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TABLE OF CONTENTS

Section No. COVER SHEET CONTENT SHEET 1 2 3 4 5 GENERAL TECHNICAL SPECIFICATION DETAILED TECHNICAL SPECIFICATION LIST OF TENDER DRAWINGS TECHNICAL DATA SHEETS & SCHEDULES PRICE SCHEDULES Description No. of pages 01 01 40 61 03 12 05

SECTION - 1 GENERAL TECHNICAL SPECIFICATIONTABLE OF CONTENTS


1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 INTENT OF SPECIFICATION...................................................................................3 SCOPE OF WORK FOR ERECTION........................................................................3 TERMINAL POINTS..................................................................................................6 EXCLUSIONS FROM THE BIDDER'S SCOPE OF WORK........................................6 PERFORMANCE TEST............................................................................................7 PROJECT INFORMATION........................................................................................7 APPROVED SUB VENDORS/MAKES.......................................................................7 TAGGING..................................................................................................................7 PAINTING..................................................................................................................7 QUALITY ASSURANCE, TESTING AND INSPECTION.............................................7 DOCUMENTATION.................................................................................................10

ANNEX-1.1 PROJECT INFORMATION.......................................................................................14 ANNEX- 1.2 BILL OF MATERIAL................................................................................................17 ANNEX- 1.3 PIPING CLASSIFICATION.....................................................................................32 ANNEX - 1.4 LIST OF SUB-VENDOR...........................................Error! Bookmark not defined. ANNEX- 1.5 PAINTING ...........................................................................................04 SHEETS

SECTION 1 1.0.0 GENERAL TECHNICAL SPECIFICATION INTENT OF SPECIFICATION

1.1.0 This specification covers the minimum technical requirements and essential particulars for Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports Erection, Laying, inspection & testing at site, cleaning & painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc. 1.2.0 Services shall be rendered in conformity with proven design principles, taking into account the current technology. The requirements of the contract must be fulfilled in its entirety. The services shall be rendered inclusive of all appliances and interconnecting arrangements with other supplies, necessary for installation of all accessories, needed for proper and reliable continuous operation and for satisfactory maintenance and repair. 1.3.0 In so far as data on the execution of services as contained in drawings, but none in specification and vice versa, such data shall be deemed to be contained in both. Contradictions, if any, between drawings and specifications and within various sections of the specification shall be brought to the attention of the Purchaser/Consultant by the Bidder and the correct requirement shall be obtained. 1.4.0 It is mandatory for the bidder's to furnish along with the bid the deviations if any, whether major or minor in the Schedule of Deviations' only. In the absence of the deviations listed in the Schedule of Deviations', the offer shall be deemed to be in full conformity with the specification not withstanding anything else stated elsewhere in the offer, data sheet, etc. The hidden deviations or stated / implied deviations in the offer shall not be acceptable OR binding on the Purchaser. 1.5.0 All materials supplied under this contract shall be new and unused.

1.6.0 The Bidder shall furnish along with the Bid the necessary information meeting the above

requirement.

