection drawing and model name. The fabrication drawing
number shall start with erection drawing number. For this example, the fabrication
drawing for assembly with mark number “2FPGB001” shall be numbered as : Z311-
653-2FPGB001,
Where, last 8 digit is for assembly mark numbers with number

• “2” signifying sequence of release,

• “FPG” signifying construction of main member as full pen butt welded plate
fabricated section (see notes in clause 5.8.4 for list of options),
• “B” for member type as identification as beam (see tabulation in clause 5.8.4
for list of options) and “001” the running number.
• Fabrication drawings shall be issued as “Issued for Fabrication” or “Issued for
Construction”
5.8.4. Assembly Mark Number
Following mark nos. shall be used to identify different structural components –
Sr. No. Member Description Assembly Mark No.

1 BEAMS B001 to Bnnn
2 COLUMNS C001 to Cnnn
3 HORIZONTAL BRACINGS HB01 to HBnn
4 VERTICAL BRACINGS VB01 to VBnn
5 STUB COLUMN SC01 to SCnn
6 STRINGER ST01 to STnn
7 CRANE GIRDER CG01 to CGnn
8 PURLIN P001 to Pnnn
9 CLADDING RUNNER CR01 to CRnn
10 GABLE RUNNER GB01 to GBnn
11 ROOF TRUSS TR01 to TRnn
12 BRACKET BKT1 to BKTn
13 SAG ROD SR01 to SRnn
14 WELDED FRAME FR01 TO FRnn
15 WELDED EQUIPMENT PLATFORM EP01 TO EPnn
16 HANDRAIL HR01 to HRnn
17 LADDER LD01 to LDnn
18 CIRCULAR PLATFORM CP01 to CPnn
19 FABRICATION OF LATTICE TOWER BT01 to BTnn
20 CABLE TRAY SUPPORT CT01 to CTnn
21 JOIST J001 to Jnnn
22 GRATING GR01 to GRnn
23 CHEQUERED PLATE CHK1 to CHKn
Notes:-
1). Mark No. of members made out of plate girders / built up sections with fillet welds shall be
prefixed with "0PG". eg. “0PGB001” etc.

2). Where plate girders / built up section is prepared with full penetration butt welding, Mark
No. of members made out of plate girders / built up sections shall be prefixed with "FPG". eg.
“FPGB001” etc.
3). Mark No. of members where cover plate (flange plates or web plates or both) is involved
shall be prefixed with "0CM". eg. “0CMB001” etc.
4). If the structure is released in sequence, sequence no. to be provided as prefix. eg.
1000B001, 10PGB001, 10CMB001 etc. 1 shall be used as default no.
5). Mark no. of members made of channel box of size up to & including ISMC 150 or
equivalent shall be prefixed with "CB". eg. “0CBC001” etc.
6). Mark no. of members made of channel box of size above ISMC 150 or equivalent shall be
prefixed with "CBA". eg. “CBAC001” etc.
7). If members not covered in the above list is available in the structure, Detailing Coordinator
may be contacted for clarification.
5.9. Detailing Deliverable Release Type:

• Models with tonnage equal to or less than 500 MT to be released in a single
sequence, unless notified by BUYER.
• Models with tonnage greater than 500 MT can go for sequential release. In
case of sequential release, DETAILER need to discuss and get clearance from
Engineer in Charge for sequence type i.e. grid wise or elevation wise to match
erection sequence.
5.10. Revision Control:
• First submission of erection and fabrication drawings shall be Revision 0.
• If new assemblies are added on account of revisions, then the fabrication
drawings containing these new assembly mark numbers shall be released in
Revision 0.
• If during revision, an assembly gets deleted, a revised and “issued for deletion”
fabrication drawing along with related revised erection drawing shall be
submitted. Revised portion of the erection drawing shall be clouded with
revision mark.

• If during revision, members of a fabrication drawing acquire a new mark

number, then the old fabrication drawing shall be revised to next revision to
accommodate change in mark quantity. This revised fabrication drawing shall
indicate that - “X” no. of mark quantity has been changed to “Y” mark no., in
the note. In the same way the new fabrication drawing containing “Y” mark no.
shall indicate the same note in it. The new fabrication drawing shall be released
in Revision 0.
• Clouding in erection and fabrication drawing shall be done to highlight affected
portion in revised drawings.
• In case of revision to erection drawing, changes made during the latest revision
shall be clouded. If there are holds, the same shall be clouded with a hold
remark.
• In case of revision to fabrication drawing, changes made during the latest
revision shall be clouded.
• Revision to reports shall have both old and new data with new data highlighted.
• If some mark nos. were placed under hold and released later, these mark nos.
shall be released in Revision 0.
• If due to release of hold, mark quantity of released fabrication drawing is
changed, then revised fabrication drawing shall be issued for the same.
• Drawings revised on account of discrepancies shall be released in next revision.
• In the above cases, along with revised drawings, total and affected MTO
reports and CNC files, wherever applicable shall be submitted.
• For “Issued for Construction” and “Issued for Fabrication” drawings, revision
number shall be numerical i.e. 0, 1, 2 etc.
• For “Issued for Approval” drawings, revision number shall be alphabets in
capital i.e. A, B, C etc.
5.11. Discrepancy Resolution:
Discrepancies in detailing deliverables shall be addressed to Detailing Coordinator
of the project. Logs shall be maintained at both BUYER’s and DETAILER’s end.
Pending list shall be circulated by BUYER on regular interval for quick resolution.
Discrepancies shall be resolved within 3 working days. Detailing deliverables
revised on account of discrepancy resolution shall be uploaded in REIMS.
REIMS upload date shall be considered as discrepancy resolved date. Revision
control as stated in Section 5.10 shall be followed.
Check Lists for checking and validation of deliverables shall be submitted by
Contractor for RIL approval before starting of work.

7. Vendor data
Vendor in title of this section to be read as DETAILER for purpose of this
specification.
The DETAILER shall control the quality of items and services to meet the
requirements of this specification, of applicable codes and standards, and purchase
order. The DETAILER shall submit a quality plan outlining the fabrication package
checking process.
Checked erection and fabrication drawings shall be submitted to Engineer in Charge
for approval along with *.IFC model files for primary/ secondary steel and
miscellaneous steel/connection material. Work shall not proceed without
approval.
Revisions of final detailing deliverables including reports, data deliverables and
Tekla models shall be submitted to Buyer for record purposes.
Not used.

Guide Specification for Structural Steel Work-Detailing Date: 25/08/2020 Rev. 0
Annexure 1
Guidelines for Preparation of Fabrication Drawings
RIL Confidential
Plant North
Sheet 1 shall have
general notes, legends,
field installation notes
Sheet 1 shall show

an isometric view
Sample Erection
Drawing
1 of 18
Specific
Notes
Field
installation
notes such as
Orientation mark
pretensioning of on all individual
bolts pieces
2 of 18
Orientation
mark
Paint system or Fireproofing type
3 of 18
4 of 18
5 of 18
6 of 18
7 of 18
8 of 18
9 of 18
10 of 18
11 of 18
12 of 18
13 of 18
14 of 18
15 of 18
16 of 18
17 of 18
18 of 18
Standard Specification for

Passive Fireproofing - Materials and Installation
0 25.08.2020 Issued for Implementation PGN AM SPC/VKM

By By By
Standard Specification for Passive Fireproofing – Date: 25.08.2020, Rev. 0
Material and Installation

(DD.MM.YYYY)
2 S Sammaddar _________________ ___________
4 _____________________________ _________________ ___________
5 _____________________________ _________________ ___________
6 _____________________________ _________________ ___________
7 _____________________________ _________________ ___________
8 _____________________________ _________________ ___________
9 _____________________________ _________________ ___________
10 _____________________________ _________________ ___________

RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
7. Vendor Data ............................................................................................................ 30
Annexure-1 - Typical Details for Dense Concrete Fireproofing…………………………….31

Annexure-2 - Typical Details for Lightweight Fireproofing……………………………………32
1. Purpose
This specification defines the minimum technical requirements for supply and
installation of passive fireproofing material on steel surfaces (structural steel and
vessel/equipment supports) and provide guidelines on inspection & testing
requirements.
2. References
The products and services shall adhere to the requirements laid down in the codes,
publications and OWNER specifications referenced below. The documents shall be
current edition or revision including amendments and errata as applicable at the
Time of Enquiry, unless expressed otherwise. Revision, amendment or errata
published afterwards shall be incorporated at the direction of the Engineer in
Charge after approval from the OWNER.
Indian Codes:
Code No. Title

IS 383 Coarse and Fine Aggregate for Concrete –
Specification
IS 1199 (Part 1) Fresh Concrete – Methods of Sampling, Testing and
Analysis,
Part 1 - Sampling of Fresh Concrete
IS 1363 (Part 3) Hexagon Head Bolts, Screws and Nuts of Product
Grade C,
Part 3 – Hexagon Nuts (Size Range M5 to M64)
IS 1367 (Part 6) Technical Supply Conditions for Threaded Steel
Fasteners,
Part 6 - Mechanical Properties and Test Methods
for Nuts with Specified Proof Loads
IS 2585 Black Square Bolts and Nuts (Diameter Range 6 to
39) and Black Square Screws ((Diameter Range 6 to
39)
IS 12330 Specification for Sulphate Resisting Portland
Cement
International Codes:
Code No. Title

ACI C660.1 Certification Policies for Shotcrete Nozzleman and
Shotcrete Nozzleman-In-Training

Code No. Title

API 2218 Fireproofing Practices in Petroleum and
Petrochemical Processing Plants
ASTM A29/ A29M Standard Specification for General Requirements
for Steel Bars, Carbon and Alloy, Hot-Wrought
ASTM C177 Standard Test Method for Steady-State Heat Flux
Measurements and Thermal Transmission
Properties by Means of the Guarded-Hot-Plate
Apparatus
ASTM C156 Standard Test Method for Water Loss [from a
Mortar Specimen] Through Liquid Membrane-
Forming Curing Compounds for Concrete
ASTM C309 Standard Specification for Liquid Membrane-
Forming Compounds for Curing Concrete
ASTM D790 Test Method for Flexural Properties of Unreinforced
and Reinforced Plastics and Electrical Insulating
Materials
ASTM D2240 Standard Test Method for Rubber Property -
Durometer Hardness
ASTM D4285 Standard Test Method for Indicating Oil or Water in
Compressed Air
ASTM D4417 Standard Test Methods for Field Measurement of
Surface Profile of Blast Cleaned Steel
ASTM E84 Standard Test Method for Surface Burning
Characteristics of Building Materials
ASTM E337 Standard Test Method for Measuring Humidity with
a Psychrometer (the Measurement of Wet- and
Dry-Bulb Temperatures)
ASTM E605/ E605M Standard Test Methods for Thickness and Density of
Sprayed Fire-Resistive Material (SFRM) Applied to
Structural Members
ASTM E736/ E736M Standard Test Method for Cohesion/Adhesion of
Sprayed Fire-Resistive Materials Applied to
Structural Members
ASTM E760/ E760M Standard Test Method for Effect of Impact on
Bonding of Sprayed Fire-Resistive Material Applied
to Structural Members

Code No. Title

ASTM E761/ E761M Standard Test Method for Compressive Strength of
Sprayed Fire-Resistive Material Applied to
Structural Members
ASTM E859/ E859M Standard Test Method for Air Erosion of Sprayed
Fire-Resistive Materials (SFRMs) Applied to
Structural Members
ASTM E937/ E937M Standard Test Method for Corrosion of Steel by
Sprayed Fire-Resistive Material (SFRM) Applied to
Structural Members
ASTM G21 Standard Practice for Determining Resistance of
Synthetic Polymeric Materials to Fungi
AWS D1.1/ D1.1M Structural Welding Code – Steel
SSPC-AB 1 Abrasive Standard No. 1 - Mineral and Slag
Abrasives
SSPC-AB 2 Abrasive Standard No. 2 - Cleanliness of Recycled
Ferrous Metallic Abrasives
SSPC-AB 3 Abrasive Standard No. 3 - Ferrous Metallic (Steel)
Abrasive
SSPC-PA 2 Coating Application Standard No. 2 – Procedure for
Determining Conformance to Dry Coating Thickness
Requirements
SSPC-SP 1 Surface Preparation Specification No. 1 - Solvent
Cleaning
SSPC-SP 3 Surface Preparation Specification No. 3 – Power
Tool Cleaning
SSPC-SP 7/ NACE No. 4 Joint Surface Preparation Standard - Brush-off Blast
Cleaning
SSPC-SP 10/ NACE No. 2 Joint Surface Preparation Standard - Near-White
Metal Blast Cleaning
SSPC-SP 11 Surface Preparation Specification No. 1 - Power
Tool Cleaning to Bare Metal
SSPC-VIS 1 Pictorial Surface Standard - Guide and Reference
Photographs for Steel Surfaces Prepared by Dry
Abrasive Blast Cleaning

Code No. Title

SSPC-VIS 3 Pictorial Surface Standard - Guide and Reference
Photographs for Steel Surfaces Prepared by Hand
and Power Tool Cleaning
UL 1709 Underwriters Laboratories – Rapid Rise Fire Tests of
Protection Materials for Structural Steel
Specifications:
Specification No. Title

RPMS-ENGG-SPC-CS-001 Specification for Plain and Reinforced Concrete
Materials and Construction

Fabrication
RPMS-ENGG-DBD-HS-003 Design Basis for Fireproofing


Conflicts
shall govern:
a. The Purchase Order
b. This Specification
c. Codes and Standards specifically referred
d. Other National and International Standards as referenced
engineer in charge shall be final and SUPPLIER shall implement that without any

Deviations
OWNER.
0C Degree Centigrade
ACI American Concrete Institute
c/c Centre to Centre spacing
IS Indian Standard
MS Mild Steel
SSPC The Society for Protective Coatings Standard
SWG Standard Wire Gauge
UL Underwriter’s laboratory
CONTRACTOR
CONTRACTOR Party that carries out all or part of the design, engineering,
procurement, installation, application and commissioning
of a product (fireproof coating applicator for purpose of this
specification)
Engineer in Charge BUYER’s authorised representative with overall authority
and responsibility for engineering, design, quality, and
performance of works related to this specification
FABRICATOR Party responsible for furnishing fabricated structural steel
and miscellaneous steel
MANUFACTURER Party that manufactures or supplies a product and services
to perform the function as specified by the BUYER
OWNER Reliance Industries Limited (RIL) or specified Reliance
Group Companies

SUPPLIER Party responsible for design, fabrication, supply,

installation and/ or commissioning of equipment at job-
site.
Fireproofing Systems
This specification covers following types of fireproofing system:
 Type 1 – In-situ dense cement concrete for steel structure
 Type 2 – Lightweight cementitious material (vermiculite based or proprietary
material)
 Type 3 – Proprietary Intumescent system
Extent of Fireproofing
The purchase order and design/ fabrication drawings indicate the extent of
fireproofing. Fireproofing heights and construction block-outs are indicated on
structural steel fabrication drawings. Equipment skirts/ saddles/ support legs
requiring fireproofing are indicated on equipment design drawings. Fireproofing of
stainless steel surfaces, cryogenic vessels, chiller packages, cable trays, junction
boxes and controls/ instrumentation equipment is excluded from the scope of this
specification.
Fireproofing Thickness
The thickness of fireproof coating shall be adequate to prevent structural steel and
equipment skirts/ saddles/ supports from reaching a temperature above 538 0C for
a period of not less than 2 hours, when exposed to hydrocarbon pool fire of about
1100 0C, unless a higher exposure time is specified in purchase order or the design/
fabrication drawings. Thickness of coating shall be determined based on section
factor such as HP/A (Heated perimeter per unit length / cross section area) or W/D
ratio (weight per unit length over heated perimeter) of the steel member for the
type of coating system adopted.
Thickness of coating for structural steel and equipment skirts/ saddles/ supports
shall correspond to 2-hour fire rating under UL 1709 (XR Category), subject to
minimum thickness requirement.
Cementitious or intumescent fireproofing system shall have coating thickness as
recommended by MANUFACTURER subject to minimum specified in this
specification.
Minimum thickness of fireproof coating shall be as per following unless noted
otherwise on design/ fabrication drawings.

5.3.3.1. In-situ dense concrete fireproofing thickness shall be 50mm, to a tolerance of (-)2/
(+)3 mm, over structural surfaces and additionally be of sufficient thickness to
provide a 25mm minimum cover over fireproofing anchor studs and reinforcing
steel. 50 mm thick concrete fireproofing provides in excess of two and a half hours
of protection to steel subjected to a UL 1709 type hydrocarbon pool fire.
5.3.3.2. The minimum thickness for proprietary cementitious coating shall be 30 mm.
Vermiculite based non-proprietary lightweight cementitious concrete fireproofing
shall be minimum 38 mm thick.
5.3.3.3. Intumescent fireproofing coating with mesh reinforcement shall be minimum 15
mm thick and is permitted to be minimum 12 mm thick for mesh free system.
Deviations from minimum thickness requirement shall be approved by BUYER.
Fireproofing in excess of the above requirements may be specified by BUYER for
high-valued equipment (such as reactors), or equipment handling large quantities
of flammable and toxic material in congested areas which are impacted by fire
scenarios.
Responsibilities
Steel Structure
5.4.1.1. Design Engineering is responsible to identify structures which need to be
fireproofed and shall specify members to be fireproofed on the structure general
arrangement drawings. Structural steel detailer shall identify fireproofed member
with designation ‘FP’ or ‘FPX’ (See Annexure 1 and 2) on erection drawings and
identify type and extent of fireproofing on shop fabrication drawings along with
leave-out portions or blockouts.
5.4.1.2. Thickness and fireproofing type shall be confirmed by the fireproofing
CONTRACTOR.
5.4.1.3. Structural FABRICATOR shall provide welded anchors for installation of reinforcing
mesh, unless specified otherwise in purchase order. Structural FABRICATOR shall
provide primer coat after fabrication of the structure to meet corrosion protection
requirement. Galvanisation of structural steel, if required, is responsibility of
Structural FABRICATOR.
5.4.1.4. Fireproofing CONTRACTOR shall install non-welded or driven pin type of anchors
and any additional mesh clips/ anchors required to support mesh. CONTRACTOR
shall provide touch up to primer coat and the tie coat over primer coat (if required
by MANUFACTURER). The CONTRACTOR is responsible for installation of
fireproofing material, associated reinforcing mesh and weatherproof top coat.

Equipment Supports
5.4.2.1. Design Engineering is responsible to identify the supports of specific equipment
which need to be fireproofed and shall ensure adequate details including extent,
general profile and leave-out areas are provided on equipment SUPPLIER’s general
arrangement and detail drawings.
5.4.2.2. Thickness and fireproofing type shall be confirmed by the fireproofing
CONTTACTOR.
5.4.2.3. Equipment SUPPLIER shall provide welded anchors for installation of reinforcing
mesh or supports and on pressure envelope as required, unless specified otherwise
in purchase order. Equipment SUPPLIER shall provide primer coat after fabrication
of the equipment to meet corrosion protection requirement.
5.4.2.4. Fireproofing CONTRACTOR shall install non-welded or driven pin type of anchors
and any additional mesh clips/ anchors required to support mesh. CONTRACTOR
shall provide touch up to primer coat and the tie coat over primer coat (if required
by MANUFACTURER). The CONTRACTOR is responsible for installation of
fireproofing material, associated reinforcing mesh and weatherproof top coat.
In-situ Dense Concrete Fireproofing
In-situ dense concrete fireproofing shall be provided on equipment skirt/ saddles/
legs as specified and detailed on design drawings by equipment SUPPLIER.
Material
The material used in primer coat on steel, reinforcing system, cement concrete,
curing compound, sealant at edges & weather proof top coat for dense concrete
fireproofing system shall have compatible components. Materials shall conform to
following
5.5.1.1. Cement concrete used for fireproofing application shall be minimum M20 grade
and shall use materials and water as per Technical Specification RPMS-ENGG-SPC-
CS-001. The minimum cement content of concrete shall be 320 kg/m 3. The slump
range for the concrete shall be between 75 mm and 150 mm when tested per IS
1199 Part 1. Cement used for fireproofing structures/ equipment in sulphur
handling units shall be sulphate resisting portland cement conforming to IS 12330.
Fine aggregates conforming to grading zone IV of IS 383 shall not be used. The
maximum size of coarse aggregate shall be limited to 10 mm.
5.5.1.2. Galvanised MS reinforcing mesh shall be 50 mm by 50 mm by 14 SWG in rectangular
or hexagonal pattern.
5.5.1.3. Anchors used for mesh support system shall be MS Nelson Studs (of a suitable
height for the rating and thickness), material grades 1010 through 1020 per ASTM
A29/ A29M and conforming to AWS D1.1/D1.1M or equivalent for structural steel
and large flat surfaces such as vessel skirts.

Alternatively, mild steel nuts of M10 dia. bolts conforming to IS 2585 or IS 1363 and
property class 5 of IS 1367 welded to steel surface are acceptable. Welding shall
be as per AWS D1.1/ D1.1M as referenced in Technical Specification RPMS-ENGG-
SPC-CS-002 or stud MANUFACTURER’s written procedure.
Pneumatically driven anchors such as “Hilti X-EDN” or “X-ENK” type or equivalent
installed as per MANUFACTURER’s direction or furring clips are permitted to avoid
field welding and in case of brownfield works where hot work may not be allowed.
Use of driven anchors on equipment skirts/ saddles shall be subject to minimum
and maximum thickness of steel substrate and shall be permitted only after
concurrence from Engineer in Charge for each equipment.
Other anchoring/ anchor fixing system proposed by MANUFACTURER shall be pre-
approved by Engineer in Charge.
5.5.1.4. MS tie wires to fasten reinforcing mesh to anchors shall be 18 SWG and galvanised.
5.5.1.5. Cover blocks shall be prepared in 1:3 cement sand mortar with minimum 50 mm x
50 mm size or PVC make readily available covers of thickness equal to half the
fireproofing thickness. MS tie wires with adequate length shall be left protruding
out for tying with wire fabric.
5.5.1.6. Edge sealant shall be non-bituminous polysulfide or silicon rubber mastic such as
Dow Corning Dowsil 795, Carboline Acrilast 570 WB, or approved equal. The sealing
compound shall be compatible to concrete material.
5.5.1.7. Membrane curing may be used in lieu of moist curing with the permission of the
Engineer in Charge. The curing compound shall be compatible with the concrete
substrate.
5.5.1.8. Primer coat on steel surface shall be inorganic zinc silicate primer, Type 1, applied
in specified thickness as per paint schedule “S” - Annexure C of Technical
Specification RPMS-ENGG-SPC-PP-014, or as per MANUFACTURER’s
recommendation.
5.5.1.9. Weather proof coating system, if specified in purchase order, shall consist of
water based cement paint SNOWCEM or equivalent applied in thickness as per
purchase order.
Mock Up
For shotcrete applications, a sample 1 meter long ISMB 250 column shall be
fireproofed by each nozzle operator qualified for the work. The mix shall have
minimum 20 Mpa strength at 28 days and shall incorporate Recron PP fibers at
dosage of 900 gms/ cum to have increased fire resistance. The sample shall be
inspected and tested in accordance with clause 5.5.5. Upon acceptance of physical
properties, the finish shall be subject to inspection by the BUYER. If accepted, the
finish shall serve as a comparator to judge the trowel finish on the work. The finish

of the work for surfaces shall be at least as smooth as the surface of one of the
accepted mock-ups.
Application Method
5.5.3.1. Steel surface to be fireproofed shall be provided with anchors welded to equipment
skirt/ saddles/ legs by the equipment SUPPLIER and structural steel by the
FABRICATOR, unless directed otherwise in purchase order.
Flat surfaces such as walls, ceilings, decks, and column web areas over 300 mm
deep require the use of reinforcing mesh anchored on 300 mm centers Anchors
shall be spaced at 300 mm centers in both directions in a staggered pattern.
5.5.3.2. The steel surface shall be coated with primer paint or galvanised (if required) as per
relevant requirement of Technical Specification RPMS-ENGG-SPC-PP-014 or RPMS-
ENGG-SPC-PP-042 respectively by equipment SUPPLIER/ structural steel
FABRICATOR, unless directed otherwise in purchase order. The anchors shall also
be provided with relevant primer (or touch up coat in case of galvanised steel) as
per shop or field coating specification.
Alternatively, if specified in purchase order, pneumatically driven pins may be
installed by CONTRACTOR only on structural steel supplied by steel FABRICATOR.
5.5.3.3. Where clips, support angles, etc., must be welded to coated surfaces, touch-up
paint must be provided to the weld area and attachment by equipment SUPPLIER/
structural steel FABRICATOR.
5.5.3.4. Steel surface to be coated with fireproof material shall be cleaned of oil, grease,
loose rust, scales, glossy surfaces, loose or flaking paint, dust, or similar surface
conditions which would affect adhesion by wire-brushing and washing with
detergents before fireproof coating application by the CONTRACTOR.
5.5.3.5. Structure, equipment and commodities nearby shall be suitable covered and
shielded during fireproofing by CONTRACTOR.
5.5.3.6. Reinforcing mesh securely tied to anchors using tie wires shall be placed
approximately at middle of fireproof coating thickness. Cover blocks tied to wire
fabric shall be provided at maximum 300 mm c/c and at suitable location along
periphery of application zone. The mesh shall be bent conforming to profile of
finished coating.
5.5.3.7. Fireproof coating shall be “formed” or “shotcrete applied” by qualified &
experienced nozzle operators. The nozzle operators shall be qualified to ACI C660.1
recommendation. Qualification testing shall be subject to inspection, review and
acceptance by the BUYER.
5.5.3.8. Fireproofing not placed in forms shall be finished smooth through the use of a wood
float or trowel. The final appearance shall be smooth, even, and aesthetically
pleasing. Light sanding or troweling of uncured surfaces may be required to obtain
an acceptable corner for joint sealing or surface appearance.

5.5.3.9. For equipment support, the coating material shall be applied in horizontal bands
working upwards from bottom of support base plate. Thickness of fireproof coating
shall be maintained by use of suitable means such as thickness gauges. The coating
shall be troweled to provide a clean surface finish.
5.5.3.10. For steel structure, the concrete shall be poured into suitable forms and shall be
vibrated to ensure smooth surface, free of voids, honeycombing and irregularities.
5.5.3.11. The base plate, anchor bolts, gussets and structural bolts shall be covered with
required thickness of fireproofing material. However, for saddle supported
equipment, fireproofing shall be done such that complete accessibility to
foundation bolts is available for maintenance.
5.5.3.12. Visible edges of fireproof coating shall be chamfered by 20 mm.
5.5.3.13. Slope of about 30 degree with respect to horizontal plan shall be provided in
coating at interface of dense concrete and cementitious/ intumescent material to
be applied later.
5.5.3.14. The fireproofing material shall be cured by regular method of keeping it moist or
coating with a membrane of curing compound. The curing compound used shall be
approved by Engineer in Charge prior to use. The membrane curing shall be applied
to exposed surface by spraying or brushing soon after the fireproofing material has
set as per directions of MANUFACTURER. Film thickness shall be adequate to
ensure to obtain a 90% efficiency per ASTM C156. The film shall be removed from
the surface after the curing period specified by MANUFACTURER.
5.5.3.15. Edges of fireproofing at termination of fireproofing shall be formed/ sloped to
prevent water ingress at joint and shall be sealed by suitable sealant. The seal shall
be applied in a 10 mm deep x 10 mm wide U shaped groove cut in fireproofing
material at terminations.
5.5.3.16. Weather proof coating system shall be applied to the completed and cured
fireproofing in accordance with the MANUFACTURER's written procedure and the
project specifications.
Vendor Data
The CONTRACTOR shall submit documents as required in Technical Specification
RPMS-ENGG-SPC-CS-001. CONTRACTOR shall submit detailed sketches showing
location of reinforcement and cross section of typical fireproofed steel shapes and
equipment supports.
Inspection & Testing
5.5.5.1. The CONTRACTOR’s inspector shall provide on-site inspection on following points
as a minimum.
a. The CONTRACTOR shall furnish the necessary testing and inspection
instruments, properly calibrated and maintained. Such equipment shall be
available for use by the BUYER in conducting surveillance of the work.
b. Surface to be coated must be clean and free of loose particulate matter. All
coatings must be intact.
c. Anchors shall be randomly tested to ensure sound welds by means of a
hammer test.
d. Reinforcement shall be inspected to assure conformance to approved design
sketches.
e. For shotcrete applications, compressed air quality of the air downstream of the
separator to indicate no visible contamination, oil, or moisture.
f. Wet thickness shall be measured in accordance with ASTM E605/ E605M,
before material sets hard. Four sets of random measurements shall be taken
for each unit or for each 15 linear meters.
g. Visual inspection of fireproofing shall be performed to ensure no
honeycombing, hollow voids, or other defects exist. Observations shall be
made to ensure that the curing membrane, if utilised, are applied properly.
h. The applied fire protection shall be free of defects such as excessive cracks,
voids, spalls, or exposure of the substrate. The appearance and workmanship
shall conform to the mock-up.
5.5.5.2. Material used for application of coating shall be tested for bulk density and
compressive strength. Collection of test samples and acceptance criteria shall be
as per Technical Specification RPMS-ENGG-SPC-CS-001.
5.5.5.3. Defects observed shall be made good by CONTRACTOR by patching after approval
of proposed repair method by Engineer in Charge.
Lightweight Cementitious Fireproofing
Lightweight cementitious fireproofing shall be provided on equipment skirt/
saddles/ legs as specified and detailed by SUPPLIER on equipment design drawings.
Steel structures shall be fireproofed with cementitious fireproofing in shop or on-
site as detailed on fabrication drawings.
Material
The material used in components of lightweight cementitious fireproofing such as
primer coat on steel, reinforcing system, cementitious material, curing compound,
sealant at edges & weather proof top coat shall be as recommended/ approved by
MANUFACTURER and shall be compatible to the system proposed.
5.6.1.1. Fireproofing materials shall conform to one of the following
a. Proprietary Light Weight Cementitious Fireproofing
Proprietary light weight cementitious fireproofing material shall be one of the
following:

 Pyrocrete 241
 Fendolite/ Isolatek M II (spray applied only)
 Fendolite/ Isolatek TG (trowel applied only)
 Monokote Z-146PC
 Firecut F-100
 Alternate equivalent materials may be acceptable but require prior
approval from Engineer in Charge
 Each bag of fire proofing material supplied at site shall be labelled with UL
certified stamp/certificate pasted on the bag.
b. Vermiculite Based from Local MANUFACTURER
Vermiculite based material used for fireproofing application shall be certified
for UL 1709 and classified under individual design (XR) category. The material
shall be factory blended, packed and supplied in a dry form by
MANUFACTURER. The premixed material shall be free from lumps, non-
flaking, non-dusting and shall be suitable for spray application. Material shall
not contain asbestos, mineral wool and toxic materials which may be released
when heated. Suitable mold and fungi inhibitor may be added to mixture. The
material shall comply with following minimum requirement tabulated below.
Characteristics Unit Limiting Value Standard

Loose material density kg/m3 ~ 400
Applied dry density kg/m3 700 - 800 ASTM E605/
E605M
Compressive Strength kg/cm2 25 - 40 ASTM E761/
E761
Flexural Strength kg/cm2 20 - 25 ASTM D790
Bond Strength kPa ~ 500 ASTM E736/
E736M
Bond Impact Pass ASTM E760/
E760M
Hardness Shore D (28 day) 40 min ASTM D2240
Thermal Conductivity at 200C W/mK 0.19 ASTM C177
Flame spread 0 ASTM E84
Smoke development 0 ASTM E84

Characteristics Unit Limiting Value Standard

Air erosion g/mm2 0 ASTM E859/
E859M
Corrosion g/mm2 0 ASTM E937/
937M
Fungal resistance Pass ASTM G21
Sulphate (SO3) content SO3 % <1%
c. Reinforcement wire mesh shall be minimum 18 SWG as per clause 5.5.1.2.

Alternatively, plastic coated chicken wire mesh can also be used.
d. Anchors for mesh support system shall be as per clause 5.5.1.3.
e. Galvanised MS tie wires shall be as per clause 5.5.1.4.
f. Cover blocks, if required, shall be as per clause 5.5.1.5.
g. Edge sealant shall be as per clause 5.5.1.6.
h. Membrane curing may be used in lieu of moist curing with the permission of
the Engineer in Charge. The curing compound shall be compatible with the
concrete substrate.
i. Primer coat on steel surface shall be inorganic zinc silicate primer, Type 1,
applied in specified thickness as per Annexure C: “S” paint schedule of
Technical Specification RPMS-ENGG-SPC-PP-014, unless specified otherwise by
MANUFACTURER.
If required by MANUFACTURER, a tie coat shall be applied over primer coat by
CONTRACTOR as per MANUFACTURER recommendation prior to fireproof
coating.
j. Weather proof coating system, if specified in purchase order, shall be as per
MANUFACTURER’s recommendation consistent with fireproofing material and
shall be approved by Engineer in Charge.
Mock Up
Nozzle operators shall prepare a mock up as per clause 5.5.2 for each type of
fireproofing product they are qualified to work on. The sample shall be inspected
& tested in accordance with clause 5.5.5.
Application Method
5.6.3.1. The steel surface to be fireproofed shall be prepared as in clause 5.5.3.1. through
clause 5.5.3.3. by equipment SUPPLIER/ structural steel FABRICATOR, unless
specified otherwise in purchase order. The primer coat shall be consistent with
MANUFACTURER’s recommendation.

5.6.3.2. CONTRACTOR shall clean the surface to be fireproofed as in clause 5.5.3.4 and
protect nearby commodities per clause 5.5.3.5.
5.6.3.3. If required by MANUFACTURER, the primer coat shall be overcoated with a
MANUFACTURER approved tie coat of required thickness by the CONTRACTOR.
5.6.3.4. Reinforcing mesh shall be installed as in clause 5.5.3.6.
5.6.3.5. For structural members with field installed fireproofing, and a web depth of 200
mm or less, the fireproofing shall be a "solid boxed in" configuration. (Box casing
configuration is not acceptable. For structural members with a web depth greater
than 200 mm, and shop installed fireproofing, the fireproofing shall be a contoured
configuration. The applications shall conform to the UL 1709 design for the
appropriate rating.
5.6.3.6. Blockouts of the fireproofing for the field connections are identified on design/
fabrication drawings. Shop applied reinforcement mesh shall extend at least 60
mm into the area where the fireproofing material is blocked out to facilitate tie-in
with site applied mesh and site fireproofing.
5.6.3.7. Fireproof coating shall be carried out by qualified & experienced personnel and
nozzle operators as in clause 5.5.3.7 thru clause 5.5.3.9, clause 5.5.3.11 and clause
5.5.3.12.
5.6.3.8. Fireproofing shall be applied between 12°C and 38°C ambient temperature with
maximum relative humidity of 95%, or as specified by MANUFACTURER.
5.6.3.9. Unless specified otherwise by MANUFACTURER, curing shall be accomplished by
continuous dampening the fireproofing or use of an ASTM C309 coating/curing
membrane.
5.6.3.10. For field application, overspray or waste shall be removed while still wet and before
setting at CONTRACTOR's expense.
5.6.3.11. The external topcoat, if required by the purchase order, shall be applied to the
completed and cured fireproofing in accordance with the MANUFACTURER's
written procedure and the coating specifications. For shop applied fireproofing, the
topcoat shall be applied, cured, and inspected prior to shipment.
Vendor Data
5.6.4.1. The CONTRACTOR shall submit a listing of materials to be used in shop and field
fireproofing including field repair of blockouts. CONTRACTOR shall submit detailed
sketches showing location of reinforcement and cross section of typical fireproofed
steel shapes and equipment supports.

5.6.4.2. The CONTRACTOR's written procedures for storage, shipping, handling, top coating,
surface preparation, environmental control, application, touch up and repair,
curing, and inspection of the fireproofing system shall be submitted for BUYER’s
review and permission to proceed prior to use. For shop applied fireproofing,
blockouts, handling and shipping procedures, as well as the schedule must be
covered in detail. Conflicts between CONTRACTOR's recommendations and this
Specification shall be noted; however, this specification shall prevail.
5.6.4.3. The CONTRACTOR's proposed fireproofing verification ITP’s and inspection forms
for daily inspection records shall be submitted for BUYER’s review and permission
to proceed prior to use.
5.6.4.4. A detailed fireproofing verification report, in accepted form, shall be completed
each day during the work and shall be submitted for record. The final verification
report shall include the values from testing obtained in accordance with this
specification and a statement of conformance verifying that the required materials
were used and that the accepted application procedures and specifications were
followed. The responsible inspector must approve and sign these reports on a daily
basis.
5.6.4.5. The CONTRACTOR shall furnish MANUFACTURER's UL 1709 certificate and test
certificates indicating that the fireproofing material conforms to guaranteed data
sheet values for the laboratory tests listed above in clause 5.6.1.1 for each batch of
material supplied for review and acceptance by the BUYER.
The package/ container shall bear UL 1709 mark and UL design number under XR
categorization.
5.6.4.6. Detailed weld procedure shall be submitted for BUYER’s review and permission to
proceed prior to use if the required reinforcement anchors are not attached by the
steel or equipment FBRICATOR and must be attached by welding by the
CONTRACTOR.
Inspection & Testing
5.6.5.1. The CONTRACTOR’s inspector shall provide on-site inspection on points specified
in clause 5.5.5.1.
5.6.5.2. Following additional examinations shall be performed by the CONTRACTOR's
Inspector in case “shotcrete” method is used.
 Compressed air quality shall be checked at the beginning and end of each shift,
after an interruption and at not less than four-hour intervals. If contaminants
are evident, the equipment deficiencies shall be corrected, and the air stream
shall be retested.
 Shore D, Durometer readings shall be taken on completed fireproofing surfaces
after curing is complete. All test results shall be reported to the BUYER.

 Samples of fireproofing as installed shall be taken daily from each installer and
tested for property listed below. Test results shall be reported to the Buyer.
▪ Density
▪ Durometer Hardness
▪ Compressive Strength
▪ Impact Resistance
▪ Flexural Strength
▪ Thermal Conductivity
5.6.5.3. Defects or damaged areas detected during assembly or handling shall be repaired
in accordance with procedures as permitted by the Engineer in Charge. Defects
disclosed by inspection shall be re-inspected after correction.
Intumescent Fireproofing System
Intumescent fireproofing shall be applied on equipment skirt/ saddles/ legs as
specified and detailed by SUPPLIER on equipment design drawings.
Steel structures shall be fireproofed with intumescent fireproofing as detailed on
fabrication drawings, on-site or in shop.
Materials
The material used in components for intumescent fireproofing application such as
reinforcing system, coating material, thinners, solvents and cleaners, curing
compound, sealants, weather proof top coat shall be as recommended/ approved
by MANUFACTURER and shall be compatible to the system proposed.
5.7.1.1. Fireproofing materials shall conform to one of the following:
 Chartek VII
 Pitt-Char XP
 Jotachar 1709 meshfree
 Alternate equivalent materials may be acceptable but require prior approval
from Engineer in Charge
Materials shall be submitted in writing for BUYER’s review and acceptance.
5.7.1.2. Mesh reinforcement, if required, shall be in accordance with the intumescent
fireproofing material MANUFACTURER’s recommendation and shall conform to
acceptance testing documentation. The reinforcing mesh shall be minimum 3.5
mm by 3.5 mm nominal coated glass fiber mesh with a nominal weight of 245 g/m2
(for a two hour rating) —applied to the entire surface with a 50 mm overlap on side
joints and end joints butted. The mesh shall be placed at approximately mid-depth
of the coating for the hourly ratings.

5.7.1.3. Abrasives for blast cleaning shall comply with SSPC-AB 1 (mineral and slag
abrasives), SSPC-AB 3 (steel abrasives) or equivalent. Abrasives shall be clean, dry
and free of oil and contaminants. The particle size shall be capable of producing
the specified surface profile. Silica sand abrasives shall not be used at the
construction site.
5.7.1.4. Primer coat on blast cleaned steel surface shall be consistent with fireproof coating
as specified by MANUFACTURER and shall be applied as per MANUFACTURER’s
direction.
If required by MANUFACTURER, a tie coat shall be applied over primer coat by
CONTRACTOR as per MANUFACTURER recommendation prior to fireproof coating.
5.7.1.5. Thinners, solvents, and cleaners shall be as manufactured or recommended in
writing by the coating material MANUFACTURER and shall be identified on the
MANUFACTURER’s data sheets by the product name and number.
5.7.1.6. Materials for touch-up of damaged areas shall be the same as those originally
applied unless otherwise specified. Touch-up materials shall be in pre-measured
units, and only complete kits shall be mixed.
5.7.1.7. External coating materials shall be a clear epoxy sealer or other coating as specified
by MANUFACTURER consistent with fireproofing material. Deviations shall be
approved by BUYER.
5.7.1.8. Fireproofing material delivery and storage
 Fireproofing materials shall be delivered to the place of application in the
MANUFACTURER's unopened, original containers having legible product
designation, batch number, and date of manufacture. Containers of
fireproofing material or components shall not be opened unless for immediate
use. Containers that are damaged shall not be used.
 The fireproofing material shall be handled and stored in accordance with the
MANUFACTURER's published instructions and shall be protected from damage,
moisture, direct sunlight, and temperatures below 5°C or above 32°C. Air
conditioned and/or heated storage shall be required and is the responsibility
of the CONTRACTOR.
 The fireproofing materials shall be used within the MANUFACTURER's
published shelf life. Containers that have exceeded the published shelf life
shall be segregated from other material and disposed of in accordance with
local regulations.
5.7.1.9. CONTRACTOR shall provide equipment suitable to perform the fireproofing work,
such as heated plural airless spray equipment and other necessary appurtenances,
as specified by the MANUFACTURER. The equipment shall be capable of regulating
and controlling the specified environmental conditions within the work area as
necessary.

Mock Up
Nozzle operators shall prepare a mock up as per clause 5.5.2 for each type of
fireproofing product they are qualified to work on. The sample shall be inspected
& tested in accordance with clause 5.7.6.
Shop work by equipment SUPPLIER/ Structural Steel Fabricator
The steel surface to be fireproofed shall be abrasive blast cleaned/ primer coated
or galvanised (if required) by equipment SUPPLIER/ structural steel FABRICATOR,
unless note otherwise in purchase order. The primer coat shall be consistent with
MANUFACTURER’s recommendation.
5.7.3.1. Surface Preparation
 Water shall be removed from the surface prior to beginning surface
preparation. The steel surface temperature shall be at least 30C above the dew
point.
 Prior to blast cleaning, oil, grease, and dirt shall be removed by solvent cleaning
in accordance with SSPC-SP 1.
 Surfaces to be fireproofed shall be initially abrasive blast cleaned to SSPC-SP
10 near white blast in accordance with the MANUFACTURER’s surface
preparation requirements.
 Where abrasive blasting is impractical, power tool cleaning to bare metal in
accordance with SSPC-SP 11 may be substituted in limited areas and only with
BUYER's written acceptance.
 The surface profile of the steel cleaned by blasting shall be as specified by the
fireproofing MANUFACTURER.
 Blasted surfaces shall be swept and wiped free of dust and spent abrasive
media immediately before primer coating. Vacuuming shall be used if the
surface cannot be made dust free by sweeping. Blowing down with
compressed air is not permitted.
 Equipment SUPPLIER/ structural steel FABRICATOR shall provide a primer coat
of required DFT as per MANUFACTURER’s published instruction.
5.7.3.2. Burrs, slivers, scabs, laminations, and weld spatter which become visible after
blasting shall be removed.
5.7.3.3. Blast cleaning shall not be performed in the immediate area where application or
curing of fireproofed surfaces is in progress. Surfaces and equipment which are not
to be fireproofed shall be suitably protected from blast cleaning. Equipment shall
have openings plugged, masked, and/or blinded sufficiently to protect internals
before abrasive blasting. Precautions shall be taken to protect equipment, valves
etc. adjacent fireproofed areas from damage caused by local abrasive blasting.

5.7.3.4. If visible rusting occurs, or if the cleaned surface become wet or otherwise
contaminated, these surfaces shall be re-cleaned to the degree specified. Cleaned
surfaces remaining un-fireproofed overnight shall be re-cleaned to the specified
degree of surface preparation.
5.7.3.5. The abrasive mixture and the compressed air shall be clean, dry, and oil-free. Traps
shall be used in compressed air lines close to the point of use, to remove oil and
moisture from air, in addition to oil and water extractor mounted on the
compressor.
5.7.3.6. In case structural steel is to be galvanised, the requirements of Technical
Specification RPMS-ENGG-SPC-PP-042 shall be followed.
Application Method
5.7.4.1. Prior to the start of work, the CONTRACTOR shall examine surfaces to be
fireproofed to determine their acceptability for the specified work per
MANUFACTURER’s requirement. If surfaces are found to be unacceptable, the
CONTRACTOR shall either prepare the surface to an acceptable condition or
immediately notify the BUYER in writing if the repairs are outside the scope of work.
Work shall not commence until corrective action has been taken.
5.7.4.2. CONTRACTOR shall clean the surface to be fireproofed as in clause 5.5.3.4 and
protect nearby commodities per clause 5.5.3.5.
5.7.4.3. Surface Preparation – On Site (Field) Work
After erection and/or installation but before fireproofing, items previously coated
(fireproofed) in shop shall be examined for damaged and for un-coated areas.
Oil and grease shall first be removed in accordance with SSPC-SP 1 by solvent
cleaning. Loose dirt and other contaminants shall be removed by high-pressure
water wash or other BUYER accepted techniques. Inspection shall be completed
after cleaning to ensure that the protective coating has not been damaged.
Un-coated and damaged areas shall be power tool cleaned to bare metal in
accordance with SSPC-SP 11 or spot blasted to the degree originally specified.
5.7.4.4. Surface Preparation - On Site (Field) Work Galvanised Steel
If galvanised steel is to be fireproofed, the surface shall be solvent cleaned per
SSPC-SP 1 and then allowed to dry. After cleaning, the dry galvanised surface shall
be lightly abrasive blast cleaned in accordance with SSPC-SP 7, uniformly
roughening the surface while removing a minimum of the galvanising thickness (not
more than 25 microns).
Damaged hot-dip galvanised steel shall be repaired as follows:
 Clean the damaged area per SSPC-SP 3.

 Touch-up with a zinc rich epoxy coating as per MANUFACTURER’s

recommendation or BUYER approved equal. “Cold galvanising” products
applied using aerosol cans are not acceptable.
5.7.4.5. If required by MANUFACTURER, the primer coat shall be overcoated with a
MANUFACTURER approved tie coat of required thickness by the CONTRACTOR.
5.7.4.6. All procedure in clause 5.7.4.1 to clause 5.7.4.4 remain same in case fireproofing is
required to performed at shop.
5.7.4.7. Mixing, applying, and curing of the coating material shall be in accordance with the
MANUFACTURER’s published instruction and the requirements specified herein.
Component mix ratio, material temperatures, pressures, and pump displacement,
ambient temperature and relative humidity during operation shall follow
MANUFACTURER’s required parameters.
5.7.4.8. Mixing
 When multiple component units are mixed, each component shall be mixed
separately prior to the mixing of the combined materials.
 Only complete kits of multi-component coatings/fireproofing shall be mixed.
No partial kits will be allowed.
 Mixed material shall be used within the MANUFACTURER’s published pot life.
Material that has exceeded its pot life shall be discarded.
 If it is found that material from a partially mixed kit or material that has
exceeded its pot life was used, the coating shall be completely removed, and
the surface restored to the original degree of cleanliness specified. The
prepared surface shall then be re-coated/ fireproofed with material from a
fully mixed kit within its pot life.
 Coating/ fireproofing materials shall be thoroughly mixed until they are
smooth and free from lumps, and then strained through a size 30 mesh or finer
screen. Material shall be agitated to keep the solids in suspension. Inorganic
zinc coatings shall be mechanically agitated at all times.
5.7.4.9. Applying coating
 The cleaned surface shall be primed as per procedure and material specified
by MANUFACTURE before visible rust forms on the surface.
Coating/fireproofing material shall not be applied when there is moisture on
the surface, dust is present that can contaminate the freshly coated surface, or
when dirt or other detrimental material has re-contaminated the surface.
 No coating material shall be applied closer than 150 mm from adjacent non-
cleaned surfaces.
 The application of the fireproofing shall be performed only when the steel
surface is at least 3°C above the dew point. Both ambient and surface

temperature shall be in accordance with the MANUFACTURER’s written

requirements.
 The reinforcing layer shall be applied as per MANUFACTURER's direction and
details. The reinforcing mesh shall be applied to the entire coated surface with
a 50 mm overlap on side joints and end joints butted. The mesh shall be placed
at approximately mid-depth of the coating for the hourly ratings.
CONTRACTOR shall leave minimum 150 mm mesh exposed at connection
blockouts for tie-back.
 Over-layers/ topcoats shall be applied within the MANUFACTURER's minimum
and maximum times.
 Fireproofing shall be free of defects. Where possible, defects such as runs, sags,
drips, and voids shall be corrected as detected during application of the
fireproofing. Loss of adhesion, blistering, peeling, mud cracking, inadequate
cure, or rusting of the substrate shall be reworked.
 Fireproofing shall be applied using clean equipment. Air supply lines shall be
equipped with filters/traps to remove moisture and oil as close to the point of
use as possible.
 Surfaces that may become inaccessible shall be fireproofed before assembly,
tagging, fitting, or welding.
5.7.4.10. Fireproofing can be applied by hand trowel only for block-outs and small repair
areas that are less than one (1) m2. Hand trowel applications shall be done in strict
accordance with MANUFACTURER’s instructions.
5.7.4.11. After the fireproofing operation is complete, equipment internals shall be blown
clean or vacuumed to remove dust or abrasive blast media that may have entered
the fireproofed equipment.
5.7.4.12. The external topcoat, if required by the purchase order, shall be applied to the
completed and cured fireproofing in accordance with the MANUFACTURER's
written procedure and the coating specifications. For shop applied fireproofing,
the topcoat shall be applied, cured, and inspected prior to shipment.
Vendor Data
5.7.5.1. The CONTRACTOR shall submit a listing of materials to be used in shop and field
fireproofing including field installation/repair of blockouts.
5.7.5.2. The CONTRACTOR shall submit detailed sketches showing location of
reinforcement and cross section of typical fireproofed steel shapes and equipment
supports.
5.7.5.3. The CONTRACTOR's written procedures for storage, shipping, handling, primer,
topcoating, surface preparation, environmental control, application, touch up and
repair, curing, and inspection of the fireproofing system shall be submitted for
BUYER’s acceptance and permission to proceed prior to use.
5.7.5.4. For shop applied fireproofing, blockouts, handling and shipping procedures, as well
as the schedule shall be covered in detail. Conflicts between CONTRACTOR's
recommendations and this Specification shall be noted; however, this specification
shall prevail.
5.7.5.5. The CONTRACTOR's proposed fireproofing verification forms for daily inspection
records shall be submitted for BUYER’s review and permission to proceed prior to
use.
5.7.5.6. A detailed fireproofing verification report, in accepted form, shall be completed
each day during the work and shall be submitted for record. The final verification
report shall include the values from testing obtained in accordance with this
specification and a statement of conformance verifying that the required materials
were used and that the accepted application procedures and specifications were
followed. CONTRACTOR’s responsible inspector shall approve and sign these
reports on a daily basis.
5.7.5.7. The CONTRACTOR shall furnish MANUFACTURER's test certificates indicating that
the fireproofing material conforms to printed data sheet values for the following
laboratory tests:
 Flexural strength per ASTM D790.
 Surface hardness per ASTM E2240.
5.7.5.8. A detailed welding procedure shall be submitted for BUYER’s review and permission
to proceed prior to use if the required reinforcement anchors are not attached by
the steel or equipment fabricator and shall be attached by welding by the
CONTRACTOR.
Inspection and Testing
5.7.6.1. General Requirements for Shop work
 The equipment SUPPLIER/ structural steel FABRICATOR shall perform abrasive
cleaning and primer coat application and furnish the necessary testing and
inspection instruments, properly calibrated and maintained. Such equipment
shall be available for use by the BUYER in conducting surveillance of the work.
 The following steps are subject to inspection by BUYER's representative:
▪ Following surface preparation (immediately prior to the primer coating
application)
▪ Following the application and curing of each layer of primer.
▪ Final inspection and sign-off, in accordance with the requirements
specified in purchase order
 Surface Preparation Inspection in shop

▪ Blast cleaned surfaces shall be compared with SSPC pictorial surface

standard SSPC-Vis 1. Power tool cleaned surfaces shall be compared with
SSPC-Vis 3. The anchor pattern profile depth shall be verified in
accordance with Method C of ASTM D4417.
▪ Recirculated shot and grit used for abrasive cleaning shall meet the
requirements of SSPC-AB 2. Steel blasted since the last satisfactory test
shall be re-blasted.
5.7.6.2. General Requirements for On Site (Field) Work
 The CONTRACTOR shall furnish the necessary testing and inspection
instruments, properly calibrated and maintained. Such equipment shall be
available for use by the BUYER in conducting surveillance of the work.
 The following steps are subject to inspection by BUYER's representative:
▪ Following surface preparation (immediately prior to the coating
application)
▪ Following the application and curing of each layer of tie coat/
fireproofing/ topcoat.
▪ Final inspection and sign-off, in accordance with the requirements
specified in purchase order.
 Prior to using compressed air, the quality of the air downstream of the
separator shall be tested in accordance with ASTM D4285. The test shall be
performed at the beginning of each shift and at approximately four-hour
intervals.
 Prior to surface preparation and coating application, surface temperature, dew
point and relative humidity shall be determined using a surface temperature
thermometer, sling Psychrometer or BUYER accepted equal following
procedures in ASTM E337. Readings are required approximately every four
hours or at other time intervals accepted in writing by the Project.
 Alternatively, continuous monitoring may be performed using systems
established and/or accepted by Project.
 The substrate temperature shall be at least 3°C above the dew point. The work
shall not proceed if the ambient temperature or relative humidity is outside
the requirements of this specification.
5.7.6.3. Coating Inspection
 The dry film thickness shall be verified in accordance with SSPC-PA 2. The
number, frequency and location of dry film thickness measurements shall
comply with SSPC-PA 2.

 The coating shall be visually inspected for defects such as overspray, runs, sags,
voids, blistering, peeling, rusting, mud cracking, inadequate cure, and lack of
adhesion. Mud cracking must be removed by re-blasting.
The CONTRACTOR shall repair defects per the BUYER accepted touch-up and repair
procedures. Areas where defective materials have been repaired or replaced shall
be re-inspected to the original requirements.
Other Considerations
CONTRACTOR shall provide equipment suitable to perform the fireproofing work,
such as heated plural airless spray equipment and other necessary appurtenances,
as specified by the MANUFACTURER. The equipment shall be capable of regulating
and controlling the specified environmental conditions within the work area as
necessary.
Surface preparation, materials, and coating work shall comply with applicable
environmental and safety provisions, laws, regulations, ordinances, etc., of the
country, state or local authority pertaining to the work being performed and the
coating materials being used. The volatile organic compound (VOC) content of
materials shall meet National, State, and Local or other Regulatory requirements.
Material Safety Data Sheets (MSDS’s) shall be available for review at the jobsite.
CONTRACTOR shall comply fully with local regulations or the applicable country
code.
Where applicable and shown on design/ fabrication drawings, CONTRACTOR to
provide 200 mm deep blockouts in shop 200 mm each way from centerlines of hole
in top and bottom flange of fireproofed steel beams for erection of equipment,
column base plates, column cap plates, slotted connections and at grounding
contact points.
Following steel assembly and acceptance at site/ modularization yard, fireproofing
blockouts shall be field patched by CONTRACTOR to match the shop/
modularization yard fireproofing thickness following the contour of fireproofed
member. Weld seams, damaged coatings, bare areas, other surfaces as required
shall be prepared and coated/ recoated in accordance with this specification.
Erection Marking
Where no stamped or embossed identification codes are evident on structural steel
members, erection codes and mark numbers shall be applied in a contrasting colour
using a coating compatible with the specified coating system and accepted by the
BUYER.
Inspection and testing shall be as per clause 5.5.5, clause 5.6.5 & clause 5.7.6 of this
specification.

7. Vendor Data
Vendor data submission shall be as per clause 5.5.4, clause 5.6.4 & clause 5.7.5 of
this specification.
Surface preparation and coating inspection shall be documented using the
MANUFACTURER’s forms.
Handling of Fireproofed Items
Fireproofed items shall be protected on non-abrasive supports during storage and
shipment. Fireproofed surfaces shall be protected from damage during lifting,
handling, and shipment until accepted by the BUYER at the designated destination.
Fireproofed surfaces that are damaged during assembly, handling, or shipment
shall be repaired in accordance with procedures accepted by the BUYER.
Damaged and loose adhering coating shall be removed and the surface thoroughly
cleaned. Edges of the breaks shall be feathered prior to repair and the designated
number of prime and finish coats applied. The surface profile shall be restored to
meet the specified surface preparation requirements for cleanliness and profile.

Annexure-1 - Typical Details for Dense Concrete Fireproofing
The above details are for broad guidelines/ sample only. The details shall be modified and
finalised after confirmation of fire proofing material, as the material characteristic may
vary from supplier to supplier. Details shall be confirmed with and approved by the
Engineer in Charge before proceeding with work.

Annexure-2 - Typical Details for Lightweight Fireproofing

The above details are for broad guidelines/ sample only. The details shall be modified and
finalised after confirmation of fire proofing material, as the material characteristic may
vary from supplier to supplier. Details shall be confirmed with and approved by the
Engineer in Charge before proceeding with work.

GENERAL NOTES TABLE 1
1. ALL DIMENSIONS ARE IN mm UNLESS NOTED OTHERWISE.
TYPE 2 TO 4 & 6 TO 9 ARE NOT USED.
2. THE GENERAL SPECIFICATION OF THE ANCHOR BOLT ASSEMBLY SHALL BE AS PER TABLE 1. THE DETAILED MATERIAL SPECIFICATION & OTHER REQUIREMENTS
BOLT BOLT
ARE RESERVED.
SHALL BE AS PER TECHNICAL SPECIFICATION RPMS-ENGG-SPC-CS-025. BOLTS TO NUTS WASHERS PLATES SLEEVES REMARKS
TYPE MATERIAL TO
3. BOLTS SHALL BE SUPPLIED COMPLETE WITH NUTS, WASHERS ANCHOR PLATES, SLEEVES, COUPLING NUTS & DUCT TAPE ASSEMBLED AND LIGHTLY OILED
FOR PROTECTION DURING TRANSPORT. PROPERTY

PUNCHED
4. THE TOP ELEVATION OF BOLTS SHALL BE CHECKED BEFORE PLACEMENT OF CONCRETE. CLASS 4.6 IS 1363 IS 1363 NOT USED FOR
1 TYPE A OF - -
FOR BOLT PROJECTION, ACCEPTABLE TOLERANCE IS : OF IS 1367 (PART 1) (PART 3) DUCTILE BEHAVIOUR
IS 2016
(PART 3)
GHTS
+5 mm FOR BOLTS UP TO 24 mm DIA.

+8 mm FOR BOLTS 30 mm DIA. AND ABOVE. PROPERTY
GHT OW NER.ALL RI
PUNCHED GRADE POLYSTYRENE

CLASS 4.6 IS 1363 IS 1363
5. CENTRE TO CENTRE OF ANY TWO ANCHORS IN A GROUP SHALL NOT EXCEED 3 MM. BOLTS SHALL BE PLUMB TO 4 MM IN 1 M LENGTH. E250BR OF TO HD OF
5 TYPE A OF
TED.
OF IS 1367 (PART 1) (PART 3)

TOLERANCES FOR CENTER POINT OF BOLT GROUP SHALL BE WITHIN 6 MM FROM SPECIFIED POSITION. IS 2016 IS 2062 BS 3837
MI
(PART 3)
THE ACCUMULATED VARIATION IN DIMENSION OF BOLT GROUP ON ANY COLUMN LINE SHALL BE PERMITTED TO BE 6 MM PER 30M NOT EXCEEDING 25 MM.
ES LI
PROJECTION 'P' SHALL BE AS PER THE DETAIL DRAWING. PROPERTY

PUNCHED GRADE POLYSTYRENE
NDUSTRI
CLASS 4.6 IS 1363 IS 1363

6. ALL BOLTS SHALL BE PROVIDED WITH DOUBLE NUTS, EXCEPT FOR TYPE-1 E250BR OF TO HD OF
5A TYPE A OF
OF IS 1367 (PART 1) (PART 3)
OF THE COPYRI
7. UPON REMOVAL OF TEMPLATE THE BOLTS SHALL BE CHECKED FOR PLAN LOCATION. ACCEPTABLE TOLERANCES ARE 3mm WITHOUT SLEEVE & NO IS 2016 IS 2062 BS 3837
(PART 3)
ANCE I
OVERSIZE HOLE IN BASE PLATE; AND 6mm WITH SLEEVE OR OVERSIZE HOLE IN BASE PLATE IN ANY DIRECTION FROM THE TRUE LOCATION.
GRADE 2H
8. MINIMUM CENTER TO CENTER DISTANCE OF BOLTS SHALL 4 X BOLT DIA FOR NON-TORQUED BOLTS & FOR TORQUED BOLTS, MIN. C/C DIST = 6 X BOLT DIA. GRADE B7 GRADE POLYSTYRENE
10 / HEAVY HEX
RELI
OF ASTM F436M E250BR OF TO HD OF

9. MINIMUM EDGE DISTANCE FROM CONCRETE FACE TO CENTRE OF BOLT SHALL BE THE CONCRETE COVER AS PER PROJECT STANDARD FOR UNTORQUED 10A SERIES TO
ASTM A193M IS 2062 BS 3837
BOLTS AND 6 X BOLT DIA OR COVER WHICHEVER IS MORE FOR TORQUED BOLTS. THE ANCHOR PLATE SHALL HAVE MINIMUM CONCRETE COVER IN ALL CASES. ASTM A194M
TO
ON
SSI
10. BOLT CAPACITIES, EMBEDMENT ARE VALID ONLY FOR THE GRADE OF CONCRETE INDICATED ON DRAWING. MINIMUM GRADE OF CONCRETE SHALL BE M20 FOR
ETARY
OR PERMI
TYPE 1 AND 5 BOLTS; M25 FOR TYPE 5A, 10 AND 10A BOLTS.
LEGENDS
PROPRI
11. PRIOR TO AND DURING CONCRETING, ALL BOLTS SHALL BE SECURELY HELD IN POSITION BY USE OF SUITABLY ROBUST TEMPLATES.
1. P - PROJECTED LENGTH OF BOLT ABOVE TOC.
THOUT PRI
12. BEFORE CONCRETING AND UNTIL ERECTION OF BASE PLATE/VESSEL, THE PROJECTING PORTION OF THE BOLT SHALL BE WRAPPED WITH A SUITABLE 2. C - BOLT EMBEDDED LENGTH
ON
MATERIAL AFTER APPLYING GREASE.BOLT PROJECTION SHALL ALSO BE PROTECTED FROM DAMAGE DUE TO MOVEMENT OF CONSTRUCTION EQUIPMENT IN 3. D - DIA, DIAMETER OF BOLT
NFORMATI
VICINITY.
4. L - LENGTH OF BOLT
WI
13. ALL POCKETS AND SLEEVES SHALL BE GROUTED AFTER FINAL ERECTION OR IN SEQUENCE AS REQUIRED BY EQPT SUPPLIER. GROUT STRENGTH SHALL 5. S - SLEEVE EMBEDDED DEPTH
AL I
SCLOSED
BE AT LEAST SAME AS PARENT CONCRETE OR AS SPECIFIED ON DESIGN DRAWING. 6. TOC - TOP OF CONCRETE.
DENTI
14. MECHANICAL (STATIC EQUIPMENT GROUP) SHALL USE STANDARD BOLT TYPE, DIAMETER AND LENGTH COMBINATIONS AS SHOWN IN TABLES ON SHEET 3 OF 4, 7. T - BOLT THREAD LENGTH
BE REPRODUCED,DI
UNLESS REQUIRED OTHERWISE BY EQUIPMENT VENDOR.

NS CONFI
8. Ld
- DEVELOPMENT LENGTH FOR REBAR
15. TO PREVENT BONDING OF BOLTS WITH GROUT, BOLTS SHALL BE WRAPPED WITH DUCT TAPE FOR LENGTH UPTO 8 TIMES DIAMETER OF BOLT BELOW
9. L-dhDEVELOPMENT LENGTH OF REBAR IN TENSION TERMINATING IN STANDARD HOOK
BOTTOM OF NUT. FOR ANCHOR BOLTS TO BE TORQUED, FULL LENGTH OF SHAFT SHALL BE WRAPPED WITH DUCT TAPE.
db
DOCUMENT CONTAI
10. - DIA OF BAR

16. THE POLYSTYRENE SLEEVES SHALL REMAIN INTACT UNTIL JUST PRIOR TO THE INSTALLATION OF THE EQUIPMENT/STRUCTURE. THE GROUTING, WHICH
f
11. ck - CHARACTERISTIC STRENGTH OF CONCRETE
SHALL COMPLETELY FILL THE SLEEVE VOID, SHALL BE IN ACCORDANCE WITH THIS STANDARD, UNLESS DIRECTED OTHERWISE BY EQUIPMENT VENDOR.
12. BOLTS SHALL BE MARKED ON DRAWING AS UNDER :-
17. APART FROM THE TYPE 1 BOLT, NO BOLT SHALL BE PLACED IN A PREPARED POCKET, THEREBY RELYING ON THE GROUT ALONE TO RESIST THE
S DOCUMENT MAY
A B C D P L (G)
APPLIED FORCES.
18. THE EMBEDDED DEPTH OF SLEEVES SHALL NOT EXCEED THE REQD. SLEEVE EMBEDMENT DEPTH "S" IN TABULATIONS ON SHEET 3. EXCESS SLEEVE
SURFACE COATING GALVANISED
S
AL DOCUMENT.THI
PROTRUDING ABOVE SHALL BE CUT TO FLUSH WITH CONCRETE SURFACE.
19. WATER OR LOOSE MATERIAL SHALL NOT BE ALLOWED TO COLLECT IN SLEEVES. BOLT LENGTH
THER W HOLE NOR PART OF THI
20. THE SLEEVES FOR ANCHOR BOLTS OF STRUCTURE/ STATIONARY EQUIPMENT SHALL BE FILLED WITH NON-SHRINK CEMENTITIOUS GROUT AFTER PROJECTION ABOVE CONCRETE
STRUCTURE/ EQUIPMENT IS IN PLACE AND BOLTS ARE ALIGNED, UNO ON DESIGN DRAWINGS.
N1 - SINGLE NUT
21. THE SLEEVES FOR ANCHOR BOLTS OF VIBRATING EQUIPMENT SHALL BE FILLED WITH NON-BONDING ELASTOMERIC MATERIAL BEFORE GROUTING N2 - DOUBLE NUT
DENTI
THE BASE PLATE, UNO ON DESIGN DRAWINGS. DIAMETER OF BOLTS

CONFI
22. ANCHOR BOLTS SHALL BE TIGHTENED TO SNUG TIGHT CONDITION ACHIEVED WITH A FEW IMPACTS IMPACT WRENCH. FOR ANCHOR BOLTS TO BE TORQUED, TYPE OF BOLT
TENSIONING OPERATION SHALL BE PERFORMED AS PER DIRECTIONS OF EQUIPMENT VENDOR.
NUMBER OF BOLTS
23. INTERNAL THREADS OF COUPLING NUT SHALL BE PROTECTED BY SUITABLE MEANS TILL THE TOP STUD IS INSTALLED. e.g. 6-5-M24-N2-150-875-G
24. FOR DAMAGED BOLTS, REPAIR PROCEDURE OF BOLT INCLUDING COATING PROCEDURE SHALL BE SUBMITTED FOR APPROVAL OF ENGINEER IN CHARGE.
SURFACE COATING (OPTIONAL)
NEI
G - GALVANISED
B - NO COATING
(DEFAULT OPTION - LEAVE FIELD BLANK FOR NO COATING)
THE DESIGN DRAWING SHALL SEPERATELY INDICATE BOLT TYPE, SIZE, NUMBERS
RPMS-A3-BDR-00
REQUIRED IN THE GROUP, BOLT PROJECTION ABOVE CONCRETE, NUMBER OF NUTS PER
BOLT, OVERALL LENGTH OF BOLT AND SURFACE COATING REQUIRMENT FOR EACH SET
LCBBW FF01
OF BOLT GROUP. SPECIFIC NOTES SHALL BE PROVIDED ON DESIGN DRAWINGS IF SPLIT
BOLT WITH COUPLING NUTS ARE REQUIRED.

\\srtcm j3es70\A0RI
RBS
2 04/03/22 SHEET-3 REVISED AS MARKED & ISSUED FOR IMPLEMENTATION CG PGN SPC SCALE : NTS
RBS
1 07/09/21 REVISED AS MARKED & ISSUED FOR IMPLEMENTATION CG PGN SPC STANDARD No. REV
RBS DRAWING TITLE:

0 25/08/20 ISSUED FOR IMPLEMENTATION CG PGN SPC RPMS-SD-C15-303
STANDARD CAST-IN ANCHOR BOLT WITH 2
REV DATE REVISION DESCRIPTION DRAWN BY CHECKED BY APPROVED BY DUCTILE DETAILING SHEET 1 OF 4
USERNAME : Chandan.Gawas DESIGN FILE : IP_PWP:dms07022\RPMS-SD-C15-303_SH1.dgn PLOT DATE /TIME: 04-MAR-2022 13:59: 10
(WHERE APPLICABLE)
INDENTED DOUBLE NUT D = BOLT DIA.
BOLT
D = BOLT DIA.
DOUBLE NUT
THREAD
LENGTH
D = BOLT DIA. ANCHOR BOLT
Z
CHAIR
GHTS ARE RESERV ED.
GROUT
T
DOUBLE NUT D = BOLT DIA.
T
T
P
P
X
P
TOC TOC
Z
T
BE INDICATED ON WORKING DRG)
P
GROUT
TOC TOC
G HT O W NER.ALL RI
GROUT
GROUT
Ld / Ldh
POCKET DEPTH
TED.
L
MI
S
C
ES LI
Ld / Ldh
OR 150MM
Ld / Ldh
F(DIA)
MAXM OF
NDUSTRI
L
C
INDENTED
C
OR 150MM
OR 150MM
O N O F THE CO PY RI
MAXM OF
MAXM OF
LENGTH
F(DIA) F(DIA)
°
B
35
ANCE I
35
6XD
°
°
(TO
RELI
35
35
35
35
t
Ld / Ldh
6XD
6XD
E
E
°
°
20 MIN.
15MM
TO
B SQ. TYP
t
SSI
Ld / Ldh
ETARY
Ld / Ldh
O R PERM I
REINFORCEMENT FOR
1.5D
1.5D
ON PROPRI
F
TENSION TRANSFER B SQ. B SQ.
SQ,OR ROUND
THOUT PRI
REINFORCEMENT FOR REINFORCEMENT FOR

C/2 C/2 TENSION TRANSFER TENSION TRANSFER
NFO RMATI
MAX. MAX.
TYPE 1
C/2 C/2 C/2 C/2
WI
FOR MINOR FOUNDATIONS FOR

STAIRS,LADDERS, HANDRAILING ETC. TYPE 5 MAX. MAX. MAX. MAX.
AL I
SCLOSED
WHERE TENSION IN BOLT IS NOT DEVELOPED TYPE 10 TYPE 10A

DENTI
BE REPRODUC ED,DI
NS CO NFI
DOUBLE NUT D = BOLT DIA.

S DO CUMENT C O NTAI
ANCHOR BOLT
Z
CHAIR
T
P
S DOC UMENT MAY
TABLE 2 FOR BOLT TYPE 1

AL DO C UM ENT.THI
TOC
DIA.
OF A B T F L = SHORTEST BOLT
GROUT
THER W HO LE NO R PART O F THI
BOLT LENGTH
L
LENGTHS
25mm
IN
DENTI
12 24 60 30 65 125
Ld / Ldh
ORDERED
OF
BOLT
OR 150MM
C ONFI
16 32 80 40 70 150
MULTIPLES
MAXM OF
F(DIA)
LONGER
BE
20 40 100 50 80 175
TO
°
°
35
35
6XD
E
NEI
Ld / Ldh
t
15MM
B SQ. TYP
REINFORCEMENT FOR
RPMS-A3-BDR-00
TENSION TRANSFER
LCBBW FF01
C/2 C/2
MAX. MAX.
TYPE 5A
\\srtcm j3es70\A0RI
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RBS
1 07/09/21 GENERALLY REVISED & ISSUED FOR IMPLEMENTETION CG PGN SPC STANDARD No. REV
RBS DRAWING TITLE:

STANDARD CAST-IN ANCHOR BOLT WITH 2
NOTES : (FOR TABLES 3 TO 6)
TABLE-3 APPLICABLE FOR BOLT TYPE 5
1. SHEAR CAPACITY OF BOLT (STEEL STRENGTH) IN COLUMN 3 MAY BE INCREASED BY
1 2 3 4 5 6 7 8 9
A FACTOR OF 1/0.8 = 1.25 IF BASE PLATE DIRECTLY RESTS ON CONCRETE OR IF THE
REINFORCEMENT FOR REINFORCEMENT
GHTS ARE RESERV ED.
BOLT CAPACITY GROUT THICKNESS IS < 0.5 * DIA. OF BOLT. THE SHEAR CAPACITY OF BOLT SHALL BE
FULL TENSION FOR FULL SHEAR BOLT DIMENSIONS (MIN.) PROJECTION DATA SLEEVES
SUITABLY REDUCED FOR FLEXURE AS PER RPMS-ENGG-DB-CS-001, IF GROUT THICKNESS
DIA. ULTIMATE ULTIMATE
TRANSFER TRANSFER IS > 2.5 * DIA. OF BOLT.OR 40 MM, WHICHEVER IS LESS.
OF TENSION SHEAR WELD
AREA OF STEEL AREA OF STEEL ANCHOR THREAD DIM. NUT WASHER 2. AREA OF REINF. FOR TENSION IN COLUMN 4 IS PERMITTED TO BE REDUCED PER DESIGN
BOLT (kN) (kN) SIZE
PLATE LENGTH THICKNESS THICKNESS COMPUTATIONS FOR NON-SEISMIC DESIGNS OR IF PROVISIONS OF OPTION (D) IN CL.17.2.3.4.3
(MIN) mm 2 (MIN) mm 2
L B x t T Z F S OF ACI 318M-14, THAT INCLUDES OVERSTRENGTH LOAD COMBINATION. ARE USED IN SEISMIC DESIGN.
"D" "P
t" "P
s" Fe500D/Fe500S Fe500/Fe500D 2 NUTS
G HT O W NER.ALL RI
3. AREA OF REINF. FOR SHEAR IN COLUMN 5 IS PERMITTED TO BE REDUCED PER DESIGN

16 47 19 151 53 600 35X12 75 45 15 3 50 130 6 COMPUTATIONS FOR NON-SEISMIC DESIGNS.
TED.
20 73 30 236 82 750 40X12 85 55 19 3 75 160 6 4. AREA OF REINF. FOR SHEAR IN COLUMN 5 MAY NOT BE VALID FOR TIES OR HAIRPINS
MI
ES LI
24 105 44 339 118 875 45X12 90 60 22 4 75 200 6 IN CASE OF PEDESTAL. TIES AND HAIRPIN ARRANGEMENT AND DESIGN SHALL BE AS PER
30 168 70 539 187 1075 60X16 100 70 26 4 100 240 8 PROCESS INDUSTRY PRACTICE STANDARD PIP STE05121.
NDUSTRI
36 245 101 785 272 1300 70X20 115 85 31 5 100 290 10 5. VALUE IN THE COLUMN 2 & 3 ARE BASED ON ULTIMATE STRENGTHS OF MATERIALS.
42 336 139 1076 373 1500 80X20 130 100 34 7 120 340 10 THESE VALUES SHALL BE DIVIDED BY THE FACTOR OF 1.5 TO ARRIVE AT WORKING
ANCE I
48 441 183 1414 491 1725 90X25 145 115 38 8 120 390 12 LEVEL CAPACITIES.
56 608 253 1948 676 1975 105X28 160 130 45 9 140 450 16 6. VALUES IN COLUMN 2 & 3 ARE BOLT CAPACITIES FOR UNCORRODED BOLTS & ARE TO BE USED FOR
RELI
64 802 333 2568 891 2250 120X32 200 150 52 9 140 515 16 CONNECTION BETWEEN CONCRETE & STEEL STRUCTURE. FOR CONNECTING MECHANICAL EQUIPMENT
TO FOUNDATION APPROPRIATE CORROSION ALLOWANCE CAN BE TAKEN BY REDUCING THE NET THREADED
TO
2
AREA & ACCORDINGLY BOLT CAPACITIES SHALL BE CALCULATED.
SSI
ETARY
O R PERM I
7. NO. OF BARS FOR TENSION AND SHEAR TRANSFER SHALL BE SO ADJUSTED THAT THE
TABLE-4 APPLICABLE FOR BOLT TYPE 10 MINIMUM AREA OF STEEL IS THAT GIVEN IN COLUMN 4 FOR TENSION AND COLUMN 5 FOR
ON PROPRI
SHEAR OF TABLE AND Ldh

PROVIDED SHOULD NOT BE LESS THAN.
1 2 3 4 5 6 7 8 9
THOUT PRI
BOLT CAPACITY REINFORCEMENT FOR REINFORCEMENT FOR BARS TERMINATING IN STANDARD HOOK. Ldh = MAX. OF 8 x db, 150mm OR
FOR FULL SHEAR BOLT DIMENSIONS (MIN.) PROJECTION DATA SLEEVES

NFO RMATI
FULL TENSION Fyb X db

DIA. ULTIMATE ULTIMATE CHAIR (18.8.5.1 ACI 318-14)
TRANSFER TRANSFER
5.4 0.8 f
WI
OF TENSION SHEAR ck Ldh MAY BE MODIFIED FOR BAR SIZE

HEIGHT
AREA OF STEEL AREA OF STEEL ANCHOR THREAD DIM.
AL I
SCLOSED
BOLT (kN) (kN) NUT WASHER LESS THAN 22 MM (X0.8) PER ACI
2 2 PLATE LENGTH F S (MAX) X
(MIN) mm (MIN) mm 318M-14 TABLE 25.4.2.4 ---- STD. HOOK
DENTI
L B x t T Z THICKNESS THICKNESS
SHALL BE AS PER TABLE 25.3.1 OF
BE REPRODUC ED,DI
"D" "P
t" "P
NS CO NFI
ACI 318M-14
30 361 150 1156 402 1650 80X36 125 70 30 4 100 250 400
ULTIMATE TENSION OR ULTIMATE SHEAR
36 526 219 1684 585 1675 95X40 140 85 36 5 100 250 400 WHERE,Fyb =
NUMBER OF BAR X AREA OF EACH BAR

42 722 300 2311 803 1950 110X45 160 100 42 7 120 300 500
db = DIA OF BAR
48 950 395 3040 1055 2025 125X48 175 115 48 8 120 300 550
56 1309 544 4189 1453 2250 145X55 200 130 55 9 140 350 600
Ld TO BE PROVIDED
AND MINIMUM
S DOC UMENT MAY
64 1726 718 5524 1915 2375 165X65 225 150 63 9 140 350 650 1 Fyb X db
FOR STRAIGHT LENGTH BARS IS Ld = CL. 25.4.2.2 (TABLE 25.4.2.2); Ld MAY BE
76 2319 964 7421 2573 2600 195X75 260 190 75 10 150 400 700
1.7 0.8 f
100 4170 1734 13344 4627 ck MODIFIED FOR BAR SIZE < 22MM
2900 260X100 335 250 99 12 200 500 700
AL DO C UM ENT.THI
TABLE-5 APPLICABLE FOR BOLT TYPE 10A TABLE-6 APPLICABLE FOR BOLT TYPE 5A
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9
DENTI
BOLT CAPACITY REINFORCEMENT FOR REINFORCEMENT BOLT CAPACITY REINFORCEMENT FOR REINFORCEMENT
BOLT DIMENSIONS BOLT DIMENSIONS
FULL TENSION FOR FULL SHEAR PROJECTION DATA SLEEVES FULL TENSION FOR FULL SHEAR PROJECTION DATA SLEEVES
C ONFI
(MIN.) (MIN.)
DIA. ULTIMATE ULTIMATE DIA. ULTIMATE ULTIMATE CHAIR
TRANSFER TRANSFER TRANSFER TRANSFER
OF TENSION SHEAR OF TENSION SHEAR WELD
HEIGHT
AREA OF STEEL AREA OF STEEL ANCHOR THREAD DIM. AREA OF STEEL AREA OF STEEL ANCHOR THREAD DIM. NUT WASHER
SIZE
BOLT (kN) (kN) LENGTH NUT WASHER S BOLT (kN) (kN) LENGTH
PLATE F PLATE (MAX) X
(MIN) mm 2 (MIN) mm 2 (MIN) mm 2 (MIN) mm 2 THICKNESS THICKNESS
L B x t T Z THICKNESS THICKNESS L B x t T Z F S
NEI
"D" "P
t" "P
s" Fe500D/Fe500S Fe500/Fe500D 2 NUTS "D" "P
t" "P
30 361 150 1156 402 1250 80X36 125 70 30 4 100 250 16 47 19 151 53 975 35X12 75 45 15 3 50 100 6 400
36 526 219 1684 585 1275 95X40 140 85 36 5 100 250 20 73 30 236 82 1100 40X12 85 55 19 3 75 150 6 400
42 722 300 2311 803 1450 110X45 160 100 42 7 120 300 24 105 44 339 118 1150 45X12 90 60 22 4 75 150 6 400
48 950 395 3040 1055 1475 125X48 175 115 48 8 120 300 30 168 70 539 187 1350 60X16 100 70 26 4 100 200 8 400
56 1309 544 4189 1453 1650 145X55 200 130 55 9 140 350 36 245 101 785 272 1475 70X20 115 85 31 5 100 200 10 400
RPMS-A3-BDR-00
64 1726 718 5524 1915 1725 165X65 225 150 63 9 140 350 42 336 139 1076 373 1725 80X20 130 100 34 7 120 250 10 500
76 2319 964 7421 2573 1950 195X75 260 190 75 10 150 400 48 441 183 1414 491 1925 90X25 145 115 38 8 120 250 12 550
LCBBW FF01
100 4170 1734 13344 4627 2250 260X100 335 250 99 12 200 500 56 608 253 1948 676 2175 105X28 160 130 45 9 140 300 16 600
64 802 333 2568 891 2400 120X32 200 150 52 9 140 300 16 650
\\srtcm j3es70\A0RI
RBS
RBS
RBS DRAWING TITLE:

STANDARD ANCHOR BOLT WITH 2
5
TOP OF 7
CONCRETE V d
b
NUT
6 1.5C
50
GROUT N
1 2 3 1 2 3
LAYER A
GHTS ARE RESERV ED.
Ldh
35°
C
LAYER B
75
LENGTH
4 5 4 5
PROJ
Ld
Ldha ANCHOR
STUD
6 7 8 6 7 8 REINFORCEMENT
G/2
TOC 0.5C
G HT O W NER.ALL RI
TED.
B
G
ANCHOR REINFORCEMENT
MI
LAYER A LAYER B
ES LI
ELEVATION
FOR SHEAR TRANSFER
COUPLING NUT
G/2
NDUSTRI
IN PEDESTALS 1.5C
25
N
AS SMALL AS POSSIBLE
ANCE I
OBSERVING COVER
C
REQUIRMENTS 35°
RELI
Ld v
Ld
SPLIT BOLT WITH COUPLING NUT
TO
ANCHOR
SSI
OPTIONAL WITH BOLT TYPE 5 & 5A GROUP ANCHOR

ETARY
v
O R PERM I
C v 35° REINFORCEMENT
C 0.5 C
ON PROPRI
35° ANCHOR ANCHOR REINFORCEMENT

ANCHOR ANCHOR
35° GROUP PLACED SYMMETRICALLY
THOUT PRI
GROUP REINFORCEMENT
NFO RMATI
SECTION B
ANCHOR SECTION C
WI
REINFORCEMENT
AL I
PLAN PLAN
SCLOSED
(ANCHOR REINFORCEMENT
DENTI
(HAIRPIN ANCHOR REINFORCEMENT FOR SHEAR) FOR TENSION)

BE REPRODUC ED,DI
NS CO NFI
C/2 PEDESTAL C/2

Ldh Ld REINFORCEMENT
MAX. MAX.
Ldh AS SMALL AS POSSIBLE REINFORCEMENT PEDESTAL
OBSERVING COVER
EDGE
REINFORCEMENT REQUIREMENT
S DOC UMENT MAY
ANCHOR BOLT
V ANCHOR BOLT
2
TOC
K
1
K
AL DO C UM ENT.THI
S1
MAX.
C/2
K2
b
A ANCHOR
MAX.
12 d
~35°
C/2
~
1
INFLUENCE AREA
K
REINFORCEMENT
BARS EFFECTIVE AS
DENTI
V ANCHOR REINFORCEMENT
PLAN-A
C ONFI
ANCHOR GROUP S1 K2
C/2
MAX. PEDESTAL
K
THE LESSER OF 0.5
1 INFLUENCE AREA
~
~ AND 0.3 K
2
PLAN-C
°
35 ANCHOR BOLT
NEI
MAX.
C/2
PEDESTAL REBARS ONLY WITHIN THE
1
K
INFLUENCE AREA ARE TO BE USED AS
SECTION A ANCHOR REINFORCEMENT
S1 :- SPACING
S1 K2
RPMS-A3-BDR-00
REINFORCEMENT K1 :- EDGE DISTANCE OF BOLT IN

DIRECTION OF SHEAR FORCE
INFLUENCE AREA
LCBBW FF01
K1 NOTE :-
K2 :- EDGE DISTANCE OF BOLT IN
HAIRPIN ARRANGEMENT CAN BE PROVIDED FOR TENSION AND
ANCHOR REINFORCEMENT FOR SHEAR TRANSFER DIRECTION PERPENDICULAR
SHEAR TRANSFERED ACCORDING TO PROCESS INDUSTRY PRACTICES- PIP STE05121.
PLAN-B
TO SHEAR FORCE
\\srtcm j3es70\A0RI
RBS
RBS
RBS DRAWING TITLE:

STANDARD ANCHOR BOLT WITH 2
USERNAME : Chandan.Gawas DESIGN FILE : IP_PWP:dms07022\RPMS-SD-C15-303_SH4.dgn PLOT DATE /TIME: 04-MAR-2022 14:11 : 17
Electrical Design Basis

RPMS-ENGG-DBD-EL-001
0 25.08.2020 Issued for Implementation PT VGS / US SK / VKM
Prepare Checked Approved

Rev Date Revision Details
By By By
Reliance Project Management System RPMS-ENGG-DBD-EL-001
Electrical Design Basis Date: 25.08.2020, Rev 0

(DD.MM.YYYY)
1 Sundaram Kannan (Chairman) _________________ ___________
2 Ravi Ayyagari _________________ ___________
3 Sudhir Pawar _________________ ___________
5 _____________________________ _________________ ___________
6 _____________________________ _________________ ___________
7 _____________________________ _________________ ___________
8 _____________________________ _________________ ___________
9 _____________________________ _________________ ___________
10 _____________________________ _________________ ___________

RECORD OF REVISIONS
Revision
Date Revision Details
Number
25.08.2020 First Issue 0

Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
4. Abbreviations and Definitions ..................................................................................... 2
7. Supplier Data ............................................................................................................. 44
Appendix A: CODES AND STANDARDS ................................................................................ 45
Appendix B: PROJECT STANDARD SPECIFICATIONS & BEDDs ............................................. 50
1. Scope
This Design Basis is prepared to define the minimum requirements for the electrical
design, selection and protection of Electrical equipment for RIL Projects and shall
be read in conjunction with all other project specifications and the requirements of
applicable codes, standards and regulations.
The purpose of this document is to ensure safety to personnel and equipment
during operation and maintenance in general and safe starting, safe operation and
safe shutdown of units under all conditions. The scope covers both the scope of
specifications and the scope of facilities.
Project Standard Specifications as listed in Appendix B shall be applied to RIL
projects. The specifications prescribe the basic minimum requirements and
principles for the electrical design, selection, and protection of electrical
equipment, materials and installation.
The electrical facilities shall include power, lighting, earthing and supplies to
electricity consuming apparatus throughout the plant. The design basis shall ensure
safety and continuity of operations under defined conditions.
Any relevant process licensor`s requirement shall be incorporated as mandatory
overriding condition.
2. References
Referenced documents like design standards, electrical equipment standards and
other relevant for this document are listed in Appendix A and Appendix B. The latest
edition of the referenced document (including any amendments) shall be
applicable. All interdisciplinary documents shall be taken into cognizance.
Regulations, practices as listed in Appendix A shall also be read in conjunction with
this document.
In the event of a conflict or deviations from requirements stipulated in this
document and other applicable documents, the following order of precedence shall
govern:
1. Equipment Data sheets and Drawings
2. The Material Requisition of the equipment
3. This Design Basis
4. Codes and Standards specifically referred
5. Other National & International Standards as referenced

commercial implications. All local and statutory requirements as applicable shall be
complied to without any deviation.
Notes:
Requisition – Busduct Datasheets, Busduct Stock Code Item Description.
Order.
Abbreviations:
ATEX ATmosphères EXplosives
BS British Standards
CBIP Central Board of Irrigation and Power
CIMFR Central Institute of Mining & Fuel Research
CPP Captive Power Plant
DCS Distributed Control System
DGCA Directorate General of Civil Aviation
EHV Extra High Voltage
EMC Electromagnetic compatibility
EMS Energy Management System
HVAC Heating, Ventilating and Air Conditioning
HV High Voltage
IEC International Electro technical Commission
IEEE Institute of Electrical and Electronics Engineers
IECex International Electrotechnical Commission System for
Certification to Standards Relating to Equipment for Use in
Explosive Atmospheres
IP Ingress Protection

IRP Interposing Relay Panel

IS Indian Standards
LED Light Emitting Diode
LV Low Voltage
MCC Motor Control Center
MOV Motor Operated Valve
MRS Main Receiving Station
NFPA National Fire Protection Association
OFAF Oil Forced Air Forced
OISD Oil Industry Safety Directorate
ONAF Oil Natural Air Forced
ONAN Oil Natural Air Natural
OWS Oily Water Sewage
PCC Power Control Center
PD Partial Discharge
PESO Petroleum and Explosive Safety Organization
PIB Process Interface Building
PLC Programmable Logic Controller
PMCC Power Motor Control Center
PU Poly Urethane
SI Système international d'unités (International System of Units)
UCP Unit Control Panel
VRLA Valve Regulated Lead Acid
VSD Variable Speed Drive
XLPE Cross-linked polyethylene

Definitions:
Supplier Party which manufactures or supplies equipment and services to
Buyer Owner (Reliance) or Owner-appointed DEC or EPC who specifies

Owner Reliance Industries Limited or specified Reliance Group
Company

The selection of electrical equipment and systems shall be governed by fitness for
purpose, safety, reliability, maintainability, during service life and compatibility
with specified future expansion, design margins, suitability for environment, and
economic considerations.
The Project Standard Specifications listed in Appendix A shall be utilized in the
design, testing, commissioning and purchase of all electrical equipment and
systems.
Service Conditions
5.1.1. All electrical equipment, systems and their installation shall be engineered to be
suitable for operation under site conditions.
5.1.2. Equipment and systems shall have a design life of at least 25 years.
5.1.3. Marine equipment life shall be in accordance with applicable guidelines. The design
life shall be in excess of 25 years under all conditions.
5.1.4. Electrical equipment intended for outdoor installation shall have minimum Ingress
Protection to IP55. LED type street light / outdoor fittings shall have minimum
Ingress Protection to IP66.
5.1.5. Electrical equipment intended for indoor installation shall have minimum Ingress
Protection to IP41.
5.1.6. Ingress protection for Zone 20, Zone 21 & Zone 22 equipment shall be minimum as
per IS/ IEC 61241 & IEC 60079-31.

