Plant Client Contract Code Document ID Contract No.

INDIAN OIL
IOCL GUJARAT REFINERY
CORPORATION LTD.
BS-IV FLARE 6674-PIP-6174-EC-0005 66-6674

Technical requirements for Special Parts

Rev 01 Page 2 of 7

Contents:

1 INTENT OF SPECIFICATION ........................................................................................................................................ 3

2 GENERAL REQUIREMENTS.......................................................................................................................................... 3
3 TEST AND INSPECTION ............................................................................................................................................... 5
4 RADIOGRAPHY ............................................................................................................................................................. 6
5 IBR CERTIFICATION ..................................................................................................................................................... 6
6 MARKING ...................................................................................................................................................................... 7
7 PAINTING AND COATING (METALLIC PARTS) .......................................................................................................... 7
8 GUARANTEE.................................................................................................................................................................. 7
9 PACKING FOR TRANSPORTATION ............................................................................................................................. 7
10 MAINTENANCE SPARES .............................................................................................................................................. 7
Plant Client Contract Code Document ID Contract No.

INDIAN OIL
IOCL GUJARAT REFINERY
CORPORATION LTD.
BS-IV FLARE 6674-PIP-6174-EC-0005 66-6674

Technical requirements for Special Parts

Rev 01 Page 3 of 7

1 INTENT OF SPECIFICATION

This specification is intended to cover design, manufacture, assembly, cleaning, inspection, testing,
delivery & proper packing for transportation of special parts.

2 GENERAL REQUIREMENTS

2.1 Technical specification of each special piping part is as enclosed.

2.2 Size and quantities of special parts covered under this specification are indicated in Bill of Material
enclosed, unless stated otherwise.

2.3 The bidder's offer shall accompany all relevant data/information as requested in technical specification
sheet with bidder's comments marked and cross sectional drawing showing clearly all constructional
features of the item offered and the overall dimensions.

The drawing shall be clearly marked for "Constructional Features" and the relevant item code shall be
indicated on drawing. The drawing must include all the technical details like rating, material etc.

All the sheets and drawings submitted by bidder must bear the seal and signature of bidder.

The following details are required to be confirmed/ provided for the items as listed below.

2.4 STEAM TRAPS

a) Bidder to furnish model no. of trap selected.

b) Bidder to furnish the performance curve indicating the capacity in mass/hour at
various differential pressures across the trap
c) Bidder to specify minimum/maximum pressure and minimum differential pressure.
d) Bidder may offer suitable alternative type of trap.
e) If offered trap size differs from line size, bidder to provide suitable Reducer/Expander to match the
line size.
f) Parts subject to wear and tear shall be suitably hardened.
g) Traps shall function in horizontal as well as in vertical installation. Traps shall have
integral strainers
h) Bidder to furnish assembly drawing.
i) All traps shall be hydrostatically tested to twice the design pressure.

2.5 HOSES

a) Suitable hose clips shall be provided on the adaptors.

b) Suitability of hoses shall be guaranteed for the service and working conditions specified in the
requisition, even if the material is not specified in the Material Requisition for any particular
service.
c) All hoses shall be clearly marked with service and working pressure at both ends.
d) Hoses shall be resistant to ageing, abrasion and suitable for outdoor installations.
e) Steam hoses shall be subject to steam resistance test.

2.6 STRAINERS

a) Clear strainer area to nominal area ratio shall be 3 for Y strainers & conical strainers.
b) Strainer element withdrawal space needs to be indicated in constructional feature drawing.
c) For conical strainers, one open spacer shall be supplied.
Plant Client Contract Code Document ID Contract No.

INDIAN OIL
IOCL GUJARAT REFINERY
CORPORATION LTD.
BS-IV FLARE 6674-PIP-6174-EC-0005 66-6674

Technical requirements for Special Parts

Rev 01 Page 4 of 7

d) Allowable pressure drop when specified shall be certified along with the offer. If asked
specifically, pressure drop calculations shall be furnished.
e) All 2" & higher sized Y type strainers shall be provided with 3/4" threaded tap and solid
threaded plug as drain connection on the blind flange. For less than 2", this shall be 1/2"
size.
f) Bottom flange of Y-type strainer shall not have tapped hole. Full length standard size
studs shall be used for joining blind flange.
g) For fabricated strainers, all BW joints shall be fully radiographed and fillet welds shall be
100% DP/MP checked.

2.7 FACE TO FACE DIMENSION

a) Steam traps and lined sight glass shall have face to face dimension as per manufacturer's
standard.
b) Wherever the design manufacturing standard is specified as a specific sketch number in the
technical specification, the face to face dimension shall conform to that sketch unless otherwise
specified.
c) For Class 150 lined strainers, dimension specified in point no.(a) shall be followed, however this
face to face shall be considered before lining.