2.0.0

SCOPE OF WORK FOR ERECTION

2.1.0 The scope of work covered under this specification include but not limited to preparation of relevant drawings, specifications, documents and getting them approved by the Consultant and statutory authorities for necessary clearances, Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc. as detailed in the scope of work. 2.2.0 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.3.0 2.3.1 Scope of supply All handling equipment, machinery, tools, consumables etc., required for fabrication work to be carried out at site. All handling equipment, machinery, tools, consumables etc., required for erection of LP piping. Piping supports for the above ground piping complete with all accessories. Consumables and chemicals required for the piping and fittings fabrication, erection, cleaning and testing works. Temporary piping material and supports for piping system, cleaning and testing. Gasket for all flanges and Hume pipe for Buried pipe. Required hardware (like bolts, nuts, clamps, U- clamps etc.) Painting of piping. Wrapping and Coating tape for Buried piping. Scope of services Fabrication, Erection & Commissioning of LP Piping: Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc... as detailed in the scope of work. 2.3.2 The Bidder shall be responsible for examining all the consignments and notify the Project Manager immediately of any damage, shortage, discrepancy etc. The Bidder shall submit to the Project Manager every week a report detailing all the receipts during the week. However, the Bidder shall be solely responsible for any shortages or damage in transit, handling and/or in storage and erection of the equipment/ material at the site. Any demurrage, wharf age and other such charges claimed by the transporters, etc shall be to the account of the Bidder. The Bidder shall maintain an accurate and exhaustive record detailing out the list of all equipment / material received by him for the purpose of erection and keep such record open for the inspection of the Owner/ Project Manager at anytime. The equipment/material stored shall be properly protected and the same shall be moved to the actual location at an appropriate time so as to avoid any kind of damage to them. The Bidder shall ensure that all the packing materials, and protection devices used for the various equipment / material during transit and storage are removed before the same are installed. The packing materials and protection devices shall remain the property of the Owner and shall be handed over by the Bidder to the Owner after the completion of works. The Bidder shall be responsible for making arrangement for suitable indoor storage facilities to store required equipment/ material. In general, all the electrical equipment/ material such as motors, control gears and consumables like electrodes, lubricants etc. shall be stored in the closed storage space. The Project Manager, in addition, may direct the Bidder to move certain other materials that in his opinion will require indoor storage to the designated indoor storage areas, which the Contractor shall strictly comply with.

2.3.3

2.3.4 2.3.5

2.3.6

2.3.7

If the materials belonging to the Bidder are stored in areas not acceptable to the Owner, the Project Manager will have the right to get them moved to the area earmarked for the Bidder at the Bidder's cost. All the materials stored in the open or dusty location must be covered with suitable weather proof and flame proof covering of material wherever applicable. Any damage or deterioration of the material while in the custody of the Bidder shall be recovered by the Owner from the Bidder. The erection quantities involved are listed in Annex 1.2 this section of the specification.

2.3.8

2.3.9

2.3.10 The scope includes fabrication design of pipes & accessories which includes preparation of fabrication and spool drawings. Time is the essence of contract in completing each phase of the work so that the plant can be in commercial operation on the specified date. The Bidder will be required to submit drawings and engineering data in accordance with the schedule and requirements specified herein to assure compliance with the overall construction and operating schedule. 2.3.11 Obtaining necessary approvals from various agencies as applicable. 2.3.12 Providing all man power, material and complete erection equipment including cranes/hoists, tools and tackles, consumable, welding electrodes, filler wires, oxygen, acetylene, sequence of erection, calibration & measuring instruments etc. to enable execution of job including final testing, calibration and handing over in a planned manner and within the schedule of stipulated time. 2.3.13 After completion of job arrange to clear the area of work of all loose materials, scraps, tools equipment etc. Also update Purchaser's construction drawings to incorporate all the modifications carried out and get same certified as 'as-built' drawings by the Project Manager. 2.3.14 Assisting the Purchaser in successful commissioning of the system by providing skilled/unskilled personnel, equipment & tools etc. 2.3.15 Participation in design conferences, as specified herein. 2.3.16 The onsite construction / erection / installation work shall be in accordance with the requirements specified in this specification. 2.3.17 All pre-commissioning and commissioning activities. 2.3.18 All the tests as specified in this specification. 2.3.19 Welding of pipes /flanges at terminal points shall be included under the scope of this package and required to be done by the Bidder. 2.3.20 The Bidder shall allow not less than 30 days for mailing, processing, and Owner review of drawings and data in his Engineering Schedule and Procurement / Production / Shipping Schedule. 2.3.21 Field Supervision: The Bidder shall furnish the services of one or more construction / erection supervisors for resident supervision of all erection work, testing, and placing the piping into successful operation. The erection supervisors shall be present during and shall supervise the unloading of equipment and materials from vehicles, hauling, storing, cleaning, erection, start up, and testing. 2.3.22 Technical Services: In addition to the resident field supervision specified herein before, the Bidder shall furnish the services of one or more technical service representatives. The service representatives shall be technically competent; trained; experienced in the fabrication, erection and testing of the LP piping; and authorized to perform the work stipulated. 2.3.23 Design Conference: The Bidder's design engineer shall attend a design conference at a time and place prescribed by the Owner to discuss matters relative to the execution of this Contract. The Bidder's design engineer shall attend additional design conferences as required by the Owner thereafter to expedite the work. 2.3.24 Quality Assurance and Quality Control: As specified in Cl.11.0.0 of this specification, the Bidder shall submit a documented Quality Assurance and Quality Control program capable of providing assurance that all involved equipment, materials, and services meet requirements of the contract documents. 2.3.25 Submission of Daily, Weekly, Monthly progress report including reconciliation statement of free issue materials at the end of the month.