5.1.7. All equipment and materials shall be suitable for operation in service conditions
typical of a Refinery/Petrochemical plant within a coastal environment in the
tropics. The atmosphere is to be considered saline, sulphurous and dusty. The
possibility of condensation exists, as experienced during large temperature
variations in a humid environment.
5.1.8. Equipment located indoors shall normally work in forced ventilated/air-
conditioned environment. However, failure of cooling or ventilation shall not affect
the operation of these equipment. For Highly polluted area, additional filter for
equipment ventilation system may be considered.
5.1.9. Soil resistivity data (Electrical resistivity for grounding calculation and thermal
resistivity for UG cable sizing in Duct bank) obtained from Geotechnical
Investigation Report shall be used.
5.1.10. In areas where the soil may become contaminated due to hydrocarbon spillage,
electrical cables shall be installed in suitable concrete trenches/ duct banks and
shall not be installed directly buried underground.
5.1.11. Site specific controlled Basic Engineering and Design Document (BEDD) shall be
referred for service conditions.
System Design
5.2.1. The design of electrical system shall include but not be limited to the following:
i) Planning and basic power distribution system and single line diagram
ii) Hazardous area classification
iii) Electrical Substation Design for New Substation / expansion / modification
iv) Specification of main electrical equipment
v) Lighting system
vi) Earthing system
vii) Cabling system, underground and above ground, including cable tray
support and routing through pipe racks
viii) Power system studies
ix) Electrical Heat Tracing,
x) Cathodic Protection
xi) Public Address System.
xii) Siren system
xiii) Lightning system
xiv) Energy Management System (EMS) / Automation system
5.2.2. The designed electrical system shall facilitate and provide:
i) Standard products application

ii) Safety to personnel and equipment

iii) Reliability of service
iv) Constructability access
v) Cabling access
vi) Minimum fire risk
vii) Cost effectiveness
viii) Ease of maintenance and convenience of operation
ix) Adequate provision for changes during design development and for future
expansion and modification (as appropriate engineering margins and or
space provisions)
x) Adequate redundancy to ensure minimum impact to operations
xi) Provision for future automation
xii) Maximum interchangeability
xiii) Automatic protection of all electrical equipment and isolation of faulty
system through selective relaying systems or intelligent control devices.
xiv) Remote control and monitoring facilities & interfacing for selected devices
with other discipline systems.
System Studies
5.3.1. Study/Calculations shall be carried out to substantiate the selection and sizing of
all electrical facilities, e.g. transformers, bus-duct, switchgear, cables.
5.3.2. Relevant system studies shall be carried out for adequacy check, if any major
equipment added, deleted or changes made in existing Main Receiving Substations.
Required system studies for these changes shall be approved by Owner.
5.3.3. Study shall include, but not be limited to the following:
i) Plant and Unit Electrical Load
ii) Load Analysis
iii) Load Flow Study
iv) Motor Starting Study
v) Short circuit study (Fault Calculations)
vi) Power Factor
vii) Feeder and Circuit Voltage Drop
viii) Relay Settings & coordination
ix) Earthing
x) Lighting Calculations (Indoor/Outdoor/Egress)
xi) Lightning Study (Protection of structures against lightning)
xii) Re-acceleration Study, when specified

xiii) Auto Changeover & Fast Bus Transfer Study

xiv) Harmonic Study
xv) Islanding Study
xvi) Transient Stability and Switching Studies including Transformer
Energization. Transient analysis shall be carried out for various scenarios but
not limited to tie-in line cables switching and outgoing cable switching for
EHV system. For the Transient system study recognized software/tool shall
be used for the transient system study
xvii) Load shedding study
xviii) Insulation coordination study
xix) Sound Propagation Study, if required
xx) Arc Flash Study
xxi) Reliability and Availability Analysis, when specified
xxii) Multi scenario studies to identify minimum generation requirement to
energies specific transformer and to start specific large motor in island
mode and integrated mode.
xxiii) Any other specialized study, as required.
Power Supply
5.4.1. Main Power Sources and Systems
5.4.1.1. The main power source is captive power generation with primary distribution
proposed to be preferably at 33 kV.
5.4.1.2. The system may be connected to the utility grid.
5.4.1.3. Primary power distribution shall be governed both from considerations of power
distribution capacity and from considerations of process flare loading under
abnormal plant operating conditions. Flare loading and the required Electrical
distribution to mitigate excess flare loading shall be decided by process group based
on process hazard analysis.
5.4.1.4. Electrical system configuration will be as follows:
i) PLANT DISTRIBUTION
6.6 kV, 11 kV, 690 V and 415 V - Three phase
240 V and 110 V - Single phase
Plant Primary HV Distribution Voltage 33 kV ± 10%, 50 Hz ± 3%, 3 Wire
Plant Secondary HV Distribution Voltage 6.6 kV ± 10%, 50 Hz ± 3%, 3 Wire
Plant LV Distribution Voltage 415 V ± 10%, 50 Hz ± 3%, 4 Wire

Plant LV Distribution Voltage 240 V, ± 10%, 50Hz ±3%, 3 Wire

Emergency Generation & Distribution 415 V ± 10%, 50 Hz ± 3%, 4 Wire
Or
6.6 kV ± 10%, 50 Hz ± 3%, 3 Wire
(Based on the emergency load
requirements)
ii) POWER PANELS

Auxiliary Distribution Board 415 V, ± 10%, 50Hz ± 3%, 4 wire
Package Panels Single point supply per package at
415 V, ± 10%, 50 Hz, ±3%, 4 wires
(shall be decided on case to case basis)
iii) SOCKETS & RECEPTACLES
Welding Receptacles 415 V ± 10%, 50 Hz ± 3%, 5 PIN (Three
phase, Neutral and Earth)
Convenience Receptacle 240 V, ± 10%, 50Hz ±3%, 3 PIN
5.4.1.5. On case to case basis, other standard voltage levels may be considered for HV
Distribution, LV Distribution and Emergency Generation & Distribution levels if
required from power system perspective.
5.4.2. Plant Emergency Power Sources and Systems
5.4.2.1. Emergency power generating capacity shall be provided to satisfy the critical
services necessary to permit safe plant shutdown in the event of main power
failure.
5.4.2.2. Emergency power in the process complexes shall be generated by the use of
electrically started diesel engine driven generator sets which shall be located at the
associated main/satellite substation(s).
5.4.2.3. Each major plant substation (or group of substations) shall be provided with local
adequately rated emergency generating plant and emergency switchboard(s).
5.4.2.4. The emergency generating plant shall be arranged to start up and connect to the
emergency busbar automatically should the normal supply fail.
5.4.2.5. From the emergency switchboard in each major plant substation, emergency
supply shall also be distributed to plant satellite substations. If satellite substations
warrant large emergency power due to load size or distance from unit substation,
the satellite substation shall be provided with dedicated emergency diesel engine
Generator set and it's distribution network.
5.4.3. Utilization
5.4.3.1. Utilization voltage for electric motors (Note-1) will be as follows:
Rating Utilization Voltage
Up to 0.37 kW 415 V, 3 phase, (415 V ± 10%, 50 Hz ± 3%, 3 Wire)

(Note 3)
(240 V, 1 Phase motors only permitted, if 3 phase
motors are not available and single phase motors
are accepted by Buyer)
Above 0.37 kW up to and 415 V, 3 phase, (415 V ± 10%, 50 Hz ± 3%, 3 Wire)
including 160 kW Note-2
Above 160 kW 6.6 kV, 3 phase, (6.6 kV ± 10%, 50 Hz ± 3%, 3 Wire)

Note-1: Not applicable for motors running on variable speed drives
Note-2: In exceptional cases, 690 V shall be considered for low voltage motors.
The cases shall be evaluated individually, for merit, before motors with nominal
voltage other than 415 V are selected. Overlap/ marginal motor selection for LV
and HV shall be considered on a case-by -case basis if additional 690 V is
considered in the system.
Note-3: The preference shall be for 3 phase equipment wherever possible;
However, Chemical dosing pumps and more intricate electrical apparatus may
require a single-phase feed. In such instances, exceptions from the above may be
permitted.
5.4.3.2. Generally, for motors rated above 3500 kW, consideration shall be given to use of
assisted start through unit transformers (step down transformer, primary HV to
11.5 kV) connected directly to the Primary HV distribution system or a soft-starter
based on techno-commercial evaluation. This requirement shall be governed by
system studies. The neutral of the 11 kV system shall be resistively earthed.
5.4.3.3. Variable Speed Drives shall be provided for motors where required by process
control requirements / energy optimization. The voltage drop in line chokes, filters
and cables shall be considered while sizing variable speed drive driven systems.
5.4.3.4. The kW ‘break point’ between utilization voltages may be varied for individual cases
where this will provide an economical advantage.
5.4.3.5. Power to electrical systems (excluding motors) shall be provided as follows:
i) MOVs 415 V ± 10%, 50 Hz ± 3%, 3 Wire
ii) LIGHTING CIRCUITS
Normal Lighting Luminaries 220 Volts ± 10%, 50Hz ±3%, 3 wire

Emergency lighting luminaries 220 Volts ± 10%, 50Hz ±3%, 3 wire, when
fed from emergency supply (considering
(Power from DG on failure of
lighting transformers being used for
Normal Power) plant loads on all sites by now)
Substation and PIB lighting 220 V ± 10%, 50 Hz, ±3%, 3 wire

(fed from dedicated inverter)
iii) PROCESS HEATERS
Heaters above 3 kW 415 V ± 10%, 50 Hz ± 3%, 3 Ph, 3 Wire
Heaters up to 3 kW 240 Volts ± 10%, 50Hz ±3%, 3 Wire.
iv) NON-PROCESS HEATERS
Panel space Heater 240 Volts ± 10%, 50Hz ±3%, 3 Wire
Motor space Heater (37 kW and 240 Volts ± 10%, 50Hz ±3%, 3 Wire
above)
Motor space Heater (Below 37 kW) 24 Volts ± 10%, 50Hz ± 3%, 2 Wire
v) INSTRUMENTATION POWER
DCS / PLC / Automation Power 110 V +6% - 3%, 50 Hz +/- 1%, 2 Wire.
EMS (Control room equipment) 110 V +6% - 3%, 50 Hz +/- 1%, 2 Wire.
vi) CONTROL VOLTAGE
MCCs 240 Volts ± 10%, 50 Hz +/-3%, 3 Wire
EMS/RIO (for panel space heaters, 240 Volts ± 10%, 50 Hz +/-3%, 3 Wire
fans and lighting)

5.4.3.6. 220V DC systems shall be provided for circuit breaker controls, relays and
substation monitoring equipment.
CONTROL VOLTAGE
HV Switchgear 220 Volts +10%, -15%, dc, 2 Wire
LV PMCC/PCCs 220 Volts +10%, -15%, dc, 2 Wire
Protection relays 220 Volts +10%, -15%, dc, 2 Wire
EMS/RIO (For electronic equipment) 220 Volts +10%, -15%, dc, 2 Wire
Standalone MV / LV VSD Panel, VSD MCC 220 Volts +10%, -15%, dc, 2 Wire
5.4.3.7. Lighting shall operate at 220 V, 50 Hz derived from a phase-to-neutral connection

on a 415V / 400V, 3 phase 4-wire lighting transformer secondary system. Primary
distribution and supply to plant area and street lighting may be with three phase 4-
wire circuits.
5.4.3.8. Equipment shall be designed and selected according to the specified maximum
short circuit levels.
5.4.4. AC Voltage and Frequency Tolerances (Except for Motors)
i) Steady State Limits
a) Non-UPS
Voltage ± 10%
Frequency ± 3%
The combined voltage and frequency deviation shall not exceed an
absolute value of 10 %
b) UPS
UPS main bus bar Voltage (115 V) ± 1%
Equipment Voltage (110 V) +6%, -3%
Frequency ± 1% feed via inverter
± 3% feed via bypass transformer
ii) Transient Limit for normal loads
Voltage +10%, - 20%
Frequency ± 5%

5.4.5. System Harmonics

The limitations of harmonics currents & voltages appearing at point of common
coupling (PCC) in the system shall comply with IEEE 519 and IEC 61000-3-
6, Standard Practices and Requirements for individual & total harmonic distortion
considering the design values at the worst case system operating scenario that
could extend longer than one hour of normal operation.
5.4.6. Power Factor corrections
Power factor correction devices shall be provided, if required based on the
acceptable power factor values.
Power Distribution
5.5.1. General
5.5.1.1. A load summary shall be prepared for recording and calculating the electrical loads.
This Load Summary shall be revised during the detail development phase of the
project to reflect ‘as purchased’ load ratings. The Load Summary shall indicate
continuous, intermittent and stand-by loads.
5.5.1.2. The maximum running plant load shall be determined as follows:
Load = 100% (Continuous) + 50% (Intermittent) or largest intermittent load,
whichever is more
5.5.1.3. The peak running plant load shall be determined as follows:
Load = 100% (Continuous) + 50% (Intermittent) or largest intermittent load if
greater + 10% (Standby) or largest standby load, if greater.
This shall be used to verify the numbers and rating of Transformers, Emergency
Diesel Generator, Switchgears and other associated equipment.
5.5.1.4. An allowance for future and contingency, multiplication factor of 1.10 shall be
applied to the plant maximum running load for deciding the rating of equipment.
5.5.2. Main Power Distribution
5.5.2.1. Primary HV distribution switchgears for main power distribution shall be housed in
a number of main receiving substations (MRSs).
5.5.2.2. The MRSs will provide power at primary HV distribution level to the unit substations
located in process complexes, off-sites, utilities, marine terminal and tanker berth
facility. Step down power transformers shall be located at each major substation,
as required.
5.5.2.3. Satellite substations shall be provided near load centers based on techno-economic
considerations. These shall generally be fed from major substations by secondary
HV distribution feeders.
5.5.2.4. Tri-vector meter shall be provided wherever tariff metering is required. The tri-
vector meter shall be installed in a separate panel independent of the switchgear

and shall be connected through a dedicated sealable current and potential

transformer.
5.5.2.5. LV power shall be provided at substations by means of local 6.6/0.433 kV, 11/ 0.433
kV and 33/0.433 kV transformers, as required.
5.5.2.6. Secondary Selective power supply will be provided to switchboards which supply
power to all loads essential for the continuous operation of the facility.
5.5.3. Within the process areas, primary distribution of power shall be by means of
directly buried cables, unless designed otherwise. Permissible voltage drop in
cables shall be as follows:
Feeder cables/ Feeder Permissible
Remarks
Circuits Voltage Drop in %
Main Feeders
(e.g. Incomers, Tie Incomers & 1% At full rated current
Outgoing to Tie Boards)
At full load current running
Motor Feeders 5%
condition
(excluding VSD driven motors)
15% At starting condition
Secondary Feeders
(lighting, small power and 2% At full rated current
other low voltage circuits)
Lighting sub-circuits 5% At the farthest fitting
Voltage drop in cables- DC
5% -
Circuits
5.5.3.1. Where by applying the above permissible volt drops result in to excessively
oversized cables, each case is to be individually assessed taking the end user
requirements into account (e.g. for a main feeder to a transformer having ‘taps’,
the volt drop in that feeder may exceed the above specified percentage. This
increased volt drop can be compensated by the transformer tap(s), if the
transformer secondary voltage remains within specified tolerances from zero load
to full load on the transformer).
5.5.3.2. During any motor start, voltage at the motor terminal of motor being started, shall
not be less than 80 % of the rated voltage. Voltage at associated bus and other
bus(es) should not be less than 90 % of the bus base voltage to avoid contactor
drop off or stalling of any of the running motor.
5.5.3.3. In cases where the PCC and MCC are situated in different substations, the feeder
cable from PCC to MCC shall be sized based on maximum MCC connected load with
a 20% future load growth margin.

5.5.3.4. For identified process critical single line equipment, number of runs for cable circuit
shall be with N+1 configuration wherein continuity of service (at rated capacity of
circuit) shall be available even after outage of one run.
Substations
5.6.1. General
5.6.1.1. All substations shall be strategically located near load centers and outside
hazardous areas. Substation buildings shall be force ventilated with filtered air and
shall generally comprise elevated structures permitting the use of bottom entry
switchgear with cable cellar for cable racking and trays below. Sub-station with
cable trench (without cable cellar) shall be considered on case to case basis after
due techno-commercial evaluation and implementation feasibility.
5.6.1.2. Batteries shall be housed in separate rooms. VRLA batteries shall be located in an
environment where the ambient temperature does not exceed 25 oC. An access
door shall lead directly to the outside from each switch room. Internal personnel
doors may connect adjacent rooms.
5.6.1.3. Ventilation system of substation shall trip on activation of fire and gas detection
signal.
5.6.1.4. Manometer shall be considered for pressure monitoring as part of HVAC system.
5.6.1.5. Chemical filter and gas detection shall be provided in substation pressurization
system and HVAC system.
5.6.1.6. Temperature, humidity monitor, and transmitter shall be considered as part of
instrumentation / building management system or similar monitoring system.
5.6.1.7. Heat sensitive electronic equipment like variable speed drives shall be located in a
separate room provided with air conditioning.
5.6.1.8. Substations shall be provided with smoke extraction fans which shall be fed from
Emergency bus of nearby substations through dedicated cables.
5.6.1.9. Failure of Battery Room exhaust fans status should be wired to Battery Charger and
AC UPS to inhibit the boost charging.
5.6.1.10. Gas detectors shall be installed in Battery Rooms and the status of the detector
shall be taken to associated control rooms.
5.6.1.11. Electrical equipment (e.g. light fittings, sockets, junction box, temperature sensors,
etc.) for use in battery rooms shall be certified for Zone 2 gas group IIB + H2 or IIC
and temperature class T3 if as VRLA batteries are used and shall be certified for
Zone 1 gas group IIB + H2 or IIC and temperature class T3 if vented type lead acid
batteries / Ni-CD batteries are used.

5.6.1.12. At least two escape routes shall be made available in the Switchgear room with exit
doors and each exit at least to cover an escape (egress) route/distance of 20 meters
(for voltage up to 52kV) as per IEC 61936 - Part 1.
5.6.2. Transformer Bay Layout
5.6.2.1. Oil filled transformers shall be located at grade level in fenced enclosures adjacent
to the substation building and shall be provided with oil containment pits with
suitable drainage system/ gully sucker.
5.6.2.2. Fire walls shall be provided based on oil volume, and as per the relevant codes and
standards. Transformers shall be located in safe area. Transformer area floor shall
be minimum 300 mm above the grade level of substation plot. Required fire
protection and prevention system shall be provided where applicable by codes &
standards and CEA (Central Electricity Authority) regulations. Fire suppression
system shall not impact escape route.
5.6.2.3. Outdoor certified (IP55 rated) emergency stop push button with shrouding facility
shall be provided nearby the Transformers.
5.6.2.4. The following shall be considered as minimum for Transformer bays:
Height of Fence : 2.4 m (Chain link fence)
Clearance : 1.00 meter clear from all sides (minimum)
Separation : Fireproof wall extending 600 mm above highest point
Between of transformer, Separation as per OISD Standard 173
Transformers
Aggregate Oil : Transformer Installed adjacent to substation building
capacity up to shall be provided with layer of 100 mm deep stones of
2000 Liters about 40 mm granulation, all around the transformer,
for a width equal to 20% of the transformer height or
with a minimum width of about 800 mm. Transformers
shall be provided with oil containment pits.
Aggregate Oil : Transformers installed adjacent to substation building
capacity exceeding shall be provided with oil soak pit/containing pits. Oil
2000 liters containing pit may be shaped as per OISD standard
173. The pit shall extend all around the transformer for
a width equal to 20 % of the transformer height, with a
minimum width of around 800 mm. In case oil capacity
exceeds 9000 liters, in any chamber, provision shall
made for draining of oil with separate oil catchments
sumps to remove the excess oil.

5.6.3. Switchgear Area Layout
Spare Space : To install two vertical sections on either

side of HV and LV switchgear in general.
Minimum Clearance (Clear) : Minimum clearance shall be as follows,
for general guideline unless otherwise recommended by
equipment Supplier
a) Front clearance of all : 2500 mm for 33 kV Panel
Switchboard /panels in 2000 mm for 11 kV/ 6.6 kV Panel
general.
1500 mm for PMCC /MCC
b) Rear clearance for panels : Less than 200 mm or more than 750 mm
having maintenance access
from front only
c) Rear clearance for panels : 1500 mm for 33 kV /11 kV /6.6 kV Panel
requiring maintenance 1000 mm for 415 Volt panel
access from rear panels in
general.
d) Side clearance between : Minimum 750 mm after considering space
two switch boards or from for future panels or extension of panels
nearest obstruction
e) All around clearance for : 1000 mm (minimum)
Dry type transformer
f) Battery Rack to wall : 100 mm
clearance-Single row /
Single / double tier
Double row, single tier : 100 mm
Double row / Double tier : 1000 mm
Battery rack to rack : 1000 mm
clearance
g) Head room clearance : 1000 mm (minimum) (Unless specified
between top of switchgear otherwise by Supplier)
/part of it to bottom of roof
beam
h) Front clearance for wall : 750 mm or equal to width of door
mounted equipment whichever is higher.

i) GIS : Minimum all around clearance and

vertical clearance shall be as per Supplier
recommendation
j) Consideration of Cable : Substation design shall be with cable
cellar cellar. Cellar floor shall be raised 300 mm
above the grade level
Cabling in Plant Area : Generally, above ground, using pre -
fabricated hot-dipped galvanized steel
cable trays. For corrosive areas and
cooling tower area (suitable material of
construction – Aluminium or FRP -for
cable trays to be selected based on the
chemistry of acid. However, FRP trays
shall not to be used in hazardous area).
Supply cables of redundant systems,
including Incomers, shall be separated by
minimum 1000 mm.
Cabling in Substation : In cellar, using Ladder Trays in general.
There shall be at least one corridor with
Head room of 1.8 meter min along the
length of the substation. Spacing between
cable tray & top layer of cable tray shall
able to accommodate cable bending
radius of cable with largest bending
radius. The corridor shall connect to
nearest emergency exit doors of cable
cellar.
k) Fire protection equipment : Fire Extinguisher, first aid box and other
safety equipment are required as per
statutory requirements. Insulating mats of
required voltage rating shall be provided
in front of switch boards. Fire protection
of transformer and substation shall
comply to requirements of OISD –STD -
173
5.6.4. CPP EHV Switchyard & Substation

Project specific CPP design basis to be referred for details on EHV Switchyard,
interconnection with state electricity grid and interconnection with existing
complexes.

5.6.5. Main Receiving Substations (MRSs)

A number of Main Receiving Substations shall be provided within the captive power
plant area depending on the total load. Each MRS shall accommodate the primary
HV distribution switchboard(s) for main power distribution, LV switchboards and
Motor Control Centers for MRS auxiliaries.
5.6.6. Plant Area Substations
Plant area substations shall be designated to be either a ‘Unit Substation’ supplied
with power at 33 kV and housing both 6.6 kV and LV systems, or as ‘Satellite
Substation’ supplied with power at 6.6 kV (from one of the Unit Substations) and
which may house only LV distribution.
Hazardous Areas
5.7.1. Hazardous Area Classification
5.7.1.1. Plant areas shall be classified in accordance with IS 5572 - Classification of
hazardous areas (other than mines) having flammable gases and vapours for
Electrical installation.
5.7.1.2. Area handling combustible dust shall be classified as Zone-20, Zone -21 and Zone -
22 as per IEC-60079-31 and selection of the equipment shall be done accordingly.
5.7.2. Equipment Selection
5.7.2.1. Electrical equipment shall meet the requirements of the Indian Standard IS 5571 -
Guide for Selection of Electrical equipment for hazardous areas (other than mines),
or the Institute of Petroleum Model Code of Safe Practice: Part 15, IEC 60079, Part
14 shall be followed for the selection of fluorescent fittings used in Gas Group IIC
areas.
5.7.2.2. Electrical equipment manufactured outside India and to be used in hazardous areas
falling within the purview of latest Petroleum Rules, shall be approved by PESO
before use.
5.7.2.3. PESO does not provide certificates for Dust hazardous Zone 20, 21 & 22 items. For
these motors, Suppliers shall submit certificates from nationally and/or
internationally recognized Laboratories to RIL. For the imported motors and items
Supplier shall provide ATEX or IECEx or certificated from any approved agency in
the country of origin.
5.7.2.4. VSD fed Motors, operating in classified area, needs the PESO approved combined
testing certificate.
5.7.2.5. Imported electrical equipment for use in hazardous applications require PESO
approval. Further details regarding for obtaining PESO certificate are available at
www.peso.gov.in/index.aspx.

5.7.2.6. For Electrical equipment (except motors) the following types of protection shall be
selected for the various hazardous areas:
Areas Type of Protection

Flameproof or explosion proof, Exd equipment with Exeb
terminals.
Zone 1
Pressurized, Exp equipment
Intrinsically safe, Exia or Exib equipment
a) Non-sparking, Exec equipment
b) Increased safety, Exeb equipment
Zone 2 c) Equipment complying with the requirements for Zone 1
areas. Exde and Exp equipment shall be avoided as far as
possible in Zone 2 areas.
a) Increased safety, Exeb equipment
Zone 2 Areas b) Equipment complying with the requirements for Zone 1
(within/around area. Exde and Exp equipment shall not be specified as far
tank bunded as possible in Zone 2 areas.
areas) c) Non-sparking Exec equipment may be considered on a
case by case basis
Zone 20 Ex"ta" IIIA/IIIB/IIIC
Zone 21 Ex “ta/tb” IIIA/IIIB/IIIC
Zone-22 Ex “ta/tb/tc” IIIA/IIIB/IIIC
a) Standard industrial equipment

Unclassified b) Equipment complying with the requirements for zone 1
Areas and 2 areas. Exde, Exp and Exec equipment shall not be
specified as far as possible in unclassified areas

5.7.2.7. For motors, the following types of protection shall be selected for the various
hazardous areas:
Area Type of Protection
6.6/11 kV motors
Zone 0 No Motor is allowed.
LV motors
Exde for rating < 1 MW,

6.6/11 kV motors
Exde or Exp for rating ≥ 1MW
Zone 1
LV motors Exde
Exec* for rating < or equal 2 MW,

6.6/11 kV motors
Zone 2 Exp for rating > 2MW,
LV motors Exeb**, Exec* ,
Zone 20 6.6/11 kV motors

No Motor is allowed.
LV motors

Ex “ta/tb”, IIIA/IIIB/IIIC
LV motors

Ex “ta/tb/tc”, IIIA/IIIB/IIIC
LV motors
Notes:
* Risk assessment for possible air gap shall be carried out for Exec type motors
in accordance with IEC 60079-7.
** Risk assessment for possible air gap shall be carried out for Exeb type
motors. Stator winding insulation type test shall be carried out in accordance
with IEC 60079-7.
1. Ex eb degree of protection will only be considered for induction motors of
non-sparking design.
2. Electrical protection for motors with Ex eb protection must take the motor’s
tE time (locked rotor withstand time) into account.

3. With the exception of Exp motors, the above must be used in conjunction
with an Exd or Exeb termination box. Exp classification shall envelops the
termination box also.
4. For Zone 2 applications, Exeb protection shall be deployed where feasible,
unless agreed otherwise with the driven equipment Supplier. Exeb motors
should successfully pass gas-test in an explosive gas environment.
5. Motors of protection Ex "ta/tb/tc" for dust hazardous area Zone 20, 21, 22
shall comply with IEC 60079-31. The equipment shall satisfy the
requirements of ingress protection IP65.
6. In case of Ex"p" motor, Supplier shall provide details e.g. make, purge time,
purging airflow, requirement of external power supply, provision of
pressure transmitters for tripping and trip logic of purging kit.
7. When Impulse Voltage Insulation Class (IVIC) comes into effect as per IEC
60034-18-41, the same needs to be considered.
5.7.2.8. The following guidelines shall be adopted for the selection of bulk items (light
fittings, junction boxes, glands, convenience outlets, receptacles, local control
stations & switches) in classified areas.
i) Units which have IIA, IIB & IIC Gas groups
Bulk material items for IIA, IIB and IIC applications shall be factory painted by
manufacturer with respective colour codes as per relevant IS 5 standard.
All cable glands used at the bulk equipment shall be Exd IIC.
ii) Units which have IIA and/or IIB but not IIC Gas groups
All bulk material items shall be suitable for IIB as this is the most stringent gas
group. Exeb and Exec equipment shall be specified as suitable for Gas Group II
(covering at least IIA, IIB) and Exde equipment shall be specified for Gas Group
IIB. All cable glands used at the bulk equipment shall be Exd IIC.
5.7.2.9. EPC contractor shall prepare and maintain Ex Register for all the certified
equipment suitable for installation in Hazardous classified areas. The Ex Register
shall be submitted to client for their further use.
Equipment
Electrical equipment IP rating shall be IP42 for indoor application.
5.8.1. Switchgear/Motor Control Centers
5.8.1.1. The main 33 kV switchgear and 33 kV ICOG (Incoming and Outgoing Panel complete
with CB, CT, PT, Relays, Indication, meters, Surge arrestor, Cable Box or any other
associated equipment) shall be of the gas insulated type and designed and procured
in accordance with project specification RPMS-ENGG-SPC-EL-027.

5.8.1.2. 11 kV Switchgear, 6.6 kV switchgear, 11 kV ICOG Switchgear and 6.6 kV ICOG shall
be of the air insulated, metal clad type with vacuum circuit breakers and shall be
designed and procured in accordance with project specification RPMS-ENGG-SPC-
EL-001.
5.8.1.3. All HV and MV Switchgears shall be equipped with spare feeders on each bus
section. Both rating of the feeder and the circuit type shall be taken into
consideration while deciding the number of spare feeders. On each bus, at-least
one feeder of each type, out of existing feeders on the bus, shall be provided as
spare.
5.8.1.4. 415 V Power Control Centers (PCCs) shall be designed and procured in accordance
with project specification RPMS-ENGG-SPC-EL-002. LV Motors rated from 90 kW
and up to 160 kW shall be fed from a PCC by means of air circuit breakers. Outgoing
feeders rated above 250 A shall be supplied from air circuit breakers located in a
PCC.
5.8.1.5. 415 V Motor Control Centers (MCCs) shall be designed and procured in accordance
with project specification RPMS-ENGG-SPC-EL-002. Motors rated less than 90 kW
shall be fed from an MCC by means of fused contactors. Fuse switch circuits shall
generally be used for outgoing feeders up to and including 63 A and fused
contactors for circuits greater than 63 A and up to and including 250 A. Motor
feeders rated greater than 22 kW shall be provided with a separate core-balance
current transformer for earth fault protection.
5.8.1.6. All MCCs shall have provision for two control supplies with automatic change-over
facility.
5.8.1.7. Critical MCC shall be identified during detailed engineering to use UPS power as
second control supply.
5.8.1.8. Provision shall be made for 20% spare feeders in PMCC/PCC & MCC with minimum
one feeder of each type having all components. All switchgear shall be loaded to
80% of incomer rating at the end of design completion. All incoming cables to
switchgear shall be suitable for the incomer current rating.
5.8.1.9. Single point supply shall be considered for Process heaters of a package.
5.8.1.10. Emergency switchgear complete with automatic changeover facilities shall be
provided where required in substations. Under normal operating conditions,
power to the emergency switchboard shall be derived from the normal supply
network. On loss of normal supply, the automatic changeover facilities shall change
over the source supply from the normal to an emergency source to be provided by
a standby diesel generator.
5.8.1.11. Where redundant feeds are provided to 6.6 kV and 415 V switchboards, an
Automatic Transfer Scheme (ATS) shall be provided to switch to the alternative
Source if a failure occurs in one supply feeder. Protection shall be provided to

prevent transfer in the case of a fault downstream of the circuit breaker. The
Automatic Transfer Systems shall be independent for each switchboard and shall
include time delay such that transfer takes place at the MV level before transfer at
LV is affected. The auto-changeover timing shall also be adjusted such that
switching to the emergency supply feeder shall only take place if upstream
transfers have failed to restore the supply. Return to normal after main power
restoration shall be manual. Momentary paralleling shall be permitted, even short
circuit current exceeds the switchgear fault rating.
5.8.1.12. Fast Bus Transfer (FBT) scheme shall be considered for MV (11 kV/6.6 kV)
switchboards, where ever specified.
5.8.1.13. Lighting and small power distribution boards shall be located in each substation, in
other buildings and at strategic locations outdoors around the plant areas.
Depending upon their application, these shall be supplied either from astronomical
timers or manually operated circuits on either the normal or the emergency
services LV switchboards. The distribution switchboards shall be suitable for indoor
or outdoor use and the hazardous area classification in which they are to be
installed. Distribution boards located in hazardous areas shall be limited to 18
single phase ways.
5.8.1.14. Automatic motor re-acceleration/restarting following voltage dips shall not be
provided based on the process requirements.
5.8.1.15. Power system monitoring, control and protection shall be in accordance with
project specifications and protection philosophy shall be in accordance with RPMS-
ENGG-SPC-EL-039 and RPMS-ENGG-SPC-EL-046.
5.8.1.16. Emergency Shut Down (ESD) systems and emergency stops shall be hard wired back
to the switchgear/MCC.
5.8.1.17. Large motors fed via 33/11.5 kV unit transformers shall be controlled by ICOG 11
kV switchgear. Both, transformer and 11 kV switchgear shall be located in the local
substation.
5.8.1.18. Power busbar of all ICOG feeding motor above 3500 kW rating shall be of electrical
grade copper.
5.8.2. Protective relays
5.8.2.1. Protective relays for Incoming feeders, Bus Ties and Motors having rating of 90 kW
and above shall be numerical type. Other Auxiliary relays, lock-out relays and Timer
relays considered shall be of standard Electro-mechanical type.
5.8.2.2. Protection relays and other components shall be as per relevant metering and
protection diagrams and designed and procured as per project specification RPMS-
ENGG-SPC-EL-039 and RPMS-ENGG-SPC-EL-046.

5.8.2.3. Protective relaying philosophy shall be based on at-least a single contingency

planning so that the relay system will provide fault clearing for one of the following:
i) Failure of either primary or backup relay function or the related control
circuit
ii) Failure of a circuit breaker to interrupt, including a faulty circuit breaker,
5.8.2.4. The protection relaying philosophy for 220 kV and 33 kV systems shall also include
suitable main and backup schemes.
5.8.3. Power and Distribution Transformers
5.8.3.1. EHV Power Transformers and MV Power transformers shall be designed and
procured in accordance with project specification RPMS-ENGG-SPC-EL-031 and
RPMS-ENGG-SPC-EL-005 respectively.
5.8.3.2. Oil Immersed Distribution transformers shall be designed and procured in
accordance with project specification RPMS-ENGG-SPC-EL-006. Dry type
Distribution transformers shall be designed and procured in accordance with
project specification RPMS-ENGG-SPC-EL-044. Distribution Transformer shall also
comply with Bureau of Energy Efficiency (BEE) guidelines for star rated
transformers.
5.8.3.3. Transformer insulating oil shall be in accordance with project specification RPMS-
ENGG-SPC-EL-033.
5.8.3.4. The cooling arrangement of all power transformers shall be ONAN/ONAF with the
possible exception of the main generator step-up transformers and main
distribution transformers, which will have cooling requirements as specified in the
relevant data sheets. Where required, transformer cooling can also be of the OFAF
type. The method of cooling shall be as specified in the data sheets.
5.8.3.5. Automatic on-load tap changers (OLTCs) shall be provided for Transformer as
required, based on system study.
5.8.3.6. For harmonic mitigation, use of zigzag distribution transformers or transformers
with special vector groups may be considered for supplying large non-linear loads
such as VSD's and thyristor-controlled process heaters.
5.8.3.7. Outdoor power transformers shall be provided generally with no roof and will be
rated and designed accordingly.
5.8.4. Emergency Diesel Generators
5.8.4.1. The electrical requirements for Emergency Diesel Generators shall be designed and
procured in accordance with project specification RPMS-ENGG-SPC-EL-010 and
Alternator data sheet.
5.8.4.2. Emergency Diesel Generator set shall form an independent package, consisting of
diesel engine, alternator, control panel and other auxiliary systems.

5.8.4.3. The automatic voltage regulator (AVR) for emergency Diesel Generator shall be of
the static type and shall be high speed compounded for parallel operation.
5.8.4.4. Generators shall be capable of withstanding without damage, a sudden three-
phase, a line-to-line, a line-to-earth or two-line-to-earth short-circuit, for a period
of 3 seconds when operating at rated speed and with the excitation corresponding
to 5% over voltage at no load.
5.8.4.5. Emergency Diesel Generators shall have provision for forward and reverse
synchronization and no-load test runs.
5.8.4.6. To collect waste oil, Emergency Diesel Generators shall be provided with oil
containment pits. EDG Oil containment pit which shall not be connected any other
pit.
5.8.4.7. Required input to provide access road to facilitate maintenance & operation (fuel
filling etc.) of Emergency Diesel Generator shall be provided during interdisciplinary
checks such as layout and model review.
5.8.5. Power Factor Correction Equipment
5.8.5.1. Power factor correction equipment shall be provided as required and will be
analyzed, during detailed engineering.
5.8.5.2. Consideration may be given to the use of synchronous machines to improve the
overall system power factor at the point of grid connection during normal
operation.
5.8.6. Neutral Earthing Resistors
5.8.6.1. Neutral earthing resistors (NER) shall be in accordance with project specifications
RPMS-ENGG-SPC-EL-045.
5.8.6.2. Each earthing resistor shall be rated to withstand the prospective earth fault
current for duration of not less than 10 seconds. Low resistance grounding is
suitable for 10 seconds. High resistance grounding is suitable for continuous
operation. Prospective earth fault current for resistive grounded system shall be
based on system requirements and in line with applicable codes and standards.
5.8.7. DC Supply Units
5.8.7.1. DC supply units shall be modular switch mode power supply based and designed
and procured in accordance with project specification RPMS-ENGG-SPC-EL-008.
5.8.7.2. Redundant system using two sets of chargers with two battery banks shall be
utilized. Battery shall be of the VRLA type designed and procured in accordance
with project specification RPMS-ENGG-SPC-EL-009. Each battery bank shall be rated
to give two hours back-up and shall be rated for 50% of the total load.
5.8.7.3. DC supply Units shall be provided in each substation for:
i) Switchgear protection and tripping supplies
ii) Energy Management system

iii) Disturbance Recorder system
iv) Synchronous Motor Excitation panel
v) Remote Input/output (RIO) panel
vi) VSD MCC
vii) Transformer Marshalling box
viii) Emergency Diesel Generator (EDG), Automatic Main Failure (AMF)
Panel
ix) MV VSD Panel
x) LV VSD Panel, If required
xi) Any other equipment, as required
5.8.8. AC Uninterruptible Power Supplies (UPS) Systems
5.8.8.1. AC UPS systems shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-007. AC UPS system shall generally be dual
redundant, 115 V, 50 Hz, single phase systems with dual load bus.
5.8.8.2. Batteries for UPS shall in accordance with project specification RPMS-ENGG-SPC-
EL-009. Each Battery bank shall be rated for 6 hours backup for Fire and Gas System
(F&G), Public Address and General Alarm System (PAGA) / Telephone
/Security/Radio systems & IT Networks and 30 minutes backup for other loads that
include DCS/Process Monitoring & Control System, Emergency shutdown and de-
pressuring control system, flare ignition, etc. and shall be rated for 50% of the total
load.
5.8.8.3. Distribution for AC UPS systems shall take into consideration the short-circuit
capability of the UPS and its bypass supply.
5.8.8.4. AC UPS systems shall be provided, as required to provide no break supplies to the
following systems:
i) Distributed Control System (DCS)
ii) Fire and Gas System
iii) ESD System
iv) PLC cabinets/ UCP
v) Essential instrumentation including field instruments
vi) Analyzer Houses
vii) Machine/Process Condition Monitoring System (e.g. vibration, analyser
and anti-surge).
viii) Public Address/General Alarm System
ix) Talkback Intercom System
x) Telephone System
xi) WAN/LAN System

xii) Radio System
xiii) Access Control System
xiv) CCTV System
xv) MV VSD
xvi) GTG and STG Auxiliary MCC Control Supply Note 1
xvii) Critical MCCs Control Supply, if required Note 1
Note 1: Separate UPS system and associated batteries, with specified voltage level,
shall be considered located in respective substation for this application.
5.8.8.5. The battery autonomy (back-up time) for critical application such as
Telecommunication, F&G System shall be in accordance with HSE discipline or as
per NFPA requirements. Similarly, for DCS applications, the autonomy shall be in
accordance with relevant standards and Plant process (safe shutdown)
requirements.
5.8.9. Power busducts
5.8.9.1. Power busducts shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-013 for Air insulated busducts and RPMS-ENGG-
SPC-EL-020 for Sandwich type.
5.8.9.2. Type of Busduct shall be based on techno-commercial consideration and
implementation feasibility.
5.8.9.3. In general power connections exceeding 1000 A shall be carried out using power
busducts. However, in the case of the Emergency Diesel Generators, busducts shall
be used only for power connections above 2000 A.
5.8.10. Relay Panels and Protective Devices
5.8.10.1. The metering, protection and control equipment associated with the EHV
switchgear shall be housed in dedicated panels located in a relay room within CPP
control building / MRS, which shall be housed in HVAC room.
5.8.10.2. The bus zone protection equipment associated with the 33 kV switchgear shall be
housed within the same switchgear or in dedicated panels located in a relay room
based on implementation feasibility.
5.8.10.3. With the exception of EHV switchgear, all other protective devices and meters shall
generally be housed within the switchgear cubicles.
5.8.10.4. The metering, protection and control equipment associated with the combustion
turbine driven generating sets as well as steam turbine driven generating sets shall
be housed in dedicated panels located inside the Captive Power Plant Control
Room. Tariff metering arrangement shall be provided for all generating sets.

5.8.11. Interfaces with Process Control Systems

5.8.11.1. Process control and monitoring of the various motors shall be via either one of two
systems (but not both):
i) Dedicated Unit Control Panel (UCP)
ii) DCS actioned control
5.8.11.2. For detailed interface with process control RPMS Design Basis for Control &
Instrumentation (C&I) to be referred.
5.8.12. Energy Management System (EMS)
5.8.12.1. An Energy Management System (EMS) shall be provided comprising of following
modules -
a) Electrical Distribution Management System (EDMS) – This module comprises of
centralized SCADA with Remote Monitoring and control of complete electrical
power network and distribution network inclusive of EHV, HV, MV and LV
(Incomer, Bus Coupler level only). Controls shall be decided based on operating
philosophy. There shall be dedicated Time Synchronization over SNTP for entire
EDMS network devices and IEDs.
b) Load Management system (LMS) - It provides the protection and security of

overall captive generation in case of any eventualities due to generation short
fall.
Main Load Shedding System (MLS): A fast acting load shedding system
considering various contingencies of power system
Under Frequency Based Load Shedding System (UFLS) backup to MLS
c) PQ / Tie Line Control System– This module to be interfaced with Governor /
Turbine control system (TCS) and AVR (voltage) systems to provide generation
control of electrical power generation to maintain Active and Reactive Power
flow on Grid Tie lines and Intra-Tie lines.
d) Network Management System (NMS) – This module provides remote

monitoring and alarm logging of the communication network (Ethernet switch
network) of the entire EMS system.
e) Disturbance Recorder System (DR) – DRS is provisioned to capture high speed

transient records of voltage, current and SOE at EHV / HV level for post fault
analysis. DRS will have independent dedicated time synchronization system
over IRIG-B.

5.8.12.2. Dedicated Fiber optic (Single Mode FO) cables, exclusive for EMS system, shall be
provided between substations to upstream MRS system EMS system equipment
like servers, Operator HMI and Engineering workstations equipment shall be
allocated at a pre-defined central control location whereas the controller nodes to
be distributed across the substation and MRS locations based on requirement and
system design. System shall implement all cyber security guidelines as defined by
relevant standard / RIL guidelines without any adverse impact on operational
flexibility. The EMS shall have facility to communicate with Refinery Information
Management System (RIMS) via OPC links using necessary IT firewall. EMS shall be
designed and procured in accordance with EMS System Specification RPMS-ENGG-
SPC-EL-014.
5.8.13. Variable Speed Drives
5.8.13.1. Low Voltage variable speed drive (VSD) equipment shall be in accordance with
project specification RPMS-ENGG-SPC-EL-011 and Medium Voltage variable speed
drive in accordance with project specification RPMS-ENGG-SPC-EL-029.
5.8.13.2. The requirement of variable speed drives shall be considered based on an economic
and technical basis subject to process requirements.
5.8.13.3. MV VSD and critical LV VSD control supply shall be from UPS.
5.8.13.4. Converter equipment controlling plant motors shall be located inside the
substation, except the associated transformers and reactors, which shall be located
outside within a transformer/reactor bay adjacent to the substation. For specific
requirement, the transformer and rectifier may be housed within the substation.
5.8.13.5. Converter equipment feeding air handling units for comfort air-conditioning and
similar requirements may be located close to the motor in the same room or may
be mounted integral to the motor.
Motors and Local Control Stations
5.9.1. High voltage motors shall be in accordance with project specification RPMS-ENGG-
SPC-EL-003/API 541/API 547 and Low voltage motors shall be in accordance with
project specification RPMS-ENGG-SPC-EL-004.
5.9.2. Motors generally shall be of the squirrel cage induction type. LV motors shall
normally be selected to have ratings in accordance with the preferred rated output
values of the primary series as listed in IEC 60072, IS 325 and IS 12615.
5.9.3. The type of motor and local control station shall be in accordance with the
hazardous area classification.
5.9.4. Each motor shall be provided with a start/stop local control station (LCS) installed
on suitable steel support adjacent to the motor. Exceptions shall be critical drives
such as emergency DC lube oil pumps for combustion turbines. Exceptions shall be
evaluated on case to case basis considering safety of personal & equipment and

operational integrity of associated system. For HVAC blowers, lock-off stop push
buttons shall be provided for each blower outside the pressurization room in order
to aid maintenance access.
5.9.5. Start/stop control station shall have stay-put stop and lock-off stop features
(padlocking).
5.9.6. Start/stop control stations for motors rated above 30 kW and motors driving
agitators, compressors and blowers or any other special application (if required)
shall be provided with ammeters. Ammeters shall have connection to a CT (1 amp
secondary) located within the motor starter.
5.9.7. 4-20 mA analog type ammeter in Start/Stop Control station shall be considered for
VFD fed motors.
5.9.8. Start/stop control stations for all fin-fan and cooling tower fan motors shall be
located at about 1 meter above grade. A separate lock-off stop emergency
pushbutton shall be located adjacent to each fan motor. Similarly, compressor
houses shall also be provided with additional emergency stop control stations at 1
meter above grade. In case Emergency Stop is part of Unit Control Panel located in
vicinity, applicability of additional emergency stop control station to be evaluated
on cases to case bases.
5.9.9. Motors which have automatic process control or motors which are started from
more than one location shall be provided with control stations incorporating
Hand/Auto selector switch.
5.9.10. Motor operated valves and electric cranes shall be fully equipped with integral
motor control gear.
5.9.11. Belt driven fin fan cooler motors shall be provided with undercurrent protection.
Earthing and Lightning Protection System
5.10.1. Earthing and lightning Protection system shall be designed and procured in
accordance with project specification RPMS-ENGG-SPC-EL-023. Earthing systems
shall provide low impedance earth paths for earth faults, static discharge and
lightning protection.
5.10.2. Power system earthing, lightning protection and equipment bonding shall be
achieved by overall common earthing system. All units shall be bonded together
to form a single continuous earthing system. All the inter process plants and
neighboring plant expansion earthing grid systems shall be interconnected at least
two point when their power systems are interconnected.
5.10.3. A separate earthing connection above ground shall be provided for
instrumentation in each area.

5.10.4. Earthing and bonding of tanker berth facilities shall be designed and installed in
accordance with relevant standards. Earthing and bonding at road and rail loading
facilities shall be designed and installed in accordance with the relevant Codes and
Standards.
5.10.5. Maximum values of resistance of equipment earthing systems to the general body
of earth shall be as follows:
General Earthing 1 ohm
Earthing for Lightning Protection & Static 10 ohms
Bonding
5.10.6. Chemical earth pits will be used, as required.
5.10.7. Buildings, structures, tanks and other assets which may be subjected to lightning
and subsequent damage shall be provided lightning protection system in line with
relevant Indian and international codes and standards.
Lighting
5.11.1. Plant lighting shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-037. Normal lighting shall be fed through a
lighting transformer specifically provided for the purpose. Emergency lighting,
while operating on normal supply, shall be fed through the same lighting
transformer. Care shall be taken during lighting distribution to ensure convenience
receptacles, except 5 A outlets provided as a part of lighting switchboards, are not
fed from the lighting transformer. The lighting transformer shall be housed in the
switchgear room.
5.11.2. Substation and PIB lighting shall be fed from dedicated inverters located in the
respective buildings. The inverters shall be located in the area housing electronic
equipment, in a controlled atmosphere.
5.11.3. General Lighting
5.11.3.1. Lighting in industrial plant hazardous and non-hazardous areas shall generally be
by means of LED luminaires. All LED luminaires shall be rated L70 with a minimum
of 50,000 hours and colour rating of 4000K. Luminaires shall be mounted on the
structures, directly beneath beams, or on platform mounted poles.
5.11.3.2. Means for locally isolating the lights, fed from normal supply, on process columns
and vessels shall be provided to enable switching off lights when they are not
required.
5.11.3.3. Emergency light fixtures shall not have local isolation.
5.11.3.4. In Hazardous area, emergency lighting shall be explosion proof Ex (d) type,
irrespective of hazardous areas being Zone 1 or Zone 2.

5.11.3.5. Where required, general lighting for open areas within non-hazardous areas shall
be by means of LED floodlight luminaires mounted on adjacent structures or on
strategically located floodlight columns. High mast floodlighting installations shall
also be used where appropriate.
5.11.3.6. Where required, general lighting for open areas within hazardous area process
plants shall be by means of LED floodlight luminaires mounted on adjacent
structures or on strategically located floodlight columns. Buildings/Enclosures such
as compressor houses within hazardous areas shall be illuminated by High Bay type
LED lighting fixtures. LED light fixtures may also be selected for lighting in plant
areas.
5.11.3.7. Consideration shall be given to the utilization of LED streetlight fittings in outdoor
areas and for building lighting.
5.11.3.8. High Bay type LED luminaires shall be used in appropriate non-hazardous locations
such as warehouses, workshops etc.
5.11.3.9. Lighting in industrial buildings such as substations, canteens, control rooms, PIB's
etc. shall be by LED type ceiling or cable tray mounted luminaires.
5.11.3.10. Safety showers and eye wash in plant areas shall be provided with ‘Exd’ Type green
LED fixtures for proper identification. Supply for these fixtures shall be provided
from emergency lighting distribution board with 24 x 7 ON feature.
5.11.3.11. Lighting in non-plant buildings shall be as per respective building design basis.
5.11.3.12. Control Room luminaires shall be in accordance with the specialist lighting design.
All LED luminaires shall be rated L70 with a minimum of 50,000 hours and colour
rating of 4000K.
5.11.3.13. Motion controlled light sensors shall be provided in hallways and conference rooms
to enable switching off lights when not required.
5.11.3.14. Lighting in all unmanned buildings (e.g. substations) shall be controlled by motion
sensors and 10 min. time delay shall be provided before light turn off, in addition
manual override switch shall be provided at the entrance of building.
5.11.3.15. Light fitting, sockets, junction box, temperature sensor & accessories in battery
room housing only VRLA batteries shall be certified for Zone 2, gas group IIB+H2 or
IIC, temp class T3
5.11.3.16. Light fitting, sockets, junction box, temperature sensor & accessories in battery
room housing vented type lead acid batteries or Ni-Cd batteries shall be certified
for Zone 1, gas group IIB+H2 or IIC.
5.11.3.17. Based on requirement, Lighting Blackout scheme (i.e. critical lighting for safe egress
requirement fed from UPS Power Supply) shall also be engineered in line with
applicable guidelines.

5.11.3.18. Following the minimum average intensity levels, measured 1 m above the floor
level, unless specified otherwise shall be in a horizontal plane, shall form the basis
for the lighting design: Average lighting intensity levels shall be as per OISD
requirement / Guidelines.
Type of Location Lux
General lighting/laboratories 400/500

Control Building Rear of instrument panels, aux. and panel rooms. 100
Outside, near entrances 150
Controls, valves, gauges- Instrumentation 500
Pump houses, Sheds 100
compressor houses, at or near equipment (operating areas) 300
Boiler house, turbine house, platforms, coal conveyors, pulverizes,
150
feeders, precipitators
Steam raising plants, reactor areas, boilers, galleries 150
Conveyors houses, junction towers 70-100
Switch rooms and PIB (including Charger/UPS rooms) etc. 150-200
Cable Cellar 100
Auxiliary equipment, battery rooms, blowers, transformer bays 100-150
Transformers and outdoor switchgears 100
Furnace and boiler areas 100
Outdoor operational areas (Process areas, pipe racks, heat
exchanger, heater, separators, cooling-tower, columns, launching 100
/receiving loading area, flare etc.
Outdoor non-operational areas 10*
Coal unloading areas 20

Coal storage areas 20
Conveyors 50
Stairways, platforms and walkways 60

Type of Location Lux

Road / Rail loading gantries 50
Rail siding coupling/uncoupling areas 20
Rail storage sidings generally 5*
Road truck parking areas 5*
Drawing offices 750
Offices 500
First-aid rooms 700
Toilets and locker rooms 150
Interior generally/ Specialized area 250/500
Workshops
Exterior 50
Interior between racks 150
Stores /
material yards 5*
Warehouses
Bulk storage operating areas 50
Tank farms 20
Oil storage tanks, fuel oil delivery headers 50
Jetty approaches (Landing Platform Level) 10*
Main roads (along process units, power houses, workshops, etc.) 20
Secondary roads (along storage tanks settling basins etc.) 20
Complex entrance gates 50*
Basements 70
EHV/HV switchyards 100
Gate and watchman booth 100
Fire House, garage 100-150
* At grade

5.11.3.19. Lighting Control

Outdoor lighting circuits shall generally be controlled via Astronomical timers
(latitude/longitude timed switches). Manual override shall be provided to permit
maintenance.
Indoor lighting shall be controlled locally by suitably located switches.
Automation systems shall be considered for control rooms, offices, conference
rooms and similar facilities.
5.11.4. Emergency Lighting
5.11.4.1. Emergency lighting shall comprise two categories:
Category 1: No break lights, comprising LED luminaries fed from

centralized inverter with 1 hour autonomy
Category 2: Short break lights fed from the emergency generators.
Luminaires shall be of the LED type.
5.11.4.2. The number of emergency luminaries in relation to normal luminaries shall be as
follows:
Type of location Category 1 Category 2

Process area - 10%
Utility area - 20%
Machinery rooms (Workshops) 5% 25%
Road/Rail loading gantries - 10%
Switch rooms, equipment rooms,

5%NOTE1 25% (Note 2)
instrument shelters and DG sheds
Off plot tankage areas and pump stations - -
Control Room 100% -
Medical rooms, Central fire station and Fire

10% 90% (Note 2)
Water Pump House
Administration buildings and offices 5% (Note 3) -
Fire exit doors from buildings 100% (Note 3) -

100% for 100% for

Non plant buildings (offices etc.) internal Internal External
and external stairways. Stairways Stairways
(Note 3) (Note 2)
100% for 100% for

Plant buildings (e.g. substations) internal Internal External
and external stairways. Stairways Stairways
(Note 3) (Note 2)
ISBL Process Unit stairways and vertical - 100%

ladders (Note 2)
Muster Areas 100% (Note 3)
Substations and PIB's 100% (Note 3) -

NOTE 1 :There
shall be minimum two fixtures.
Note 2: 25 % of category 2 light shall be “Transitional Lighting” (60 minutes
battery pack)
Note 3: 25 % of category 1 light shall be “Transitional Lighting” (60 minutes
battery pack)
5.11.5. Road and Parking Area Lighting

Area lighting shall utilize high mast flood lighting columns. Supplementary road and
parking area lighting shall be provided by means of 150W, 250W, 400W or 1000W
equivalent LED light fittings mounted on high mast floodlighting columns. This
lighting shall be connected to the normal power supply system.
5.11.6. Coke Rail Siding LED Lighting
High mast floodlighting shall be utilized in areas where trains are coupled or
uncoupled, in switching areas and on the loading/unloading areas and their sidings.
Apart from the loading gantries, the rail siding lighting shall be fed from the normal
power system only.
5.11.7. Tank Farm LED Lighting
High mast floodlighting columns located in non-hazardous locations outside tank
farm bund walls shall be utilized. Local lighting may be provided as necessary in
areas of regular plant operational activity.

Power and Convenience Outlets

5.12.1. 415 V, 63 A, TP&N+E power outlets of switched socket type shall be provided in
workshops and at strategic locations in industrial areas, plant areas and OSBL pipe
racks. All principal equipment locations shall be reached by the use of 50 meters of
extension cable. All outlets shall have local isolation. Short circuit protection and
sensitive earth fault protection with Core Balance Current Transformer (CBCT) shall
be provided in the upstream switchboard.
5.12.2. 240 V, 16 A, SP&N+E convenience outlets with local isolation shall be provided
throughout the industrial areas such that all principal equipment locations can be
reached by use of 25 meters of extension cable. MCB with RCCB (Residual Current
Circuit Breaker) shall be provided in the upstream DB for short circuit protection
and sensitive earth fault protection.
5.12.3. Convenience outlets for hand lamp supplies with integral transformer, rating – 100
VA, 240/24 V (center point earthed), shall be provided near to the manholes of
vessels, tanks columns etc. Convenience outlets shall be fed through earth leakage
circuit breakers of 30 mA sensitivity.
5.12.4. Sufficient 240 V, dual 15/5 A, SP&N+E convenience outlets shall be provided in all
domestic and administrative buildings, PIBs (Process & Instruments Buildings),
switch and equipment rooms and workshops and offices. These shall be fed from
normal supplies only.
5.12.5. Power outlets and Convenience outlets per circuit shall be designed in line with
loading and voltage drop limitations of the circuit.
5.12.6. All outlets located within hazardous areas shall be certified for such locations.
5.12.7. Power outlet of rating 800 Amp shall be provided in the field near process
condensers for operating hydro-jetting motors. Local push button shall be provided
near power outlets to trip upstream feeder.
5.12.8. For specific power requirement (Such as smaller hydro jetting & portable
equipment) during plant shut-down, power distribution boards shall be located in
process areas, where required by Buyer, for facilitating power connections during
plant shut-down activities.
5.12.9. Number & Location of Hydro-jetting DBs & Shutdown DBs shall be decided during
detailed engineering in consultation with all stake holders.
Cable Data and Cable Installation
5.13.1. Cable Types
5.13.1.1. High voltage cables shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-021 and Low voltage power and control cables
shall be designed and procured in accordance with project specification RPMS-
ENGG-SPC-EL-022.
5.13.1.2. Power and control cables of all voltage grades shall have XLPE insulation. Cables for
earthing shall be PVC insulated.
5.13.1.3. Conductors of 6 mm2 and greater shall be aluminium, unless specified otherwise.
Conductors smaller than 6 mm2 shall be copper.
5.13.1.4. 6.6 kV, 11 kV and 33 kV grade cables shall be rated 3.8/6.6 kV, 6.35/11 kV and 19/33
kV respectively, and shall include earth screen. Maximum line voltage (Um) shall be
of 7.2 kV, 12 kV and 36 kV respectively.
5.13.1.5. Optical fibers cables & Special Cables i.e. EHV Cable, VSD Cable, Battery Cables, PA
system Cables or any other special cable shall be specified separately.
5.13.1.6. All cables used above or below ground in industrial areas shall have non-
hygroscopic fillers, wire armouring and PVC overall sheath.
5.13.1.7. Unarmored cables and wires may be used where proper mechanical protection
(e.g. metallic conduit) is provided or where sheathed cables are installed above
ceilings or below floors in non-industrial locations. Concealed metallic conduits
shall be used for buildings where appropriate.
5.13.1.8. All cables shall be of FRLS type as per OISD guidelines/requirements.
5.13.1.9. Cables that are routed fully within occupied buildings shall have Low Smoke Zero
Halogen (LSZH) sheath.
5.13.1.10. Cables for conduit installation shall be FRLS (Flame Retardant Low Smoke), PVC
(Poly Vinyl Chloride) insulated, multi-stranded conductor.
5.13.1.11. Earthing of lighting and small power systems shall be by means of an earth
conductor integral with the cable or conduit.
5.13.2. Cable Installation
5.13.2.1. The default method of cable installation is for cables to be installed above ground,
laid on racks and trays within dedicated levels of overhead pipe racks and on the
sleepers of low level pipe ways.
5.13.2.2. In certain instances, cables may be routed underground, these include:
i) High voltage distribution cables and associated control cables
ii) Cables entering or leaving buildings
iii) Cables in areas where ground contamination is unlikely and economic
consideration precludes the erection of special cable supports
iv) Cabling within the power generation area
v) Feeder cables to satellite substations
5.13.2.3. Cables routed underground shall be direct buried and / installed in formed precast
concrete / brick walled trenches within process areas and if possible in OSBL area
also.
5.13.2.4. Main incoming feeders cables to MRS from upstream source substation shall have
redundant route. Where redundant route is not feasible, as a minimum these
cables shall be routed in separate cable ladders/trays, subject to Owner approval.
5.13.2.5. For 220 kV cable laying, supplier guideline for cable laying shall be followed.
5.13.2.6. 33 kV cables shall be laid in a single layer at 300 mm centers at a depth of 1050 mm
below grade.
5.13.2.7. 6.6 kV and 11 kV cables shall be laid in one or two layers at 150 mm centers and at
a minimum depth of 900 mm below grade.
5.13.2.8. 415 V cables may be laid in up to three layers at 150 mm centers and at a minimum
depth of 500 mm.
5.13.2.9. Control cables and lightly loaded cables may be grouped together or laid between
loaded cables.
5.13.2.10. All cables shall be laid on a sand bed with well compacted sand around and above.
Concrete or earthenware tiles shall be laid above the cables in unpaved areas.
Trenches shall be sized to allow for a future 20% increase in cabling which shall be
segregated and clearly marked. Trench walls shall be chamfered at tee-offs to allow
adequate bending radius.
5.13.2.11. Where cables leave the main trenches and for road crossings, they shall be run in
duct banks of concrete encased HDPE ducting.
5.13.2.12. Where cables rise above grade to equipment they shall be protected by HDPE ‘kick’
sleeve up to 150 mm above grade and from there shall be run on rack or tray or
secured by some other suitable means.
5.13.2.13. Cables shall be installed with spacing to minimize derating but consistent with the
total space available.
5.13.2.14. All underground cables shall be fitted with aluminium engraved identification tags
at terminations, at 30m intervals over their entire length, at all points where they
enter and leave ducts, and at changes in cable direction etc. The identification tags
shall show the complete cable number.
5.13.2.15. Suitable route markers shall be provided to indicate trench locations and shall be
located at 50 m intervals, cable joints and where the trench changes direction.
When the trench is within paved areas, a red coloured concrete cover shall be used
to seal and mark cable routes.
5.13.2.16. Cables shall be in one length where practical, but cable joints may be installed when
necessary. Cable joints shall be recorded, and their locations marked accurately on
‘as built’ drawings. Above ground cable joints shall not be installed in hazardous
areas. All underground through joints shall be PU filler, type shall be approved by
Buyer. Cable joints inside the substation cable cellar shall be avoided. Shear head
bolt type mechanical connectors shall be used for HV Cable joints.
5.13.2.17. EPC contractor shall maintain EHV and HV cable joints register with record of date
of installation, name of cable jointer, name of cable jointer’s company and
jointer/company competency certificates detail. After handover of project to
owner these registers shall be handed over to client for their further use.
5.13.2.18. Cables pass through a building foundation, ducts, or an opening in the foundation
is allowed. Cables entering an occupied building above-ground shall pass through
fire rated barriers matching or exceeding the fire rating of the wall.
5.13.2.19. Fire retardant coating approved by Buyer shall be applied on cable joints. Where
appropriate, particularly where cables transition takes place in process units, cables
shall be treated with fire retardant coating. All remote operated shut-off valves
within a fire zone, which are designed to limit the duration and severity of a fire by
shutting off the fuel source, shall be powered using fire resistant cables as per IEC
and IEEE standards.
5.13.2.20. Adequate segregation shall be maintained between different services. In general,
power and instrumentation/telecommunication cables shall not be laid in the same
trench. However, optical fibre “pilot-wire” cables may be run in 33 kV cable
trenches. Cables from variable speed drives shall be run in separate cables trays
and a separation of 600 mm shall be maintained between cables operating on
sinusoidal supplies and cables connected to the output of variable speed drives.
5.13.2.21. Power (and associated control) and instrumentation/telecommunication cables
shall be run in their own racks. Electrical cables shall be, where practical, separated
from instrumentation and telecommunication cables except at switchgear/MCC
and substations. Minimum space between Electrical Power cables &
instrumentation and telecommunication cables shall be as follows:
Power cable Minimum Spacing
33 kV 1000mm
6.6 kV 600mm
415 V 600mm
110/240V 300mm
5.13.2.22. Cables of redundant Incoming feeders to substations shall be separated by at least
1 meter.
5.13.2.23. Cable racks and trays within close proximity of the non-hazardous area of cooling
towers, desalination plants and marine facilities shall be of FRP (Fibre-reinforced
plastic) material subject to its suitability to acid chemistry. FRP cable trays shall not
be used in Hazardous Area. Above ground cables shall be supported by cable racks
or trays. A clear space of minimum 400 mm between bottom of the lower tray to
bottom of top tray shall be provided to facilitate cable laying. Power cables shall
generally be laid on racks or trays in a single layer. Control cables may be bunched
together. Cables shall be secured at required intervals.
5.13.2.24. Cable racks and trays shall be fabricated from steel and hot dipped galvanized after
fabrication.
5.13.2.25. EHV and HV cables underground cables shall be laid in pre-cast/built-up concrete
cables trenches or at least by concrete troughs.
5.13.2.26. Instrumentation and Control system underground cables shall be laid in direct
buried cable trenches in OSBL and in concrete pre-cast/built-up trenches in ISBL
(Inside Battery Limits) area.
5.13.2.27. PA system cables shall be routed in Non-IS cable trenches / trays.
5.13.2.28. All cables shall be terminated using an approved double compression type cable
gland.
5.13.2.29. Wiring for lighting, small power and telecommunication systems within non-
industrial occupied buildings shall be single core LSZH insulated copper conductors
run in seamless, LSZH Heavy Duty conduits / under–floor raceways. Conduits shall
be chiseled into the block work of walls having a plastered finish, elsewhere conduit
installations shall be surface run clipped to brickwork, concrete or structural steel.
All outlet boxes shall be polycarbonate or metal and approved for either surface
mounting or flush mounting system.
5.13.2.30. Within substations, PIBs and plant areas, lighting and small power cables shall be
multicore XLPE insulated and terminated using compression type cable glands.
5.13.2.31. Derating factor for partially under ground and partially above ground cables for a
circuit shall be considered based on factor calculated for under ground installation.
5.13.2.32. Suitable Cable cleats / clamps shall be provided considering but not limited to Cable
type, installation type and method, mechanical loading of cable, short circuit rating
etc.
Aircraft Warning Lights and Navigational Aids
5.14.1. The type of Aircraft warning lights shall be in accordance to international and local
regulations. Aircraft warning lights shall be designed and procured in accordance
with project specification RPMS-ENGG-SPC-EL-037.
5.14.2. Navigational aid lighting of LED type shall be installed on the Jetty as required by
international and local regulations.
5.14.3. Aircraft warning lights shall be powered from emergency PCC as per international
and local regulations.
5.14.4. Navigational aid lighting in Jetty will be powered from emergency PCC as per
international and local regulations.
Electrical Heat Tracing
Where necessary, electrical heat tracing shall be provided for process pipelines.
Electrical heat tracing shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-030. As far as is practical, suitably certified self-

regulating heating tapes shall be employed. Special types of heating (e.g. skin
effect, impedance or induction heating) may be employed in particular applications
as per process requirement.
Cathodic Protection
5.16.1. CP for in-plant underground steel piping shall be provided by impressed current CP
(ICCP) systems. Sacrificial Anode CP (SACP) systems shall be provided for temporary
cathodic protection in the initial phase of the project and as a supplement to the
ICCP under special circumstances (where necessary due to complex structures,
short stretches of isolated underground piping, etc.)
5.16.2. Underground buried vessels and bases of tanks at grade level shall be protected
with ICCP systems.
5.16.3. ICCP shall be provided for all corrosive water (untreated) and potable (treated)
water storage tanks. For all other tanks where a water phase may be expected due
to precipitation from the product or from ingress of rain water (floating roof tanks),
sacrificial anode CP in conjunction with coating of the internal base and first shell
course is required.
5.16.4. Design life of SACP system shall be minimum of 10 years. ICCP system shall be
designed for minimum design life of 25 years [This needs to be coordinated with
design life mentioned in RPMS-ENGG-SPC-EL-015 and RPMS-ENGG-SPC-EL-016].
Soil investigation shall be carried out to determine the soil resistivity and
corrosiveness
5.16.5. Cathodic protection for UG piping shall be designed and procured in accordance
with project specification RPMS-ENGG-SPC-EL-015. Cathodic protection for grade
tank bottom, tank internal and underground vessels and Marine Structures (Piles /
Birth Platforms) shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-016. Electrical group shall provide power supplies
for the impressed current cathodic protection equipment.
5.16.6. Cathodic protection system shall be provided but not limited to the following
services and shall comply with NACE/DNV/ISO/BS/API guidelines:
i) Underground metallic pipe lines (cooling water and fire water)
ii) Fire hydrants underground portion.
iii) Underground storage vessels and tanks
5.16.7. All final As-Built of cathodic protection system layout, shall be incorporated in
underground. Native files from Supplier shall be transmitted to DEC for
incorporation in respective drawings.
5.16.8. Cathodic protection cables shall have provision for routing in lighting cable trays.

5.16.9. Cathodic Protection system TR (Transformer Rectifier) units & Junction Boxes shall
be provided with suitable earthing as required.
PA System
Public Address/Plant intercom System being emergency communication system,
shall be provided for all the facilities (Plants and buildings). Public Address/Plant
intercom System shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-038. In the cases where facility is very small and
not requiring communication with other areas, small standalone system shall be
designed and implemented on case to case basis depending on requirement of that
facility. PA system is being considered as emergency system is with reference to
allocation of power distribution from emergency source.
Emergency Siren System
Emergency Siren system being emergency communication system, shall be
provided for all manufacturing facilities as per applicable OISD guidelines.
Emergency Siren system shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-036. In the cases where facility is very small,
standalone system shall be designed and implemented on case to case basis
depending on requirement of that facility.
Fiber Optic Cable
Fiber Optic Cable shall be provided as per the requirement of different systems.
Fiber Optic Cable shall be designed and procured in accordance with project
specification RPMS-ENGG-SPC-EL-012.
IT Infrastructure
IT Infrastructure shall be designed and implemented in co-ordination with
Manufacturing IT team.
Security Automation System
Security automation system for MRS Buildings, Sub-stations, Switchgear Rooms,
GTG / STG Building and any other identified building housing electrical equipment
shall be designed and implemented in co-ordination with security engineering cell
and site security team.
CCTV shall be installed in MRS Buildings, Sub-stations, Switchgear Room, GTG/STG
buildings and any other identified building housing electrical equipment to ensure
equipment and personnel safety in key locations.
Standardization
5.22.1. For ease of maintenance and to limit the spare parts inventory, as far as is possible,
each class and category of electrical equipment shall be of the same type and
supplied by the same Supplier.

5.22.2. When similar classes and categories of electrical equipment are included in
packages, Suppliers shall be required to purchase the same standard types subject
it meets the package system requirement.
Installation
The installation of the all electrical power & control, telecommunication, fiber optic
cables and equipment shall be carried out under one or more subcontracts. Main
equipment, cables and bulk materials will be free issued to the installation
subcontractor but minor installation materials including fixings, brackets, steelwork
for site fabricated supports, conduit and conduit wiring, floor trunking, sand for
cable bedding and cover, cable tiles, trench markers and all consumables shall be
supplied under the subcontract on case to case basis.
Asset Management System
Critical equipment such as 220 kV GIS,33 kV GIS, critical power transformers
Process critical single ended large drives & Motors and other critical equipment etc.
shall have online condition monitoring sensors and associated monitoring devices.
These devices will be connected to Owner’s Asset Management System. Detailed
requirement shall be listed in specific equipment data sheets.
This section is not applicable for this document.
7. Supplier Data

Appendix A: CODES AND STANDARDS

IEC STANDARDS
Information Technology – Generic Cabling for Customer
IEC 11801
Premises
IEC 60028 International Standard of Resistance for Copper
IEC 60038 IEC Standard Voltages
IEC 60050-511 International Electrotechnical Vocabulary (IEV).
IEC 60079 Electrical Apparatus for Explosive Atmospheres
IEC 60085 Electrical Insulation-Thermal Evaluation and designation
Method for determination of the proof and comparative tracking
IEC 60112
indices of solid insulating materials
IEC 60120 Dimensions of ball and socket couplings of string insulator units.
IEC 60183 Guide to the selection of high AC voltage cables System
IEC 60204 Safety of Machinery – Electrical Equipment of Machines.
IEC 60216 Electrical Insulating Materials - Thermal Endurance Properties
Standard colours for insulation for low frequency cables and
IEC 60304
wires.
IEC 60364 Low -Voltage electrical Installations
IEC 60417 DB Graphic Symbols for Use on Equipment
IEC 60617-DB Graphical symbols for diagrams.
Optical fibres - Part 1-40 to 53: Measurement methods and test
IEC 60793-1-40 to 53
procedures
IEC 60794-1-1 Optical fibre cables - Part 1-1: Generic specification – General
Optical fibre cables - Part 1-2: Generic specification – Basic
IEC 60794-1-2
Optical cable test procedures
Residual strength of string insulator units of glass or ceramic
IEC 60797 material for overhead lines after mechanical damage of the
dielectric.
Heating Cables with Rated Voltage of 300/500V for Comfort
IEC 60800
Heating and Prevention of Ice Formation
IEC 60825-2 Safety of Laser Products- Part 2: OFCS
IEC 60909 Short-Circuit Currents in Three-Phase A.C. Systems
IEC 61082 Preparation of Documents used in Electrotechnology.
Round wire concentric lay overhead electrical stranded
IEC 61089
conductors.
IEC 61131 Programmable Controllers
Functional safety of electrical/electronic/programmable
IEC 61508
electronic safety-related systems.

Functional safety - safety instrumented systems for the process

IEC 61511
industry sector.
Electrical installations for lighting and beaconing of aerodromes -
IEC 61822
Constant Current Regulator
IEC 61823
AGL series transformers
Communication Network and systems for Power utility
IEC 61850
automation
IEC 62305 Protection against lightning
Electromagnetic compatibility (EMC) - Part 2-5: Environment
IEC TR 61000-2-5
description and Classification of electromagnetic environments
Surge Overvoltage and Surge Protection in Low-Voltage a.c.
IEC TR 62066
Power Systems - General Basic Information
Optical fibers - Measurement methods - Microbending
IEC TR 62221
sensitivity
IEC TS 61827 Characteristics of inset and elevated luminaires used on
aerodromes & Heliports
IEC TS 62033 Attenuation uniformity in Optical Fibers
IEC TS 62100 Cables for aeronautical ground lighting primary circuits
IEEE STANDARD
IEEE Standard for Surge Withstand Capability (SWC) Tests for
IEEE C37.90.1 Relays and Relay Systems Associated with Electric Power
Apparatus
IEEE C37.101 IEEE Guide for Generator ground protection
IEEE C37.102 IEEE Guide for AC Generator protection
Recommended practice for testing insulation resistance of
IEEE 43
electric machinery
IEEE Guide for the Application of Neutral Grounding in Electrical
IEEE C62.92.2
Utility Systems, Part II--Synchronous Generator Systems
Recommended practice for Electric Power Distribution for
IEEE 141
Industrial Plants
IEEE recommended practice for excitation system models for
IEEE 421.5
Power System Stability Studies
IEEE Recommended Practice and Requirements for Harmonic
IEEE 519
Control in Electric Power Systems

INDIAN STANDARDS
IS 513 Cold reduced low carbon steel sheets and strips
Porcelain insulators for overhead power lines with a nominal
IS 731
voltage greater than 1000 V
Use of Structural Steel in Overhead Transmission Line Towers -
IS 802
Code of Practice
Dimensions for hot rolled steel, beams, column channel and
IS 808
angle sections.
Code of practice for use of metal arc welding for general
IS 816
construction in mild steel.
IS 1076 Preferred Numbers
IS 1271 Electrical Insulation - Thermal Evaluation and Designation
IS 1646 Fire Safety of building (General) : Electrical Installations
IS 2121 Conductors and earth wire accessories for overhead power lines.
Code of practice for the protection of buildings and allied
IS 2309
structures against lightning
Metal fittings of insulators for overhead power lines with
IS 2486
nominal voltage greater than 1000 V
IS 2551 Danger notice plates.
IS 2629 Recommended practice for hot dip galvanizing of iron and steel.
IS 2633 Methods of testing uniformity of coating of zinc coated articles.
IS 3043 Code of practice for earthing
IS 3646 Code of practice for interior illumination
IS 3961 Recommended current ratings for cables
IS 4171 Copper rods and bars for general engineering purpose
Preferred panel cut-out dimensions for electrical relays – flush
IS 4483
mounting IDMTL relays
Guide for Selection and installation of Electrical Equipment for
IS 5571
Hazardous Areas (other than mines)
Classification of hazardous areas (other than mines) having
IS 5572
flammable gases and vapours for electrical installation
Code of practice for design, installation and maintenance of
IS 5613
overhead power lines.
IS 7816 Guide for testing insulation resistance of rotating machines
Guide for Preparation of diagrams, charts & tables for
IS 8270
electrotechnology.
IS 8945 Electrical measuring instruments for explosive gas atmospheres
IS 9080 Safety in electro heat installation

IS 9537 Conduits for electrical installations

IS 9628 Three phase induction motors with type of protection ‘n’
Tests on indoor and outdoor post insulators of ceramic material
IS/IEC 60168
or glass for systems with nominal voltages greater than 1000 V
ISO STANDARDS
ISO 1461 Hot dip galvanized coatings on iron and steel articles
ISO 1680 Acoustics – test code for the measurement of airborne noise
emitted by rotating electrical machines
ISO 2954
Mechanical vibration of rotation and reciprocating machinery –
requirements for instruments for measuring vibrations severity
ISO 3864 Graphical Symbols -Safety colors and safety signs
OTHER STANDARDS, ACTS, RULES & REGULATIONS

ANSI American National Standard Institute
ASTM American Society for Testing & Materials
Oil Industry Safety Directorate safety regulations and standards
OISD
for new petroleum, petrochemical, oil and gas installations
OISD-RP-149 Design aspects for Safety in Electrical system
Oil Industry Safety Directive (India) Guidance on Lightning
OISD-GDN-180
Protection.
CMRS Central Mining Research Station (Certifying Authority)
Underground armoured cable protected against solvent
EEMUA 133
penetration and corrosive attack.
Standard Test Procedure for Fiber Optic Fibers, Cables,
EIA/TIA 455-B Transducers, Sensors, Connecting and Terminating Devices, and
Other Fiber Optic Components
Structured cabling systems. This standard includes the
EIA/TIA 568A standards EIA/TIA TSB-36 and EIA/TIA TSB-40 covering UTP
cables and components.
EIA/TIA 568-A &-B Commercial Building Cabling for telecommunications
EIA/TIA 569 Telecommunication Pathway and Spaces
EIA/TIA 598-B Optical Fiber Cable Colour Coding
Customer-Owned Outside Plant Telecommunications
EIA/TIA 758-A
Infrastructure Standard
International Civil Aviation Organization – Annex 14
ICAO
Aerodromes

Standard for Vertical and Horizontal clearances of overhead

IRC 32 electrical power and telecommunications lines as related to
roads.
Definition and test methods for statistical non-linear attributes
ITU-T G.650.2
of single-mode fibre and cable
ITU-T G.652 Characteristics of a single-mode optical fibre Cable.
Optical interfaces for equipment and systems relating to the
ITU-T G.957
synchronous digital hierarchy
Form-Wound Squirrel Cage Induction Motors–375 kW (500 HP)
API 541
and Larger
Recommended Practice for Lightning Protection of
API 545 Aboveground Storage Tanks for Flammable or Combustible
Liquids.
API 546 Brushless Synchronous Machines – 500 kVA and Larger
NFPA 780 Standard for the Installation of Lightning Protection Systems.
The Electricity Act,
The Petroleum Act,
The Petroleum Rules,
The National Electrical Code of India
The National building code of India (NBC)
Tariff Advisory Committee (TAC) - India Insurance
The Indian Electricity Rules
Central Electricity Authority (CEA)- Regulations/Guidelines
National Association of Corrosion Engineers (NACE): (Guidelines for CP system)
DGCA Guidelines for Civil Aviation
CBIP Manual on Sub-Station Layout

Appendix B: PROJECT STANDARD SPECIFICATIONS & BEDDs

RPMS-ENGG-SPC-EL-001 Standard Specification for MV Switchgear
RPMS-ENGG-SPC-EL-002 Standard Specification for LV Switchgear
RPMS-ENGG-SPC-EL-003 Standard Specification for HV Motors
RPMS-ENGG-SPC-EL-004 Specification for LV Motor
RPMS-ENGG-SPC-EL-005 Standard Specification for MV Power Transformer
Standard Specification for Oil Immersed Distribution
RPMS-ENGG-SPC-EL-006
Transformer
RPMS-ENGG-SPC-EL-007 Standard Specification for AC UPS
Standard Specification for DC Uninterruptable Power Supply
unit
RPMS-ENGG-SPC-EL-009 Standard Specification for Batteries (DC and AC UPS)
Standard Specification for Diesel Engine Driven Synchronous
AC Generator Sets
RPMS-ENGG-SPC-EL-011 Standard Specification for Low Voltage Variable Speed Drives
RPMS-ENGG-SPC-EL-012 Standard Specification for Fiber Optic Cable
Standard Specification for Low and Medium Voltage Air
Insulated Busducts
RPMS-ENGG-SPC-EL-014 Specification for Energy Management System
Standard Specifications for Cathodic Protection System for
Underground Plant Piping
Standard Specifications for Cathodic Protection System for at
RPMS-ENGG-SPC-EL-016 Grade Tank Bottom, Tank Internal and Underground Vessels,
Marine Structures (Piles / Birth Platforms)
RPMS-ENGG-SPC-EL-017 Standard Specification for Off-line Lighting Inverter
RPMS-ENGG-SPC-EL-018 Standard Specification for Remote IO system
RPMS-ENGG-SPC-EL-020 Standard Specification for LV sandwich type Bus Duct
RPMS-ENGG-SPC-EL-021 Standard Specification for HV Cables
RPMS-ENGG-SPC-EL-022 Standard Specification for LV Power and Control Cables
RPMS-ENGG-SPC-EL-023 Design Guide for Earthing & Lightning Protection System
RPMS-ENGG-SPC-EL-024 Standard Specification for 220 KV Cable system
RPMS-ENGG-SPC-EL-025 Specification for 220 kV Switchyard (AIS)
RPMS-ENGG-SPC-EL-026 Standard Specification for Power System Studies
RPMS-ENGG-SPC-EL-027 Standard Specification for 33V KV Gas Insulated Switchgear
RPMS-ENGG-SPC-EL-028 Standard Specification for 220V kV GIS
Standard Specifications for Medium Voltage Variable Speed
Drives
RPMS-ENGG-SPC-EL-030 Standard Specification for Electrical Heat Tracing
RPMS-ENGG-SPC-EL-031 Standard Specification for EHV Power Transformer
RPMS-ENGG-SPC-EL-032 Standard Specification for IPBD

RPMS-ENGG-SPC-EL-033 Standard Specification for Transformer Oil
RPMS-ENGG-SPC-EL-034 Specification for 33kV Grade Solid Insulated Bus duct
Specification for Electrical requirements for packaged
Mechanical equipment
RPMS-ENGG-SPC-EL-036 Standard Specification for PLC Based Emergency Siren System

Standard Specification for Public Address / General Alarm
(PA/GA) System
RPMS-ENGG-SPC-EL-039 Protection Philosophy for Electrical Distribution System
Standard Specification for Electric Heater and Thyristor
Control Panel for Electric Heater
RPMS-ENGG-SPC-EL-044 Standard Specification for Dry Type Transformer
RPMS-ENGG-SPC-EL-045 Standard Specification for Neutral Earthing Resistor
RPMS-ENGG-SPC-EL-046 Philosophy for Unit Protections
Basic Engineering Design Data – Jamnagar Manufacturing
RPMS-ENGG-DBD-PS-001
Division
RPMS-ENGG-DBD-PS-007 Basic Engineering Design Data – Dahej Manufacturing Division

Standard Specification for HV Induction Motors

0 25.08.2020 Issued for Implementation KC/ PDG VGS/ US SK / VKM

By By By
Reliance Project Management System RPMS-ENGG-SPC-EL-003
Standard Specification for HV Motors Date: 25.08.2020, Rev 0
Sr. Name Signature Date (DD.MM.YYYY)

No.
Sundaram Kannan (Chairman)

1 _________________ ___________
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3
Kuddallur Seshadri _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
5. Technical and Design requirements ............................................................................ 3
6. Inspection and Testing: ............................................................................................. 20
7. Supplier Data ............................................................................................................. 21
Appendix A: Codes and Standards ...................................................................................... 26
Appendix B Modalities for Combined string Test ............................................................... 30
1. Scope
This Specification defines the minimum technical requirements for the design,
material, manufacture, inspection, testing, packaging, shipment and
documentation of high voltage induction motors up to and including a nominal
voltage of 11000 V AC, for Supplier and/or Contractor to comply with, to achieve
Owner’s objective of standardization.
The specification applies to motors to be used in safe areas and areas having
explosive gas or dust atmospheres.
Synchronous motors and submerged motors are not covered by this specification.
Supplier and/or Contractor may propose adoption of standard “off the shelf” sub-
systems, auxiliary equipment and components if those have proven past references
in similar service conditions. Owner will review, evaluate and approve deviations to
this standard specification that Supplier and/or Contractor may seek on this
account, prior to execution of Project Purchase Order.
Contractor shall be responsible for incorporation of relevant process licensor
2. References
Motors shall be designed, manufactured and tested in accordance with the latest
applicable sections of the codes and standards, detailed in Appendix A.
The following project specifications shall also be read in conjunction with this
document.
Electrical Design Basis RPMS-ENGG-DBD-EL-001
Project Paint Specification RPMS-ENGG-SPC-PP-027
Additional project specifications, as applicable to items of equipment, shall be
detailed in the Material Requisition.
shall govern:
1. Data Sheets and Drawing

Notes:
• “Data Sheets and Drawings” represent those attached to the Material Requisition
- Motor Datasheets, Motor Stock Code Item Description, etc.
Order.
ATEX Atmosphere Explosible
BEDD Basic Engineering design data
CIMFR Central Institute of Mining and Fuel Research.
ERTL Electronics Regional Test Laboratory
IEC International Electro technical commission
IS Indian Standard
ISO International Organization for Standardization
PESO Petroleum and explosives Safety Organization
RMS Root Mean Square
Definitions


Company
5. Technical and Design requirements

5.1. Service and Environmental Conditions
a) Motor shall be suitable for site environmental condition as stated in Datasheet.
b) Motors shall be suitable for use in a saline, sulphurous and dusty atmosphere as
commonly encountered in oil refineries, chemical plants or other such facilities.
Condensation, solar radiation shall be taken into account.
c) The motors shall normally be installed outdoors without shelter with a common
base plate on the foundation, unless otherwise stated in Motor Datasheet.
d) Motor shall be suitable to hazardous area classification as specified in data
sheet.
e) Motors shall be designed for operating in Seismic Zone, as specified in the
datasheet.
f) Service condition shall be as specified in the Motor Datasheet.
5.2. General
This specification shall be read in conjunction with all specifications, drawings and
datasheets attached with the Project Purchase requisition.
5.3. Codes, Standards Compliance
Motors manufactured in India shall be designed, manufactured and tested in
accordance with either IEC or IS codes and standards.
Motors and its components as applicable for use in hazardous areas shall be
certified by an approved testing authority and bear a label to show conformance
with the requirements. For gaseous hazardous area motors i.e. Zone 1 and 2 motors
manufactured in India shall have a test certificate from recognized labs and an
approval certificate from the PESO. For imported motors, PESO certificate can be
obtained by the local partner of the foreign vendor. The procedure for getting PESO
for motors should be as per document "Procedure for Approval of Ex (Electrical)
Equipment" available in the web portal http://peso.gov.in/index.aspx.