2.8 All galvanized items shall be hot dip galvanized as per ASTM A123/A153 as applicable based on product
specification.

2.9 Austenitic Stainless Steel :

2.9.1 All items shall be supplied in solution annealed condition.

2.9.2 For all Austenitic Stainless steels, Intergranular Corrosion (IGC) Test shall be
conducted as per following :

ASTM A262 Practice 'B' with acceptance criteria of 60 mils/year (max.) for casting.

ASTM A262 Practice 'E' with acceptance criteria of 'No cracks as observed from
20X magnification' & microscopic structure to be observed from 250 X magnification" for
items other than casting.

For IGC test, two sets shall be drawn from each solution annealing lot; one set
corresponding to highest carbon content and other set corresponding to the highest
rating/thickness.

2.9.3 For all items of stabilised SS grades (SS 321 / 321H / 347 / 347H), stabilizing heat treatment shall also
be done. It shall be carried out subsequent to normal solution annealing. Soaking
temperature and holding time shall be 900ºC and 4hrs respectively.

2.10 Components under “NACE” service :

All components in NACE service (as indicated on datasheets) shall comply with requirements of
NACE MR-0103 with following additional requirements:

a) For carbon steels, hardness of the material shall be below 22HRC. Hardness for any weld & HAZ
shall be limited to HB 200 max.
b) Carbon steel must be fully killed type.
Plant Client Contract Code Document ID Contract No.

INDIAN OIL
IOCL GUJARAT REFINERY
CORPORATION LTD.
BS-IV FLARE 6674-PIP-6174-EC-0005 66-6674

Technical requirements for Special Parts

Rev 01 Page 5 of 7

c) Ni content in CS items shall be less than 1%.

d) Carbon content shall be 0.2% max.
e) Max. Carbon equivalent shall be 0.42%
With Ceq = C + Mn/6 + (Cr +Mo + V)/5 + (Ni + Cu)/15
f) Max. allowable phosphorus content : 0.030%
g) Max. allowable Sulphur content : 0.020% for seamless pipe and 0.025% for fittings, flanges and
castings.
h) All welds shall be stress relieved.
i) All plates & plate fabricated items including welded pipes and fittings shall be HIC resistant. Steel
shall be produced by vacuum degassing. HIC test shall be carried out in accordance with NACE
TM0284 by using the acidified test solution ‘A’ specified in NACE TM0177 with CLR <=5%. Vendor
to demonstrate its capacity of producing “Sour Service items” through previous HIC testing data.
Additional chemical requirements to be followed for HIC resistant steel are:

1. Oxygen content less than 0.0025%

2. Max. allowable Phosphorus – 0.010%
3. Max. allowable sulfur content – 0.002%

3 TEST AND INSPECTION

3.1 Vendor / manufacturer shall have and maintain a quality control system which will establish that all
specified requirements including raw material control system, manufacturing, heat treatment, NDT and
all other tests will be met.

It is vendor's responsibilily to arrange for third party inspection to be undertaken during execution for the
order on behalf of IOCL, as per IOCL approved Third Party Inspectors (TPI) under clause 3.10.

Third party inspection stages shall be included under vendor's ITP. Vendor shall offer the products to TPI
at manufacturer’s shop with all necessary gauges and measuring instruments. Material/Heat Treatment
Certificate shall be 100% reviewed. Original mill test certificate in accordance with EN10204: 3.1 shall be
furnished for review.The completeness of each piece shall be verified.

3.2 Surface, dimension, identification, marking, leakage and functioning shall be inspected/ or witnessed by
inspector for 25% of the pieces, per size, per lot, per code including IBR items. For traps quantity to be
inspected shall be 1 no per size, per code, per visit. Visual inspection will be 100% by TPI.

3.3 Non-destructive testing (if specified in the technical specification) shall be witnessed for PT & MPT for
100%. RT films & UT report shall be offered for TPI review including IBR items.

3.4 The test pressure against each rating/material for strainers & sight glass (without glass) same shall be
indicated on drawing. All the strainers & traps shall be hydrostatically tested at minimum twice the
design pressure.

3.5 Complete hose assembly shall be tested at two times the design pressure and the bursting pressure
shall be minimum 3.15 times design pressure(Hydro), specified in the technical specification and it shall
be mentioned in drawing. Only certificate for burst test in lieu of actual testing is acceptable.

3.6 Hydro test for sight glass (with glass) shall be done at a pressure of 1.5 times the design pressure
specified in the technical specification.