2.3.26 Any other activities found necessary for the successful completion of the job. 2.4.0 2.4.1 Drawings Purchaser shall provide the following drawings & documents a. b. c. b. Plot Plant. Symbol and Legends. P&ID Drawings. Piping layout drawings.

d. Isometric / 2D drawings. c. d. Standard piping support details. Equipment layout drawings.

The list of drawings indicated above is furnished else where in this tender document. However these are tentative and indicative only. The final drawings will be made available to the contractor progressively after the award of contract. 2.4.2 Coordinating for approvals from the statutory authorities like Inspector of Explosives CCOE (if required) and for calibration from Weights & Measures Department etc. & others for the system under their purview. This includes getting approval of the welders from the above authorities, arranging for the Inspector to visit site and obtain necessary approvals and certificates for the erected pipe work etc. Location, type and details of support for lines will be indicated in the Piping / G.A. drawing support details wherever not shown in GA drawing, but required for the piping stability the Contractor shall carry out supporting with the approval of Project Manager after developing necessary support drawings. All fabrication drawings for piping shall be developed by the Contractor and submit to the Project Manager for approval. Any alteration in pipe routing / supporting required to suit the site condition shall be done by the Contractor to the satisfaction of the Project Manager at no extra cost. Consumables Supply of all consumables required for commissioning and performance test shall be included in the scope and the same shall be supplied by the successful Bidder at appropriate time. 3.0.0 3.1.0 4.0.0 4.1.0 TERMINAL POINTS Terminal point has been indicated in the P&I Drawings (All Terminal point details are preliminary only and which shall be finalised after award of the contract). EXCLUSIONS FROM THE BIDDER'S SCOPE OF WORK Mechanical Erection of Piping beyond battery limits. All valves, expansion joints their counter flanges along with fastener and gaskets. All instruments with their accessories.(required stubs and fitting to be provided by bidder as indicated in the P & ID'S Supply of pipes and fittings (other than fabricated from the plate material). Plate for fabricated pipe and fittings. Pipe Support materials.(structural materials only) All specialties their counter flanges along with fastener and gaskets. 4.2.0 Civil All Civil Engineering works such as RCC foundation, buildings, roads, pipe racks/ pipe

2.4.3

2.4.4 2.4.5 2.5.0

trenches etc. 5.0.0 5.1.0 Encasement for the buried piping.

PERFORMANCE TEST Guarantee requirements In addition to compliance with the requirements of the Specification, the Bidder shall meet the specific guarantees of performance as required and as stated in the specification. All tests shall be carried out in accordance with the relevant international standards unless otherwise specified or approved by the Purchaser. Performance test will be carried out, within the appropriate time period as specified to demonstrate the achievement of guaranteed parameters.