For dust hazardous area motors i.e. Zone 21 and 22 motors manufactured in India,
Supplier must submit certificates from recognized labs to Buyer. For imported
motors, Supplier to provide ATEX or IECEx certificate.
Motors intended for hazardous area application, when driven by a VSD, shall be
certified as a combined unit for operation with the VSD. Hazardous area motor
designed for operation with a variable speed drive shall be string tested as specified
in Appendix B.
If any one of the components or the whole system does not comply with the
specifications and any agreed amendments, the Supplier shall rectify and re-test
the motor(s) within a mutually agreed time.
VSD fed Motors, operating in gaseous hazardous area, manufactured in India,
needs the combined testing certificate from PESO. For imported motors, vendors
to provide ATEX or IECEx certificate and PESO certificate can be obtained by the
local partner of the foreign vendor.
VSD fed Motors, operating in dust hazardous area manufactured in India, needs the
combined testing certificate from approved testing labs. For imported motors,
vendors to provide ATEX certificate. Buyer shall check for performing the string test
before ordering of VFD motor with an extra quotation.
5.4. Life
a) The minimum life of the motor shall be at least 25 years. The motor shall be
suitable for continuous uninterrupted operation for periods of at least 5 years.
However, within this five year period, periods of running may alternate with
idle periods of up to 6 months. Re-greasing of bearings or replenishment of lube
oil, if required, shall be possible with the motor in operation. Rolling element
bearings are exempted from the expected lifetime requirement. A self-
lubricated bearing will require periodic lubricating oil changes. A five year
continuous uninterrupted operation may require the installation of a forced oil
lubrication system for the bearings.
b) Machines shall be designed for continuous operation and long periods of
inactivity in an atmosphere that is made corrosive by traces of chemicals
normally present in a petroleum processing facility. This environment may also
include high humidity, storms, salt laden air, insects, plant life, fungus, and
rodents. Machines shall be suitable for operation, periods of idleness, storage,
and handling at the ambient temperatures specified under “Site Data” on the
datasheets.
5.5. General Design Features
5.5.1. Degree or Protection

Unless otherwise specified on the Motor Data Sheet, motors shall be totally
enclosed fan cooled, TEFC, totally enclosed with air to air cooled TEAAC or CACA,
or totally enclosed tube ventilated, TETV.
Large motors, especially where air-cooling alone cannot suffice the cooling
requirements, CACW can be offered and subject to Buyer approval . For CACW
motors, the water composition details are to be shared with motor vendor. The
Supplier shall mention the material of construction (MOC) for the heat exchangers
for CACW motor. Motors installed On-shore shall have a minimum degree of
protection of IP55 and those installed Off-shore shall have a minimum degree of
protection of IP56. Motors for dust hazardous area shall have a minimum degree
of protection IP65.
5.5.2. Type of construction and mounting
Unless otherwise specified, the type of mounting for standard motors shall be
either IM B3 (IM 1001), IM B5 (IM 3001), IM V1 (IM 3011), or IM V6 (IM 1031) in
accordance with IEC 60034-7.
Vertical motors with a downward drive-end shaft shall be provided with a canopy
over any upward facing air inlets to prevent entry of water or any other
contaminant.
Bearing housings, especially for vertical motors with upwards drive-end shaft,
(mounting arrangement IM V3 [IM 3031] and IM V6 [IM 1031] to IEC 60034-7) shall
be sealed to prevent water entry to the motor via the shaft. Water and dirt
collecting on the upper bearing end-shield shall not reduce the performance or
lifetime of the motor. If sealing of bearing housing is not possible, the motor shall
have rainwater deflectors fitted to the shaft which prevents the ingress of water
into the motor and/or bearing housing via the shaft or grease relief drains.
Bearing sealing arrangement to be provided for all types of motors as per their
design. Vendors to ensure proper bearing fitment tolerance with respect to shaft
and end shield cover during assembly stage.
Oil reservoirs and housings that enclose moving lubricated parts such as bearings,
shaft seals, highly polished parts, instruments, and control elements, shall be
designed to meet the requirements of IP 55 as a minimum to reduce contamination
by moisture, dust, and other foreign matter.
The mounting requirement shall be indicated in the motor datasheet.
Frame sizes shall be in accordance with IEC 60072-1 and IEC 60072-2.
All insulation materials shall be class F and the rating of the motor offered by the
Manufacturer shall be based on a class B temperature rise for all parts of the motor
windings.

The design of piping system shall achieve the following:

a. Proper support and protection to prevent damage from vibration or from
shipment, operation, and maintenance
b. Easily accessible for operation, maintenance, and thorough cleaning
c. Installation in a neat and orderly arrangement adapted to the contour of the
machine without obstructing access openings
d. Elimination of air pockets and traps
e. Complete drainage through low points without disassembly of piping
f. Provision for easy removal of covers for maintenance and inspection
For horizontal mounted motor feet, the acceptable limit of co-planar tolerance of
motor feet and the parallelism error should be below the figures mentioned under:
• The coplanar tolerance between two different mounting pads shall be limited
to below 0.08 mm i.e. 80 microns.
• Individual pad bottom surface leveling should be limited below gradient of
0.32 mm/meter in longitudinal as well as transverse direction. While verifying
this limit a feeler gauge of 80 micron should not penetrate any gap between
bottom of the feet and surface plate in at least 80% of the contact area of the
feet.
• Motors rated higher than 2 MW may have coplanar tolerance limited to 125
microns.
• These checks will be done as the stage check inspection on the machined
stator frame. Test records will be offered as part of test certificate.
5.5.3. Hazardous Area Motors
Motors for use in hazardous areas shall meet the explosion requirements as
specified in the Motor Data Sheet. Explosion protection shall be in accordance with
IEC 60079.
For motors intended for use in hazardous areas, component parts of the motor
enclosure shall be provided with bonding conductors to prevent incendive
sparking.
The datasheet will specify the details of the classification of the area of installation.
This will include the zone, gas group and temperature class.
The specification of electrical motors for use in areas where there is a dust hazard
shall be in accordance with IEC 60079-31, datasheet shall provide the relevant
details.

Unless otherwise stated in the requisition the following types of protection are
acceptable:
Zone 2 Exec* for rating <or equal
2 MW, Exp for rating ≥
2MW
Zone 1 Exde for rating < 1 MW,
Exde or Exp for rating ≥
1MW
Zone 20 No motor is allowed
Zone 22 Ex “ta/tb/tc” IIIA/IIIB/IIIC
* Risk assessment for possible air gap shall be carried out for Exec type motors
in accordance with IEC 60079-7.
For the motors of protection class Ex "ta/tb/tc" rated for dust hazardous area Zone
21, 22 shall comply the requirement of IEC 60079-31 and ingress protection be
IP65.
As per new IEC guidelines IEC/EN 60079-7:2015, markings of motors will be
changed from Ex nA to Ex ec and from Ex e to Ex eb. Motors with protection Ex-d
shall comply with the requirement of IEC 60079-1. Terminal box for Ex-d motor shall
be of protection Ex eb or Ex-d.
Motors with protection Ex-p shall comply with IEC 60079-2. Terminal boxes fitted
to the motor shall be of protection Ex eb, Ex-p or Ex-d.
Motors with protection Ex eb shall comply with IEC 60079-7. Winding and rotor
temperatures shall, under operating conditions, not exceed the limiting
temperature determined by the applicable temperature group and winding
temperatures rise shall be limited to Class B insulation materials.
Motors with protection class Ex ec shall comply with IEC 60079-15. Auxiliary devices
mounted (for protective, alarm or other purposes) on the motor with protection
class ec shall be of protection class suitable to hazardous area (zone, gas group,
and temperature class).
Ex ec motors shall be provided with prestart purge system with necessary
connections for the enclosure for purging. Supplier shall provide purging air
volume, purging time and maximum purge air flow rate for Ex ec motors with
quotation.

Ex ec motors gas test shall be performed for both stator and rotor as a part of type
tests. The type test reports shall be furnished along-with the quotation. The frame
sizes which have valid PESO certification for gas test shall be indicated by Bidders.
Exp motor shall have purging provision in terminal box as well as motor enclosure.
Supplier shall provide following details of purging kit e.g. make, purge time, purging
airflow, requirement of external power supply, provision of pressure transmitters
for tripping , trip logic etc.
Note: For motors having Purge / Pressurization unit, the trip on loss of pressure
shall be taken from 3 separate sensors and trip is initiated only if 2 sensors are
indicating loss of pressure.
Motor fed from voltage converter shall have insulation systems assigned to stress
categories defined in IEC 60034-18-41 and 42 and plan of introduction of “Impulse
Voltage Insulation Class” (IVIC).
5.5.4. Anti-Condensation Heaters
Anti-condensation heaters shall be provided for all motors and shall be of a fully
insulated design. Heaters shall be designed to operate on 240 V, 50 Hz single phase
ac supply. Motor vendor to perform internal quality checks for healthiness of space
heaters.
Heaters shall be arranged to provide uniform heating of the stator and, if
applicable, the rotor windings, and shall maintain the temperature of the windings
at approximately 5oC above ambient temperature.
The surface temperature of the heater element, or the motor enclosure, shall not
exceed the limiting temperature specified in data sheet based on temperature
class.
The connecting leads of the heater elements shall be brought out to terminals in a
separate heater terminal box mounted on the motor frame. A prominent warning
label shall be provided to indicate that the circuit may be live when the motor is
stationary.
5.5.5. Vibration
The measurement of vibration shall be carried out with half key in its shaft
extension for motors. Vibration severity shall be measured in state of rigid
mounting only (free suspension method of vibration measurement is not
acceptable).
The vibration velocity shall be measured in RMS value in mm/sec. This measured
value shall not exceed value as stated in IS 12075/IEC 60034-14 (Grade A). This is
applicable for motors of all ratings and speed.

The maximum allowable vibration levels shall apply to all operating temperatures
of the motor between ambient and maximum operating temperature and for
operation on no-load.
5.5.6. Cooling
Heat exchangers shall be manufactured from materials which are corrosion
resistant to the site atmospheric conditions and other cooling mediums. The
specification of the materials to be used shall be submitted to the Client for
approval. Aluminum, if used for heat exchangers, shall be copper free. The material
shall confirm to IEC 60079-0. The flow of cooling medium shall be towards the
driven equipment.
Heat exchangers for air-to-water cooled motors shall be of the single tube design
and shall have a 20 % surplus number of tubes to allow for plugging of leaking tubes
over the lifetime of the motor.
The water box/header construction of heat exchangers shall be such that leaking
tubes can be readily plugged and all tubes are accessible for cleaning.
Minimum accessories for cooling water arrangement motor shall include cooling
water outlet temperature gauge, cooling water outlet pressure gauge, water
leakage detector and water flow measurement device. Motor vendor shall confirm
that the water flow measurement device for the motor shall be supplied as a loose
item. Piping contractor to install the water flow measurement device during the
fabrication stage.
The coolers shall be pressure-tested at 1.5 times the maximum working pressure
for 15 minutes to demonstrate the withstand capability. If the water pressure in
the cooler is controlled by a valve or pressure-reducing device connected to a water
supply of higher pressure than the working pressure of the cooler, the cooler shall
be designed for the higher pressure, and tested at 1.5 times the higher pressure
value.
Cooling fans shall be unidirectional for all motors. The direction of rotation shall be
as indicated in the data sheets.
Fan cooled motors shall be provided with non-sparking, non-corroding fans. If
aluminum fans are provided for motors intended for use in hazardous areas, they
shall be of copper free aluminum.
External fans shall be selected to have the most favorable noise characteristics.
Separately driven fans shall be employed only where performance requirements
cannot be met by a shaft driven fan.
5.5.7. General

Materials that are hygroscopic or toxic shall not be used for motor
housing/enclosure. The materials used shall be selected to prevent contact
corrosion. All motors shall be designed for continuous running duty, type S1 in
accordance with IEC 60034-1 or IS 12824 unless otherwise specified in the
datasheet.
All frames and bearing end-shields shall be made of ferrous materials. Aluminum
enclosures are not acceptable for motors intended for use in hazardous areas.
Aluminum is acceptable for auxiliary terminal boxes provided the material confirms
to IEC 60079-0.
Non-metallic materials shall be fire resistant, antistatic and stable in the presence
of hydrocarbon liquids, vapors and H2S gas.
All motors shall be equipped with a corrosion resistant drain in the low point of the
enclosure, accessible from the exterior of the motor except where the design is
such as to make the collection of condensation within the casing impossible or a
drain cannot be provided due to requirements of standards.
The direction of rotation of the motor shall be clearly indicated on the drawing and
on the motor by raised or embossed markings. If bi-directional fans are provided
the direction of arrow shall have two points.
Motors shall have pilot holes for tapered dowels on the drive end. Holes shall be
located so that the field drilling, reaming and placement of dowels shall not require
removing parts of the motor.
Split type lugs OR split type studs shall not be used for electrical connections /
terminations.
All motors shall be provided with threaded holes for vertical jacking. There should
not be any thorough holes between Eye bolts (lifting hooks) and End shields.
5.6. Electrical Operational Requirements
The nominal voltage and frequency shall be as indicated in the motor datasheet.
Motors shall be suitable for switching by all normal switching devices including SF 6
and vacuum break type contactors and circuit breakers without the installation of
surge arrestors.
All motors shall be provided with a minimum of six embedded resistance
temperature detectors in the stator winding with the connections brought out to a
separate terminal box. These shall be the platinum resistance thermometer
elements, resistance 100 ohms at 0 oC, three wire simplex type preferably.
Motors intended for variable speed applications shall be as per IEC/TS 60034-25 -
2014. Motors shall be designed to ensure that there is no overheating at the design
minimum speed.
Motor rotor with rigid (stiff) shaft design, the first critical speed shall be 125%
higher than the motor synchronous speed. Motor rotor with flexible shaft design
the first critical speed shall be between 60% and 80% of synchronous speed and
the second critical speed shall be above 125% of synchronous speed.
5.7. Voltage and Frequency variations during Operations
The motor shall be suitable for operating under voltage and frequency variations
as given below:
Voltage: ± 10%
Frequency: ± 3%
The maximum combined voltage and frequency variation will not exceed 10%.
5.8. Starting, re-starting and re-acceleration requirements
The starting current shall not exceed 6 times (including positive tolerance) the rated
current of the motor. Stringent requirements if any will be specified in the motor
datasheet.
To facilitate the successful starting of DOL Motors at varying system voltages and
to prevent from inadvertent tripping due to conservative relay settings, motor
'Run-up time at 80% of rated voltage' shall have sufficient margin with the Motor
'Locked-rotor withstand time at 100% of rated voltage', as committed in the Motor
datasheet. A minimum value of 2 seconds is essential for the protection relay to
distinguish between a 'successful start' and a 'Locked-rotor' condition. For high
inertia loads if above mentioned requirement shall not be achievable, supplier shall
inform and provide the alternate solution during quotation stage for Buyer
approval.
Motors shall be suitable for direct-on-line.
Motors shall be capable of re-acceleration under full load conditions following a
power interruption if specified in data sheet. Driven equipment speed-torque
reference and any special reacceleration -curve reference (Voltage variation with
time), maximum voltage interruption time and voltage available at motor terminal
to reaccelerate shall be indicated in data sheet.
All motors requiring re-acceleration shall be suitable for restarting against:
• A residual voltage and voltage interruption time as defined in data sheet.
• 180 degrees out of phase
• Under full load conditions
• Voltage between 80% to 100% of rated voltage applied at motor terminals

The torque-speed characteristic of the motor with rated frequency and 80% rated
voltage applied at the motor terminals shall be adequate for starting the driven
load under the most severe conditions. Under these conditions the accelerating
torque shall be not less than 10% of the full load torque at any point.
At any voltage between 80% and 100% rated voltage, motors (including their unit
transformers if applicable) shall be capable of:
• 3 consecutive starts with 20 minutes rests between starts (cold start)
• 2 consecutive starts per hour right after coasting down (hot-start)
Between consecutive starts the motor may be assumed to decelerate under

operating conditions. Required cool down period between two consecutive start
(hot-start) shall be indicated by Supplier.
After a cooling period of 30 minutes at standstill, another starting sequence of at
least two successive starts shall be possible.
5.9. Terminal Boxes
Unless otherwise stated in the motor datasheet, the main terminal box shall be
located at the left hand side of the motor when viewed from the non-drive end.
The design shall allow the box to be rotated to accommodate cable entry from
three positions 90 degrees apart, not facing the driving end.
Terminal boxes for main cable connections shall be air insulated phase segregated
type and sized to accommodate termination of cables specified on the motor
datasheet. Terminal boxes for neutral shall be air insulated type. The mounting
flange for both phase and neutral terminal boxes shall be the same to facilitate
interchange of terminal boxes. Adequate lead length shall be provided from motor
stator winding to enable interchange of terminal boxes.
Main terminal box dimensions shall be sufficient enough to accept heat shrinkable
termination kit components. The requirement of type of kit to be agreed between
Buyer and motor supplier before ordering of motor. In case of multiple runs, it is to
be ensured that cores of different phases should not touch each other. There shall
be sufficient clearance as per termination kit manufacturer to avoid surface
tracking.
Terminal boxes shall be provided with synthetic resin bushings and/or post
insulators for the termination of the main cables. Porcelain shall not be used for
these components.
The terminal boxes and associated fittings shall be capable of withstanding short
circuit current for time as specified in data sheet. Vendors to provide fault
withstand current certificate during ordering of motor.

Clamping devices shall be provided inside the main terminal box to separate and
support the cable conductors and, if applicable, the winding end-tails, thereby
ensuring that the ability to withstand the short-circuit current will be maintained
after completion of the termination. Materials used for the clamping devices shall
be non-hygroscopic. The arrangement of clamping devices inside main terminal box
shall not hinder cable connection.
The design of the terminal box shall ensure to prevent small parts from dropping
into the motor housing. All leads shall be brought out to the terminal box through
gasketed seals.
Inside the terminal box an earthing clamp or bolt of adequate dimensions shall be
provided for connection of the cable earthing and earth continuity shall be
established between the connector and the motor frame. The earthing facility shall
be clearly marked with the appropriate symbol.
For type Ex ec, Ex- eb, Ex-p and non-hazardous area motors, undrilled gland plate
shall be provided. For type Ex-d motors, tapped entries shall be provided in
accordance with the motor data sheet. The tapped entries shall be supplied with
Ex-d blanking plugs. Supply of cable glands shall not be in the scope of motor
supplier.
The design of box shall allow for the removal of the motor without breaking or
stressing of the cable sealing. An easily disconnect able type of connector is
preferred for the termination of the incoming stator cable on HV motors. The cable
box shall have flanges or pads so that it can be supported in place when the motor
is removed. Terminal connectors provided inside motors shall be as per suitable
cable sizes. Lugs to be provided by the motor vendor in case the connectors do not
match with the actual cable size.
The neutral terminal box shall be located at the opposite side of the motor from
the main terminal box. For motors of rating 1500 kW and above, the neutral
terminal box shall be sized to accommodate current transformers for differential
protection. The current transformer supply shall not be in the scope of motor
manufacturer; however, all the details of current transformer will be provided to
the motor manufacturer by the Client in order to size the neutral terminal box.
Neutral TB arrangement should be as per type of CT (wound type/window type)
defined by Buyer.
If self-balancing type differential protection specified in motor data sheet, all the
CT shall be supplied and installed by motor supplier.
Terminal boxes shall be made weatherproof by the use of non-sticking, non-
hygroscopic re-usable gaskets unless precluded by certification requirements.

Terminal diagrams of a suitable non-degradable material shall be fixed inside the

terminal boxes. All terminals shall be clearly marked as per the terminal diagram.
Terminal marking of the main cable connections, and the direction of rotation, shall
be in accordance with IEC 60034-8.
Separate terminal boxes shall be provided for space heaters, current transformer
connections and other auxiliary devices like RTD, BTD, Vibration probes, water
leakage detector etc. The glands for the cable entry of RTD/BTD should be Exd IIC
type.
In order to enable ease of cable entry without obstructing the driven equipment/
motor base frame, the main terminal box shall have the cable entry angled at 20
degree to the vertical. Motor manufacturer may also propose main terminal box
extended from the motor body through an adaptor box as an option.
Main and neutral terminal box cover shall have handles.
5.10. Rotor
The shaft shall be made of one-piece, heat-treated steel. Welding on finished shafts
is not allowed. Shafts and spiders subjected to welding shall be post-weld heat-
treated. Rotor material to be specified for all the motors in the general
arrangement drawing.
If non-contacting eddy current proximity probes are to be fitted, the surface finish
of the shaft at the fitting point shall be as specified in API 670.
The rotor, internal fan(s) and other components, if fitted, shall be dynamically
balanced with the key-way(s) fully filled with half key(s).
The external fan shall be independently balanced, also with the key-way fully filled
with a half key, prior to balancing the complete assembly. The deviation shall not
exceed the G2.5 limits in accordance with ISO 1940-1.
Lead or similar ductile material shall not be used for balance weights.
If metal is to be removed to achieve static or dynamic balance, it shall be removed
in a manner that maintains the structural integrity of the rotor and does not result
in hot spots liable to distort or otherwise harm the rotor.
The balancing material shall be secured in such a way that there is absolutely no
possibility of it becoming loose during the lifetime of the motor.
Mechanical shaft runout shall not exceed 0.05 mm for horizontal motors and 0.025
mm for vertical motors.
Magnetic center & float shall be marked on the shaft.
Circlips for shafts shall be in accordance with IS 3075 (Part1).

Rotor bars shall be fully locked into place or insulated.

5.11. Stator windings
Coils shall be made using rectangular copper conductors, covered by a mica tape or
other insulation material of similar dielectric strength and ageing properties. Wire
windings are not acceptable.
All windings shall be adequately supported, braced and wedged over the total slot
length to limit coil and end winding vibration and subsequent cracking of the
winding insulation. Bracing, blocking and wedging shall be positively secured to
allow for the vibration and forces experienced during the expected 25 year service
life of the motor.
Windings, including joints, connectors and leads to the main and star point
terminations shall be able to withstand the dynamic forces which result from
frequent starting and from re-starting against full opposite residual voltage over
the lifetime of the motor.
All coils shall have anti-corona protection, achieved by means of a semi-conducting
tape in the slot part of the coil.
Where the rated voltage is in excess of 7 kV, all coils shall, in addition to anti-corona
protection, have stress grading.
The insulation shall be form-wound, epoxy vacuum pressure impregnated (VPI)
sealed insulation system.
5.12. Coupling
The shaft ends shall be provided with a suitably threaded hole or holes to facilitate
the assembly or removal of the coupling and bearing races.
Shaft extensions, keys and keyways shall be in accordance with IEC 60072-1 and IEC
60072-2.
5.13. Bearings
All motors, except those required to be explosion proof, shall have non-contact
labyrinth or taconite dust resistant shaft seals. Proper bearing fitment tolerance
with respect to shaft and end shield cover should be maintained for all motors.
All two pole horizontal motors above 750 kW and all four or higher number of pole
motors above 1500 kW shall be provided with sleeve bearings.
All motors shall be provided with duplex platinum resistance thermometer element
(RTD), resistance 100 ohms at 0 oC, three wire type, in each bearing. All motors shall
be provided with local bearing temperature gauge without alarm and trip contacts.

If the shaft voltage measured across the ends of the shaft exceeds 250 mV (rms) for
rolling element bearings/ball bearings or 400 mV (rms) for sleeve bearings, bearings
or the end shield shall be insulated.
Bearing insulation, if required, shall comply with the following:
• It shall be provided on all bearings.
• The method of insulation shall be permanent and non-deteriorating during
assembly and disassembly of the bearing.
• An earthing connection, removable for test purposes, shall be provided at the
coupling-end bearing. Care shall be taken not to bridge the insulation by any
other connection.
• For single pedestal bearing motors, the insulation system shall be of
‘sandwich’ construction with two separate insulating layers. A removable
earthing connection shall bridge one layer to ensure equipotential bonding of
the middle conducting block.
• Insulation layers which must be kept non-conducting during normal running
shall bear a prominent warning label reading: “Caution: Bearing must be kept
insulated”. Warning label shall be affixed at the non-drive end of the motor.
Motor supplier should clearly mention the requirement of insulated bearings,
insulated couplings, shaft grounding devices etc. before ordering of motor to keep
shaft voltage within limit. All motors shall have provision for installation of vibration
monitoring equipment, (X and Y probes), on each bearing. The type and make of
vibration monitor (Accelerometer and proximity probes) shall be informed to the
motor manufacturer by the Client. Provision of installation of vibration probes shall
be properly checked and provided by motor vendor. Wiring logic shall be as per
standard specifications for machine condition monitoring system( MCMS) RPMS-
ENGG-SPC-CI-011.
5.13.1. Roller Bearings
Vertical motors driving direct coupled pumps shall have the thrust bearing at the
non-drive end. Stacked bearings are not acceptable. Where the thrust exceeds the
capacity of antifriction bearings, Kingsbury-type or equivalent thrust pad bearings
with high oil or bearing temperature alarm contacts shall be provided. Proposal
shall state the method of cooling the thrust bearing and the losses due to it that
are not included in the motor efficiency.
The use of angular contact bearings shall be restricted to vertical motors where the
bearings have to accept high axial forces.
Rolling element bearings shall have grease relief systems where new grease
displaces the old grease which, together with any surplus, is automatically ejected
to the outside of the motor casing. Unless otherwise specified by the Client, lithium
based greases shall be used in the bearings.
Bearings shall have a rated L10 lifetime in excess of 50,000 hours under the worst
case operating conditions as specified in the requisition and in this specification.
The lifetime shall be calculated in accordance with ISO 281.
Re-lubrication shall be possible with the motor in operation and without
dismantling parts. Bearings shall be constructed so that excess grease is positively
ejected from the bearing to the outside of the motor to prevent formation of a skin
which can prevent grease from reaching the rolling elements. Motor should have
proper inlet and outlet provision of grease.
Ball bearings shall have a C3 internal radial clearance. Roller bearings may have a
normal or C3 internal radial clearance.
5.13.2. Sleeve Bearings
Sleeve bearings shall be of the spherical seated, self-aligning type
Radial sleeve bearings shall have replaceable liners or shells.
The bearing design shall suppress hydrodynamic instabilities and provide sufficient
damping to limit rotor vibration to the maximum specified amplitudes at both
operating and critical speeds.
Bearings shall be suitable to start the motor without the aid of oil jacking.
The bearing housing design shall permit replacement of the bearing liners without
disassembly of coupling or other motor parts.
For all horizontal sleeve bearing motors 12 mm minimum rotor end play shall be
provided. The clearance shall be exclusive of the bump washer. Bump washers shall
carry no load in normal operation.
The shaft position when electrically centered, and the end play limits, shall be
scored on the motor shaft extension with a corresponding mark on the bearing
housing. The shaft position indicator shall be protected from damage or movement.
Manufacturers shall state the permissible end float of the motors. Motors will not
normally be required to absorb thrust from driven equipment.
Where sleeve bearings are furnished with oil-ring lubrication only, each bearing
housing shall have an oil level indicator, which shall be visible without disassembly
of any motor parts or noise abatement material. The recommended oil levels shall
be marked to show stationary, running, normal, and minimum levels.
Where pressure lubrication is offered, the lubrication oil system shall include
sealing of the bearing housing to prevent oil leakage.
5.14. Lube Oil System
Where common lube-oil systems are used, the driven equipment Supplier is
responsible for supplying the common lube-oil system. The motor Supplier is
responsible for informing the driven equipment Buyer of the lubrication
requirements for the motor bearings. All oil piping shall be flanged or studded,
and/or welded. Screwed connections and unions shall not be used in pressure
containing lines and connections Motors which requires forced lubrication, driven
equipment vendor shall consider the forced lubrication requirement for the motor
in their scope and interconnecting piping between lube oil system (skid) & motor
bearing house. This shall be discussed during motor ordering stage. Surface Finish
Motors shall have external surface finish as indicated in the motor datasheet. The
finish shall provide adequate protection against corrosion under the specified site
conditions.
Variable Speed Drive motors shall be painted with shade Lemon (RAL shade 1012)
If special treatment is needed because of extreme environmental service
conditions as indicated in the requisition, the Manufacturer shall provide details of
the proposed special surface treatment in the quotation. Vendor to provide C5M
paint for safe area motors used in in highly corrosive areas like Sea Water, cooling
tower, coker, sulphur areas etc. For hazardous area classification, the C3 paint to
be considered unless otherwise recommended by site.
5.15. Noise
The sound pressure level of the loaded motor shall not exceed limits prescribed in
IS 12065/IEC 60034-9, measured in accordance with IS 12998 / ISO 1680 unless
otherwise stated in the requisition.
Motors shall meet the maximum allowable noise limits by design and not by
corrective measures. If this is not possible, the Supplier shall state the proposed
corrective measures for the approval of the Buyer.
Where the use of internal soundproofing material is unavoidable, the liners shall be
fixed in such a way that no parts can become loose within the motor housing, e.g.
by means of a suitable retaining mesh.
The acoustic measures shall not obstruct routine inspection and maintenance
activities such as lubrication of bearings, and inspection of oil levels. The maximum
allowable temperature rise of the motor windings and bearings shall not exceed
the limits specified in this specification.
5.16. Rating Plate & Serial Number
Every motor shall be provided with a rating plate or plates. Rating plates shall be
made of stainless steel and shall be securely fixed to a non-removable part of the
frame. If additional rating plates are mounted on removable parts, the

Manufacturer's serial number and reference shall be repeated on these rating

plates.
The rating plates shall be marked with data in accordance with Codes and
Standards.
Marking of Serial Number shall be done at a non-detachable part of the motor body
also in addition to the main name plate.
Marking and data shall be provided in motor rating plate as per IEC 60034 -1 but
not limited to data given below:
• Manufacturer’s name
• Country of origin
• Rated output.
• Rated voltage and winding connection.
• Rated current.
• Rated frequency and number of phases.
• Rated speed.
• IP Rating of motor, main, neutral & auxiliary terminal box.
• Efficiency at full load.
• Power factor at full load.
• Maximum ambient temperature, if other than 40 degree Celsius
• Class of insulation and temperature rise.
• Client’s Purchase Order number and Order date.
• Bearing details like make, type, size, lubricant, re-lubrication interval, etc.
• Locked rotor current/torque at rated voltage and frequency.
• Purchaser's equipment tag number.
• Net Weight of the motor.
• Manufacturer's order number, serial number, month and year of
manufacture.
Hazardous area motors shall have a separate rating plate providing following data:
• Certification provided for the motor
• Certification provided for main and neutral terminal box

• Certification provided for auxiliary terminal box

• Certificate number provided by relevant testing authority
6. Inspection and Testing:
a) All motors shall be subjected to the routine tests. The motor Supplier shall
provide certified test results of all the routine tests carried out on each motor
b) Type tests, if specified in the material requisition, shall be carried out on at least
one motor of each type of the lot ordered. The motor that need to undergo type
test shall be decided with the Buyer during Purchase order stage.
c) Type tests and routine test should comply with relevant IEC 60034 standards .
d) The purchase requisition shall state the tests to be witnessed by Buyer or their
nominated agency.
6.1. Routine Tests
Routine tests shall comprise of the tests listed below as a minimum.
• Visual check, Dimensional check, name plate details, statutory references
• Resistance of windings (cold)
• No-load losses and current
• Withstand voltage test
• High voltage test and insulation resistance test on Heater & Built-in
temperature detectors
• Direction of rotation and phase sequence
• Locked rotor current and torque
• Vibration measurement under no load
• Polarization Index test on stator windings
• Shaft voltage at no-load
• Physical inspection for compliance with this specification and the requisition
including inspection of cable entries, earthing bolts, terminal boxes,
enclosures, name plates, lubrication and re-lubrication facilities, etc.
• Purge kit tests for functionality test of Purging & Pressurization unit shall be
included in case of Ex p motor and water leakage detection test in case of
water cooled motor (CACW)
• The measured soft foot value shall be shared with RIL for all motors.
• Assembly stage reports or check sheets like labyrinth sealing arrangement,
dimension of spigot length of NDE/DE side outer bearing caps, correct
direction and design of external cooling fans, proper tightness of internal

cooling fan, bearing fitment tolerances with respect to end shield bores and
shaft, correct bearings types, fixing of Inner bearing cap and outer bearing
cap at correct position etc. shall be reviewed during inspection.
Note: Locked rotor current and torque shall be measured at rated voltage, or as
near as limitations at the test site allow. Where rated voltage cannot be achieved,
the method of extrapolation used to obtain the full voltage values shall be detailed.
6.2. Type Tests
Type tests, where required, shall be indicated separately in the purchase order. The
tests to be performed shall be as per standards. However, type test reports shall be
submitted along-with the offer.
Type tests shall comprise of the routine tests as well as tests listed below as a
minimum: -
• Temperature rise test
• Load test
• Calculation of Efficiency, Slip, PF on 100%75%, 50% load,
• Momentary overload test
• Over speed measurement
• Noise level
• Shaft Voltage measurement
• Starting current, starting torque measurement by calculation method
Note: In addition to the above mentioned tests, Vendor is required to perform the
following tests at their works:
• Combined testing/simulation of prototype Motor and Relay: This is required
to program and replicate the actual thermal characteristics in the Relay and
to prevent inadvertent tripping of the Motor in case of Run-up, Re-starting
and Locked rotor conditions.
• Termination activity of prototype Motor with committed Cable size: Vendor
to display the termination for prototype motor with the maximum power
cable size as approved by RIL. This is required to validate the compatibility
of power cables with Motor terminal box.
For VFD fed motors, "Appendix B", shall be referred for applicable test.
7. Supplier Data
Document to be submitted along with quotation and post order shall be as per the
list provided in the Material requisition. Following documents are at a minimum to
be submitted to the Buyer in soft copy.

Sr. No. Description Along Post

with Bid Order
1 General arrangement √ √
(Preliminary)
(Each frame size of motor showing arrangement of
components, terminal boxes and lifting points)
2 Performance characteristics √ √
(efficiency, power factor at Full,3/4,1/2,1/4
Load, starting current, noise level at no load)
3 Speed Torque and Speed current √ √

(Preliminary)
curves
4 Motor Datasheet √ √
5 Hazardous area Motor certificate √ √

(from IECEx / CIMFR / ERTL / CCoE (PESO) /
DGMS and DGFASLI)
6 Type Test Certificates (Valid) √ √
7 Technical literature √
8 Reference list √
(Supplied motor of comparable rating during

the last five years)
9 List of recommended commissioning √

spares
10 List of recommended operational √
spares
11 Supplier’s quality assurance program √
12 Deviation list √
13 Quality Plan √
14 FAT/SAT Procedure √
15 Detail drawing of main terminal box √
16 Detail drawing of auxiliary terminal √

box
17 Complete test reports √
18 Declarations of Conformity √

(for explosion protected equipment)

19 List of capital spares √
20 Utility requirement for cooling water √

and Instrument air
21 Instrument data sheets for all √
instruments associated with motor
22 Motor shaft loading diagram √
23 For Ex p motor Purge Kit GA, Wiring √

Diagram, O & M manual, P & ID to be
provided
24 Lubrication schedule and √
specification of lubricant
25 Installation, Operation and √
maintenance manual
26 Outline drawings for each motor √
(showing main dimensions, mass,

arrangement of components, terminal boxes,
foundation loading, center of gravity,
magnetic center and lifting point)

for each motor
28 Schematic and connection diagrams √
for each motor
29 Filled up motor data sheet for each √
motor
30 Purge air requirements such as flow √
rate, pressure and time for pre-start
purging of the motor in case of Ex ‘n’
motors for each motor
31 Motor torque speed curve plotted √

against the load torque speed curve
at both 100% and 80% of rated
voltage: A table showing the values of
torque vs speed plotted shall be

submitted – for each Motor
32 Motor GD2 and Locked rotor power √
factor for each Motor
33 Hot and Cold thermal withstand curve √
voltage for each Motor.
(A table showing the values of current
vs withstand time plotted shall be
submitted. Additionally, Hot and Cold
withstand values shall be provided
through enlarged curve and/or table
for Motor current ranging from 100%
to 200% of rated current)
34 Time vs motor current characteristics √
for each Motor (A table showing the
values of current vs time plotted shall
be submitted for the starting of
Motor at different voltage levels as
per the requirement preferably from
80% to 100% at steps of 5% each)
35 Negative sequence withstand curve √
for each motor
36 Routine test reports for each motor √
37 Spare parts √
(along with part nos. uploaded in Client

portal Equipment spares information
management system (ESPIL)

Preparation for shipment shall be made after all inspection and testing of
equipment has been completed and equipment has been released for shipping by
the Purchaser.
Preparation for shipment shall protect the component parts against corrosion,
dampness, and breakage or vibration injury during transportation or handling.
All rotors shall be secured during transport to avoid damage to the bearings.
Exposed finished and machined surfaces, including bolting, shall be given a coating
of rust inhibiting compound before shipment.
Location of lifting points, the weight and the center of gravity shall be clearly
marked on all shipping containers.
Each shipping container shall be clearly identified with the contents, purchase order
number and item number.
Loose equipment shall be appropriately packaged and secured for shipment inside
the enclosure or shipping container. These items shall be properly tagged for easy
identification.
Packing list shall be provided in each shipping enclosure or container.
Space heater leads shall be accessible without disturbing the shipping package and
shall be tagged for easy identification.
Vendors shall follow best packing procedure for long storage of motors and to avoid
damages from rain fall.

Appendix A: Codes and Standards

The following codes are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies.
IEC Standards
IEC 60034 Rotating Electrical Machines
Rotating electrical machines- Part 18-41: Partial discharge
IEC 60034- free electrical insulation systems (Type I) used in rotating
18-41 electrical machines fed from voltage converters-qualification
and quality control tests.
Rotating electrical machines- Part 18-42: Qualification and
IEC 60034- acceptance tests for partial discharge resistant electrical
18-42 insulation system (Type II) used in rotating electrical
machines fed from voltage converters
IEC 60050 International Electro technical Vocabulary
Dimensions and Output Series for Rotating Electrical
IEC 60072
Machines
IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres
IEC 60079- Explosive atmospheres - Part 15: Equipment protection by
15: 2017 type of protection "n"
IEC 60079- Explosive atmospheres - Part 7: Equipment protection by
7: 2017 increased safety "e"
IEC 60079- Explosive atmospheres Part 31: Equipment dust ignition
31 protection by enclosure “t”
IEC 60085 Electrical Insulation - Thermal Evaluation and Designation
High voltage test technique- Partial discharge

IEC 60270
measurements
Basic and safety principles for man-machine interface,

IEC 60445 marking and identification - Identification of equipment
terminals, conductor terminations and conductors
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60721 Classification of environmental conditions

Industrial platinum resistance thermometers and platinum

IEC 60751
temperature sensors
Guide for a test procedure for the measurement of loss
IEC 60894
tangent of coils and bars for machine windings
Instrument Transformers – Part 2: Additional Requirements
IEC 61869-2
for Current Transformers
Indian Standards
IS 5 Colors for ready mixed paints and Enamels
Thermal evaluation and classification of Electrical
IS 1271
Insulation
IS 2071 Methods of High Voltage testing
Designation for type & Construction and mounting
IS 2253
arrangement of rotating electrical machines
IS 2968 Dimensions of Slide rails for Electrical Motors
IS 3075 Specification for circlips
IS 4029 Guide for testing of Three Phase Induction Motors
Method of Determination of efficiency of rotating Electrical
IS 4889
Machines
Guide for selection of Electrical Equipment for Hazardous
IS 5571
Area
Classification of Hazardous areas (other than mines) having
IS 5572
flammable gases and vapors for Electrical Installations
IS 6362 Designation of methods of Cooling of Rotating Machines
Guide for testing insulation resistance of Rotating
IS 7816
Machines
Dimensions and output series for rotating Electrical

IS 8223
Machines
IS 9628 Three phase Induction Motors with type of Protection 'n'

Permissible limits of noise level for Rotating Electrical
IS 12065
Machines

Mechanical vibration of Rotating Electrical Machines with

IS 12075 shaft heights 56mm and higher measurement, evaluation
and limits of Vibration severity
Voltage Bands for Electrical Installations Including

IS 12360
Preferred Voltages and Frequency
Code of practice for selection, installation and
IS 13408 maintenance of Electrical apparatus for use in potentially
explosive atmospheres
Guide on effects of unbalanced voltages on the
IS 13529
performance of three phase Induction motors
Guide for selection and application of three phase
IS 13555
Induction Motors for different type of driven equipment
Impulse voltage withstands levels of rotating electrical
IS 14222
machines with form-wound stator coils
Dimension and output series for rotating electrical
IS 14568 machines, frame numbers 355 to 1000 and flange numbers
1180 to 2360
Guide to the use of Electrical Apparatus for Potentially
IS 15142 Explosive Atmospheres in the Presence of Combustible
Dust
IS 15880: Three phase cage induction motors when fed from IGBT
2009 converters Application guide
IS Three phase cage induction motors specifically designed
15881:2009 for IGBT converter supply
ISO Standards
ISO 15 Rolling Bearings, Radial Bearings, Boundary Dimensions
ISO 281 Rolling Bearings - Dynamic Load Ratings and Rating Life
ISO 1680 Methods of Measurement of Airborne Noise Emitted by
Rotating Electrical Machinery
ISO 1940/1 Mechanical vibration – Balance quality requirements of
rigid rotors – Part 1: Determination of permissible
residual unbalance

ISO 1680 Acoustics -- Test code for the measurement of airborne

noise emitted by rotating electrical machines
ISO 1132-1 Rolling bearings. Tolerances. Terms and definitions
(British Standard)
ISO 1132-2 Rolling bearings. Tolerances. Measuring and gauging
principles and methods (British Standard)

Appendix B Modalities for Combined string Test

Procedure for combined testing of Hazardous area motors and VFD specified
below:
For Quadratic Torque Application Motor
a) Temperature rise is to be measured (not more than 3 readings of 15 minutes
Interval) for partially loading i.e. 50% and 75% load of motor corresponding to
the speed as per superimposed Torque speed curve of load. Motor is not
required to be run till thermal equilibrium is achieved.
b) Temperature rise test is to be measured at 100% load of motor corresponding
to full load speed of motor:
• Motor body temperature & ambient temperature to be recorded after
every 15 minutes.
• Temperature difference between motor body & ambient to be calculated &
recorded.
• Motor to be switched off when temperature difference between two
consecutive readings is within 1 deg. C.
• Measure winding temperature and calculate temperature rise by resistance
method.
c) Temperature rise is to be measured (not more than 3 readings of 15 minutes
interval) at minimum speed corresponding to motor load. Motor is not
required to be run till thermal equilibrium is achieved.
This test is to be carried out only if it is feasible to load the motor at minimum
speed.
Constant Torque Application motor
a) Temperature rise test is to be carried out for 25%, 50%, 75% and 100% load
and corresponding motor speed as per the TS curve.
• Motor body temperature & ambient temperature to be recorded after
every 15 minutes.
• Temperature difference between motor body & ambient to be calculated &
recorded.
• Motor to be switched off when temperature difference between two
• Measure winding temperature and calculate temperature rise by resistance
method.

b) Temperature rise test is to be carried out at minimum speed less than 25% of
the rated speed, provided Load Torque curve calls for such an operation. Also
voltage boost feature should be provided in the converter so as to carry out
test below 17 Hz (which is 1/3rd of rated frequency)
c) Field weakening mode Test:
Motor will be run at maximum speed as mentioned in data sheet or at 120%
of synchronous speed. This test will be carried out for 3 readings of 15 min
interval. Winding temperature at the end of the test will be recorded.

Standard Specification for LV Motor

0 25.08.2020 Issued for Implementation KC/ PDG VGS / US SK / VKM

By By By
Standard Specification for LV Motor Date: 25.08.2020, Rev 0

No.

1 _________________ ___________
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
7. Supplier Data ............................................................................................................. 18
Appendix B: VFD Motor String Testing Procedure .............................................................. 23
1. Scope
documentation of low voltage squirrel cage induction motors having voltage range
up to & including 1000V AC, for Supplier and/or Contractor to comply with, to
achieve Owner’s objective of standardization.
The specification applies to motors to be used in safe areas and areas having
explosive gas or dust atmospheres or combination of both gas & dust atmosphere.
2. References
Motors shall be designed, manufactured and tested in accordance with the latest
document.
shall govern:
1. Data Sheets and Drawing

Notes:
• “Data Sheets and Drawings” represent those attached to the Material Requisition
- Motor Datasheets, Motor Stock Code Item Description, etc.
Order.
ATEX Atmosphere Explosible
CIMFR Central Institute of Mining and Fuel Research.
ERTL Electronics Regional Test Laboratory
ERDA Electrical research & development association
IS Indian Standard
PESO Petroleum and explosives Safety Organization
RMS Root Mean Square
UBC Uniform Building code
Definitions


Company

a) Motor shall be suitable for site environmental condition as stated in Datasheet.
b) Motors shall be suitable for operating in a humid, saline, sulphurous, corrosive
and dusty atmosphere as commonly encountered in oil refineries, chemical
plants or other such facilities. Supplier shall employ materials of construction,
surface treatment and surface coating to comply with requirements of ISO
12944. Motor insulation shall be subject to topicalization and fungicide
treatment complying with IS 9628.
c) The motors shall normally be installed outdoors without shelter with a common
base plate on the foundation, unless otherwise stated in Motor Datasheet.
d) Area classification shall be as specified in the motor datasheet.
e) Service condition shall be as specified in the Motor Datasheet.
5.2. Life
The life of the motor and its components forming part of it, if applicable shall have
a minimum lifetime of at least 25 years. The motor shall also be suitable for
continuous uninterrupted operation for periods of at least 4 years. However, within
this four-year period, periods of running may alternate with idle periods of up to 6
months. Re-greasing of bearings, if required, shall be possible with the motor in
operation. Rolling element bearings are exempted from the expected lifetime
requirement. For further details regarding bearing, refer sec 5.8.
5.3. General Design Features
5.3.1. Degree of Protection
Unless otherwise specified on the Motor Data Sheet, motors shall be totally
enclosed fan cooled, TEFC. For motors installed On-shore shall have a minimum
degree of protection of IP55 and those installed Off-shore shall have a minimum
degree of protection of IP56.Motors for dust hazardous area shall have a minimum
degree of protection IP65.

5.3.2. Type of construction and mounting

a) Motor Enclosure shall be as per Motor Datasheet. Aluminum enclosures are not
acceptable for motors.
b) Frame sizes shall be in accordance with IEC 60072-1 and IEC 60072-2.
c) All insulation materials shall be class F and the rating of the motor offered by
the Supplier shall be based on a class B temperature rise for all parts of the
motor windings.
d) Motor mounting type shall be as per Motor datasheet. The type of mounting for
standard motors shall be either IM B3 (IM 1001), IM B5 (IM 3001), IM V1 (IM
3011), or IM V6 (IM 1031) in accordance with IEC 60034-7.
e) Vertical motors with a downward drive-end shaft shall be provided with a
canopy over any upward facing air inlets to prevent entry of water or any other
contaminant. Bearing housings, especially for vertical motors with upwards
drive-end shaft, (mounting arrangement IM V3 [IM 3031] and IM V6 [IM 1031]
to IEC 60034-7) shall be sealed to prevent water entry to the motor via the shaft.
The motor end-shield shall be so shaped as to prevent water collecting in the
region of the bearing housing. If sealing of bearing housing is not possible, the
motor shall have rain water deflectors fitted to the shaft which prevents the
ingress of water into the motor and/or bearing housing via the shaft or grease
relief drains.
f) All frames and bearing end-shields shall be made of ferrous materials.
g) For small induction motors, PVC fans are acceptable non-metallic material
option, and shall be fire resistant, antistatic and stable in the presence of
hydrocarbon liquids, vapors and hydrogen sulfide gas.
h) All motors shall be equipped with a corrosion resistant drain in the low point of
the enclosure, unless the provision of drains is precluded by certification (drain
may not be applicable for Ex d motor).The drain shall be accessible from the
exterior of the motor except where the design is such as to make the collection
of condensation within the casing impossible.
i) Protection shall be provided against galvanic action between dissimilar metals
using gaskets, washers or other appropriate means.
j) Motors shall be designed for operating in Seismic Zone, as specified in the
datasheet.
k) All motors of a weight greater than 25kg shall be supplied with an eye bolt for
lifting. Motors for vertical mounting shall have total three lifting lugs to facilitate
safe and easy lifting of motor. All motors above 450kg shall be provided with
threaded holes for vertical jacking.

l) Two earth terminals (bolt) located preferably on diametrically opposite sides

shall be provided for each motor. The motor base shall be drilled for the fitting
of an earthing bolt. The bolt shall be provided complete with nut and washers.
m) For horizontal mounted motor feet, the acceptable limit of co-planar tolerance
of motor feet and the parallelism error should be below the figures mentioned
under:
• The coplanar tolerance between two different mounting pads shall be
limited to below 0.127mm i.e. 127 micron. The tested values should reflect
in the test reports of all the motors.
• Individual pad bottom surface levelling should be limited below gradient of
0.32mm/meter in longitudinal as well as transverse direction.
• While verifying this limit, a filler gauge of 200 micron should not penetrate
any gap between bottom of the feet and surface plate in at least 80% of the
contact area of the feet. These checks will be done as the stage check
inspection on the machined frame. Test records will be offered as part of
test certificate during final inspection of motors.
5.3.3. Motors for Hazardous Area
a) Motors for use in hazardous areas shall meet the explosion requirements as
specified in the Motor Data Sheet. Explosion protection shall be provided in
accordance with IEC 60079.
b) For motors intended for use in hazardous areas, component parts of the motor
enclosure shall be provided with bonding conductors to prevent incendive
sparking.
c) The data sheet will specify the details of the classification of the area of
installation. Based on its location, area classification requirements (zone, gas
group and temperature group) for each equipment shall be specified in the data
sheet.
d) The design, construction and testing of electrical motors for use in Hazardous
and Dust areas shall be in accordance with IEC 60079 and IS 5571.
e) Unless otherwise stated in the material requisition the following types of
protection are acceptable:
Ex-ec (Ex-n) (preferred)
Zone 2
Ex-eb (Ex-e)
Ex-de
Zone 1 Ex-de

Zone 0/20 No motor is allowed
f) Motors and its components as applicable for use in hazardous areas shall be
certified by an recognized testing authority, such as “ERTL”,” ERDA” and
“CIMFR” and bear a label to show conformance with the requirements. For
gaseous hazardous area motors i.e. Zone 1 and 2 motors manufactured in India
shall have a test certificate from recognized testing authority, such as “ERTL”,”
ERDA” and “CIMFR” and an approval certificate from the PESO.
g) For imported motors, PESO certificate can be obtained by the local partner of
the foreign Supplier. The procedure for getting PESO for motors should be as
per document "Procedure for Approval of Ex (Electrical) Equipment" available in
the web portal http://peso.gov.in/index.aspx.
h) For dust hazardous area motors i.e. Zone 21 and 22 motors manufactured in
India, Suppliers to submit certificates from authorized certifying agency such as
““ERTL”,” ERDA” and “CIMFR” to Buyer. For imported motors, Suppliers to
provide IECEx certificate or certificated from any approved agency in the country
of origin.
i) VSD fed Motors/ Motor started with Soft starter, operating in gaseous and dust
hazardous area, manufactured in India, needs the combined testing certificate
from authorized certifying agency and approval certificate from PESO. For
imported motors, Suppliers to provide IECEx certificate or certificated from any
approved agency in the country of origin. As an option, Supplier shall provide
quotation for combined string test (VFD shall be shipped to Motor Supplier shop
for testing).
j) As per new guidelines of PESO, for hazardous area motors, the Ex accessories
fitted with the motor such as temperature sensor, RTD/BTD, thermistors, space
heaters, auxiliary terminal box, cable glands, reducers etc. shall also be type
approved by PESO. Motor Supplier shall get PESO Certification from their sub
suppliers and share the certificates with Buyer.
k) Exd motor shall be used in Zone 2 area having frequent start/stop requirement,
such as for EOT crane, Elevator, MOV.
l) Terminal boxes fitted to the Ex ‘d’ motor shall be of protection Ex`d’/ Ex ‘eb’.
m) As per new IEC guidelines IEC/EN 60079-7:2015, markings of motors will be
“Ex ec” instead of “Ex nA” and “Ex eb” instead of “Ex e”.

n) When Impulse Voltage Insulation Class (IVIC) comes into effect as per IEC 60034-
18-41, the same needs to be considered.
5.4. Terminal Boxes
a) The terminal boxes, in general, shall be mounted at the top of the motor as
defined in IEC 60034-7, unless otherwise specified in the datasheet. Cables
boxes shall be adjustable for cable entry from either the left or right of the motor
as a minimum. Where side mounted terminal box has been provided, the design
shall allow the box to be rotated to accommodate cable entry from three
positions, 90 degrees apart, and not facing the driving end.
b) Terminal boxes shall be suitable for termination of cables sizes specified in the
motor datasheet. If cable sizes are not indicated, the terminal box shall be
suitable for cable of one sizes higher than the cable size agreed under Frame
agreement for that particular motor rating. The motor Supplier shall provide
side entry terminal boxes for such motors with the cable entry direction from
the non-drive end or extended terminal box from motor body through adaptor
box.
c) For side mounted terminal box, in order to enable ease of cable entry without
obstructing the driven equipment / motor base frame, the main terminal box
shall have the cable entry angled at 20 degree to the vertical. Motor Supplier
may also propose a diagonally split terminal boxes or main terminal box
extended from the motor body through an adaptor box as an option.
d) Main terminal box dimensions shall be sufficient enough for cable termination.
For cable size and type it is to be ensured that cores of different phases should
not touch each other, and terminal box can accommodate the suitable cable size
mentioned in datasheet.
e) The terminal box shall be suitable for a fault level as specified in the Motor
Datasheet.
f) The design of Terminal box shall allow the removal of the motor without
breaking or stressing of cable sealing. The design of the terminal box shall be
such as to prevent small parts from dropping into the motor housing. All leads
shall be brought out to the terminal box through a gasketed seal.
g) Inside the terminal box an earthing clamp or bolt of adequate dimensions shall
be provided for connection of the cable earthing and earth continuity shall be
established between the connector and the motor frame. The earthing facility
shall be clearly marked with the appropriate symbol.
h) For type Ex ‘ec’ (Exn), Ex ‘eb’ (Exe) and non-hazardous area motors, drilled gland
plate shall be provided. Drilled opening of Ex ‘ec’ (Ex n), Ex ‘eb’ (Ex e), Ex d and
safe area motors shall also be supplied with suitable Exd blanking plugs and

tapped entries shall be provided in accordance with the motor data sheet.
Supply of cable glands shall not be in the scope of motor Supplier.
i) Terminal boxes shall be made weatherproof by the use of non-sticking, non-
hygroscopic re-usable gaskets unless precluded by certification requirements.
j) Terminal diagrams of a suitable non-degradable material shall be fixed inside
the terminal boxes. All terminals shall be clearly marked as per the terminal
diagram. Terminal marking of the main cable connections, and the direction of
rotation shall be in accordance with IEC 60034-8.
k) Separate terminal boxes shall be provided for space heaters and other auxiliary
devices like thermistors as applicable, except where the small physical size of
the motor makes this impractical.
l) Split type lugs OR split type studs shall not be used for electrical connections /
terminations.
5.5. Cooling
a) Motors shall be fan cooled and shall be provided with non-sparking, non-
corroding fans. If aluminum fans are provided and acceptable for motors
intended for use in hazardous areas, they shall be of copper free aluminum. The
material shall conform to IEC 60079-0. Nonmetallic (poly propylene or PVC) fan
may be used up to frame size 132. For higher frame only metallic fan shall be
used. The flow of cooling air shall be towards the driven equipment.
b) Internal fans shall preferably be bi-directional unless uni-directional fans are
necessary to achieve particular performance criteria such as Noise.
c) Motors shall be designed such that lowest part of the fan cover for horizontal
motors shall not touch the motor base frame.
d) The external fan shall be independently balanced, also with the key-way fully
filled with a half key, prior to balancing the complete assembly. The deviation
shall not exceed the G2.5 limits in accordance with ISO 21940-1.
5.6. Rotor
a) The shaft shall be made of one-piece, heat-treated steel. Welding on finished
shafts is not allowed. Shafts and spiders subjected to welding shall be post-weld
heat-treated.
b) If non-contacting eddy current proximity probes are to be fitted, the surface
finish of the shaft at the fitting point shall be as specified in API 670.
c) The rotor, internal fan(s) and other components, if fitted, shall be dynamically
balanced with the key-way(s) fully filled with half key(s).
d) Lead or similar ductile material shall not be used for balance weights.

e) If metal is to be removed to achieve static or dynamic balance, it shall be

removed in a manner that maintains the structural integrity of the rotor and
does not result in hot spots liable to distort or otherwise harm the rotor.
f) The balancing material shall be secured in such a way that there is absolutely no
possibility of it becoming loose during the lifetime of the motor.
g) Mechanical shaft run out shall not exceed 0.05 mm for horizontal motors and
0.025 mm for vertical motors.
h) Rotor bars shall be fully locked into place or insulated.
i) The direction of rotation of the motor shall be clearly indicated on the drawing
and on the motor by raised or embossed markings. Direction of rotation shall be
as required by driven equipment, when terminal R-Y-B are connected to a power
supply giving a terminal phase sequence in the order R-Y-B. If bi-directional fans
are used the direction of arrow shall have two points. Motor direction with
supply phase sequence RYB shall be clearly marked at Terminal box drawing.
5.7. Coupling
a) The shaft ends shall be provided with a suitably threaded hole or holes to
facilitate the assembly or removal of the coupling and bearing races.
b) Shaft extensions, keys and keyways shall be in accordance with IEC 60072-1 and
IEC 60072-2.
5.8. Bearing
a) Motors with belt, pulley coupling shall be provided with Roller bearings on the
driving end side (typically all fin fan motors). Where high radial forces occur,
motor manufacture shall analyses this scenario along with driven load and
propose type of bearing and their combination.
b) Bearings shall have a rated L10 lifetime of minimum 50,000 h under the worst
case operating conditions as specified in this Specification. The lifetime shall be
calculated in accordance with ISO 281.
c) If horizontal motors are to be operated in the vertical position, the motor
Supplier shall certify that the motor is suitable for applicable thrust loading. In
such case, shielded bearings shall not be acceptable unless the grease chamber
is on top of the bearing when the motor is in its operating position.
d) Re-lubrication shall be possible with the motor in operation and without
dismantling parts. Bearings shall be constructed so that excess grease is
positively ejected from the bearing to the outside of the motor to prevent
formation of a skin which can prevent grease from reaching the rolling elements.
Unless otherwise specified by the Buyer, lithium-based greases shall be used in

the bearings. Same grease shall be used for both DE and NDE bearings for
complete scope of supply.
e) Motors with rated outputs up to and including 37 kW may be equipped with
sealed-for-life bearings pre-charged with grease. The Supplier shall ensure that
such bearings are selected to meet the above L10 lifetime. The interval between
grease application for bearings shall be as per the bearing Supplier’s
recommendation. Bidder shall clearly state the interval in his offer.
f) Ball bearings shall have a C3 internal radial clearance. Roller bearings may have
a normal or C3 internal radial clearance.
g) Vertically mounted motors, rigidly connected to equipment producing axial
loads, shall be designed to carry all transmitted thrust loads, at all operating
conditions, whilst maintaining specified bearing life. Thrust bearings shall be at
the non-drive end of the motor. Stacked bearings are not acceptable.
h) All motors, except those required to be explosion proof, shall have shaft seals
suitable for the environment specified. Any special requirements will be
identified in data sheet.
i) Motor Supplier shall make provision, in accordance with his standard practice,
to prevent damage to bearings by shaft currents. Insulated bearings shall be
provided at Non-Drive end for VSD driven motors for frame sizes 160 and above.
j) Bearing insulation, where required for application such as VFD motor drives,
shall comply with the following:
i) The method of insulation shall be permanent and non-deteriorating during
assembly and disassembly of the bearing.
ii) An earthing connection, removable for test purposes, shall be provided at
the coupling-end bearing. Care shall be taken not to bridge the insulation by
any other connection.
iii) Provision to measure the bearing insulation resistance without
disassembling the motor or removing it from its base.
5.9.1. General Electrical Characteristic
a) The nominal voltage and frequency and their corresponding variations shall be
as indicated in the motor datasheet.
b) Motors of rating below 0.37kW shall be single phase motors. Motors of rating
0.37kW and above shall be three phase motors. Three phase motors shall
normally be delta connected. Where Supplier’s standard is for star connected
windings, this shall be stated in the quotation. Both ends of the windings shall

be brought into the terminal box along with suitable links to connect them in
star or in delta unless precluded by certification.
c) Motors shall be designed for continuous running duty, type S1 in accordance
with IEC 60034-1 and IS 12615, and maximum continuous rating unless
d) Motors chosen for operation with a variable speed drive (Inverter duty motors)
should be dimensioned suitably, i.e. motor winding should be suitable for the
voltage rise time of the VSD. The motor shall comply with IEC 60034-25. This can
include VPI treatment to the stator windings and double coated stator windings.
The Stator winding shall be provided with temperature sensing element i.e. 3
thermistors (without control).
e) For motors which are designed to run at different speeds as opposed to those
noted above, the corresponding speeds and loads shall be used for the test.
f) Motors intended for variable speed applications shall be designed to ensure that
there is no overheating at the design minimum speed. The minimum speed shall
be mentioned in data sheet. Motor rotor shall be rigid (stiff) shaft design and
first critical speed shall be 125% higher than the motor synchronous speed.
Where, rigid design is not possible, flexible shaft design shall have first critical
speed between 60% and 80% of synchronous speed and the second critical
speed shall be above 125% of synchronous speed.
g) All motors shall be of minimum IE2 efficiency class as per IS 12615/IEC 60034-
30. When used with variable frequency drive, the efficiency of the motor can be
one class lower for IE2 motors. The method of determining efficiency shall be in
line with IEC 60034-2-1/IS 15999(Part 2/Sec1). The determination of stray load
loss shall be through actual measurement using torque meter/dynamometer
with low uncertainty. Materials that are hygroscopic or very toxic shall not be
used for motor housing / enclosure. The materials used shall be selected to
prevent contact corrosion.
The requirement of sensors for remote condition monitoring solution shall be
as specified in datasheet.
h) Anti-condensation heaters shall be provided for motors rated 37kW and above
and shall be of a fully insulated design. For motors of rating 37kW and above,
heaters shall be designed to operate on 240V, 50Hz single phase AC supply. For
motors below 37kW, suitable heating shall be provided by connecting 24V,
50Hz, single phase to two of the motor terminals. Heaters shall be arranged to
provide uniform heating of the stator and the rotor windings (if applicable), and
shall maintain the temperature of the windings at approximately 5˚C above
ambient temperature.

i) The surface temperature of the heater element, or the motor enclosure, shall
not exceed the limiting temperature.
j) The connecting leads of the heater elements shall be brought out to terminals
in a separate heater terminal box mounted on the motor frame. A prominent
warning label with inedible red description, shall be provided to indicate that
the circuit may be live when the motor is stationary.
k) For hazardous area certified motor, the hazardous certification shall be along
with the space heater.
l) Special Note on VFD Motor/ Motor started with Soft starter:
The following are specific construction features of the motor for compatibility
with VSD’s:
i) 415V VSD duty motors of frame size 200 and above shall be provided with
Class F special reinforced insulation system which shall be used for 690 Volt
motors.
ii) Motors should be dimensioned for suitability of operation with a VSD, i.e.
motor winding is suitable for the voltage rise time of the VSD. This is ensured
by providing Vacuum Pressure Impregnation (VPI) treatment to the stator
windings and by using double coated stator windings.
iii) The insulation scheme should be such that the allowed Phase to Ground
voltage peaks at the motor terminals will be 1800 Volts and Phase to Phase
voltage peaks will be 2200 Volts or should follow the requirement
mentioned in IEC 60034-18-1 & 60034-27-1 i.e. Impulse insulation class C
(Severe).
iv) Motors will be random wound type, unless otherwise stated in Datasheet.
Copper wire which is used will be Enameled Copper round wire of Grade-2,
Thermal Class-200 Deg. C, Corona resistant.
v) Since motors are to be operated with VSD’s, the rotor should be constructed
without deep bars or double slots. This ensures that rotor heating is not
unduly increased. With a deep rotor cage construction, the inner
conductors/bars will have an increased slip with respect to outer bars and
consequently will carry larger current and contribute to increased rotor
heating.
vi) Epoxy gel coat shall be provided on motor winding overhang portion.
vii) For VSD duty motor suitable derating shall be considered with respect to the
application on case to case basis and calculation to be submitted to Buyer
for review.
viii) VSD duty motor shall be provided with force cooling arrangement if the
operating speed range is less than 30% (constant torque application).
ix) The motors if required to be transfer to DOL bypass mode shall be rated for
specified variation in line voltage and frequency.
5.9.2. Starting, Restarting and Reacceleration Requirements
a) The starting current of the motor shall be as per IS 12615/IEC 60034-30. Stringent
requirements, if any will be specified in the motor datasheet.
b) To facilitate the successful starting of DOL Motors at varying system voltages and
to prevent from inadvertent tripping due to conservative relay settings, motor
'Run-up time at 80% of rated voltage' shall have sufficient margin with the Motor
'Locked-rotor withstand time at 100% of rated voltage', as committed in the
Motor datasheet. A minimum value of 2 seconds is essential for the protection
relay to distinguish between a 'successful start' and a 'Locked-rotor' condition.
For high inertia loads, above mentioned requirement shall be discussed during
bid stage on case-to-case basis.
c) Motors shall be suitable for direct-on-line starting, at least for 1000 starts per
year (unless otherwise specified in datasheet).
d) Starting torque and minimum pull-up torque of the motor shall be compatible
with the speed torque curve of the driven equipment under specified starting
and operating conditions.
e) Motors shall be capable of withstanding an excess torque of at least 60% of their
rated torque for 15 sec without stalling or exhibiting an abrupt change of speed.
The voltage & frequency shall be maintained at their rated values.
f) For cage induction motors specifically designed to ensure a starting current of
less than 4.5 times the rated current, the excess torque can be below the value
of 60%, but not less than 50%, or the value of the excess torque shall be subject
of agreement with Buyer.
g) Motors shall be capable of re-acceleration (if specified in datasheet) under full
load conditions following a power interruption not exceeding 0.2s.
h) The Starting torque and minimum torque of the motor shall be compatible with
the speed torque characteristic of the driven equipment with rated frequency
and 80% rated voltage applied at the motor terminals. Under these conditions
the accelerating torque shall not be less than 10% of the full load torque at any
point.
i) Under full load conditions and at any voltage between 80 % and 100 % rated
voltage, motors shall be capable of:
• Three successive starts with the motor initially at maximum ambient
temperature.

• Two successive starts with the motor initially at full load operating
temperature.
After a cooling period of 30 minutes at standstill, another starting sequence of at
least two successive starts shall be possible.
5.10. Surface Finish
a) Motors shall have an external surface finish as indicated in the motor datasheet.
The finish shall provide adequate protection against corrosion under the
specified site conditions.
b) Variable Speed Drive motors shall be painted with shade Lemon as per RAL 1012.
If special treatment is needed because of extreme environmental service
conditions as indicated in the material requisition, the Supplier shall provide
details of the proposed special surface treatment in the quotation.
c) Supplier to provide CX (as per ISO 12944-9) paint for safe area motors used in in
highly corrosive areas like Sea Water, cooling tower, Coker, Sulphur areas. For
hazardous area classification, the C3 paint to be considered unless otherwise
mentioned in Datasheet.
5.11. Noise and Vibration
a) The sound pressure level of the motor shall not exceed values as specified in
Motor Datasheet. The sound level shall be measured in accordance with ISO
1680/ IS 12998, unless otherwise stated in the material requisition or datasheet.
b) Motors shall meet the maximum allowable noise limits by design and not by
corrective measures. If this is not possible, the Supplier shall state the proposed
corrective measures for the approval of the Buyer.
c) Where the use of internal soundproofing material is unavoidable, the liners shall
be fixed in such a way that no parts can become loose within the motor housing,
e.g. by means of a suitable retaining mesh.
d) The acoustic measures shall not obstruct routine inspection and maintenance
activities such as lubrication of bearings, and inspection of oil levels.
e) The Vibration velocity limits value shall be as per IS 12075/IEC 60034-14 (Grade
A). This is applicable for motors of all ratings and speed.
f) The maximum allowable vibration levels shall apply to all operating
temperatures of the motor between ambient and maximum operating
temperature and for all operating conditions, from no-load to full load.

5.12. Rating Plate & Serial Number

Every motor shall be provided with a rating plate or plates. Rating plates shall be
made of stainless steel and shall be securely fixed to a non-removable part of the
frame.
The rating plates shall be marked with data in accordance with IEC 60034-1 and all
other relevant Codes and Standards.
In addition to the above, the Nameplate shall also include the following details:
• Locked rotor current/torque at rated voltage and frequency
• Class of insulation and temperature rise
• Bearing details (Make, Type, Size, Lubricant, re-lubrication interval etc.) Grease
lubrication quantity and interval as per operating condition and Supplier
recommendation shall be mentioned
• BUYER Equipment tag number
• SUPPLIER's order number, serial number, month and year of manufacture
• Name plate for VFD motor shall reflect the ratings of the actual motor and not
the Brake Kilo watt rating
Hazardous area motors shall have a separate rating plate providing following data:
• Ex marking of motor as per IEC 60079-0
• Certification provided for the motor
• Certification provided for main terminal box
• Certification provided for auxiliary devices if any
• Maximum Space heater (where provided) surface temperature in degrees C
when operated at ambient temperature
• Certificate number provided by relevant testing authority
• For VFD fed/Soft starter application: speed variation, frequency range, which end
bearing is insulated to be provided
Where the Datasheet call for an enhance rating plate, it shall be of same material
as that of Main rating plate and shall be fixed to a non-removable part of the frame.
If these additional rating plates are mounted on removable parts, the Supplier's
serial number and reference shall be repeated on these rating plates. The following
information included in addition to data in accordance with IEC 60034-1 and all
other relevant Standards.
• IVIC as applicable
• Allowable run up time in seconds
• The approximate mass of the machine

a) All motors shall be subjected to the routine tests. The motor Supplier shall
provide certified test record of all the routine tests carried out on each motor.
b) Type tests if specified in the material requisition, shall be carried out on at least
one motor of each type of the lot ordered. The motor that need to undergo Type
tests shall be decided with the Buyer during Purchase Order stage. Type test may
be waived off on availability of valid type test certificate.
c) Type tests and routine test should comply with relevant IEC 60034 standards.
d) Package Supplier shall obtain routine and type test certificates from motor
Supplier for each type and rating. Type test need not be conducted on motor
supplied by package Supplier.
e) If any one of the components or the whole system does not comply with the
specification and any agreed amendments, the Supplier shall rectify and re-test
the motor(s) within a mutually agreed time, without any cost impact.
6.1. Routine Tests
Routine tests, as a minimum, shall comprise of the tests as listed below. For each
batch 10% of the total no. of motors shall be checked and witnessed by BUYER.
• Visual Inspection (Dimension, Name Plate data, Terminal Box location, cable
entries, space adequacy, earthing bolts, enclosures, lubrication and re-greasing
facilities).
• Internal quality checks for functional acceptance of space heater.
• Measurement of resistance of winding of Stator (Cold).
• Measurement of starting torque, starting current, full load torque, breakdown
torque.
• No Load Current & losses at rated Voltage and frequency.
• Locked Rotor readings of voltage, current and power input.
• Motor shall be tested at 10%. 60%, 80% and 100% speed along with the
corresponding load as per its load -speed curve.
• High Voltage test on Motor Winding and space heater circuit.
• Insulation Resistance test on Motor Winding, space heater circuit, embedded
temperature detectors (where provided).
• Reduced Voltage start and run up test.
• Direction of Rotation and phase sequence.
• Vibration Test at rated voltage and frequency.

• Noise level test.
• Measurement of co planar tolerance.
Assembly stage reports or check sheets like labyrinth sealing arrangement,
dimension of spigot length of NDE/DE side outer bearing caps, correct direction and
design of external cooling fans, proper tightness of internal cooling fan, bearing
fitment tolerances w.r.t. end shield bores and shaft, correct bearings types, fixing
of Inner bearing cap and outer bearing cap at correct position etc. shall be reviewed
during visual inspection.
Note: Locked rotor current and torque shall be measured at rated voltage, or the
nearest maximum available voltage at the testing facility. Where rated voltage
cannot be achieved, the method of extrapolation used to obtain the full voltage
values shall be detailed.
6.2. Type Tests
Type tests shall comprise of the tests listed below as a minimum unless otherwise
specified in the Purchase Order. Type test, if specified in material requisition, for
one motor of each rating and type shall be witnessed by BUYER. Type tests shall
comprise of the routine tests as well as tests listed below as a minimum: -
• Winding Resistance (Hot and Cold).
• No Load Current & losses at rated voltage to determine input current, power and
speed.
• Reduced voltage running up test at no load.
• Locked rotor reading of voltage, current, power input and torque.
• Efficiency Slip and Power Factor at 100%, 75% and 50 % Load.
• High Voltage test (before and after Heat Run) on Motor Winding and space
heater circuit.
• Insulation Resistance Test (before & after Heat Run) on Motor Winding and space
heater circuit.
• Heat Run Test.
• Momentary Overload Test.
• Over speed Test.
• Test for vibration severity of motor.
• Test for noise level of motor.
• Test certificate for degree of protection by enclosure (Certificate only)

• Rotor Balancing Test after complete assembling of Rotor is acceptable. Only type
test certificate is required. (Certificate only)
Note: In addition to the above mentioned tests, Supplier is required to perform the
following tests at their works (optional quotation to be provided):
• Combined testing/simulation of prototype Motor and Relay: This is required to
program and replicate the actual thermal characteristics in the Relay and to
prevent inadvertent tripping of the Motor in case of Run-up, Re-starting and
Locked rotor conditions.
Termination activity of prototype Motor with committed Cable size: Supplier to
display the termination for prototype motor with the maximum power cable size
as approved by Buyer. This is required to validate the compatibility of power cables
with Motor terminal box.
For VFD fed motors, "Appendix B", shall be referred for applicable test.
7. Supplier Data
list provided in the Material requisition. Following documents are at a minimum to
be submitted to the Buyer in soft copy format.
with Bid Order
1 General arrangement √ √
(Preliminary)
(showing arrangement of components,
terminal boxes and lifting points,)
2 Performance characteristics √ √
(efficiency, power factor at Full,3/4,1/2,1/4
Load, starting current, noise level at no load)
3 Speed Torque and Speed current √ √

(Preliminary)
curves
4 Motor Datasheet √ √
5 Hazardous area Motor certificate √ √

(from IECEx / CMRI / ERTL / CCoE (PESO) /
DGMS and DGFASLI)
6 Type Test Certificates (Valid) √ √
7 Technical literature √
8 Reference list (Switchgear of comparable √

rating during last five years)

9 List of recommended commissioning √

spares
10 List of recommended operational √
spares
11 Supplier’s quality assurance program √
12 Deviation list √
13 Quality Plan √
16 Detail drawing of auxiliary terminal √

box
17 Complete test reports √
18 Declarations of Conformity √
(for explosion protected equipment)

with Bid Order
19 List of capital spares √
20 Lubrication schedule and √

specification of lubricant
21 Installation, Operation and √
maintenance manual
22 Outline drawings √
(showing main dimensions, mass,

arrangement of components, terminal boxes,
foundation loading, center of gravity,
magnetic center and lifting point)
23 Schematic and connection diagrams √
24 Motor GD2 and Locked rotor power √

factor
25 Hot and Cold thermal withstand curve √
voltage.
26 Time vs motor current characteristics √
27 Negative sequence withstand curve √

28 Routine test reports √
29 Spare parts √
(along with part nos. uploaded in Client

portal Equipment spares information
management system (ESPIL)

a) Preparation of shipment shall be made after all inspection & testing of
equipment has been accomplished and equipment has been released for
shipping by the Buyer.
b) Loose equipment shall be appropriately packaged & secured for shipment inside
the enclosure or shipping container. These items shall be properly tagged for
easy identification.
c) Packing list to be provided in each shipping enclosure or container.
d) Space Heater leads shall be accessible without disturbing the shipping package
and shall be tagged for easy identification.
e) Exposed finished and machined surfaces, including bolting shall be given a
coating of rust inhibiting compound.
f) Preparation for shipment shall protect the component parts against corrosion,
g) All rotors shall be secured during transport to avoid damage to the bearings.
h) Location of lifting points, the weight and the center of gravity shall be clearly
i) Suppliers shall follow best packing procedure for long storage of motors and to
avoid damages from rain fall.
j) Each shipping container shall be clearly identified with the contents, Buyer order
number and item number.


IEC STANDARDS
IEC 60034 Rotating Electrical Machines
Rotating electrical machines- Part 18-41: Partial discharge free
IEC 60034- 18- electrical insulation systems (Type I) used in rotating electrical
41 machines fed from voltage converters-qualification and quality control
tests.
Rotating electrical machines- Part 18-42: Qualification and acceptance
IEC 60034-18-
tests for partial discharge resistant electrical insulation system (Type
42
II) used in rotating electrical machines fed from voltage converters
IEC 60050 International Electrical Vocabulary
IEC 60072 Dimensions and Output Series for Rotating Electrical Machines
IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres
IEC 60085 Thermal Evaluation and Classification of Electrical Insulation
Basic and Safety Principles for Man-Machine Interface, Marking and
Identification - Identification of Equipment Terminals and of
IEC 60445 Terminations of Certain Designated Conductors, Including General
Rules for an Alphanumeric System-Third Edition; Corrigendum 1: July
2002
IEC 60529 Classification of degrees of protection provided by enclosures
INDIAN STANDARDS
IS 5 Colours for ready mixed paints and Enamels.
IS 1231 Dimensions of three phase foot mounted induction motors.
IS 1271 Thermal evaluation and classification of Electrical Insulation.
IS 2223 Dimension of flange mounted AC Induction motors.
Designation for type & Construction and mounting arrangement of
IS 2253
rotating electrical machines.
IS 4029 Guide for testing of Three Phase Induction Motors.
IS 4889 Method of Determination of efficiency of rotating Electrical Machines.
IS 5571 Guide for selection of Electrical Equipment for Hazardous Area
Classification of Hazardous areas (other than mines) having flammable
IS 5572
gases and vapors for Electrical Installations.
IS 6362 Designation of methods of Cooling of Rotating Machines.
IS 8223 Dimensions and output series for rotating Electrical Machines.
Values of performance characteristics for three phase induction
IS 8789
motors.
IS 9628 Three phase Induction Motors with type of Protection 'n'.
IS 12065 Permissible limits of noise level for Rotating Electrical Machines.

Mechanical vibration of Rotating Electrical Machines with shaft

IS 12075 heights 56mm and higher measurement, evaluation and limits of
Vibration severity.
Voltage Bands for Electrical Installations Including Preferred Voltages
IS 12360
and Frequency.
IS 12615 Energy Efficient Induction Motors - Three Phase Squirrel Cage
Methods of Measurement of Airborne Noise Emitted by Rotating
IS 12998
Electrical Machinery.
Guide for selection and application of three phase Induction Motors
IS 13555
for different type of driven equipment.
Standard methods for determining losses and efficiency from tests
IS 15999
(excluding machines from traction vehicles) on the methods of testing.
Three phase cage induction motors when fed from IGBT converters
IS 15880
Application guide.
Three phase cage induction motors specifically designed for IGBT
IS 15881
converter supply.
IS 7816 Guide for testing insulation resistance of rotating machines.
Guide to the use of Electrical Apparatus for Potentially Explosive
IS 61241-14
Atmospheres in the Presence of Combustible Dust.
ISO STANDARDS
ISO 15 Rolling Bearings, Radial Bearings, Boundary Dimensions-General Plan
ISO 281 Rolling Bearings - Dynamic Load Ratings and Rating Life.
Test code for the Measurement of airborne noise emitted by rotating
ISO 1680
electrical machines.
Paints and varnishes- Corrosion protection of steel structures by
ISO 12944-5
protective paint systems- Part 5: Protective paint systems.
Paints and varnishes- Corrosion protection of steel structures by
protective paint systems- Part 9: Protective paint systems and
ISO 12944-9
Laboratory performance test methods for offshore and related
structures.
Mechanical vibration – Balance quality requirements of rigid rotors –
ISO 21940/11
Part 1: Determination of permissible residual unbalance.
API
STANDARDS
API 670 Machinery Protection Systems.

Appendix B: VFD Motor String Testing Procedure
Modalities for Combined testing procedure attached.

Indian Standard 5571 requires certification of a motor VSD combination as per
clause 11.3.4. The relevant clause in the Indian Standards states that “Motors
supplied at varying frequency and voltage by a converter shall have been type
tested for this duty as a unit in association with the converter specified in the
descriptive documents according to IS /IEC 60079-0 and with the protective devices
provided or shall be evaluated in accordance with IEC 60079-7”.
Procedure for combined testing of Hazardous area motors and VFD.
For VFD driven Motor, the following parameters shall be measured during the
testing. Empirical calculations shall then be carried out by the motor Supplier to
ensure that the end installation shall be safe:
a) Voltage waveform during no load starting of motor.
b) Voltage waveform during no load tripping of motor.
c) Temperature of stator during partial load (10%, 60% and 80%) running of
motor.
d) Temperature of rotor during partial load (10%, 60% and 80%) running of
motor.
e) Temperature of bearings during partial load (10%, 60% and 80%) running of
motor.
f) Voltage waveform during full load starting of motor.
g) Voltage waveform during full load tripping of motor.
h) Temperature of stator during full load running of motor.
i) Temperature of rotor during full load running of motor.
j) Temperature of bearings during full load running of motor.
k) Temperature of stator while operating in the field weakening zone.
l) Temperature of rotor while operating in the field weakening zone.
m) Temperature of bearings while operating in the field weakening zone.
The motor-VSD driven equipment combination shall also be tested for dynamics
(establishing system critical frequencies and magnitude of pulsating and transient
torques).
Before commencement of the test, the motor must be at ambient temperature. In
this condition, the temperature and resistance of the windings shall be recorded.

(i) No load test:

a) The motor shall be run at no-load. Voltage and current at motor terminals
shall be measured using a true reading voltmeter and ammeter respectively.
b) Voltage waveform shall be recorded using an oscilloscope. The waveform
shall be recorded for the duration taken for the motor to attain steady state
no-load speed.
c) The supply to the VSD shall be disconnected subsequently and the voltage
waveform shall be recorded using an oscilloscope for the duration taken for
the voltage waveform to reach zero volts.
(ii) Load Test:
For carrying out load tests on motors, motors are normally loaded using the brake
and pulley method, dynamometer method or using by using calibrated generator
to load the motor. The motor shall be shielded from currents of air coming from
adjacent pulleys, belts, fans and other components to avoid inaccurate results.
It should be noted that the results obtained through this test shall generally be
more pessimistic. For carrying out the test, the test setup shall be set to load the
motor to its desired load at desired speed. Subsequently, the test is commenced.
Load tests shall be carried out for motor loaded at 10%, 60%, 80% and 100% of its
name plate rating. Cooling down period shall not be required, as motors are
susceptible to similar cycling. The speed, at which the motor shall run during this
test, shall be as per the torque-speed characteristic of the driven load or motor,
The following readings are taken:
a) Voltage and current at motor terminals.
shall be recorded for the duration taken for the motor to attain steady state
speed.
c) The temperature of the stator, rotor and bearings shall be recorded. The
temperature shall continue to be measured and recorded until the motor
has attained thermal equilibrium.
d) The supply to the VSD shall be disconnected subsequently and the voltage
waveform shall be recorded using an oscilloscope for the duration taken for
the motor to come to a standstill.
The readings shall be taken for the motor running at synchronous speed with full
voltage applied across the motor terminals. The motor shall be loaded to its full-
load name plate rating. The following readings are taken:
a) Voltage and current at motor terminals.


will be recorded for the duration taken for the motor to attain steady state
full load speed.
c) The temperature of the stator, rotor and bearings shall be recorded. The
temperature shall continue to be measured and recorded until the motor
has attained thermal equilibrium.
(iii) Tests during operation in field weakening zone
Field weakening point is defined as the condition when the voltage across the
motor terminals is maximum and the frequency is increased to increase the speed
of the motor. Theoretically, this is the point when the motor is subjected to the
worst-case harmonic voltages and currents and consequently, there is maximum
heating of the motor.
For Quadratic Torque Application Motor: ‐
1) Temperature rise is to be measured (not more than 3 readings of 15 minutes
Interval) for partially loading i.e. 50% and 75% load of motor corresponding to the
speed as per superimposed Torque-Speed Curve of load. Temperature rise is also
to be measured (not more than 3 readings of 15 minutes interval) at minimum
speed (only if it is feasible) corresponding to motor load. Motor is not required to
be run till thermal equilibrium is achieved.
2) Temperature rise test is to be measured at 100% load of motor corresponding to
full load speed of motor: ‐
a) Motor body temperature & ambient temperature to be recorded after every
15 minutes.
b) Temperature difference between motor body & ambient to be calculated &
recorded.
c) Motor to be switched off when temperature difference between two
d) Measure winding temperature and calculate temperature rise by resistance
method.
For Constant Torque Application motor: ‐

1) Temperature rise test is to be carried out for 25%, 50%, 75% and 100% load and
corresponding motor speed as per the Torque-Speed curve.
a) Motor body temperature & ambient temperature to be recorded after every
15 minutes.

b) Temperature difference between motor body & ambient to be calculated &

recorded.
c) Motor to be switched off when temperature difference between two
d) Measure winding temperature and calculate temperature rise by resistance
method.
2) Temperature rise test is to be carried out at minimum speed less than 25% of the
rated speed, provided Load Torque curve calls for such an operation. Also, voltage
boost feature should be provided in the converter so as to carry out test below 17
Hz (which is 1/3rd of rated frequency)
3) Field weakening mode Test:
Motor will be run at maximum speed as mentioned in data sheet or at 120% of
synchronous speed. This test will be carried out for 3 readings of 15 min interval.
Winding temperature at the end of the test will be recorded.


Low Voltage Variable Speed Drives
0 25.08.2020 Issued for Implementation VD/MI VGS/US SK/VKM

By By By
Specifications for Low Voltage Variable Speed Drives Date: 25.08.2020, Rev.0

No.

1 _________________ ___________
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
7. Supplier Data Requirement ....................................................................................... 14
Appendix B: String Test Procedure ..................................................................................... 21
1. Scope
documentation of low voltage Variable Speed Drive (VSD) panels and low voltage
variable speed drive motor control centers, for Supplier and/or Contractor to
comply with, to achieve Owner’s objective of standardization.
This document is applicable for all drives with nominal input voltage less than or
equal to 1000 V.
2. References
LV VSD shall be designed, manufactured and tested in accordance with the latest
document.
Specification for LV Switchgear RPMS-ENGG-SPC-EL-002
shall govern:
a) Data Sheets and Drawing
b) The Material Requisition
c) This Standard Specification
d) Codes and Standards Specifically Referred
e) Other National and International Standards as Referenced

Notes:
Requisition – LV VSD Datasheets, LV VSD Stock Code Item Description.

Order.