3.7 Any other test as per vendor’s regular quality control procedure needs to be carried out by the vendor.

3.8 Potable water shall be used for testing of Carbon steel & Alloy steel parts. For testing of Stainless
Steel parts maximum chlorine content in water shall be 15-20 ppm.
Plant Client Contract Code Document ID Contract No.

INDIAN OIL
IOCL GUJARAT REFINERY
CORPORATION LTD.
BS-IV FLARE 6674-PIP-6174-EC-0005 66-6674

Technical requirements for Special Parts

Rev 01 Page 6 of 7

3.9 Special parts shall be subjected to P.M.I test as per EIL standard 6-81-0001 & below listed table.

Sr.no Scope Manufacturer Trader TPIA Remarks

1 Special parts – 100% - 10%* *In the case of imported items,

material and scope to be decided by Client /
welds TPIA.
- 100% 100%*
Note:-
1)TPI reserves the right to increase the % of witness based on vendor performance.
2)In case of failures noticed during witness by TPI, 100 % of items of lot shall be PMI tested.

3.10 The name of the IOCL approved TPI agencies is as under :

1. M/s ABS lndustrial Verification (India) Pvt. Ltd.

2. M/s Projects and Development India Ltd.
3. M/s TUV SUD South Asia Pvt. Ltd.
4. M/s IR Class Systems and Solutions Private imited
5. M/s Velosi Certification Services India Pvt. Ltd.
6. M/s TUV Rheinland India Pvt. Ltd.
7. M/s Certification Engineers International Limited
8. M/s Rites Ltd.
9. M/s TUV India Private Limited
10. M/s Moody International India Pvt. Ltd.

4 RADIOGRAPHY

4.1 Radiography wherever specified shall be done by X-ray/GAMMA ray to get the sensitivity. The RT shall be
carried out after heat treatment (if heat treatment is applicable).

4.2 Percentage of radiography to be carried out shall be as per individual technical specification.

5 IBR CERTIFICATION

5.1 For items described “IBR”, the same shall be in accordance with the latest IBR (Indian Boiler Regulation)
including the requirements specified in the specification.

For SW/BW end carbon steel items under IBR, the chemical composition shall confirm to the following:
Carbon (Max) : 0.25%
Others (S, P, Mn) : As per IBR regulations
The above composition is not applicable for non-IBR items.

5.2 For items described “IBR”, test certificate in applicable IBR forms shall be furnished, signed by IBR
Inspection Authority or an approved representative. IBR Items will be inspected by TPI in addition to IBR
Inspection Authority.

5.3 For IBR items, test certificate shall indicate all additional requirements (other than IBR) of Order Spec.,
Project Spec., item nos. etc. If not, manufacturers certificate with all details duly witnessed / or reviewed
by TPI as applicable shall be submitted.
Plant Client Contract Code Document ID Contract No.

INDIAN OIL
IOCL GUJARAT REFINERY
CORPORATION LTD.
BS-IV FLARE 6674-PIP-6174-EC-0005 66-6674

Technical requirements for Special Parts

Rev 01 Page 7 of 7

6 MARKING

The marking on each piece shall be done as per Design Manufacturing Standard and the identification
indicated in the Bill of Material attached. Use of hard punch is not allowed for wall thickness less than
3.2mm to avoid notch effect. In such case marking shall be done on stainless/aluminum tag which
should be secured to the special part. Wherever applicable, the direction of flow shall be clearly marked.

7 PAINTING AND COATING (METALLIC PARTS)

7.1 All carbon steel parts shall be painted with two coats of synthetic enamel/aluminum paint/silicon paint or
as per technical specification.

7.2 Galvanized items shall be hot dip galvanized as per ASTM A153 / A123 as applicable based on product
specification.

8 GUARANTEE

8.1 All special parts covered under this specification shall be guaranteed for mediums with their applicable
conditions (wherever applicable) as mentioned in respective technical specification sheets and also for
trouble free operation for twelve (12) months from the date of commissioning, unless otherwise specified
in purchase order or any other document.

9 PACKING FOR TRANSPORTATION

9.1 After inspection and testing, the special parts shall be properly packed in wooden boxes. The flanges
shall be closed with plate covers, wooden planks / plastic to avoid transportation damage. Socket
weld/screwed ends shall be closed using plastic caps.

9.2 Each variety and size of item shall be supplied in separate packaging marked with the purchase order
no., item code and the salient specifications.

10 MAINTENANCE SPARES

10.1 Bidder should furnish a complete list of maintenance spares required for two years trouble free operation
along with recommended quantities and quote the price for the same.