6.0.0 7.0.0

PROJECT INFORMATION Project Information is furnished in Annex 1.1 of this section of the specification. APPROVED SUB VENDORS/MAKES

7.1.0 The makes of all material/equipment/ instruments under this specification shall be subject to Purchaser's approval in the event of order. Bidder shall furnish a list of makes/ sub-vendors/ sub-contractors along with his bid. Purchaser reserves the right to accept/ reject any make or sub-vendor or add new makes/ sub-vendors for the project, after award of contract. Approval, rejection or addition of makes shall not have any cost implication to the Purchaser after award of contract. 8.0.0 TAGGING

8.1.0 Components whose identity is important for operation and maintenance of the plant viz., all apparatus, motors, signal tapping points, instruments and control equipment, cubicles, as well as the terminal boards, etc., installed in the latter shall be provided with permanently attached tag bearing the Purchaser's coding together with relevant text clearly inscribed. The inscription shall be approved by the Purchaser/Consultant. The tag shall be of engraved plate of sufficient rigidity and figures and letters embossed and painted. Such nameplates or labels shall be of white non- hygroscopic material with engraved black lettering. The language of inscription shall be English. The method of implementation and labeling will be informed for all components after award of contract. 9.0.0 PAINTING

9.1.0 The painting specification for all the piping shall be as specified in Annex 1.5 of this specification. 10.0.0 QUALITY ASSURANCE, TESTING AND INSPECTION 10.1.0 Quality Assurance Programme 10.1.1 To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Bidder's works or at his Sub-Vendor's premises or at the Purchaser's site or at any other place of work are in accordance with the specifications, the Bidder shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programmes shall be outlined by the Bidder and shall be finally accepted by the Purchaser after discussions before the award of Contract. A quality assurance programme of the Bidder shall generally cover the following: a) Bidders organisation structure for the management and implementation of proposed quality assurance programme, b) Qualification data of his key personnel, c) The procedure for purchase of materials, parts, components and selection of Sub- Vendor's services including Vendor analysis, source inspection, incoming raw material inspection, verification of materials purchased, etc., d) System for shop manufacturing including process controls and fabrication and assembly controls, e) Inspection and test procedure both for manufacture and field activities, f) Control of calibration and testing of measuring and testing equipment,

g) System for indication and appraisal of inspection status, h) System for quality audits,

i) j)

System for handling, storage & delivery, System for authorising release of manufactured product to the Purchaser,

k) System for maintenance of records, and l) A quality plan detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component furnished.

10.2.0 Quality Assurance Documents 10.2.1 The Bidder shall be required to submit the following Quality Assurance Documents as required. a) All non-destructive examination procedures, stress relief and weld/repair procedure actually used during fabrication. b) Welder and welding operation qualification certificates. c) Welder identification list, listing welder's and welding operator's qualification procedure and welding identification symbols. d) Material mill test reports on components as specified by the specification. e) The inspection plan with verification, inspection plan check points, verification sketches, if used, and method used to verify that the inspection and testing points, in the inspection plan were, performed satisfactorily. f) Sketches and drawings used for indicating the methods of traceability of the radiographs to the location on the equipment.

g) Non-destructive examination result reports. h) Stress relief time temperature charts. i) Factory test results for testing required as per applicable codes and standards referred in the specification.

10.2.2 The Purchaser shall be given reasonable notice of all tests and shall have the right to witness all tests, and shall have access to the works of Bidder and Sub-Vendor at all times for the purpose of carrying out system audits, conducting quality surveillance witnessing of tests and inspections etc. 10.2.3 The Purchaser or his authorized representative may periodically check the work and the Constructor's method of operation to assure that quality control practices are being followed. At the time of Purchaser's visit all quality documentation pertaining to test, qualifications, inspections etc., shall upon request be made readily available. 10.2.4 All reports of tests and inspections as per Quality Control Practices and Quality Plans shall be furnished to the Purchaser. 10.3.0 General Requirements for Testing and Inspection 10.3.1 All equipment covered under these specifications shall be subject to inspection and tests by the Purchaser/his authorized representative or third party during erection and commission. The approval of the Purchaser or passing of such inspection of test will not, however, prejudice the right of Purchaser to reject the equipment if it does not comply with specifications when erected or does not give complete satisfaction in service. The cost of all such tests as well as third party inspectors shall be borne by the Bidder. 10.3.2 The Bidder shall furnish the quality plan for erection and commissioning activities indicating stage wise all tests and inspections, procedures and acceptance norms to be adopted for each piece of equipment under this specification. 10.3.3 Testing/inspection procedures as detailed herein is to give a basic quality control programme to be followed by the Bidder and are in no way comprehensive and in no way form a complete quality assurance programme. Any other inspection stages not mentioned in these clauses but required as per the Bidder's quality assurance programme or the Purchaser shall be deemed to be included. Any tests necessary from operation, safety and reliability point of view shall also be included. Such quality plan shall be subject to the approval of the Purchaser. 10.3.4 The cost of all inspections at site by other regulatory institutions shall be borne by Bidder and