BTD: Bearing Temperature Device
DCS: Distributed Control System.
IGBT: Insulated Gate Bipolar Transistor.
LCS: Local Control Stations.
MCC: Motor Control Centre.
MOV: Metal Oxide Varistor.
MTBF: Mean Time Between Failure
MTTR: Mean Time To Repair
PCC: Power Control Centre.
PLC: Programmable Logic Control.
PWM: Pulse Width Modulation
RTD: Resistance Temperature Device
Definitions
Company



5.1. Life
The life of the VSD and the components forming part of it shall be at least 20 years.
The VSD shall be the latest available product and not a product at the end of its
lifecycle or in a limited phase of availability. Supplier shall provide MTBF, MTTR and
life cycle of offered equipment for Buyer review.
5.2. Service Conditions
a) The VSD shall be suitable for continuous operation under the service conditions
as stated in the datasheet.
b) The VSD shall be suitable for use in an oil refinery, chemical plant or other
facility with saline, sulphurous, dusty atmosphere. The equipment as a
minimum shall comply with IEC 60721-3-3, class 3C2.
c) Unless otherwise specified, VSD’s shall be installed in indoor area and climate-
controlled environments.
5.3.1. Input Power
The electrical supply shall be 3 phase, 3 wire, 50 Hz, solidly earthed, with a
maximum fault level of 50 kA for 1 second, unless otherwise specified in data sheet.
The system voltage and frequency variations shall be as given below:
Voltage: ± 10%
Frequency: ± 3%
Combined voltage and frequency variation: ± 10%
The two extremes of voltage and frequency variations are only to be considered to
coincide during transient conditions. The VSD shall be suitable for operating in
transient conditions, with voltage variation in the range of -20% to +10% of nominal
voltage.
5.3.2. Harmonic Compliance and General Requirement
a) Electrical harmonics at the point of common coupling shall not exceed the limits
as stipulated in IEEE-519. The point of common coupling shall be the power
control center (PCC) to which the VSD MCC /VSD is connected unless otherwise
stated in the data sheet.
The voltage harmonics shall be as per Table 10.2 in IEEE standard 519 which
establishes harmonic limits on voltage as 5% for total harmonic distortion and
3% of the fundamental voltage for any single harmonic.
The current harmonic limits shall be as per Table 10.3 in IEEE Standard 519.
Computer simulated estimates of harmonic level produced by VSD shall be
provided to Buyer for review and approval.
b) The Supplier shall specify if any output filter is required based on the motor
cable length as specified in data sheet, to ensure that the motor terminal
voltages shall be within the Insulation level of Motors. Necessary calculations
of voltages at motor terminals shall be furnished by the Supplier based on the
cable and motor data (with & without filter) provided in motor data sheet.
Selected filter type shall be validated by calculation IEC 61800-8 and its
performance shall be guaranteed by Supplier.
c) Power cables between the motor and the VSD shall be a standard 650/1100
V, 3 core,. Al conductor, XLPE insulation, Al round wire armored, PVC outer
sheath. (in case of absence of separate PE conductor armor shall be sized to
at least 50% conductivity of phase conductor)
Refer the VSD cable specification/datasheet provided by the buyer.
In case the above-mentioned cable is not suitable, the Supplier shall clearly
bring to the notice of the Buyer, about recommended cable size and cable type.
Supplies
d) Power factor shall be more than 0.95 lagging over the entire speed range.
e) Efficiency of the VSD shall be a minimum of 97% at full load of drive rated power
output and at 100% speed.
f) Where force cooling is required for VSD, redundant blowers and a loss of
cooling alarm dry contact shall be provided.
g) For the hazardous area motors, string test shall be performed which include
VSD and motor combination with identical cable size, type and length and any
input/output chokes or filters, as applicable.
String test shall be witnessed and certified. Refer Appendix B for the string test
procedure.
h) Combined test, which include VSD and motor coupled with driven equipment
shall also be performed for the system dynamic performance (establishing
system critical frequencies and magnitudes of pulsating and transient torques)
as a part of site acceptance test (SAT).

5.4. Construction
a) If specified on the data sheet, the VSD will be mounted within the low voltage
motor control center (MCC). The MCC requirement shall be covered by Low
Voltage Switchgear specification (RPMS-ENGG-SPC-EL-002).
b) The VSD MCC shall be metal enclosed for indoor service, vermin proof, free
standing with a dead front. Panels shall be constructed from sheet steel of
adequate thickness. Minimum thickness for non-load bearing members like end
covers shall be 2 mm.
c) VSD Panels or MCC cubicle housing VSD shall be equipped with adequate space
for termination of all power and control & interlock cables, as specified in data
sheet. Removable un-drilled gland plate of adequate size and thickness shall be
provided. The gland plates shall be located to provide ease of access for
terminating the specified cable size and type. Where single core cables are
specified, gland plates shall be made of Aluminum.
d) The VSD shall be of modular construction and shall be housed in cabinet(s) in
such a way that its main components are physically segregated and arranged in
a logical manner as to minimize risk of internal short circuits and to limit the
extent of damage on internal faults. All components shall be clearly labeled and
the labels shall correlate with the schematic diagrams.
e) Components and terminals of different voltage ratings shall be clearly
segregated and identified by phase barriers or color coding.
f) VSD panel shall have copper bus bars rated for the full load current. The VSD
shall be adequately protected against short-circuit current and time, as
specified in data sheet.
g) All conductors other than heat sinks shall be copper.
h) Bus bars shall be insulated for power frequency voltage withstand. Power
supply terminals and terminals powered from outside sources shall be
shrouded (guarded).
i) Suitable rated anti-condensation heaters shall be provided to prevent the
formation of harmful condensation inside the enclosure. The heater shall be
supplied complete with a thermostat and ON/OFF switch.
j) All insulation materials shall be non-hygroscopic, flame retardant, non-toxic
and shall be with low smoke index.
k) VSD or VSD MCC shall be of front access only. The equipment shall allow the
removal of components without any special tools. The design shall be such as
to facilitate inspection, rapid repair or replacement and ensure absolute safety
of operator during operation, inspection and maintenance.
l) All electronic cards shall have conformal coating, complying to G3 standards.

m) VSD MCC or VSD standalone panel shall be suitable for bolting or stich welding
to its preinstalled channel. Supplier shall certify that the equipment has been
designed for the seismic service conditions, as specified in the data sheets.
n) The MCC incomer shall be provided with 4-Pole disconnect switch (Pad
lockable) and shall be suitable to withstand short circuit current as specified in
data sheet. Disconnect switch (pad lockable) with momentary withstand rating
greater than the available fault current (as shown in data sheet) shall be
provided at input of VSD. Door of the MCC cubicle/VSD panel shall be provided
with mechanical interlock. If multiple doors are applied for single VSD
feeder/panel, each door shall be mechanically interlocked with disconnect
switch.
Mechanical interlock with disconnect switch shall include provisions to
manually override for test and operation.
o) The degree of protection shall be minimum IP42, unless otherwise specified in
datasheet. All cabinets shall be provided with suitable lifting lugs. Self-tapping
screws shall not be used in the construction of the equipment.
p) The exterior temperature of the equipment and the temperature of items or
components that may be touched by operating personnel shall not exceed
55oC.
q) Each drive system vertical / panel (Standalone as well as VSD MCC) comprising
of power devices, filters and other active components will be designed and
installed with heat extraction FAN for overall thermal management.
r) Enclosures shall not have sharp edges or pointed objects, such as the pointed
ends of sheet, metal screws on the exterior or inside any wire way. Adhesives
shall not be used for mounting any devices, parts, or components. All devices,
parts, and components including nameplates, wire ways, and wire supports
shall be mounted with screws.
s) Where specified converter transformer (for 690 Volt standalone VSD) shall
meet:
• Converter transformer shall be as per the requirement of project
specification of dry type transformer “RPMS-ENGG-SPC-EL-044”, and
applicable code and standard which includes IEC 61378-1 and IEC 61378-3.
• The impedances of converter transformers with two or more secondary
windings for multi-pulse systems shall be selected to ensure equal load
sharing between all secondary transformer windings, the converters and
the motor windings under all operational conditions including starting and
restarting.
• The converter transformer shall be suitable for operation with the non-
sinusoidal current wave shapes and DC components under normal and
abnormal (e.g. short-circuits) conditions of the VSDS without exceeding its

temperature or other limits under the conditions of this specification.
t) The maximum height of the operating handles and switches shall not exceed
1800 mm and the minimum height shall not be below 300 mm.
u) Multi-channel 4-20mA Transducers/repeater (2 Nos) shall be provided in VSD
panel/MCC for motor parameters such as speed, current etc. for remote
locations annunciations. These signals shall be wired to the terminal block for
Buyer interface.
v) The drive display and control keypad shall be installed on the MCC/ Panel door.
The control keypad should have a history log of minimum 100 alarms and
events.
A Voltmeter shall be provided on each Incomer feeder door for reading of
supply voltage.
VSD shall as a minimum shall have provisions for the following controls and
outgoing signals:
i. Start
ii. Stop
iii. External speed adjustment via 4-20 mA or raise/lower pulse
iv. Inhibit to start
v. Inputs for the thermal protection devices of the motor (pt 100 or
thermistor)
vi. Motor Running
vii. Motor Stopped
viii. Motor Tripped
ix. ESD Trip
x. “Motor Available” signal
xi. Common alarm
xii. External load current/speed/power indications
The following annunciation shall be readily available on the VSD MCC, either
through indication lamps or through the door mounted control keypad:
The "Motor Available" signal to DCS for auto start shall be healthy only if:
i. Control and mains supply is available.
ii. Motor has not tripped
iii. “Stop” Push Button on VSD is not activated
iv. “Stop” Push Button on LCS is not activated

v. “Stop” command from DCS/PLC is not activated
vi. “Hand-Auto” switch on LCS is in “Auto” position
Additional required inputs and/or outputs will be as specified in the data sheet.
Output contacts shall be potential-free change-over contacts.
5.5. Performance Requirements
a) Unless otherwise stated in the requisition, the VSD’s shall be suitable for single
quadrant operation and for an operational speed range between 5% and 100%
of the maximum speed, and should be capable of developing at least the
following torques:
For constant torque drives:
(i) During starting and restarting: 150% maximum rated torque for 10s.
(ii) After starting and restarting and during reacceleration: 120 % maximum
rated torque for 60s.
(iii) Continuously: the maximum torque according to the maximum rated
torque curve of the motor or 110% of the maximum torque according to the
maximum rated torque curve of the driven equipment.
(iv) The VSD one-minutes over load current rating shall be 150% of rated output
current.
For all other drives:
(i) During starting and restarting: 120% maximum rated torque for 10s.
(ii) After starting and restarting and during reacceleration: 110 % maximum
rated torque for 60s.
(iii) Continuously: the maximum torque according to the maximum rated
torque curve of the motor or 110% of the maximum torque according to the
maximum rated torque curve of the driven equipment.
(iv) The VSD one-minute overload current rating shall be 110% of rated output
current.
The VSD shall meet the above torque requirements at any line voltage between
90% and 110% of the nominal line voltage.
b) VSD shall have an output frequency range of 0.1 Hz to 300 Hz. The speed
regulation of 0.1% in open loop and 0.01% in closed loop is required.
Output frequency accuracy shall be +/- 0.01% of maximum frequency for digital
input and +/-0.2% of maximum frequency for the analogue input.

c) Suitably rated semiconductor fuses shall be provided for protection of the VSD.
MOV’s shall be provided across phases and between phase and earth to make
the VSD immune to voltage surges.
d) The VSD shall be speed, torque or power controlled as required by the driven
equipment characteristics. The VSD control system shall be microprocessor
based and shall provide all required control, protection, indication and
metering.
e) VSD shall be a voltage source inverter operating on sinusoidal pulse-width
modulation (PWM) technology. It should be possible to program the carrier
frequency for PWM inverters within a user selectable range. IGBT’s shall be
provided to achieve higher switching frequency.
f) A keypad and display shall be provided as the operator interface on the VSD.
The control system shall monitor the VSD, providing metering and fault details
on demand. The cause of an alarm or shutdown shall be shown on the display.
The keypad shall be suitably protected from unauthorized operation by having
password controls. It should be possible to download the relevant electrical
quantities of the previous faults for analysis.
g) All necessary protection shall be provided for the complete VSD system, motor
cable, motor and the converter power and control & auxiliary circuits.
h) The VSD shall have the facility for data communication with DCS.
Communication protocol (Profibus or Modbus over TCP /IP or RS 485) shall be
as specified in data sheet. The VSD shall feature a Real-Time-Clock for the
correct fault stamping data. It shall be possible to time synchronize the clock
over serial link from higher level control system.
The VSD shall also have hardwire interface with DCS as per project specific DCS
interface list.
i) The VSD shall have the capabilities to provide internal diagnostic information,
remote condition monitoring over a communication link and integrate with
owner’s cloud-based digitalization platform. VSD vendor to deliver specific data
model for mapping of offline and online measurement parameters to the cloud
platform.
j) The VSD shall be capable of responding to a 20% alteration in set point within
5 seconds and shall be capable of continuous readjusting to the set point.
k) The VSD shall have hardwire interface with local control stations. The
emergency stop button on the local control station shall perform an Electrical
break operation by providing dynamic breaking, if specified in data sheet.
l) Where 4 (four) quadrant application is required, suitable technology of the
drive shall be offered by the supplier, VSD shall have interface with local central

interface with Dynamic breaking resistor (DBR). Supplier shall provide the
suitably sized DBR based on the operation requirement.
If mechanical shaft breaking is required based on process application (such as
restrict fan reverse rotation due to back draft) necessary arrangement shall be
made in VSD for safe break and safe start of motor.
m) For identified critical applications, the control supply for drive functions shall
be derived from external source (UPS if specified in material requisition). The
Panel/MCC shall have redundant control supply scheme (either AC or DC), from
two separate sources or as mentioned in datasheet.
n) The VSD shall have "catch-on-the-fly" (speed search) feature i.e. the VSD shall
be capable of starting a coasting motor.
o) VSD shall have provision of programmable skip frequencies with adjustable
band widths as required by the mechanical equipment.
p) Where used for fin fan application, the VSD shall have fan belt broken
protection in-built based on undercurrent detection.
q) The VSD shall be suitable for reacceleration schemes (Power ride through
feature), i.e. the VSD shall restart the motor after resumption of power
following a power failure automatically, unless a STOP command is enabled. It
should be possible to enable or disable the reacceleration facility through the
control keypad.
For critical applications (as specified in datasheet), external energy source,
coupled to VSD, for improving the ride through performance during external
voltage dips shall be considered.
r) The VSD shall be capable of accepting a thermistor input (PTC-130°C) from the
motor for over-temperature protection. Additionally, the VSD shall also have
the provision for connecting RTD and BTD inputs (2-wire/3-Wire), as specified
in datasheet.
s) The VSD shall be capable of withstanding the thermal and dynamic stresses and
transient mechanical torques resulting from a short circuit of the level stated in
the data sheets.
t) Controlled charging of DC bus capacitor shall be ensured and necessary
interlock with incoming power supply feeder shall be implemented.
Requirement of any external auxiliary power for recharging, shall be provided
by Supplier with quotation.
5.6. Wiring
a) Internal cubicle wiring shall be insulated stranded copper conductor. All wiring
shall be adequately designed to meet the load and short circuit currents.

b) Wiring shall be run in wireways with ample spare capacity. Each wire end shall
have thermal transfer sleeve type label/ferrule and ferrule shall be consistent
with wiring diagrams and terminal numbers.
c) All control wiring within the panels shall be through multi-stranded, FRLS PVC
insulated, copper flexible cables. The minimum size of wire shall be 2.5 mm2
unless precluded by end connectors on electronic components. All such
deviations from the minimum wire size shall be stated in the bid offer.
d) For control wiring, pre-insulated crimped terminals shall be used and for power
wiring crimped lugs with PVC shrouds shall be used.
e) Terminals shall be of the cage-clamp screw-less type.
f) Flexible cable shall be used for connections to door mounted equipment.
Wiring shall be wrapped in flexible PVC conduit and shall be firmly clamped at
both ends to prevent movement at terminations.
g) FO patch cables in the panel shall have dedicated routing arrangement. Proper
care to be taken to ensure that the FO cables are not susceptible to any
damages/cuts due to panel edges. Sufficient bending clearance shall be
ensured for FO cables.
h) Wiring terminations at different voltages and of different signal levels shall be
segregated and clearly marked.
i) The cable for serial interface (RS485) shall be 0.3/0.5 kV, twisted pair and
overall screened.
j) Terminal blocks shall be supplied and clearly marked for wiring that will be
installed by Buyer. Supplier’s wiring for external connection shall be
terminated to one side of terminal blocks and not more than one wire at each
side of the terminal shall be permitted. Individual terminals shall be provided
for all external connections. External connections shall not be made directly to
component terminals.
k) All terminal blocks shall have 20% spare terminals. The minimum terminal size
shall be 2.5 sq. mm.
l) Power terminals shall be suited for cable size as specified in the Datasheet.
5.7. Earthing
An copper earth bar, sized according to equipment fault current rating. The Earth
bar shall run throughout the equipment full length. All non-current carrying metal
parts and cable gland plates shall be bonded to this earth bar. The earth bar shall
have a connecting stud, or nut and bolt, for terminating the plant earth. Stud/bolt
size shall not be less than 10 mm.

All doors shall be bonded to the main structure by means of flexible copper
connection arranged so that it cannot be trapped as the door is opened or closed.
5.8. Noise
The sound pressure level of the VSD shall not exceed 85 dB (A) at 1 m, measured in
accordance with IEC 60076-10 unless otherwise stated in the data sheet. All
equipment shall operate without undue vibration and with least noise. In case the
specified sound level cannot be achievable due to use of high/high speed cooling
fan , supplier shall quote the different options available to reduce the motor noise
level in quotation stage for Buyer review and approval.
5.9. Surface Finish
The finish shall be in accordance with the Supplier’s standards for the service
conditions specified. The colour of the VSD MCC shall be RAL 7032.
Supplier shall supply 500 ml of field touch-up paint for each colour used for each
MCC or VSD Panel. All components shall be fully tropicalized.
5.10. Name Plate, Labels & Serial Number
The rating plates shall be marked with data in accordance with IEC 61439 and other
applicable Codes and Standards.
Danger / Warning labels shall have white letter on a red background. All other
labels shall have black letter on a white background. All labels shall be fixed by
stainless steel screws.
Name plates shall be machine engraved phenolic and shall be attached with
stainless steel screws.
Name plates shall be fitted at each main assembly and shall include the following:
i) Weight in kilograms
ii) Name of Supplier and year of manufacture
iii) Type of equipment
iv) Input and Output ratings, voltage, phases and frequency
v) Maximum short circuit current
vi) Purchase order number
vii) Supplier’s serial numbers
In addition to the Supplier’s nameplate, the equipment shall be identified with
Buyer's equipment tag number plate(s).
Each major electrical component shall have a label fitted to it (or alongside), with
an item description, number or significant data indicated on it. This shall reflect the
components identified in equipment internal circuit diagrams.
One complete set of schematic diagrams inside a weatherproof document wallet

shall be provided. This shall be stored in an appropriate holder behind the
enclosure door of each unit.
5.11. Spares
The Supplier shall provide a complete separate priced list of recommended
commissioning and operating spares with the quotation.
Commissioning spares, approved by the Buyer, shall be included with the
equipment.
The Supplier shall provide local support for parts which have short life periods and
stock spares.
5.12. Accessories
A complete set of accessories, including any special tools, shall be provided for
operating, maintaining and testing the equipment. Supplier shall provide a list of
accessories and special tools, if required.
Accessories and special tools shall include any software, manuals and
commissioning tools required for commissioning and operation of the VSD's.
Requirement of supply of Licensed software and lap top with above mentioned
accessories shall be decided by Buyer based on the quantum of order/Model of the
drive.
VSD’s supplied shall be a type tested design.
All equipment, including any sub-supplier equipment, shall be subject to
inspection, at any time prior to shipment, and also subject to witness of tests by
Buyer's representative at the place of manufacture.
Supplier shall perform all standard routine tests in accordance with the relevant
standards and agreed test procedures. The following tests shall be included as a
minimum:
i) Full load heat run (one unit of each rating for 8 hours)
ii) Noise test
iii) Acceleration/deceleration test using a simulated load
iv) Inverter current limiting
v) Input and output voltage waveform measurements/analysis at 50% and 100%
load (one of each rating)
vi) Functional alarm and tripping check
vii) Operation of all equipment
Supplier shall carry out all tests on the complete equipment and shall commence
any remedial work or correction of faults found during inspection or testing.
Supplier shall notify buyer, eight weeks prior to the tests. Buyer or his
representative reserves the right to inspect the VSD at any time prior to dispatch
and witness the tests at the factory.
Before final inspection by Buyer, Supplier shall confirm satisfactory completion of
all in-house routine tests and shop inspection. A certified test report including
reading/graph(oscillograph) shall be submitted to Buyer.
7. Supplier Data Requirement
list provided in the Material requisition.
The minimum Supplier data requirement shall cover the document to be submitted
by a Supplier during the following stages:
Sl. No. Document Description Along Post
with Bid Order
1 General arrangement (#) √ √
(Preliminary)
(Outline drawing showing main dimension, including
arrangement of components, termination
arrangements and lifting points)
2 Datasheet (#) √ √
3 Single line diagram (#) √ √
(Preliminary)
4 Performance characteristics √
(such as overall efficiency, heat load and noise level at

full load)
5 Supplier Quality Assurance Program √
6 Quality Plan √
7 System Architecture (#) √ √
(Block diagram showing the interconnectivity between

various control/IO cards)
8 Calculations √ √
(for electrical component size / ratings, chokes & filter,

harmonic calculation for compliance to IEEE-519)

9 Calculations √
• Application check to meet the performance

requirement (Torque – Speed Characteristics and
VSD selection)
• Validation of the Peak Voltage, dv/dt levels at

Motor Terminal from VSD do not exceed the Motor
Insulation capability
10 Schematic & Wiring Diagram (#) √
11 Logic block diagram (#) √ √
(Preliminary)
12 Foundation plans (#) √
13 Type test certificates √
14 Routine Test report √
15 Radio Frequency Interference (RFI) √

compliance certificate
16 Derating chart √
(for VSD)
17 Deviation List √
(Equipment of similar design and rating during last five

years)
19 Catalogues √
(on VSD and other accessories)
20 Heat Load Calculation √ √
(for panel and components) (Typical)
21 Inspection and test plan √
22 Training Manual √
23 Manufacturing & Testing facilities √
24 Rating and Diagram Plate √
26 Painting and coating procedure √
27 Complete inspection & test reports carried out √
28 Test certificates of all bought out items √

29 Compliance certificate √
(indicating that the Equipment supplied, comply with

the corresponding Specification and all the relevant
codes and standards)
30 Installation and commissioning instructions √
31 Operation and maintenance manual √
32 Parts List / Bill of Material (#) √
33 Guaranteed Technical Parameters √ √
34 List of recommended operational √ √

/commissioning spare parts
35 Instructions for handling at site including √
Shipping dimensions and weight
36 Configuration Files √
(editable format)
37 String (Combined) Test Reports on VSD, √

Converter transformer and Motor in Supplier's
works (if specified in requisition)
38 Life Cycle documentation - System Life Cycle √ √
Plan, product evolution with current version
details, obsolescence plan (Hardware /
Software / Firmware) including all major key
components – Power and Control
components.
Note:
1) Software required for VSD operation (to be included base offer)
2) (#): As built documents shall be submitted as a minimum requirement, including
final Parameterization Document.
a) Preparation of shipment shall be made after all inspection and testing of
equipment has been accomplished and equipment has been released for
shipping by the Buyer.
b) The VSD shall be shipped in the largest possible shipping sections whilst
permitting ease of handling for transportation and installation.
c) Each shipping section shall be provided with supports such as steel sections,
lifting eyes, etc. to maintain alignment of parts during shipping, handling,
hoisting and installation. Location of lifting points shall be clearly marked on
shipping containers and on drawings. Each shipping section shall have the
weight and center of gravity clearly marked on the container.
d) Preparation for shipment shall protect the component parts against corrosion,
dampness and breakage or vibration injury during transportation or handling.
e) Each shipping container shall be identified with the contents, Buyer's purchase
order number and item number. Packing list should be provided in each
shipping enclosure/container.
f) Where equipment has to be split for shipping, instructions shall be provided for
reassembly. Materials and special tools shall be provided, if necessary, for
reassembly at site.
g) Loose equipment shall be appropriately packaged & secured for shipment
inside the enclosure or shipping container. These items shall be properly tagged
for easy identification.
h) Space heater leads shall be accessible without disturbing the shipping package
and shall be tagged for easy identification.


IEC Standards
IEC 60050 International Electrotechnical Vocabulary.
IEC 60051 Direct Acting Indicating Analogue Electrical Measuring
Instruments and their Accessories
IEC 60073 Basic and Safety Principles for Man-Machine Interface,
Marking and Identification. Coding Principles for Indicators
and Actuators.
IEC 60076-10 Power transformers - Part 10: Determination of sound
levels
IEC 60076-11 Power Transformers- Part 11 Dry- type transformer
IEC 60079-0 Explosive atmospheres - Part 0: Equipment - General
requirements
IEC 60079-7 Explosive atmospheres - Part 7: Equipment protection by
increased safety "e"
IEC 60085 Electrical Insulation-Thermal Evaluation and Designation
IEC 60146-1 Semiconductor converters - General requirements and line
commutated converters
IEC 60146-2 Semiconductor converters - Self-commutated
semiconductor converters including direct d.c. converters
IEC 60227 PVC insulated cables of rated voltages up to and including
450/750 V
IEC 60228 Conductors of Insulated Cables
IEC 60255 Electrical Relays
IEC 60269 Low-Voltage Fuses
IEC 60417 Graphical Symbols for use on equipment
IEC 60445 Basic and Safety Principles for Man-Machine Interface,
Marking and Identification. Identification of equipment
terminals and of terminations of certain designated
conductors. Including general rules for an alphanumeric
system.

IEC 60529 Degree of Protection Provided by Enclosures (IP Code).

IEC 60715 Dimensions of low-voltage switchgear and control gear.
Standardized mounting on rails for mechanical support of
electrical devices in switchgear and control gear
installations.
IEC 60721-3-3 Classification of environmental conditions - Part 3-3:
Classification of groups of environmental parameters and
their severities - Stationary use at weather protected
locations.
IEC 60898 Circuit-Breakers for Overcurrent Protection for Household
and Similar Installations
IEC 60947 Low-voltage Switchgear and Control gear.
IEC 61000 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment.
IEC 61204 Low-voltage power supply devices, d.c. output -
Performance characteristics
IEC 61378-1 Converter transformers - Part 1: Transformers for
industrial application
IEC 61378-3 Converter transformers - Part 3: Application guide
IEC 61439 Low-Voltage Switchgear and Control gear Assemblies
IEC 61800 Adjustable Speed Electrical Power Drive Systems
IEC 61800-8 Adjustable speed electrical power drive systems - Part 8:
specification of voltage on the power interface
IEC/CISPR 11 Industrial, scientific and medical equipment - Radio-
frequency disturbance characteristics - Limits and
methods of measurement
locations
IEEE Standards
IEEE 519 IEEE Recommended Practices and Requirements for

Harmonic Control in Electrical Power Systems
Indian Standards
IS 5571 Guide for Selection and installation of Electrical
Equipment for Hazardous Areas (other than mines)
IS 9628 Three-phase induction motors with type of protection n
Other Standards
Environmental conditions for process
ISA Standard 71.04
measurement and control systems

Appendix B: String Test Procedure

(Refer Attachment-1)
Attachment-1
RPMS-ENGG-SPC-EL-011.docx

Attachment-1 to Standard Specification for

Low Voltage Variable Speed Drives
String Test Procedure for LV VSD Date: 25.08.2020, Rev.0
Contents
1. Scope ........................................................................................................................... 1
2. Purpose........................................................................................................................ 1
3. Motor Details .............................................................................................................. 1
4. VSD Details .................................................................................................................. 2
5. Test Parameters .......................................................................................................... 2
6. Test Procedure ............................................................................................................ 3
7. Test Measurements..................................................................................................... 5
8. Test Success Criteria .................................................................................................... 6
1. Scope
This test procedure describes the proposed combination test for assessing
suitability of motors for operation on a Variable Speed Drive (VSD) in a classified
environment.
2. Purpose
Indian Standard 5571 requires certification of a motor VSD combination as per
clause 11.3.4. The relevant clause in the Indian Standards states that “Motors
supplied at varying frequency and voltage by a converter shall have been type
tested for this duty as a unit in association with the converter specified in the
descriptive documents according to IS/IEC 60079-0 and with the protective devices
provided or shall be evaluated in accordance with IEC 60079-7.
The perceived risk as per Rotating Electrical Machines Association (REMA) is due to
the following:
a) Reduced cooling for self-ventilated motors at reduced speeds, due to reduced
air flow
b) Increased losses due to non-sinusoidal supply at the motor terminals leading to
increased temperature rise, compared to sinusoidal supply
c) Specific additional heat generation, particularly in the rotor cage and
supporting structure as a result of harmonic currents
d) Induced voltages in the rotor, which can lead to currents through the bearings
(due to PWM technology and high switching frequency)
e) Dielectric heating due to high frequency/voltages, and
f) Additional stresses on motor winding due to rise time of voltage wave
The purpose of carrying out the combination testing for one motor of each rating,
to be operated in conjunction with a VSD, is to ensure that the installation is safe
for operation in a hazardous environment.
3. Motor Details
Motors selected for operation with VSD in hazardous areas are mostly Ex ‘ec’
(previously Exn) type, manufactured as per IS 9628. The motors are self-ventilated,
totally enclosed fan cooled (TEFC) type. The following are specific construction
features of the motor for compatibility with VSD’s:
• Motors have been dimensioned for suitability of operation with a VSD, i.e.
motor winding is suitable for the voltage rise time of the VSD. This is ensured
by providing VPI treatment to the stator windings and by using double coated
stator windings.

• Motors are provided with insulated bearings at non-driven end. The insulated
bearings ensure that shaft induced voltages do not cause circulating currents
and contribute to shaft heating and bearing failure. Consequently, the
proposed test does not attempt to measure the shaft induced voltages,
currents and shaft temperature. However, considering bearing expansion and
failure in case of undue temperature rise, it is proposed to carry out
measurements of bearing temperature.
• Since motors are to be operated with VSD’s, the rotor has been constructed
without deep bars or double slots. This ensures that rotor heating is not
unduly increased. With a deep rotor cage construction, the inner
conductors/bars will have an increased slip with respect to outer bars and
consequently will carry larger current and contribute to increased rotor
heating.
• Motors have Class F insulation; however, the temperature rise of the
insulation has been restricted to Class B. This ensures that the stresses on the
winding during operation with a VSD are accounted for. However, considering
the criticality of the voltage rise time, especially during starting of the motor,
the voltage waveform to be recorded during motor starting.
4. VSD Details
The following are specific construction features of the VSD’s provided for additional
safety in the installation:
• All VSD’s are provided with output chokes/sine filter to ensure that the
voltage wave rise time does not exceed the voltage rise time as permitted by
the insulation class of the motor.
• VSD’s calculate and create a thermal image of the motor which trips the
motor in case the calculated thermal image exceeds the motor’s thermal
capability, or the permitted temperature rise as per the area classification of
the motor.
• VSD’s shall have low speed protection, which shuts-down the motor in case
the motor is running for prolonged duration at a speed which can impair the
self-cooling of the motor. Motor cooling fan has been dimensioned for
satisfactory cooling for a motor speed range of 5-100% of rated speed. The
undercurrent protection has been set to operate at approximately 30% of
motor’s rated current to provide a thermal safety margin.
5. Test Parameters
The following parameters shall be measured during the testing. Empirical
calculations shall then be carried out by the motor vendor to ensure that the end
installation shall be safe:

(i) Voltage waveform during no load starting of motor.

(ii) Voltage waveform during no load tripping of motor.
(iii) Temperature of stator during partial load (10%, 60% and 80%) running of
motor.
(iv) Temperature of rotor during partial load (10%, 60% and 80%) running of motor.
(v) Temperature of bearings during partial load (10%, 60% and 80%) running of
motor.
(vi) Voltage waveform during full load starting of motor.
(vii) Voltage waveform during full load tripping of motor.
(viii) Temperature of stator during full load running of motor.
(ix) Temperature of rotor during full load running of motor.
(x) Temperature of bearings during full load running of motor.
(xi) Temperature of stator while operating in the field weakening zone.
(xii)Temperature of rotor while operating in the field weakening zone.
(xiii) Temperature of bearings while operating in the field weakening zone.
6. Test Procedure
Before commencement of the test, the motor must be at ambient temperature (All
readings shall subsequently be extrapolated to design ambient temperature). In
this condition, the temperature and resistance of the windings shall be accurately
recorded. Resistance across the line terminals of the windings shall be recorded,
the phase resistance shall be determined by computation from the recorded
values.
6.1. No load test
(i) The motor shall be run at no-load. Voltage and current at motor terminals shall
be measured using a true reading voltmeter and ammeter respectively.
(ii) Voltage waveform shall be recorded using an oscilloscope. The waveform shall
be recorded for the duration taken for the motor to attain steady state no-load
speed.
(iii) The supply to the VSD shall be disconnected subsequently and the voltage
waveform shall be recorded using an oscilloscope for the duration taken for the
voltage waveform to reach zero volts.
6.2. Load Test
For carrying out load tests on motors, motors are normally loaded using the brake
and pulley method, dynamometer method or using by using calibrated generator

to load the motor. The motor shall be shielded from currents of air coming from
adjacent pulleys, belts, fans and other components to avoid inaccurate results.
It should be noted that the results obtained through this test shall generally be
more pessimistic. For carrying out the test, the test setup shall be set to load the
motor to its desired load at desired speed. Subsequently, the test is commenced.
Load tests shall be carried out for motor loaded at 10%, 60%, 80% and 100% of its
name plate rating. The test shall commence for motor loaded to 10% of its name
plate rating and shall subsequently be done for 60%, 80% and full load (in the same
order). Cooling down period shall not be required, as motors are susceptible to
similar cycling. The speed, at which the motor shall run during this test, shall be as
per the torque-speed characteristic of the driven load or motor, whichever is
higher.
The following readings are taken:
(i) Voltage and current at motor terminals shall be measured using a true reading
voltmeter and ammeter respectively.
(ii) Voltage waveform shall be recorded using an oscilloscope. The waveform shall
be recorded for the duration taken for the motor to attain steady state speed.
(iii) The temperature of the stator, rotor and bearings shall be recorded. The
temperature shall continue to be measured and recorded until the motor has
attained thermal equilibrium. Thermal equilibrium shall be deemed to be
attained when there is a variation of 1 degree Centigrade or less between two
consecutive measurements of temperature taken within 15-minute intervals.
(iv) The supply to the VSD shall be disconnected subsequently and the voltage
waveform shall be recorded using an oscilloscope for the duration taken for the
motor to come to a standstill.
6.3. Tests during operation in field weakening zone
Field weakening point is defined as the condition when the voltage across the
motor terminals is maximum and the frequency is increased to increase the speed
of the motor. Theoretically, this is the point when the motor is subjected to the
worst-case harmonic voltages and currents and consequently, there is maximum
heating of the motor.
The readings shall be taken for the motor running at synchronous speed with full
voltage applied across the motor terminals. The motor shall be loaded to its full-
load name plate rating. The following readings are taken:
(i) Voltage and current at motor terminals shall be measured using a true reading
voltmeter and ammeter respectively.

(ii) Voltage waveform shall be recorded using an oscilloscope. The waveform will
be recorded for the duration taken for the motor to attain steady state full load
speed.
(iii) The temperature of the stator, rotor and bearings shall be recorded. The
temperature shall continue to be measured and recorded until the motor has
attained thermal equilibrium. Thermal equilibrium shall be deemed to be
attained when there is a variation of 1 degree centigrade or less between two
consecutive measurements of temperature taken within 15-minute intervals.
7. Test Measurements
Test Measurements shall be carried out using calibrated and true reading
instruments where applicable. All test measurements shall be recorded and time-
tagged. Method of measurement is as detailed below:
7.1. Measurement of Winding Resistance
Winding resistance is normally measured using the drop of potential method or the
bridge method. For purpose of this test, the bridge method shall be used where the
resistance shall be compared with a known resistance. The Kelvin double bridge
shall be used as the resistance values of the motor are usually less than 1 ohm.
Temperature of the winding shall also be recorded during initial (cold) winding
resistance measurements using a thermometer placed in contact with the stator
surface. The temperature of the surrounding air shall not be taken as the
temperature of the windings, unless the motor has been idle for a long period
under similar atmospheric temperature conditions.
7.2. Measurement of Current
Current at motor terminals shall be measured using a true-reading ammeter
connected at the motor terminals. The VSD current reading (from its display panel)
shall not be taken as it is a computed value, from the dc bus current. Conventional
ammeters, measuring only the fundamental value of the current, shall not be used.
7.3. Measurement of Voltage
Voltage shall be measured using a true-reading voltmeter connected at the motor
terminals. The VSD voltmeter reading (from its display panel) shall not be used, as
it will not account for the output chokes connected at the VSD output terminals.
The voltage at the motor terminals will be different from the voltage at the VSD
output terminals due to the presence of the output chokes.
7.4. Measurement of Temperature
Stator temperature shall be measured using the thermometer method. The
temperature of the winding is determined by thermometers applied to the external
stator body surface. Mercury thermometers shall not be used as they are
susceptible to magnetic fields and are hence unreliable. Only Alcohol bulb
thermometers shall be used. On completion of the test, the temperature of the

winding shall also be determined by observing the increase in resistance of the
winding with respect to the cold resistance.
Rotor temperature shall be measured using an Infrared scanner/gun. The
temperature shall be taken at regular intervals during the test and also at the end
of the test. A probe shall be inserted into the motor as close to the air gap as
possible for the measurement of temperature.
Temperature of bearings shall be measured using alcohol bulb thermometers
placed in contact with the bearings.
7.5. Waveform Capture
Waveform capture shall be done using a continuous recording oscilloscope with
sufficient buffer memory to prevent data overflow.
7.6. Measurement of Speed
Speed shall be measured using direct reading tachometer.
8. Test Success Criteria
Test shall be deemed to be successfully only if
(i) Motor Temperature (Stator, Rotor and Bearings) do not exceed the specified
temperature class of the motor.
(ii) Voltage rise at motor terminals cannot lead to flashing, tracking, etc. or
premature insulation deterioration.

Standard Specification For HV Cables

0 25.08.2020 Issued for Implementation BM/VRS/ VGS/ US SK/ VKM

PDG

By By By
Standard Specification for HV Cables Date: 25.08.2020, Rev 0

No.

1 _________________ ___________
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number
First Issue
25.08.2020 0
Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
6. Inspection and Testing ................................................................................................ 7
7. Supplier Data ............................................................................................................. 11
APPENDIX A: Codes and Standards ..................................................................................... 13
APPENDIX B: Guaranteed Technical Parameters for HV Cables ......................................... 15
1. Scope
This specification defines the minimum technical requirements for design, material,
manufacture, inspection, testing, packaging, shipment and documentation for High
Voltage cables (for working voltages from 3.3 kV, up to and including 33 kV) for
Supplier and /or Contractor to comply with, to achieve Owner`s objective of
standardization.
Fire Survival cables, Elastomeric cables, and cables suitable for Variable voltage
variable frequency applications are excluded from this specification.
in similar service conditions. Owner will review, evaluate and approve deviations
to this standard specification that Supplier and/or Contractor may seek on this
2. References
The HV Cables shall be designed, manufactured, assembled and tested in
accordance with the latest applicable sections of the code and standards detailed
in Appendix A.
document.
RPMS-ENGG-DBD-EL-001 Electrical Design Basis

shall govern:
a) Data Sheets and Drawings
e) Other National & International Standards as Referenced

Notes:
• “Data sheets and Drawings” represent those attached to the Material
Requisition – Cables data sheets, Cable Stock code item description,
• “Material Requisition” represents Material Requisition for quotation,
Order.
AWA Aluminium wire armour
DIN Deutsches Institut für Normung
FRLS Flame Retardant Low Smoke
IEC International Electrotechnical Commission
IS Indian Standard
PVC Poly Vinyl Chloride
SWA Steel Wire Armoured
XLPE Cross Linked Poly Ethylene
VCV Vertical Continuous Vulcanization
Definitions



Company

5.1. Cables shall be suitable for use in site conditions described in data sheet(s). Cable
shall have minimum design life of 25 yrs.
5.2. All cables shall be suitable for installation on:
a) Above ground fastened to cable racks or trays in the open air exposed to direct
sunlight
b) Suitable for Hydrocarbon processing facility
c) Direct buried in the ground (including water / chemical logged ground)
d) In Underground duct bank
e) Below ground in enclosed air-filled trenches, fastened to cable racks or tray
5.3. The design ambient temperature shall be considered as 430 C, unless otherwise
specified in the data sheet(s). The relative humidity shall be considered as 100%.
The cables shall be suitable for operation in a fully tropical atmosphere.
5.4. Cables shall be suitable and rated for the electrical system characteristics given in
the data sheet(s) and Electrical design basis.
5.5. Cable Construction
Cable construction shall be as detailed below:
5.5.1. Conductor
a) The conductors shall be composed of plain Aluminum or Copper Wires
complying with IS 8130.
b) Aluminium used for conductor shall be Electrolytic grade Aluminium, stranded,
grade H4, Class 2 as per IS 8130.
c) Copper used for conductor shall be standard annealed high conductivity,
complying with IS: 613 for resistivity, density, coefficient of linear expansion
and chemical composition.
d) The conductor shall be stranded and compacted circular for all HV cables.

5.5.2. Conductor Screen

The conductors shall be screened by extruded semi-conducting compound. Screen
shall be free from voids and shall withstand all mechanical and thermal stresses
under steady state and transient operating conditions.
5.5.3. Insulation
a) Insulation for cables shall be XLPE unless otherwise specified in the data
sheet(s) and shall conform to the properties covered in the applicable
standards.
b) Insulation for underground cables shall be TR-XLPE (Tree-retardant cross-linked
polyethylene) exhibiting water-tree retardance properties, unless otherwise
specified in the data sheet(s) and shall conform to the properties covered in the
applicable standards.
c) The manufacturing process shall ensure that the insulation be free from voids.
d) Insulation shall be suitable for rated voltage and conductor temperature of 900
C continuously rated current and 2500C in case of short circuit condition as per
IEC 60502 Part 2.
5.5.4. Insulation Screen
a) The cores shall be screened by extruded freely strippable semi-conducting
compound in combination with non-magnetic metallic tape (copper tape
preferred).
b) The semi-conducting compound shall be suitable for the operating temperature
of the cable and compatible with the insulating material.
c) Unless specified otherwise, the copper screen for all the three cores together
and armour shall be capable of carrying the single line to ground fault current
value for the duration as specified in the data sheet(s). Supplier shall furnish
calculation in support of selection of size of copper screen.
d) For 33kV cables, Water Swellable tape shall be provided under the copper tape
Conductor screen. XLPE insulation and insulation screen shall be extruded in
one operation by ‘Triple Extrusion’ process (dry curing by CCV/VCV technology)
to ensure perfect bonding between the layers. Triple extrusion by SIOPLAS
technology is not acceptable. Dry curing by CCV technology, equipped with EHT
system (Entry Heat Treatment), is preferred.
5.5.5. Core Identification
Colour coding shall be provided for all cables. For 3 core cables, the core
identification shall be done through RED, YELLOW & BLUE colour strips placed
above copper tape and natural colour for single core cables.

5.5.6. Laying up of Cores and Fillers

In three Core cables, the cores shall be laid together with a suitable right hand lay.
Non-hygroscopic filler materials used to fill up the interstices (space between the
power cable cores, under the inner sheath) shall be Polypropylene. Further, it shall
be such that the transmission of gas and hydrocarbons along the length of the
cable, under normal pressure is not possible and shall prevent / reduce the water
propagation through the cable.
5.5.7. Inner Sheath
a) Inner sheath when specified shall be PVC applied by extrusion and shall be
compatible with the insulation provided for the cables. Binder tape shall be
provided as per IS 7098 (Part 2).
b) The inner sheath shall be so applied that it fits closely on the laid-up cores and
it shall be possible to remove it without damage to the insulation. Minimum
thickness of inner sheath shall be as per IS 7098 (Part 2).
c) The inner sheath shall conform to the requirements of type ST 2 compound of
IS 5831.
d) The extruded inner sheath shall be of uniform thickness. In case of single core
cables where there are both metallic screening and armouring, there shall be
extruded inner sheath between them.
5.5.8. Armour
a) Armouring for the cables shall comprise galvanized steel or hard drawn
aluminum, in the form of strips or round wires as indicated in the data sheet(s).
b) Minimum area of coverage of armouring shall be 90%. The gap between any
two armour strip/wire shall not be more than width of strip/diameter of
armour. Type, dimension, resistance of armour shall be according to applicable
IS standards. The Joint in the armour wires/strip shall be made by brazing and
welding and any surface irregularities shall be removed.
c) For multi-core cables, the armouring shall be by galvanized steel strips as per IS
7098 (Part 2) Table 6, section (a). If armouring is specified for single core cables
in the data sheet(s), the same shall be round aluminum wire as per IS 7098 (Part
2) Table 6, section (b).
d) Calculation for Fault level and withstand duration for armour shall be submitted
by Supplier.
e) Direction of lay of Armour shall be left hand. For double wires/strips armoured
refer IS 7098 Part 2, Section 17.1.2.
5.5.9. Outer Sheath

a) The outer sheath of the cables shall be applied by extrusion over the armouring
and shall be of PVC compound conforming to the requirement of Type ST 2
compound of IS 5831. The thickness of outer sheath shall be as per IS 7098 (Part
2) for both un-armoured and armoured cables.
b) The sheath shall be resistant to water, ultra violet radiation, fungus, termite and
rodent attacks. Cable outer sheath shall be coloured black for all voltages,
unless otherwise specified in data sheet(s).
c) If specified in the cable data sheet(s) the outer sheath shall be Flame Retardant
Low Smoke type.
d) The overall diameter shall not vary from Supplier`s declared technical
information subject to maximum tolerance +/- 2 mm up to overall dia. of 60
mm and +/- 3 mm for greater than 60 mm
e) The outer sheath of cables shall be embossed or engraved with:
i) The voltage designation
ii) Supplier`s identification
iii) Number of Cores and nominal cross-sectional area of conductors
iv) Cable Insulation Type
v) Year of Manufacturing
vi) The drum progressive length of cable at every meter. (The starting point
being the cable end at its inner coil on the cable drum).
5.6. General
5.6.1. Cables shall be supplied in non-returnable wooden / returnable steel drums of
suitable barrel diameter, securely battened with take-off end fully protected
against mechanical damage. The returnable steel drums should be constructed in
such a way that they can be easily dismantled at RIL premises. The wood used for
construction of the drum shall be properly seasoned and free from defects and
wood preservative shall be applied to the entire drum. All ferrous parts shall be
treated with a suitable rust preventive coating to avoid rusting during transit or
storage. Cable drums shall be proofed against attack by white ants or termite.
Reference of Cable IS shall be stenciled on cable drum. Cable drums shall conform
to IS 10418.
5.6.2. Cables shall be provided in Supplier`s standard drum lengths, as one continuous
piece, unless otherwise specified
5.6.3. Negative tolerance on cable length of cable drums is not acceptable.

5.6.4. Cable ends shall be sealed and fixed to the drum so that both ends are accessible.
To protect the cable during shipment battens shall be fitted around the entire
periphery of the drum. Drums shall be suitable for long term outdoor storage at
site.
5.6.5. All cable drums shall have the Purchase Order Number, Purchase Order Item
Number, Drum Number and Cable Code clearly stenciled on the outside of both
flanges. The cable drum number shall be stenciled on each side of drum in 50mm
high letters as minimum.
5.6.6. Drum identification labels shall be of non-corrosive, non-hygroscopic material and
attached to the outside and inside of the drum flanges. Labels shall be protected
by transparent plastic envelopes and provide the following information:
a) Reference of IEC or IS
b) Drum identification number and its direction of rotation for cable removal.
c) Cable voltage grade
d) Cable construction (e.g. XLPE SWA PVC)
e) Number of cores and cross-sectional area
f) Cable quantity (meters)
g) Purchase order number and item number
h) Total weight of cable and drum (kg)
i) Supplier's name
j) Country & Year of manufacture
k) Cable code
Cables shall be subjected to routine and acceptance tests per applicable IS. Test
methods shall conform to relevant IS Standard. Type tests if specified in the
Material Requisition shall be witnessed by BUYER or BUYER's representative. Cables
offered shall be of type tested by a recognized national/ international laboratory in
accordance with the relevant standards. Copies of the type test certificates shall be
submitted with the quotation. Type test certificates shall not be older than 5 years.
6.1. Routine Tests
Routine tests shall comprise of the tests listed below as per IS 7098- Part II, Clause
No. 15.3 as a minimum.
a) Conductor Resistance Test
b) Partial discharge test (for screened cables only and on full drum length)
c) High Voltage Test
6.2. Acceptance test

Acceptance tests shall comprise of the tests listed below as per IS 7098–Part II
Clause No. 19.2 as a minimum.
a) Annealing tests (for copper),
b) Tensile test (for Aluminium),
c) Wrapping test (for Aluminium),
d) Conductor resistance tests,
e) Test for thickness of insulation (eccentricity) and sheath,
f) Hot set test for insulation,
g) Tensile strength and elongation at break test for insulation and Outer sheath,
h) Partial Discharge Test ( for screened cables only),
i) High voltage test,
j) Insulation resistance (volume resistivity) test,
k) Test for cross linking for extended semi-conducting screen,
l) Oxygen Index,
m) Flame retardance test on single cable,
n) Flame retardance test on bunched cables,
o) Tests for halogen acid gas evolution,
p) Test for Smoke density
In addition to above listed acceptance tests, following inspection and tests to be

performed by Supplier:
a) Dimensional Check
b) The critical oxygen index value shall be minimum 29 when tested at 27+2oC as
per ASTM-D-2863.
c) Flammability test
d) Cables shall pass test under fire conditions as per IS-10810- Part-53. Cables shall
also pass tests as per IS-10810 Part- 61 & Part-62 (Cat AF).
6.3. Type Tests
Type tests shall comprise of the tests listed below IS 7098–Part II, Clause No. 19.1
as a minimum. For type tests, a certified copy of such tests performed on a similar
rated cable shall be accepted.

a) Tests on conductor:
i) Annealing test (for copper)
ii) Tensile test (for Aluminium)
iii) Wrapping test (for Aluminium)
iv) Conductor Resistance test
b) Test for armouring wires / stripes
c) Test for thickness of insulation (eccentricity)and sheath
d) Physical tests for insulation:
i) Tensile strength & elongation at break
ii) Ageing in air oven
iii) Degree of cross linking
iv) Hot set test
v) Shrinkage test
vi) Water absorption (Gravimetric)
e) Test on Extruded Semi conducting screens:
i) Test for Strip ability of Semiconducting strippable insulation screen ( when
applicable)
ii) Volume Resistivity
f) Physical tests for outer sheath:
i) Tensile strength & elongation at break
ii) Ageing in air oven
iii) Loss of mass in air oven
iv) Hot deformation
v) Shrinkage test
vi) Heat shock test
vii) Thermal stability test
viii) Carbon black content of polythene sheath
g) Thermal ageing test for complete cable
h) Partial Discharge Test
i) Bending test

j) Di-electric Power factor Test (Tan-delta test) , as a function of voltage and as a

function of temperature
k) Insulation Resistance (Volume resistivity test)
l) Heat cycle test
m) Impulse Withstand Test
n) High Voltage Test
o) Oxygen index.
p) Flame retardance test on single cables
q) Flame retardance test on bunched cables
r) Smoke density test (on sheathing material)
s) Test for Halogen acid gas evolution
t) Temperature Index
In addition to above listed tests, following tests to be performed by Supplier.

a) Oxygen Index as per ASTM-D-2863
b) Flammability Test
c) Test for Smoke Generation
• The maximum smoke density rating shall not be more than 60% when
tested as per ASTM-D-2843.
d) Tests for Acid Gas Generation
• The hydrochloric acid generation when tested as per IEC 60754-1 shall be
less than 20% by weight.
e) Temperature Index Test
• The temperature index value shall be minimum 250oC at oxygen index of
21 when tested as per ASTM-D-2863.
f) Wafer Boil test for XLPE cable as per ASTM -2765
g) Anti-rodent & Termite repulsion test
6.4. Optional Tests
Optional tests shall comprise of the tests listed below as per IS 7098 Part II, Clause
No.19.4 as a minimum.
a) Cold impact test for outer sheath
Besides above listed test, following additional tests to be performed by Supplier.
• Cold bend test for outer sheath

• Gel content test as per ASTM-D-2765.
7. Supplier Data
Document to be submitted with quotation and post order shall be as per the list
provided in the Material requisition. Following documents are at a minimum to be
submitted to the BUYER.
Sr.
Description
No Along with Bid Post Order
1 Duly filled cable data sheet(s). √ √
Calculations for Fault level and withstand
duration for Conductor, Conductor Screen √ √
2 and Armor for each size
Supporting Calculations for Cable Electrical
√ √
3 Parameters
Dielectric Stresses at Conductor Screen and
Insulation for Rated Voltage and Impulse √ √
4 Voltage
Physical parameters viz. Inductance and
√
5 Capacitance of the cable
Dielectric losses and Ohmic losses in
√ √
6 kW/km/phase
7 Inspection and test plan √ √
Valid Type test certificates for the cables
from CPRI or equivalent and sample routine √ √
8 test certificate
Details of Supplier`s quality assurance
program, Quality assurance Plan, ISO 9000 √ √
9 series or equivalent national certification
Descriptive literature giving technical detail
√
10 of the product offered
Reference list of supplied cables during the
√
11 last five years
12 List of deviations if any √
Cross sectional drawings showing
dimensions, arrangement of cores, weight, √
13 etc.
Factory Acceptance Test Procedure /
√ √
14 Routine Test Procedure
15 Inspection Test reports √

Sr.
Description
No Along with Bid Post Order
Conformance Certificate indicating all the
cables supplied against the purchase order
√
comply with the STANDARD SPECIFICATION
16 and all the relevant codes and standards
Certificates for the Bought-out items and
√
17 raw materials
18 User manual √

a) Preparation of shipment shall be made after all inspection & testing of the
cables has been accomplished and equipment has been released for shipping
by the BUYER.
b) Preparation for shipment shall protect the cable against corrosion, dampness,
heavy rain and breakage during transportation or handling.
c) Each shipping container shall be clearly identified with the contents, purchase
order number and item number.
d) Handling and storage instructions shall be supplied along with the package.

APPENDIX A: Codes and Standards
IEC STANDARDS
IEC 60028 International Standard of resistance for Copper
IEC 60228 Conductors of insulated cables.
IEC 60287 Electrical Cables - Calculation of the continuous current rating
IEC 60304 Standard colours for insulation for low - frequency cables and
wires.
IEC 60331
Tests for electric cables under fire conditions- Circuit Integrity
IEC 60332 Tests on electric and fiber cables under fire conditions, Part 3-10:
Test for vertical flame spread of vertically-mounted bunched
wires or cables - Apparatus, Part 3-21 : Test for vertical flame
spread of vertically-mounted bunched wires or cables - Category
A F/R
IEC 60502 Power Cables with Extruded Insulation and Their Accessories for
rated voltage from 1kV (Um = 1.2kV) up to 30kV (Um= 36kV), Part
2: Cables for rated voltages from 6kV (Um = 7.2) up to 30kV (Um =
36kV)
IEC 60754 Test on gases evolved during combustion of materials from
cables. Part 1: Determination of halogen acid gas content.
IEC 60811 Electric and optical fiber cables- test methods for non- metallic
materials.
IEC 60885 Electrical test methods for electric cables.
IEC 60949 Calculation of thermally permissible short circuit currents, taking
into account of non-adiabatic heating effects.
Measurement of smoke density of electric cables burning under
IEC 61034
defined conditions.
INDIAN STANDARDS
IS 613 Copper Rods and bars for Electrical Purposes
IS 3975 Mild steel wires, formed wires and tapes for armouring of cables.
IS 4826 Hot-Dipped Galvanized Coatings On Round Steel Wires
IS 5831 PVC insulation & sheath of electric cables.

IS 7098 Cross-linked Polyethylene Insulated thermoplastics PVC

sheathed cables Part 2: for working voltages from 3.3kV up to
Part 2
and including 33kV.
IS 8130 Conductors for Insulated Electric Cables and Flexible cords.
IS 10418 Drums for Electric Cables.
IS 10810 Methods of test for cables.
ASTM STANDARDS
ASTM D2765 Standard Test Methods for Determination of Gel Content and
Swell Ratio of Cross-linked Ethylene Plastics
ASTM D2843 Standard Test Method for Density of Smoke from the Burning or
Decomposition of Plastics
ASTM D2863 Standard Test Method for Measuring the Minimum Oxygen
Concentration to Support Candle-Like Combustion of Plastics
(Oxygen Index)
OTHER STANDARDS
DIN-EN ISO Plastics -Methods of exposure to laboratory light sources -Part 2:
Xenon Arc Lamps.
4892-2
SS 424 14 75 Swedish standard for Swedish Chimney Flame Test (Class F3)

APPENDIX B: Guaranteed Technical Particulars for the HV Cable

Sr. Vendor's
Description Specification
No. Reply
A Manufacturer's Name Vendor to Specify
B Cable Description Vendor to Specify
C Cable Size Vendor to Specify
D No of cores Vendor to Specify
E Earthing system (earth/unearth) Vendor to Specify
F Maximum short circuit current for conductor Vendor to Specify
Insulation Coordination
Highest System Voltage, kV Vendor to Specify
Nominal Voltage between conductors, kV Vendor to Specify
Rated frequency, Hz Vendor to Specify
1 Nominal voltage between conductor and
Vendor to Specify
sheath (Uo), kV
Rated impulse withstand voltage (Up), kV Vendor to Specify
Rated short duration power frequency
Vendor to Specify
withstand voltage, kV
2 Voltage grade : kV Vendor to Specify
Short Circuit withstand capacity (in kA for 1
sec)
a) Conductor Vendor to Specify
b) Insulation/Screen (for all the 3-Cores
Vendor to Specify
3 together)
c) Armour Vendor to Specify
d) Combine Armour & Insulation/screen Vendor to Specify
e) Maximum permissible conductor
Vendor to Specify
temperature during Short Circuit
Conductor details :
a) Size (mm²) (Nom.) Vendor to Specify
b) No. of strands Vendor to Specify
c) Material Vendor to Specify
4 d) Shape of conductor Vendor to Specify
e) Water swellable tape provided, if yes than

Vendor to Specify
provide details

Sr. Vendor's
No. Reply
Insulation details
Extruded XLPE as
a) Material
per IS:7098-II
b) Nominal thickness (mm) Vendor to Specify
c) Minimum thickness (mm) Vendor to Specify
d) Nominal overall diameter (mm) (over
Vendor to Specify
insulation)
e) Maximum continuous operating
5 Vendor to Specify
temperature
f) Maximum stress at nominal voltage
i) At conductor screen (kV/mm) Vendor to Specify
ii) At insulation screen (kV/mm) Vendor to Specify
g) Maximum stress at impulse voltage
i) At conductor screen (kV/mm) Vendor to Specify
ii) At insulation screen (kV/mm) Vendor to Specify
h) Make of Insulation Vendor to Specify
Conductor Screen
Extruded
a) Type of material Semiconducting
XLPE Compound
6 b) Nominal thickness Vendor to Specify
c) Minimum thickness Vendor to Specify
d) Nominal overall diameter (mm) Vendor to Specify
e) Make & Grade of semiconducting
Vendor to Specify
compound
Insulation Screen
Extruded Semi-
a) Non-metallic part type (bonded conducting
/strippable) compound
(strippable type)
Helically applied
7 b) Metallic part single layer of
copper tape
c) Nominal thickness (non-metallic) Vendor to Specify
d) Nominal thickness (metallic) Vendor to Specify
e) Nominal overall diameter over laid-up
Vendor to Specify
cores (Approx.) (mm)

Sr. Vendor's
No. Reply
XLPE manufacturing methods
a) Extrusion line type e.g. CCV, MDCV, VCV CCV
b) Single pass, triple extrusion Triple extrusion
8 c) Curing method Dry curing
Nitrogen Cooling
d) Cooling Method followed by
water cooling
9 Core Identification Vendor to Specify
Inner Sheath details
a) Material PVC Type ST-2
10 b) Extruded or wrapped Extruded
c) Min. Thickness (mm) Vendor to Specify
d) Calculated dia. over Inner sheath (mm) Vendor to Specify
11 Fillers (Not Applicable for Single Core Cable) PP Fillers
Armouring details
a) Material Vendor to Specify
b) Type of Armouring Vendor to Specify
c) Nom. Dimension of Strip (mm) / Nom. Dia.
12 Vendor to Specify
of wire
d) Calculated dia. over armour (mm) Vendor to Specify
e) Maximum D.C. Resistance of armour at:
Vendor to Specify
20°C. (Ohm/Km)
Outer Sheath details
Extruded FRLS
PVC Type ST-2
Compound
a) Material : OR
Extruded PVC
Type ST-2
13 Compound
b) Min. Thickness: (mm) Vendor to Specify
c) Colour Black
Vendor to
d) Termite & Rodent resistant
Confirm
Vendor to
e) Suitability to resist attack from chemicals
Confirm
14 Overall Diameter: (mm) Vendor to Specify

Sr. Vendor's
No. Reply
Weight of completed cable:
a) Conductor (Aluminium) Vendor to Specify
15 b) Insulation Vendor to Specify
c) Armour Vendor to Specify
d) Gross weight Vendor to Specify
16 Net weight of cable: (kg/ km) Approx. Vendor to Specify
Vendor to Specify
17 Normal delivery length : (No negative
tolerance)
Current rating laid underground with ground
18 temperature 30°C & maximum conductor Vendor to Specify
temperature 90°C
As per S.No.21 of
18. a Emergency current rating (in amps)
the datasheet
Current rating in air at ambient temperature
of --°C with maximum conductor
19 Vendor to Specify
temperature 90°C ( Single core cable laid in
trefoil formation with both end bonded)
As per S.No.21 of
19. a Emergency current rating (in amps)
the datasheet
Maximum permissible conductor
20 90 deg. C 90 deg. C
temperature for continuous operation
Permissible Emergency Overload
a) Emergency current rating, Amp Vendor to Specify
b) Maximum emergency temperature, Deg C Vendor to Specify
c) Allowable duration of operation, Hours Vendor to Specify

21
d) Allowable total duration per annum, Hours Vendor to Specify
e) Maximum average duration on total life of

Vendor to Specify
cable, Hours

Sr. Vendor's
No. Reply
Losses
a) Maximum dielectric loss per W/km/phase
@ Max guaranteed Tan d value (as in Row
no. 25) when operating at nominal voltage
Vendor to Specify
and frequency and at maximum conductor
22 temperature (along with calculation) (at 90
Deg. C, 50 Hz)
b) Total loss of cable per km/phase of three
phase circuit cable laid in ground (KW) (sheath
Vendor to Specify
loss is negligible for 3 core cable) (This includes
dielectric losses + copper losses) (kW/km/phase)
23 Maximum D.C. Resistance at: 20°C. (Ohm/Km) Vendor to Specify
24 A.C. Resistance at 90°C at 50 Hz.(Ohm/Km) Vendor to Specify
25 Reactance at 50 Hz. :(Ohm/Km) Approx. Vendor to Specify
26 Capacitance per phase at 50 Hz.: (µf/Km) App. Vendor to Specify
27 Guaranteed maximum partial discharge value As per IS: 7098-II
28 Guaranteed maximum TAN d value As per IS: 7098-II
29 Charging current per phase at 50 Hz : (Amp/Km) Vendor to Specify
30 Bending Radius. Vendor to Specify
Installation Data
a) Minimum cable bending radius when laid:
i) Direct burial
ii) In air As per IS 1255
iii) In ducts
iv) At termination (with former)
b) Maximal permissible pulling force of total
Vendor to Specify
cable, N/sq.mm.
31 c) Maximum unsupported run of cable both

Vendor to Specify
horizontally and vertically
d) Weight of cable drum without cables kg.
e) Weight of cable drum with cables kg. (Approx.)
f) Drum dimensions: (Approx.)
Vendor to Specify
i) Flange diameter
ii) Core diameter
iii) Width
Non-hygroscopic
g) Type of end sealing
PVC end caps

Sr. Vendor's
No. Reply
32 Additional Data
A laying up Vendor to Specify
“LOGO”
"MANUFACTURE
NAME" "XLPE
CABLE" “KV"
B Embossing Details "CABLE SIZE"
"CABLE TYPE-FRLS"
”YEAR” "ISI" "BIS
License No."
"METER MARKING"
C FRLS Tests
Oxygen index (Tested as per ASTMD 2863 at
i) Vendor to Specify
27+2°C.)
Temperature Index (Tested as per ASTMD
ii) 2863 by extrapolation method at 21 oxygen Vendor to Specify
index)
Acid gas generation (Tested as per IEC-
iii) Vendor to Specify
60754-1 weight)
Smoke density rating (Tested as per ASTMD
iv) Vendor to Specify
2843)
v) Flammability test as per Vendor to Specify
IS:7098/II &
D Reference standard RPMS-ENGG-SPC-
EL-021


LV Power and Control Cables
0 25.08.2020 Issued for Implementation BM/VRS/ VGS/ US SK/ VKM

PDG

By By By
Standard Specification for LV Power & Control Cables Date: 25.08.2020, Rev 0

No.

1 _________________ ___________
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number
First Issue
25.08.2020 0
Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
6. Inspection and Testing ................................................................................................ 7
7. Supplier Data ............................................................................................................. 10
Appendix A : Codes and Standards ..................................................................................... 12
1. Scope
manufacture, inspection, testing, packaging, shipment and documentation for LV
Power and Control Cables (for working voltage up to and including 1100V) for
Supplier and /or Contractor to comply with, to achieve Owner`s objective of
standardization.
Fire Survival cables and Special cables for Variable voltage variable frequency
applications are excluded from this specification.
Supplier and/or Contractor may propose adoption of standards of proven past
references in similar service conditions. Owner will review, evaluate and approve
deviations to this standard specification that Supplier and/or Contractor may seek
on this account, prior to execution of Project Purchase Order.
2. References
The LV Power and Control Cables shall be designed, manufactured, assembled and
tested in accordance with the latest applicable sections of the code and standards
detailed in Appendix A.


shall govern:
a) Data Sheets

Notes:
• “Data sheets” represent those attached to the Material Requisition – Cables
data sheets, Cable Stock code item description,

AWA Aluminium wire armour
DIN Deutsches Institut für Normung
FRLS Flame Retardant Low Smoke
PVC Poly Vinyl Chloride
SWA Steel Wire Armoured
XLPE Cross Linked Poly Ethylene
Definitions

Company


5.1. Cables shall be suitable for use in site conditions as mentioned in data sheet. Cable
shall have minimum design life of 25 years.
5.2. Cable shall be suitable and rated for electrical system characteristics as indicated in
the data sheet and Electrical design basis
5.3. All cables shall be suitable for installation on:
a) Above ground fastened to cable racks or trays in the open air exposed to direct
sunlight
b) Suitable for Hydrocarbon processing facilities like Petrochemical and Refinery
c) Direct buried in the ground (including water / chemical logged ground)
d) In Underground duct banks
e) Below ground in enclosed air filled trenches, fastened to cable racks or tray
f) Below ground trenches filled with sand
5.4. The design ambient temperature shall be considered as 430 C, unless otherwise
specified in the datasheet(s). The relative humidity shall be considered as 100%.
The cables shall be suitable for operation in a fully tropical atmosphere. Cable shall
be suitable for use in saline, sulphurous, dusty atmosphere as commonly
encountered in oil refineries, chemical plants or other facilities. Condensation, solar
radiation and other conditions shall be considered as stated in data sheet.
5.5. Cable Construction
5.5.1. Cable construction shall be as detailed under:
5.5.1.1. Conductor
a) The conductors shall be composed of plain copper or aluminum Wires
b) Aluminum used for conductor shall be Electrolytic grade Aluminum, stranded,
grade H4 and Class 2 as per IS 8130.
c) Copper used for conductor shall be made from high conductivity copper rods
d) The conductor shall be stranded and either compacted circular or sector shaped
for all LV cables. Conductor shall have circular cross section for sizes up to and
including 10 sq.mm and of sector shape for sizes above 10 sq.mm No. of wires
in a conductor shall be as per IS: 8130.
e) Conductors up to & including 6 sq.mm shall be stranded annealed copper.
Conductors above 6 sq.mm shall be stranded aluminum, unless specified
otherwise in the datasheet or Material Requisition.

5.5.1.2. Insulation
a) All cables of all voltage grades shall have XLPE insulation except Earthing cables.
Earthing cables shall have PVC insulation. The insulation shall be applied over
conductor by extrusion process only.
b) Special metal deactivation additives (antioxidant compound) shall be added to
XLPE used with copper conductors. This shall be confirmed during bidding stage.
Test certificate from XLPE insulation Supplier indicating above shall be provided
during detail engineering.
c) XLPE Insulation properties at rated voltage, rated current and under thermal
conditions arising out of continuous operations at conductor temperature of
900 C and 2500 C under short circuit conditions shall be as per IEC 60502 Part 1.
In case of PVC insulation, it shall be suitable for continuous conductor
temperature of 700 C and Short circuit conductor temperature of 1600 C as per
IEC 60502 Part 1.
5.5.1.3. Core Identification
Following color coding shall be acceptable for all cables up to four cores. Cables
with more than four cores shall have printed numerals on each core.
a) 1 Core : Black
b) 2 Core : Red and Black
c) 2 Core + Earth: Red, Black and Green/Yellow
d) 3 Core : Red, Yellow and Blue
e) 4 Core : Red, Yellow, Blue and Black
f) 5 or more cores - numbered (Black numbers printed on grey coloured insulation)
5.5.1.4. Fillers
Non-hygroscopic filler materials used to fill up the interstices (space between the
power cable cores, under the inner sheath) shall be Polypropylene. Further, it shall
be such that the transmission of gas and hydrocarbons along the length of the
cable, under normal pressure is not possible and shall prevent the water
propagation through the cable. Fillers shall be compatible with the temperature
rating of the cables and shall have no harmful effects on other components of cable.
5.5.1.5. Inner Sheath
a) Inner sheath, shall be PVC applied by extrusion and shall be compatible with the
insulation provided for the cables. Plastic binder tape shall be provided as per
IS 7098 - part I.
b) The inner sheath shall be so applied that it fits closely on the laid up cores and
it shall be possible to remove it without damage to the insulation. Minimum
thickness of inner sheath shall be as per IS 1554 (part-1) for PVC insulated cables
and IS 7098 (part-1) for XLPE insulated cables.
c) The inner sheath shall conform to the requirements of type ST1 compound of
IS 5831 for PVC insulated cable and type ST2 compound of IS 5831 for XLPE
insulated cables. The extruded inner sheath shall be of uniform thickness.
d) Single core cables shall have no inner sheath.
5.5.1.6. Armour
a) Armouring for the cables shall comprise galvanized steel or hard drawn
aluminum, in the form of round wires or strips as indicated in the datasheet.
b) Minimum area of coverage of armouring shall be 90%. The gap between any
two armour strip/wire shall not be more than width of strip or diameter of
armour. Type, dimension and resistance of armour shall be according to
applicable IS 7098- Part I.
c) The joints in the armour wires or strips shall be avoided in completed cable on
the drum.
d) For multi-core XLPE insulated cables, the armouring shall be by galvanized steel
strips or round wire as per IS 7098 (part-1). If armouring is specified for single
core cables in the datasheet, the same shall be of non-magnetic material.
e) Mass and uniformity of zinc coating of round wires & strips shall be as per IS
4826 and IS 3975 respectively. Test certificates conforming to the standards
mentioned shall be submitted during detailed engineering.
5.5.1.7. Outer Sheath
a) The outer sheath of the cables shall be applied by extrusion over the armouring
and shall be of PVC compound conforming to the requirement of type ST1 for
PVC insulated cable and type ST2 for XLPE insulated cable as per IS 5831.
b) The sheath shall be resistant to water, ultra violet radiation, fungus, termite and
rodent attacks. The color of the outer sheath shall be black unless otherwise
specified in data sheet
c) The outer sheath shall be Flame Retardant with reduced Halogen evolution and
smoke (FR-LSH) as per IS 7098 Part 1, Appendix A.
d) The outer sheath of cables shall be embossed or engraved with:
i. The Voltage grade designation
ii. Supplier's identification
iii. Number of Cores and nominal cross sectional area of conductors
iv. Cable insulation Type
v. Year of manufacturing
vi. The drum progressive length of cable at every meter. (The
starting point being the cable end at its inner coil on the cable
drum.)

5.6. General
5.6.1. Cables shall be supplied in non-returnable wooden/ returnable steel drums of
suitable barrel diameter, securely battened with take-off end fully protected
against mechanical damage. The wood used for construction of the drum shall be
properly seasoned and free from defects and wood preservative shall be applied to
the entire drum. All ferrous parts shall be treated with a suitable rust preventive
coating to avoid rusting during transit or storage. Cable drums shall conform to IS
10418.
5.6.2. PVC or Rubber end caps shall be supplied free of cost for each drum with a
minimum of eight per thousand meter length. In addition, ends of the cables shall
be properly sealed with caps to avoid ingress of water during transportation and
storage.
5.6.3. Negative tolerance on cable length of cable drums is not acceptable.
5.6.4. Sealed cable ends shall be fixed to the drum so that both ends are accessible. To
protect the cable during shipment battens shall be fitted around the entire
periphery of the drum. Drums shall be suitable for long term outdoor storage at
site.
5.6.5. There shall be proper labelling on cable drum, which shall be of non-corrosive, non-
hygroscopic material and attached to the outside and inside of the drum flanges.
Labels shall be protected by transparent plastic envelopes and give the following
information:
a) Reference of IEC or IS
b) Drum identification number and its direction of rotation for cable removal.
c) Cable voltage grade
d) Cable construction (e.g. XLPE SWA PVC)
e) Number of cores and cross sectional area
f) Cable quantity (mtrs.)
g) Purchase order number and item number
h) Total weight of cable and drum (kg)
i) Supplier's name
j) Country & Year of manufacture
k) Cable code


Cables shall be subjected to routine and acceptance tests in accordance with IS
7098 Part I and IS 1554 -Part I. Test methods shall conform to IS 10810 (Methods
of Test for Cables).
Cables offered shall be of type tested quality. Type tests shall be performed in
accordance with latest relevant standard in recognized national / international
laboratory. Supplier shall ensure use of calibrated test equipment having valid
calibration test certificates from standard laboratory traceable to National /
International Standards. Type test certificates shall not be older than 5 years.
6.1. Routine Tests
Routine tests shall comprise of the tests listed below as per IS 7098-Part 1, Clause
No 15.3 and IS 1554 Part 1, Clause No 15.3 for XLPE and PVC insulated cables
respectively as a minimum.
a) Conductor Resistance Test
b) High Voltage Test
Besides above listed tests, following inspection and tests to be performed
a) Dimensional Check
b) Insulation Resistance Test
6.2. Acceptance test
Acceptance tests shall comprise of the tests listed below as per IS 7098- Part I,
Clause No: 15.2 and IS 1554 Part 1, Clause No 15.2 for XLPE and PVC insulated cables
a) Annealing test (for copper)
b) Tensile test (for Aluminum)
c) Wrapping test (for Aluminum)
d) Conductor resistance test
e) Test for thickness of insulation and sheath
f) Hot set test for insulation
g) Tensile strength and elongation at break test for insulation and sheath
h) High voltage test
i) Insulation resistance (volume resistivity) test

6.3. Type Tests

Type tests shall comprise of the tests listed below as per IS 7098- Part 1, Clause No:
15.1 and IS 1554 Part 1, Clause No 15.1 for XLPE and PVC insulated cables
a) Tests on conductor
i. Annealing test (for copper)
ii. Tensile test (for Aluminum)
iii. Wrapping test (for Aluminum)
iv. Resistance
b) Test for armouring wires / stripes
c) Test for thickness of insulation and sheath
d) Physical tests for insulation
i. Tensile strength & elongation at break
ii. Ageing in air oven
iii. Hot set test
iv. Shrinkage test
v. Water absorption (Gravimetric)
e) Physical tests for outer sheath
i. Tensile strength & elongation at break
ii. Ageing in air oven
iii. Loss of mass in air oven
iv. Hot deformation
v. Shrinkage test
vi. Heat shock test
vii. Thermal stability test
f) High Voltage Test
g) Insulation Resistance (Volume resistivity test)
h) Flammability Test
The following shall constitute cables additional Type Tests for improved fire
performance compatibility
a) Oxygen Index test
b) Flame retardance test on single cable
c) Flame retardance test on bunched cables

d) Test for specific optical density of smoke
e) Smoke density
f) Test for halogen acid gas evolution
g) Temperature index
Besides above listed tests, following additional tests to be performed
a) Oxygen Index
i. The critical oxygen index value shall be minimum 29 when tested
at 27+20 C as per ASTM-D-2863.
b) Test for Smoke Generation (where applicable)
i. The maximum smoke density rating shall not be more than 60%
when tested as per ASTM-D-2843.
c) Tests for Acid Gas Generation
i. The hydrochloric acid generation when tested as per IEC 60754-
1 shall be less than 20% by weight.
d) Tests for Resistance to Ultra Violet Radiation
i. This test shall be carried out as per DIN 53387. The retention
values of tensile strength and ultimate elongation after the tests
shall be minimum 60% of tensile strength and ultimate
elongation before test.
e) Temperature Index as per ASTM-D-2863.
ii. The temperature index value shall be minimum 250oC at oxygen
index of 21 when tested as per ASTM-D-2863.
f) Swedish Chimney test as per SS 424-14-75
g) Anti-rodent & Termite repulsion test
6.4. Optional Tests

Optional tests shall comprise of the tests listed below AS PER is 7098- Part I, Clause
No, 15.4 and IS 1554 Part 1 , Clause No 15.4 for XLPE and PVC insulated cables
a) Cold bend test for outer sheath
b) Cold impact test for outer sheath

7. Supplier Data
Documents to be submitted along with quotation and post order shall be as per the
below list provided.
Sl. Along with

DESCRIPTION Post Order
No Quotation
1 Duly filled cable data sheet(s). √ √
2 Inspection and test plan √ √
3 Inspection Test report √
Valid Type test certificates for the cables from
4 CPRI or equivalent and sample routine test √ √
certificate
Details of Supplier’s quality assurance
5 Programme, ISO9000 series or equivalent √ √
national certification
Descriptive literature giving technical detail of
6 √ √
the product offered
Reference list of supplied cables during the last
7 √ √
five years
8 List of deviations, if any √ √
9 Quality Assurance Plan √
Factory Acceptance Test Procedure / Routine
10 √
Test Procedure
Calculations for short circuit capacity for each
11 √
size
Conformance certificate indicating all the
cables supplied against the purchase order
12 √
comply with this Specification and all the
relevant codes and standards.
Cross sectional drawings showing dimensions,

13 √
arrangement of cores, weight, etc.
Certificates of the bought-out items and raw

14 √
materials
Cable derating factors in aboveground,
15 Underground (direct buried and in duct bank) √ √
and other installed conditions
16 Detailed cable catalogues √


• Preparation of shipment shall be made after all inspection & testing of the
cables has been accomplished and equipment has been released for shipping
by the Buyer.
• Preparation for shipment shall protect the cable against corrosion, dampness,
heavy rain and breakage during transportation or handling.
• Each shipping container shall be clearly identified with the contents, purchase
order number and item number.
• Handling and storage instructions shall be supplied along with the package.


IEC Standards
IEC 60028 International Standard of Resistance for Copper
IEC 60227 PVC insulated cables of rated voltages up to and including
450/750 V.
IEC 60228 Conductors of insulated cables
IEC 60287 Calculation of the continuous current rating of cables (100%
load factor)
IEC 60304 Standard colours for insulation for low frequency cables and
wires.
IEC 60331 Tests for electric cables under fire conditions
IEC 60332 Tests on electric and fiber cables under fire conditions. Part 3-
10 : Test for vertical flame spread of vertically-mounted
bunched wires or cables - Apparatus, Part 3-21 : Test for vertical
flame spread of vertically-mounted bunched wires or cables -
Apparatus - Category A F/R
IEC 60502 Power Cables with Extruded Insulation and Their Accessories
for rated voltage from 1kV (Um = 1.2kV) Up To 30kV (Um= 36kV),
Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV
(Um = 3,6 kV)
IEC 60754 Test on gases evolved during combustion of materials from
cables. Part 1: Determination of halogen acid gas content
evolved during combustion of polymeric material taken from
cables.
IEC 60811 Common test methods for insulating and sheathing materials
of electric cables.
IEC 60885 Electric test methods for electric cables.
IEC 61034 Measurement of smoke density of electric cables burning
under defined conditions.
Indian Standards
IS 613 Copper Rods and Bars for Electrical purposes
IS 1554 Part 1 PVC insulated (heavy duty) electric cables for working
voltages up to and including 1100V
IS 3975 Mild steel wires, formed wires and tapes for armouring
of cables.

BIS IS 3961 : Recommended Current rating for Cables Part 6 Cross

PART 6 : 2016 linked Polyethylene insulated PVC sheathed cables
IS 4826 Specification for Hot dipped Galvanized coatings on
Round wires
IS 5831 PVC insulation & sheath of electric cables.
IS 7098 Part 1 Cross linked polyethylene insulated PVC sheathed cables
for working voltages up to and including 1100V.
IS 8130 Conductors for insulated electric cables and flexible

cords.
IS 10810 Methods of test for cables.
IS 10418 Specification for drums for electric cables
ASTM Standards
ASTM—D-2843 Standard Test Method for Density of Smoke from the
Burning or Decomposition of Plastics
ASTM—D-2863 Standard Test Method for Measuring the Minimum Oxygen
Concentration to Support Candle-Like Combustion of
Plastics (Oxygen Index)
ASTM—D-2765 Standard Test Methods for Determination of Gel Content
and Swell Ratio of Cross linked Ethylene Plastics
ISO Standards
ISO 877-1 Plastics -- Methods of exposure to solar radiation -- Part
1: General guidance
Other Standards
DIN-53387 Artificial weathering and ageing of plastics and elastomers by
exposure to filtered xenon arc radiation.
SS 424-14-75 Standard for flammability test
Project Standards
RPMS-ENGG-DBD-PS-001 Basic Engineering Design Data (BEDD)


Medium Voltage Variable Speed Drives
0 25.08.2020 Issued for Implementation VD/MI VGS/US SK/VKM

By By By
Specification for MV Variable Speed Drives Date: 25.08.2020, Rev.0

No.

1 _________________ ___________
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
7. Vendor Data .............................................................................................................. 19
Appendix A: Codes and standards ...................................................................................... 24
Appendix B: System Study/ Analysis requirement for Large drives (30 MW and larger) ... 26
1. Scope
documentation of Medium voltage Variable Speed Drive (VSD) panels, for Supplier
and/or Contractor to comply with, to achieve Owner’s objective of standardization.
This document is applicable for all drives with nominal input voltage more than
1000V and less than or equal to 33000 V.
This specification is applicable for the following configurations:
a) Voltage Source Inverters (with Diode Front End and with Active Front End) and
b) Load Commutated Inverter (LCI)
2. References
MV VSD shall be designed, manufactured and tested in accordance with the latest
applicable sections of the codes and standards as listed in Appendix A.
document.
shall govern:
a) Data Sheets and Drawing

Notes:
Requisition – MV VSD Datasheets, MV VSD Stock Code Item Description.
Order.
AFE Active Front End
DFE Diode Front End
LCI Load Commutated Inverter
MTBF Mean Time Between Failure
MTTR Mean Time To Repair
MOV Metal Oxide Varistor
PCC Point of Common Coupling
PDS Power Drive System (Complete Power equipment - harmonic filter,
input transformer, converter section, output transformer, AC Motor)
PVC Polyvinyl Chloride
RPS Rotor position sensor
RTD Resistance Temperature Detector
VSI Voltage Source Inverter

Definitions
Company

Unless otherwise specified in the datasheet(s), equipment will be installed indoor
in air-conditioned building(s).
MV VSD shall be suitable for site environmental condition as stated in VSD
Datasheet.
5.2. Life
The life of the MV VSD and its components forming part of it, shall have a minimum
lifetime of at least 20 years excluding component require periodic maintenance.
This shall include availability of spare parts and field service support.
Supplier shall provide an expected MTBF and MTTR for the VSD under required
service condition for Buyer review. MTBF and MTTR shall be calculated as specified
in IEEE 1566.The Supplier shall list all components that are expected to required
replacement in a 20 year operating life.
5.3. General & Technical Requirements
The Supplier shall define the requirement for matching the motor and VSD to the
load, this will include input transformer, if required, to the power system such that
this operate as a system with no unsatisfactory transient, torsional, heating or
power quality problems.
Metering, protection, indication, operating requirements, bypass, isolation, shall
be as per single line diagram. Requirements indicated in Single line Diagram are

minimum and Supplier shall advise if any additional requirement is there to

integrate supplier’s proposed VSD.
Capacitors shall be self-healing, solid epoxy filament type or equivalent. VSD’s,
using electrolytic capacitors in the power circuit shall not be accepted.
Input Harmonic Filter and Power Factor Correction Filter, if required, shall be
factory installed, complete with internal & interface wiring with VSD enclosure.
All electronic cards mounted in the VSD shall have conformal coating complying to
G3 standards.
During normal operation and for a fault condition, the drive shall not pose a risk of
fire, electric shock or injury to operating or maintenance personnel.
Supplier shall state the number of switching semiconductors, diodes and fuses in
the bid.
AFE increases complexity in system and will be used only when required as per
material requisition.
Pre-charging circuit such as DC bus pre-charge, pre-charge reactor, or other system
(like SoftMag), shall be provided to reduce transformer inrush. Supplier schematics
diagram shall clearly indicate any interlock requirement with upstream feeder.
Unless otherwise specified in the data sheet, minimum number of converter pulses
shall not be less than 18 pulses for VSI and 12 pulses for LCI.
VSD shall pose no limit (VSD transformer charging/capacitor charging) on direct
upstream breaker or contactor operation.
It shall be possible to vary the speed of the drive in either manual or auto mode.
Auto/Manual selection shall be from VSD panel, unless otherwise specified.
For cases, such as for high inertia drive, input from the rotor position sensor (RPS)
shall be provided in the VSD. Requirement & location of the RPS on the motor shaft
shall be specified in the datasheet.
Where VSD is used for starting purposes with bypass, the VSD shall have
synchronous transfer capabilities. The synchronous transfer should be a seamless
make before break transfer for both synch-up and synch-down sequence. Sync
transfer switchgear shall be procured by Buyer (If specified in data sheet),
necessary coordination between switchgear Supplier shall be by Supplier.
The drive system shall have By-pass arrangement, if specified in data sheet.
5.4. Electrical Characteristic
For VSD, the nominal power supply voltage and frequency and their corresponding
variations shall be as indicated in the motor datasheet.VSD shall be designed to

operate under the electrical service condition, as specified in Table 2 of IEC 61800-
4.
Control and Auxiliary power supply (external) shall be redundant and shall be as
specified in data sheet.
Necessary arrangements shall be made to segregate VSD cooling circuit auxiliary
supply from other auxiliary and control supply circuit with separate feeder.
Control power supply shall be from AC or DC UPS(as mentioned in the datasheet)
to facilitate power loss ride through/flying start feature. Supplier shall provide the
list of external power supply requirement during the bid stage.
5.5. Input Transformer/ DC link Reactor
The converter transformer shall be designed and tested in accordance with IEC
60146 and IEC 61378, as applicable.
The input transformer or reactor, as required, shall comply to relevant IEC
standards (refer appendix A). Input transformer shall be rated for maximum
harmonic current duty imposed by the drive. It shall be equipped with standard
accessories and protection, as required.
The transformer winding arrangement shall be as required by the drive system. The
arrangement shall be specified by the Supplier in the data sheet. The transformer
winding material shall be as specified in the data sheet.
Transformer rating shall be based on average temperature rise of any winding
above ambient temperature, as specified in data sheet.
Dry type converter transformer to be located indoor in substation with positive air
pressure. Oil filled type converter transformer shall be located outdoor. Supplier
shall propose the transformer type for Buyer with bid.
The Supplier shall state the limiting distance between the converter transformer
and the VSD panel in the quotation.
Transformer impedance shall be coordinated with the short-circuit rating of the
drive. The transformer shall have a minimum basic insulation level (BIL) rating as
given in the data sheet.
The outdoor transformer color shall be as specified in the data sheets.
Liquid-filled transformers shall be equipped with a sudden-pressure device unless
An electrostatic shield is required between primary and secondary winding of the
transformer in order to prevent high voltage transients being transferred to the
secondary due to capacitive coupling.

DC reactors (for Load commutated Inverter) shall be air core with natural air cooling
or forced air cooling mounted integral with the VSD panels. Use of an oil cooled
reactor or water cooled reactor require prior approval from Buyer.
Because rectifiers inherently produce harmonic currents, which increase winding
heat generation because of the increased eddy current losses, extra losses to
account these shall be considered in the thermal design.
Any operating condition of a power converter can place unusual voltage conditions
on the transformer windings shall be identified by the transformer supplier. Two
common problems caused by voltage offsets are:
• Increased insulation stress due to common mode voltages
• Core saturation due to DC voltage or DC current magnetization
Transformer shall be suitably selected considering the above parameters.
5.6. Cooling System
Supplier shall provide all necessary equipment for cooling of drive component,
along with the proposed cooling method.
5.6.1. Air Cooling
Cooling fans of air-cooled drives shall be redundant with automatic switch-over.
Redundant cooling system components shall be fed from independent power
sources. Automatic switch-over in case of a fan failure or for any system
disturbances, shall be provided. Periodical cycling between active and stand-by fans
shall be initiated automatically. Failure of a single fan shall operate an alarm
without shutting down the drive. Failure of the redundant fan shall shut down the
drive. Voltage dip on main power supply shall not result fan changeover suitable
hardwire and soft logic shall be implemented in VSD to avoid any fan changeover
due to main power supply under voltage. Fan motors shall have an L10 bearing life
of at least 50, 000 hours. Heat load of the drive at 100% output shall be specified
by the Supplier at the proposal stage. Design shall ensure filter changing with drive
in operation.
5.6.2. Liquid cooling
The coolant shall be formulated to prevent freezing at the lowest temperature
specified in the data sheets. The cooling system shall use redundant centrifugal
pumps located in a separate cubicle (separate from power cubicle) that is accessible
during drive operation. Pump motors shall have an L10 bearing life of at least
50,000 hours. If the primary pump shuts down for any reason, the backup pump
shall start automatically, and an alarm shall operate. Valves on the inlet, outlet and
drains of each pump shall permit servicing during drive operation.