accordingly included in his lumpsum price in the Bid. 10.3.5 The Purchaser, his duly authorised representative shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its Fabrication or erection and if part of the works is being fabricated or assembled on other premises or works, the Bidder shall obtain for the Project Manager and for his duly authorised representative permission to inspect. 10.4.0 Non-destructive Examination 10.5.0 All non-destructive examinations shall be performed in accordance with written procedure to meet ASME Sec. 1 and Sec. V code requirements. The personnel shall be qualified with Practice SNT-TC-1A of the American Society of Non-destructive Testing or equivalent. Each non-destructive examination shall be recorded in a report which summarises methods and equipment used, results evaluation, date and identification of personnel employed. 10.6.0 Welding Procedure 10.6.1 All welding procedures adopted for performing welding work shall be qualified in accordance with the requirements of Section IX of ASME code. 10.6.2 These welding procedures shall clearly state the type of material, thickness, the joint details, the preheat temperature maintained, the post-weld heat treatment given, the welding current and voltage used during qualification of welding procedures. 10.6.3 All records of the welding procedures, the welders qualifications, tests and welders performance details for the work performed under these specifications shall be maintained by the Bidder and be made available to the Purchaser on request. 11.0.0 DOCUMENTATION 11.1.0 Drawings, data / documents to be submitted along with tender 11.1.1 Duly filled-in technical data and prices as per specified schedules. 11.1.2 List of drawings/documents attached. 11.1.3 Time schedule for erection, testing, and commissioning. 11.1.4 List showing auxiliary piping furnished for all equipments. 11.1.5 List of tests the Bidder proposes to carry out at site after installation including those pertaining to their sub-contractor. 11.1.6 A bar chart indicating fabrication, installation, testing and commissioning activities. 11.1.7 A comprehensive write-up or brochure on the details of facilities / man power available with the Bidder. 11.2.0 Drawings, data / documents to be furnished by the successful Bidder The following drawings, data / documents shall be submitted for the approval / review of the Purchaser / Consultant by the successful Bidder. Description 11.2.1 Piping fabrication/spool piece details. 11.2.2 Test procedures and details of test to be conducted. 11.2.3 Technical data sheet and GA drawings for supply items 11.2.4 Quality assurance document for erection of piping system 11.2.5 Fabrication procedure for piping 11.2.6 Final welding procedure for piping. 11.2.7 Any other details if required by purchaser/Owner. 11.2.8 Type and Routine Test certificates, material test certificates for major components. Category I A I A I A A A

Note: Category-A : For Approval Category-I : For Information/Reference. 11.3.0 General a. b. c. d. e. f. g. Contract network schedule Detailed painting specification. Detailed interface schedule for all terminal points identifying terminal point no., size, material, type of connection, design flow, pressure and temperature at the terminal points QAP for all manufactured and sub contracted items. Detailed write-up for shop tests Test certificates for type/routine tests, standard acceptance tests and performance tests Field Quality Plans

h. Storage instructions for all equipment i. j. k. l. Installation drawings and manuals for all equipment/systems Detailed write-up on all pre-commissioning and commissioning activities. Detailed write-up for site performance tests Integrated operation and maintenance manuals for the complete plant as well as for all

individual equipment m. As-built drawings for all equipment/systems supplied under this contract and works executed under this contract incorporating all changes/modifications upto the time of commissioning / handling over to the Purchaser/consultant, n. Drawings/data to be required/submitted to statutory authorities o. Documents as listed in respective sections of Technical specification. 11.4.0 Drawings/ Documents Submission 11.4.1 All drawings shall be made in latest Autocad version. 11.4.2 The contractor shall submit drawings/ documents as per the no. of copies listed below: To PLL : 7 copies