To maintain coolant integrity, a liquid filter and deionizer shall operate in a bypass
mode, with inlet and outlet valves to permit servicing during drive operation.
Coolant electrical conductivity shall be monitored by alarm and shutdown sensors
and metered at a visible location.
Located at the system’s highest point, the coolant reservoir shall have low-level
alarm and shutdown. Topping up the reservoir shall be possible during drive
operation, and all entrapped air shall bleed into the reservoir. At the system’s
lowest point, there shall be a drain and sampling valve that is usable during drive
operation.
The piping and tubing for the cooling system shall consist of two different materials.
The main piping in the pumping cabinet, piping between the cabinets and manifold
piping shall be thick wall CPVC/stainless steel. The tubing from the manifold to the
chill blocks and the DC link shall be silicone/rubber hose. The tubing shall be fitted
onto hose barbs and secured with standard stainless steel hose clamps.
Where a water to air heat exchanger is required, the Supplier shall provide an
external heat exchanger with redundant fans driven by three-phase motors. These
fans shall be supplied and controlled from the pump cubicle, however the bigger
fans shall be powered from external bus (MCC/PCC) starters.
Hoses in the coolant system shall be designed for twice the maximum operating
pressure and shall be rated for a minimum of 20 °C above the design maximum
liquid temperature. The Supplier shall submit pressure data plus details of the hoses
and the hose clamping system along with quotation.
The liquid cooling system shall have alarm and shutdown sensors to protect against
over temperature, under temperature, and inadequate flow and leakage in each
branch.
Flow diagrams shall be provided by the Supplier that show the cooling system and
describe all components, fluids, fluid paths, temperatures and pressures, reservoir
capacity, pressure relief points, and drains.
5.7. Panel Construction
The VSD shall be of modular construction.
The VSD Converter shall be front access only, unless otherwise specified.
Panels shall be constructed from sheet steel of adequate thickness. Sheet metal
members shall be treated and painted to be suitable for operation in a sulphurous
and saliferous atmosphere.
The VSD panel shall be dust and vermin proof with a minimum degree of protection
to IP 42. Air for cooling shall be taken through filters which are easily removable
from the front for cleaning.

The panel construction and arrangement of components shall provide full access
for all regular operation and complete maintenance from the front. If any
component or assembly requires rear access, the Supplier shall clearly state the
requirement in his offer.
VSD panel shall have copper bus bars rated for the full load current. The enclosure
shall confine bolted fault at the available short circuit energy, which need to be
calculated by the Supplier.
Bus bars shall be insulated for power frequency voltage withstand. Power supply
terminals and terminals powered from outside sources shall be shrouded
(guarded). Acrylic type transparent insulating material shall be used for covering
live components.
All insulation materials shall be non-hydroscopic and shall be class 105 deg C or
better.
Panels shall be free-standing, floor mounting, with a cast iron base frame for fixing
to Buyer floor through anchor bolts or to steel member through stitch welding.
The VSD panels shall be provided with hinged lockable doors suitable for handling
the weight of the components mounted on the door. The doors shall not hinder
any regular maintenance and repair activities to be carried out on the drive
assemblies.
Panel door shall have necessary electro mechanical interlock and mechanical castle
key interlock with upstream Switchgear so that door can be only opened when
incoming power circuit breaker switch off.
The VSD enclosure doors with access to live parts shall include an
electromechanical interlocking system with a safety grounding switch. The
enclosure doors can be opened only if the safety ground switch connects all DC
buses to ground, to ensure all stored VSD and motor energy is discharged.
Grounding of any power circuit via resistor is not acceptable.
The panel doors shall be provided with quarter-turnkey locks with keys which
cannot be used for opening other electrical panel doors. Compartments not
requiring access for any maintenance or repair activities shall be with bolted or
welded covers.
Spacing between energized parts, and between energized parts and ground, shall
be equal to or exceed those listed in relevant IEC standards (refer appendix A).
When clearances do not meet those requirements, insulated barriers shall be used.
The barriers shall be non-hygroscopic, have adequate fire resistance, plus
mechanical and electrical strength for the application.

Insulating barriers shall be provided between high voltage and control cabinets and
between each vertical section. Appropriate warning labels shall be prominently
installed on these compartments. It shall be possible to access the low voltage
component with the VSD panel energized without danger to operating personnel.
The maximum and minimum operating height of the VSD panel shall be restricted
to 1800 mm and 300 mm above floor level respectively. All meters and indication
lamps shall be mounted at eye level (between 1500 mm and 1800 mm above floor
level).
Cable entry provision shall be as specified in single line diagrams and general
arrangement drawing. Adequate space which include cable spreading and bending
space, shall be provided to terminate the number, size and type of cables shown in
the single line diagrams, including all interlock and control cables. Shield ground
connection points shall be provided in the vicinity of power connections when
shielded cable is used.
Removable un-drilled gland plate of adequate size and 3 mm thickness shall be
provided for facilitating entry of cables. Where single core cables are specified,
gland plates shall be made of non-magnetic material like Aluminum with 5mm
thickness.
Terminations for high, low and control voltage cables shall be in separate
compartments. It shall be possible to open and work within the low voltage
compartment with the high voltage compartment energized. Test points and
terminals shall be accessible from the front of the enclosure without removal of
any adjacent component. The Supplier shall state if rear access is required for
service of any components and identify which components require rear access.
All control wiring within the panels shall be through multi-stranded, PVC insulated,
fire retardant, low smoke, copper flexible cables. Each wire shall be identified at
both ends by self-sticking wire marker tapes or PVC ferrule. The minimum size of
wire shall be 1.5 mm2 unless precluded by end connectors on electronic
components. All such deviations from the minimum wire size shall be stated in the
offer. All control wiring shall be enclosed in plastic metal channel.
Anti-condensation heaters rated to prevent the formation of harmful condensation
inside the enclosure shall be provided .The heater shall be supplied complete with
a thermostat and ON/OFF switch.
The equipment shall allow the removal of components without special tools. The
design shall be such as to facilitate rapid repair or replacement.
Panel construction shall have the provision of online filter replacement without
disturbing the functioning of the drive.

Eyebolts or lifting clamps shall be provided for lifting of the panel or shipping
section. The bolts, when removed shall not leave any opening in the panel.
5.8. Performance Requirements
The Drive system must be designed to avoid harmonic and inductive heating and
eliminate radio frequency interference in compliance to IEEE 519/ IEC 61800-3.
dv/dt limits and Vpeak shall be as per IEC 61800-2. For EMC requirement, IEC 61800-
3 / IEC 61000-3-6 shall be complied.
VSD shall start, accelerate, and operate the motor through the specified speed and
load range with an input voltage and frequency variation as stated in datasheet.
VSD vendor shall perform and submit the application check document giving sizing
details of VSD system, derating factors applied, frame size selection, short time
rating of the drive components, protection mechanism and settings applicable.
VSD system shall operate reliably and without interruption when subjected to
occasional converter input power-supply overvoltage transients of total peak
transient plus supply magnitude (2.8 times the nominal rms line-to-line supply
voltage) with a rise time of 0.1 micro-sec and base width of 70 micro-sec, inline with
IEEE 1566, sec 6.7.
Unless otherwise specified, the drive system shall ride through and maintain
control of the motor during an input power and/or control supply voltage sag down
to 65% of nominal voltage on one or more phases for a duration of 500 ms,
considering that the load/system has sufficient kinetic energy. Marking to be
provided on the equipment indicating discharge time along with LED indicators.
Supplier shall state, if UPS control power supply require to meet this requirement
Sag event could be any phase-to-phase, any phase-to-ground, any phase-to-
neutral, multiple phases, multiple phase-to-ground, or multiple phase-to-neutral.
The drive system shall withstand a 100% loss of voltage in one or more phases of
the input power supply for 600 ms without losing control capability if load has
sufficient inertia. In this case, the drive shall cease output and upon restoration of
supply, shall have the capability to restart, catch, and reaccelerate the spinning
motor to its original speed.
VSD equipment shall operate satisfactorily with a continuous total harmonic
voltage distortion of less than 10%, a crest factor of less than 2.5, and voltage notch
area of less than 75 Vnom micro-sec without affecting equipment performance
where Vnom is the incoming power supply voltage.
The drive system shall be designed to operate with random common-mode voltage
(CMV) disturbances of magnitudes twice the line-voltage peaks with rise times of
0.1 micro-sec.

The VSD overall efficiency (and its tolerance), including its subsystem system shall
be as per clause 11 of IEC 61800-4. The guaranteed efficiency of the VSD shall be
specified by the system supplier at rated load and base speed.
VSD response time shall be as per IEC 61800-4, Sec 7.2.2.2.
The Supplier shall ensure, that the voltage stress level of the motor does not exceed
the insulation system voltage stress capability. Therefore, the Supplier is
responsible for specifying the voltage stress level at the motor terminals, taking
into account possible voltage reflection depending on the topology of the
converter, cable type and length. Relevant parameters for insulation stress are:
transient peak voltage values, peak rise time and repetition rate.
Motor Supplier shall check the voltage stress withstand capability according to the
system supplier's specification. To ensure that no service lifetime reduction of the
motor insulation occurs, the actual stress due to converter operation shall be lower
than the repetitive voltage stress withstand capability of the motor winding
insulation system.
The typical voltage stress capability of the motor shall be as per Table 7 of IEC
61800-4.
Suitably rated semiconductor fuses shall be provided for protection of the VSD.
MOV’s shall be provided across phases to make the VSD immune to voltage surges.
The VSD shall be speed, torque or power controlled as required by the driven
equipment characteristics.
VSD shall be suitable to the quadrant operations based on application requirement
for an maximum and minimum speed range between 5% and 100% of the
maximum speed.
Supplier will match the load speed/torque requirement with selected VSD.
The VSD shall be capable of withstanding the thermal and dynamic stresses and
transient mechanical torques resulting from a short circuit of the level stated in the
data sheets.
Protection shall be provided for the complete VSD system, motor cable, motor and
the converter power, control and auxiliary circuits. This should include the
protection as listed in Table 8 of IEC 61800-4, as a minimum.
The VSD shall be capable of accepting thermistors, stator RTDs and bearing RTDs.
Requirement of braking shall be as indicated in data sheets.
VSD shall be provided with ARC guard relay for monitoring and detection system.

The output from the VSD shall be nearly sinusoidal in nature. Supplier needs to
specify if any output choke/filter is required, to ensure that the motor terminal
voltages are within the Insulation level of Motors.
Wherever required, the Output filter capacitor shall be provided with discharged
circuits to ensure that all residual stored charge is reduce to less than 50V DC within
300 sec after a loss of AC voltage, in line with IEEE 1566, sec 4.2.5. All capacitor shall
be maintenance free and self-healing type.
5.9. VSD Control and Communication
VSD control system shall be microprocessor based and shall provide all required
control, protection, indication and metering as indicated in the single line diagram.
Local control shall be either through front-panel-mounted push buttons or through
a keypad and alphanumeric display; or a combination of these methods for drive
testing purpose. Local control selection from drive is programmable and can be
disabled through drive parameter.
An emergency stop shall be provided via a red mushroom-head push button, which
shall be interlocked to unit control power to ensure drive stoppage. Emergency
stop buttons shall be guarded with plastic covers to protect it from unintentional
operation.
Remote control and monitoring shall be either via dry contacts and analogue (4-20
mA) signals, and /or through a digital interface as indicated in data sheet.
It should be possible to program the carrier frequency for inverters and shall be by
Supplier.
VSD shall have the facility for data communication (Profibus or Modbus over TCP
/IP or RS 485) with DCS, as specified in data sheet. Supplier proposals shall include
all software and interface devices required to provide the remote link.
Firmware details as used for main converter shall be furnished by the Supplier along
with upgrade or release revision history. Necessary diagnostic tools and software
shall be provided.
VSD shall have the facility for data communication with the DCS and local control
station over hard-wired links.
5.10. VSD Monitoring and Alarms
Keypad and display shall be provided as the operator interface on the VSD. Control
system shall monitor the VSD, providing metering and fault details on demand.
Local displays shall include an alarm and fault diagnostic indicator capable of
annunciating alarms in a first-out report sequence. Loss of control power shall not
result in loss of alarm and shutdown information. Alarm and shutdown indications
shall provide both normally closed (NC) and normally open (NO) contacts and shall

be wired to individual terminals on a common terminal strip. Alternatively a digital

link shall be supplied, if specified in datasheet. Keypad shall be suitably protected
from unauthorized operation by having password controls.
All relevant operating data shall be available in a buffer memory with sufficient
capacity to assist in drive troubleshooting. Supplier shall list the points monitored
and the time before and after a fault that is available. It should be possible to
download the relevant electrical quantities of the previous faults for analysis. VSD
shall feature a Real-Time-Clock for the correct fault stamping data. It shall be
possible to time synchronize the clock over serial link from higher level control
system.
VSD shall have the capabilities to provide internal diagnostic information, remote
condition monitoring over a communication link and integrate with owner’s cloud-
based digitalization platform. VSD vendor to deliver specific data model for
mapping of offline and online measurement parameters to the cloud platform.
During SAT, it shall be possible to program skip frequencies to avoid mechanical
resonance and shall be by Supplier.
5.11. VSD Ride through and Reacceleration
VSD shall be suitable for reacceleration schemes (Power ride through feature), i.e.
the VSD shall restart the motor after resumption of power following a power failure
automatically and have speed search feature unless a STOP command is active. It
should be possible to enable or disable the reacceleration facility through the
control keypad.
5.12. VSD Signal Conditioning and Filters
VSD shall accept a Buyer-supplied analogue (4 to 20 mA) or equivalent digital speed
reference signal. All external signals and contacts, including motor temperature
sensor outputs, shall be wired to terminal blocks in the end-user termination
section of the VSD assembly. Loss of speed reference signal shall result in activation
of an alarm plus one of the following user selectable conditions:
• Operation of the VSD at the last command speed signal
• Ramp to a predetermined minimum speed
• Ramp to zero speed and stop
VSD shall provide both NC and NO dry contacts, wired to terminal blocks for Buyer
use, indicating the following drive status:
• Run
• Forward/reverse (if applicable)
• Fault
• Alarm

• Local/remote
• I/O and bypass (if any) contactor or circuit breaker
Following annunciation shall be readily available on the VSD panel, either through
indication lamps or through the door mounted control keypad:
i) Motor Running
ii) Motor Stopped
iii) Motor Tripped
iv) ESD Trip
v) Motor tripped on Over-temperature
vi) “Motor Available” signal.
The "Motor available" signal shall be healthy only if:

i) Control and mains supply is available.
ii) Motor has not tripped
iii) “Stop” Push Button on VSD is not activated
iv) “Stop” Push Button on LCS is not activated
v) “Stop” command from DCS/PLC is not activated
vi) “Hand-Auto” switch on LCS is in “Auto” position
5.13. System Study/ Analysis requirement for Large drives (30 MW and larger)
For large drives (30MW & larger), please refer Appendix B, which covers necessary
studies to be performed by supplier.
5.14. Earthing
Copper earth bar, sized according to equipment rating, shall run through the
equipment full length, with all non-current carrying metal parts and cable gland
plates connected to it. The earth bar shall have a connecting stud, or nut and bolt,
for terminating the plant earth. Stud/bolt size shall not be less than 10 mm.
All doors shall be bonded to the main structure by means of flexible copper
connection arranged so that it cannot be trapped as the door is opened or closed.
All points of connection between the ground bus, equipment-grounding conductor,
and structural assemblies shall be free of nonconducting material such as paint.
Structural members of adjacent compartments shall be securely bolted together or
equipped with bonding jumpers.

Earthing of the VSD, as a whole system, may be made in different places. The
location of the earthing shall be chosen according to the nature of the system:
neutral of a common transformer (if any) middle point of a common d.c. bus, the
star point of any frequency converter output filter or the star point of the motor.
The point and the type of earthing, together with the PDS topology (with or without
output filter) defines the resulting insulation stress.
Supplier shall indicate earthing requirement for complete drive system as a whole
during bid stage.

5.15. Noise
The sound pressure level of the VSD shall not exceed 85 dB(A) at 1 m. All equipment
shall operate without undue vibration and with least noise. For high speed
applications, supplier should quote the different options available to reduce the
motor noise level.
VSD noise level shall be less than 85 dB(A) for air cooled and less than 75 dB(A) for
water cooled drives at 1 meter distance.
5.16. Surface Finish
a) Finish shall be in accordance with the Supplier’s standards for the service
conditions specified.
b) Colour of the VSD panel shall be RAL 7032.
c) Supplier shall supply a small quantity (500 ml) of field touch-up paint for each
colour used for each panel.
d) All components shall be fully tropicalized.
5.17. Name Plate, Labels & Serial Number
Rating plates shall be marked with data in accordance IEC 60146 (relevant parts).
Additional details to be provided in the rating plate shall be as follows:
i) Cooling method
ii) Overall Weight in Kilogram,
iii) Mass of cooling fluid (if applicable)
iv) Degree of protection
Danger / Warning labels shall have white letter on red background. All other labels
shall have black letter on white background. All labels shall be fixed by stainless
steel screws.
Label shall be non-deteriorating and non-warping type, generally shall be made up
of 3 layer, Traffolyte material. Adhesive backed plastic labels will not be permitted.
Name plates shall be machine engraved phenolic and shall be attached with
stainless steel screws. Main function labels, fixed centrally to cubicles, shall have
20 mm high letter. Control devices and terminal boards shall have 6 mm high letter.
One complete set of schematic diagrams inside a weatherproof plastic bag shall be
provided behind the enclosure door of each unit.
In addition to the Supplier’s nameplate, the equipment shall be identified with
Buyer's equipment tag number plate(s).

Each major electrical component shall have a label fitted to it (or alongside), with
an item description, number or significant data indicated on it. This shall reflect the
components identified in equipment internal circuit diagrams.
One complete set of schematic diagrams inside a weatherproof document wallet
shall be provided. This shall be stored in an appropriate holder behind the
enclosure door of each unit.
5.18. Spares
The Supplier shall provide with his quotation, a complete separate priced list of
recommended commissioning and operating spares.
Commissioning spares, approved by the Buyer, shall be included with the
equipment.
Supplier shall provide local support for renewal parts and stock spares.
As a minimum, the VSD Supplier shall include these spare parts as part of the bid:
a) 100% spares of each type of medium voltage fuse
b) Supplier's recommended number of low voltage fuse
c) Supplier's recommended number of semiconductor
5.19. Accessories
Complete set of accessories, including any special tools, shall be provided for
operating, ` and testing the equipment. Supplier shall provide a list of accessories
and special tools, if required, which need to be separately priced.
Accessories and special tools shall include any software, manuals and
commissioning tools required to operate and commission the VSD's.


VSD’s supplied shall be a type tested design. Supplier shall provide certified test
record of all the routine and Type test carried as per IEC 61800-4. Type test may be
waived off on availability of valid type test certificate. Drive system test, when
specified in material requisition, as a part of special test, shall be conducted as per
Table 11 of IEC 61800-4.
All equipment, including any sub-supplier equipment, shall be subject to inspection,
at any time prior to shipment and witnessing of tests by Buyer's representative at
the place of manufacture.
Supplier shall perform all standard routine tests in accordance with the relevant
standards and agreed test procedures. The following tests shall be included as a
minimum:
i) Full load heat run (one unit of each rating for 8 hours
ii) Noise test
iii) Acceleration/deceleration test using a simulated load
iv) Inverter current limiting
v) Input and output voltage waveform measurements/analysis at 50% and 100%
load (one of each rating)
vi) Functional alarm and tripping check
vii) Operation of all equipment
viii) Routine and Type tests to be included for MV VSD, Converter Transformer
Supplier shall carry out all tests on the complete equipment and any remedial work
or correction of faults found during inspection or testing, within mutually agreed
time without any cost impact.
VSD supplier shall participate in the string test (VSD, motor, driven equipment), if
specified in the data sheet. (Data sheet shall include section for this)
VSD Supplier shall participate in DCS communication integration tests with DCS
Suppliers.
Supplier shall notify Buyer eight weeks prior to when the tests are to be performed.
Buyer or his representative reserves the right to inspect the VSD at any time prior
to dispatch and witness the tests at the factory.
Before final inspection by Buyer, Supplier shall confirm satisfactory completion of
all in-house routine tests and shop inspection. Certified test report including
oscillograph shall be submitted to Buyer.

6.1. Combined Testing

For the hazardous area rated motor, the motor & VSD shall be combined tested at
motor supplier work. The test shall be carried out on one VSD of each rating
offered. VSD supplier shall assist in carrying out these tests.
Complete string test (test with VSD, Motor and driven load) if specified in material
requisition shall be performed at mechanical supplier work. VSD and Motor
supplier shall assist in carrying out these tests.
VSD supplier shall supply as pre-bid documents the waveforms requested by Buyer
to establish suitability of the VSD for use with motors located in classified areas.
The motor-VSD-driven equipment combination shall be tested for dynamics
(establishing system critical frequencies and magnitudes of pulsating and transient
torques) at site. VSD supplier shall assist in carrying out these tests.
7. Vendor Data
Document to be submitted along with the bid and post order shall be as per the list
provided in the Material requisition. All documents and drawings shall be in English.
Minimum Supplier data requirement shall cover the document to be submitted by
a Supplier during the following stages:

with Bid Order
1 General arrangement (#) √ √
(Preliminary)
(Outline drawing showing main dimension, including
internal arrangement of components, termination
arrangements and lifting points, cooling system/unit)
2 Datasheet (#) √ √

with Bid Order
3 Single line diagram (#) √ √
(Preliminary)
4 Performance characteristics √
(such as overall efficiency, heat load and noise level at

full load)
5 Supplier Quality Assurance Program √
6 Quality Plan √

7 System Architecture (#) √ √
(Block diagram showing the interconnectivity between

various control/IO cards)
8 Calculations √ √
(for electrical component size / ratings, chokes & filter,

harmonic calculation for compliance to IEEE-519,
adequacy of protective devices)
9 Calculations √
• Application check to meet the performance

requirement (Torque – Speed Characteristics and
VSD selection)
• Validation of the Peak Voltage, dv/dt levels at
Motor Terminal from VSD do not exceed the Motor
Insulation capability
10 Schematic & Wiring Diagram (#) √
11 Design Data √ √
12 Utility Consumption Data √ √
(incl water flow rate for water cooled drives)
13 Logic block diagram (#) √ √
(Preliminary)
14 Water Cooling Unit Drawings √
15 Write-up on specific requirements √
(eg. Upstream circuit breaker sensing and trip time influence on safe
operation)
16 Foundation plans (#) √
17 Type test certificates √
18 Routine Test report √
19 Radio Frequency Interference (RFI) √

compliance certificate
20 Derating chart (for VSD) √
21 Deviation List √
(Equipment of similar design and rating during last five years)
23 Catalogues √

(on VSD and other accessories)
24 Heat Load Calculation √ √
(for panel and components) (Typical)
25 Inspection and test plan √
26 Training Manual √
27 Manufacturing & Testing facilities √
28 Rating and Diagram Plate √
30 Painting and coating procedure √
31 Complete inspection & test reports carried out √
32 Test certificates of all bought out items √
33 Compliance certificate √
(indicating that the Equipment supplied, comply with the

corresponding Specification and all the relevant codes and standards)
34 Installation and commissioning instructions √
35 Operation and maintenance manual √
36 Parts List / Bill of Material (#) √
37 Guaranteed Technical Parameters √ √
38 List of recommended operational √ √

/commissioning spare parts
39 Instructions for handling at site including √
Shipping dimensions and weight
40 Configuration Files √
(editable format)
41 String (Combined) Test Reports on VSD, √

Converter transformer and Motor in Supplier's
works
(if specified in material requisition)
42 Maintenance and replacement schedule √
(of all major components like pumps, ionizer, strainer, hoses, in the
water-cooling circuit for Water Cooled VSD’s)
43 Torsional analysis √

(VSDs that produce torque pulsations more than 2% at any frequency,

in the operating speed range)
44 Power factor & Efficiency curves √
(at input to drive isolation transformer given for 50 / 75 / 100% load)
45 Control & Trip Sequence Flow chart √
46 Life Cycle documentation - System Life Cycle √ √

Plan, product evolution with current version
details, obsolescence plan (Hardware /
Software / Firmware) including all major key
components – Power and Control
components.
Note:
1) Software required for VSD operation (to be included base offer).
2) (#): As built documents shall be submitted as a minimum requirement, including
final Parameterization Document.
Preparation of shipment shall be made after all inspection and testing of equipment
has been accomplished and equipment has been released for shipping by the
Buyer.
VSD shall be shipped in the largest possible sections whilst permitting ease of
handling for transportation and installation.
Each shipping section shall be provided with supports such as steel sections, lifting
eyes to maintain alignment of parts during shipping, handling, hoisting and
installation. Location of lifting points shall be clearly marked on shipping containers
and on drawings. Each shipping section shall have the weight and centre of gravity
clearly marked on the container.
The packing shall be completely suitable for outdoor storage in areas with heavy
rains/high ambient temperature.
dampness and breakage or vibration injury during transportation or handling.
Where storage condition is likely to involve rodent or fugus attack, equipment
specification shall include necessary protective items. Appropriate measure shall
be taken by the VSD Supplier to prevent any condensation and humidity inside the
packages. If in internal cabinets space heater is provided, then it should be provided

with external connection to facilitate connection without disturbing the external

shipping materials.
Each shipping container shall be identified with the contents, Buyer's purchase
order number and item number. Packing list should be provided in each shipping
enclosure/container.
Where equipment has to be split for shipping, instructions shall be provided for
reassembly. Materials and special tools shall be provided, if necessary, for
reassembly at site.
Loose equipment shall be appropriately packaged & secured for shipment inside
the enclosure or shipping container. These items shall be properly tagged for easy
identification.
Space heater leads shall be accessible without disturbing the shipping package and
shall be tagged for easy identification.

Appendix A: Codes and standards

IEC Standards
IEC 60034 Rotating electrical Machines
IEC / EN 60071-1 Insulation coordination - Part 1: Definitions, principles and
rules
IEC 60076 Power Transformers
IEC 60079 Explosive Atmospheres
IEC 62103 Electronic equipment for use in power installations (EN
50178)
IEC / EN 61000-2-4 Electromagnetic compatibility (EMC) - Part 2-4:
Environment - Compatibility levels in industrial plants for
low-frequency conducted disturbances
IEC 60146 Semiconductor Converters
IEC 60289 Power Transformers
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60616 Terminal and tapping markings for power transformers
IEC / EN 60664-1 Insulation coordination for equipment within low-voltage
systems - Part 1: Principles, requirements and tests
locations
IEC / TR 61000-3-6 Electromagnetic compatibility (EMC) - Part 3-6: Limits -
Assessment of emission limits for the connection of
distorting installations to MV, HV and EHV power systems
IEC 61378 Converter Transformers
IEC 61800 Adjustable speed electrical power drive systems
EMC requirements and specific test methods

IEC 61800-4 Adjustable speed electrical power drive systems Part 4:

General requirements - Rating specifications for a.c.
power drive systems above 1 000 V a.c. and not exceeding
35 kV
specification of voltage on the power interface
IEEE Standards
IEEE 1566 IEEE standard for performance of Adjustable-speed AC
drives rated 375kW and Larger
Indian Standards
IS 3700 Essential Ratings and Characteristics of Semiconductor
Devices
IS 3715 Letter symbols for semiconductor devices
IS 5001 Guide for Preparation of Drawings of Semiconductor
Devices
IS 5469 Code of Practice for the Use of Semiconductor Junction
Devices
IS 9628 Three-phase induction motors with type of protection
‘n’
Other Standards
ISA Standard Environmental conditions for process measurement
71.04 and control system

Appendix B: System Study/ Analysis requirement for Large drives (30

MW and larger)
Large drives (30 MW and larger), the following studies shall be performed:
a) Load Flow Study (By Buyer/EPC contractor)
• Study contents: Power Flow performed for various operating configurations to
ensure the power factor criteria is satisfied at point of interconnection,
equipment loading, and steady state voltage satisfy the project requirements.
Provide recommendation for no-load tap settings for the various substation and
load center transformers in the facility.
• Input required: Electric Grid interface data such as voltage level, voltage
variations in the grid, voltage drop limit requirements by the grid, minimum and
maximum short circuit levels and X/R ratio, and relevant operating conditions to
be provided.
• Study outcome: Support the required technical information for advancement of
the design.
• Software/Tool: ETAP
b) Short Circuit Study (By Buyer/EPC contractor)
• Study contents: Determine the interrupting and momentary fault duties at all
buses to establish recommended short circuit ratings for all circuit breakers and
switching devices. In addition, the short-circuit study is used for determining
settings of the protective devices.
be provided.
• Study outcome: To support the required technical information for advancement
of the design.
c) Motor Starting / Acceleration Study (By Buyer/EPC contractor)
• Study contents: Calculate the voltage drops at all major distribution system
buses during the starting of these representative medium voltage and low
voltage motors and identify any buses where the calculated voltage drops are
outside of the customer specifications.

be provided.
• Study outcome: Identify potential motor starting and/or excessive voltage drop
issues and suggest remedial measures to mitigate the objectionable voltage
drops if any.
d) Harmonic Load Flow Study (By Buyer/EPC contractor)
• Study contents: Simulate the current and voltage harmonic distortion injected
by the VSDS within the plant by utilizing ETAP.
be provided.
• Study outcome: Evaluate the influence of the drives injected harmonics
throughout the plant and evaluate the harmonic distortion performance at main
buses respect to the IEEE-519 limits.
e) Protection Coordination study (By Buyer/EPC contractor)
• Study contents: Determine recommended settings for the phase overcurrent
and ground overcurrent protection functions associated with the protective
relays in the plant electrical distribution system in order to maximize the
selectivity of the circuit breakers intervention and ensuring the isolation and
protection of faulty equipment, minimizing the plant interruptions.
be provided, as well as the protection settings at the interface feeders.
• Study outcome: determination of recommended settings for proper selectivity
and co-ordination for subsequent implementation into the individual protection
devices and for further studies (e.g. Arc-Flash hazard calculations).
f) Harmonic Distortion and Filter Design study (By VSD Supplier)
• Study contents: Design the HF and PFC system in compliance with power system
standards (IEEE519) and customer requirements. Perform the harmonics
assessment for various grid configurations.

• Input required: Detailed data of the electric grid, capacitors and filters outside
of the plant need to be known and relevant operating conditions to be provided.
• Study outcome: Define the design of HF & PFC and relevant specification.
Provide the harmonics sources and harmonics voltage at the point of common
coupling versus project requirements.
g) Network Dynamic/ Transient Stability Study (By VSD Supplier)
• Study contents: A transient stability study is performed to investigate
compliance of the plant against Low Voltage Ride-Through (LVRT) and High
Voltage Ride-Through (HVRT) requirements for grid faults. Analysis should
ensure the plant loads are capable of stable power recovery for normally cleared
3ph faults and delayed clearing of 1ph to ground faults in the electric grid.
Several pre-selected operating scenarios and different transmission grid
contingencies will be analyzed.
• Input required: Electric grid interface data such as voltage level, voltage
be provided. Dynamic models of large synchronous machines and their
moments of inertia are required.
of the design.
• Software/Tool: ETAP and Manufacturer Specialized Software
h) Sub synchronous torsional interaction – SSTI (By VSD Supplier)
• Study contents: Evaluates large scale motor driven systems with VFD regarding
the possibility for the excitation from the motor end to impact the generators in
the Electric Grid
be provided. Dynamic models of large synchronous machines, drives, their
moments of inertia and detailed mechanical models are required.
of the design.
• Software/Tool: Manufacturer Specialized Software
i) Sub synchronous control interaction - SSCI (By VSD Supplier)

• Study contents: Evaluate the potential interaction of the E-drive controls (LCI or
VSI) with controls on generating units in the connected Electric Grid. Verify that
the E-drive controls (LCI or VSI) do not cause an adverse impact on post transient
event power swings or voltages.
• Input required: Electric grid interface data such as voltage level, voltage
be provided. Dynamic models of large synchronous machines, drives, their
moments of inertia and detailed mechanical models are required.
of the design.
• Software/Tool: Manufacturer Specialized Software
j) Inter-harmonics Filter design (By VSD Supplier)
• Study contents: Confirm design of DC Loop Reactor (LCI) or confirm DC
Capacitors (VSI AFE) to comply with power system standards (IEC61000-3-6) and
customer requirements. Evaluate VSDS inter-harmonics currents at grid side and
motor side for large machines operating simultaneously within the operational
speed range of the loads.
be provided.
• Study outcome: Confirmation of DC Loop reactor value and component
specification. The assessment of currents considering the entire inter-harmonic
spectrum associated with compressor operating speeds and with attention to
the region of concern [15Hz-30Hz], torque pulsations and every resonant
frequency.
• Software/Tool: ETAP and Manufacturer Specialized Software

Specification for Electrical requirements for Packaged

Mechanical Equipment
0 25.08.2020 Issued for Implementation SP/RT VS/US SK / VKM

By By By
Standard Specifications for Electrical requirements for Date: 25.08.2020 Rev. 0
Packaged Mechanical Equipment

No.
Sundaram Kannan (Chairman) _____________ ___________

1
Ravi Ayyagari _________________ ___________

2
Sudhir Pawar _________________ ___________

3

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ........................................................................................................................... 1
2. References ................................................................................................................... 1
7. Supplier Data ............................................................................................................. 20
Appendix A: Code and Standards ...................................................................................... 22
1. Scope
manufacture, inspection, testing, packaging, shipment, Installation, commissioning
and documentation for Electrical requirements of the package mechanical
equipment for Supplier and/or Contractor to comply with, to achieve Owner`s
objective of standardization.
in similar service conditions. Owner will review, evaluate and approve deviations
to this standard specification that Supplier and/or Contractor may seek on this
2. References
The electrical equipment and materials supplied under the package equipment
shall be designed, manufactured and tested in accordance with the latest revision
of the relevant Codes and Standards as detailed in Appendix A.
document. Also, all inter-disciplinary documents shall be taken in to cognizance.
LV Motors RPMS-ENGG-SPC-EL-004
HV Motors RPMS-ENGG-SPC-EL-003
HV Cables RPMS-ENGG-SPC-EL-021
LV Cables RPMS-ENGG-SPC-EL-022
LV Switchgear (Motor Control Centre) RPMS-ENGG-SPC-EL-002
MV Variable Speed drive RPMS-ENGG-SPC-EL-029
LV Variable Speed Drive RPMS-ENGG-SPC-EL-011
Electrical Heat Tracing RPMS-ENGG-SPC-EL-030
Electrical Heater and Thyristor & RPMS-ENGG-SPC-EL-043
Control Panel for Electrical Heaters
HV Synchronous Machines RPMS-ENGG-SPC-EL-040


specification and any other applicable documents, the following order of
precedence shall govern:
Notes:
Requisition – Electrical Equipment’s Datasheets, LV Switchgear Datasheets,
MV and LV Single Line Diagrams, Stock Code Item Description etc.
Order

CCOE Chief Controller of explosives
CSIR Central Institute of mining and fuel research
DCS Distributed Control system
IEEE Institute of Electrical and Electronics Engineers

IS Indian Standard
LCP Local Control Panel
LCS Local Control Station
MCC Motor Control Center
MOV Motor Operated Valve
OISD Oil Industry Safety Directorate (India)
PESO Petroleum and Explosive Safety Organization
UCP Unit control Panel
UPS Uninterruptible power supply
VRLA Valve Regulated Lead Acid
Definitions

Company


5.1.1. Equipment shall be designed for suitable and reliable use under the site
environmental conditions described in associated electrical equipment data sheet.
5.1.2. The Panels shall be designed for earthquake design criteria as per IS 1893 & IEC
60068-3. The seismic zone for design purpose shall be as specified in equipment
data sheet.
5.1.3. The Package equipment shall, in all respects, be suitable for operation in the
conditions typical of a petrochemical complex and refinery in a tropical coastal
location.
5.1.4. Where electrical equipment is located indoors or in a housing the Supplier shall
ensure that the equipment is rated to operate at the anticipated indoor ambient
temperature. Otherwise Supplier shall provide suitable ventilation or air
conditioning.
5.1.5. The design life of electrical equipment shall be minimum 25 years.
5.2. Electrical System
5.2.1. Power Supplies
The following voltages are available and shall be used for the functions listed below:
Supply Application
11 kV, 50 Hz, 3 phase, 3 Wire, neutral For directly Transformer fed High Voltage
high resistance earthed Motors rated above 3.5 MW
6.6 kV, 50 Hz, 3 phase,3 Wire, Power distribution and high voltage
neutral low resistance earthed motors (> 160 KW to 3500 KW)
415 V, 50 Hz, 3 phase and neutral, 4 Power distribution and low voltage
Wire, neutral solidly earthed motors. (>0.37 kW Up to 160 KW)
415 V, 50 Hz, 3 phase and neutral, 4 Process heaters above 3 kW

Wire , neutral solidly earthed.
Supply Application

240 V, 50 Hz, single phase,3 Wire, Process Heater up to 3 kW, Anti-

one wire solidly earthed. condensation heater, small power and
lighting supply.
In case of low voltage motor up to 0.37kW,
The preference shall be for 3 phase
equipment wherever possible. 240 V , 1
Phase motors only permitted. if 3 phase
motors are not available and single phase
motors are accepted by BUYER
110 V AC, 50Hz, single phase, 2Wire, Maintained instrument supply circuits to
one wire solidly earthed DCS, PIB instruments & systems
220 V DC/110 V DC. Control and protection power for HV
Switchgear (circuit breaker), LV PMCC,
PCC, Protection relays, EMS/RIO,
Standalone MV/LV VSD panel, VSD MCC
(Supplier to refer equipment data sheet to
confirm DC control voltage 220 V or 110 V
DC)
For motors, above table is to be used as guideline and motor voltage ratings and
starting methods shall be selected to arrive at the best techno commercial solution
fulfilling power system study recommendations and consent of BUYER.
All other voltages required for the package shall be derived by the Supplier.
5.2.2. Electrical Supply Tolerances
Steady State Limits are:
Non UPS
• Voltage ± 10%
• Frequency ± 3%
The combined voltage and frequency deviation shall not exceed an absolute
value of 10%.
UPS
• UPS main bus bar Voltage (115 V) ± 1%
• Equipment Voltage (110 V) +6%, -3%
• Frequency ± 1% feed via inverter
• Frequency ± 3% feed via bypass transformer
Transient Limit for normal loads
• Voltage +10%, - 20%

• Frequency ± 5%
DC Voltage Tolerances
• Voltage + 10% /-15%
The limitations of harmonics currents & voltages appearing at any point in the
system shall comply with IEEE 519.
With transient voltage variations such as those due to short circuits or due to
disturbances from outside supplies, consequent effect on plant operation cannot
always be avoided. In such cases, the following criteria shall apply:
• Voltage depression down to 80% of rated equipment voltage shall not affect
package equipment satisfactory performance & operations.
• Equipment having special requirements with respect to transient or
sustained variations in voltage level and/or waveform shall be provided with
a power supply that is adequately stabilized and/or filtered.
• Supply of electricity to package equipment shutdown systems shall always
be ensured to allow safe shutdown of plant.
• Equipment (switchgear, motor control, motors etc.) shall be suitable for
operation, without deleterious effect, with variations of voltage and
frequency as stated above.
5.3. Area Classification and Selection of Electrical Equipment
Electrical equipment shall meet the requirements of the IS: 5571 – Guide for
Selection of Electrical equipment for hazardous areas - other than mines , or the
Institute of Petroleum Model Code of Safe Practice: Part 15, IEC 60079 Part 14 for
the selection of fluorescent fittings used in Gas Group IIC areas.
Equipment of Indian origin for installation in hazardous areas shall have a test
certificate from the CSIR (Central Institute of Mining and Fuel Research, previously
known as Central Mining Research Institute -CMRI) and approval certificates from
the Chief Controller of Explosives (CCOE) under PESO.
Electrical equipment manufactured outside India and to be used in hazardous areas
falling within the purview of Petroleum Rules, 2002 shall be approved by PESO
before use.
PESO does not provide certificates for Dust hazardous Zone 20, 21 & 22 items. For
these motors, Suppliers shall submit certificates from nationally and/or
internationally recognized Laboratories to RIL. For the imported motors Supplier
shall provide ATEX or IECEx or certificated from any approved agency in the
country of origin.

VSD fed Motors, operating in classified area, needs the PESO approved combined
test certificate.
Imported electrical equipment for use in hazardous applications require PESO
approval. Further details regarding for obtaining PESO certificate are available at
www.peso.gov.in/index.aspx.
For Electrical equipment (except motors) the following types of protection shall be
selected for the various hazardous areas:
Areas Type of Protection

Flameproof or explosion proof, Exd equipment with Exb
terminals.
Zone 1
Pressurised, Exp equipment
Intrinsically safe, Exia or Exib equipment
a) Non-sparking, Exec equipment
b) Increased safety, Exeb equipment
Zone 2 c) Equipment complying with the requirements for Zone
1 areas. Exde and Exp equipment shall be avoided as far
as possible in Zone 2 areas.
a) Increased safety, Exeb equipment
Zone 2 Areas b) Equipment complying with the requirements for Zone
(within/around 1 area. Exde and Exp equipment shall not be specified as
tank bunded far as possible in Zone 2 areas.
areas) c) Non-sparking Exec equipment may be considered on a
case by case basis
Zone 20 Ex"ta" IIIA/IIIB/IIIC
a) Standard industrial equipment

Unclassified b) Equipment complying with the requirements for zone
Areas 1 and 2 areas. Exde, Exp and Exec equipment shall not be
specified as far as possible in unclassified areas.

For motors, the following types of protection shall be selected for the various
hazardous areas:
Area Type of Protection
Exde for rating <1 MW

6.6/11 kV motors
Zone 1 Exde or Exp for rating ≥ 1MW
LV motors Exde
Exec* for rating < or equal 2 MW
6.6 /11 kV motors
Zone 2 Exp for rating ≥ 2MW
LV motors Exeb**, Exec*
6.6/11 kV motors
Zone 20 No Motor is allowed.
LV motors
6.6/11 kV motors
LV motors
6.6/11 kV motors
LV motors
* Risk assessment for possible air gap shall be carried out for Exec type motors in
accordance with IEC 60079-7.
** Risk assessment for possible air gap shall be carried out for Exeb type motors.
Stator winding insulation type test shall be carried out in accordance with IEC
60079-7.
• Ex eb degree of protection will only be considered for induction motors of non-
sparking design.
• Electrical protection for motors with Ex eb protection must take the motor’s tE
time (locked rotor withstand time) into account.
• With the exception of Exp motors, the above must be used in conjunction with
an Exd or Exeb termination box. Exp classification shall envelops the
termination box also.
• For Zone 2 applications, Exeb protection shall be deployed where feasible,
unless agreed otherwise with the driven equipment Supplier. Exeb motors
should successfully pass gas-test in an explosive gas environment.

• Motors of protection Ex "ta/tb/tc" for dust hazardous area Zone 20, 21, 22 shall
comply with IEC 60079-31. The equipment shall satisfy the requirements of
ingress protection IP65.
• In case of Ex"p" motor, Supplier shall provide details e.g. make, purge time,
purging airflow, requirement of external power supply, provision of pressure
transmitters for tripping and trip logic of purging kit.
• When Impulse Voltage Insulation Class (IVIC) comes into effect as per IEC
60034-18-41, the same needs to be considered.
5.3.1. The following guidelines shall be adopted for the selection of bulk items (light
fittings, junction boxes, glands, convenience outlets, receptacles, local control
stations & switches) in classified areas.
• All bulk material items including lighting shall be suitable for IIC as this is the
most stringent gas group. This means that Zone 2 Exec and Exeb equipment
shall be specified as being suitable for Gas Group II covering (IIA, IIB and IIC)
and Exd equipment shall be specified for Gas Group IIC (Exd IIC).
• All cable glands used at the bulk equipment shall be Exd IIC.
5.3.2. Equipment for use in a hazardous area shall be certified based on the project
specification (in accordance with the respective hazardous area classification
drawings). Area handling combustible dust in the plant and bagging
area/warehouse shall be classified as Zone -21 and Zone -22 as per IEC 60079-10-2
depending upon the extent of dust hazard and selection of the equipment shall be
done accordingly.
5.4. Equipment
5.4.1. Motor Starter and Control
In general Motor starters for all motors will be provided by BUYER and installed
remote from the package unit unless stated otherwise. If motor starters are in
package supplier scope, protection co-ordination shall comply with Type 2
coordination as per IEC 60947-4-1.
The Motor control Center (MCC) shall be as per specification RPMS-ENGG-SPC-EL-
002
5.4.2. Skid Mounted Starter Panels
The skid mounted starter panels shall be IP55 for safe area and IP65 for Dust
hazardous area. Rain protection hood (canopy) shall be provided. Starter feeder’s
isolator shall have pad locking facility for LOTO (Lock Out Tag Out) purpose.
The Constructional features and components for the skid mounted starter shall be
in accordance with Specification No. RPMS-ENGG-SPC -EL-002 as applicable, except
the paint shade. Paint shade shall match with the skid colour.

Each skid mounted starter shall be provided with Voltmeter, Ammeter and R, Y, B
indicating lamps. Emergency stop PB shall also be provided on the front door.
Adequate space shall be provided in the starter cabinet for terminating the
incoming Aluminium cable. If the PLC is provided as part of local starter panel it
shall be segregated from starter components with non-conducting barrier.
Components required for communication between this PLC and Unit Control panel
shall be provided by Supplier.
All skid-mounted motor controllers shall preferably be grouped at one location,
within sight of the driven equipment.
5.5. Lighting
Buyer will be responsible for the design, purchasing and installation of the external
operational area lighting on a package unless otherwise agreed upon or defined in
Division of Responsibility Matrix. The Lighting, wherever included in Supplier scope
shall be designed as per specification RPMS-ENGG-SPC-EL-037.
Supplier is responsible for design, supply, and installation of light fittings on the
skid.
The Supplier shall provide lighting for panels (controlled by door limit switches),
cabins, cabin passages, operating platform, instrument panel front spaces and
equipment enclosures. Gauge lights shall be provided, where applicable. The
switches shall be LOTO (Lock Out Tag Out) compliant.
5.5.1. Emergency Lighting
Emergency lighting shall comprise following category:
The number of emergency luminaries in relation to normal luminaries shall be as
follows:
Location type Lighting Category-2 Illumination Level
(Emergency DG powered) (Minimum Lux)
Machinery Rooms 25% 150

Cabin 25% 200
Enclosure - 25
Passages/operating 25% 100
platform/front instrument
panels… etc.
The normal and category 2 light fittings shall be connected to separate terminal
boxes on the package skid.
Single phase utility convenience power and lighting sockets shall be provided inside
each control panel. Each socket shall be with separate ELCBs with 30 mA leakage.
Utility socket shall be universal type.
Supplier shall supply bus bar terminals to terminate multiple number of Aluminum
power cables terminations and Copper control cables as per system design
requirement.
Special Lighting like lights for Inspection of Burners and Process vessels shall be
supplied by Supplier. Lighting fixtures shall be LED type. Each such Lights shall have
a Junction box for terminating the power cable and associated control switch.
These shall comply with area classification requirement and CCOE/PESO certificate
for same shall be provided.
Aviation lighting as per ICAO guidelines shall be supplied by Supplier wherever
applicable. Aviation light shall be powered from Emergency DG Power supply.
5.6. Electrical Control Circuits and Components
5.6.1. All control circuits shall be designed so that loss of power or component failure
places the controlled process in a "fail-safe mode".
5.6.2. All alarm circuits that are operated by devices designed to protect the equipment
shall be designed "fail-safe" and first out sequence - i.e. failure or malfunction acts
to de-energize the circuit and initiate an alarm in sequential order of occurrence of
faults.
5.6.3. Indicating lights that designate the operating status of machinery shall be red for
running and green for stopped, Amber for trip.
5.6.4. All the indicating lamps shall be LED (LVGP- Low Voltage Glow Protection) type.
5.6.5. Stop functions shall be initiated by de-energizing control devices, and not by
energizing control devices.
5.6.6. Where automatic and sequential control circuits have an application that requires
sequential operation of limit switches like pressure switches, a manual mode shall
be provided to recycle the system in the event of stoppage or mid-cycle failure. The
manual mode shall not bypass the limit switches, pressure switches and other pilot
devices.
5.6.7. AC control solenoids shall be individually protected by miniature circuit breakers
on all ungrounded power supply circuit conductors. Direct actuation by push
buttons or selector switches, etc. is not acceptable. Surge suppressors shall be
provided where necessary but are must for DC powered solenoids. Programmable
controllers shall use discrete output modules with individually fused circuits and
blown fuse indicators.

5.6.8. In applications requiring reversal, control of mechanically linked solenoids,

acceleration steps of speed control, provision shall be made to prevent
simultaneous operation of control devices by using mechanical and electrical
interlocking.
5.6.9. All push buttons, indicating lights and selector switches shall be heavy duty AC/DC.
5.6.10. Push button operators, lens caps of indicating lights and legend plates shall be
colour coded for functional indication.
5.6.11. Selector switches shall be equipped with lever or pistol grip handles.
5.6.12. Emergency stop pushbuttons shall be mushroom head stay-put type (Push to stop
and turn to release type), red colour and hard wired.
5.6.13. Operating coil voltage, contact make or break, and continuous rating of general-
purpose AC/DC control relays shall be suitable for the application. Relay coils must
be capable of continuous and reliable operation under conditions +/- 15% rated
voltage. Continuous rating shall not be less than 10 amps AC, or 5 amps DC.
5.6.14. Supplier shall accomplish all necessary interface required with BUYER's main MCC
and PLC with Supplier's MCC wherever required and as specified in data sheets.
5.7. Cables and Wiring
5.7.1. The Supplier shall provide all electrical cabling for the interconnection of the
various components forming the package unit.
5.7.2. Cables shall be in accordance with the project specification, RPMS-ENGG-SPC-EL-
022
5.7.3. All cable glands shall be of the mechanical double compression type with PVC
shroud. For classified area the cable glands shall be Exd IIC type and for balance
area, cable glands shall be of heavy duty industrial type.
5.7.4. All the cables terminating at the package battery limit from the main power supply
source will be provided by BUYER. 6.6kV cables and terminal boxes shall be suitable
for Raychem™ heat shrink type or equivalent type of terminations. The use of
Elastimould TM / Euromuold TM can be evaluated on case to case basis where
number of cables to be used is more than one.
The Supplier shall provide suitably sized terminal boxes to suit cables/cable glands
provided by BUYER . The details of the sizes , types of cables and clearances for
internal termination, glanding and required cable supports will be as per data
sheet. Supplier shall accordingly size the Terminal Box including terminals and
internal space for management of cable entries.
5.7.5. Power, control and instrumentation circuits shall be terminated in separate
junction boxes .

5.7.6. Junction boxes shall have removable gland plates and degree of enclosure
protection shall be IP 55 (minimum). Exd Junction boxes can have integral threaded
Gland plate.
5.7.7. All cables that run within the package unit shall be adequately supported on heavy
duty ladder rack or tray. Ladder rack or tray shall be hot-dip galvanized. Unarmored
cables, if used to be run in heavy duty rigid steel conduit, hot-dipped galvanized
after fabrication, and threads on fittings shall be ISO metric. Cable shall be
clamped/supported at every 2 meters for horizonal ladder/tray and at every 1.5
meter for vertical ladder/tray.
5.7.8. Scope of Power and control cabling shall be as per below table:
Scope of
Equipment Supply Location Cabling Scope Remarks
Remote In BUYER scope Supplier to
BUYER (outside (tray within the provide the
Switchgear/ (Refer Note- Package package by cable
MCC 1) Equipment) Supplier) schedule
Within the package,
by Supplier, Cabling Supplier to
between Supplier provide the
PB equipment to cable
station/Local Within BUYER equipment, schedule,
Control Packaged by BUYER (Refer cable block
Panel Supplier Unit Note-2) diagram
Remote In BUYER scope

VFDs/Electric (outside (tray within the
al heater Package package by
control Panel Supplier Equipment) Supplier)
Notes:
1. Above scope of supply and installation shall be adhered, unless specified

otherwise in material requisition.
2. Where control panels are installed remote from the package, all electrical,
instruments and control equipment shall be wired by the Supplier to
separate junction boxes mounted within the package. Cabling between the
junction boxes and remote panels will be provided by BUYER.
Any special cable such as VFD application shall be by Supplier, unless specified
otherwise in Material Requisition.

5.7.9. Terminal blocks shall be of Wago / Phoenix make, or equivalent. Not more than
one connection shall be allowed at each side of a terminal, 20% spare terminals
shall be provided. Cage Clamp type terminals shall be used for control wiring.
5.7.10. Power cable terminal block shall be of busbar or stud type fittings suitable for cable
termination using ring type lugs with phase barrier. Control terminals shall be of
screw less design ‘clamp type’. All cable terminations shall be with lug only.
5.7.11. All wiring shall be clearly identified by means of ferrules. All internal and external
wiring shall have cross ferruling reference.
5.7.12. Minimum space between Electrical Power cables & instrumentation and
telecommunication cables shall be as follows:
Power Cable Minimum Spacing
33 kV 1000 mm
6.6 kV 1000 mm
415 V 600 mm
110 & 240 V 300 mm
5.7.13. Instrument cables serving common equipment with power cables, e.g. motors with
RTD's, shall maintain the separation as far as possible and then be brought to the
equipment terminal box as near as possible to 90° to the power cable entry.
5.7.14. All cables shall be tagged with the Supplier’s cable designation number at both ends
local to gland termination. All wires terminated at junction boxes and
instrumentation shall be ferruled.
5.7.15. Mechanical equipment, pipes, etc. shall not obstruct access to electrical equipment
and instrumentation. Also, there shall be adequate clearances between these
equipment for installation, operation and maintenance.
5.7.16. Process structure and utility piping or their support shall not be used to support
electrical equipment, cables & trays etc.
5.7.17. Cable entries shall be from bottom wherever possible with adequate vertical spaces
for cable support if required.
5.7.18. The minimum cross section of interconnecting cabling shall be as follows;
a) Power 2.5 mm2 copper.
b) Control 1.5 mm2 copper
c) CT circuit. 2.5 mm2 / 4 mm2 copper
5.7.19. The cable lugs shall be heavy duty tinned copper.
5.7.20. Cables ladders shall be installed to allow for thermal expansion and must be
securely fastened via hold down clamp at least every 2 meters. Mechanical
protection shall be provided to vertical Cable ladder/tray for the height of 1 meter
from the finished ground level. All cable trays shall have 20 % spare capacity.
5.8. Control Panels and other components / accessories
5.8.1. Control panels for outdoor installation shall be suitable for the environmental
conditions of plant and with degree of enclosure protection to IP55 (minimum) , IP
65 minimum in case of Dust Hazard & canopy(rain hood).
5.8.2. Degree of enclosure protection for control panels located indoor shall be IP41
(minimum).
5.8.3. Pushbuttons, selector switches and indicating lights shall be of heavy duty, dust and
oil-tight construction.
5.8.4. Each switch contact shall have a minimum continuous rating of 10 A, 240V AC 50
Hz / 220V DC, 2A unless specified otherwise and be in accordance with IEC 60947-
3 duty requirements.
5.8.5. The maximum height of the control panel shall not exceed 2.5m. Each device
requiring operation by an operator shall be semi-flush mounted on doors or panels
for dead front operation. Controls shall be mounted between 0.3m and 1.8m above
floor level. The outdoor panels and LCS shall have an extended canopy.
5.8.6. Audible alarms, howlers, buzzers, horns and hooters shall be provided with a
silence push-button and automatic reset.
5.8.7. Visual alarms, indicating lights, beacons and flashers shall be provided with a test
facility.
5.8.8. Control panels shall be furnished as a complete control system. All controls shall
be wired to clearly labelled terminal blocks. Free standing control panels shall be
provided with an internal light, switch and receptacle wired to a junction box. The
panel shall be designed to ensure maximum safety during operation, inspection and
maintenance.
5.8.9. Piping in control panels shall be separated from electrical items by a physical
barrier.
5.8.10. Push-buttons and indicating lights shall be wired in the control panel for start-up of
all motors associated with driven equipment. An ammeter shall be provided for all
motors of 30kW rating and above. All motors shall have a STOP pushbutton
mounted adjacent to them. The STOP pushbutton shall be provided with protection
against accidental operation and shall be Lockable on OFF position.

5.8.11. All initiating contact inputs from direct process operated switches, receiver
switches, manual shutdown switches and equipment status switches shall be
closed during normal operating conditions and opened under abnormal conditions.
All contacts shall be wired into circuits in the fail-safe condition. Switch contacts
shall be dry, single-pole, double-throw (SPDT) type, with a minimum contact rating
of 5 A, 240 VAC, 50 Hz/ 2A, 220V DC, 2P.
5.8.12. All Light fittings, Fans and Space heaters shall have individual 2 Pole Isolation in the
form of MCB or Fuse.
5.8.13. A Power supply Isolator, MCB and MCCB shall be fitted to each control panel. These
shall be Lock out Tag Out (LOTO) compliant.
5.8.14. Fuse links shall be high rupture capacity type in accordance with IEC 60269-2.
5.8.15. All control panels shall be fitted with an anti-condensation heater (240V AC Single
phase), complete with thermostat, isolating switch and fuse. The temperature
alarm contacts shall be wired up to the terminal block.
5.8.16. Control circuits shall be separately protected against short circuit. Small power
branch circuits shall be provided with separate earth fault protection.
5.8.17. When miniature circuit breakers are used special attention shall be paid to their
breaking capacity and in case of ELCB, the leakage current sensitivity shall be
minimum 100 mA.
5.8.18. Thermal overload devices shall have a manual reset.
5.8.19. Enclosures and boxes shall be accessible from platform, ladders and stairways and
supported independent of the raceway system.
Junction boxes with dimensions exceeding 200 mm shall be fitted with drain
breather. Adequate space shall be provided around the terminal boxes to allow the
BUYER to train and terminate his cables in the bottom or side of the box
5.9. Earthing
5.9.1. The earthing installation on the package unit shall include the safety earthing, static
earthing, lightning protection and instrument earthing as required as per RPMS-
ENGG-SPC-EL023 and the area classification requirements.
5.9.2. All electrical equipment including the local control panel & junction box on the
package unit shall be bonded to the package unit skid.
5.9.3. Cable ladder/tray shall be bonded to nearest earth pad at every 30 meters. Cable
ladder and trays shall also be electrically bonded with 50 x6 mm mild steel flat bar
at every 12 Meter to each other (multi-layer/horizontal run) for earthing continuity.

5.9.4. Two numbers of M10 size earthing terminals, one at each end of the package unit
skid located diagonally opposite each other, shall be provided. The two earthing
terminals shall be electrically continuous & part of skid metallic base frame.
5.9.5. Junction boxes shall be provided with appropriately sized internal and external
earthing terminals.
5.9.6. All metallic non-current carrying parts shall be made electrically continuous with
the package unit skid. The resistance from any metallic part to a skid earthing boss
shall be less than 1 ohm.
5.9.7. Copper conductors shall be used for earthing or bonding of minimum size 6mm2.
5.9.8. Panels shall be equipped with and earth bar over the full width of the cable
connection compartment. The armouring of cables and/or earthing conductors
shall be connected to this bar.
5.9.9. Requirement of separate instrument's earthing, if any shall be clearly specified by
Package Supplier.
5.10. Lightning Protection
5.10.1. Non-metallic structures shall be provided with lightning protection in accordance
with IEC 62305 .
5.10.2. Metallic structures that are electrically continuous and bonded to the package skid
do not need additional lightning protection.
5.11. Motors
When electric LV Induction motors or HV Induction motors or HV synchronous
motors/ generators are provided as part of the packaged equipment, it shall comply
with requirement specified below;
a) LV motor requirement shall comply with the relevant project motor
specification RPMS-ENGG-SPC-EL-004
b) HV motor requirement shall comply with the relevant project motor
specification RPMS-ENGG-SPC-EL-003 or API 541 or API 547
c) HV synchronous motors or generator requirement shall comply with the
relevant project HV Synchronous Machines specification RPMS-ENGG-SPC-EL-
040 or API 546.
Partial Discharge (PD) measurement sensors/capacitive couplers shall be supplied
by supplier installed on HV motors as indicated in datasheet. Following are the
general requirement with respect to PD measurement provisioning on HV Motor:
a) PD sensors/capacitive couplers for each phase shall be designed and mounted
suitably on motor and terminated on a termination box.

b) The termination box shall have facility to connect these PD sensors/capacitive

couplers with ‘Online’ or ‘Portable’ PD data acquisition units/measurement unit
with standard BNC connectors or ‘N-Type’ connectors.
c) PD sensors/capacitive couplers shall be complied as per IEC 60034-27-2 for PD
measurement monitoring.
d) PD sensors/capacitive couplers shall be complied as per hazardous area
classification requirement as mentioned in datasheet.
e) PD sensors/capacitive couplers shall be suitable for PD measurement in
different frequency bands (40kHz – 100MHz) unless specified in datasheet.
Supplier to provide designed frequency band and calibration requirement
details as part of product datasheet.
5.12. LV Variable Speed Drives

LV Variable Speed Drives / Panels shall be as per specification RPMS-ENGG-SPC-EL-
011.
5.13. MV Variable Speed Drives
MV Variable Speed Drives / Panels shall be as per specification RPMS-ENGG-SPC-
EL-029.
5.14. Precaution against Static Electricity
All Vessels shall be fitted with external earthing Boss at minimum two points.
Earthing Bosses are to be supplied with GI Bolts. In Process equipment other than
vessels earthing boss can be fitted to the body or supporting frame of the
equipment for terminating earthing conductor, wherever required to take
precaution against static electricity.
5.15. Sun Shades
Where equipment is to be located outdoors in direct sunlight, Supplier shall provide
protection against detrimental effect due to solar radiation.
5.16. Degree of Protection
In general, the minimum degree of control panel enclosure protection shall in
accordance with IEC 60529 and as follows:
Outdoor IP 55 (IP 65 in case of Dust Hazard)
Indoor IP 41
Floor mounted panels shall be equipped with undrilled gland plates ( Not applicable
for Ex-d equipment) which maintain the specified degree of protection & adequate
clearances between gland plate and terminal blocks.
5.17. General Requirements

5.17.1. The electrical installation on the packaged equipment shall be in accordance with
IEC 60204.
5.17.2. For Electromagnetic Compatibility (EMC) the requirements of IEC 61000 shall be
applicable.
5.17.3. Materials that are highly persistent or toxic to the environment or considered
international carcinogens shall not be used.
5.17.4. The Heat tracing inside Package shall be carried out by BUYER unless agreed
otherwise. Supplier shall provide the Heat Tracing requirement to buyer and make
provision for cabling and supports for mounting heat tracing Equipment.
5.17.5. The colour and finish shall be in accordance with the project paint specification.
5.17.6. All electrical equipment shall be provided with engraved labels denoting its
function and where necessary the operating instructions. The language to be used
on labels or tag plates shall be English. The Electrical Equipment shall be sourced
from suppliers listed in Project Master Supplier List, unless specifically agreed upon
with Buyer.
5.17.7. All cable Glands shall be supplied by Supplier within package. For BUYER cables
terminating at Package interface, individual motors, Glands other than ET threads
shall be supplied by Supplier.
5.17.8. The relay settings / Transducer scaling / Alarm and Trip values within the package
shall be worked out by supplier and submitted to BUYER.
5.18. Accessories
5.18.1. Supplier shall include as part of his quotation an itemized, price list of installation,
commissioning, recommended operation spares (Duration as per MRQ) and Capital
spares.
5.18.2. Maintenance and operational tools shall be provided in a wall-or-floor mounting
sheet steel lockable box
6.1. The Supplier shall provide the BUYER, or his representative, access to his offices
and manufacturing facilities throughout the duration of the order. The Supplier
shall provide the necessary assistance when equipment or documentation is being
inspected.
6.2. Where specified in the order, electrical equipment shall be separately tested in the
Supplier’s plant and witnessed by the BUYER and /or his representative. The
Supplier shall give at least ten working days’ notice to the BUYER before the test
are carried out.

6.3. The package unit shall be tested at the Supplier’s workshop generally in accordance
with Clause 19 of IEC 60204-1.
6.4. The Supplier shall submit his itemized inspection and test plan along with Test
Procedures for comment and approval.
In general, tests would include:
a) String Test in case of Hazardous area motor (Exec) operated with variable
frequency drive as a part of package/equipment
b) Wiring continuity check
c) Voltage withstand tests
d) Check on operation and accuracy of metering and protection devices
e) Check operation of controls and indicators
f) Check control sequence Interlocks
g) Check earth continuity
As a minimum the test plan shall include tests specified in specifications of

individual equipment like Motors, Switchgear, VFDs, and Heater Panels.
7. Supplier Data
Documents to be submitted with quotation and post order shall be as per the list
provided in Material Requisition . Following documents are at a minimum to be
submitted to the BUYER
Sr. Along Post
Description
No with Bid Order
Over all one-line diagram showing electrical
√ √
1 equipment and interface with BUYER system
Electrical items shown on overall layout drawing . Use
√ √
2 graphical symbols as per IEC 60617 (as applicable)
Details of manufacturer’s quality assurance plan, ISO-
9000 series or equivalent national certification. The
√ √
QAP shall include the details of sub-supplier’s quality
3 monitoring system also.
Electrical load list ( include electrical item`s individual
√ √
5 consumption in kW and Voltage level in Volts)
Electrical equipment List / Bill of Material with make,
type and model. This also includes equipment located √ √
6 in hazardous area with CCOE/PESO certificate number

Rating and Diagram Plate for electrical equipment √

7
Factory Acceptance Test Procedure / Routine Test
√
8 Procedure.
9 Complete Routine/ Type test reports √
Drawing and necessary information for Electrical

√ √
10 equipment ( included in MRB and O& M manual)
Detail drawing of Power and Control cables JBs for
√
11 BUYER cables termination
Schematic cable block diagram and interconnection
diagram within the package and external interface with √ √
12 BUYER systems
Installation and commissioning instructions.( for loose
√
13 supplied items)
√
14 Operation and maintenance manual.

Package equipment shall be secured during transport to avoid damage.
Location of lifting points, the weight and the center of gravity shall be clearly
Each shipping container packages shall be clearly identified with the contents,
purchase order number and item number.

Appendix A: Code and Standards

The National Electrical Code of India, 1985
The Petroleum Act, 1934
The Petroleum Rules, 2002
Central Electricity Authority guidelines
IEC Standard
IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres.
Safety of Machinery – Electrical Equipment of
IEC 60204
Industrial Machines.
IEC 60364 Electrical Installations of Buildings
Basic and safety principles for man-machine interface,
marking and identification – Identification of
IEC 60445 equipment terminals and terminations of certain
designated conductors, including general rules for an
alphanumeric system.
Degrees of protection provided by enclosures (IP
IEC 60529
Code)
IEC 60617 Graphic Symbols for Diagrams.
Dimensions of Panel Areas and Cut-outs for Panel -
IEC 60668 and Rack Mounted Industrial Process Measurement
and Control Instruments.
IEC 61000 Electromagnetic Compatibility
IEC 61082 Preparation of Documents used in Electro-technology.
IEC 61346 Industrial Systems, Installations and Equipment and
Industrial Products – Structuring Principles and
Reference Designations.
IEC 61346-3 Industrial systems, installations and equipment and
industrial products - Structuring principles and
reference designations - Part 3: Application guidelines
IEC 61346-4 Industrial systems, installations and equipment
and industrial products - Structuring principles

and reference designations - Part 4: Discussion

of concepts
IEC 62305 Protection against lightning
IEC 81346 Industrial systems, installations and equipment and

industrial products - Structuring principles and
reference designations
Indian Standard
IS 5 Colors for ready mixed paints and enamels
IS 1893 Earthquake design criteria
IS 3618 Phosphate treatment of Iron and steel for protection
against corrosion.
IS 5572 Classification of hazardous areas (other than mines)
having flammable gases and vapors for electrical
installation
IS 5578 Guide for marking of insulated conductors
IS 6005 Code of Practice of phosphating of Iron and steel
IS 11353 Guide for Uniform system of marking and
identification of conductors and Apparatus terminals
IS 12360 Voltage bands for Electrical Installations including
preferred Voltages and Frequency
ISO Standard
ISO 1461 Hot dip galvanized coatings on iron and steel

articles
ISO 1680 Acoustics - test code for the measurement of
airborne noise emitted by rotating electrical
machines
ISO 3864 Safety colors and safety signs
ISO 9001 Quality systems

IEEE Standard
IEE IEE 16th Edition – Wiring Regulations
IEEE 1717 IEEE Standard for Testing Circuit Integrity Cables
Using a Hydrocarbon Pool Fire Test Protocol
OISD Standard
OISD-RP-110 Recommended Practices on Static Electricity
OISD-RP-147 Inspection & safe practices during electrical
installations
OISD-RP-149 Design Aspects for safety in Electrical System
OISD-STD-180 Lightning Protection
Other Standard
American National Standard Institute ANSI
American Society for Testing & Materials ASTM
Central Mining Research Station (Certifying Authority) CMRS
EEMUA 133 Underground armoured cable protected
against solvent penetration and corrosive
attack.
EIA/TIA 455-B Standard Test Procedure for Fiber Optic
Fibers, Cables, Transducers, Sensors,
Connecting and Terminating Devices, and
Other Fiber Optic Components
EIA/TIA 568A Structured cabling systems. This standard
includes the standards EIA/TIA TSB-36 and
EIA/TIA TSB-40 covering UTP cables and
components.
ICAO International Civil Aviation Organization -
Annex 14 Aerodromes

Guideline for Approved Vendor List – Electrical

(Semi-Bulk Items)
RPMS-ENGG-GUD-EL-041
0 17.12.2020 Issued for Implementation SC / AAJ SMP/ RRN US / SP
Rev Date Revision Details Prepared Checked Approved By

By By
Reliance Project Management System RPMS-ENGG-GUD-EL-041
Guideline for Approved Vendor List – Electrical (Semi-Bulk Item) Date: 17.12.2020, Rev 0

No.
_____________________________
1 _________________ ___________
_____________________________ _________________ ___________

2
_____________________________ _________________ ___________

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ....................................................................................................................... 1
2. Approved Vendor List – Electrical (Semi-Bulk Item) .................................................. 1
1. Scope
This Approved vendor list vendors/suppliers/sub-suppliers shall be selected from the approved
vendor List. This list given below is to assist the concern parties, any deviation shall be brought to
knowledge of DEC / Owner and prior approval shall be taken before proceeding.
2. Approved Vendor List – Electrical (Semi-Bulk Item)
**Category A - Vendors do not require permission for sending enquiry
**Category B - Vendors to whom enquiry can be sent only after taking permission from Category
Manager.

Equipment Supplier Category

Item Description Supplier Name
Type Location **
ABB INDIA LTD INDIA A
SIEMENS LTD INDIA A
Asset Asset
SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A
Management Management
GE T & D INDIA LTD INDIA A
FISCHER BLOCK, INC USA B
AMARA RAJA BATTERIES LTD INDIA A
Battery VRLA Battery EXIDE INDUSTRIES LTD INDIA A
HBL POWER SYSTEMS LTD INDIA A
Nickel Cadmium HBL POWER SYSTEMS LTD INDIA A

Battery
Batteries SAFT USA A
EXICOM TELE SYSTEMS (SINGAPORE) SINGAPORE A
Lithium Ion SAMSUNG C&T INDIA PVT LTD INDIA A

Battery
Batteries VISION TECHNOLOGY CO. LTD CHINA A
HARBIN COSLIGHT POWER CO LTD INDIA A
VERTIV ENERGY PVT LTD INDIA A
Battery
Battery Charger
Charger MASS TECH CONTROLS PVT LTD INDIA A
(220/110 V)
(SMPS)
DELTA POWER SOLUTIONS INDIA PVT INDIA A
Battery
SMPS Battery
Charger DELTA POWER SOLUTIONS INDIA PVT INDIA A
Charger (48 V)
(SMPS)
EXICOM TELE SYSTEMS SINGAPORE B
C&S ELECTRIC LTD (SIEMENS) INDIA A
Compact IIGM PVT LTD(EAE) INDIA A
Bus duct
(Sandwich type)
SOUTH
LS CABLE & SYSTEM LTD A
KOREA
GODREJ & BOYCE INDIA A
GLOBE ELECTRICAL INDUSTRIES INDIA A
Air Insulated
(Phase SWITCHGEAR & STRUCTURE INDIA B
Bus duct
Segregated)- POWERGEAR LTD INDIA A
6.6/11kV
POWERGEAR LTD INDIA A
Bus duct Isolated Phase

Type Location **
Air Insulated GLOBE ELECTRICAL INDUSTRIES INDIA A
(Non-
Bus duct POWERGEAR LTD INDIA A
Segregated)-
415V/690V C&S ELECTRIC LTD (SIEMENS) INDIA A
EPCOS INDIA PVT LTD (TDK) INDIA A
Capacitor APFC Panels
LARSEN & TOUBRO INDIA A
MADHAV CAPACITORS PVT LTD INDIA B
MV Capacitor MANOHAR BROTHERS INDIA B

Capacitor
(6.6/11 kV) ABB INDIA LTD INDIA A
MADHAV CAPACITORS PVT LTD INDIA B
LV Capacitor (415 MADHAV CAPACITORS PVT LTD INDIA B

Capacitor
V) ABB INDIA LTD INDIA A
LARSEN & TOUBRO LTD INDIA A
CORRTECH ENERGY LTD INDIA A
LARSEN & TOUBRO LTD INDIA B
SAIPEM INDIA B
Cathodic Cathodic
CORRTECH INTERNATIONAL PVT LTD INDIA A
protection protection
CORROSTION TECHNOLOGY A
BSS TECH INDIA B
SARK EPC PROJECTS PVT LTD INDIA A
SUPERNOVA ENGINEERS LTD INDIA A
GMMCO/CATERPILLAR ELECTRIC PVT LTD INDIA A
STERLING & WILSON INDIA A
GREAVES COTTON LTD INDIA B
Diesel Generator
DG Set WARTSILA INDIA LTD INDIA A
Sets (Integrator)
KIRLOSKAR BROTHERS INDIA B
RAI & SONS INDIA B
SUDHIR SALES AND SERVICES LTD INDIA A
SUDHIR POWER LTD/CUMMINS INDIA A


Type Location **
FCG FLAMEPROOF CONTROL GEARS INDIA A
FLEXPRO ELECTRICALS PVT LTD INDIA A
Distribution
Hazardous BALIGA LIGHTING EQUIPMENTS PVT LTD INDIA A
Board
R STAHL PVT LTD INDIA A
FCG POWER INDUSTRIES PVT LTD INDIA A
INTRELEC INDIA A
M K ENGINEERS & CONTROLS PVT LTD INDIA A
Distribution Industrial HORIZON MICROTECH PVT LTD INDIA B

Board (fabricated) BHARAT ENGINEERS INDIA B
POPULAR SWITCHGEARS PVT LTD INDIA A
ASCENT ENGINEERS INDIA B
Distribution Industrial SIEMENS LTD INDIA A

Board (Standard) SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A
LEGRAND (INDIA) PVT LTD INDIA A
HENSEL ELECTRIC (INDIA) PVT LTD INDIA B
GE T & D INDIA LTD INDIA A
EDMS EDMS SIEMENS LTD INDIA A

SCHWEITZER ENGINEERING
INDIA B
LABORATORIES
SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA B
AMI INDUSTRIES INDIA A
Electric
Electric Ovens SPHEREHOT DISTRIBUTORS PVT. LTD. INDIA B
Ovens
SHIKOVI HEATGEN TECHNOLOGIES INDIA B
SANDVIK ASIA PVT LTD INDIA A
S M Enterprises INDIA B
Electrical EXHEAT LTD UK A

Electrical Heaters
Heaters CHROMALOX INDIA PRECISION HEAT & INDIA A
PATEL HEATERS & CONTROL PVT LTD INDIA A
KANTILAL CHUNILAL & SONS INDIA A

Type Location **
WATLOW THERMAL SOLUTIONS INDIA INDIA A
THERMON HEAT TRACERS PVT LTD INDIA A
THERMON INC USA B
Electrical Electrical Heat
Heat Tracing Tracing PENTAIR THERMAL MANAGEMENT
INDIA A
(INDIA)
BARTEC INDIA PVT LTD INDIA B
HITACHI HI-REL POWER ELECTRONICS INDIA A
Inverters NOVATEUR ELEC & DIGITAL SYSTEMS P L INDIA A

Inverter
(Lighting) DELTA POWER SOLUTIONS INDIA PVT INDIA A
FUJI ELECTRIC CONSULNEOWATT PVT LTD INDIA A
LUMINOUS POWER TECHNOLOGIES INDIA B
BHARAT HEAVY ELECTRICALS LTD INDIA B
SIEMENS LTD INDIA A
Induction Motor CROMPTON GREAVES LTD INDIA B
Motors (6.6 / 11 KV, up SOUTH
to 4.5 MW) HYUNDAI HEAVY INDUSTRY HHI A
KOREA
WEG EQUIPAMENTOS ELECTRICOS S/A BRAZIL B
JEUMONT ELECTRIC INDIA PVT LTD INDIA A
TMEIC INDUSTRIAL SYSTEMS INDIA PVT INDIA A
BHARAT HEAVY ELECTRICALS LTD INDIA B
CROMPTON GREAVES LTD INDIA B
Synchronous ABB INDIA LTD INDIA A
Motor (6.6 / 11
Motors SIEMENS LTD INDIA A
KV, above 4.5
MW) JEUMONT ELECTRIC INDIA PVT LTD INDIA A
VEM MOTORS GMBH GERMANY B
Motors Purge System EXPO TECHNOLOGIES LTD UK A
LT Motors
Motors SIEMENS LTD INDIA A
(415/690V)


Type Location **
BHARAT BIJLEE LTD INDIA A
WEG EQUIPAMENTOS ELECTRICOS S/A BRAZIL B
LHP (SPECIAL MOTORS) INDIA B
NATIONAL SWITCHGEARS INDIA A
NGR NGR S R NARKHEDE ENGG PVT LTD INDIA A
NATIONAL RESISTORS INDIA A
NEUMANN ELEKTRONIK GMBH GERMANY A
LARAON ENGINEERS & CONSULTANTS
INDIA A
(FOR NEUMANN)
INDUSTRONIC GERMANY A
DEE-EM SYSTEMS (FOR INDUSTRONIC) INDIA A
PA System PA System TELENET INSTRUMENTATION PVT LTD INDIA B
ARMTEL RUSSIA B
GAI-TRONICS UK B
A SQUARE TECHNO SOLUTIONS INDIA B
BOSCH LTD B
LOTUS FIBRE INDIA A
Canopy for PA SATYAM COMPOSITES PVT LTD INDIA B

PA System
System ERCON COMPOSITES INDIA A
FIBRO CHEM INDUSTRIES INDIA A
Pre-Feb Pre-Feb SIEMENS LTD INDIA A
Substation (E Substation (E
House) House) SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A
GE T&D INDIA LIMITED INDIA A
Protection SIEMENS LTD INDIA A
Numerical Relays
Relays
SCHWEITZER ENGINEERING
INDIA B
LABORATORIES (SPECIAL RELAYS)
Remote IO DCS ROCKWELL AUTOMATION INDIA PVT LTD INDIA A

Interface System SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A


Type Location **
Remote IO
DCS Interface LARSEN & TOUBRO LTD INDIA A
System
SSM INFOTECH SOLUTIONS PVT LTD INDIA A
SUPERTECH INSTRUMENTATION SERVICES INDIA A
Siren System Siren System
APS POWER SYSTEMS PVT LTD INDIA B
SWA AUTOMATION PVT LTD INDIA A
Siren System Siren Motor KHERAJ ELECTRICAL INDUSTRIES PVT INDIA A
ROCKWELL AUTOMATION INDIA PVT LTD INDIA A
GE POWERCONVERSION A
Soft Starter HT Soft Starter
SIEMENS LTD INDIA A
Soft Starter LT Soft Starter
SIEMENS LTD INDIA A
DANFOSS INDUSTRIES PVT LTD INDIA A
Switchgear (11 LARSEN & TOUBRO LTD INDIA A
Switch Gear KV, 6.6 KV)
GIS/AIS SIEMENS LTD INDIA A
Switchgear (415 LARSEN & TOUBRO LTD INDIA A
Switch Gear V)
(PCC/PMCC/MCC) SIEMENS LTD INDIA A
Switch Gear Ring Main Units
SIEMENS LTD INDIA A


Type Location **
LUCY Electric INDIA B
Tariff Meters SECURE METERS LTD INDIA A
Tariff Meters (Regulatory
approved) LARSEN & TOUBRO LTD INDIA B
Testing & DNV GL INDIA A
Online 33 kV
Monitoring
Cable PDMS Garrad Hassan INDIA A
Equipment
Power/Unit
VOLTAMP TRANSFORMERS LTD INDIA A
Transformer
Transformers
33KV, > 5 MVA till TRANSFORMERS & RECTIFIERS INDIA B
16 MVA TOSHIBA TRANSMISSION AND
INDIA B
DISTRIBUTION SYSTEMS
Power/Unit ABB INDIA LTD INDIA A

Transformer SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A
Transformers
33KV, 20 MVA till
53 MVA TRANSFORMERS & RECTIFIERS INDIA B
TOSHIBA TRANSMISSION AND
INDIA B
Distribution RAYCHEM RPG PVT LTD INDIA B

Transformer TRANSFORMERS & RECTIFIERS INDIA B
Transformers
(ONAN) Up to
33KV, 5 MVA CROMPTON GREAVES LTD INDIA B
INDIA B
GUJARAT TRANSFORMERS PVT LTD INDIA B
Distribution ABB INDIA LTD INDIA A

Transformer (Dry RAYCHEM RPG PVT LTD INDIA A
Transformers
Type) Up to 5
MVA SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A
INDIA B
Transformers VOLTAMP TRANSFORMERS LTD INDIA A

Type Location **
Auto Transformer SCHNEIDER ELECTRIC INFRASTRUCTURE INDIA A
(6.6KV / 11KV)
TRANSFORMERS & RECTIFIERS INDIA B
INDIA B
Rectifier TRANSFORMERS & RECTIFIERS INDIA A
Transformers Transformer
(process) ABB INDIA LTD INDIA A
AUTOMATIC ELECTRIC LTD INDIA B
Lighting GUJARAT PLUG-IN DEVICES PVT LTD INDIA A

Transformers
Transformer QUALITY POWER INDIA B
RAYCHEM RPG PVT LTD INDIA B
JAYSHREE POWER VOLT PVT LTD INDIA A
VERTIV ENERGY PVT LTD(CHLORIDE) INDIA A
UPS (Industrial
UPS Grade-25KVA and GUTOR ELECTRONICS LTD SWITZERLAND A
above)
GUTOR ELECTRONIC ASIA PACIFIC MALAYSIA A
UPS (Industrial HITACHI HI-REL POWER ELECTRONICS INDIA B
UPS Grade-Up to
20KVA) GUTOR ELECTRONICS LTD SWITZERLAND A
GUTOR ELECTRONIC ASIA PACIFIC MALAYSIA A
SCHNEIDER ELECTRIC IT BUSINESS (I) INDIA A
UPS (Commercial
UPS Grade/ VERTIV ENERGY PVT LTD INDIA A
Infrastructure)
FUJI ELECTRIC CONSULNEOWATT PVT LTD INDIA A
ROCKWELL AUTOMATION INDIA PVT LTD INDIA B
VFDs MV VFDs
SIEMENS LTD INDIA A
TMEIC INDUSTRIAL SYSTEMS INDIA INDIA A
GE POWERCONVERSION INDIA A

Type Location **
DELTA POWER SOLUTIONS INDIA PVT INDIA B
VFDs LV VFDs
SIEMENS LTD INDIA A
GE POWERCONVERSION INDIA B
DANFOSS INDUSTRIES PRIVATE LIMITED INDIA B
Vibration BENTLY NEVADA INC USA A
Motor Vibration
Monitoring
System KRONHE MARSHALL(SHINKAWA) INDIA B
System

Guideline for Approved Vendor List – Electrical

(Bulk Items)
RPMS-ENGG-GUD-EL-042
0 17.12.2020 Issued for Implementation SC / AAJ SMP / RRN US / SP

By By By
Guideline for Approved Vendor List – Electrical (Bulk Item) Date: 17.12.2020, Rev 0

No.
_____________________________
1 _________________ ___________
_____________________________ _________________ ___________

2
_____________________________ _________________ ___________

3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope.................................................................................................................. 1
2. Approved Vendor List – Electrical (Bulk Item) ...................................................... 1
1. Scope
This Approved vendor list vendors/suppliers/sub-suppliers shall be selected from the approved
vendor List. This list given below is to assist the concern parties, any deviation shall be brought
to knowledge of DEC / Owner and prior approval shall be taken before proceeding.
2. Approved Vendor List – Electrical (Bulk Item)
**Category A - Vendors do not require permission for sending enquiry
**Category B - Vendors to whom enquiry can be sent only after taking permission from Category
Manager.

Equipment Item Supplier Category

Supplier Name
Type Description Location **
PRAVIN ELECTRICALS PVT LTD INDIA B
Earthing Strips/ INDIANA GRATINGS PVT LTD INDIA A
Earthing
GI Earthing
Materials KANADE ANAND UDYOG PVT LTD INDIA A
Pipe/ Earth Bus
PARMAR METALS PVT LTD INDIA A
R K ENGINEERING WORKS INDIA A
Junction
Box / LCS
LEGRAND (INDIA) PVT LTD INDIA A
Junction BALIGA LIGHTING EQUIPMENTS PVT LTD INDIA A

Industrial
Box / LCS POPULAR SWITCHGEARS PVT LTD INDIA A
HENSEL ELECTRIC (INDIA) PVT LTD INDIA B
ELM Components (for street light JB) INDIA B
Lightning
Lightning Rods KANADE ANAND UDYOG PVT LTD INDIA A
Protection
FOREND TURKEY A
Lightning
Lightning
Arrestor (for ABB INDIA LTD INDIA A
Protection
Buildings)
DEHN INDIA PVT LTD INDIA A
Plugs &
Receptacles


Supplier Name
HENSEL ELECTRIC (INDIA) PVT LTD INDIA A
Plugs &
Industrial LEGRAND (INDIA) PVT LTD INDIA A
Receptacles
POPULAR SWITCHGEARS PVT LTD INDIA A
PRAVIN ELECTRICALS PVT LTD INDIA B
GI Cable trays INDIANA GRATINGS PVT LTD INDIA B
Cable Tray (Ladder /
Perforated) KANADE ANAND UDYOG PVT LTD INDIA A
R K ENGINEERING WORKS INDIA A
SUMIP COMPOSITES PVT LTD INDIA A
ERCON COMPOSITES INDIA A
Cable Tray FRP Cable Trays
AERON COMPOSITE PVT LTD INDIA B
SATYAM COMPOSITES PVT LTD INDIA A
Switch -
Sockets
HENSEL ELECTRIC (INDIA) PVT LTD INDIA A
Switch - BEST & CROMPTON ENGINEERI INDIA B

Industrial
Sockets LEGRAND (INDIA) PVT LTD INDIA A
POPULAR SWITCHGEARS PVT LTD INDIA B
BELDEN SINGAPORE PTE LTD SINGAPORE A
Cable &
Co-Axial Cables KABELWERK EUPEN AG BELGIUM A
Accessories
DELTON CABLES LTD INDIA A
FINOLEX CABLES LTD INDIA B
BIRLA ERICSSON OPTICAL LTD INDIA A
Cable & Optical Fibre
HIMACHAL FUTURISTIC COMMUNICATIONS INDIA A
Accessories Cable
STERLITE TECHNOLOGIES LTD INDIA A
USHA MARTIN LTD, INDIA A


Supplier Name
KABELWERK EUPEN AG BELGIUM A
LAPP INDIA PVT LTD INDIA A
Instrumentation
Cable &
Cable POLYCAB WIRES PVT LTD INDIA B
Accessories
(PA System)
LEONI KERPEN A
DELTON CABLES A
UNIVERSAL CABLES LTD INDIA A
TORRENT Power Ltd INDIA A
KEI INDUSTRIES LTD INDIA B
High Voltage
Cable & LS CABLE AND SYSTEM LTD INDIA A
Cables (22 KV /
Accessories
33 KV) KEC INTERNATIONAL LTD INDIA A
FUJAIRAH(U
POWER PLUS CABLE CO. L.L.C B
AE)
STERLITE TECHNOLOGIES LTD INDIA B
TORRENT POWER LTD INDIA A
KEI INDUSTRIES LTD INDIA B
Medium Voltage
Cable & LS CABLE AND SYSTEM LTD INDIA A
Cables (Above
Accessories
3.3 KV to 22 KV) KEC INTERNATIONAL LTD INDIA A
FUJAIRAH(U
POWER PLUS CABLE CO. L.L.C B
AE)
STERLITE TECHNOLOGIES LTD INDIA B
MIRACLE CABLES (INDIA) PVT LTD INDIA A
Cable &
Uninyvin Cables INDUSTRIAL GLASS INSULATION INDIA A
Accessories
PAGODA CABLES PVT. LTD. INDIA B
POLYCAB WIRES PVT LTD INDIA A
Cable & RAVIN CABLES LTD INDIA A

VFD Cables
Accessories BELDEN SINGAPORE PTE LTD SINGAPORE A
KABELWERK EUPEN AG BELGIUM A
POLARIS CABLES & WIRES PVT LTD INDIA A
Low Voltage
Cable &
Braided & POLYCAB WIRES PVT LTD INDIA A
Accessories
Flexible Cables
MECAB CABLES PVT LTD INDIA B


Supplier Name
KEC INTERNATIONAL LTD INDIA A
Low Voltage
Cable &
Braided & KEI INDUSTRIES LTD INDIA A
Accessories
Flexible Cables
Apar Industries Ltd. INDIA B
POLYCAB WIRES PVT LTD INDIA A
Low Voltage RAVIN CABLES LTD INDIA A
Cable & Cables (Up to
TORRENT Power Ltd INDIA B
Accessories 415 V) (Power /
Control) KEI INDUSTRIES LTD INDIA B
HAVELLS INDIA LTD INDIA B
KEC INTERNATIONAL LTD INDIA A
HT - Jointing / 3M ELECTRO & COMMUNICATION INDIA INDIA B
Cable & Termination kits
Accessories (6.6 KV to 33 RAYCHEM RPG PVT LTD INDIA A
KV)
GIS CABLE END SWITZERLA
Cable & PFISTERER IXOSIL AG A
TERMINATION ND
Accessories
(33 kV) RAYCHEM RPG PVT LTD INDIA B
LT - Jointing / RAYCHEM RPG PVT LTD INDIA A
Cable &
Termination kits
Accessories 3M ELECTRO & COMMUNICATION INDIA INDIA B
(415 V)
COMET BRASS PRODUCT INDIA A
Glands FLEXPRO ELECTRICALS PVT LTD INDIA A
Cable &
(Industrial &
Accessories POLYCAB WIRES PVT LTD INDIA A
Hazardous)
BALIGA LIGHTING EQUIPMENTS PVT LTD INDIA A
Cable & Optical Fibre
TE CONNECTIVITY INDIA PVT LTD INDIA A
Accessories Accessories
BAJAJ ELECTRICALS LTD INDIA A
CFL/ HPSV/ OSRAM (INDIA) PVT LTD INDIA A

HPMV Lamp/ CROMPTON GREAVES LTD INDIA A
Lighting
Fluorescent
Accessories HAVELLS INDIA LTD INDIA A
Lamps/ Metal
Hallide Lamp PHILIPS ELECTRONICS INDIA LTD INDIA A
VENTURE LIGHTING INDIA LTD INDIA A
Lighting CROMPTON GREAVES LTD INDIA A

HID Lamp
Accessories BAJAJ ELECTRICALS LTD INDIA A

Supplier Name
K L INDUSTRIES INDIA A
INDIA ELECTRIC POLES MANUFACTURING INDIA A
Lighting Streetlight /
UTKARSH TUBES & PIPES LTD INDIA B
Accessories Flood light Poles
SKIPPER LTD INDIA B
TRANSRAIL LIGHTING LTD INDIA A
Lighting BAJAJ ELECTRICALS LTD INDIA A
Lighting
(TELESCOPIC)
Accessories TRANSRAIL LIGHTING LTD INDIA B
High Masts
High Bay/ BAJAJ ELECTRICALS LTD INDIA A
Medium Bay/
Low Bay/ Tube CROMPTON GREAVES LTD INDIA A
Light fixture/ HAVELLS INDIA LTD INDIA A
Lighting
Well glass/
fixtures
Downlighter/ PHILIPS ELECTRONICS INDIA LTD INDIA A
(Non-
Office Lighting
Hazardous) LIGHTING TECHNOLOGIES INDIA PVT LTD INDIA A
Fixture/ Street
light fixture/ LED HALONIX TECHNOLOGIES PVT LTD INDIA B
& Conventional
fixture WIPRO ENTERPRISES LTD INDIA A
Lighting CROMPTON GREAVES LTD INDIA A
fixtures Landscape
PHILIPS ELECTRONICS INDIA LTD INDIA A
(Non- Lighting
Hazardous) WIPRO ENTERPRISES LTD INDIA A
LIGHT SOURCE INTERNATIONAL INDIA B
Decorative SMITA ELECTRICAL INDUSTRIES INDIA A
Lighting
Lighting (*This list is not RUBYCON ELECTRICAL & ELECTRONIC INDIA A
fixtures exhaustive and YES CHANDELIERS INDIA A
(Non- will be updated as
Hazardous) and when LIGHTALIVE SOLUTIONS PVT INDIA A
required as per
architect requrmt) GLS LIGHTING SOLUTIONS PVT LTD INDIA A
PHILIPS ELECTRONICS INDIA LTD INDIA A

Lighting
fixtures Dynamic LIGHTING TECHNOLOGIES INDIA PVT LTD INDIA A
(Non- Lighting Solution ZUMTOBEL LIGHTING GMBH AUSTRIA A
Hazardous)
WIPRO ENTERPRISES LTD INDIA A

Supplier Name
Lighting FLEXPRO ELECTRICALS PVT LTD INDIA A
fixtures Aviation Lighting
BALIGA LIGHTING EQUIPMENTS PVT LTD INDIA A
(Non- (Non-Hazardous)
Hazardous) BINAY OPTO ELECTRONICS PVT LTD INDIA B
High Bay/ Medium FCG FLAMEPROOF CONTROL GEARS INDIA A
Bay/ Low Bay/
Tube-Light FLEXPRO ELECTRICALS PVT LTD INDIA A
Lighting
Fixture/ Well- BALIGA LIGHTING EQUIPMENTS PVT LTD INDIA A
fixtures
glass/ Street light
(Hazardous)
fixture/ LED & R STAHL PVT LTD INDIA A
Conventional
fixture Hazardous FCG POWER INDUSTRIES PVT LTD INDIA A

Lighting
Aviation Lighting
fixtures BALIGA LIGHTING EQUIPMENTS PVT LTD INDIA A
(Hazardous)
(Hazardous)
BINAY OPTO ELECTRONICS PVT LTD INDIA B
Special Rubber / Special SUYOG ELECTRICALS INDIA A

Cables Cables APAR INDUSTRIES INDIA A

Manufacturer name & address INSPECTION & TEST PLAN FOR LT MOTORS
CUSTOMER :
Project : QAP No:RPMS-PROC-ITP-EL-001
Detailed Engineering Consultant : ITEM : LT Motors ; REV No.: 00
Ref.docs:RIL specification RPMS-ENGG-SPC-EL-004, FRAME SIZE: DATE: 18.03.2020
approved documents& IS reference standards Machine details: PAGE 1 OF 5
SR. COMPONENT & CHARACTERISTICS / TYPE EXTENT OF REFERENCE ACCEPTANCE FORMAT OF Inspection By
REMARKS
NO OPERATIONS CHECKS CATEGORY OF CHECK CHECK DOCUMENT NORM RECORD supplier TPIA RIL/DEC
1 2 3 4 5 6 7 8 9 10 11
1. INCOMING MATERIALS a) Overall Diameter Major Mechanical Internal stndards/ IS 13730 supplier t.c. P R R
1.1 Enamelled Copper wire b) Conductor Diameter major Mechanical - do -
c) Peel Test Major Visual - do -
d) Abrasion test Major Electrical - do -
e) Cut Through Test Major Electrical - do -
f) Breakdown Voltage @ Room Major Electrical 1sample / Reel / - do -
Temperature Bobbin
g) Elongation Major Mechanical - do -
h) Springiness Major Mechanical - do -
i)Continuity Test Major Electrical - do -
j)Mandrel winding test Major Visual - do -
k)Heat shock Test Major Thermal - do -
stamping drg/ internal standards

1.2 Stampings a) Material Criticle Mechanical supplier t.c. P R R
b)Thickness Major Mechanical - do -
c) waviness Major visual
d.) coating thickness Major Mechanical
1 Sample / Coil
e.) Burr height Major Mechanical - do -
f.) permeability Major Electrical - do -
g) Insulation resistance Major Electrical - do -
h) Vendor Identification Major Visual - do -
I ) specific Core loss Major Electrical - do -
Mfr. Drawing / internal standards

1.3 Stator Stack a) Dimension Conformity Major Mechanical sup.t.c. P R R
(Core length & Innner Diameter)
b)Slot alignment Major Visual 1sample / Lot No Mismatch
c) Deburring and Cleanliness Major Visual No Burr / Foregin Particles
Mfr. Data / internal standards
d) core loss testing Major Visual
1.4 Aluminium Die Cast a)Aluminium composition Major Chemical 1 sample / Lot supplier t.c./ IS 4026 cl. 7.1 sup.t.c. P R R
Rotor b) Free from Blow Hole & Cracks Major Visual 100% no blow holes & cracks insp.record
c.) Dimension confirmity 1sample / Lot Mfr. Drawing sup.t.c.
(core length & diameter) Major Mechanical
d) Vendor Identification Minor Visual 1Peice Mfr. Drawing insp.record
1.5 Steel Shaft rolled bar P R R
Mfr. Drg./ internal standards
a) Dimension - outside dia. Major Mechanical VQAR
b) Chemical Composition Criticle Chemical - do - VQAR
1 sample / Lot
c.) mechanical properties
( tensile strength, hardness, % elongation) Criticle Mechanical - do - VQAR
d) Flaws - ultrasoninc test Criticle Ultrasonic - do - VQAR
1.6 Bearings a) Identification - Major Visual 1 sample / Lot Manufacturer's Catalogue / - V R R
catalogue no. and clearance No rust /Scratch
1.7 End shields a) surface defects, dimension confrimity Major Mechanical 1 sample / Lot QAR / VQAR P R R
b) Chemical Composition Criticle Chemical 1 sample / Lot VQAR
c) Hardness, Tensile Strength Criticle Mechanical 1 sample / Lot Mfr. Drg. VQAR
d) Identification Major Mechanical 100% QAR / VQAR
RIL Confidential 1 of 5 RPMS-PROC-ITP-EL-001-LT Motor.xlsx

REMARKS
1 2 3 4 5 6 7 8 9 10 11
1.8 Insulating paper a) Type of paper Major Review TC 1 sample / Lot internal standards VQAR P R R
Class - F b) Thickness Major Mechanical 1 sample / Lot internal standards VQAR / QAR
(Slot Insulation) c) BDV Test after folding Major Electrical 1 sample / Lot internal standards VQAR / QAR
1.9 Varnish & resin a) Shelf life, viscosity Major Visual 100% supplier t.c./ internal standards VQAR P R R
b.) viscosity Major Ford cup 1 sample / Lot - do -
b) Type Major Visual 100% - do - VQAR
2.0 Stator Frame a) surface defects, Dimension Major Mechanical 1 sample / Lot Mfr. Drg. VQAR P R R
c) Hardness, Tensile Strength Criticle Chemical 1 sample / Lot VQAR
d) Identification Major Visual 1 sample / Lot VQAR
2.1 Terminal Box a) surface defects ,Dimension Major Mechanical 1 sample / Lot Mfr. Drg. VQAR P R R
c) Hardness, Tensile Strength Major Mechanical 1 sample / Lot VQAR
d) Identification Criticle Mechanical 1 sample / Lot VQAR
2.2 Bearing Covers a) surface defects, Dimension Major Mechanical 1 sample / Lot Mfr. Drg. VQAR P R R
c) Hardness, Tensile Strength Major Mechanical 1 sample / Lot VQAR
d) Identification Criticle Mechanical 1 sample / Lot VQAR
2.3 Terminal Plate a) IR test before and after water
Major Electrical 1 sample / Lot VQAR P
immersion Mfr. Drg. R R
b) H.V. test Major Electrical 1 sample / Lot VQAR
2.4 cooling Fans a) Dimension Major Mechanical 1 sample / Lot QAR / VQAR P R R
b.) protective paint Major visual 1 sample / Lot Mfr. Drg.
c) Identification Major Mechanical 100% QAR / VQAR
2.5 Space heater a) IR Major Electrical 1 sample / Lot VQAR P R R
b) HV test Major Electrical 1 sample / Lot supplier t.c./ internal standards VQAR
c) Continuity & Wattage check Major Electrical 1 sample / Lot VQAR
2.6 RTD a) HV Test Major Electrical 100% VQAR P R R
b.) resistance Major Electrical 100% supplier t.c./ internal standards
b) IR Major Electrical 100% VQAR
2.7 Thermistors a) HV Test Major Electrical 1 sample / Lot VQAR P R R
b.) resistance Major Electrical 1 sample / Lot supplier t.c./ internal standards
b) IR Major Electrical 1 sample / Lot VQAR
INPROCESS INSPECTION :
winding specification/ internal
3.0 Wound Stator a) High voltage test Major Electrical 100% standards QAR
b) Insulation Resistance. Major Electrical 100% - do - QAR
before and after HV
c)Partial Discharge Inception P R R
- do -
Voltage (PDIV) on Motor Insulation Major Electrical 100% QAR
d) Surge Test Major Electrical 100% - do - QAR
e) Winding Resistance Major Electrical 100% - do - QAR
per phase.
3.1 Rotor ISO 1940/G
a) Dynamic Balancing Major Mechanical 100% ISO 1940/G 2.5 QAR
Balancing 2.5
Mfr.
b) Rotor OD runout with respect to
Major Mechanical 1 Sample/Frame Specificatio Mfr. Specification QAR
Bearing step
n
c)Vaccum Impregnation and
Major visual 100% QAR P R R
Bracing of Winding
d)Core Assembly Major Measurement 100% QAR
ISO 1940/G
e)Rotor bar and ending assembly ISO 1940/G 2.5
2.5
Major visual 100% VQAR

REMARKS
1 2 3 4 5 6 7 8 9 10 11
a) Terminal Box Location , blow Mfr.
3.2 Assembled Motor holes, gasketting ,mounting& Minor Visual 100% Specificatio Mfr. Specification QAR
b) Phase marking Identification major Visual 100% Mfr. Drg Mfr. Drg QAR
in terminal box
c) Greasing & Earthing arrangement Minor Visual 100% Mfr. Drg Mfr. Drg QAR
d) Accessories fitment Minor Visual 100% Mfr. Drg Mfr. Drg QAR
(Cable glands,RTD/BTD,
P R R
Space Heater assy, PTC) &
Completeness.
Coplanar tolerance <

e)measurement of Co planer 0.127 mm to be
major Mechanical 100% Mfr. Drg Mfr. Drg QAR
tolarance maintained for atleast
80% of the contact
area of the foot
Approved Datasheet / Shade
3.3 Painting a) Paint Shade Major Visual 100% card. QAR P W W
b) paint Thickness Major Mechanical 1 per lot /frame Mfr. specification QAR P W W
4.0 FINAL TESTING
A ROUTINE TEST P W W
a)Resistance of stator winding and
space heater Major Electrical As per contract QAR P W W
* Routine test shall be
b)Insulation resistance before and Major Electrical (10 % to 20 % of QAR P W W
offered for customer
after stator winding H.V. Test. the batch offered
witness as per order
c)High Voltage Test on stator based on the lot
requirement.
winding Major Electrical size) QAR P W W
d)No load test at rated voltage. Major Electrical QAR P W W
e)Reduced voltage running Major Electrical QAR P W W
at no load.
IS : 12615/ IEC: 60034 / motor
f) direction of rotation and phase data sheet,design data / Mfr.
sequence Work instructions
g)Vibration measurement on no Major Mechanical QAR P W W
load at rated Voltage & frequency
h)Locked rotor test at suitable
reduced voltage Major Electrical QAR P W W
i) insulation resistance and High
Voltage test of space heaters , &
Major Electrical QAR P W W
Resistance of Thermistors & RTD
j) Shaft Voltage measurement Major Electrical QAR P W W

k)Noise Level test Major Electrical
l)measurement of coplanar
Major Mechanical QAR P W W
tolerance (soft foot)
B Visual checks 1. Name plate verification.
(RIL Tag No., IP requirement,
Earthing locations, terminal
box,cable entries,enclosures
regressing facilities , lubrication Approved Approved data
and greasing facility.) Provide Major Visual 100% QAR P W W
data sheet. sheet.
proper size of connectors in MTB
for cable connection based on the
cable size mentioned in datasheet.
Approved
2. Dimensional Check. Major Machanical 1 sample/lot /frame Approved Drg. QAR P W W
Drg.

REMARKS
1 2 3 4 5 6 7 8 9 10 11
4.1 TYPE TEST

a)Resistance of stator winding. Major Electrical 1sample/rating QAR P W W
b)Insulation resistance before and Major Electrical 1sample/rating QAR P W W
after H.V. Test of stator winding and
space heater ckt
c)Measurement of starting torque,
starting current, full load torque, Major Electrical 1 sample/rating
breakdown torque
Type test shall be
d)High Voltage Test after heat run test Major Electrical 1sample/rating QAR P W W carried out as per
e)No load test at rated voltage. Major Electrical 1sample/rating QAR P W W order requirement.
f)Reduced voltage running Major Electrical 1sample/rating QAR P W W
at no load. W
g)Locked rotor test Major Electrical 1sample/rating QAR P W W
h)Vibration measurement Major Mechanical 1sample/rating QAR P W W
i)Noise level during no load run test Major Mechanical 1sample/rating QAR P W W
j)Temperature Rise Test Major Electrical 1sample/rating QAR P W W

k) Momentory Overload test at 160% IS : 12615/ IEC: 60034 / motor
of rated load or rated current for 15 data sheet
sec.
Major Electrical 1sample/rating QAR P W W
l) measurement to calculate Pull
Out Torque
m) measurement to calculate
Efficiency, power factor and slip at
100%, 75%, 50% load.
n) measurement to calculate
Starting torque and starting
current. Major Electrical 1sample/rating QAR P W W
n)String test for Motor (VFD driven)
shall be tested at 10%, 60%, 80%
and 100% speed along with the
corresponding load as per Load-
speed curve.
p)Overspeed Test at 120% of rated
speed for 2 min. Major Electrical 1sample/rating QAR P W W
Additional Quality a.) v- seal arrangement on DE/ NDE

checks side
b.) check of correct direction,
proper tighning and design of
cooling fans (external / internal)
c.) check provision of
accelerometer/ proximitor probe as
per site requirement.
d.) All the quality issues like
dislodging of flinger over shaft,
poor motor body casting and end Major Mechanical 100% IS/IEC 60034-5/Motor Data sheet QAR P W W
shields, looseness of connectors in
MTB and NTB, crack in flingers,
IBCs, poor gasket fitments are
taken care
.e)Bearing fitment tolerances w.r.t
bearing bracket bore, bearing size
(DE/NDE side as per design), Fixing
of IBC, OBC at correct position.

REMARKS
1 2 3 4 5 6 7 8 9 10 11
Submission of certificates as
applicable:
5 Statutory approvals
a.)CMRI/ ERTL/PESO/BIS for type
"Ex ec", and "Ex eb" & Ex(d) Certificate from
motors IS/IEC 60034-5/Motor Data sheet statutory P R R
b)Encloser degree of proctection authority.
Major Visual 100%
case marking
6 Despatch instructions visual 100% P
Manufacturing order Mfr. order
Documents for submission: 1)MTCs , rotor balancing, soft foot & Routine test certificates for all motors 2) Type test reports 3) IP test ,PESO/CIMFR certificates as applicable
Note:This is Indicative ITP of LT motors to cover all major stages in line with Data sheet,Relevant MR and Drawings .Vendor shall make their own ITP separately in line with this and submit for approval.
LEGEND: PREPARED BY CHECKED BY APPROVED BY
QAR : QA record VQAR : vendor QA record
P : PERFORM W: WITNESS R : REVIEW OF DOCUMENT V : VERIFY
Rev:00 Dt:18-03-2020 Revision Details:Issued for Implementation PRADEEP CHINTA PARTHA DAS TUSHAR MUKHERJEE

Manufacturer name & INSPECTION & TEST PLAN FOR HT MOTORS
Customer :
address
Project : ITEM : HT Motors ; QAP No:RPMS-PROC-ITP-EL-002
Detailed Engineering Consultant : KW, poles, KV, frame size REV No.: 00
Ref.docs. : RIL specification RPMS-ENGG-SPC-EL-
DATE: 18.03.2020
03,approved documents Quantity :
& IS/ IEC reference standards
supplier t.c.s
supplier t.c.s
RIL Confidential 1 of 3 RPMS-PROC-ITP-EL-002-HT Motor

R
MANUFACTURER
PREPARED BY CHECKED BY APPROVED BY
SIGNATURE : PERFORM : WITNESS R : Review of document
Rev:00 Date:18-03-2020 Revision Details:Issued for implementation PRADEEP CHINTA PARTHA DAS TUSHAR MUKHERJEE

INSPECTION & TEST PLAN FOR VFD/VSD
SUPPLIER'S NAME & ADDRESS : CUSTOMER :- RELIANCE
P.O. NO : RPMS-PROC-ITP-EL-020
INDUSTRIES LIMITED
PROJECT:- P.O. Item no. REV. NO:- 00 , Dt:24:02:2020
Detail Engineering
P.O. item tag no. :
Contractor(DEC):-
INSPECTION CLASS
Reference Docs:-RIL Speccification RPMS-ENGG-SPC-EL-029,Aproved Datasheet,GA
Drawing,Material Requistion,IS&IEC Standards.
Type of Reference
Sl.No Component & Operations Characteristics Extent of Check Acceptance Norms Format of Records INSPECTION BY Remarks
Check Document
vendor TPIA RIL/DEC
After review of
Minutes of
I PRE-INSPECTION MEETING & Approval of CV of Third party inspection Surveyor H H H first set of major
meetings/CV
documents.
Weld Map,WPS/PQR/WPQ, NDE PROCEDURES( PT,UT,RT, MPT),PROCEDURE FOR CASTING WELD

II REPAIR,HYDRO,PMI,FUNCTIONAL AND PERFORMANCE,SURFACE PREPARATION & PAINTING,PACKING & Procedures P R H
SHIPPING,PRESERVATION & STORAGE.
Type of Reference
Sl.No Component & Operations Characteristics Extent of Check Acceptance Norms Format of Records Remarks
Check Document
Electromechanical
III
Components :
Visual Relevant purchase drawings and / or

1 Thermal overload relay Visual manu.t.c. V R R
Functional Manufacturer data sheet/IS 13947
Type/Marking
Visual/ Relevant purchase drawings and / or Review of supplier
2 Control transformer 100% manu.t.c. V R R
Functional Electrical Manufacturer data sheet/IS 12021 TC
Type
Visual/ Relevant purchase drawings and / or
3 Contactors 100% manu.t.c. V R R
Configuration Electrical Manufacturer data sheet/IS 13947
Rating ,Mounting
dimensions Visual/ Relevant purchase drawings and / or
4 Fuse fitting 100% manu.t.c. V R R
Electrical Manufacturer data sheet/IS 13703
high voltage
Rating ,dimensions
Visual/ Relevant purchase drawings and / or
5 HRC Fuse Links 100% manu.t.c. V R R
Continuity Electrical Manufacturer data sheet
Dimensions
Relevant purchase drawings and / or

6 Lamp Holder Make visual 100% manu.t.c. V R R
Manufacturer data sheet/IS 4795
Colour
7 Pilot Lamp Rating visual 100% manu.t.c. V R R
Manufacturer data sheet/IS 4795
Make
Type
Push button with contact Colour visual/ Relevant purchase drawings and / or
8 100% manu.t.c. V R R
elements Functional electrical Manufacturer data sheet/IS 6875
Make
Type
visual/ Relevant purchase drawings and / or
9 Switch Fuse Unit Functional 100% manu.t.c. V R R
electrical Manufacturer data sheet/IS 13947
HV Test
Rating
10 Lamp visual 100% manu.t.c. V R R
Make Manufacturer data sheet
Type of Reference
Check Document
vendor TPIA RIL/DEC
Type
visual / Relevant purchase drawings and / or
11 Switch / Rotary switch Rating 100% manu.t.c. V R R
electrical Manufacturer data sheet /IS 13947
Functional
Rating
Polarity visual / Relevant purchase drawings and / or Review of supplier
12 Current Transformer 100% manu.t.c. V R R
Functional electrical Manufacturer data sheet / IS 2705 TC
HV test
Type visual /
13 Terminal Block electrical/ 100% manu.t.c. V R R
Dielectric-strength Manufacturer data sheet
measure
Type visual /
14 Auxiliary Relays electrical/ 100% manu.t.c. V R R
Functional Manufacturer data sheet/ IS 13947
measure
Type visual /
15 Breakers electrical/ 100% manu.t.c. V R R
Functional Manufacturer data sheet /IS 13947
measure
IV Measuring instruments :
Rating visual /
Voltmeter / Ammeter / MFM / Relevant purchase drawings and / or Review of supplier
1 Functional electrical/ 100% manu.t.c. V R R
VAF meter Manufacturer data sheet /IS 1248 TC
Make measure
visual /
Relevant purchase drawings and / or Review of supplier
2 Speedometer -do- electrical/ 100% manu. T.c. V R R
Manufacturer data sheet TC
measure
V Fabrication, Hardware & Assembly :

Raw material
Dimensions
Surface Levels visual/ Relevant purchase drawings and / or

1 Fabrication 100% test report V R R
measure Manufacturer data sheet
Welding
Bending
Finish
Thickness
Adhesion
Shade thickness Relevant purchase drawings and / or
Type of paint tester,scratch Manufacturer data sheet / shade cards as
2 Painting / Powder coating 100% test report V R R
Surface defects tester,visual, per approved drawings/RAL paint shade
Surface finish salt sparay test card
Masking
Life of paint surface
Dimensions
Type of material Relevant purchase drwgs and / or
3 Hardware Major 100% manu. T.c. V R R
Manufacureer data sheet
Finish
Type of material
Relevant purchase drwgs and / or
4 Insulator Major 100% manu.t.c. V R R
Dimensions Manufacureer data sheet
Type
visual/
Thickness Relevant purchase drwgs and / or
5 Plating measure/burnis 100% manu.t.c. V R R
Adhesion Manufacureer data sheet
hing/visual
Finish
Type of Reference
Check Document
vendor TPIA RIL/DEC
VI VARIABLE SPEED DRIVE :
a.) Visual Inspection visual 100% App GAD P W W
Completeness ,
Labelling,(components,
panel) shrouding
b.) BOM Check : visual 100% App BOM P W W
Make ,
Rating , App GAD P W W
Mounting
c.) Wiring checks,
neatness of wiring
and accessibility &
App AGD p W W
adequacy of
space for external wiring
termination visual/
100%
electrical
Size ,Colour code,Feruling

,Continuity, Earthing App AGD P W W
(floating)
d.) Insulation level test

test report P W W
(Before & After HV)
Power circuit ,Control electricle 100%
circuit (As per control test report P W W
Logic)
e.) HV Test electrical 100% test report P W W
f.) Operational &
test report P W W
Functional tests
Checking Functioning Of
Auxiliary as per RIL approved Factory
test report P W W
Devices & Control Acceptance Test procedure
Equipments /specification/data sheet /IEC 61800-
2/IEC 61800-4
Checking of Protective
test report P W W
device
Check of Speed at
different frequency at 100%
test report P W W
various mode as
applicable.
Leakage test and
pressure test for cooling test report P W W
system, if provided.
Checking Functioning Of
AC Variable test report P W W
Frequency Drive
g.) Light Load Test with

Fractional HP 100% test report P W W
Motor.
h.) No Load Functional

test With test field AC test report W W
Motor
i.)Observed Min & Max

test report W W
speed*
100%
ii.) Response W W
iii.) Protection
iv.) Interlocks , simulation
i.) interchangeability physical

Type of Reference
Check Document
vendor TPIA RIL/DEC
TYPE TESTS :
Full load test
Heat run test

Noise Test
Dynamic performance test
as per RIL approved Factory Acceptance

Current sharing & Voltage
Efficiency ,Power factor electrical sample Test procedure /specification/data sheet test report P W W
division (for Special rating).
/IEC 61800-2I/EC 61800-4
String test (includes VFD, Motor

& Driven equipment)
power loss measurement
EM Emmision
VIII OTHER TESTS
Acceleration/deceleration test
1 P W W
using a simulated load
2 Inverter current limiting P W W
measurement of ripple voltage

3 P W W
and current
4 measurement of power factor P W W
5 overcurrent capability P W W
as per RIL approved Factory Acceptance
Input and output voltage Electrical sample Test procedure /specification/data sheet test report
measurements/analysis at 50% /IEC 61800-2/IEC 61800-4
6 P W W
and 100% load (one of each
rating)
7 Harmonics Measurement P W W
8 Operation of all equipment P W W
9 Paint Shade &Thickness P W W
10 IP Ratinng P R R
visual
IX Readiness of shipment : Packing & Marking
examination
100% As per Purchase Order & MR P P R --- _ --
NOTE : This is Indicative ITP of VSD/VFD cover all major stages in line with RIL Specifications,Data sheet,Relevant MR and Drawing, Vendor shall make their own ITP separately in line
with this along with Factory Acceptance Test procedure and submit for approval.
P = Perform PREPARED BY
W = Witness TPIA = THIRD PARTY INSPECTION AGENCY
R = Review RIL = RELIANCE INDUSTRIES LTD
V : Verify DEC = Detail Engineering Contractor
PRADEEP CHINTA
H= Hold
Rev:00 Dt:24.02.2020 Revision Details:Issued for Implementation
Design Basis for Control and Instrumentation

RPMS-ENGG-DBD-CI-001
0 17.08.2020 Issued for Implementation SYD URJ JKK/VKM

By By By
Reliance Project Management System RPMS-ENGG-DBD-CI-001
Design Basis for Control and Instrumentation Date: 17.08.2020, Rev. 0

(DD.MM.YYYY)
1 Mr. Jatindar Khushu_____________ _________________ ___________
Mr. Jagdish Gupta _______ _________________ ___________

2
Mr. Rajkumar Ghosh ___________ _________________ ___________

3
Mr. Kuddallur Seshadri__________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number
Contents
1. Purpose...................................................................................................................... 6
2. Scope ......................................................................................................................... 6
3. Cost Competitive Engineering and Design ................................................................ 6
4. References ................................................................................................................. 6
5. Conflicts and Deviations .......................................................................................... 10
6. Abbreviations and Definitions ................................................................................. 10
7. Units of Measurements........................................................................................... 12
8. Environmental Conditions ....................................................................................... 13
9. Basic Selection Criteria for Field Instruments ......................................................... 13
10. Power Supply for Control Systems and Field Instruments ..................................... 17
11. Pneumatic Requirements ........................................................................................ 21
12. Explosive Hazard Protection and Intrinsic Safety ................................................... 22
13. Protection from the Environment ........................................................................... 22
14. Connection Size and Types ...................................................................................... 23
15. Spare Philosophy ..................................................................................................... 28
16. Instrument Component Identification Philosophy ................................................. 30
17. Painting.................................................................................................................... 37
18. Instruments on Utility lines at plant B/L ................................................................. 38
19. Control Philosophy .................................................................................................. 38
20. Fibre Optic Cable ..................................................................................................... 41
21. Datasheets ............................................................................................................... 42
22. Pressure Instruments .............................................................................................. 43
23. Temperature Instruments ....................................................................................... 45
24. Level Instruments .................................................................................................... 47
25. Flow Instruments..................................................................................................... 49
26. Range and Span of Analogue Instruments .............................................................. 52
27. Diaphragm Seals ...................................................................................................... 52
28. Fill Fluid for Diaphragm Seal ................................................................................... 53
29. Seal / Condensate Pot ............................................................................................. 53
30. Vortex Cooler .......................................................................................................... 54
31. Solenoids ................................................................................................................. 54
32. Corrosion Protection ............................................................................................... 54
33. Oxygen Service ........................................................................................................ 54
34. Instrument Panels Alarms ....................................................................................... 54
35. Instrument Panels ................................................................................................... 55

36. Instrumentation Cable ............................................................................................ 59
37. Junction Boxes ......................................................................................................... 61
38. Hook-ups ................................................................................................................. 62
39. Inspection, Testing and QA / QC ............................................................................. 64
40. Accuracy and Repeatability ..................................................................................... 64
41. Earthing System....................................................................................................... 65
42. Construction ............................................................................................................ 66
43. Instrument Piping and Tubing ................................................................................. 67
44. Control Buildings ..................................................................................................... 68
45. Automation Tools .................................................................................................... 69
46. Calculations ............................................................................................................. 69
47. Documentation ....................................................................................................... 70
Appendix-01: Codes and Standards .................................................................................. 75
Appendix-02: Flow Meter Selection Guide ....................................................................... 93
Appendix-03: Level Instrument Selection Guide .............................................................. 94
Appendix-04: Typical Schematic for Remote Operated Valve (ROV) ............................... 95
Appendix-05: Details for Close Coupled Hook-up............................................................. 96
1. Purpose
The purpose of this design basis is to define the general design requirements for
Control Systems and Instrumentation. It also provides guidelines for design, selection
and preparation of detailed specification for Control Systems and Instrumentation.
This document shall be used by the Design Engineering Contractor as technical
baseline for all Control Systems & Instrumentation work on the project.
2. Scope
The scope of this document is to set the minimum requirements for design and detail
engineering requirements for various Control systems and field Instruments. This
document shall be applied to all Reliance group companies, and thereby achieve
maximum technical and economic benefit from standardization
Individual design requirements and constraints of any particular process facility are
outside the scope of this design basis.
3. Cost Competitive Engineering and Design
The Detail Engineering Contractor team shall maintain the cost focus throughout all
phases of the project. This should be done without compromising any specification
and design requirements.
4. References
All design, materials, construction and performance shall conform to the latest
revision or addendum of relevant national and international codes and standards
including, but not limited to detailed in Appendix-01.
4.2. RPMS Standards
All equipment and accessories covered by this specification shall comply with latest
revision of below RPMS standards and documents & drawings forming part of the
material requisition, as applicable
a) RPMS Design Basis Documents:
Document Number Document Name
RPMS-ENGG-DBD-CI-002 Design Basis for SPI Implementation
RPMS-ENGG-DBD-CI-003 Design Basis for Foundation Fieldbus
Design Basis for Control System and Electrical
Interface
Design Basis for Instrument Piping and Tubing
Material
Functional Safety Management For Safety
Instrumented System
RPMS-ENGG-DBD-CI-007 Design Basis for Fire and Gas System

RPMS-ENGG-DBD-CI-008 Withdrawn
RPMS-ENGG-DBD-CI-011 Design Basis for Cyber Security
Design Basis for Instrument Components - Stock
Catalogue Index
Design Basis for On-line Continues Corrosion
measurement
b) RPMS Standard Specifications:

RPMS-ENGG-SPC-CI-001 Standard Specifications for Instrumentation
Standard Specifications for Instrumentation
RPMS-ENGG-SPC-CI-002
Requirements for Package Units
Standard Specifications for Programmable Logic
Controller
RPMS-ENGG-SPC-CI-004 Standard Specifications for Control Valves
RPMS-ENGG-SPC-CI-005 Standard Specifications for Safety Relief Devices
Standard Specifications for Isolation / Shutdown
Valves
Cable
RPMS-ENGG-SPC-CI-008 Standard Specifications for Fire and Gas System
RPMS-ENGG-SPC-CI-009 Standard Specifications for Process CCTV System
RPMS-ENGG-SPC-CI-010 Standard Specifications for Analyzer Package
Standard Specifications for Machine Condition
Monitoring System
Standard Specifications for Custody Transfer
Flow Metering
Standard Specifications for Continuous Emission
and Effluent Monitoring System (CEEMS)
Standard Specifications for Emergency
Shutdown System
Standard Specifications for Automatic Tank
Gauging System
Installations
Standard Specifications for Distributed Control
Systems (DCS)
Standard Specifications for Steam and Water
Analysis System (SWAS)

RPMS-ENGG-SPC-CI-020 Standard Specifications for Analysers

Standard Specifications For BMS (Building
management system)
Standard Specifications For Building Fire Alarm
System
c) RPMS Guidelines:
RPMS-ENGG-GUD-CI-001 Guideline for Wireless Technology Application
RPMS-ENGG-GUD-CI-002 Withdrawn
RPMS-ENGG-GUD-CI-003 Guideline for Nucleonic Instruments
RPMS-ENGG-GUD-CI-004 Guideline for Compressor Control System
Guideline for Revision of Manufactured Tagged
RPMS-ENGG-GUD-CI-005
Instrument
Guideline for Engineering Clearance of
Instrumentation Items
iRPMS-ENGG-GUD-CI-007 Guideline for Audit Checklist
Guideline for Control & Instrumentation Check
iRPMS-ENGG-GUD-CI-008
Lists
RPMS-ENGG-GUD-CI-009 Guideline for Control Buildings
Guideline for Centralised systems I/O count
format
Guideline for Material Issue Procedure for Inline
iRPMS-ENGG-GUD-CI-011
Instruments
RPMS-ENGG-GUD-CI-012 Guideline for SPI Instrument Index
RPMS-ENGG-GUD-CI-013 Guideline for Wiring & Loop Generation in SPI
RPMS-ENGG-GUD-CI-014 Guideline for Hook-Up Generation in SPI
RPMS-ENGG-GUD-CI-015 Guideline for Process Data Entry in SPI
RPMS-ENGG-GUD-CI-016 Guideline for Accessing SPI thru VPN
Guideline for Generating Deliverable in PSR
Format
RPMS-ENGG-GUD-CI-018 Guideline for SPI Integration
RPMS-ENGG-GUD-CI-019 Guideline for SPI Dimensional Data for Piping
RPMS-ENGG-GUD-CI-020 SIL Verification- Basis and Assumptions
Guideline for Approved Vendor List-Control &
Instrumentation
RPMS-ENGG-GUD-CI-022 Guideline for Control Hazard and Operability
Study
RPMS-ENGG-GUD-CI-023 Guideline for Safety Requirements Specification
(SRS)

d) RPMS Standard Drawings:
RPMS-SD-J55-XXX Instrumentation Hook-ups

RPMS-SD-J10-XXX Standard Drawings
e) RPMS Cross Discipline Documents:

RPMS-ENGG-DBD-PS-001 Basic Engineering Design Data

Project Specific Basic Engineering Design Data
RPMS-ENGG-DBD-CS-007 Design Basis for Plant Interface Building
RPMS-ENGG-SPC-PP-004- Standard Specification For Piping Component
Part I to VI
RPMS-ENGG-SPC-PP-038 Piping Material Class Details
Part I & II
RPMS-ENGG-DBD-ST-004 Design Basis for Pipe Support
RPMS-SD-P14-022 Level Instrument Connection Details
RPMS-SD-P14-027 Vent Drain & instrument Connections Hydrostatic
Drains
RPMS-SD-P14-171 Close Coupled Hook-Ups (CCH) Pressure
Connections
RPMS-SD-P14-110 Details of Pressure connection
RPMS-SD-P14-171 Piping - Standard Drawing for CCH Pressure
Connections
RPMS-ENGG-SPC-EL-022 Standard Specification for LV Power and Control
Cable
RPMS-ENGG-SPC-EL-012 Standard Specification for Fiber Optic Cable
RPMS-ENGG-SPC-EL-023 Standard Specification for Grounding & lightning
protection system
Instrument Junction Box For Intrinsically Safe (IS)
RPMS-SD-E12-005
Circuit Schedule and Arrangement
Instrument Junction Box Schedule And
RPMS-SD-E12-009
Arrangements
Electrical Installation Standard for Field Run Earth
RPMS-SD-E12-195
Connection to Instruments
RPMS-SD-E12-196
RPMS-SD-E12-197
RPMS-ENGG-SPC-MT-004 Welding and Welding procedure qualification
requirements for suppliers
f) RPMS Inspection and Test Plans
RPMS-PROC-ITP-CI-XXX Inspection and Test Plans

In the event of conflict or deviation from requirements stipulated in this document
and other applicable documents, the following order of precedence shall govern:
c) This Design Basis
Latest revisions of codes and other statutory requirements as applicable at the time of
enquiry, shall be applicable. In case of any conflict, the decision of owners engineer in
charge shall be final and seller shall implement that without any commercial
implications. All “local and statutory requirements as applicable shall be complied to
without any deviation”.
Notes: “Material Requisition” represents Material Requisition for Quotation,

Abbreviations
AC Alternating Current
AL/HDPE/PA Aluminium / High Density PolyEthylene / PolyAmide (nylon)
AMS Asset Management System
APC Advance Process Control
ATEX ATmosphere EXplosibles
ATG Automatic Tank Gauging
CCH Close Coupled Hook-ups
CCOE Chief Controller Of Explosives (India)
CCR Central Control Room
CCTV Closed Circuit Television
CPCB Central Pollution Control Board
CS Collective Screen (overall screen)
DC Direct Current
DP Dye Penetrant Test
EM Electro magnetic
ESD Emergency Shutdown System
FF Foundation Fieldbus

FOC Fibre Optic Cable

FRP Fibre Reinforced Plastic
F&G Fire and Gas
HART Highway Addressable Remote Transducer
HAZOP Hazard and Operability
HMI Human Machine Interface
HVAC Heating, Ventilation and Air Conditioning
IP Ingress Protection
IRP Interposing Relay Panel
IS Intrinsically Safe
ITK Interoperability Test Kit
I/O Input / Output
LCD Liquid Cristal Display
LSD Large Screen Display
LSLH Low Smoke Low Halogen
MCC Motor Control Centre
MCMS Machine Condition Monitoring System
MCT Multi Cable Transit
MTO Material Take-Off
MOC Material of Construction
MP Magnetic Particle Test
MPMS Manual of Petroleum Measurement Standards
MUX Multiplexer
NPT National Pipe Thread
OD Outside Diameter
O’s and U’s Offsite and Utilities
P&ID Process & Instrumentation Diagram
PA Public Addressing
PE Polyethylene (used as conductor insulation or inner sheathing)
PESO Petroleum and Explosives Safety Organization (India)
PIB Plant Interface Building
PSU Power Supply Unit
PCV Polyvinyl Chloride
PVC Polyvinyl chloride
RTD Resistance Temperature Detector
SCN Screen
SFER Shift Field Executive Room
SIL Safety Integrity Level
SOV Solenoid Valve

SPCB State Pollution Control Board

SPI Smart Plant Instrumentation
SWA Steel wire armouring
UPS Uninterruptible Power Supply
VAC Voltage Alternate Current
VDC Voltage Direct Current
General Definition
Owner Reliance Industries Ltd.

Detail Engineering The party which carries out detailed design engineering
Contractor (DEC) services.
The Manufacturer / Supplier is the party which manufactures
Manufacturer /
or supplies equipment and services to perform the function
Supplier
as specified by DEC / Owner.
7. Units of Measurements
Quantity Unit Abbreviation
Acceleration meter per sec square m/s2
Amount of Mole mol
Substance
Area Square meter m2
Concentration Parts per million PPM
Concentration Parts Per Billion PPB
Conductivity Micro Siemens µS
Corrosion Mils penetration per year, it equals to MPY
one thousandth of an inch.
Micron per year μmpy
mm per year mmpy
one ten-billionth of meter per year for Angstrom
very low corrosion measurement e.g.
environmental corrosion monitoring.
Density Kilograms per cubic meter kg/m3

Electrical current Ampere A
Energy - electrical kilowatt hour kWh
Flow - liquid cubic meter per hour m3/Hr
Flow - gas and vap actual cubic meters per hour Am3/Hr
Flow - gas and vap normal cubic meters per hour Nm3/Hr


Flow - steam Kilogram per hour or Tonnes per hour Kg/Hr or Ton/Hr
Force Kilogram force Kgf
Heat Kilocalorie Kcal
Length Millimetre mm
Length Metre M
Length Kilometre Km
Level Percentage %
Mass Kilogram Kg
Mass Tonne te or t
Molecular weight kilogram per kilogram mole Kg/mol
Percentage Percentage %
Power Kilowatt kW
pH PH pH
Pressure – (gauge) Kg/cm2 gauge Kg/cm2 g
Pressure – Kg/cm2 Absolute Kg/cm2 a
(Absolute)
Pressure (Vacuum) Millimetre in mercury mmHg
Production metric tons per year Te/y or T/y
capacity
Speed (linear) meters per second m/s
Speed (rotating) revolutions per minute RPM
Radioactivity Becquerel or millicurie Bq or mCi
Temperature degree Celsius C
Time Hour hr
Viscosity (dynamic) Centipoise Cp
Vibration Micrometers µm
Volume Cubic meter m3
Voltage Volt V
8. Environmental Conditions
Environmental conditions (Climate condition & Meteorological) for all field
installations shall be as per project specific “Basic Engineering Design Data "
9. Basic Selection Criteria for Field Instruments
a) All field mounted instrumentation and associated equipment shall in all respects
be suitable for reliable and continuous operation in service conditions stated in the
project specific “Basic Engineering Design Data” and respective datasheet.
Instruments shall be able to withstand the solar radiation and temperatures as
given in the “Basic Engineering Design Data”. Instruments shall be designed to
withstand the salt laden costal atmosphere and marine conditions.

b) The design requirements for each type of instruments are covered by the individual
standards and specifications.
9.1. Materials of Construction
a) Inline Instrument
Reference shall be made to the project piping specification for inline Instrument
Material of Construction, including instruments subject to stress, corrosion,
cracking, “Sour” or “Wet H2S” services. Wherever applicable, field instrument
specifications shall be according to NACE standards. Where inline instruments are
made from a material with lower tensile strength than the piping material, e.g.
stainless-steel flow meters in carbon steel lines, then the design conditions shall
be checked to make sure the instrument flange rating is suitable.
b) Offline Instrument
Material of Construction of wetted part shall be compatible with process fluid and
process conditions as specified in Instrument datasheets.
c) Material of Construction of Instrument enclosures / housing shall be as per
manufacturer standard subject to suitability of Hazardous Area Classification and
environment conditions of the plant, especially when corrosive environment e.g.
Chlorine etc. is present in plant.
d) All Electronic / Electrical equipment shall have CE marking and certification.
9.2. Selection of Instruments
a) All instruments and associated items shall be of heavy-duty industrial type and be
suitable for use in the stated environment.
b) Aluminium and aluminium alloys shall be avoided. Where use of such alloys cannot
be avoided the equipment shall be epoxy / polyurethane coated and meet the
requirements of the stated environmental condition and hazardous area
classification.
c) No transmitters shall be shared between DCS and ESD.
d) All field Instrument (HART & FF) devices shall comply with NAMUR NE 107 for self-
monitoring and Diagnosis functions. All FF device shall be FDI compatible and
certified.
e) Each type of HART and FF analogue device with diagnostic and error mapping as
per NAMUR NE107 shall be made available at DCS supplier location for
interoperability test.
f) The ranges of all pressure and temperature gauges shall be standardized.
g) Prior approval from owner shall be obtained for use of Process Switches. Switch if
used, the contact shall be Hermitically Sealed or coated with anti-corrosive coating
h) Pneumatic transmitters shall not be used.

9.2.1. Input Requirements to SIF

a) The input signals to shutdown systems shall originate from:
 Discrete hard-wired and Software configured switches as direct, normally
closed inputs into the ESD logic
 Smart digital or analogue transmitter(s)/ transducer(s) with HART protocol
utilizing a 4-20 mA DC output current.
b) Each field instrument or device utilized as an ESD input shall have a separate and
distinct process connection (i.e. separate from a process control instrument), and
shall not be associated with process control or monitoring functions except in the
following situations:
 In the case of a differential pressure element (e.g. orifice) a transmitter used
for ESD service may be installed in parallel with a process control
measuring/alarm element (using separate isolation valves) or branching off a
different set of process taps originating from the same primary element
provided at orifice flange level.
 Where 2oo3 input voting arrangement is required for ESD function and the
same input is required for BPCS. Four transmitters shall be connected to same
orifice assembly with two sets taping and making a common header, one for
High Pressure side taping and second for Low pressure side taping, refer to the
hook-up details defined on RPMS-SD-J55-033A.
 Analogue or discrete ESD signals may be communicated to an external control
system by way of a hard-wired output, a signal isolator or approved data
highway connection. These ESD signals may be used to validate the health of
the ESD device or for data reconciliation purposes between ESD and regulatory
control/monitoring instruments.
c) A single analogue (or 'Smart' digital) transmitter with ‘HART’ protocol may be used
to provide both a Low-Low (LL) and High-High (HH) ESD input signal for applications
requiring both HH and LL measurements provided that the transmitter's calibrated
range spans both LL and HH set-points and that measurement accuracy is not
degraded. Where HH and LL SIFs share sensors then both of the following shall not
be true:
 Spurious failure of the sensor subsystem in one direction (e.g., LL) results in a
demand on the other SIF (e.g. HH)
 Output actions for HH and LL SIFs are different
d) The selection, application and installation of ESD input and output devices shall be
performed in such a manner as to ensure that they meet specified process
parameters, environmental conditions, and can be monitored and tested on-line
or in-service. (Note: Emphasis is placed on the use of 'Smart' digital input devices
which have diagnostic health monitoring capabilities rather than discrete process
actuated switches).

e) Multiple process measuring input and safe action output devices (dual or triplicate)
should be applied to improve SIL level of SIF as per SIL report.
f) 2oo2 or 2oo3 voting for field Instrument including solenoid valve shall be as per
P&ID and SIL verification report.
g) Position feedback switch contacts, if used, shall be selected to be closed during
normal process operation and shall open when the shutdown or alarm condition
is reached. Hermetically sealed, or totally encapsulated, proximity switches or
micro switches shall be utilized for contact inputs to avoid degradation of switch
contact surfaces.
9.3. Protection of Dissimilar Materials
a) Prevention from electrolytic corrosion shall be provided on installations where
required, e.g. Protection between stainless steel tubing and its galvanized cable
tray.
b) Consult with DEC/Owner to ensure approved welding procedure is followed,
where welding of Dissimilar Material is involved.
9.4. Statutory requirements
a) Wherever specified in the datasheets, IBR (Indian Boiler Regulations) requirement
shall be applicable. Details are as below:
 Line ID below 10”: Steam and Condensate are at a pressure including and
greater than 3.5 kg / cm2(g).
 Line ID 10” & above: Steam and Condensate are at a pressure including
greater than 1 kg / cm2(g).
Correspondingly IBR FORM IIIC certificate with item 11 (wherever applicable) shall
be provided.
b) All Electrical devices, Electronic devices, Cable Glands, Switches, blind plugs,
Junction Boxes etc. which are to be placed in Hazardous area (Zone 0, Zone 1 and
Zone 2) shall carry PESO (CCOE) certification as minimum. Devices manufactured
outside India, shall also carry ATEX / IECEx approvals (as per latest IEC 60079
Standard) as additional apart from PESO (CCOE) Certification. Valid certificate
from certified agency shall be provided.
c) Each equipment shall be marked either by raised lettering cast integrally or by
name plate attached to the main structure to indicate conspicuously:
 Name of the Manufacturer
 Name and number by which the equipment is identified
 Name and Date of the test report applicable to the equipment
 CCEs Identification number or this letter by which apparatus is approved.
 ATEX / IECEx (wherever applicable) Certificate no.

d) All Electrical devices, Electronic devices, Cable Glands, Switches, blind plugs,
Junction Boxes, RTD/TC terminal head etc. which are to be placed in Zone 20, Zone
21 and Zone 22 shall carry valid Central Mining Research Institute – Dhanbad
Certificate.
e) Radioactive type level instrument shall be type approved by AERB (Atomic Energy
Regulatory Board). Refer RPMS-ENGG-GUD-CI-003 “Guideline for Nucleonic
Instruments” for other regulatory formalities.
f) All weighing systems, weighing platforms shall be approved and stamped by
Weights & Measures Department of India.
g) Calibration of Custody and Gantry transfer flow meters shall be approved and
stamped by Weights & Measures Department of India.
h) If a combined CCoE certificate is submitted for a system / package having more
than one electrical or electronic items in the system/package, than valid ATEX /
IECEx certificates shall be submitted for the individual items.
9.5. Warranty
a) The warranty period shall be of 2 years after the date of Site Acceptance Test or 3
years from the date of delivery of the material, whichever is earlier. Warranty
clause applies to all field instruments, control systems, including accessories
supplied by Manufacturer / Supplier,
b) Warranty shall apply to defective material workmanship, facility design and/or
facility software. The warranty shall include periodic maintenance, on-call
maintenance, replacement of failed components and software upgrades and
provide root-cause analysis report. In case of failure of any Instrument control
system hardware and software, Manufacturer / Supplier engineer (with necessary
required Hardware / Software /tools) shall be available at site within 24 hours of
notification.
c) Warranty work shall be done at equipment installation location. The cost of
diagnostics and/or correction of any warranty items shall be borne by the Supplier.
d) Supplier shall ensure that selected hardware shall be currently in Active stage of
production and shall remain in active phase of production for minimum 10 years
from the date of dispatch. Any obsolete items or items in matured phase i.e. not
offered for green field project supplied by Supplier shall be replaced by Supplier
free of cost. Supplier shall also supply obsolescence life cycle plan for the product.
Spare should be available for minimum 15 years from the date of obsolescence.
e) Supplier shall provide software upgrades (e.g. version changes including features
changes & service pack etc.) for 5 years free of cost including patches update
(Microsoft/Antivirus/OEM Software etc.) as and when released. Supplier shall also
ensure the system application software support for minimum 25 years.
10. Power Supply for Control Systems and Field Instruments
10.1. UPS Power supply 110VAC

a) Power Supply for Control System shall be from Redundant UPS (110VAC) with
Battery backup (one battery backup for each UPS).
 Power Supply Tolerance: 110VAC ±3 % and 50 Hz ±3 %
 UPS Battery backup Duration after Main supply failure: 30 minutes for all
control systems, except 6-hours for F & G, Process CCTV and CEEMS Analyzer
 If field transmitter is 4-wire instrument, then preferred power supply is 24VDC.
110VAC shall be only considered where field transmitter is not suitable for
24VDC
 24VDC shall be derived from the appropriate control systems marshalling
cabinet
b) The following electrical power supplies shall be considered available to control
systems and field Instruments:
 Redundant 110VAC UPS feeder shall be supplied for each consumer.
 Where an instrument or panel is only capable of accepting a single power
supply (UPS power 110VAC) feed, a static transfer switch shall be used provide
power. The Static Transfer Switch (STS) shall be fed from two 110VAC UPS
supplies continuously and provide one output feed to the user. In case of
failure of one 110VAC UPS sources, the Static Transfer Switch (STS) shall
automatically transfer the load to the other input source thus providing a bump
less transfer between the two UPS feeds.
 For Control System equipment, Static transfer switch and Power distribution
shall be in respective Control System Manufacturer / Supplier Scope.
 Where there is single power supply (UPS power 110VAC) user is in the field
including package vendor supplied field items, Static Transfer Switch (STS) and
Power distribution shall be in electrical scope. All power distribution board
including static transfer switch to be provided by electrical.
 Where an instrument or equipment is capable of accepting redundant Power,
the one power supply shall be from Source-A and second power supply shall
be from Source-B.
 Where there is redundant equipment with single power supply, one equipment
shall be powered from Source-A and Second shall be powered from Source-B.
Source-A means supply from UPA-A or 24VDC Power which is powered from
UPS-A. Source-B means supply from UPA-B or 24VDC Power which is powered
from UPS-B
 Redundant supply from 24VDC busbar ( from two 24VDC Bulk Power Supply) is
acceptable.
 Where an instrument or panel is only capable of accepting a single power
supply (UPS power 110VAC) feed, a static transfer switch shall be used provide
power.
Note: Refer RPMS-SD-J10-016 for Schematic

10.2. Emergency Power Supply Requirement:

a) Minimum one UPS shall have Emergency power backup.
b) 415VAC 3ph 50 Hz Emergency back-up power supply for Analyses Shelter.
c) 415VAC 3ph 50 Hz Emergency back-up power supply for MOV as per project
specific requirement, if any.
d) As per project specific requirement, if any.
10.3. Utility Power
Non-redundant 220 - 240 VAC, 50 Hz, single phase, for non-critical services (i.e.
lighting, exhaust/cooling fan and maintenance sockets of cabinets & console).
10.4. 415 VAC, 50 Hz, 3 Phase
415 VAC, 50 Hz, 3 phase, for motorized valves and Analyzer House.
10.5. 24-volt DC supply (derived from 110V UPS)
a) 24-volt DC supply required for panel mounted equipment and field devices shall
be provided by all control system vendors and Package Suppliers. 24VDC Power
supply units for the control panel shall be redundant with dual diode-O-ring. Each
power supply unit shall be loaded less than 50% of its total rated capacity Individual
power supply shall be capable of handling 120% load of its rated capacity. It shall
have the necessary LED indications for power ON. Power supply module shall have
the relay contact output for power supply failure alarm.
b) DIN Rail mounted Diode Module shall be suitable for achieving 100% redundancy.
Note: Refer RPMS-SD-J10-005 for Schematic
10.6. Power Supply Requirement
110v AC 110v AC
240v AC
50 Hz. 50 Hz.
Sr. 50 Hz. 415v AC
Item Description UPS UPS 24V DC
No. (Single 3ph 50 Hz.
(Dual (Single
Feed)
Feeds) Feeds)
Distributed
A
Control System
Supervisory
B
Computer
Package Units
C
(Refer Note-1)
D PLC
E Solenoid Valves

110v AC 110v AC
240v AC
50 Hz. 50 Hz.
Sr. 50 Hz. 415v AC
(Dual (Single
Feed)
Feeds) Feeds)
F Interrogation
F & G Detection
G
System
H Analyzer
Training Kit for
I
DCS
Level Gauge
J
Illumination
Lighting and Fans
of all control
K panels, Field
panels, Analyzer
Field, Shelter etc.
Analyzer and
Analyzer House
L Including CEEMS
Note - 3
Analyzer Cabinet
located in field
Maintenance
M
Sockets
Machinery
Condition
N
Monitoring
System
Motor Operated
O
Valves
Specialty
P Instruments
Note -1
Emergency
Q Shutdown
System
Analyzer
R management
System
S CCTV System

110v AC 110v AC
240v AC
50 Hz. 50 Hz.
Sr. 50 Hz. 415v AC
(Dual (Single
Feed)
Feeds) Feeds)
Automatic Tank
T Gauging System
Note -1
Instrument Relay
U Panel (IRP) See
Note 4
Notes:
1) Power supply shall be dual feed / single feed based on criticality of application.
2) For SOVs requiring high power such as in Hydraulic circuit, use 110VAC UPS.
3) One of Dual Analyser HVAC and other air conditioning system shall be fed from
Emergency 415VAC supply. 415VAC supply (by electrical) shall be redundant for
Analyzer HVAC where GC/Analyzer measurement is part of plant trip interlock.
4) IRP shall have a redundant power supply with redundant diode ring
11. Pneumatic Requirements

a) Dry, oil free instrument air supply pressure, unless otherwise specified shall be as
follows: -
 Maximum: 10.0 Kg/cm2G
 Normal: 7.0 Kg/cm2G
 Minimum: 4.5 Kg/cm2G
 Dew Point: - 40 °C
b) Maximum 40 µm particle size in the instrument air is acceptable for majority of
pneumatic devices. Any pneumatic devices that require instrument air with less
than 40 µm particle sizes shall be provided with additional filtration to meet the
particulate size limit for the device. For Digital valve controller, filter element size
shall be 5 Micron or better. All instrumentation consuming air shall be fitted with
Air filter regulator, Supply and Output gauges. Gauge body shall be of minimum
SS304.
c) Metallic Filter regulator assemblies shall be provided for all instruments requiring
an air supply. Filtration size shall be selected to match the tolerance limit of the
consuming devices. Glass and Polycarbonate bowls for Air Filter regulators are not
acceptable. Air Filter Regulators with only metallic bowls without indicator,
metallic regulating knob and metallic drain knob to be used.

12. Explosive Hazard Protection and Intrinsic Safety

a) All field instruments / Equipment (including Air conditioner) having electrical or
electronic connections shall be suitable for installation in the defined hazardous
area classification. All equipment shall be tested and certified for the appropriate
area classification, gas group and temperature class by authorized testing and
certifying agency. Foundation Fieldbus Devices shall be Intrinsically Safe, certified
FISCO (Fieldbus Intrinsically Safe Concept) / Entity compliant and use field
mounted Fieldbus Barriers.
b) All signals to and from safe to electrically hazardous areas shall be through suitably
fused IS-isolators with status indicating LED’s. Dual channel isolators shall not be
used.
c) All signals to and from safe to electrically non-hazardous areas Isolators or Barriers
shall NOT be used, provided control system I/O card have channel to channel
Isolation. If control system I/O cards do not have channel to channel Isolation, NIS-
Isolator shall be used for safe area signals also. NIS-Isolators shall be used for
Analogue signal interface between Electrical and Control Systems.
d) All field instrument shall be intrinsically safe with EEx ‘i’a certification as minimum
(as per IEC-60079) and shall have valid certificate from certified agency for use in
applicable hazardous area.
e) Explosion Proof devices shall only be used in Zone 1 and Zone 2, where Intrinsic
Safe device is not suitable/applicable OR not available, as per the requirement.
f) All field instrument, equipment etc. located in Hazardous Area Classification for
combustible dust environment shall have valid certification (as per IEC-60079)
from Central Mining Research Institute – Dhanbad for use in applicable hazardous
area.
g) Special attention shall be paid to maximum process temperature limits as specified
in the hazardous area certificate. In applications where the maximum process
design temperature is close to or above the T rating temperature for the hazardous
area the hazardous area certificate needs to be checked to ensure the field
instrument is suitable.
13. Protection from the Environment
a) The minimum acceptable standard of protection against moisture or dust ingress
for externally mounted equipment shall be to IEC 60529 classification IP-65 and IP-
66 for marine application or equivalent NEMA standard.
b) Cabinets / Enclosure located inside building shall have IP 54 / equivalent NEMA
protection, prior to cut-outs for louvers and fans, shall be provided as minimum.
c) Instruments shall be tropicalized for humidity and fungus and shall be termite
resistant. Electronic boards shall be varnished/potted and electrostatically
protected.
d) Prefabricated FRP sunshades shall be provided for all field instruments exposed to
solar radiation, located in Open space including Guided Wave Radar (GWR).

e) Sunshades for all field Instruments (excluding instrument mounted on valves or

directly on vessel/equipment) shall be provided.
f) Sunshades are required for FF JBs, MUX JBs and Mega block JBs. Sunshades are not
required for conventional Junction Boxes.
g) Closed FRP enclosure shall be considered for all field mounted instrument located
in dust environment, e.g. PTA (Purified Terephthalic Acid) plant.
h) Electro-magnetic compatibility shall be in accordance with IEC 61000. All electronic
cards shall be Class G3 protection as per ISA S71.04.
14. Connection Size and Types
14.1. Electrical Connections
Entries for the connection of instrument cables shall be as follows:
a) At Instrument side ½" NPT female is preferred, in cases ½" NPT is not possible or
not available due to certification, ISO M20 shall be used.
b) Junction Box (JB) cable entry connection shall be M20 on both side and M25, M32
and M40 at bottom. 4-way JB ( Gang Box) is allowed for field 2-core/single pair
cable. Main JB with top entry is not allowed.
14.2. Pneumatic Connections
All pneumatic connection tube and fittings shall be Tungum or SS316. Monel Tube &
Fittings or 6Mo tube shall be considered in special services and environmental
conditions wherever specified.
a) SS316 / Any higher material tube fittings shall be double ferrule type
14.3. Close Coupled Installation
a) In order to decrease the overall Total Installed Cost (TIC) and increase the ease of
installation and maintenance, the use of close coupled instruments for DP type
flow, pressure and differential transmitters are recommended wherever possible.
Close coupled design has the following potential benefits:
 Reduction in impulse tubing (which may be pre-traced) quantities
 Reduction in heated enclosure
 Reduction in Installation hours
 Ease of maintenance (Less plugging as impulse tubing is eliminated and less
potential for leakage because there are fewer pressure components)
 No weld adapters
 Reduction in Instrument stands or racks
 Electrical Power cable for pre-traced tubing
 Modelling effort for off-line instruments

b) One important limitation of using close coupled instruments is that the transmitter
electronics and capsules can typically withstand up to 180 F (80 deg C) of direct
temperature exposure. For high temperature process applications (~540 F (280
deg C) and above), close coupled installations can’t be effective due to limited heat
loss.
c) An important design consideration for implementing close coupled
instrumentation is accessibility of the transmitter from grade, platform or by a
portable ladder. This needs to be ascertained while modelling and should be
mentioned as a note on the P &ID so that this can be taken care of while modelling.
Another important design consideration is the capability to withstand vibration
while selecting close coupled instruments and associated manifolds and fittings.
This aspect needs to be verified with instrument and manifold/fittings suppliers
prior to implementation of close coupled instrumentation.
d) Effective installation is achieved by line mounting the device as close to the process
connection. This allows shorter tubing, reduces heat tracing, and limits liquid head
problems, plus eliminates vapor and liquid traps as well as reducing the possibility
of leaks and plugging. Ideally, an installation would fit inside a 600 mm (2 ft.)
square box.
14.4. Process Connections
a) Tube and fittings shall minimum SS316. Instrument impulse tubing shall be
minimum ½" OD x 0.049" wall thickness, seamless 316 stainless steel as a
minimum. Connections to instruments shall be ½"NPT.
b) Use of coiled continuous tubes shall be the preferred method for specific service
condition, process fluid and recommend by licensor to minimise the threaded
joints.
c) Any special tubing, fitting and bulk items required to be specified as a Project
specific requirement as per process data.
d) Process side connection/tapping at pipe, equipment, vessels, including for all inline
instrument etc. shall be Welded type or Flanged for Hydrocarbon and Toxic
services. Threaded process connection/tapping is NOT allowed for Hydrocarbon
and Toxic services.
e) In-case of Venturi the dP cell tapping shall be butt-weld type.
f) Tube fittings shall be double ferrule type
g) Below table defines the various process connections:
Connection on
Equipment Vent &
First Connection
Instrument Drain
Block at Remark
Devices Vessel Piping Piping Valve Instrument Instrument
Connection
or Tank Scr. Flg, BW
Spec or SW
Flow Instruments

Connection on
Equipment Vent &
First Connection
Instrument Drain
Block at Remark
Connection
Spec or SW
½” Pipe
Spec
Flow dP Cells ----- ½” NPT ½” ½” NPT ½” NPT NA
dP Cells with
Remote Chemical
2” Flg 2” Flg 2” Flg 2” Flg ----- ----- NA
seals
As per pipe
Variable Area Meter Line Size Line Size spec
----- ----- ----- -----
End pipe
Averaging Pitot ----- Seller’s Seller’s Seller ’s ----- ----- support as per
Std Std Std Manufacturer /
Supplier
Level Instruments
Refer
Stand Pipe
2” Flg Individual Refer applicable RPMS-SD-P14-
(Minimum 3” pipe 2” Flg ----- ----- Instrument 022
size)
Refer applicable RPMS-SD-P14-

External Displace 2” Flg ----- ----- 2” Flg 2” Flg 022
/ Guided RADAR
Internal Displacer / 4” Flg ----- ----- ----- 4” Flg ----- NA

Radar
1” to
External Ball Floats pipe 1” to pipe spec Refer applicable RPMS-SD-P14-
2” Flg ----- ----- 022
spec
Internal Ball Floats NA

4” Flg ----- ----- ----- 4” Flg -----
Magnetic Follower
Level Gauge Refer applicable RPMS-SD-P14-
2” Flg ----- ----- 2” Flg 2” Flg 022
dP Cell with Remote

Chemical Seals
2” Flg 2” Flg 2” Flg 2” Flg ----- ----- NA
Level dP Cell 2” Flg ----- ----- 2” Flg ½” NPT ----- NA
Direct Vessel 3” ----- ----- ----- ----- 3” NA

Mounted dP Cell

Connection on
Equipment Vent &
First Connection
Instrument Drain
Block at Remark
Connection
Spec or SW
Tank Gauging Head

RADAR/Servo / Open 8” ----- ----- ----- ----- 8” NA
path RADAR)
Pressure Instruments
* Except
¾” to
¾” NPT* ¾” NPT* Pipe Where 1” to
Pressure Gauge 2” Flg ½” NPT ½” NPT Pipe Spec
Spec*
¾” to
¾” NPT* ¾” NPT* Pipe
Transmitters 2” Flg ½” NPT ½” NPT
Spec*
¾” to
¾” NPT* ¾” NPT* Pipe
dP Cell 2” Flg ½” NPT ½” NPT
Spec*
Pressure
Instruments with
Remote Chemical 2” Flg 2” Flg 2” Flg 2” Flg Seller Std -------- NA
Seals
Thermowells 2” Flg 1½” Flg 1½” Flg --- Seller Std ------- Note 1
NA
Analyzer Probe 2” Flg 1½” Flg 1½” Flg --- Seller Std Seller Std
Notes:
1) The thermowell connection shall be minimum 2" flange where line specification
calls for corrosion allowance > 6 mm or pipe schedule is XXS.
2) Minimum flange ratings shall be 300lb on vessels / Pipe and minimum of 150lbs on
tanks and shall increase to match the pipeline/vessel rating as indicated in the
Piping Specification “Piping Material Specification”.
3) Piping Vent and Drain Valves associated with Instruments on vessels or standpipes
shall be 3/4” flanged.
4) Vent and Drain connections on flow and pressure instruments to be ½" NPT.
5) For closed drains and vents, the drain/vent connection shall be ¾" flanged.
6) Adapters shall not be used for vent and drain connection.
7) Flange material of construction selected shall be suitable for design pressure and
temperature as per ASME standard. All flange connection shall be as per ASME

B16.5. All threaded pipe fittings, valve connection of instruments shall conform to
ASME B1.20.1
8) For inline instruments, which are connected to pipelines through flanges, should
have a metal link between instrument flange and pipe flange at both ends for static
potential discharge, as required.
9) Gasket types and flange face finishes shall match the requirements of the Piping
Standard Specification “RPMS-ENGG-SPC-PP-004, Piping Material Specification”.
10) For HYDRSTEP, connection shall be as per project specific and OEM
recommendation.
11) For lined pipe process connection and flange rating shall be as per pipe class
14.5. Installation Notes
a) Piping isolation valves shall be supplied for all connection of Instruments and
Instrument impulse lines. For shutdown applications each instrument shall have its
own process connection with individual locked open isolation valves.
b) Process line tapping shall be fitted with line class isolating valves of roddable type.
Instruments can be close coupled wherever possible.
c) Double Block and Bleed valve (Root Isolation valve for Instrument process tapping)
shall be considered as per RPMS-ENGG-DBD-PS-001 and Process requirement and
same shall be in piping or package vendor scope of supply. Double Block and Bleed
shall not be integral (single) assembly.
d) In the case of a differential pressure element, (e.g., orifice flange and plate) a
transmitter used for ESD service may be installed in parallel with a process control
measuring/alarm element (using separate isolation valves), or branching off a
different set of process taps originating from the same primary element
e) A three-way manifold shall be provided for all differential pressure transmitters, as
minimum.
f) A two-valve manifold shall be provided for all gauge/absolute pressure
transmitters.
g) Manifold screwed bonnet is acceptable only, if it is provided with proven Anti
Rotation mechanism pin design (Bonnet locking pin) to prevent the accidental
detachment of the bonnet from the body.
h) Mounting of the manifold shall be by means of 50mm pipe clamp to the instrument
stand. Transmitters shall be supported by the manifold.
i) Manifold vents and drains shall be piped to a safe place or disposal system.
Exceptions to this shall be instruments in low pressure, non-toxic or non-
flammable services. Safe location to be decided during detail engineering in
consultation with Process department.

j) The use of condensate pots and vent chambers shall be minimized by use of
respective instrument tapping elevations. Dry gasses shall be self-draining. Liquids
and condensates shall be self-venting/wet leg filling.
k) DEC shall ensure that offline instruments are NOT exposed to vibration and
mechanical stresses, the same shall be taken care while finalizing the Instrument
location layout.
l) PRVs of the balanced type shall have a continuously vented bonnet. For valves in
acidic, caustic, toxic and hazardous services, the vent shall be routed to a safe
location and this shall be noted on the P&ID.
m) There are several methods to clear an instrument sensing line in lieu of blowdown.
 Flushing of Instrument Sensing Lines
Provisions shall be made for periodic flushing of instrument sensing lines to
clear out any accumulated dirt, corrosion products, or other residue which can
enter the instrument with harmful effects. For systems, which operate at
elevated pressure or temperature, flushing shall be confined to periods of
system shutdown. Flushing valves may be the same type as the instrument
isolation valve. It will be used only when the associated system is out of service
and cooled.
 Purging of Instrument Sensing Lines
An external liquid or gas supply may be connected to the instrument sensing
lines. This method maintains a constant source of pressurized fluid in the
sensing line and prevents the line from becoming restricted. This method is
normally used in dirty air or gas and for slurry service. A purge medium is
introduced through a restriction orifice, flowmeter or rotameter. The purge
medium must not create a hazardous condition during normal, abnormal or
start-up operations, contaminate the process or affect the product quality.
15. Spare Philosophy
Spare shall be considered as per below table:
Sr.
Item Description Qty
No.
1 Field Instruments
Pressure Gauges, Temperature Gauges,
Differential Pressure Gauges, Draft Gauge, 3% subject to minimum 1No. of
1.1
Field Indicators, RTD/ Thermocouple, Skin each type
Thermocouple Sets,
Transmitters for Pressure, Temperature &
3% subject to minimum 1No. of
1.2 Differential Pressure (except special
each type
transmitters) pH and Conductivity probes

2% of each type of detector,

1.3 All types of detectors for F&G System
minimum 1 no. of each type.
Prefabricated cables for Mass flow meter,
5% subject to minimum 1No. of
1.4 Vortex flow meter, Ultrasonic flow meter
each type
etc.
Speed probe with cable, Proximitor with 5% subject to minimum 1No. of
1.5
cable, JBs and transmitters each type
2 Control Valves, Shutdown Valves
5% subject to minimum 1 No. of
2.1 Proximity switches / Limit switches
each type
3% of each type, minimum 1 no.
2.2 Solenoid valve
of each type.
E/P Converters, Valve Positioners, AFR,
AFR/Positioner Pressure Gauge, Volume 5% of each type, minimum 1 no.
2.3
booster, Volume Tank pressure gauge and of each type
PSVs
2.4 Valve and Actuator repair kit each type (Special valve 100%
spare kit)
3 Control Systems (DCS/ESD/PLC/F&G/MCMS/ATG/CTMS etc.)
For Control Systems, overall 15% (in total)

3.1 spare IO shall be considered at the time of
despatch.
Each type of Module used in Control

Systems like I/O Cards, all type of processor
3% of each type, minimum 1 no.
3.2 cards, all type of power supply cards,
of each type.
communication cards, Interface cards, Bulk
Power supply (24VDC).
3.3 IS / NIS Isolators and Signal Splitters
each type
KVM, Network switch, NIC card, Field
3.4 3% of each type
Barriers, MUX, Mega Block, Pig tail, LIU
Fan Assembly, Thermostat, Fan failure 3% subject to minimum 1 No. of
3.5
switch/relay each type
3.6 Prefabricated cables,
each type
3.7 Patch Cord cable 10% of each type
3.7 Relays
each type


3.8 Auxiliary Console Lamps and Switches
each type
3.9 Fuses 10% of each type
4 Bulk Items
20% spare to be considered at the
All bulk items like cable, tubes, fittings, beginning of engineering to meet
4,1
Junction Box etc. the engineering changes/growth
during detail engineering.
5 Analyzer Shelter
Sampling System Accessories and purge
5.1 5% of each type
controller
Safety PLC - Module like I/O Cards,
processor cards, power supply cards, 5% subject to minimum 1No. of
5.2
communication cards, Interface cards, Bulk each type
Power supply (24VDC).
16. Instrument Component Identification Philosophy

The structure of instrument component identification shall be in accordance with
Project Engineering Procedure. Examples are as follows: -
16.1. Instrument Identification Labels
All instrument items shall be permanently and clearly marked with a stainless steel, or
corrosion resistant labels as follows: -
Nameplate : Shall include proprietary manufacturer’s details
Certification Plate : As per CCoE / PESO requirement
Tag No : Each instrument, Junction Box and Field Panels shall be
provided with a stainless-steel tag number plate/label
with the full alpha/numeric tag number hard stamped, or
deep engraved, permanently attached. The tag number
plate/label may be integral with the “Nameplate”
provided the tag number is large, clear and easily read in
the final installed position
Exceptions to the above shall be Pressure Gauges and Dial Type Temperature
Indicators which shall have the tag number plate/label attached via stainless steel wire
of 1.0 mm minimum diameter.
16.2. Instrument Commodity Codes
The instrument commodity group codes, and sequence prefixes are indicated in the
matrix below:

Unit Control Aux

Comple
Commodit Specif Sequence Room Local and
x No Marshallin
y Group ic No System (Panels Remote
Applies Prefix Title g Cabinets
Code Applie Cabinet ) Relay
s s Cabinet
Sequence C L R s M
Prefix
Commodity
JA   Instrument 
Assemblies
JB  Junction Box
JC   Panels    
JD  Close Circuit  
TV
JE  General
Instrumentati
on (including
wireless Tx)
JF  Fire Smoke   
Detection
and Alarm
JG  Gas   
Monitoring
JH  Environment  
al Monitoring
JI  Vibration   
Monitoring
JJ  DCS & ESD   
JK  Seismic  
Monitoring
JL  PLC based   
control
systems.
JM  Meteorologic
al Monitors
JN  Analytical   
Instruments
(Systems)
JP  Packaged    
Instrument
Systems

Unit Control Aux

Comple
Commodit Specif Sequence Room Local and
x No Marshallin
y Group ic No System (Panels Remote
Applies Prefix Title g Cabinets
Code Applie Cabinet ) Relay
s s Cabinet
JQ  Plant s 
Computer
JR  Inst. racks
Supports and
Shelters
JS  Plant Security    
JT Tubing and
Fittings
JU  Plant    
Annunciators
JV  Control 
Valves and
Desuperheat
ers
JW   Inst & F&G
Cable and
Glands
JX Inst. V/V's
and
Manifolds
and
Installation
JY   Inst.    
Specialty
Equipment
(including
wireless
gateway)
Where both Unit Specific and Complex No. are ticked, either can be applied. If Unit
Specific and Complex No. are not ticked, then neither is applicable.
16.3. Instrument Tag Numbering
Example of a pressure differential indicating switch in Unit No BBB AAA.
JE - BBBAAA PDIS CCC123 - A
Where : JE is Commodity group code
BBB is Project/Complex unit name

AAA is Project/Complex unit number

CCC is Plant section number
PDIS is Function code, can be up to 5 character (as per ISA standard
S5.1)
123 is Loop sequence
A is suffix*
Note:
1) Commodity Code and first two alphabets (JE-BBB shown in italics) of
Project/Complex Unit name will not be shown in the instrument tag numbers so
that sufficient field length is available for SPI and DCS.
2) For the Distributed Control System (DCS) the tag number will be rationalised to a
maximum of 16 characters.
3) For field devices the tag number will be a maximum of 16 characters.
4) Hyphens “-” shown above and spaces will not form part of the tag number and are
only included here for clarification purposes.
5) *The suffix in the instrument tag number is only used if it is necessary to indicate
where more than one identical instrument tag number appears in a loop. Where
this suffix is required the first shall be ‘A’ and then ‘B’ etc.
6) e.g. PDSLL001A and PDSLL001B
7) If required, suffix can be two characters “AA”, this may be required for motor
status Indication.
16.4. Instrument Panels Control Room Mounted and locally mounted
Example of a Marshalling Cabinet: -
JL - BBBAAA - CCC M001
Where : JL is Commodity group code
M is sequence prefix*
001 is sequence number**
For a full list of commodity group codes and sequence prefixes refer to Project
specification for Equipment Numbering and Component Identification.
*“C” = System Cabinet, “M” = Marshalling Cabinet.

16.5. Instrument Junction Boxes

Example of an analogue, 4-20 mA, junction box for Unit No BBB AAA
JB - BBBAAA - CCC 001 - E
Where : JB is Commodity group code
001 is sequence number
E is service level suffix*
* Where the service level suffix identifies the signal type as follows: -
A = Alarms, 24V DC
C = Control/Solenoid outputs, 24V DC
E = Analogue, 4-20 mA
FF = Foundation Fieldbus H1
S = Serial links/Data hi-ways
T = Temperature
V = Vibration
VXE = Vibration (shutdown Service)
AX = Alarm (Shutdown Service)
CX = Control/Solenoid outputs, 24V DC (Shutdown Service)
EX = Analogue (Shutdown Service)
TQ = Temperature Multiplex
TX = Temperature (Shutdown Service)
F = Fire and Gas Service
16.6. Instrument Multicore Cables (Including Multipair and Multitriple)
Example of an Analogue, 4-20 mA, Instrument Cable in unit no BBBAAA.
JW - BBBAAA - CCC 0001 - E - 1
Where : JW is Commodity group code

0001 is Cable sequence number

E is service level suffix*
1 is Numerical suffix
*For descriptions of the service level suffix refer to section 16.5 of this specification.
Hyphens and spaces do not form part of the cable number and are shown for clarity
only.
Numerical suffix added after service level suffix to all multi cores. If a JB has only one
multi core the cable will carry a suffix of “1” as shown in example. If two multi cores
are used, then the suffix will be “2” for the 2nd cable.
16.7. Junction Box to Field Instrument
Individual cables running between field junction boxes and field mounted
instrumentation shall be identified by the instrument tag number.
e.g. BBBAAA-CCC-PDIS-123-A
Hyphen and spaces do not form part of the cable number and are shown for clarity
only.
16.8. Panel to Panel Cables
Example of a Digital (Shutdown Service) Instrument Cable in any unit linking DCS
Marshalling Cabinet JJ-BBBAAA-M01 with ESD Marshalling Cabinet JL-BBBAAA-M01.
JW - BBBAAA - CCC 2096 - AE
2096 is Cable sequence number*
AE is service level suffix**
*Four-digit sequence number (number series based on the project specification) for
each unit number. This number will be used once only and should not be used with
another service level suffix.
**For descriptions of the service level suffix refer to Section 16.5 of this specification.
only.
16.9. Wire Number Ferrules
Wire Number Ferrules consist of Tag Number, Terminal Block Number and Terminal
Number.

e.g. BBBAAAFT001/TB1/1
This also applies to Junction Boxes.
N.B. Oblique stroke”/” is acceptable but no hyphens or spaces.
Cross ferruling shall be used.
Ferruling is applicable to all types of wiring including FO, RJ45, Serial cable etc.
16.10. Foundation Fieldbus Junction Boxes
Example of an Intermediate J/B for Fieldbus signals for the Unit No. BBBAAA.
JB - BBBAAA - CCC 001 - FF
001 is unique sequence number
FF is service level suffix
16.11. Example of an FF Field Barrier J/B for the Unit No. BBBAAA.
JB - BBBAAA - CCC 001 - FF - A
FF is service level suffix
A is Alphabetical suffix
16.12. Example of an FF Multiplexer J/B for Unit no. BBBAAA.
JB - BBBAAA - CCC 201 - TQ
TQ is Service level suffix

Note:
Each Multiplexer JB will contain two devices which, in the example above, would be
tagged as XXXYYYTU201A and XXXYYYTU201B.
16.13. Segment Trunk Cable
Example of cable running between Field Barrier J/B and an Intermediate J/B for the
Unit no. BBB AAA.
JW - BBBAAA - CCC 001 - FF - A
001 is number of upstream JB
FF is Service level suffix
A is alphabetical suffix
only.
16.14. FF Segment Numbering
Example of Fieldbus Segment numbering for the Unit no. BBBAAA.
BBBAAA - CCC 001 - A
Where : BBB is Project/Complex unit name
001 is number of upstream JB
A is alphabetical suffix
17. Painting
a) For painting requirements reference shall be made to the “Project Painting
Specification”. RPMS-ENGG-SPC-PP-014
b) Only Nickel plating is permissible as the final finish on cable glands.
c) Field Instrument painting (other than control and on/off valve) shall be as per
manufacturer / supplier specification.
d) Mounting boards, brackets and small moving parts not suitable for painting shall
be manufactured from stainless steel.
e) Fasteners, where fitted, shall be stainless steel.

f) Instruments and the following items shall be protected against paint used on
equipment and process units: -
 Glass fronts
 Moving parts. For example: Control Valve stems and positioners.
 Vents and Drains
 Nameplates
 Tube fittings and cable glands
 Isolation and Vent valves
18. Instruments on Utility lines at plant B/L
Instrument Air Pressure low (at ISBL Battery limit) alarm shall be configured in DCS.
19. Control Philosophy
Plant Operation shall be unit-wise from centralised location. Control Philosophy shall
be finalised in consultation with Operations and Technology Group. A project specific
control philosophy document shall be published that include control room and PIB
requirements for the project.
a) Redundant in I/Os (for critical loops) shall be as per Licensor’s requirement and
with Owner’s approval.
b) Emergency stop push buttons on UCP, and LCP shall be properly protected against
accidental / unintentional actuation. It shall have twin contact elements for
configuring it in 2oo2 voting system. Different cable routes shall be followed and
to be wired in different junction boxes.
c) Exchange of all process trip signals & critical process control signals between two
control system shall be hardwired signal and NOT on serial link, the same shall be
further evaluated during detail engineering phase.
d) The available range of IP address and node numbers shall be verified with
respective Reliance site by the Owner and convey to DEC and System Vendor and
new allocation of IP address shall be accordingly.
e) If field devices are used in M-o-o-N voting, the branch cable shall be wired in
different Junction Boxes and separate multipair/multicore cables from field
Junction Box to marshalling shall be routed.
f) Foundation Fieldbus technology /Transmitters / Instrument shall be used only as
per Project Specific Requirement with prior approval of Owner"
19.1. Control Room Requirement
Centralised / Independent Control room to be considered for all process units, offsite,
Utility and CPP as per Operational requirement.

19.2. Plant Interface Building (PIB)

Plant Interface Building (PIB) to be considered for all process units, offsite, Utility and
CPP as per Control Philosophy. Each PIB shall have SFER (Shift Field Executive Room)
attached to PIB. PIB size shall be standardised. Refer “RPMS-ENGG-DBD-CS-007 Design
Basis for Plant Interface Buildings Design” for minimum requirements of layout, detail
engineering and design of Plant Interface Building.
19.3. Type of Control and Monitoring Systems
a) Centralized Distributed Control System (DCS) for all process units, offsite, Utility
and CPP as per Control Philosophy.
b) Centralized Emergency Shutdown System (ESD) for all process units, offsite and
Utility as per Control Philosophy.
c) Dedicated Control System / PLC for packages as applicable.
d) Fire & Gas detection System: Redundant PLC based F&G system shall be used for
Fire and Gas detection system.
e) CCTV System shall be as per project specification and licensor requirements
f) Anti-Surge Control System shall have dedicated special controller, CCC
(Compressor Control Corporation) or equivalent control system.
g) Machine Condition and Monitoring System (MCMS): Centralized MCMS system
shall be provided for all compressor, pumps, motors etc. for monitoring and
control. The requirement of sensors shall be as per RPMS-ENGG-SPC-MR-022,
Guidelines for Online Condition Monitoring of Rotating Equipment.
h) Analyzer Management System shall be as per project specification and licensor
requirements
i) Analyzer Shelter and Safeguarding System shall be as per project specification
j) CEEMS (Centralized Emission and Effluent Monitoring System) shall be as per CPCB
/SPCB requirement. Refer RPMS-ENGG-SPC-CI-013 for details.
k) Auto Tank Gauging (ATG) system shall be as per project specification. Refer RPMS-
ENGG-SPC-CI-015 for details
l) Custody Transfer Management System shall be as per project specification. Refer
RPMS-ENGG-SPC-CI-012 for details. Large Screen Display (LSD) shall be as per
project specification and licensor requirements
m) Over speed and Governor control system, Compressor Turbine Control System.
n) Wireless System
o) Motor Operated Valve (MOV) system
Applicable design basis and specification of respective Control System shall be referred
for details.
19.4. Interlock System

Logic Representation shall be as per ISA 5.2. Process by-pass switches shall be provided
as per logic/interlock specification. The by-pass switches shall be soft (on HMI with
notification) along with Hardwired switch with indication lamp. Emergency Shutdown
system specification and PLC specification shall be referred for details.

19.5. Surge and Lightning Protection

DEC shall identify criteria for protections and perform a study against those criteria to
determine which instrumentation require surge and lightening protection, both the
criteria and the final report will be subject to Owner approval.
The following should be considered when defining the criteria for surge and lightening
protection.
a) Instrument elevation in relation to the associated junction box, if the elevations is
greater than 10m then protection is required
b) ESD and F&G instrumentation should be protected
c) DCS control loops should also be protected
d) Safety Related / High Priority Alarms and Independent Layers of Protection (IPL)
should also be protected
e) Instruments located at grade in exposed areas (i.e. not under pipe rack) may not
require protection if that there are taller structures located nearby which would
take any lightning strike. To determine the protection provided by the structure
the DEC Electrical team shall conduct a study in accordance with RPMS-ENGG-SPC-
EL-023 and IEC-62305 to establish the protected area. There are two methods of
determining the protected area in IEC-62305, rolling sphere and protection angle,
preference would be to use the rolling sphere method.
f) FF trunk runs shall be protected from surge or lightning strike at both ends of the
cable using two dedicated surge protection devices
g) Surge Protection Devices (SPDs) for 4-20mA HART instrument should be installed
at the field device and in the marshalling cabinet
h) Surge Protection Devices (SPDs) for FF instrumentation should be installed at the
device coupler and the FF module in the marshalling cabinet
i) If the field device had a power supply and requires surge protection, then the
power supply should have additionally had surge protection installed
20. Fibre Optic Cable
a) All data cable outside building shall be armoured Single mode FO cable between
PIB and Control Room.
b) Two separate (redundant) FO cable shall be considered
 FO cable for DCS and ESD
 FO cable for other control systems.
c) Redundant FO cable shall be used between PIB and control room with separate
routes for maximum availability
d) Refer to the Standard Specification for Fiber Optic Cable (RPMS-ENGG-SPC-EL-012)
for details of FO cable requirements.

21. Datasheets
a) DEC shall collect all applicable and relevant technical information e.g. Process data,
service condition, Hazardous Area classification, Instrument technical
specification, Installation details etc. and fill all the datasheet form in SPI for all
tagged Instruments. Technical requirement and specification of associated
accessories shall be part of main Instrument datasheet. For all tagged items
Datasheets shall be generated from SPI.
b) If SPI datasheet format does not have provision to specify necessary technical
information and technical specification of accessory, the same shall be covered
under note.
c) SPI automation tool shall be used for carrying out detail engineering Wherever SPI
is not being used by any Package Supplier, DEC shall manage to enter Package
supplier data in SPI to complete the Instrument & control systems deliverables &
datasheets.
d) Multi-tag datasheets are only applicable for Pressure Gauge, Temperature Gauge
and Temperature Elements.
21.1. Instruments – General
a) Electronic transmitters shall be 2-wire, 24 VDC with output either Foundation
Fieldbus or 4-20 mA “SMART” with HART. The transmitters shall be selected with
latest model with proven technology.
b) For ESD applications only 4-20 mA HART transmitters shall be considered.
c) FF Transmitters shall have latest ITK version with all required support files. All FF
Transmitters shall be FDI compatible and certified. Care shall be taken to ensure
compatibility between host system configuration and “as delivered” version of the
transmitters.
d) All 4-20 mA HART devices shall be supplied with applicable Device/DD file, be
NAMUR NE 43 compliant and supplied with diagnostic and error mapping as per
NAMUR NE107.
e) Use of wireless transmitters are acceptable only for monitoring loops where
update time is not critical. Wireless transmitters shall be selected in consultation
with Licensors and Process group.
f) The span of analogue instruments shall be adjusted to cover the operating window
which includes applicable abnormal operation and alternative operating modes
(such as start-up and shutdown).
g) Transmitters used for ESD applications shall have the same range and uncertainty
class as corresponding DCS transmitters to facilitate measurement validation and
comparison (MVC).
h) Electronic transmitters shall meet the relevant electrical hazardous area
classification requirement and shall have an integral digital indicator

i) Conventional 4-20mA Transmitters shall be used only as per Project Specific

Requirement with prior approval of Owner.
j) Foundation Fieldbus Transmitters shall be used only as per Project Specific
Requirement with prior approval of Owner
22. Pressure Instruments
a) Pressure Units: shall be as specified at Section – 7.
b) For Hydrogen service, sensing diaphragm shall be gold plated to avoid permeation
of hydrogen thereby causing errors in measurement.
c) For Hydrogen service differential pressure transmitter to be used, differential
pressure gauge to be avoided.
d) Pressure instruments on LPG services shall be fitted with a restriction orifice of 3
mm diameter downstream of the piping class block valve
22.1. Pressure Transmitters
a) For pressure measurement, control and shutdown requirements, only transmitters
shall be used. Field transmitters shall be smart using FF or HART protocol for
control and monitoring, except for special applications, such as Anti Surge Control
transmitter shall be either conventional analogue type or smarts type as per OEM
recommendation. For shutdown, only HART protocol transmitters shall be used.
b) For low temperature applications (PT/FT/DPT) the below philosophy shall be
applied,
 For a minimum design temp; down to -40 °C a normal Transmitter should be
used.
 For a minimum design temp between -40 °C to -90 °C and operating temp of
up to +30°C then Diaphragm seal (capillary) should be used. The use of a
capillary shall be avoided and where the range of the transmitter allows shall
be replaced with electronic seals.
 For a minimum design temp between -40 °C to -90 °C and operating temp of
greater than +30°C then a normal Transmitter should be used.
 For a minimum design temp below -90 °C a normal transmitter with heat
tracing hook up should be used.
c) For low pressure ranges between minus 1 Kg / cm2G, and plus 2 Kg / cm2G,
differential pressure instruments shall be used. The low-pressure connection shall
be open to atmosphere with protection against sudden atmospheric changes or
connected to a reference zero.
d) Special attention must be given to those instruments, which will be exposed to a
considerably higher static pressure than normal during plant start-up and
shutdown period. Suitable over range protection must be provided especially
pressure gauges.

e) For pressure transmitters, the use of a 2-valve manifold or instrument valve is

usually recommended. The method of installation using isolation valve, tee and
drain or vent valve is also acceptable. Differential pressure transmitters shall be
provided with 3 –valve or 5 valve manifolds for transmitter equalization and
isolation.
22.2. Pressure Switches
The use of Pressure Switches shall be avoided in all process applications. Use of direct
mounted pressure switches are allowed only for deluge system initiators and pump
seal plans with a prior approval from DEC / Owner. Switch if used, the contact shall be
Hermitically Sealed or coated with anti-corrosive coating
22.3. Pressure Gauge
Pressure gauges, receiver gauges, differential pressure gauges.
a) Bourdon Type Pressure Gauges only shall be used, other type shall be considered
only if bourdon type is not suitable.
b) Pressure Gauge glass shall be shatter proof
c) Dial size shall be 100mm,
d) Dial Size for boiler and steam generation applications 150mm as per IBR
requirements, with red marking for Maximum Allowable Working Pressure
(MAWP).
e) Marking on dial shall be as per IBR requirement for boiler and steam generation
f) Accuracy : +/- 1% of Full scale
g) Material : SS316 minimum for Case and Element
h) Connection : ½” NPT(M)
i) Gauges exposed to vibration or process pulsations (such as discharge of
reciprocating compressors, pumps etc.) shall be silicone oil filled and shall be fitted
with pulsation dampers/Snubbers to the same material as the element.
j) Gauge saver shall be used when the design pressure is more than 130% of pressure
gauge range.
Note:
1) All gauges shall be fitted with Shatter-proof Safety glass. Gauges up-to 25 kg/cm2
service shall have Open front with blow-out plug/disc in the back. Gauges above
25kg/cm2 service shall be full safety pattern type (i.e. with solid front and blow-
out back).
2) Laminated safety glass window and safety pattern gauges shall be complying to
EN-837. Pressure gauge used in pure oxygen and acetylene shall be safety pattern
type.

23. Temperature Instruments

Temperature Units: shall be as specified at Section – 7.
23.1. Thermowell
a) Thermowell design shall be flanged only. Screwed thermowells are not acceptable.
Welded thermowells may be used only for special cases, such as very high velocity-
where wake frequency calculations require welded solution, with prior approval
from Detail Engineering Contractor. Wake Frequency Calculations shall conform to
ASME PTC 19.3 latest edition.
b) For Toxic and Hydrogen service Thermowell connection (Flanged OR welded) shall
be as per Piping specification and project specific requirements.
c) Thermowell flange rating shall be minimum 300lb on vessels / Pipe and 150lbs on
tanks (open to atmosphere) and shall increase to match the pipeline / vessel rating
as indicated in the project “Piping Material Specification. Care shall be taken when
installing a thermowell of lower tensile strength material than the than the
piping/equipment material, e.g. stainless steel thermowell in carbon steel lines,
then the design conditions shall be checked to make sure the flange rating is
suitable.
d) In-order to avoid condensation on extensions when measuring a fluid temperature
below 0°C (32°F), the length of the head extension shall extend outside the
insulation by a minimum of 200 mm (8 in).
e) The following installation requirements for thermowells shall be applied:
 Thermowell shall not be installed directly downstream of flashing or cavitation
valve, due to the risk of breakage because of excessive vibration.
 Located at least 10 pipe diameters downstream of a mixing point.
 Located at least 30 pipe diameters downstream of the mixing point in case of
mixed vapour streams and for steam desuperheaters.
 Located outside the straight length of flow meters.
 Provided with a tag plate indicating its tag number.
 Provided with a plug when no element or gauge is installed, in-order to prevent
corrosion. This also applies to the period between installation of the
Thermowell and installation of the element or gauge.
 If long elements with multiple sensing points are installed in equipment or
tanks, the equipment design and lay-out shall be examined to ensure that the
multiple sensors and their associated thermowells can be installed and
removed from the equipment without being obstructed by adjacent
equipment.
 The Thermowell and support design shall be in accordance to overall load
(including catalyst load) on thermowell, if installed in horizontal position in
reactor or vessel.

 For the measurement of tray temperatures in distilling columns, special

attention should be paid to the thermowell length and nozzle location.
23.2. Thermocouple
Thermocouple Types selection as below,
a) Type E : - 200°C to +900°C
b) Type K : -200°C to +1250°C
c) Type J : 0°C to +750°C
d) Type S : 0°C to +1450°C
e) Type T : 250°C to +350°C
f) Type B : +871 ͦC to +1704 ͦC, used in extremely high temperature applications.
g) Type N : 0°C to +1260°C, used in applications where Type K elements have a
shorter life and stability problems
Only ungrounded Thermocouples shall be used, Except for averaging or differential
measurement. Grounded TCs shall be used, if recommended by process licensor/OEM.
Note: Above 800°C Licensor recommended Temperature Element shall be used.
23.3. Resistance Temperature Detectors (RTDs)
For temperatures from -180 to 450 °C, PT-100 element, compliant with IEC 60751, with
3-wire configuration shall be used.
23.4. Special Temperature Sensor
Infrared camera or any special sensor for the temperature measurement shall be used
as per licensor recommendation.
23.5. Special Multipoint temperature sensor assembly
a) Customized suitable to application and Installation requirement, Multipoint
temperature sensor assembly shall be used wherever required and applicable.
Multipoint temperature sensor assembly is generally used for reactor catalyst beds
where individual connections through the reactor wall are not practical. Sufficient
multipoint temperature sensor should be installed to provide a reactor bed
temperature profile.
b) Multipoint temperature sensor assembly shall provide multiple temperature
measurements for monitoring temperature and temperature differences, profiles
and alarms. Below are examples of Multipoint temperature sensor:
 Temperature measurement throughout Reactor
 Reactor catalyst beds Temperature measurement
 Temperature measurement at various elevations along a straight line or axis
parallel with the reactor axis.
 Radial temperature measurements of catalyst bed distribution trays.

c) Special Multipoint temperature sensor assembly, such as those used in catalytic

cracking units, are usually long, having most of the sensor in a dead space with only
a small portion exposed to the flowing stream. Operating conditions are often
above the flanged connection’s first critical vibration frequency and normal
temperature limits. Special coatings may be used on these elements to improve
erosion resistance.
d) Multipoint temperature sensor assembly fitted in reactor, vessels etc., the reactor,
vessel design and equipment layout shall be critically examined to ensure that the
multiple assemblies and their associated protective wells can be installed and
removed from vessels without being obstructed by adjacent equipment.
23.6. Electronic Temperature transmitter
a) For monitoring, control and shutdown application, field mounted Temperature
transmitters shall be used. The transmitters shall be remote mounted type.
b) Temperature transmitters shall be smart using FF or HART protocol. For shutdown,
only HART protocol transmitters shall be used.
c) FF Transmitters shall have latest ITK version with all required support files. All FF
device shall be FDI compatible and certified. Care shall be taken to ensure
compatibility between host system configuration and “as delivered” version of the
transmitters.
d) The use of field mounted multiplexers (HART / FOUNDATION FIELDBUS) shall be
considered for large number of non-critical and monitoring loops based on location
of various temperature sensing points.
23.7. Temperature Gauges
Temperature gauges shall be Bi-metallic type, with every angle design.
24. Level Instruments
a) Refer Appendix-03 for level Instrument selection.
b) Where possible two independent Instruments shall be used for Level
measurement of vessels / tanks. Preference is for both instruments to be of
different type (different technology / working principle). If level instruments with
different type (different technology / working principle) in not feasible, then both
Instrument shall be of different manufacturer or if same manufacturer then
different production batch.
c) Where differential pressure level measurement using two separate pressure
measurements (one at low pressure & second at high pressure) is being considered
then interconnected electronic sensors shall be explored instead of using
traditional differential pressure transmitter with impulse tubing or diaphragm seal
with capillary method, provided it satisfies the process requirements such as
pressure, temperature, accuracy and response time.
d) To prevent the occurrence of liquid overflow the range of displacers, pressure
differential transmitters and other head based instruments shall be based upon

the lightest process fluid expected in the vessel at its highest temperature. These
calculations shall include the start-up and shutdown conditions
e) Level Measurement Units: shall be as specified at Section – 7.
24.1. Continuous Level Measurement Applications
a) DP Type Transmitters
b) Guided Wave Radar (GWR), not to be used for low dielectric liquids as well as
viscous and dirty service
c) GWR shall not be used for measuring interface level with varying dielectric
constant for upper media.
d) Displacer type Transmitters, where Guided Radar cannot be used
e) Hydrastep / Bi-Colour type level instrument can be considered as an additional for
Boiler drum level measurement.
f) Use of Ultrasonic level transmitter can be explored in services like underground
pits, cooling tower basin etc.
g) Special level measurement instrument shall be used with prior approval of Owner.
h) For Hydrogen service, sensing diaphragm shall be gold plated to avoid permeation
of hydrogen thereby causing errors in measurement
Notes for cryogenic applications:
1) Diaphragm seal type Level Transmitter can be used for design temperature up to -
90 °C,
2) Displacer LT to be used if the design temp is below -90 °C and Centre to Centre
distance up-to 3000mm.
3) Normal DP transmitter with heat tracing hook-up to be used for design
temperature below -90 °C and centre to centre distance is greater than 3000mm.
4) Ultrasonic Level Transmitter shall be provided with temperature compensations to
avoid measurement error.
24.2. On/Off Level Measurement Applications
a) Direct connected level switches allowed, subject to Owner’s approval. For API
Pump seal Plans applications also, Owner’s approval is required for the use of
direct connected level switch.
b) Level displacers or Guided Wave Radar
c) Capacitance Type switch
d) Vibrating Fork type switch
e) Nucleonic Level measurement shall be as specified by process licensor for
continuous or single point applications.

f) Level Standpipe philosophy for Radar level measurement shall be as per

datasheets and project specification.
24.3. Tank Level Gauging
RADAR type gauge shall be used for all tanks and spheres
24.4. Tank Farm Management System
Tank Farm Management system shall be provided where identified by project
requirements. The System shall be interfaced with DCS.
24.5. Level Gauge
Only Magnetic type level gauge shall be used. Gauge Glass, Reflex type level gauge to
be used only with prior approval of owner.
24.6. Level Setting Diagrams
The DEC shall produce Level Setting Diagrams for all level instrument installations.
These diagrams will show:
a) Level Instrument tag numbers and types
b) Reference drawings
c) Design parameters of the vessel
d) Vessel dimensions
e) Process data used for calculations
f) Elevation of connection nozzles from the tangent or zero reference point
g) Calculation of dp instrument ranges for calibration Level setpoints used for alarms
and trips
h) Connection nozzle sizes and ratings
i) Notes and Remarks used to provide specific detail of levels included on the
diagram.
25. Flow Instruments
Flow Units: shall be as specified at Section – 7.
DP Type flow transmitter installation shall be as per applicable J55 hook-up drawing.
For steam service welded root valve shall be considered.
25.1. Flow Elements
a) For line size greater than or equal to 2” Orifice plate shall be considered.
b) When feasible for lines smaller than 2” the line shall be swaged to a two-inch NPS
run. Otherwise, integral orifice assemblies with standard elements or honed meter
runs shall be used.

 Standard orifice sizes shall be used with integral orifices. Honed meter runs
shall be provided for systems that require special alloys or when flange ratings
greater than ANSI Class 600# are required.
 Flanges of Integral / meter-run orifice shall be as per ASME B16.36 with corner
tap.
 The β (Beta) ratio for meter runs shall be between 0.3 to 0.7
c) Orifice tapping
 For Line size ≤ 1.5”: Corner tap
 For Line size ≥ 2” to 16”: Flanged tap, including for conical entrance orifice.
 For Line size > 16”: Radius Tap (D, D/2 Taps)
d) For FRP or lined pipeline the orifice assembly shall have carrier ring assembly for
tapping. Carrier ring assembly shall be part of Orifice Plate manufacturer / supplier
scope of supply.
e) ISO 5167-2, Table-3, Option-B to be referred for upstream and downstream
straight length requirement. Option-A to be used only if specifically required.
f) For pressure compensation of flow meters, the pressure tapping shall be separate
and on the upstream of flow meters according to ISO 5167.
Notes:
1) For DP type flow transmitters square root shall be in transmitter, except for DP
type flow transmitters in anti-surge application. In anti-surge application raw value
should be transmitted to controller.
2) When orifice plate is installed in vertical line, the difference between HP and LP
tapping elevation shall be considered during hook-up design.
25.2. Special Flow Meters
a) For highly viscous and fouling service, Mass flow meter (Coriolis type), Wedge
meter, Orifice (Eccentric or Quadrant Edge) or Ultrasonic flow meter shall be
considered.
b) Where straight length for upstream and downstream is not available, V-Cone Type
flow meter or Conditioning Orifice Plate shall be considered.
c) For Custody and Product Metering in liquid service, Coriolis Flow meter, Turbine
flow meter or Ultrasonic flow meter shall be considered
d) For Custody and Product Metering in Gas service, Turbine or Ultrasonic flow meter
shall be considered
e) For High Rangeability applications Turbine or Vortex flow meter shall be
considered. Coriolis and ultrasonic flow meters shall also be considered.

f) For Flare Flow Measurement Ultrasonic flow meter or Thermal mass flow meter
shall be considered.
g) Magnetic flow meters shall be considered in conductive liquid service or
conductive liquid containing suspended solids services only.
h) Effluent discharge flow measurement for CPCB/SPCB compliance should be using
Electro-magnetic flow meter.
i) Vortex meters shall not be used for applications requiring the measurement of
back flow
j) Vortex flow meters shall not be used in oscillating flows or mechanical vibration or
compressor discharge, the following shall also be considered;
 Since thermowells also produce vortices they shall be installed downstream of
the vortex meters.
 Unless pulsation dampers are provided, vortex meters shall not be located
downstream of positive displacement compressors or pumps.
 Care should be taken in design to minimise the effect of upstream
pulsation/vibration producing equipment on the performance of the vortex
flow meter.
 The vortex meter electronics shall be remotely mounted for high temperature
and cryogenic applications. Otherwise, for high temperature applications the
sensor head shall be mounted at a 45° angle from the vertical position and
preferably in the horizontal position to avoid heating by thermal convection
from the process line.
 If mounted in horizontal pipes carrying slurries the meter shall be mounted
with the shedder bar between 45° to 90° from the vertical position with 90°
preferred to prevent the build-up of particles and debris.
 For gas measurements in horizontal lines, the vortex meters shall not be
located at low points where condensate slugs could impact the measuring
element.
k) For ultrasonic flowmeters the following shall apply;
 The timing or frequency measurement circuits shall be based upon low drift
communication technology. The uncertainty in time measurement shall be in
the nanosecond range. The transmitter shall be digitally configurable.
 The manufacturer’s minimum distances from the meter to valves, tees, elbows,
pumps and the like shall be provided.
 If an ultrasonic meter is installed near a valve that operates above the critical
pressure ratio or has anti-cavitation trim the following design accommodations
shall be considered:
 Installing the meter upstream of the valve
 Installing the control valve and the meter as far apart as possible

Notes:
1) Refer RPMS-SD-J10-026, for straight lengths requirement for Orifice plates” for
straight length requirement for Orifice plate installation.
2) Refer to Appendix-02 for a flow meter selection guide.
3) Refer RPMS-SD-J10-023 for straight length requirement for Venturi flow element.
4) Refer RPMS-SD-J10-024 for straight length requirement for Pitot flow element.
26. Range and Span of Analogue Instruments

a) The span of analogue instruments shall be adjusted to cover the operating window
which includes applicable abnormal operation and alternative operating modes
(such as start-up and shutdown).
b) The normal process value should be between 50% and 75% of the adjusted span.
c) Transmitters used for Safety Instrumented Functions (SIF) shall have the same
adjusted range and uncertainty class as corresponding process control
transmitters in order to facilitate measurement validation and comparison (MVC).
d) The Lower Range Value should be selected so that the displayed result represents
the zero or sub-zero value of the process variable.
e) Suppressed zero range should not be used.
f) Only elevated zero ranges should be selected, including the Lower Range Value as
zero.
27. Diaphragm Seals
a) Diaphragm seals shall be used instead of standard pressure or differential pressure
transmitter for the following application
 In viscous (> 200 cSt) application. (Subjected to the manufacture’s temperature
limit on diaphragm.
 In Waxy, sticky, coke forming, plugging service.
 Highly toxic, Corrosive fluids or fluids with solids
 Where impulse line requires process tracing to prevent condensation/clogging.
Where there are plugging concerns that would otherwise require rod out
facilities or a purge.
 If the fluid temperature at the instrument under any normal or abnormal
operating condition exceeds the maximum allowable temperature of the
sensing element.
b) For Differential Pressure level measurement, the use of capillary to be avoided and
same can be replaced by Electronic Remote Sensor (ERS) technology, (refer Section
– 26).
c) For instruments with remote seals, the capillary material shall be 316 stainless
steel and shall be mechanically protected by flexible 316 stainless steel armouring.

The capillary tubing shall be welded at both ends of the sensor. Screwed
connection shall not be used.
d) If capillary tube cannot be avoided, then the length of capillary tubing shall suit the
application but shall be at least 1 meter (3.0 feet).
e) Diaphragm seals used in vacuum service shall have fill liquids and connection
suitable for vacuum service.
f) If capillary tubing is exposed to direct sun radiation or to extreme or to extreme
temperature fluctuation, thermal insulation and, if required, tracing of the capillary
tubing shall be used, to reduce measurement errors as result of varying ambient
temperature and exposure to solar radiation. Supplier/vendor shall provide
calculations comparing different bore capillaries for speed of response and
temperature effects due to thermal expansion of fill fluid.
g) Diaphragm seals shall be provided with a flushing ring as specified in Instrument
datasheet. Refer applicable RPMS-SD-J10-152 for flushing ring details. Nipple shall
be welded at both end (with flushing ring and drain valve).
h) Wetted parts of diaphragm seal shall be made of corrosion resistance material.
i) Diaphragm seals shall be rated to 130 percent of the maximum design differential
pressure.
j) Capillary shall have metallic Protective Armoured Sleeve.
k) If Diaphragm seal Pressure Gauge, Pressure or Diff. Pressure Transmitter are
required with capillary, the length of capillary shall be calculated by locating
instrument at desired position on PDS/PDMS model and calculated length shall be
specified in respective instrument datasheet.
28. Fill Fluid for Diaphragm Seal
a) The sealing fluid liquid shall be suitable for the upper and lower pressure and
temperature limits of the process and shall not harm the process or have a
chemical reaction with the process upon rupture of the diaphragm.
b) The lowest possible temperature rating for a fill fluid should be selected since both
response time and accuracy shifts (due to fill fluid thermal expansion) are affected.
In vacuum applications a fill fluid should be selected which will not vaporize.
c) Temperature and absolute pressure should be considered when selecting a fill
fluid. Fill fluids must not react with the process fluid.
29. Seal / Condensate Pot
a) The main purpose of Seal / condensate pot is to catch steam and hold condensate.
This prevents damage to the transmitters or gauge. The condensate may be
drained from the bottom. The use of Seal / condensate pot shall act as a liquid
barrier between the line fluid and the condensate.
b) The Seal / Condensate pot to be used for
 In steam service or other vapours which condense to a liquid state.

 To cool down very high temperature liquids.

30. Vortex Cooler
Vortex cooler shall be considered for electronic/electrical equipment, which are
installed in vicinity of high temperature area. Prior approval of owner is required.
31. Solenoids
Solenoid valve shall be with SS Body, H-Class Insulated Single coil, 24VDC, Intrinsic safe,
auto-reset type. Manual reset where called for shall be specified in P&ID and in
Instrument data sheet and shall be with mechanical latching (not spring-loaded
mechanical lever type) / reset device. Flying leads not acceptable.
32. Corrosion Protection
Corrosion protection shall be considered for corrosive, aggressive, industrial, and
coastal environments
a) Instrument housings shall be copper free aluminium for non-marine environments.
b) For marine environments, electronic instrument housings shall be 316 stainless
steel.
c) Corrosion protection of external components and housings of instruments other
than that made of 316 stainless steel, shall be in accordance with corrosion
category C5-I (very high, Industries) C5-M. (very high, marine) per ISO 12944-2)
d) The finish of all plant-mounted instruments may be in the Manufacturer’s standard
colour (except for Control valves, On/Off valves, Safety valves etc.)
e) In addition to the protection of external parts, protective compounds and durable
coatings shall be used to prevent corrosion in the event of condensation and
corrosion inside the instrument housing.
33. Oxygen Service
Any inline or offline Instrument components, which are subject to Oxygen service,
refer Piping specification RPMS-ENGG-SPC-PP-004 for technical requirement.
34. Instrument Panels Alarms
For each panel below alarm shall be considered and hard wired to Plant DCS System
a) For DCS / ESD Panels
 Fan failure alarm
 Temperature alarm
 24VDC Power supply failure alarm.
b) Fire and Gas Detection Panels
Panel alarms shall be wired to F&G system. Refer document no. “RPMS-ENGG-SPC-
CI-008 Standard Specification for Fire and Gas System” for detail alarm philosophy.

c) For other system cabinets and package vendor supplied cabinets, one common
alarm (Fan failure, high temperature, 24VDC power supply failure) from each
cabinet shall be hard wired to DCS.
35. Instrument Panels
a) Panels located inside buildings such as Control Rooms and PIB’s shall be free
standing and weatherproof to IP 54 before any cut outs.
b) Panel shall be provided with anti-vibration pads.
c) Panel shall be with Seismic kit.
d) Cable entry (cut out with foam rubber) shall be at the bottom. Prior approval of
managing contractor / owner is MUST for Cable entry from top.
e) Adequate cooling through bottom mounted mesh filters (adjacent to cable entry)
and top mounted cooling fans shall be provided. Unless otherwise specified,
cooling air intake shall be provided through the bottom plenum in the false floor
void.
f) Each cabinet/panel shall have exhaust fans and louvers with dust filters. Capacity
and numbers of fans, size of louvers shall be adequate for heat dissipation of the
panel/cabinet heat. Fan shall be top (roof) mounted with canopy/pagoda.
35.1. Panel Size
a) Panel sizes of Control Room / PIB shall be as below:
 System / Controller (CPU) Panel: Single door, both (front and back) side
accessible, 800 mm (W) X 800 mm (D) X 2100 mm (h) including plinth
 Foundation Fieldbus Panel: Single door, only front side accessible, 800 mm (W)
X 400 mm (D) X 2100 mm (h) including plinth OR Single door, both (front and
back) side accessible, 800 mm (W) X 800 mm (D) X 2100 mm (h) including plinth
 Marshalling Panel, Interposing Relay (IRP), Power Distribution Panel: Double
door, only front side accessible, 1200 mm (W) X 400 mm (D) X 2100 (h) mm
including plinth or as per Supplier's standard with Owner’s approval.
 Server / LAN (Network): Single door, both (front and back) side accessible, 800
mm (W) X 1000 mm (D) X 2100 mm (h) including plinth, door shall be
perforated.
b) Each Door shall be fitted with louvers and filters at the bottom.
c) Panel supplier shall provide air flow displacement (panel temperature rise)
calculations to ensure that cooling is adequate.
d) Exhaust fan noise level shall not be higher than 65 dBA measured at a distance of
1 meter from source with cabinet doors closed. Filters associated with cooling
mechanisms should be readily and easily accessible and replaceable.
e) Panel lighting shall be LED Tube light.

f) The components arrangement/ installation inside panels (including

barriers/isolators) shall be such that all components are properly cooled ensuring
proper heat dissipation in the same direction of airflow and there shall not be local
heating. Isolators/Barrier shall be mounted in the vertical position or in line with
air flow direction to have proper air flow to achieve heat dissipation.
The cooling Fan / exhaust fan numbers and capacity shall be designed for fully
loaded cabinet
g) For each panel below alarm shall be considered and hard wired to Plant DCS
System,
 For DCS / ESD Panels
 Fan failure alarm
 Temperature alarm
 24VDC Power supply failure alarm.
 Fire and Gas Detection Panels
Panel alarms shall be wired to F&G system. Refer document no. “RPMS-ENGG-
SPC-CI-008 Standard Specification for Fire and Gas System” for detail alarm
philosophy.
 For other system cabinets and package vendor supplied cabinets, one common
alarm (Fan failure, high temperature, 24VDC power supply failure) from each
cabinet shall be hard wired to DCS.
35.2. Colour
All cabinets shall be Rittal (or equivalent) make and inside/outside colour shall be Light
Grey RAL 7035 whereas Plinth colour shall be Dark Grey RAL 7022.
35.3. Field Panel(s)
a) Field panels should be preferably located in non-hazardous area and shall be
weatherproof. If panels are required to be located in hazardous area below
preference of priority shall be considered: -
 Panel shall be with weatherproof certificate and suitable for installation in
hazardous area, if panel mounted devices and components are suitable and
certified for Intrinsic Safe Ex ia.
 Panel shall be explosion proof (Exd) and certified for installation in Zone 1 and
Zone 2 with active components.
 If certified explosion proof local panel system is not available, then Local panel
with purging system shall be provided. The preferred purging system Z – Type
Purge. If due to any technical reason the Z – Type Purge is not suitable, X-Type
purge or Y-Type purge to be considered based on area classification and
technical functionality.
b) The Purging system shall be as per IEC 60079-2.

c) Field panels to be ‘Ex d’ with air conditioned (if housing PLCs, Electronic controller,
etc.)
d) Annunciator, digital display, etc, which are required view or access by operators
shall be located on panel door by Panel supplier)
35.4. Wiring
35.4.1. Conductor size of internal signal wiring shall be minimum 1.0 sq. mm and all power
cabling inside the cabinet shall be minimum 2.5 sq.mm. Conductor shall be stranded
type terminated with crimped wire lugs.
35.4.2. Panel internal wiring colour coding shall be as below: -
Power Distribution
a) 240V AC Utility (Live) - Brown
b) 240V AC Utility (Neutral) - Blue
c) 110V AC (Live) - Brown
d) 110V AC (Neutral) - White
e) 24V DC (Positive) - Red
f) 24V DC (Negative) - Black
Signal
a) Wiring for IS signals - Blue
b) Wiring for non-IS signals - Grey
Earthing
a) Intrinsic Safe Earth (ISE) - Green
b) Instrument (Non-Intrinsic Safe) Earth (IE) - Green
c) Plant/Safety Earth (PE) - Green/Yellow
Core Colour Code
a) Analogue - W (+) & Bk (-)
b) Temperature – RTD (other than MCMS) - Bk, W & R (Resistance
Between Bk &W)
c) Thermocouple Type J - W (+) & R (-)
d) Thermocouple Type K - Y (+) & R (-)
e) Thermocouple Type S - Bk (+) & R (-)
f) Thermocouple Type E - P (+) & R (-)
g) Thermocouple Type T - B (+) & R (-)
h) Foundation FieldBus - B (+) & Org (-)
i) Digital, SOV, Alarm and Control Switches -

 2 Core - B (+) & Bk (-)

 4 Core and above - Bk with white number
j) RS 233 / 485 - PR 1. W (+) & B (-)
PR 2. W (+) & B (-)
k) Vibration Signals - R (power), Bk (Com) &
W (Signal)
l) MCMS RTD - R, Bk, W (Resistance between
R & B)
Notes:
1) Termination: Terminal shall be spring loaded type. Double deck or tire terminals
are not allowed. Especially for power cable termination, up-to 4mmsq cable size,
terminals shall be spring loaded type, above 4mmsq cable size terminals shall be
stud bolt type terminals.
2) Multi-pair and Multi-core shall have maximum 20% spare core/pair. Spare
core/pair shall be terminated at both end (in JB and at Panel side). All spare
core/pair cable shall be looped and connected to Instrument earth bar at panel
side.
3) IS and non-IS wiring and cable duct shall be adequately segregated. Cable duct
colour shall be blue for IS and Gray for NON-IS applications.
4) Except HMI Display unit, Indication lamps, push buttons and switches, no any
equipment / components shall be mounted on doors or side panels.
5) Maximum number of wires/cables per terminal shall be only one.
6) FF Cable wiring and Installation shall be as per AG 140 & FF 844.
7) FF Terminators shall be provided at both ends of an FF segment. The field
terminator shall be installed in the FF Spur JB at the farthest end of the Trunk. No
terminators shall be installed in the FF device as this may impact the whole
segment if device needs replacement.
8) FF Spare pair from Intermediate JB to marshalling/FF cabinet shall be terminated
in spare TB’s and are further connected to instrument earth bus bar.
9) Unused /spare segment on its H1 card shall be terminated with end terminator.
10) Metallic conduit shall be provided for unarmoured sensor cable in field. DEC shall
provide the size and quantity.
11) Two wires shall not be lugged together & terminated on one terminal. Comb shall
be used for looping wherever required.

Panel terminal type shall be spring loaded type Phoenix, Wago or equivalent make.
Terminal colour shall be Blue for IS signals and Grey for NIS signals. 25% spare
terminals of each type shall be considered.
35.4.3. Fused Terminals
a) Where isolators are being used
 For Analogue signals (AI/AO), Knife-edge disconnect type terminals shall be
used
 For digital signals (DI/DO), fused TB shall be used
b) Where isolators are not being used
 For All signals (AI/AO/DI/DO), fused TB shall be used
 All terminals with fuses shall have fuse blown LED indication
36. Instrumentation Cable
a) Instrumentation Cable shall be in accordance with EN 50288-7 or equivalent
standard.
b) Following types of Cables which are generally used in Instrumentation are as
below:
 Instrumentation Signal cables for Analogue and Digital Signals.
 Field Bus Cables
 RS 422/485 Communication cables
c) Armoured cables shall be used for following conditions:
 Direct buried in the ground (Note: Cables shall be suitable for direct burial in
water-logged ground).
 In underground ducts
 Above ground, fastened to cable ladder rack or tray in the open air exposed to
direct sunlight
 Below ground in enclosed, air filled trenches, fastened to cable ladder rack or
tray.
 Sea atmosphere and marine application (wherever specified cable shall be
designed in accordance to specified conditions/special requirements).
d) Cables shall have design temperature range limits of -30oC to +90oC (Except Fire
Resistant Cables). Fire resistance cable shall be considered, where manual call
point signals, Horns, Beacons and other energize to trip circuits except deluge valve
solenoid etc. are required to maintain circuit integrity during the fire i.e. able to
withstand temperatures of at least 750 °C for a period of 90 minutes. However, for
use of fire-resistant cable, prior approval from owner shall be obtained.
e) Conductor size for instrument cables, FGS device cables and thermocouple
extension cables shall be minimum 1.0 mm2. However, the Instrument cable

conductor size for high power devices such as Horns, Beacons, open path gas
detector, high power solenoids for deluge systems etc. shall be calculated based
on voltage drop calculation and the engineered routing length.
f) Various signal level class are as below:
Signal Signal Type Examples
Level
Class
1 Low energy digital systems Computer bus signals
Analogue low level (mV signals) Thermocouples
Analogue medium level Resistance temperature
measurements, analysers
2 Analogue high level Electronic instrumentation
[e.g. 1-10 V(dc), 4-20 mA] loops
Binary low level [below 24 VDC and Actuating logic systems,
below 0.5 VA] annunciators
Digital low level (pulse train) Turbine meters, proximity
sensors
Fieldbus Signals FF devices
3 Digital high level (pulse train) Tank gauging system
Proximitor for machine monitoring Vibration sensors
4 On-off medium level 24 V(dc) solenoids

(< 50 V or > 0.5 VA, <40 VA)
5 High level signals > 50 VAC and DC 110 V(dc) solenoids (cable
power signals higher than class 4 by Electrical)
Power supply cables Power supply cables to
instrument cabinets and
field instruments
g) Refer standard drawing RPMS-SD-J10-020/021 for schedule of standard cables
types and cable glands for detail engineering.
h) The design shall cater for spare capacity in Multicore / Multipair cabling. When the
design is finalized, 20% of the installed cabling capacity shall be available in each
signal level class and plant area to accommodate unforeseen future plant
modifications. Based on above philosophy, 20% of spare cores/pairs shall be left in
each multi core cable.
i) Special low capacitance and inductance cable may be required in II C area,
considering engineering and system vendor requirement. Approval from client
shall be obtained prior to implementation of low capacitance cable.

37. Junction Boxes

All instrument junction boxes shall comply with minimum IP65 as per IEC 60529 or
equivalent NEMA class,
a) Protection: Eex’e’ terminals shall be provided for IS and NIS Junction Boxes
b) Material of Construction:
 Fiberglass for both IS and NON-IS Junction Box (with SS316 nut, Bolts, Plates
and hinges)
 LM6, Aluminium for ‘Ex d’ Junction Box with Epoxy painted.
c) Certification
CcoE/PESO certificate for IS, NON-IS and Eex’d’ JB. Certification shall be Eex ‘ia’ for
IS Junction Box, Eex’e’ for NON-IS Junction Box and Eex’d’ for Explosion proof
Junction Box. Eex’d’ Junction Box shall only be used (not in Zone 0) where
Electronics or Energy user is installed inside JB.
d) Cable entry and Gland plate
 Side entry for branch cables (cable between field devices and Junction Box)
 Bottom entry for multicore cables (main cable between Junction Box to Control
System)
 All unused gland entries shall be closed with certified metallic/polyamide plug.
 Gland plate shall be provided at both sides of JB for branch cable entry at site
and at bottom for multicore cable (main cable between Junction Box to Control
System)
e) Segregation of JBs (Separate J/B) for following signal types shall be provided
 Analogue input and output
 Digital Input and output
 Intrinsically Safe (IS) Signals
 Non-Intrinsically Safe (NIS) Signals
 FF Signals
 Temperature (Thermocouple)
 Temperature (RTD)
 Vibration signals
 Serial Communication link (redundant 1 JB for each
 For each voltage control level e.g. 110V ac, 24VDC etc.
f) J/B terminal type shall be spring loaded type Phoenix, Wago or equivalent make.
Terminal colour shall be Blue for IS signals and Grey for NIS signals. 25% spare
terminals for each JB shall be considered.

g) Cable Glands shall be considered for all cables. Cable gland shall be Brass with Ni/Cr
plated Flameproof, double compression type.
Notes:
1) Dedicated Junction box shall be considered for each control system and package
unit control system. No signals of different control system shall be mixed in same
Junction Box.
2) Junction Boxes shall have adequate space between terminals and sides of the box
to facilitate easy cabling and termination.
3) Junction boxes shall be provided with earthing connection stud outside of JB for
connection to safety/Plant earth.
4) All spare wires in multi-core cables to be terminated in J/B’s.
5) Any looping inside JB shall be done using special links supplied by terminal
manufacturer.
6) Sunshades are required for FF JBs, FF & Conventional MUX JBs and FF Mega block
JBs. Sunshades are not required for conventional Junction Boxes.
7) Junction Box shall be provided with Isolated earthing plate, all screen / shield wires
shall be terminated to earth plat.
38. Hook-ups
38.1. Conventional Hook-ups
Standard hook-ups shall be as per J55 drawings.
38.2. Close Coupled Hook-ups
Scope of CCH for line mounted instruments shall begin from first nipple (after
instrument tapping) and for tank/vessel mounted instruments shall begin after
instrument tapping flange.
Root isolation valve shall be provided by Piping, CCH assembly will start after root
isolation valve.
38.2.1. Selection
a) CCH shall be selected for installation of pressure gauges and pressure transmitters.
The use of CCH for & differential pressure transmitters and differential pressure
type flow transmitters should be considered where it is possible.
b) CCH shall be implemented for clean services only.
c) Accessibility with respect to operation and maintenance shall be considered while
selecting CCH.
d) Design Pressure and Temperature shall be verified against Transmitter Model,
before selection of CCH. CCH shall not be implemented for service above 120 deg.
C design temperature.

e) CCH selection on high vibrating lines shall be considered only after owner’s
approval.
f) Piping classes and corresponding instrument classes shall be referred for selection
of MOC, type of joints and type of root isolation valve. Refer to RPMS-ENGG-DBD-
CI-005 for instrument classes and RPMS-ENGG-SS-PP-038 for piping class and
specification.
g) Transmitter model no shall be verified for orientation with respect to CCH selection
by DEC.
h) CCH assemblies shall be used for all installations, if selection criteria are met as per
this section.
38.2.2. Implementation
a) DEC shall identify appropriate tags (instruments) for implementation of CCH
considering selection criteria.
b) CCH assemblies shall be reflected on P&IDs with indicating note against applicable
Tags.
c) CCH shall be modelled in piping 3D model to avoid fouling issues.
d) CCH assemblies shall be procured against stock-codes generated by owner.
e) DEC shall check for selection of existing Standard J55 (Hook-up) drawings for CCH.
For new project specific CCH development, DEC shall provide details to supplier in
format per Appendix-05 CCH supplier shall develop and provide graphics with
dimension for hook-up development. DEC shall generate and issue Hook-up for the
same after owner’s consent.
f) For development of new stock-codes, DEC shall provide request in NSCR format
per RPMS-ENGG-DBD-CI-012 considering below points and existing CCH codes.
 MOC, Schedule, length etc. of Nipple
 Root isolation valve type, size etc.
 Type, mounting orientation etc. of instrument.
g) Hook-up assignment in SPI and provision of MTO in required formats shall be done
by DEC based on which further procurement action shall be taken by Owner.
h) All CCH assemblies shall be pre-tested as per approved ITP prior to supply by
supplier.
i) Owner’s approval on ITP shall be obtained by supplier before manufacturing.
j) CCH supplier shall submit applicable certificates as per requirement mentioned in
stock-code or in input file per Appendix-05.
k) Documentation as per owner approved document requirement schedule shall be
carried out by supplier.
l) All Butt-weld joints shall be 100% radiographed, and all fillet joints shall be 100%
DP/MP tested.

m) NDT requirements shall be followed per piping specification requirements.

n) Post weld heat treatment for the welding joints, that are part of CCH assembly shall
be done by CCH Supplier as per piping specification requirement.
o) Prefabricated GRP sunshades for the wired instrument CCH shall be provided by
CCH supplier (complete with mounting arrangement).
38.2.3. Installation
a) Complete assemblies shall be provided prefabricated and pretested for a single
weld at site.
b) Eccentric Weldolets (for FT installation) shall be supplied loose by CCH supplier.
c) Piping shall provide a beveled end nipple at every identified CCH installation
tapping. Nipple length shall be in accordance with required insulation thickness.
d) Piping contractor shall install the assembly at site. Refer standard drawing RPMS-
SD-P14-171 (CCH Pressure Connections).
e) Support, if required other than supplied with CCH, shall be fabricated and installed
at site. Refer document RPMS-ENGG-DBD-ST-004 (Design Basis for Pipe Support).
f) Bolts for vessel/tank mounted CCH, shall be in CCH supplier scope.
g) CCH assembly post installation shall be hydrotested as per service requirement.
39. Inspection, Testing and QA / QC
Refer specifications of respective Instruments and Controls systems.
40. Accuracy and Repeatability
Minimum accuracy shall be considered as below :
a) Major flow meter (minimum accuracy or better, as specified in datasheet)
 Electromagnetic : ± 0.5 - 1 % of flow rate
 Coriolis : ± 0.05 - 0.5 % of flow rate
 Thermal : ± 1 % of rate
 Custody transfer meter : ± 0.25 % of flow rate
 Orifice : ± 2 - 4 % of full scale
 Turbine : ± 0.25 – 0.5 % of flow rate
 Ultrasonic : ± 1 - 5 % of full scale
 Vortex : ± 1 – 1.5 % of flow rate
b) Level Measurement
 For level gauge : Minimum ±5 % of full scale or better, as specified in datasheet
 Other level measurement : ± 2 % of full scale or better, as specified in datasheet
c) Pressure Measurement

 Minimum 0.075% of overall span or better, as specified in datasheet

d) Temperature Measurement
 Thermocouple : Accuracy shall be as per IEC 60584-2, tolerance Class-1.
 RTD (Resistance Temperature Detector) : Accuracy shall be as per IEC 60751,
tolerance Class-A.
Above are the minimum accuracy requirement, however better accuracy shall be
considered as per process requirement at the time of technical bid evaluation.
41. Earthing System
Each Panels, Racks, Cabinets, Consoles, and Shelters etc. should provide earthing bus
bar in combination as applicable. Below are the options of earthing bus bar
combination:
a) Intrinsic Safe Earth (ISE), Instrument (Non-Intrinsic Safe) Earth (IE) and Plant/Safety
Earth (PE),
b) Intrinsic Safe Earth (ISE) and Plant/Safety Earth (PE)
c) Instrument (Non-Intrinsic Safe) Earth (IE) and Plant/Safety Earth (PE)
Earth Bars shall be tin plated manufactured from high conductivity annealed copper
with a cross section of at least 25 mm x 6mm with minimum length of 250mm.
41.1. Intrinsic Safe Earth (ISE),
All individual shields and overall shields of cable within Intrinsic safe loop shall be
connected separately on the ISE earth bar. Any earthing requirement of
Barrier/Isolator within Intrinsic safe loop shall also be connected ISE earth bar, if
applicable. ISE earth bar shall be located at the bottom of cabinet / panel near the
cable entry and mounted on insulators spaced at a minimum of 25mm from
cabinet/console steelwork.
41.2. Instrument (Non-Intrinsic Safe) Earth (IE)
All individual shields and overall shields of cable within Non-Intrinsic safe loop shall be
connected separately on the IE earth bar. IE earth bar shall be located at the bottom
of cabinet / panel near the cable entry and mounted on insulators spaced at a
minimum of 25mm from cabinet/console steelwork.
41.3. Plant/Safety Earth (PE)
All power supply earth, Panel body earth, Rack body earth, Cabinet body Earth,
Console body earth, Instrument body earth, Junction box body earth, enclosure earth
etc. to be connected to PE earth bar. PE earth bar shall be located at the bottom of
cabinet / panel and mounted on Metallic support, spaced at a minimum of 25mm from
cabinet/console steelwork.
Notes:

1) Manufacturer / Supplier shall provide all earth continuity links required for his
equipment. Provision shall be made for terminating 35 mm2 stranded copper earth
cable for Panels, Racks, Cabinets, Consoles, Shelters etc.
2) Manufacturer/Supplier shall ensure design of earthing scheme, its implementation
and integrity.
3) Any special earthing requirement for specific system or control loop, shall be
designed and implemented within applicable system or for applicable loop
separately.
4) Earth pit for Intrinsic Safe Earth (ISE), Instrument (Non-Intrinsic Safe) Earth (IE) and
Plant/Safety Earth (PE) shall be provided near PIB’s and Control Rooms.
5) Instrument Junction Box and local control panel Location shall also be shown in
Electrical Earthing layout drawing for Plant/safety earth strip layout.
6) Inside panel earthing cable shall be minimum 6 sq.mm.
7) Flexible conduits, soldered joints or door hinges shall not be accepted as earth
returns.
8) All earth connections shall be made direct from each cabinet to respective earth
bar (Intrinsic Safe Earth, Instrument (Non-Intrinsic Safe) Earth and Plant/Safety
Earth)
9) Field run earth connection to Instrument shall be as per RPMS-SD-E12-
195/196/197, Implementation of earthing method A, B or C shall be suit to site.
10) Acceptable resistance between earth strips to earth pit shall be less than 1 ohm.
11) Parallel Earth Conductor (PEC) or earth strip shall be laid along the FRP cable tray
or inside trench (Parallel to Instrument Cable). Electrical shall provide the MTO.
12) Refer relevant RPMS-SD-J10-009 drawing for detail Earthing.
13) Surge Protector earthing shall be connected to Plant/Safety Earth (PE)
42. Construction
a) Cable Tray: FRP Cable tray shall be used for seawater and cooling tower
application, GI (Galvanized) tray shall be used for other area.
b) Separate Branch and Main Cable Tray shall be considered as below:
 Cable Tray for IS Cable Tray
 Cable Tray for NIS Cable and FF Cable
 Cable Tray for Power cable
Note:
1) Cables shall be laid in 2 to maximum 3 layers, 25% spare space for future cable shall
be considered in each cable tray.

2) When cables are laid in common trench, brick wall partition to be provided for
Power cable.
3) PA and IT cable shall NOT be laid in IS, NIS and FF Cable tray.
4) Minimum safe distance shall be maintained between Instrument cables and hot
surfaces/hot zone.
c) Cable Entry to Control Room, PIB (Plant Interface Building), Local Control Room,
Analyzer House shall be through MCT Blocks. MCT frames size shall be
standardized and segregated for below cable type and signals
 MCT Frame for IS Cable
 MCT Frame for NIS & FF Cable
 MCT Frame for Power Cable and Earthing Cable
 MCT Frame for FO, Telecom, PAGA and CCTV (only FO cable)
d) Cable segregation requirements are defined in RPMS-ENGG-DBD-CI-004
e) Hook-ups: Standard hook-up drawing as per J55 shall be followed. Special hook-
ups shall be developed by DEC for special requirement and licensor specific
requirement, Owner’s approval shall be taken for special hook-ups. Close Coupled
Hook-up should be considered wherever technically acceptable and possible from
maintenance point of view.
f) Installation: Standard Installation drawing as per J10 shall be followed. Special
Installation drawing shall be developed by DEC for special requirement and
licensor specific requirement. Owner’s approval shall be taken for special hook-
ups.
g) Installation drawing and Installation material MTO for installation of Local Field
Mounted panels shall developed and issued by DEC as a part of Project
Deliverables.
h) Main Cable from field to PIB / Control trench room shall be above ground. Prior
Owen approval is required for underground cable laying.
43. Instrument Piping and Tubing
Heat and Cold Insulation shall be considered as specified in P&ID and Piping
specification, to protect the Instruments pressure piping or process fluid from freezing,
vaporizing, crystallization and thermal shock as per piping insulation specification. All
instrument isolation valves shall be equipped with bonnet Anti rotation Pin/Lock.

43.1. Installation/Tubing hook-ups

a) In general, J55 hook-ups documents to be considered for Instrument Installation,
close coupled or remote installation shall be as per project specification.
b) For rating less than 600#, Tubing shall be used for Instrument Impulse lines.
c) For rating 600# and above, Piping shall be used for Instrument impulse lines.
d) In Special cases Piping hook-up shall be considered, below are few examples,
 Hydrogen service.
 Toxic applications (wherein diaphragm seal is NOT suitable).
 For PDT’s installed at columns due to longer length
e) Special Impulse line shall be as per licensor specific or project specific requirement.
f) Trace heating shall be as per Project specification and process and licensor
requirement. Electrical / Steam Tracing for Instruments shall be similar and
contiguous with steam tracing for Piping and valves.
43.2. Instrument Impulse Line Valves (After first isolation valve provided by piping)
a) Piping Hook-ups: Isolation valve shall be per piping spec.
b) Tubing Hook-ups: Needle type valve for Isolation, Vent and drain.
c) Instrument Air Line (Including Instrument Air Manifolds): Ball valve for Isolation
service.
44. Control Buildings
a) For details, refer document no. RPMS-ENGG-GUD-CI-009, Guideline for Control
Building.
b) The Control Rooms, Equipment Rooms and PIB shall have HVAC systems.
Minimum following design parameters for HVAC system shall be:
 Temperature: 22 °C, ±2°C. Temperature measurement sensor (loop) to be
provided and connected to DCS for continuous monitoring and alarm.
 Humidity: R.H. = 50%, ±5% (no condensation). Humidity measurement sensor
(loop) to be provided and connected to DCS for continuous monitoring and
alarm.
 Airflow: 0.15 m/s
 Pressure: Control Room / PIB shall be kept under positive pressure ventilation
to prevent smoke or toxic gases from entering to maintain the electrical area
classification. Pressure measurement sensor (loop) to be provided and
connected to DCS for continuous monitoring and alarm.
 Filtration for HVAC: Particulate filter for dust and chemical filter on
recirculation air shall be provided.
 Environment: Corrosion severity shall be in accordance to ISA S71.04 and
severity level G1 (Mild).
c) Control room or PIB, where corrosion monitoring system with integral

measurement of Pressure, temperature and Humidity is included, no need to
considered separate measurement for Pressure, temperature and Humidity. When
corrosion monitoring system is installed in PIB or Control room, individual alarms
of corrosion, temperature, pressure and humidity shall be wired to DCS. For details
of corrosion monitoring system refer RPMS-ENGG-DBD-CI-013.
Notes:
1) For PIB and Analyzer House, Temperature, Humidity and Positive Pressure
requirements are similar to Control Building.
2) False Floor: To be provided in control room, rack room and PIB.
45. Automation Tools

The following automation tools shall be used:
Microstation : 2D CAD Drafting
SPI : Instrument Engineering / Data Sheet / Valve Sizing / Hook-ups
/ Bulks MTO / Databases
Flowel / Conval : Differential Pressure Flow-meter Sizing,
Conval : Thermowell wake frequency calculation
SP3D/PDMS : Instrument location plans
Rworks : MTO (Tagged and Bulk) to be provided as per project format.
(Interfacing tool)
SPM : Smart Plant Materials
Cable Routing : Cable routing software - SP3D-SPEL/RCRA/ DEC Specific software
can be used but data shall be exported to RIL template for Import
in RCRA.
EXIDA- exSILentia : SIL assessment & verification
EXIDA- exSILentia : SRS
CyberPHAx : Cyber Risk Assessment Tool
CyberSL : Security Level SL Verification tool
Note:
1) Latest versions of all Automation Tools software shall be used
2) Cable routing in SPI is preferred
46. Calculations
a) Manufacturer / supplier shall submit design calculations of orifice plates, control
valves, relief valves, flow meters and any other instrument requiring calculations

for appropriate application/selection to DEC for approval. Final plant data books
shall have consolidated sections including all calculations.
b) SPI shall be for preliminary sizing calculations. Final calculations shall be as per
manufacturer’s/supplier’s software / methods approved by Detail Engineering
Contractor/Owner. Manufacturer’s/Supplier’s calculation software / methods
shall have reference of Indian/International code and standards.
c) All symbols used in calculations shall be identified. References shall be quoted for
the equations and methods of calculations used.
d) Sizing and noise level prediction of control valves shall be based upon the control
valve Seller’s computer program. SPI / Detail Engineering Contractor’s base
program may be used to confirm the Seller’s data.
e) Flowel / Conval Program shall be used for orifice calculations. Calculations shall be
performed in accordance with ISO 5167. For line less than 2” Orifice bore
calculation shall be as per ISO TR 15377
f) Selected manufacturer’s/supplier’s program for relief valve calculations shall be
used.
g) Noise level calculations are required for all instrumentation devices that generate
noise or contribute to the plant sound level. The maximum noise level shall not
exceed 85dB. If noise level exceeds more than 85dB, same shall be informed to
Owner / Detail Engineering Contractor (DEC).
h) DEC shall perform vessel and sump level instrument calculations/calibrations
(identifying transmitter range, zero suppression/elevation, and alarm setting/trip
point calculations). An associated sketch depicting applicable nozzle locations,
bridle dimensions, and level gauge, transmitter and switch coverage shall be
provided to illustrate the details supporting the calculations/calibrations.
i) Manufacturer/Supplier shall provide all the utility (Instrument air, UPS and Non-
UPS power supplies) requirements and Heat load with all supported back-up
documents to Detail Engineering Contractor.
j) Power and Heat Load calculation.
k) Thermowell Wake Frequency Calculation as per ASME PTC 19.3 latest edition ,
calculations need to cover all possible process conditions including start-up,
shutdown, blowdown, gas blow by. Process conditions shall be defined and
documented by the DEC Process Engineering team.
l) Voltage drop calculations shall be performed to verify cable (conductor) sizing.
m) FF Loop segment calculation shall be done for each segment.
n) Intrinsic Safe (IS) Loop Calculation
47. Documentation
As a minimum, DEC shall provide drawings in the following categories. If DEC deems it
necessary to originate a new type of drawing for the completion of the project, DEC

shall request Owner’s approval explaining the reason for the new type of drawing and
defining the new drawing format.
a) Control Systems & Instrumentation Specifications (Word format)
 Control & Instrumentation Design Basis
 Control System Design philosophy
 Individual Specification for Field Instruments and Control Systems
b) SPI Deliverables
 Instrument Index Report
 Instrument Datasheets
 Instrument Wiring Reports, Connection Diagrams (including cross panel wiring
of between various control panels of same package)
 Instrument Segment Wiring Drawing
 Alarm & Trip Schedule
 Control System I/O Schedule. (including Serial data)
 Instrument Loop Diagram
 Instrument Pneumatic Hook-up
 Instrument Process Hook-up Drawings
 Instrument heat tracing connection details
 Inter/Cross panel wiring (within same package) shall be generated from SPI.
c) Material Requisition
 MR/Enquiry Specification for Control systems, tagged and non-tagged items
 Technical Bid Analysis for Control systems, tagged and non-tagged items
 Purchase order Specification for Control systems tagged and non-tagged items.
d) 3D-Modeling Deliverables ( xls format)
 Instrumentation items modelling report
e) Documents Related to Automation System
 Control system Architectures (Micro Station)
 Overall Network Architecture (Micro Station)
 Control loop narratives (Word Format) and Logic Sequence Diagrams (BLD
form)
 Control Loop Sketches (Native file)
 Cause & Effect chart (xls format)
 Interface Block Diagram (Micro Station)

 Serial Link interface database for all third-party interfaces (xls Format)
 FF Design requirement for applicability of Foundation Fieldbus Technology and
detail design document defining loop criticality, Segment design, Segment
validation, Segment calculation, FF enclosure, No of Surge protectors etc.
(Word Format)
 Graphic sketches (Visio OR SP P&ID)
 Process / Plant Graphics specification (Word Format)
 Cable Block Diagram (Micro Station)
 Cyber Security Assessment and Management Plan
f) Safety Instrumented System
 Functional Safety Management (Native Format)
 HAZOP Report (Native format/Exsilentia)
 SIL Evaluation, Implementation & Validation Procedure (Native format)
 Safety Integrity Level report (ExSILentia)
 Safety Requirement Specification (SRS) (ExSILentia)
 SIL Verification Report (ExSILentia)
g) Layout Drawings (Micro Station)
 Control Room Layout drawings
 Plant Interface Building (PIB) Layout drawings
 Engineering room layout drawings
 Instrument rack room Layout drawings.
 Earthing Layout for control room, PIB and field installation.
 MCT Sizing and Layout drawing (Manufacturer / Supplier Software Report)
 Fire & Gas detection layout drawing
 Field Instrument, Junction Box, Air Header, local Control panel etc. Location
Plans
 Instrument Cable Tray Layout
h) Interface Documents (Microsoft Visio/Microsoft office)
 Piping
 Piping requirements for Instrumentation
 Inline Instrument data
 Plot plan space requirements
 Electrical (xls OR Word Format)

 UPS & Non-UPS power requirement

 Instrument – Electrical Interface details
 Motor co-ordination diagram
 UPS & NON-UPS single line power distribution diagram for Instruments &
Control systems
 IRP – MCC Interface wiring diagram.
 Vessels
 Level setting diagrams
i) Miscellaneous Documents (Micro Station)
 Instrument Installation sketches and drawings
 Instrument Mounting Details
 Instrument utilities consumption.
 Instrument signal & power cable sizing calculations.
 Civil & Structural support requirements.
j) Instrument Material Take Off (non- SPI items) (xls Format)
 Cable Glands
 Installation support
 Instrument Cable Accessories (Including cable clamps and earthing clips)
 Instrument Cable Ladder & Tubing Tray
 Instrument Distribution Manifold
 Multiple Cable Transit (MCT)
 Sunshades
 Tube Clamps
k) Instrument Schedules (SPI Deliverable in xls Format)
 Instrument Cables Schedule
 Instrument Cables drum Schedule
 Schedule of Quantity for construction contract.
 Junction Box Schedule
 Air-manifold Schedule

Notes:
a) Detailed packing list (including loose items and accessories) listing all Instrument
and Control System items shall be submitted to Owner / DEC by Instrument,
Control System and Package vendor/supplier under M01 category.
b) The following documents shall be reviewed and referenced during the selection
and preparation of Instruments Installation Drawings (IID’s):
 Piping and Instrumentation Diagrams
 Electrical Raceway Drawings
 Instrument Location Drawings
 General Arrangement Drawings
 Piping Isometric Drawings
 Instrument Specifications and Data Sheets
 Standard Piping Class Sheets
 Piping Material Class Specifications
 Project Line Designation Tables
 Flow Diagrams
 Line Class Summary Sheets
 Project Design Criteria and Basis
 General Project Specifications
 Supplier Drawings and Manuals including the following:
 Installation Guidelines and Instructions
 Assembly Drawings
 Operation and Maintenance Manual

Appendix-01: Codes and Standards

1. Purpose
This document defines the recommended codes and standards for design, selection,
manufacture, inspection, testing and installation of instrumentation. The latest edition
of codes and standards and its applicable parts shall apply as available at the date of
contract award.
All exceptions and deviations from the codes and standards shall be documented and
approved by the owner before implementation.
This could be applied to all projects, thereby to achieve the maximum technical and
economic benefits from standardization. Parties involved shall meet to review and
discuss the codes & standards noted in this document to determine the minimum
applicable codes & standards required for a specific Project.
Detailed below are item-wise codes & standards to be used for Control system and
Instrumentation
2. Engineering and Design
ASME B1.20.1 Pipe Threads General Purpose (inch)
ASME B16.20 Metallic Gaskets for Pipe Flanges
API RP 551 Process Measurement
API RP 552 Transmission Systems
API STD 560 Fired Heaters for General Refinery Services
Petroleum, petrochemical and natural gas industries. Fired
ISO 13705
heaters for general refinery service
Gas Turbine for Petroleum, Chemicals and Gas Industries
API STD 616
Services
API STD 617 Axial and Centrifugal Compressors and Expander-compressors
Reciprocating Compressors for Petroleum, Chemical and Gas
API STD 618
Industry Services
Rotary-Type Positive-Displacement Compressors for
API STD 619,
Petroleum, Petrochemical and Natural Gas Industries
Petroleum, petrochemical and natural gas industries. Rotary-
ISO 10440 (Part 1) type positive-displacement compressors. Process
compressors
Petroleum and natural gas industries. Rotary-type positive-
ISO 10440 (Part 2) displacement compressors. Packaged air compressors (oil-
free)
Management of Hazards Associated with Location of Process
API RP 752
Plant Permanent Building

Process Control Systems

Part-1: Process Control Systems Functions and Functional
Specification Development
API RP 554
Part-2: Process Control System Design
Part-3: -Project Execution and Process Control System
Ownership
Instrumentation, Control, and Protective Systems for Gas Fired
API RP 556
Heaters
ASTM A
193/A193M, grade
B7,
Bolts and nuts
ASTM A
194/A194M, grade
2H
ASTM Standard Specification for Seamless and welded Austenitic SS
A269/A269M tubing for general service
Standard Guide for Cleanliness Levels and Cleaning Methods
for Materials and Equipment Used in Oxygen-Enriched
ASTM G93 / G93M
Environments
Copper and copper alloys, Seamless, round tubes for general

BS EN 12449
purposes
BS EN 62444 Cable Glands for Electrical Installations
BS 3643 Part 1 ISO metric screw threads. Principles and basic data
ISO metric screw threads. Specification for selected limits of
BS 3643 Part 2
size
BS 5863 Analogue signals for process control systems. Specification for
Parts 1,2 & 3 direct current signals
Analogue signals for process control systems. Part 1: Direct
IEC 60381-1
current signals
Analogue signals for process control systems. Part 2: Direct
IEC 60381-2
voltage signals
Code of practice for instrumentation in process control
BS 6739
systems: installation design and practice
Copper and copper alloys. Seamless, round copper tubes for
BS EN 1057
water and gas in sanitary and heating applications
Mechanical cable glands. Code of practice for selection,
BS 6121 Part 5
installation and inspection of cable glands and armour glands
IEC 60068 (All
Environment Testing
applicable parts)
IEC 61310 (All
Safety of machinery – Indication, marking and actuation
applicable parts)

Basic and safety principles for man-machine interface, marking

IEC 60073 and identification – Coding principles for indicators and
actuators
IEC 60617 Graphic Symbols for Electronic Diagrams.
BS EN 61010 (All Safety requirements for electrical equipment for
applicable parts) measurement, control, and laboratory use
IEC 61298 (All
Process measurement and control devices
applicable parts)
Recommended Practice for Hot-Dip Galvanizing of Iron and
BIS IS 2629
Steel
BIS IS 3043 Code of Practice for Earthing
BIS IS 732 Code of Practice for Electrical Wiring Installations
ISA 20 / ISA-
Instrument Specification Forms / picklists
TR20.00.01
ISA 51.1 Process Instrumentation Terminology
ISA 18.1 Annunciation Sequences and Specification
Safety Standard for Electrical and Electronic Test, Measuring,
ISA 82.03
Controlling, and Related Equipment
Guidance for Application of Wireless Sensor Technology to
ISA-TR84.00.08
Non-SIS Independent Protection Layers
Environmental Conditions for Process Measurement and
ISA 71.03
Control Systems: Mechanical Influences
ISA-TR84.00.09 Cybersecurity Related to the Functional Safety Lifecycle
ANSI/ISA 5.1 Instrumentation, Symbols and Identification
ISA 5.2 Binary Logic Diagrams for Process Operations
Graphic Symbols for Distributed Control / Shared Display
ISA 5.3
Instrumentation, Logic and Computer Systems
ISA 5.4 Instrument Loop Diagrams
ISA 5.5 Graphic Symbols for Process Displays
Compatibility of Analogue Signals for Electronic Process
ANSI/ISA 50.00.01
Instruments
ANSI/ISA 12.04.04 Pressurized Enclosures
Connections for general use and fluid power. Ports and stud
BS EN ISO 1179 (All
ends with ISO 228-1 threads with elastomeric or metal-to-
applicable parts)
metal sealing
BS 4368 (All Metallic tube connectors for fluid power and general use. Split
applicable parts) collet compression fittings
IEC 80416 (All
Basic principles for graphical symbols for use on equipment
applicable Parts)
ISO 3511 (All Industrial process measurement control functions and
applicable Parts) instrumentation — Symbolic representation

IEC 60770 Part 1,2

Transmitters for use in industrial-process control systems
&3
ISO 9000 Quality Management Systems
ISO 9001 Quality Management Systems – Requirements
Petroleum, petrochemical and natural gas industries – Metallic
NACE MR 0103 /
materials resistant to 78ulphide stress cracking in corrosive
ISO 17945
petroleum refining environments
NAMUR NE107 Self-Monitoring and Diagnosis of Field Devices
NFPA 85 Boiler and Combustion Systems Hazards Code
Safety Instrumentation for Process System in Hydrocarbon
OISD-STD-152
Industry
OISD-STD-163 Process Control Room Safety
Protection against electric shock – Common aspects for
BS EN / IEC 61140
installations and equipment
IEC 60079(All
Explosive atmospheres
applicable parts)
BS EN ISO 11064
(All applicable Ergonomics Design of Control Centres
Parts)
Standardisation of the Signal Level for the Failure Information
NAMUR NE 43
of Digital Transmitters
Wireless systems for industrial automation: Process control
ANSI/ISA-100.11a and related applications
OIML R 34 Accuracy classes of measuring instruments
3. Electrical Installation / Environmental Protection
API RP 540 Electrical Installations in Petroleum Processing Plants
Recommended Practice for Classification of Locations for
API RP 500 Electrical Installations at Petroleum Facilities Classified as Class
I, Division I and Division 2
BS EN IEC 61326
Electrical equipment for measurement, control and laboratory
(All applicable
use – EMC requirements
parts)
IEC 60255 (All
Measuring relays and protection equipment
applicable parts)
BS EN / IEC 60300
(All applicable Dependability management
parts)
BS EN IEC 61204
(All applicable Low-voltage switch mode power supplies
Parts)
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

IEC TR / IEC 61000

(All applicable Electromagnetic compatibility (EMC)
parts)
IEC 62305 (All
Protection against lightning
parts)
IEEE Recommended Practice for Powering and Grounding
IEEE 1100 Electronic Equipment. (IEEE Emerald Book)
Guide for Selection and Installation of Electrical Equipment In
BIS IS 5571
Hazardous Areas (other Than Mines)
Classification of Hazardous Areas (other Than Mines) Having
BIS IS 5572
Flammable Gases and Vapours for Electrical Installation
Code of Practice for the Selection, Installation and
Maintenance of Electrical Apparatus for Use in Potentially
BIS IS 13408
Explosive Atmospheres (Other than Mining Applications or
Explosives Processing and Manufacture)
Recommended Practice for Wiring Methods for Hazardous
ISA RP 12.06.01
(Classified) Locations Instrumentation Part 1: Intrinsic Safety
Environmental Conditions for Process Management and
ISA 71.01
Control System, Temperature and Humidity
Environmental Conditions for Process Measurement and
ISA-71.02
Control Systems: Power
Environmental Equipment Conditions for Process Management
ANSI/ISA 71.04
and Control System, Airborne Contaminants
ISA TR12.2 Intrinsically Safe System Assessment Using the Entity Concept
Standard for Purged and Pressurized Enclosures for Electrical
NFPA 496
Equipment
Classification of Areas for Electrical Installation at Hydrocarbon
OISD-STD-113
Processing and Handling facilities
OISD-RP-149 Design Aspects for Safety in Electrical System
4. Control Systems
4.1 Computer Systems
Standard for the Fire Protection of Information Technology
ANSI / NFPA 75
Equipment
ANSI/ISA-18.2 (All
Management of Alarm Systems for the Process Industries
parts)
API STD 1164 Pipeline SCADA Security
IEEE-802 (All IEEE Standard for Local and Metropolitan Area Networks:
applicable parts) Overview and Architecture

International Standard for Information technology--

Telecommunications and information exchange between
IEEE 8802
systems Local and metropolitan area networks--Specific
requirements
ISA 18.1 Annunciator Sequences and Specifications
TR5.1.01 - ISA-
Functional Diagram Usage
TR77.40.01
ISA 62443 Security for Industrial Automation and Control Systems
IEC 61511 (All Functional safety. Safety instrumented systems for the process
applicable parts) industry sector.
IEC 61508 (All Functional safety of electrical/electronic/ programmable
applicable parts) electronic safety related systems
NAMUR NA 102 Alarm Management
SP 80082 Guide to Industrial Control Systems (ICS) Security
4.2 Distributed Control System / Programmable Logic Controller

ANSI/ISA-95 (All
Enterprise-Control System Integration
applicable parts)
API RP 557 Guide to Advanced Control Systems
Alarm systems - a guide to design, management and
EEMUA 191
procurement
IEC 61131 (All Industrial-process measurement and control - Programmable
applicable parts) controllers
Part 4 - Programmable controllers - Part 4: User guidelines
Part 8 - Industrial-process measurement and control -
IEC TR 61131-4 & 8
Programmable controllers - Part 8: Guidelines for the
application and implementation of programming languages
IEC 61804 (All Function blocks (FB) for process control and electronic device
applicable Parts) description language (EDDL)
ISA 88 (All
Batch Control
applicable Parts)
ANSI/ISA-62769- Field Device Integration (FDI) - Part 109-1: Profiles - HART and
109-1 Wireless HART
NAMUR NE 129 Plant Asset Management
NAMUR NE 158 Health Monitoring of PCS Assets
NIST SP 800-57,
Recommendation for Key Management: Part 1 – General
Part 1

Security and Privacy Controls for Information Systems and

NIST SP 800-53
Organizations
National Critical Information Infrastructure Protection Centre,
NCIIPC
Role, Charter & Responsibilities
ISA-62443 (All
Security for industrial automation and control systems
applicable parts)
4.3 Foundation Fieldbus System
AG – 140 Wiring and Installation Application Guide
AG – 163 Application Guide for 31.25 kbit/s Intrinsically Safe Systems
AG – 181 System Engineering Guidelines
AG – 170 Function Block Capabilities in Hybrid/Batch Applications
BS EN IEC 61158
(All applicable
parts) Industrial communication networks - Fieldbus specifications
IEC 61158 (All
applicable parts) Industrial communication networks - Fieldbus specifications
FD – 043 Technical Overview
FF – 940 Communication Profile
Foundation Fieldbus Host Interoperability Support Test
FF-569 Procedures
Foundation Fieldbus Specification 31.25 kbits/s physical layer
FF-816 profile
FF-844 H1 Cable test specification
Foundation Fieldbus Specification Function Block Application
FF-890 Process
NAMUR NE 74 Fieldbus Requirements
Best Practice Fieldbus Applications, Selection, Planning,
NAMUR NA 114 Installation, Commissioning and Operation of Fieldbuses
Specifications for Integrating Fieldbus Devices in Engineering
NAMUR NE 105 Tools for Field Devices
NAMUR NE 123 Service and Maintenance of the Physical Layer of Fieldbuses
Safety Fieldbus Design Considerations for Process Industry
ISA-TR84.00.06 Sector Applications
4.4 Emergency Shutdown System
Identification and Mechanical Integrity of Safety Controls,
ANSI/ISA-84.91.01
Alarms, and Interlocks in the Process Industry
ANSI / ISA 61511 /
Functional Safety – Safety Instrumented Systems for the
IEC 61511
Process Industry Sector
(All parts)
Guidance on the Identification of Safety Instrumented
ISA-TR84.00.05
Functions (SIF) in Burner Management Systems (BMS)
ISA-TR84.00.02 (All Safety Integrity Level (SIL) Verification of Safety Instrumented

Applicable parts) Functions
Automation Asset Integrity of Safety Instrumented Systems
ISA-TR84.00.03
(SIS)
ANSI/ISA-
TR96.05.01 Partial Stroke Testing of Automated Valves
4.5 Fire and Gas Detection System
ANSI/ISA-92 (All Performance, Installation, Operation, and Maintenance of Gas
Sections) detection systems and Instruments
Smoke detectors for use in automatic electrical fire alarm
BIS IS 11360
system
Specification for Heat Sensitive Fire Detectors for use in
BIS IS 2175
Automatic Fire Alarm System
ISA-RP92.04.02- Installation, Operation, and Maintenance of Instruments Used
Part 2 to Detect Oxygen-Deficient/Oxygen-Enriched Atmospheres
ANSI/ISA- Guide for Toxic Gas Detection as a Method of Personnel
TR92.00.03 Protection
ANSI/ISA-
Feasibility of Chlorine Detection Instrument Testing
TR92.06.03
BS EN 54 (All
Fire detection and fire alarm systems
applicable parts)
BS EN 14604 Smoke alarm devices
BS EN / IEC 62676
(All applicable Video surveillance systems for use in security applications
parts)
Fire protection for electronic equipment installations. Code of
BS 6266
practice
Energy Institute: IP
Model Code of Fire precautions at petroleum refineries and bulk storage
Safe Practice Part installations
19
Selection, Installation and Maintenance of Automatic Fire
BIS IS 2189
Detection and Alarm System – Code of Practice
Guidance on the Evaluation of Fire, Combustible Gas, and Toxic
ISA-TR84.00.07
Gas System Effectiveness
NFPA-72 National Fire Alarm and Signalling Code
Fire Protection facilities for Petroleum Refineries and Oil / Gas
OISD-STD-116
processing plant
API 2001 Fire Protection in Refineries
Fire Protection Facilities for Petroleum Depots, Terminals,
OISD-STD-117
Pipeline Installations & Lube oil installations

OISD-STD-156 Fire Protection Facilities for Ports Handling Hydrocarbons

4.6 Analyzer System
ANSI/ISA-92 (All Performance, Installation, Operation, and Maintenance of Gas
Sections) detection systems and Instruments
ISA RP76.0.01 Analyser System Inspection and Acceptance
Steam and water sampling, conditioning, and analysis in the
ASME PTC 19.11
power cycle
Standard Practice for Validation of the Performance of Process
ASTM D3764
Stream Analyzer Systems
Standard Practice for Sampling Liquefied Petroleum (LP) Gases,
ASTM D 1265
Manual Method
API RP 555 Process Analysers
Calculation of Gross Heating Value, Relative Density and
GPA 2176 Compressibility of Natural Gas Mixtures from Compositional
Analysis
IEC 61285 Industrial-Process Control - Safety of Analyser Houses
Electrical apparatus for explosive gas atmospheres. Part 16:
IEC/TR 60079 -16
Artificial ventilation for the protection of analyser(s) houses
EEMUA PUB NO
Design and installation of On-line analyser systems
138
ISO 10715 Natural Gas - Sampling Guidelines

Monitoring Certification scheme, Environment agency of
MCERTS
England & wales.
Standard for the Installation of Air-Conditioning and
NFPA 90A
Ventilating Systems
UL 555 Fire Dampers
Ul 555S Smoke Dampers
US EPA United States Environmental Protection Agency
4.7 Automatic Tank Gauging System
API STD 2552 Measurement and Calibration of Spheres and Spheroids
API MPMS Manual of Petroleum Measurement Standards - Chapter 1:
Chapter 1 Vocabulary
API MPMS
Tank Gauging
Chapter (All Parts)
API STD 2555 Liquid Calibration of Tanks
API MPMS Measurement and Calibration of Upright Cylindrical Tanks by
Chapter-2.2A the Manual Tank Strapping Method
API MPMS
Liquid-in-Glass Thermometers
Chapter 7.1

API MPMS
Fixed Automatic Tank Temperature Systems
Chapter-7.3
API STD 2350 Overfill Protection for Storage Tanks in Petroleum Facilities
Petroleum and liquid petroleum products — Measurement of
ISO 4266 (All parts)
level and temperature in storage tanks by automatic methods
API MPMS Chapter Mass Measurement of Liquid Hydrocarbons in Vertical
- 16.2 Cylindrical Storage Tanks by Hydrostatic Tank Gauging
OIML R 117 Dynamic measuring systems for liquids other than water
Automatic level gauges for measuring the level of liquid in
OIML R-85
stationary storage tanks
4.8 Metering System
Compressibility Factors of Natural Gas and Other Related
AGA Report 8
Hydrocarbon Gases
API MPMS
Operation of Proving Systems
Chapter – 4.8
API MPMS
Dynamic Temperature Measurement
Chapter – 7.4
API MPMS Chapter Continuous Density Measurement Under Dynamic (Flowing)
9.4 Conditions
API MPMS
Calculation of Petroleum Quantities Using Dynamic
Chapters 12.2.1 to
Measurement Methods and Volumetric Correction Factors
12.2.5
API MPMS Chapter Collecting and Handling of Natural Gas Samples for Custody
14.1 Transfer
API MPMS Mass Measurement of Natural Gas Liquids and Other
Chapter. 14.7 Hydrocarbons
API MPMS Natural Gas Fluids Measurement: Liquefied Petroleum Gas
Chapter. 14.8 Measurement
API MPMS
Measurement of Natural Gas by Coriolis Meter
Chapter. 14.9
API MPMS
Measurement of Gas by Vortex Meters
Chapter. 14.12
API MPMS Chapter Flow Measurement Using Electronic Metering Systems—
21.1 Electronic Gas Measurement
API MPMS Chapter Electronic Liquid Volume Measurement Using Positive
21.2 Displacement and Turbine Meters
API MPMS Chapter
Proving System - Introduction
4.1
API MPMS Chapter
Displacement Provers
4.2

API MPMS Chapter

Master-Meter Provers
4.5
API MPMS Chapter
General Consideration for Measurement by Meters
5.1
API MPMS Chapter
Measurement of Liquid Hydrocarbons by Displacement Meters
5.2
API MPMS Chapter
Measurement of Liquid Hydrocarbons by Turbine Meters
5.3
API MPMS Chapter
Accessory Equipment for Liquid Meters
5.4
API MPMS Chapter Fidelity and Security of Flow Measurement Pulsed-Data
5.5 Transmission Systems
API MPMS Chapter
Measurement of Liquid Hydrocarbons by Coriolis Meters
5.6
API MPMS Chapter Measurement of Liquid Hydrocarbons by Ultrasonic Flow
5.8 Meters
API MPMS Chapter Metering Systems for Loading and Unloading Marine Bulk
6.5 Carriers
API MPMS Chapter
Pipeline Metering Systems
6.6
API MPMS Chapter
Metering Viscous Hydrocarbons
6.7
API MPMS Chapter
Temperature Determination
7,
API MPMS Chapter
Sampling, standardized procedures for sampling petroleum
8 (All applicable
and petroleum products
Chapters)
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
Energy Institute –
Continuous density measurement
HM8
ISO 3171 Petroleum liquids — Automatic pipeline sampling
Petroleum liquids and gases — Fidelity and security of dynamic
ISO 6551 measurement — Cabled transmission of electric and/or
electronic pulsed data
4.9 Machine Condition Monitoring System
Machinery Protection Systems

API STD 670

4.10 Weigh Bridges

BIS IS 1436 Weigh Bridges Specification
- Indian weights and measures standards
BIS IS 9281 Specification for Electronic weigh bridge system
Application and Installation of Continuous-Belt Weighbridge
ISA-RP74.01
Scales
Non-automatic weighing instruments: metrological and
OIML R 76-1
technical requirements - tests
5. Field Instrumentation
5.1 Flow Measurement
AGA Report No. 11 Measurement of Natural Gas by Coriolis Meter
AGA Report No. 3, Orifice Metering of Natural Gas Part 1:
AGA XQ1201
General Equations and Uncertainty Guidelines,
AGA Report No. 3, Part 2: Orifice Metering of Natural Gas and
AGA XQ1601 Other Related Hydrocarbon Fluids - Concentric, Square-edged
Orifice Meters, Specifications and Installation Requirements
Orifice Metering of Natural Gas and Other Related
Hydrocarbon Fluids - Concentric, Square-edged Orifice Meters;
AGA XQ1304
Part 3: Natural Gas Applications
AGA Report No. 3, Orifice Metering of Natural Gas Part 4:

AGA XQ9211
Background, Development Implementation Procedure
AGA Report No. 7, Measurement of Natural Gas by Turbine
AGA XQ0601
Meter
ISO 3125 Measurement of gas flow in closed conduits — Turbine meters
API MPMS Chapter

General Considerations for Measurement by Meters
5.1
API MPMS Chapter
5.2 Measurement of Liquid Hydrocarbons by Displacement Meters
ASME B16.36 Orifice Flanges
Specification, Installation and Calibration of Turbine flow
ISA RP 31.1
meter
ISA-97.00.01 Face-to-Face Dimensions of Flanged Vortex Flowmeters
Measurement of fluid flow by means of pressure differential
devices inserted in circular cross-section conduits running full.
ISO 5167-1 General principles and requirements
ISO 5167-2 Orifice plates


ISO 5167-3 Nozzles and Venturi nozzles
ISO 5167-4 Venturi tubes
ISO 5167-5 Cone meters
ISO 5167-6 Wedge meters
Measurement of fluid flow — Procedures for the evaluation of
ISO 5168
uncertainties
Measurement of fluid flow by means of pressure-differential
ISO/TR 15377 devices — Guidelines for the specification of orifice plates,
nozzles and Venturi tubes beyond the scope of ISO 5167
Liquid hydrocarbons — Volumetric measurement by
BS ISO / ISO 2714
displacement meter
ISO 9951 Measurement of Gas Flow in Closed Conduits - Turbine Meters
API MPMS
Orifice Metering of Natural Gas and Other Related
Chapter. 14.3 (All
Hydrocarbon Fluids—Concentric Square-Edged Orifice Meters
applicable Parts)
API MPMS
Measurement of Flow to Flares
Chapter. 14.10
PIP PCEFL001 Flow Measurement Guidelines
5.2 Pressure Measurement

ASME B40.100 Pressure Gauges and Gauge Attachments
Pressure gauges. Bourdon tube pressure gauges. Dimensions,
BS EN 837 –1
metrology, requirements and testing
Pressure gauges. Diaphragm and capsule pressure gauges.
BS EN 837 –3
Dimensions, metrology, requirements and testing
5.3 Level Measurement
Specification for observation and gauge glasses for pressure
BS 3463
vessels
PIP PCELI001 Level Measurement Guidelines
5.4 Temperature Measurement
ASME PTC 19.3TW Thermowells

ASME B40.200 Thermometer direct reading and remote reading

BS EN 13190 Dial thermometers
IEC 60584 (All
Thermocouples
applicable parts)
Refrigerated hydrocarbon and non-petroleum based liquefied
BS ISO / ISO 8310 gaseous fuels — General requirements for automatic tank
thermometers on board marine carriers and floating storage
Sensory Evaluation; Temperature Measurement; Language
ASTM 14.03
Services and Products
Standard Specification and Temperature-Electromotive Force
ASTM E230/E230M
(emf) Tables for Standardized Thermocouples
Industrial platinum resistance thermometers and platinum
IEC 60751
temperature sensors
6. Valves
6.1 General
ASME B46.1 Surface Texture (Surface Roughness, Waviness, And Lay)
ASME B16.47 Large Diameter Steel Flanges: NPS 26 through NPS 60
(Series B) Metric/Inch Standard
Fire Proofing Practice in Petroleum and Petrochemical
API RP 2218
Processing Plants
API STD 598 Valve Inspection and Testing
API STD 599 Metal Plug Valves—Flanged, Threaded and Welding Ends
Steel Gate Valves—Flanged and Butt-Welding Ends, Bolted
API STD 600
Bonnets
Gate, Globe, and Check Valves for Sizes DN 100 (NPS 4) and
API STD 602
Smaller for the Petroleum and Natural Gas Industries
Corrosion-Resistant, Bolted Bonnet Gate Valves—Flanged and
API STD 603
Butt-Welding Ends
Fire Test for Quarter-Turn Valves and Valves Equipped with
API STD 607
Non-metallic Seats
API STD 608 Metal ball valves flanged, Threaded and welding ends
API STD 609 Butterfly Valves: Double flanged, Lug and Wafer Type
Standard for Actuator Sizing and Mounting Kits for Pipeline
API STD 6DX
Valves
API SPEC 6FA Standard for Fire Test for Valves
ASME B 16.10 Face to Face and End to End Dimensions of Valves
ASME B 16.34 Valves—Flanged, Threaded, and Welding End
ASME B16.5 Steel Pipe Flanges and Flanged Fittings
BS EN 60085 Electrical insulation. Thermal evaluation and designation
Valves of cryogenic service
BS 6364
Under review for withdrawal

BS EN 12266 part 1 Industrial valves. Testing of metallic valves. Pressure tests, test
&2 procedures and acceptance criteria
ISO 15848 (All Industrial valves — Measurement, test and qualification
applicable Parts) procedures for fugitive emissions
Metal valves for use in flanged pipe systems — Face-to-face
ISO 5752
and centre-to-face dimensions
6.2 Control Valve
FCI 70-2 Control Valve Seat Leakage
BS EN 593 Industrial valves. Metallic butterfly valves for general purposes
BS EN ISO / ISO
Testing of valves — Fire type-testing requirements
10497
BS EN ISO / ISO Metal ball valves for petroleum, petrochemical and allied
17292 industries
IEC 60534 (All
Industrial-Process Control Valves
applicable Parts)
ISA 75 Control Valve Standards
ISA-75.23 Control Valve Cavitation
ISA-TR75.04.01 Control Valve Position Stability
ANSI/ISA-
Control Valve Response Measurement from Step Inputs
TR75.25.02
6.3 Safety Relief Valve
API STD 2000 Venting Atmospheric and Low-Pressure Storage Tanks
API STD 521 Pressure Relieving and Depressurizing Systems
API STD 526 Flanged Steel Pressure Relief Valves
API STD 527 Seat Tightness of Safety Relief Valves
API RP 576 Inspection of Pressure Relieving Device
API STD 520 Part 1
Sizing, Selection and Installation of Pressure Relieving Devices
API RP 520 Part 2
ASME SEC I Boiler applications
ASME SEC VIII Unfired Pressure Vessel Applications
IBR Reg. 293 Minimum Aggregate Area
BS EN ISO / ISO
4126 (All Safety devices for protection against excessive pressure
applicable Parts)
7. Instrument and Fibre Optic Cable
Multi-element metallic cables used in analogue and digital
BS EN 50288-7 communication and control. Sectional specification for
instrumentation and control cables

Electric cables. Single core PVC insulated flexible cables of

BS 6231 rated voltage 600/1000 V for switchgear and control gear
wiring
BS EN / IEC 60228 Conductors of insulated cables
Specification for Conductors for Insulated Electric Cables and
IS 8130
Flexible Cords
IS 10810 Methods of test for cables
Specification for insulating and sheathing materials for cables.
BS 7655-1.3
Elastomeric insulating compounds XLPE
Specification for underground armoured cable protected
EEMUA 133
against solvent penetration and corrosive attack
Steel wire and wire products. Non-ferrous metallic coatings on
EN 10244-2
steel wire. Zinc or zinc alloy coatings
Zinc or zinc alloy coated non-alloy steel wire for armouring
EN 10257-1
either power cables or telecommunication cables. Land cables
BS EN 50289-1 Communication cables. Specifications for test methods.
Series Electrical test methods.
Communication cables. Common design rules and
BS EN 50290-2-29 construction. Crosslinked polyethylene insulation compounds:
instrumentation, control and field bus cables
BS EN / IEC 60811
Electric and optical fibre cables - Test methods for non-metallic
(All applicable
materials
parts)
BS EN 50525 (All Electric cables. Low voltage energy cables of rated voltages up
applicable parts) to and including 450/750 V (U0/U).
IEC 60028 International standard for resistance of copper
Low-frequency cables and wires with PVC insulation and PVC
IEC 60189-1
sheath - Part 1: General test and measuring methods
IEC 60227 (All Polyvinyl chloride insulated cables of rated voltages up to and
applicable parts) including 450/750 V
Standard colours for insulation for low-frequency cables and
IEC 60304
wires
IEC 60331 (All
Tests for electric cables under fire conditions - Circuit integrity.
applicable parts)
IEC 60332 (All
Tests on electric and optical fibre cables under fire conditions
applicable parts)
Power cables with extruded insulation and their accessories
for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um =
IEC 60502 Part-1
36 kV) – Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV)
and 3 kV (Um = 3,6 kV)
IEC 60702 (All Mineral insulated cables and their terminations with a rated
applicable parts) voltage not exceeding 750 V

IEC 60754 (All Test on gases evolved during combustion of materials from
applicable parts) cables
IEC 60793 (All
Optical fibres
applicable parts)
IEC 60794 (All
Optical fibre cables
applicable parts)
IEC 60825 (All
Safety of laser products
applicable parts)
Fibre optic interconnecting devices and passive components.
IEC 60874
Connectors for optical fibres and cables
IEC 60885 (All
Electric Test Methods for Electric Cables
applicable parts)
IEC 61034 (All Measurement of smoke density of cables burning under
applicable parts) defined conditions
IEC 61280 (All
Fibre-optic communication subsystem test procedures
applicable parts)
IEC 61300 (All
Fibre optic interconnecting devices and passive components
applicable parts)
IEC 61753 (All Fibre optic interconnecting devices and passive components
applicable parts) performance standard
Optical fibres - Measurement methods - Microbending
IEC/TR 62221
sensitivity
IEC/TS 62033 Attenuation uniformity in optical fibres
ISO / IEC 11801 (All Information technology - Generic cabling for customer
applicable parts) premises
Mild steel wires formed wires and tapes for armouring of
BIS IS 3975
cables
BIS IS 5831 PVC insulation and sheath of electric cables
Specification for Cross linked polyethylene insulated PVC
IS 7098 Part 1
sheathed cables
Definitions and test methods for statistical and non-linear
ITU-T G.650.2
related attributes of single-mode fibre and cable
ITU-T G.652 Characteristics of a single-mode optical fibre and cable
Optical interfaces for equipment and systems relating to the
ITU-T G.957
synchronous digital hierarchy
UL 1581 Section
UV resistance of cables
1200

Notes: Applicable for Fibre Optic Cables

1) The ITU G650 series (which includes G.651, G.652, G.653, G.654, G.655 and G.656
recommendations) of standards deals with recommended specifications for
various optical fibre types, with G.650 itself dealing with the optical test methods
used to verify the fibre specifications.
8. Instrument Air System
ISA 7.0.01 Quality Standard for Instrument Air
9. Nucleonic Instruments
BS EN / ISO 2919 Radiological protection -- Sealed radioactive sources -- General
requirements and classification”
AERB SAFETY Safety Standard for Design, Construction of Ionizing Radiation
STANDARD NO. Gauging Devices” and Latest Document is AERB SAFETY
AERB/SS/2 STANDARD NO. AERB/SS/2 (Rev-1)
10. Statutory Requirements
Indian Boiler Steam system design pressure
Regulation Act Indian Boiler Regulations for steam service
1923 and REG 1950
Petroleum and Petroleum and Explosives Safety Organisation (PESO) approval
Explosives Safety for Installation of electric wiring or electrical apparatus in
Organisation Hazardous Area. (not in Dust or mining)
(PESO)
American OSHA Nucleonic source installations
and national
Nuclear regulatory
commission rules,
and the Indian
BARC/AERB
regulations
CPCB / SPCB Approval
- Indian Government and Local Weights and Measures approval

Appendix-02: Flow Meter Selection Guide

Ga s / Va pour Li qui d
Refere nce - PIP PCEFL001 Appe ndi x A
Reverse Flow
Pres s ure Vi s cous Sl urry
V. Corrosive
High Temp
Cryogenic
Corrosive
Pulsating
Perma nent
Abrasive
Fibrous
Steam
Clean
Clean
Pre s s ure
Flow
Dirty
Dirty
High
High
Low
Low
Fl owme ter Type Li ne Si ze Ra nge a bi l i ty Los s
Ori fi ce Pl a te
- Squa re Edge >2" G G X G G G X L X X G X X L L G G 4:1 Me di um
- Integra l <2" L G X G G G C L X X G X X L L L X 4:1 Me di um
- Ecce ntri c >2" L L G G G L L L X X G L X L L G G 4:1 Me di um
- Segmenta l >4" L L G G G L L L X X G L X L L G G 4:1 Me di um
- Condi ti oni ng >2" G G X L G G L L X X G X X L L G G 4:1 Me di um
We dge <12" G G G G G G L L X L G G G L L G G 4:1 Medi um
V Cone 0.5 to 120" G G L G G G L L X X G L L X L L L 10:1 Low
Ve nturi >2" G G L G G G L L X L G G L X L L L 4:1 Low
Fl ow Nozzl e 4 to 24" G G L G G G L L X N G X X X L L L 4:1 Medi um
Avg. Pi tot 4 to 72" X G L G G G L L X N L X X L X L L 8:1 Low
Ma gme te r 0.125 to 80" X X X - - G G G G L G G G G G L X 100:1 Low
PD Me ter <12" X G X L G G X L X G L X X X X X X 50:1 Hi gh
Turbi ne 0.25 to 24" L G X Y G G X L X X L X L L L L L 20:1 Hi gh
Ul tra s oni c
- Ti me of Fl i ght 4 to 42" X L L L L G X G G L L L L G G X L 100:1 Low
- Doppl er >0.5" X X X X X X G G G L L G G G G X X 10:1 Low
Va ri a bl e Area >0.5" L G X X G G X L L X L X X X L L L 10:1 Medi um
Vortex 1.5 to 16" G G L G G G L L N X L X X X X L L 10:1 Medi um
Cori ol i s 0.125 to 12" L L L G G G G L L G G L L G L L G 100:1 Medi um
The rma l >0.5" X G L G G G G L L L G L L X L L X 100:1 Low
G = Good
L = Li mi te d
X = Not Re comme nded

Appendix-03: Level Instrument Selection Guide
Less Suitable for some High Temperature Applications

Requires Precautions for Safe Installation
Solids in Bin/Silo, Sump, Slop Oil Pits
Introduces Foreign Matter to Process

Good for Corrosive or Toxic Service
Good for Interface Measurement
Not Good for Agitated Vessels

Good for Plugging and Fouling
Requires Detailed Engineering

No Contact with the Process
Process - General Service
Sensitive to Dirty Process
Needs a Special License
Contains Moving Parts
Sensitive to Foaming
Good for Liquids
Higher Accuracy
High Initial Cost

Good for Solids
Storage Tanks
Reference - PIP PCELI001 Appendi x 1
Type Applications Limitations
Di fferenti a l Pres s ure (DP) X L X L X X L G G X Y
DP Purged Sys tem G G X G X X L X X X Y Y
DP wi th Di a phra gm Sea l G G X G X X L G G X Y
DP wi th Di a phra gm Sea l & Ca pi l l a ry G G X G X X L L L X Y
El ectroni c DP G G X G X X L G G X Y Y
Di s pl a cer X L X G L X G X X X Y Y Y
Ma ge nti c Level Ga uge X L X L X L G L G X Y Y Y
Ga uge Gl a s s X X X L X X G L G X Y
Ca pa ci ta nce Type X G X G L L L X G X Y Y Y Y
Gui ded Wa ve Ra da r L G X G G G G L G L Y Y Y Y
Non Conta ct Ra da r G G G G G G X G X G Y Y Y
Ul tra s oni c G G G G L L X L X L Y Y Y Y
Nucl e oni c G G G G G L G X X G Y Y Y Y
Ma gnetos tri cti ve X L G G X G L X X X Y Y Y Y
La s er G G G G G X X G X X Y Y
G = Good Y = Ye s
L = Li mi ted
X = Not Re commended
Design condition / process data shall be considered while selecting the level Instrument.

Appendix-04: Typical Schematic for Remote Operated Valve (ROV)

Appendix-05: Details for Close Coupled Hook-up

RPMS-ENGG-DBD-CI-001 - Attachment 10: Details For Close Coupled Hook-up

Connection Close
Process Design Design
Instrument on size Instrument Flange coupled
Sl No. Tag No. Connection Pipe Class MOC Service Temperatur Pressure Qty
Type (From Class Rating Hook Up
Type e (deg C) (Kg/cm²)
Tapping) Model No

Standard Specification for Instrumentation Cables

0 17.08.2020 Issued for Implementation ASK URJ JKK/VKM

By By By
Reliance Project Management System RPMS-ENGG-SPC-CI-007
Standard Specification for Instrumentation Cables Date: 17.08.2020, Rev. 0

(DD.MM.YYYY)
1 Mr. Jatindar Khushu____ ____ _________________ ___________
Mr. Jagdish Gupta______________ _________________ ___________

2
Mr. Rajkumar Ghosh____________ _________________ ___________

3
Mr. Kuddallur Seshadri_________ _ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS

Number

Contents
1. Scope ......................................................................................................................... 5
2. References ................................................................................................................. 5
3. Conflict and Deviation ............................................................................................... 7
4. Abbreviation and Definitions .................................................................................... 9
7. Special Cables .......................................................................................................... 20
8. Category 6 Cables .................................................................................................... 20
9. Cable Design Basis ................................................................................................... 20
Appendix-01: Cable Specification Sheets .......................................................................... 21
Standard Specification for Instrumentation cables Date: 17.08.2020, Rev. 0
1. Scope
The scope of this specification is to define the technical requirements of different
type of Instrumentation Cables for various Control systems and field
Instrumentation. This specification shall be applied to all Reliance group
companies, and thereby achieve maximum technical and economic benefit from
standardization. This document shall be used by the supplier as a specification
guideline / reference for designing, offering and supplying Instrumentation Cables.
Following types of Cables which are generally used in Instrumentation are covered
under this document.
a) Instrumentation Signal cables for Analogue and Digital Signals.
b) Field Bus Cables
c) RS 422/485 Communication cables
d) Instrumentation Power Cable
e) CAT6 cables
2. References
All design, materials, construction and performance shall conform to the latest
issues of relevant internationally recognized codes and standards including, but not
limited to, the following:
Multi-element metallic cables used in analogue and digital

BS EN 50288-7 communication and control. Sectional specification for
instrumentation and control cables
Mechanical cable glands. Code of practice for selection,
BS 6121
installation and inspection of cable glands
BS EN 62444 Cable Glands For Electrical Installations
Specification for PVC insulated cables for switchgear and
BS 6231
control gear wiring
BS EN 60228, IS
Conductors for insulated cables and flexible cords
8130
BS 6469 Insulating and sheathing materials of electric cables
IS 10810 Methods of test for cables

BS EN 60811- Electric and optical fibre cables. Test methods for non-
412 metallic materials.
Specification for insulating and sheathing materials for
BS 7655-1.3
cables. Elastomeric insulating compounds XLPE
Underground Armoured cable protected against solvent
EEMUA 133
penetration and corrosive attack.
Steel wire and wire products – Part 2: Zinc or zinc alloy
EN 10244-2
coatings.
Zinc or zinc alloy coated non-alloy steel wire – Part 1: Land
EN 10257-1
Cables.
EN 50289-1 Communication cables – Specification for electrical test
Series methods.
Communication cables – Cross-linked polyethylene
EN 50290-2-29
compound.
EN 60811 ( All Testing of Insulating and sheathing materials of electrical and
Sections) optic cables
Communication cables - Common design rules and
EN 50290-2-22
construction - PVC sheathing compounds
IEC 60028 International standard for resistance of copper
Cables and Wires for Low Frequency PVC Insulated and in
IEC 60189-1
Protective Sleeve
Conductors and Cables Insulated with Polyvinyl Chloride of
IEC 60227-1 to 6
Nominal Voltage of More Than 450/750V
Standard colours for insulation for low-frequency cables and
IEC 60304
wires
IEC 60331 Test for Electrical Cables under Fire Conditions-Fire Resistant
IEC 60332 (All Tests for Electrical Cables and Fibre Optic cables under Fire
Sections) Conditions
Mineral insulated cables, and their termination, with rated
IEC 60702
voltage not, exceeding 750V

IEC 60754-1 and Test on gases evolved during combustion of materials from
2 cables
Electric and optical fibre cables - Test methods for non-
IEC 60811
metallic materials
IEC 60885 Electric Test Methods for Electric Cables
IEC 61000 Electromagnetic Compatibility (EMC)
IEC 61034 (All
Measurement of smoke density of electric cables
Sections)
BIS IS 3975 Specification for Galvanized steel wire
Specification for PVC Insulation and Sheath of Electrical
BIS IS 5831
Cables
IS 7098 Cross linked polyethylene insulated PVC sheathed cables
UL 1581 Section
Sunlight resistance
1200
ICEA S-73-532 Oil resistance
ASTM D 2863 Oxygen index
Information technology — Generic cabling for customer
IEC 11801
premises
EN 50173 Information technology - Generic cabling systems
3. Conflict and Deviation

In the event of conflict or deviation from requirements stipulated in this document
and other applicable documents, the following order of precedence shall govern:
a) Datasheets and drawings
d) Codes and Standard Specifically Referred

Note: “Material Requisition” represents Material Requisition for Quotation,
3.1. Table of Compliance
The Package Supplier shall complete a table of compliance covering every
paragraph of this specification.
An example of the table of compliance is given below:
TABLE OF COMPLIANCE
Date:
Project:
Enquiry Number:
Package Supplier:
Paragraph
Enhancement Conforms Alternative Exception/Deviation.
Number
Definition of the column headings is as follows:
Enhancement: Feature fully complies with the specification and offers

more functionality. The Manufacturer / Supplier shall
give full description.
Conforms: Feature fully complies with the specification.
Alternative: Feature does not meet the specification, but the
functional requirements can be met in a different way.
The Manufacturer / Supplier shall give a full description.
Exception/Deviation: The Manufacturer / Supplier cannot meet the
specification.

4. Abbreviation and Definitions

Abbreviations
AL/HDPE/PA Aluminium / high density polyethylene / polyamide (nylon)

CCR Central Control Room
CS Collective Screen (overall screen)
DBD Design Basis Document
EM Electro magnetic
HDPE High density polyethylene
MCT Multi cable transit
PA Public Addressing
PE Polyethylene used as conductor insulation or inner sheathing.
PIB Plant Interface Building
PVC Polyvinyl chloride
SCN Screen
SWA Steel wire armouring
Definitions
Supplier/Vendor Party which manufactures or supplies equipment and

services to perform the function as specified by Buyer
Buyer Owner (Reliance) or Owner-appointed DEC or EPC who
specifies equipment and services for purchase from
Supplier
Parties referred within body of this Engineering Standard
Owner Reliance Industries Ltd.
Detail Engineering The party, which carries out detailed design
Contractor (DEC) engineering services.

EPC Engineering, Procurement & Construction Contractor

5.1. Service Conditions
The cables shall in all respects be suitable for operation under the service
conditions as defined in project specific Basic Engineering Design Data (BEDD).
Cable shall be designed for 20 years of operating life cycle.
Armoured cables shall be used for following conditions:
a) Direct buried in the ground (Note: Cables shall be suitable for direct burial in
water-logged ground).
b) In underground ducts
c) Above ground, fastened to cable ladder rack or tray in the open air exposed to
direct sunlight
d) Below ground in enclosed, air filled trenches, fastened to cable ladder rack or
tray.
Cables shall have design temperature range limits of -30oC to +90oC (Except fire
resistant cables).
Instrument cables shall have a rated voltage of 300V, low voltage power and control
cables shall have rated voltage of 500V.
Cables for AC Power service shall be suitable for operation at ≈50 Hz.
5.2. General
Instrumentation Cable shall be in accordance with EN 50288-7 or equivalent
standard and owner approved datasheets.
Cable construction (cable cross sectional area, conductor material, number of
cores, rated voltage, type etc.) shall be in accordance with Appendix A, approved
datasheet and material requisition.
Cable fillers shall be solid, non-hygroscopic and fill the cross section such that the
transmission of gas and hydrocarbons along the length of the cable, under normal
pressure, is not possible.
The outer sheath of cables shall be embossed with
a) Voltage designation

b) Manufacturer’s identification
c) Number of Cores (or pairs) and nominal cross sectional area of conductors
d) The drum progressive length of cable at every meter. (Zero point being the
cable end at its inner coil on the cable drum.)
e) The stock code number as specified in the material requisition.
Cable shall have uniformity in insulation and outer sheath colour.
The electrical characteristics C, L and L/R for intrinsically safe cables shall be in
accordance with clause 10.3.1.1.
The characteristics for Foundation Fieldbus cable shall be in accordance with the
requirements for Type A cable as defined by IEC 61158-2.
When specified, fire resistant cables shall be designed to withstand temperatures
of at least 750 °C for a period of 90 minutes in accordance with the applicable
standard (IEC 60331-11/21).
The tensile strength of PVC, before aging, shall be at least 12.5 N/mm2.
PVC is used as outer sheathing. PVC as outer sheathing shall be UV-resistant and
flame retardant.
5.3. Cable Drumming
Cables shall be drummed in maximum continuous lengths (minimum 1000Mts. per
drum) on non-returnable wooden drums. The manufacturer shall guarantee that
drums are of sufficient strength to protect cable during shipping and rough handling
at site.
Length Tolerance on total cable length for each type is 0% to +5%.
Tolerance on individual drum can be ±5%.
Cable ends shall be sealed and fixed to the drum so that both ends are accessible.
To protect the cable during shipment battens shall be fitted around the entire
periphery of the drum. While fixing battens with iron nails, care shall be taken not
to damage cable insulation. Drums shall be suitable for long term outdoor storage
at site. It has been observed that wooden drums are not able to sustain the
weathering effects if stored in open. If mentioned in material requisition, cables
shall be supplied on metallic drums, which could be stored in open.
All cable drums shall have the Purchase Order Number, Purchase Order Item
Number, Drum Number and Stock Code Number with description (no of core/pair,
cross section viz. 27C X 2.5mm2) clearly stencilled on the outside of both flanges.
Drum identification labels shall be attached to the outside and inside of the drum
flanges. Labels shall be protected by transparent plastic envelopes and give the
following information:
a) Drum identification number
b) Cable voltage grade
c) Cable construction (e.g. PVC SWA PVC)
d) Number of cores (or pairs) and cross sectional area
e) Cable quantity (Meters)
f) Purchase order number and item number
g) Total weight of cable and drum (kg)
h) Manufacturer's name
i) Year of manufacture
j) Stock code number
5.4. Supplier Datasheet
The Supplier shall provide following data on datasheets:
Standard and maximum drum lengths for all the types of cable offered and it’s
proposed drum lengths for all items.
a) Cable dimensions (together with tolerances) as follows:
• Diameter over inner sheath (mm)
• Diameter under armour (mm)
• Diameter over armour (mm)
• Diameter of armour wires (mm)
• Overall diameter (mm)
b) Cable weight in kg/km
c) Cable electrical data as follows:
• Conductor dc resistance per km at 20°C
• Conductor ac resistance per km at operating temperature and system
frequency
• Conductor inductive reactance per km at system frequency

• Conductor impedance per km at operating temperature and system

frequency
• Conductor capacitance per km
• Cable armour resistance per km
• Minimum bending radius (x OD)
• Maximum conductor continuous operating temperature (°C)
• Suitability of outer sheath to resist attack from chemicals
• Suitability of outer sheath to resist UV light exposure
• Mutual cable capacitance per km at system frequency
• Mutual cable inductance per km at system frequency
• Mutual cable reactance per km at system frequency
• Insulation resistance per 100m
• Insulation test voltage and duration
• Screen isolation voltage
• Oxygen index
• Core to core capacitance
• Core to screen capacitance
• Rated flame retardancy and fire resistance tests (as per IEC 60331)
• Inductance/Resistance (L/R) ratio.
d) Cable current carrying capacity when installed in defined conditions in air, in
ducts and direct buried in the soil, together with rating factors for varying
ambient temperatures, grouping and installation conditions and methods.
e) Descriptive literature (catalogues etc.).
f) Cross sectional view of the physical make up of each cable.
g) Recommended temperatures below which installation of cable should not be
carried out.
h) Minimum ambient temperature at which cables can be used.
i) Maximum pulling force for each cable and any special pulling instructions.
j) Maximum unsupported run of cable both horizontally and vertically.


6.1. General
The Manufacturer shall provide certificates for tests carried out on cables. Tests
shall be those listed in Section 6.3 of this standard specification and any additionally
specified within the material requisition. Inspection and Test Plan shall be provided
by the Supplier to Owner / DEC for approval. Inspections and testing shall be
performed based on approved ITP.
The Owner / DEC reserves the right to witness all tests specified on completed
cables.
The Manufacturer shall give two weeks’ notice of tests prior to commencement.
The Owner / DEC reserves the right to inspect cables at the Manufacturers works
at any time prior to dispatch to prove compliance with the specifications.
Cables shall not be dispatched unless the test certificates have been approved by
the Owner.
6.2. Definition of Tests
6.2.1. Routine Test (R)
Test made by the manufacturer on each manufactured length of cable to check that
each length meets the specified requirements.
6.2.2. Sample Test (S)
Test made by the manufacturer on samples of complete cable or compounds taken
from a complete cable, at a specified frequency, so as to verify that the finished
product meets the specified requirements.
6.2.3. Type Test (T)
Tests made, on a commercial basis, before supplying a type of cable covered by this
specification, in order to demonstrate satisfactory performance characteristics to
meet the intended application. These tests are of such a nature that, after they
have been made, they need not be repeated unless changes are made in the cable
materials or design or manufacturing process which might change the performance
characteristics.
6.3. Test Requirements
6.3.1. Electrical Tests
6.3.1.1. Instrument Cables

Test Type Parameter Test Method Requirements

(R) Conductor EN 50289-1-2 IEC 60228 for multi-core
resistance cables and max. value
increased by 2% for multi-
pair/multi-triple cables
(R) Dielectric strength EN 50289-1-3 300V 500V
core:core KVAC 1 2
core:screen KVAC 1 2
(R) Insulation EN 50289-1-4 5000 MΩ/km
resistance
(R) Mutual capacitance EN 50289-1-5 <85 nF/km
(< 115 nF/km up to 4
elements)
(R) Capacitance EN 50289-1-5 500 pF/500 m
unbalance (pairs)
(R) Inductance EN 50289-1-12 < 1 mH/km
(R) Inductance to EN 50289-1-12 up to 1mm2: < 25μH/Ω
resistance ratio EN 50289-1-2 for 1.5mm2: < 40μH/Ω
(L/R)
for 2.5mm2: < 60μH/Ω
(R) Electrical continuity no interruption
of screen
6.3.1.2. Thermocouple Extension Cable
Test Type Parameter Test Method Requirements

(R) Conductor EN 50289-1-2 See table below
resistance
(R) Dielectric EN 50289-1-3 core:core KVAC 1
strength core:screen KVAC 1
(R) Insulation EN 50289-1-4 5000 MΩ/km
resistance

(R) Mutual EN 50289-1-5 < 85 nF/km

capacitance (< 115 nF/km up to 4 pairs)
(R) Inductance EN 50289-1-12 KX: < 3mH/km
JX: < 8mH/km
SCA: < 2mH/km
EX: < 3mH/km
TX: < 4mh/km
(R) Electrical no interruption
continuity of
screen
Nominal DC-Resistance (circuit) of thermocouple extension cable at 20oC
Conductor material Conductor size

0.5 mm2/1 ≡ 0.8 mm OD 1.0 mm2/1 ≡ 1.13 mm OD
KX 2040 Ω/km 1020 Ω/km
JX 1257 Ω/km 629 Ω/km
SCA 282 Ω/km 141 Ω/km
EX 2502 Ω/km 1254 Ω/km
TX 1044 Ω/km 522 Ω/km
6.3.1.3. Foundation Fieldbus Cables

Cable construction shall be as per FF-844 H1, IEC 61158-2 and general requirements
shall be in accordance with section 9.0. The electrical property of FF Cable shall
meet FOUNDATION fieldbus type-A requirement. Cable Characteristics and Test
Definitions are as below,
a) Characteristic Impedance, Z0
The characteristic impedance of each twisted pair in a cable shall be 100 +/- 20
Ohms. The characteristic impedance shall be determined by any one of the
methods described in ASTM D4566-05 at 31.25 kHz.
b) Attenuation

The signal attenuation of each twisted pair in the cable shall be less than 3 dB/km
at 39 kHz.
c) Wire
The minimum Trunk wire-pair size shall have a maximum resistance of 23.5
Ohms/km at 20 °C (18 AWG) per conductor. The minimum
Spur wire-pair size shall have a maximum resistance of 59.4 Ohms/km at 20 °C (22
AWG) per conductor. Wires shall be annealed copper, tin coated.
d) Shield Construction Requirements
Each twisted pair shall be individually shielded. The shield shall be metalized
polyester tape. A drain wire shall have a resistance less than 51 Ohms/km. If
another shield construction method is used, the manufacturer shall provide
assurance that the alternate method is functionally equivalent to the metalized
polyester shield.
In a multi-pair cable, each pair is individually shielded with an overall shield.
e) Wire-to-Shield Capacitance Unbalance
The difference in capacitance between one wire (+) and the shield and the other
wire (-) and the shield shall be no more than 4 pF/meter average. A minimum of 30
m cable length shall be used to test this parameter.
f) Wire Twists per Meter
There shall be 10 to 22 wire twists per meter for single or multi-pair cables.
g) Minimum Bend Radius
The minimum bend radius of the cable shall be specified. This must consider the
specified cable temperature range and the possible loss of shield coverage due to
bending.
h) Jacket Resistance
The minimum resistance between the cable’s shield and the metal structure the
cable may be in or on shall be 1 MOhm/330 meters.
i) Cable Designation
The cable designation shall include: FF-844, Type A, zzSTP where zz is the number
of pairs in the cable.
Additional cable markings are permitted. The required approval agency markings
include the wire size.

6.3.2. Dimensional Tests (All Cables)
Test Parameter Test Method Requirements

Type
(S) Thickness of EN 60811-1-1, Conductor size Min. thickness
insulation Clause 8.1 300V 500V
mm2 mm mm
0.5 0.26 0.44
0.75 0.26 0.44
1.0 0.26 0.44
1.5 0.35 0.44
2.5 0.44 0.53
(S) Concentricity of EN 60811-1-1, Ratio of smallest to largest
insulation Clause 8.1 measured thickness to be >75%
(S) Thickness of inner EN 60811-1-1, = 0.04 x D + 0.7 mm
sheath Clause 8.2 (min 0.8 mm).
D= diameter under inner sheath
(S) Thickness of outer EN 60811-1-1, = 0.028 x D + 1.1 mm
sheath (armoured Clause 8.2 (min 1.3 mm).
cable)
D= diameter under outer sheath
(S) Diameter of steel EN 10257-1 Dia. under armour Wire dia. Above
wire armour Up to & incl.
mm mm mm
0 15 0.9
15 25 1.25
25 35 1.6
35 45 2.0
45 60 2.5
60 -- 3.15


Type
(T) Thickness of zinc EN 10244-2 EN 10244-2 Cl. A
coating of steel
wire
(S) Outer diameter of EN 60811-1-1, As manufacturer’s data sheets
cable Clause 8.2
6.3.3. Mechanical and Thermal Tests (All Cables)

Type
(T) Mechanical and IEC 60811 a) Insulation see EN 50290-2-29
thermal b) Sheaths see EN 50290-2-22
properties of
insulation and
sheaths
(S) Hot set test XLPE EN 60811-2-1, EN 50290-2-29
Clause 9
(S) Thermal stability EN 60811-3-2, EN 50290-2-22
PVC sheaths Clause 9
6.3.4. Flame Behavior Tests (All Cables)

Type
(S) Test on a single IEC 60332-1-1 IEC 60332-1-2
cable & -2
(T) Test on bunched IEC 60332-3-10 IEC 60332-3-22
cables & -22 (Cat. A)
(T) Light IEC 61034 IEC 61034
transmittance (30
%)
(T) Limiting oxygen ASTM D 2863 ASTM D 2863
index (min 29%)

(T) Temperature ASTM D2863 ASTM D2863

Index test (min
250 Deg C)
(T) HCL Gas Emission IEC 60754 IEC 60754
(Less than 20% by
Weight)
6.3.5. Other Tests:-

Type
(T) Sunlight UL 1581 UL 1581 section 1200
resistance section 1200
(T) Oil resistance ICEA S-73-532 ICEA S-73-532
7. Special Cables
For any special cables (e.g. Low Capacitance cables), the requirement shall be
detailed during engineering stage against which supplier shall submit datasheets
and production can be commenced only post approval of owner.
8. Category 6 Cables
Cat6 cable shall be in accordance with EN 50173, IEC 11801 (Class E) or equivalent
standard and owner approved datasheets.
Cable construction details shall be in accordance with Appendix 01.
9. Cable Design Basis
For cable design considerations, refer Design Basis Document RPMS-ENGG-DBD-CI-
001.

Appendix-01: Cable Specification Sheets

A1 Instrument Cables
A1.1 XLPE. CS. PVC. SWA. PVC. Twisted pairs, collective screen.
A1.2 XLPE. SCN. CS. PVC. SWA. PVC Twisted triples, individual triple screen,
collective screen.
A1.3 XLPE. SCN. CS. PVC. SWA. PVC. Thermocouple Type J extension cable.
A1.4 XLPE. SCN. CS. PVC. SWA. PVC Thermocouple Type K extension cable.
A1.5 XLPE. SCN. CS. PVC. SWA. PVC Thermocouple Type T extension cable.
A1.6 XLPE. CS. PVC Twisted pairs, collective screen
(unarmoured).
A1.7 XLPE. SCN. CS. PVC. SWA. PVC Thermocouple Type R and S
A1.8 XLPE. SCN. CS. PVC. SWA. PVC Foundation Fieldbus twisted pairs
A1.9 XLPE. SCN. CS. PVC. SWA. PVC Thermocouple Type E extension cable.
A1.10 XLPE.SCN.CS. PVC. SWA. PVC. Twisted pairs, individual screen, collective
screen.
A1.11 XLPE. SCN. CS. PVC. SWA. PVC RS 422/485 Instrument cable.
Low Voltage Power and

A2 Control Cables
A2.1 XLPE. PVC. SWA. PVC Core Cable
A3 Category 6 cable
A3.1 PO. CS. PVC Cat. 6 Cable

A1.1 Cable Type: XLPE. CS. PVC. SWA.PVC.

Twisted pairs, collective screen
Rated Voltage 300V RMS
Service: Analogue signals

Intrinsically safe and non-intrinsically safe circuits
Construction: Conductors
7-stranded plain annealed copper
Insulation
Cross-linked polyethylene
Core Identification
Colours black, white.
Pairs numbered
Laying-up
Twisted pairs
1, 2, 5, 10, 20 pairs
Screens
Overall collective screen and drain wire.
Inner Sheath/Bedding
Extruded PVC, type TM 53 TO EN 50290-2-22
Armouring
Single layer of galvanised steel wires
Over sheath
Over sheath Colour
IS cable - blue.
Non IS cable – grey
Fire Performance
As specified in the material requisition

A1.2 Cable Type: XLPE. SCN. CS. PVC. SWA. PVC.

Twisted triple conductors, individual triple screens and overall screen.
Rated Voltage: 300V RMS
Service: Resistance temperature detectors (RTDs), gas detectors, vibration

instrumentssafe
Intrinsically etc. and non-intrinsically safe circuits
Construction Conductors
Insulation
Core Identification
Colours red, black, white.
Triples numbered
Laying-up
Three conductors twisted to form a triple
1, 2, 5, 10 and 20 Triples
Screens
Individual screen and drain wire for each triple.
Extruded PVC, type TM 53 to EN 50290-2-22
Armouring
Over sheath
Over sheath Colour
IS cable – blue
Fire Performance


Single and multi-pair extension cable for thermocouples type J
in accordance with ANSI MC 96.1.
Service: Extension cable for type J thermocouples (Iron/Copper-Nickel)
Solid circular: positive-iron, negative-copper-nickel
Insulation
Core Identification
Colours in accordance with ANSI MC 96.1.
Pairs numbered
Laying-up
Twisted pairs
1, 2, 10 and 20 pairs
Screens
Individual pair screen and drain wire
Armouring
Over sheath
Over sheath Colour

Black
Fire Performance


Single and multi-pair extension cable for thermocouples type K in
accordance with ANSI MC 96.1.
Service: Extension cables for type K thermocouples (nickel chromium/nickel-

Aluminium)
Solid circular: positive-nickel chromium, negative-nickel-Aluminium
Insulation
Core Identification
Pairs numbered
Laying-up
Twisted pairs
1, 2, 10 and 20 pairs
Screens
Individual pair screen and drain wire.
Overall collective screen and drain wire
Armouring
Over sheath
Over sheath Colour
Yellow
Fire Performance
Note: Negative Conductor shall be 95% Nickel 5% Aluminium

A1.5 Cable Type: XLPE. SCN. CS.PVC. SWA. PVC.

Single and multi-pair extension cable for thermocouples type T
in accordance with ANSI MC 96.1.
Service: Extension cables for type T thermocouples (Copper/Copper-Nickel)
Solid circular: positive-copper, negative-copper-nickel
Insulation
Core Identification
Pairs numbered
Laying-up
Twisted pairs
1, 2, 10 and 20 pairs
Screens
Armouring
Over sheath
Over sheath Colour

Blue
Fire Performance

A1.6 Cable Type: XLPE. CS. PVC.

Unarmoured single and multi-pair analogue/digital signal cables with
collective overall screen.
Service: Alarm and Analogue Signals.

Intrinsically safe and non-intrinsically safe circuits.
Insulation
Core Identification
Colours in accordance with standards listed in Appendix A.
Pairs numbered
Laying-up
Twisted pairs
5, 10 and 20 pairs
Screens
Overall screen and drain wire.
Inner Sheath
None
Armouring
None
Over sheath
Over sheath Colour
IS cable - blue
Non IS cable - grey
Fire Performance
As specified in the material requisition.


Single and multi-pair extension cable for thermocouples type R and S. In
accordance with ANSI MC 96.1.
Service: Extension cables for type R&S thermocouples (Platinum

Rhodium/Platinum)
Solid circular: positive-Copper, Negative-Copper-Nickel
Insulation
Core Identification
Pairs numbered
Laying-up
Twisted pairs
1,2, 10 and 20 pair
Screens
Armouring
Over sheath
Over sheath Colour

Green
Fire Performance


Twisted pairs, individual pair screens and overall screen.
Service: Foundation Fieldbus Analogue signals
7-stranded plain annealed copper, tinned conductor.
Insulation
Core Identification
Colours orange, blue
Pairs numbered
Laying-up
Twisted pairs
1, 2, 5, 10 and 20 pairs
Screens
Individual screen and drain wire for each pair.
Armouring
Over sheath
Over sheath Colour
IS cable – orange with blue stripe
Non IS cable - orange
Fire Performance

A1.8 Cable Type Electrical Requirements
Size 1x2x 1x2x 1x2x 2x2x 5x2x 5x2x 5x2x

1.0 1.5 2.5 1.5 1.0 1.5 2.5
mm /7 mm /7 mm /7 mm /7 mm /7 mm2/
2 2 2 2 2 mm2/7
7
Individual Screen No No No Yes Yes Yes Yes
Max Loop 37.0 24.6 15.12 24.6 37.0 24.6 15.12
resistance Ω/km Ω/km Ω/km Ω/km Ω/km Ω/km Ω/km
Nominal Overall 15.0 15.0 15.0 30.0 30.0 30.0 30.0
screen resistance Ω/km Ω/km Ω/km Ω/km Ω/km Ω/km Ω/km
Impedance at 100 Ω ± 20 Ω
f = 31.25 kHz
Mutual max. 60 nF/km
capacitance
Capacitance max. 4 nF/km
unbalance to earth
Attenuation at max. 3.0 db/km
f = 39 kHz
Propagation delay max. 1.7 μs/km
change
(7.9 kHz – 39 kHz)
Inductance Nom. 0.7 mH/km
Test voltage
core:core 1500 V
core:screen 1500 V
Operating voltage max. 300 V


Single and multi-pair extension cable for thermocouples type E.
In accordance with ANSI MC 96.1.
Service: Extension cables for type E thermocouples (Chromel /Constantan)
Solid circular: Positive- Chromel, Negative- Constantan
Insulation
Core Identification
Pairs numbered
Laying-up
Twisted pairs
1,2, 10 and 20 pair
Screens
Armouring
Over sheath
Over sheath Colour

Purple
Fire Performance

A1.10 Cable Type: XLPE. SCN.CS. PVC. SWA.PVC.

Twisted pairs, Individual pair screen, Collective screen
Rated Voltage 300V RMS
Service: Analogue signals

Insulation
Core Identification
Colours black, white.
Pairs numbered
Laying-up
Twisted pairs
1, 2, 5, 10, 20 pairs
Screens
Individual screen and drain wire for each pair.
Armouring
Over sheath
Over sheath Colour
IS cable - blue.
Non IS cable - grey
Fire Performance


Twisted pairs, individual pair screens and overall screen.
Service: RS 422/485 INSTRUMENT CABLE

7-stranded tinned annealed copper
Insulation
Core Identification
Colours 1st pair: white , blue ; 2nd pair: white, orange
Pairs numbered
Laying-up
Twisted pairs
2 pairs
Screens
Individual screen
Armouring
Over sheath
Over sheath Colour
IS cable – blue
Non IS cable – Grey
Fire Performance

A1.11 Cable Type
Electrical data at 20°C
Character Unit Values
Conductor size mm2 0.75
Conductor resistance max. /km 25
Insulation resistance min. M x km 5000
Mutual capacitance at 0.8 resp. 1 kHz max. nF/km 56
Impedance at 1 MHz nom.  105
Attenuation at 1 MHz nom. dB/km 8.5
Test voltage Urms core : core V 1000

Urms core : screen V 1000
Operating voltage Urms max. V 300

A2 Low Voltage Power and Control Cables
A2.1 Cable Type: XLPE, PVC, SWA, PVC
Rated Voltage 300 / 500 V RMS
System Voltage Up to 220V, 1 phase, 3 Wire, Neutral solidly earthed. Up to 250 V DC.
Service General purpose power distribution and digital signals.
7-stranded plain annealed copper, circular section.
Insulation
Core Identification
2 core - Black, Blue
4,7,12 19, 27,37 cores - Black cores with numbers
Printed in white
Laying up
Cores to be laid up together with non-hygroscopic fillers
Inner sheath / Bedding

Armouring
Over sheath
colour : Black for Power Cables
: Blue for IS Cables
: Grey for Non-IS Cables
Fire Performance
As specified in the Material Requisition

A2 Low Voltage Power and Control Cables
Electrical data at 20°C
Size 1x2x 1x2x 1x2x

1.0 1.5 2.5
mm /7 mm2/7
2 mm2/7
Max Loop 37.0 24.6 15.12
resistance Ω/km Ω/km Ω/km
Capacitance max. 115 nF/km
Between
Core
Operating max. 500 V
voltage

A3 Category 6 Cables
A3.1 Cable Type:

Twisted pairs
System Voltage 250MHz Category 6
Service: Premise Horizontal Cable, Gigabit Ethernet, 100BaseTX, 100BaseVG
ANYLAN, 155ATM, 622ATM, NTSC/PAL Component or Composite Video,
AES/EBU, Digital Video, RS-422,
solid bare copper
Insulation
Polyolefin
Core Identification
Pair 1: Blue; Pair 2: Orange
Pair 3: Green; Pair 4: Brown
As per IEC 60304
Laying-up
Twisted pairs
4 pairs
Screens
Individual & Overall collective screen and drain wire.
Over sheath
PVC LSZH
Over sheath Colour
IS cable - blue.

RELIANCE PROJECT MANAGEMENT SYSTEM
Specification For
Guidelines for Online Condition Monitoring of Rotating
Equipment
RPMS-ENGG-SPC-MR-022
0 09.12.19 Issued for Implementation VS MHS TR/VKM
Rev Date Revision Details Prepared Checked Approved By

By By
Guidelines for Online Condition monitoring of Date: 09/12/2019 Rev. 0

Rotating Equipment

(DD.MM.YYYY)
1 _____________________________
Mr.Deepak Puri _________________ ___________
Mr. Tushar Mukherjee

_____________________________ _________________ ___________
2
Mr. Kuddalur Seshadri

_____________________________ _________________ ___________
3
_____________________________ _________________ ___________

4
_____________________________ _________________ ___________

5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
RPMS-ENGG-SPC-MR-022 Page 2 of 46

Rotating Equipment
RECORD OF REVISIONS

Number
09.12.2019 Issued for Std. Committee Implementation 0

Rotating Equipment
Contents
1. Scope ...................................................................................................................................... 5
2. References .............................................................................................................................. 6
3. Conflicts and Deviations ........................................................................................................ 6
4. Abbreviations and Definitions ............................................................................................... 7
5. Technical and Design Requirements ..................................................................................... 8
6. Inspection and Testing ......................................................................................................... 25
7. Vendor Data ......................................................................................................................... 25
8. Packing, Preservation, Shipment and Storage ..................................................................... 25
9. Annexure - I ........................................................................................................................... 26
10. Annexure - II ......................................................................................................................... 28
11. Annexure - III ........................................................................................................................ 45
12. Annexure - IV ...................................................................................................................... 46

Rotating Equipment
1. SCOPE
1.1 General
This specification defines the minimum technical requirements for design, materials,
manufacture, inspection, testing, packaging, shipment and documentation of
“Guidelines for Online Condition Monitoring of Rotating Equipment “for Supplier
and/ or Contractor to comply with, to achieve Owner’s objective of standardization.
this standard specification that Supplier and/or Contractor may seek on this account,
prior to execution of Project Purchase Order.
1.2 Condition Monitoring

Reliability & availability of rotary equipment is vital for the safe and uninterrupted
plant operation. Any damage to the critical machines could lead to interruption of
plant operation hence contribution loss and has potential of process upsets or unit
trip / shutdown. The safety of assets and personnel also become susceptible to
danger in such situations. Major and abrupt damages may take long time for
restoration of machines back into operation, which is highly undesired. These critical
machines need to be closely monitored & protected against major damages.
Unplanned and abrupt equipment outages must be prevented through effective
monitoring and improved reliability.
Condition monitoring of rotary equipment is a pro-active approach encompassing
Vibrations monitoring, bearing metal temperatures and thrust monitoring as some of
the parameters which can be effectively monitored, and can provide prediction
based on analysis and also protect the machines against major breakdowns through
tripping or planned stoppages.
Machines could be monitored continuously through online system or on periodic

basis through offline monitoring. Online or Offline monitoring and the type of
monitoring system should be selected based on the criticality, type and service of
the machine. Normally online system should be used for critical and un-spared

Rotating Equipment
machines, while the remaining rotary machines should be monitored offline using
handheld analyzers.
This document endeavors to cover:
• The philosophy & considerations for selection and design of online
monitoring system for each type of machine.
• Areas with regards to reliability of the installed system so that the spurious
and unnecessary trips are avoided.
This document specifies general guidelines for provision of online condition

monitoring on rotating equipment such as Compressors, Steam and Gas Turbines,
Expanders, Pumps, Gearboxes, Fans, Electric Motors, Generators, Agitators,
Centrifuges etc. The guidelines are for machine mechanical condition parameters i.e.
vibrations, bearing temperatures, rotor axial position, one-event-per-revolution
(Keyphasor), rod drop, valve temperature for reciprocating machines and winding
temperature etc. This document does not cover requirements for speed control,
control and protection on process parameters, over-speed protection etc. These
requirements are defined in respective equipment project specifications.
This document provides guidelines for following:

• Parameters for monitoring
• Selection of monitoring & protection system
• Transducers selection
• Alarm and Trip logics
• Minimum requirements for Field Instrumentation
2. REFERENCES
For MCM System related requirements refer Standard Specifications for Machine
Condition Monitoring System (RPMS-ENGG-SPC-Cl-011)
3. CONFLICTS AND DEVIATIONS
shall govern;
1. Data Sheets and Drawings,

2. The Material Requisition,
3. This Standard Specification,

Rotating Equipment
4. Codes and Standards Specifically referred,

5. Local Regulatory and statutory Requirements
6. Other National & International Standards as Referenced
Latest Revisions of codes and other statutory requirements as applicable at the time
of enquiry, shall be applicable. In the event of a conflict between the requirement of
the referenced codes, standards, specifications, regulations and procedures, Supplier
shall submit the recommended solution to Buyer for review and permission to
proceed prior to implementation.
“Material Requisition” represents Material Requisition for Quotation, superseded by

Material Requisition for purchase on execution of a Purchase Order
“Data Sheets and Drawings” represents those attached to the Material Requisition
4. DEFINITIONS AND ABBREVIATIONS

All definitions for use in this document shall be according to relevant APIs and
Reliance Project Specifications for respective compressors.
4.1 Definitions
Parties responsible for complying with this Engineering Standard:
“Buyer” - Owner (Reliance) or Owner-appointed DEC or EPC who specifies
equipment and services for purchase from Suppliers.
“Supplier”- Party which manufactures or supplies equipment and services to perform

Parties referred within the body of Engineering Standard

Owner - Reliance Industries Limited or specified Reliance Group Company
DEC - Detailed Engineering Contractor
EPC - Engineering, Procurement and Construction Contractor
Contractor – DEC or EPC
All Definitions and Terminology used in this specification are as per API 670, 4rth
Edition.

Rotating Equipment
4.2 Abbreviations
Abbreviations used in this specification are as per API 670, 4th Edition.
Following are the additional abbreviations:
DCS : Distributed Control System
PLC : Programmable Logic Controller
RTD : Resistance Temperature Detectors
OEM : Original Equipment Manufacturer
ESD : Emergency Shutdown System
MCMS : Machine Condition Monitoring System
UCP : Unit Control Panel
5. TECHNICAL AND DESIGN REQUIREMENT
5.1 Scope of Rotating Equipment Package Supplier
a. Package Supplier should supply the rotating equipment package with vibration,
axial, speed, bearing and/or winding temperatures sensors,
accelerometer/velometer, junction boxes, etc. that are required for the rotating
equipment.
b. Package Supplier should install all field probes and sensors and wire them up to
junction boxes complete with signal amplifiers, drivers, proximitors, etc. as
appropriate.
c. Package Supplier should also provide Speed, vibration, displacement,

temperature alarms and trip values to be configured in the MCM System.
d. When specified in the data sheet, Package Supplier should supply the Monitoring
Rack as per Standard Specifications (RPMS‐ENGG‐SPC‐CI‐011). Cabling between Field
Junction Boxes and Unit Control Panel / MCM System Rack may be by others or
Managing Contractor/Owner. System block diagrams and architecture drawings
should be prepared including scope demarcation by the Package Supplier.
e. Package Supplier should provide required information and data in a prescribed

format related to rotating machine and field probes & sensors (e.g. length of
complete assembly i.e. probe, Extension cable & Signal Amplifier
/Modulator‐Demodulator and their selection as per Rotor shaft material, etc.) to the
Managing Contractor / MCM System Seller for the configuration of Analysis and
Diagnostic System (e.g. System‐1) during detail engineering.

Rotating Equipment
f. In case drive motor is not included in Package Supplier’s scope, sufficient terminals
should be provided by Package Supplier in the Junction Boxes for motor’s Vibration
probes and Temperature sensors connections.
g. Package Supplier should supply Local display with enclosure wherever specified
5.2 Condition Monitoring Strategy
This section provides basis of requirement of online condition monitoring system for
rotating equipment.
Selection of Online Monitoring Strategy

Continuous On-line Condition Monitoring system shall be selected based on
following considerations:
a. Service Criticality:
Service criticality of machine is defined based on asset classification procedure. It
depends on impact and its severity on safety, environment and economy of the
plant in case of machine failure / machine outage.
Failure in critical machines can lead to unsafe situations in the plant and
interruptions to plant operation. Based on severity of possible unsafe situation
and extent of interruption to plant operation, service criticality of machine may
be categorized as Vital, Essential and Desirable.
b. Type and Constructional complexity of the machine

For Example: Centrifugal compressor, reciprocating compressor, Turbines, heater
ID-FD fans, pumps etc.
Vendor standard machines: Machines which are designed and manufactured
based on vendor standards. In these types of machines, there may be deviations
to the international standard (e.g. API, ISO etc.) based on the vendor experience.
c. Installation location: e.g. Finned cooler fans, Remotely operated equipment etc.
Online monitoring system is recommended for following types of equipment:

1) Axial/Inline Centrifugal process gas and air compressor /Expander trains.
2) Integrally geared centrifugal compressor trains in Process Gas/air and Plant /
Instrument air service.

Rotating Equipment
3) Reciprocating compressor trains meeting selection criteria mentioned in

Annexure-III .
4) Process gas/ air screw compressor trains meeting selection criteria
mentioned in Annexure-IV.
5) Liquid ring Compressors
6) Gas Turbine generator
7) Steam turbine generator
8) Centrifugal pump meeting selection criteria mentioned in Annexure – I.
9) Centrifugal fan (ID / FD fans etc.) train
10) Finned cooler fans.
11) Cooling tower fans.
12) Agitators
13) Centrifuge
14) Extruder Gearbox
5.3 Condition Monitoring Parameters
Based on type of specific equipment, different parameters are to be monitored and

guidelines on the same for each type of machine are as below.
Axial and Centrifugal Compressors & Expanders:

• Radial Shaft Vibrations
• Rotor axial position
• Radial bearing temperatures
• Thrust bearing temperatures
• One-event-per-revolution probe for speed as well as phase angle measurement
Reciprocating Compressors:
• Frame vibrations
• Crosshead vibrations
• Main bearing temperatures

Rotating Equipment
• Rod drop based on equipment size

• Suction & Discharge Valve temperatures
• Stuffing box packing temperatures
Gas Turbine:
• Casing Vibrations
Centrifugal Pump:
• Casing Vibrations / Radial Shaft Vibrations based on type of the bearings
• Rotor axial position based on type of bearing
Steam Turbines:
Generator / Motor:
• Radial Shaft Vibrations/ Casing vibrations based on type of bearing
• Thrust bearing temperature
• Winding temperatures
Compressor/Turbine drive Gear Box:

Rotating Equipment
• Rotor axial position based on type of bearing

• Centrifugal fans(ID / FD fan etc):
• Speed measurement
Finned Cooler Fans:
• Casing Vibrations on Fan NDE bearing
Screw Compressor:
• Radial Vibrations or Casing Vibrations
• Axial position for rotors based on type of bearings
• Keyphasor for speed as well as phase
Hyper Compressor:
• Frame Vibrations
• Crosshead Vibrations
• Plunger Position
• Main bearing temperature
• Guide Bed temperature
Liquid Ring Vacuum Pump / Compressor:
• Casing vibrations
• Bearing temperature
Centrifuge:
• Casing vibrations on bearings
• Temperature measurement on bearings
• Speed measurement

Rotating Equipment
Agitator:
• Casing vibrations on gearbox bearings
• Casing vibrations on mechanical seal bearing
• Temperature measurement on gearbox and mechanical seal bearing
Cooling Tower Fans:
• Casing vibrations on gearbox high speed and low speed shaft bearings
Extruder Gearbox
• Casing vibrations, mounted on each bearing
• Bearing temperature, mounted on each bearing
5.4 Types of Online Monitoring system:
Equipment parameters are monitored continuously or periodically scanned through

permanently mounted transducers. Online monitoring system is categorized in three
types:
a. Continuous Online Monitoring system with remote diagnostics
Continuous online monitoring system with remote diagnostics is recommended

on critical equipment i.e. Process Compressors, Critical pumps, ID / FD fans,
Turbines etc.
• Transducers are mounted permanently on the equipment and machine

condition parameters are continuously monitored. Alarm/trips are triggered
when values exceed configured set points.
• The system is equipped with special diagnostics software for monitoring and
analyzing various parameters e.g. Bently Nevada System1 , DM2000,
Prognost
• Equipment parameters are ‘measured’, ‘sampled’ and ‘stored in a server’

continuously and automatically. System may export the data to DCS for
trending which could be useful for plant operations.
• Transducers are wired up to monitors which are generally mounted inside

panels. The panels could be located either in PIBs / control buildings or in the
field near machines.

Rotating Equipment
• This type of system contains data storage server(s) for storing historic data.
For big size plants with many machines there could be a network of such
servers. In case dedicated network is designed, separate workstation(s) with
diagnostic software may be installed at central location and used by the
reliability group.
• Data back-up facility (back-up server / Tape drive) may also be provided.
Back-up server can be installed at central location like Control Building or CES
Building.
Basic features required for this type of monitoring is stated in Section 5.6 of this
document.
b. Continuous Online Monitoring system with local indication (without remote

diagnostics):
This type of system is generally recommended for machines where:
1) This system is envisaged for equipment where diagnostic capabilities are

not required but protection and continuous monitoring is necessary.
2) Service is not so critical and normally spared.
3) Machines are not accessible for vibration monitoring using handheld
analyzers.
4) Machines are in remote locations.
Examples are cooling tower fans, finned cooler fans, pumps/fans in remote
locations.
• Transducers are permanently mounted on the machine and output is

connected to the stand alone monitoring system placed near to the
machine (in field). The indication should be provided preferably at the
ground level, which can be accessed easily.
• This type of system monitors the configured parameters continuously and

has facility for connectivity to DCS and ESD systems for trending and
protection respectively.
• This system does not have facility to store the data.

Rotating Equipment
• This system generally has ‘buffered output’ ports for capturing data by
handheld devices in case vibration analysis is required using diagnostic
software. Basic features required for this type of monitoring is stated in
Section 5.7 of this document.
c. Surveillance Scanning system:
Selection criteria and application for Surveillance Scanning System is similar

as in point ‘b’ except where protection on machine parameters is not
envisaged. Surveillance Scanning system can be wired or wireless. Typical
examples of Surveillance Scanning System:
1) Wired System: GE (Bently Nevada) –ProTIM.
2) Wireless System: Emerson Wireless Vibration Monitoring System
• In this system vibrations are monitored at defined frequency

automatically and data can be stored in a server which can be used for
analysis using diagnostic software i.e. System 1 or RBMWare
• The data scanning frequency depends on number of transducers

connected to the monitor.
• In this system, local display or buffered output may not be available.
• This system can be connected to DCS only for ‘alarm’ and trending. Relay
out for trip is not possible in this system
Basic features required for this type of monitoring is stated in Section 5.8 of
this document.
5.5 Guidelines for selection of Monitoring & protection system
Selection of condition monitoring system can be decided based on service criticality

and type of equipment. Guidelines for the same are given in the table-1.

Rotating Equipment
Table-1 : Guidelines for type of monitoring system
Type of Monitoring
Type of Machine Monitoring parameter Remarks
system
Process Gas / Air a. Radial Shaft Vibrations Continuous On-Line These are generally Critical
centrifugal b. Rotor axial position Monitoring system with and unspared machines.
compressors/ Geared c. Radial bearing temperatures remote diagnostics e.g.
centrifugal d. Thrust bearing temperatures e.g. PRT in FCC plant
compressors / Axial e. Keyphasor for speed as well as Bently 3300/3500 Recycle Gas Compressors
compressors / phase angle measurement system and in Hydrotreaters
Expanders Diagnostic software
like System-1, DM2000,
Prognost
Process Gas /Air a. Radial Shaft Vibrations Continuous On-Line These are generally Critical
Screw Compressors b. Casing Vibrations Monitoring system with and unspared machines.
c. Rotor axial position remote diagnostics e.g.
d. Radial bearing temperatures e.g. Net Gas Compressor in
e. Thrust bearing temperatures Bently 3300/3500 Crude plants
f. Keyphasor for speed as well as system and etc.
phase angle measurement Diagnostic software
like System-1,
DM2000,Prognost
Process gas / Air a. Frame Vibrations Continuous On-Line These are generally Critical
Reciprocating measurement Monitoring system with and spared machines.
compressors b. Main bearing temperatures remote diagnostics E.g.
c. Rod drop e.g. Compressors in Hydrogen
d. Suction & Discharge Valve Bently 3300/3500 Compression unit,
temperatures system and Make-up gas Compressors
e. Stuffing box packing Diagnostic software in CFP, Hyper Compressor
temperatures like System-1, DM2000, etc.
f. Keyphasor for speed as well as Prognost
phase angle measurement
Hyper Compressor a. Frame Vibrations Continuous On-Line
b. Crosshead Vibrations Monitoring system with
c. Plunger Position remote diagnostics
d. Main bearing temperature e.g.
e. Guide Bed temperature Bently 3300/3500
system and
Diagnostic software
like System-1,
DM2000,Prognost

Rotating Equipment
Gas Turbine a. Radial Shaft Vibrations Continuous On-Line

Generator b. Casing Vibrations Monitoring system with
c. Rotor axial position remote diagnostics
d. Radial bearing temperatures e.g.
e. Thrust bearing temperatures Bently 3300/3500
f. Keyphasor for speed as well as system and
phase angle measurement Diagnostic software
like System-1, DM2000,
Prognost
Steam Turbine a. Radial Shaft Vibrations Continuous On-Line

Generator b. Rotor axial position Monitoring system with
c. Radial bearing temperatures remote diagnostics
d. Thrust bearing temperatures e.g.
e. Keyphasor for speed as well as Bently 3300/3500
phase angle measurement system and
Diagnostic software
like System-1,
DM2000,Prognost
Centrifugal a. Casing Vibrations / Radial Shaft Continuous On-Line
Pump(Other than Vibrations based on type of the Monitoring system with
non-API water bearings remote diagnostics
pumps) b. Rotor axial position based on
Refer Annex I for selection
type of bearing
guidelines.
c. Radial bearing temperatures
d. Thrust bearing temperatures
e. Keyphasor for speed as well as
phase angle measurement
Non-API water pumps a. Casing vibrations Continuous On-line
(CW pumps, sea b. Bearing temperature Monitoring System with
Refer Annex I for selection
water transfer pump trip & without remote
guidelines
etc.) diagnostics
Centrifuges a. Casing vibrations Continuous On-line

b. Bearing temperature Monitoring System with
c. Speed measurement trip & without remote
diagnostics
Agitators a. Casing vibrations on gearbox Continuous On-line

and mechanical seal bearings Monitoring System with
b. Bearing temperature gearbox trip & without remote
and mechanical seal bearings diagnostics

Rotating Equipment
Centrifugal Fan (ID-FD a. Casing Vibrations / Continuous On-Line These are generally Critical
fan) c. Radial bearing temperatures Monitoring system with / essential machines.
d. Thrust bearing temperatures remote diagnostics
e. speed a measurement e.g.
Bently 3300/3500
system and
Diagnostic software
like System-1, DM2000
Cooling tower fan a. Casing Vibrations on high Continuous On-Line These are generally
gear box speed and low speed shaft Monitoring system with Desirable machines.
bearings provision of protection
and local indication:
e.g. Bently Nevada
1900/65 or equivalent.
Finned cooler fan a. Casing Vibrations Surveillance Scanning These are generally
system: Desirable machines.
e.g. Bently Trendmaster
Pro or equivalent.
Liquid Ring vacuum a. Casing vibrations Continuous On-Line

pump/compressor b. Bearing temperature Monitoring system with
remote diagnostics
e.g.
Bently 3300/3500
system and
Diagnostic software
like System-1, DM2000
Extruder Gearbox a. Casing vibrations (on individual

bearing)
b. Bearing temperature (on
individual bearing)

Rotating Equipment
5.6 GUIDELINES ON ONLINE MONITORING SYSTEM - FEATURES
As a minimum different monitoring system should have following capabilities.

Continuous Online monitoring system with Remote Diagnostics:
a. System should be capable to process and monitor the following parameters.
• Shaft Vibrations using proximity probes
• Casing Vibrations using Accelerometers, Velocity transducers etc.
• Temperatures using RTDs, thermocouples etc.
• Rotor Axial Position using proximity probes
• Rod drop /Rod position measurement using proximity probes
• Phase angle measurement using proximity probes
• Speed using proximity probes
• Reverse rotation indication using proximity probes
b. System should be capable to configure following parameters in case of shaft

Vibrations.
• Overall Vibrations amplitude for monitoring and protection
• Gap Voltage for monitoring and protection.
• 1x amplitude and phase angle for monitoring and diagnosis
• 2x amplitude and phase angle for monitoring and diagnosis
• 4 additional user-defined Nx amplitudes and phase angles for monitoring and
diagnosis.
• Not 1x amplitude for monitoring and diagnosis
• Asynchronous wave form for monitoring and diagnosis
• Synchronous wave form for monitoring and diagnosis
• Trip Multiply function
c. System should be capable to configure following parameters in case of Casing
Vibrations.
• Overall Vibrations amplitude for monitoring and protection
• Bias voltage for monitoring and protection.
• Asynchronous wave form for monitoring and diagnosis
d. System should be capable of configuring Alarms and Trips as applicable on
monitored parameters.

Rotating Equipment
e. System should be capable of analyzing the collected samples and should have
provision to stop the machine in case parameter goes beyond configured set
point window.
f. System should be capable of capturing the Static and dynamic samples. i.e.
overall Vibrations, temperature are static samples and synchronous waveform,
asynchronous waveform are Dynamic samples.
g. System should be capable of collecting automatic samples in transient state as
well as steady state condition. Sampling frequency for both states should be
configurable.
h. High rate of sampling is required during transient condition and system should be
capable data collection on user defined frequency in transient condition that can
be on Delta RPM and Delta Time.
System should be capable of sampling frequency for Delta RPM of 50 or less
during transient condition. As an alternative, transient data collection can be
based on Delta time. In case of motor drive equipment, delta time should be 1
sec or minimum possible in the system
i. During steady state, sampling should be on time basis and change basis.
j. System should be capable to collect the data at higher sampling rate during
Alarm events.
k. System should be capable of collecting the pre-event data. The period of pre-
event data should be user definable and minimum of 10 minutes.
l. Temporary data storage capacity of the system monitors should be sufficient to
capture the pre-event data and post event data for all monitored parameters, at
programmable intervals, up to machine comes to a rest followed by Alarm/ trip
event.
m. System should have two way communication with other plant systems i.e. DCS,
PLC etc. and should be capable of synchronize with the plant clock in plant
system for better correlation.
n. Monitoring system should have fault detection circuit for identifying fault in
vibration transducers & temperature elements & initiate circuit fault status
alarm. In the event of fault detection, monitor should be capable to downscale
trip logic (or reduce the reading to zero in case of temperature) so that spurious
trips can be avoided.

Rotating Equipment
o. Diagnostic software should have following capabilities:
1. Analysis tools/Plots: System should have capability to display following plots.
• Machine Train Diagram

• Trend
• Spectrum
• Waterfall
• Cascade
• Bode
• Polar
• Time waveform
• Orbit
• Shaft Centerline
• Acceptance Region
• Tabular list
2. Auto-Archive: System should have provision for auto-archive the data to the
Historical database.
5.7 Continuous monitoring system with provision for protection and local indications:
• This type of system monitors the parameter continuously and protects the
machine through alarm / trips same as in Continuous on-line monitoring
system.
• Output of the transducer should be connected to the system / monitors
placed near to the machine (in field).
• System should be capable to monitor the Overall casing Vibrations.
• System should have local display to show current Vibrations amplitude and
provision for the buffer output.
• System should comply with electrical area classification of the plant as it is to
be installed in the field.
• Monitored data may not be stored in the any server / database.
• In case, further analysis required then raw data should be captured in
handheld Vibrations data collector through buffer output.

Rotating Equipment
5.8 Surveillance scanning system:
• Numbers of transducers are connected to a monitor in daisy chain wiring

scheme(wired network) or mesh topology (wireless network) and
transducers are scanned one by one in assigned sequence.
• Monitors are installed in PIBs or Control buildings.
• System should be capable of monitoring overall Vibrations and asynchronous

waveform.
• System monitors the overall Vibrations at defined frequency automatically

and stores the data in to the data storage server.
• As monitor scans the data one by one, scanning time for each transducer
depends on the number of transducers connected to the monitor.
5.9 Guidelines on Online Monitoring System- Transducer Selection
Selection of transducers for each parameter to be monitored is very important for

reliable monitoring system. Detailed guidelines for transducers to be used for
different parameters are as in following sections.
Parameters to be monitored in each type of machine and the transducer to be used

for monitoring that parameter are attached in Annexure-II
A. Bearing and Winding Temperature
• Unless specified otherwise the temperature sensors for Bearing and winding
temperature shall be RTDs (Resistance Temperature Detectors).
• RTDs shall be Platinum T‐100, 3 wire elements.
• Temperature Co‐efficient of the RTDs shall be 0.00385Ω/ Ω/°C and
Temperature Range shall be from 0 to 100 °C as minimum.
• Wherever specified, Thermocouple may be used. Thermocouple element
shall be Grounded, Type J (Iron‐Copper‐Nickel) as per ANSI MC96.1 (IEC584‐1).
• The temperature elements shall be simplex or duplex as per Annexure‐II.
• Temperature Element location and installation shall be as per API‐670.
Temperature elements shall be embedded in the bearing pads.

Rotating Equipment
B. Radial Shaft Vibration, Rotor Axial Position, once‐per‐revolution event and Rod
Drop
• Proximity probes shall be used for radial shaft vibration, rotor axial position and for
once-per-revolution event measurement (Keyphasor).
• The minimum performance requirement (calibration) and system linearity for a
complete vibration‐monitoring system (transducers/sensors, power supply, monitors
and interconnecting cables) shall conform to API‐670.
• The proximity probe and related Proximitor should be compatible with the target
shaft material.
• Type and number of probes/sensors for Vibration, Axial displacement, One-
event‐per‐revolution / speed , Acceleration, Velocity, Rod Drop, etc. shall be as per
Annexure‐II.
Probes and their installations shall be as per API‐670
C. Casing Vibrations:
• Accelerometers or Velocity Transducers shall be used for casing vibration
measurement.
• Accelerometers or Velocity Transducers shall be piezoelectric accelerometers with
internal amplifiers and low output impedance.
• Ground isolation shall be provided and the connector shall mate with a standard to
API‐670 connector.
• The transducers shall be protected using a conduit outlet body with the center
milled out. Transducer cable shall be protected using a flexible Stainless Steel
conduit up to junction box.
• The transducer housing shall be as per API‐670
D. Speed Measurement:
• A Tachometer sensor shall be provided to measure speed wherever specified.
• Design of Tachometer circuit must include signal compatibility of Tachometer with
the Sensor selected. The speed Sensors that generate these signals can be :
a) A proximity probe with the associated oscillator‐demodulator, extension cable and
monitor
b) A self‐powered magnetic pick‐up
• The Tachometer shall be able to detect reverse rotation of the shaft at lower RPM
and be able to generate appropriate alarm.

Rotating Equipment
5.10 GUIDELINES FOR INSTRUMENTATION

A. General
• All field probes / sensors and related hardware should be supplied and
installed in accordance with the latest edition of API 670.
• All field probes / sensors and instrumentation including Junction boxes
should have CCOE / ATEX approval.
• All field devices, system, accessories, etc. supplied by Package Supplier should be of
latest proven technology
B. Junction Boxes and Terminals
• Separate Junction Boxes for speed, vibrations and temperatures should be provided.
All Junction boxes should be supplied with vibration pads. Junction Boxes
should be located such a way that they are not subjected to machine
vibrations. All Junction boxes should be properly earthed.
• Tight sealing by Grommet should be provided at the ends of protecting

conduit by Package Supplier and Junction boxes should be installed at higher
elevation than that of probe/ sensor tapings to prevent ingress of lube oil in
to the Junction Boxes.
• Proximitor / Drivers / Modulators should be DIN rail mounted in the field

Junction Boxes.
• Terminals in Junction Boxes should be clamp on type WAGO, Phoenix,

Klippon or equivalent with proper grounding. Minimum 20% spare terminals
should be provided in each Junction Box.
• Junction Box terminals should be suitable for termination of Triad or Multi triad
cables with individual and overall screen with minimum of 1 sq.mm
multi strand copper conductor.
• Junction boxes should have ingress protection IP‐65 as minimum and should
be certified for use in specified hazardous area.

Rotating Equipment
C. Cables and Wiring

• Proximity probe should have integral cable of 1-meter length. Extension
cables should be armored with 4 meters or 8 meters in length depending
upon overall electrical length of 5 meters or 9 meters respectively.
• Accelerometers / Velometers should be supplied with minimum 30 feet
armor cable.
• All sensor cables (Temperature, vibration, Axial displacement, Speed, etc.)
from machine up to the Junction boxes should preferably be armored. If
not armored, these should be laid in metallic conduit for mechanical and
heat protection of the cables. The sensor cables should be laid in conduit
such that they are isolated from ground to avoid signal interferences.
• The probe cable and extension cables should be isolated from ground to
avoid signal interferences.
• All intermediate connectors i.e. connector between probe integral cable and
extension cable should be seal tight (e.g. Fluid lock or equivalent type
connectors) to prevent oil and other liquids from leaking out of the machine
through the cable’s interior. The Connectors should be provided with
Connector Protector.
• Wiring and Grounding should be in accordance with API‐670.
This chapter provides recommendations with regards to field instrumentation
inclusive of cabling and junction boxes. This should be used to specify the scope of
supply for respective packages on case to case basis.
6. INSPECTION AND TESTING

Inspection and Testing shall be as specified in API 670 4th Edition, the Material
Requisition and this specification.
7. VENDOR DATA
Vendor Data and documentation shall be provided as described in the Material
Requisition and this specification.
8. PACKING, PRESERVATION, SHIPMENT AND STORAGE

Packing, Preservation, Shipment and Storage shall be as specified in API 670 4th
Edition and the Material Requisition.

Rotating Equipment
9. ANNEXURE – I
MCMS Selection criteria for Centrifugal Pumps
API PUMPS

Rotating Equipment
Non-API Pumps

Rotating Equipment
10. ANNEXURE – II
Guidelines for Monitoring Parameters and Transducers
A. Centrifugal / Axial / Integrally Geared
Compressor/ Expander Train:
A.1 Compressor/Expander:
Sensor &
Monitoring Parameter Location No. of Sensors
Instrument
Adjacent to shaft
Shaft Vibrations Proximity probe 2 probes per bearing (X & Y)
journal
Thrust collar / 3 probes per shaft having
Axial Position Proximity probe
Target plate thrust bearing
Simplex RTD RTDs on 2 Pads: 2 RTDs on
Tilting pad bearing inserted in each pad (One inline & One
bearing pad spare)
Radial Bearing Temperature
Simplex RTD 2 RTDs on each bearing, both
Sleeve bearing inserted in inline connected to MCMS
bearing pad system
Active side:
RTDs on 3 Pads: 2 RTD on
each pad (One inline & One
Tilting pad bearing Simplex RTD
spare)
Thrust Bearing Temperature (Active & Inactive inserted in
Inactive side:
side) bearing pad
RTDs on 2 Pads: 2 RTDs on
spare)
One-event-per-revolution / On each speed shaft in the

shaft Proximity probe
speed(Keyphasor) train including driver.

Rotating Equipment
A.2 Drive Steam Turbine for Compressor:

Sensor &
Instrument
Adjacent to shaft
journal

Target plate thrust bearing

bearing pad spare)
bearing pad system
Active side:
spare)
Inactive side:
side) bearing pad
spare)
One-event-per-revolution /
On each speed shaft in the
speed shaft Proximity probe
train including driver.
(Keyphasor)

Rotating Equipment
A.3 Gear box for Compressor:
Sensor &
Instrument
Adjacent to shaft
journal

Axial Position Proximity probe thrust bearing (2 probes
Target plate acceptable if space is limited)
bearing pad spare)
bearing pad system
Active side:
spare)
Inactive side:
side) bearing pad
each pad One inline & One
spare)
One-event-per-revolution / On each speed shaft in the

speed(Keyphasor) train including driver.
Seismic probe One accelerometer probe per

Casing Vibrations Casing
accelerometer casing

Rotating Equipment
Drive Motor
I) Motor with Antifriction Bearings :
Sensor &
Instrument
2 accelerometers (One at
Casing Vibrations DE & NDE bearings Accelerometer
each bearing)
Bearing Metal Temperature DE & NDE bearings Simplex RTD 2 RTDs at each bearing
2 RTDs on each phase

Winding Temperature Stator Windings RTD All RTDs shall be connected to
MCMS
II) Motor with Hydrodynamic Bearings :

Sensor &
Instrument
Shaft Vibrations Radial bearings Proximity probe 2 Probes per bearing (X & Y)
2 RTDs at each bearing, both

Bearing Metal Temperature DE & NDE bearings Simplex RTD
connected to MCMS

Winding Temperature Stator Windings RTD All RTDs shall be connected to
MCMS

Rotating Equipment
B. Reciprocating Compressor Train:
B.1 Compressor (Driver power more than 1 MW):
Monitoring Parameter Location Sensor & Instrument No. of Sensors

On piston rod
of each 1 probe per piston rod for rod
Piston Rod Drop cylinder, Proximity Probe
sensing from drop
top
2 Accelerometers/ Velometers:
On
Accelerometers / At both ends bearings of the
Frame Vibrations Compressor
Velometers crankcase, diagonally opposite
frame
and in Horizontal direction.
Accelerometer/
Crosshead Vibrations On Crosshead 1 Per crosshead
Velometer
Main bearing metal On main 2 RTDs per each bearing, both
Simplex RTD
Temperature bearings connected to MCMS
on Stuffing
Stuffing box temperature Thermocouple / RTD 1 per each stuffing box
box
flywheel Proximity probe . 1 per flywheel
speed
B.2 Compressor (Driver power between 500 kW to 1000 kW):

On piston rod
Piston Rod Drop of each Proximity Probe One per piston rod
cylinder
2 Accelerometers/
Velometers:
On
Accelerometers / At both ends bearing of
Frame Vibrations Compressor
Velometers the crankcase, diagonally
frame
opposite and in Horizontal
direction.
Main bearing metal On main 2 RTDs per each bearing,
Simplex RTD
Temperature bearings both connected to MCMS
on Stuffing
Stuffing box temperature Thermocouple / RTD 1 per each stuffing box
box

Rotating Equipment
flywheel Proximity probe 1 per flywheel
speed
B.3 Compressor (Driver power < 500 KW but ≥ 200 KW):

2 Accelerometers/
Velometers:
Frame Vibrations On
Accelerometers / At both ends of the
(Directly connected to DCS Compressor
Velometers crankcase, diagonally
for Monitoring) frame
opposite and in Horizontal
direction.
Main bearing metal
Temperature On main 2 RTDs per main bearing,
Simplex RTD
(Directly connected to DCS bearings both connected to MCMS
for Monitoring)
B.4 Drive Motor:

2 Accelerometers/
DE & NDE Velometers at each motor
Casing Vibrations Accelerometer/Velometer
bearings bearing, One horizontal &
One vertical
2 RTDs per bearing
DE & NDE
Bearing Metal Temperature Simplex RTD Both RTDs shall be
bearings
connected to MCMS.

Stator
Winding Temperature RTD All RTDs shall be
Windings
connected to MCMS

Rotating Equipment
C. Screw Compressor Train: (Refer Annex IV)
C 1. Compressor:

2 Accelerometers.
One accelerometer per
Bearing
Casing Vibrations Accelerometers rotor (male and female
Housing
rotor) diagonally opposite
ends.
2/3 probes on each rotor
Thrust collar /
Axial Position Proximity probe depending on space
Target plate
available
On radial /
2 RTDs per bearing
thrust bearing
Bearing Metal Temperature Simplex RTD Both shall be connected to
(sleeve / tilting
MCMS.
pad bearings)
C2. Motor:
I) Motor with Antifriction Bearings :
DE & NDE 2 Accelerometers (One at

Casing Vibrations Accelerometer
bearings each bearing)
DE & NDE 2 RTDs at each bearing.
Bearing Metal Temperature Simplex RTD
bearings Both connected to MCMS

Stator
Winding Temperature RTD All RTDs shall be
Windings
connected to MCMS

Rotating Equipment
II) Motor with Hydrodynamic Bearings :

Radial
Shaft Vibrations Proximity probe 2 Probes per bearing (X & Y)
bearings
DE & NDE 2 RTDs at each bearing. Both
Bearing Metal Temperature Simplex RTD
bearings connected to MCMS
Stator
Winding Temperature RTD All RTDs shall be connected to
Windings
MCMS
D. Centrifugal Pump Train (Refer Annex I )
D.1 Pumps with hydrodynamic radial bearing & hydrodynamic thrust bearings (other than Sundyne make).
Adjacent to
shaft journal
Thrust collar / 2 or 3 probes depending on
Target plate space available
Tilting pad Simplex RTD inserted RTDs on 2 Pads: 1 RTD on each
bearing in bearing pad pad
Radial Bearing Temperature Simplex/ Duplex RTD 2 RTDs on each bearing, both
Sleeve bearing inserted in bearing inline connected to MCMS
pad system.
Active side:
Tilting pad RTDs on 2 Pads: 1 RTD on each
bearing Simplex RTD inserted pad
Thrust Bearing Temperature
(Active & in bearing pad Inactive side:
Inactive side) RTDs on 2 Pads: 1 RTD on each
pad
One-event-per-revolution / On each speed shaft in the train
speed(Keyphasor) including driver.

Rotating Equipment
D.2 Pumps with hydrodynamic radial bearing & antifriction thrust bearings (other than Sundyne make).
Adjacent to
shaft journal
Tilting pad Simplex RTD inserted RTDs on 2 Pads: 1
bearing in bearing pad RTD on each pad
Radial Bearing Temperature Simplex/ Duplex RTD 2 RTD on each bearing, both
Sleeve bearing inserted in bearing inline connected to MCMS
pad system.
1 RTD on each bearing : Both
Thrust Bearing Temperature Axial bearing Duplex RTD set of cable of duplex RTD
connected to MCMS system
One-event-per-revolution / On each speed shaft in the train
speed(Keyphasor) including driver.
D.3 Pumps with Antifriction radial bearing & Antifriction thrust bearings (other than Sundyne make):
2 Accelerometers ( One at each

Casing Vibrations Radial bearing Accelerometer
bearing)
Radial bearing Duplex RTD sets of cables of duplex RTDs
Bearing Metal Temperature
Axial bearing Duplex RTD sets of cables of duplex RTDs

Rotating Equipment
D.4 Sundyne make Pumps (Horizontal pump) :
Adjacent to 2 probes per bearing (X & Y) at

Shaft Vibrations Proximity probe
shaft journal each bearing
One accelerometer at bull gear
bearing.
Radial bearing Duplex RTD sets of cables of duplex RTD
Axial bearing Duplex RTD sets of cables of duplex RTDs
On each speed shaft for
complete train including driver
shaft Proximity probe (Only where proximity probes
speed
are installed for shaft
vibrations)
D.5 Sundyne make Pumps (Vertical pump) :
One accelerometer at sandwich

plate of gearbox.
Radial bearing Duplex RTD sets of cables of duplex RTD
Axial bearing Duplex RTD sets of cables of duplex RTD

Rotating Equipment
D.6 Drive Steam Turbine for Pump

Hydrodynamic
bearings :
Proximity probe 2 probes per bearing (X & Y)
Shaft
Vibrations
Vibrations
Antifriction
Bearings :
Accelerometer 1 accelerometer per bearing
Casing
Vibrations
Tilting pad Simplex RTD inserted RTDs on 2 Pads: 1 RTD on each
bearing in bearing pad pad
Sleeve bearing Duplex RTD set of cable of duplex RTD
connected to MCMS systems
Antifriction
Duplex RTD sets of cables of duplex RTD
Bearings
Active side:
Tilting pad RTDs on 2 Pad: 1 RTD on each
bearing Simplex RTD inserted pad
(Active & in bearing pad Inactive side:
Thrust Bearing Temperature Inactive side) RTDs on 2 Pads: 1 RTD on each
pad
Antifriction
Duplex RTD sets of cables of duplex RTD
Bearings
speed
vibrations)

Rotating Equipment
D.7 Gear box for pump :
Sensor &
Instrument
Hydrodynamic
bearings : Proximity probe 2 probes per bearing (X & Y)
Shaft Vibrations
Vibrations
Antifriction 2 accelerometer
Bearings : Accelerometer (One at each shaft, input
Casing Vibrations and output shaft)
2 or 3 probes depending on
space available
Thrust collar /
Axial Position Proximity probe (Axial position is not
Target plate
required in case of double
helical gears.)
Simplex RTD
Tilting pad RTDs on 2 Pads: 1 RTD on
inserted in bearing
bearing each pad
pad
1 RTD on each bearing :
Both set of cable of duplex
Sleeve bearing Duplex RTD
Radial Bearing Temperature RTD connected to MCMS
systems
1 RTD on each bearing :
Antifriction Both set of cable of duplex
Duplex RTD
Bearings RTD connected to MCMS
systems
Active side:
RTDs on 2 Pads: 1 RTD on each
pad
(Active & Inactive inserted in
Inactive side:
side) bearing pad
Thrust Bearing Temperature RTDs on 2 Pads: 1 RTD on each
pad
Antifriction
Duplex RTD set of cable of duplex RTD
Bearings
speed
vibrations)

Rotating Equipment
D.8 Motor for Pump:

I) Motors with Antifriction Bearings
Sensor &
Instrument
Casing Vibrations DE & NDE bearings Accelerometer 1 accelerometer per bearing

Bearing Metal Temperature DE & NDE bearings Duplex RTD set of cable of duplex RTD
2 RTDS on each phase : All
Winding Temperature Stator Windings RTD RTDs shall be connected to
MCMS systems
II) Motor with Hydrodynamic Bearings
Sensor &
Instrument
2 probes (X & Y) on each motor

Shaft Vibrations Radial bearing Proximity probe
radial bearing.

Bearing Metal Temperature Radial bearing Duplex RTD set of cable of duplex RTD
2 RTDS on each phase : All

Winding Temperature Stator Windings RTD RTDs shall be connected to
MCMS systems

Rotating Equipment
E. Centrifugal Fans (ID/FD)

E.1 Fans (All capacities):
Sensor &
Instrument
1 Accelerometer on each fan
bearing
Bearing Metal Temperature Radial bearings Duplex RTD set of cable of duplex RTD
E.2 Drive steam Turbine for Fans( Rating >500 kW)

Sensor &
Instrument
Hydrodynamic
bearings : Proximity probe 2 probes per bearing (X & Y)
Shaft Vibrations
Vibrations
Antifriction
Bearings : Accelerometer 1 accelerometer per bearing
Casing Vibrations
Simplex RTD
Tilting pad bearing inserted in
pad
bearing pad
Simplex RTD
Radial Bearing Temperature Sleeve bearing inserted in 2 RTD on each bearing
bearing pad
Antifriction
Bearings
Active side:
pad
Inactive side:
side) bearing pad
pad

Rotating Equipment

Antifriction
Bearings
Shaft Proximity probe (Only where proximity probes
speed
vibrations)
Motor for Centrifugal fans (Rating >500 kW)

I) Motors with Antifriction bearings:
Sensor &
Instrument
1 Accelerometer on each
Casing Vibrations DE & NDE bearings Accelerometer
motor bearing
Bearing Metal Temperature DE & NDE bearings Duplex RTD set of cable of duplex RTD
2 RTDS on each phase: All RTDs
Winding Temperature Stator Windings RTD
shall be connected to MCMS
II) Motor with Hydrodynamic Bearings:
Sensor &
Instrument
Shaft Vibrations Radial bearing Proximity probe 2 probes per bearing (X & Y)

Bearing Metal Temperature Radial bearing Duplex RTD set of cable of duplex RTD
2 RTDS on each phase: All RTDs
Winding Temperature Stator Windings RTD
shall be connected to MCMS
Gear box for Fan (Rating >500 kW):


Rotating Equipment
Hydrodynamic
2 probes per bearing (X
bearings : Proximity probe
& Y)
Shaft Vibrations
Vibrations
Antifriction 2 accelerometer
Bearings : Accelerometer (One at each shaft,
Casing Vibrations input and output shaft)
2 or 3 probes
depending on space
available.
Thrust collar /
Axial Position Proximity probe Axial position
Target plate
monitoring is not
required in case of
double helical gears.
Simplex RTD inserted in 2 Pads: 1 RTD on each
Tilting pad bearing
bearing pad pad
Simplex RTD inserted in
Sleeve bearing 2 RTD on each bearing
Radial Bearing Temperature bearing pad
1 RTD on each bearing
Antifriction : Both set of cable of
Duplex RTD
Bearings duplex RTD connected
to MCMS systems
Active side:
2 Pad: 1 RTD on each
Tilting pad bearing
Simplex RTD inserted in pad
(Active & Inactive
bearing pad Inactive side:
side)
2 Pad: 1 RTD on each
Thrust Bearing Temperature
pad
1 RTD on each bearing
Antifriction : Both set of cable of
Duplex RTD
Bearings duplex RTD connected
to MCMS systems
On each speed shaft
for complete train
One-event-per-revolution / including driver (Only
Shafts Proximity probe
speed where proximity
probes are installed for
shaft vibrations)
F. Finned Cooler fans:

Rotating Equipment

1 Velometer/
Casing Vibrations Fan NDE Bearing Velometer/Accelerometer
Accelerometer per fan
G. Cooling Tower fan gear box:

2 Velometers /
Accelerometers per
Casing Vibrations Velometer /
On gearbox gearbox (One each at
(Local monitoring system) Accelerometer
output and input shaft
bearing)
H. Agitators (Driver rating >500 kW)
Monitoring Sensor &

Location No. of Sensors
Parameter Instrument
Near bearing of input,

output and intermediate
Casing Vibrations Accelerometer One at each location
shafts near mechanical seal
housing bearing

Rotating Equipment
11. ANNEXURE – III
MCMS Selection Chart for Reciprocating Compressor
Reciprocating
Compressor
Datasheet
Driver Power rating

Air Service YES YES
≥ 1000 KW
NO
NO
Hydrocarbon / Hazardous /
Nitrogen Service Online
Monitoring
Required
YES
For details of
Monitoring
parameters see
Annexure-II
Driver Power rating
YES
≥ 500 KW
NO
Hydrocarbon / Hazardous Service

Driver Power rating OR
≥ 200 KW YES Single line Compressor in Continuous service YES
OR
Compressor speed > 1400 rpm
NO
NO
Online Monitoring not required

Rotating Equipment
12. ANNEXURE – IV
MCMS Selection Chart for Screw Compressor
Screw
Compressor
Datasheet
Driver Power rating ≥ 1000 KW

Or
Compressor Speed ≥ 5000 rpm YES
Or
Hydrocarbon / toxic Service
Online
Monitoring
NO Required
For details of
Monitoring
parameters see
Single line Compressor in Continuous service Annexure-II
Driver Power rating
YES OR YES
≥ 500 KW
Compressor speed > 1400 rpm
NO
NO
Online Monitoring not required

Polysilicom MFG Facility RIL Jamnagar Project

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Material Requisition MR Cover Sheet

Jobsite Location Jamnagar, Gujarat Revision No. 01

Section Section Title Notes

Requisition Revision History and Approvals

Originator Ganesh Salunkhe 23-Dec-22

IFQ - Checker Sachin Borse 5-Jan-23

Previous Revision Criticality Inspection Requisition

30 - All NDE as indicated in the Specifications/Requisition N/A N/A 9+9+2 Lots

Exceptions and Deviations:

Notes Relating to Scope of Supply:

17 Hydrotest gasket specification shall be same as service gaskets.

Worley Specification and data-sheet

J22N01-MEAD-EPE255-601502 Mechanical Datasheet for BCW Air cooler 00

Reliance Engineering Specifications

SECTION III – SDRL (SUPPLIER DATA REQUIREMENT LIST) MASTER

b) Motor & VFD schematic and

D06 COUPLING DATASHEET

J01 WELD PROCEDURES (WPS AND PQR) Yes 6 Yes

PROJECT NO.: JN3102 REQUISITION NO.: MT-J22N01-D1JEP-MEA001-WIPL-Q-00

NAME OF THE SUPPLIER:

FOLLOWING DOCUMENTS ARE COMPLETELY FILLED IN AND ATTACHED WITH OFFER.

Supplier's authorized signatory

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TCS Heavy Impurity Column #2 Condenser

Item No: EA-03202

Project No: J22N01

Polysilicon Manufacturing Facility

CONFIDENTIAL - This document is the property of Advanced Material

Project Manager_________________________ Date____________

1 29-Dec-22 Updates per Client Review ENG SPH

Issue Date Description By Appr'd Sheet 1 of 3 Spec No: J22N01-SP-EA-03202

Plot Area * m2 Weight - Bundle kg

** Give tube count of each pass when irregular.

Pressure: 3.496001 kg/cm²g

CVD OGR TCS/STC Column Condenser

Item No: EA-07002

Project No: J22N01

Polysilicon Manufacturing Facility

CONFIDENTIAL - This document is the property of Advanced Material

Project Manager_________________________ Date____________

0 1-Nov-22 ISSUED FOR REVIEW ENG JS Customer__________________________________

Issue Date Description By Appr'd Sheet 1 of 3 Spec No: J22N01-SP-EA-07002

** Give tube count of each pass when irregular.

Pressure: 2.396 kg/cm²g

CVD OGR STC Air Cooler

Item No: EA-07008

Project No: J22N01

Polysilicon Manufacturing Facility

CONFIDENTIAL - This document is the property of Advanced Material

Project Manager_________________________ Date____________

0 1-Nov-22 ISSUED FOR REVIEW ENG JS Customer__________________________________

Issue Date Description By Appr'd Sheet 1 of 3 Spec No: J22N01-SP-EA-07008

** Give tube count of each pass when irregular.

Pressure: 2.780 kg/cm²g

Hot Cooling Water Flash Condenser

Item No: EA-22001

Project No: J22N01

Reliance Industries Limited

This document is the property of AMS ADVANCED MATERIAL

Project Manager_____________ Date

Project Manager_____________ Date

Project Manager_____________ Date

Project Manager_____________ Date

0 1-Nov-22 Issued for Review JMD HJ Customer______________________Date

Project Manager_____________ Date

0 1-Nov-22 Issued for Review JMD HJ Customer______________________Date

Project Manager_____________ Date

Project Manager_____________ Date

Project Manager_____________ Date