To Consultant : 4 copies 11.4.3 All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail indicating the type, size, arrangement, weight of each component for packing and shipment, the external connection, fixing arrangement required, the dimensions required for installation and interconnections with other equipment and materials, clearance and spaces required between various portions of equipment. 11.4.4 Each drawing submitted by the Contractor shall bear a title block at the right hand bottom corner with clear mention of the name of the Contractor/Purchaser, Title block to be issued by Contractor after award of contract. If standard catalogue pages are submitted the applicable items shall be indicated therein. All titles, notings, markings and writings on the drawing shall be in English. All the dimensions shall be in metric units. 11.4.5 The furnishing of detailed engineering data and drawings by the Contractor shall be in accordance with the time schedule finalised during pre-award meeting. The review of these documents / data / drawings by the Contractor/Purchaser will cover only general conformance of the data / drawings / documents to the specifications and contract, interfaces with the equipment provided by others and external connections of the dimensions as reviewed. The review and / or approval by the Contractor/Purchaser shall not relieve the Purchaser/ Contractor of any of this responsibilities and liabilities under this contract. 11.4.6 After the approval of the drawings, further work by the Contractor shall be in strict accordance with these approved drawings and no deviation shall be permitted without the written approval

of the Contractor/Purchaser. 11.4.7 As Built Drawings a) After final acceptance of individual equipment / system by the Contractor/Purchaser, the Contractor will update all original drawings and documents for the equipment / system to "as built" conditions. b) Drawings must be checked by the Contractor prior to submission to the Purchaser. In case, drawings are found to be submitted without proper checking by the Contractor, the same shall not be reviewed and returned to the Contractor for re-submission. 11.5.0 Engineering Information Submission Schedule Prior to the award of Contract, a Detailed Engineering Information Submission Schedule shall be tied up with the Contractor. For this, the contractor shall furnish a detailed list of engineering information alongwith the proposed submission schedule. The list would be a comprehensive one including all engineering data / drawings / information for all bought out items and manufactured items. The information shall be categorised into the following parts. i) Information that shall be submitted for the approval to the Contractor/Purchaser before proceeding further and

ii) Information and would be submitted for Contractor's/Purchaser's information only. The Engineering Information Schedule shall be prepared monthwise. The schedule should allow adequate time for proper review and incorporation of changes / modifications, if any, to meet the contract without affecting the equipment delivery schedule. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performance and progress. 11.6.0 Work Progress and Exception Report 11.6.1 The Contractor shall submit every month a work progress and Exception Report giving the status of work information including a) A list of drawings / data which remains unapproved for more than four (4) weeks after the date of first submission. b) Drawings which were not submitted as per agreed schedule. c) Master list of drawings (computer output). 11.6.2 The draft format for this report shall be furnished to the Contractor/Purchaser within four (4) weeks of the award of the contract, which shall then be discussed and finalized with the Contractor/Purchaser. 11.7.0 Instruction Manuals The Contractor shall submit to the Owner/Purchaser, draft Instruction Manuals for all the work covered under the Contract by the end of six (6) months from the date of his acceptance of the Letter of Award. The Instruction manuals shall contain full details required for erection, commissioning and testing. The manual shall be specifically compiled for this project and subject to approval by Purchaser. The Contract shall not be considered to be completed for purposes of taking over until the final Instructions manuals have been supplied to the Owner/Purchaser. The Instruction Manuals shall comprise of the following. A) Erection Manuals The erection manuals shall be submitted atleast three (3) months prior to the commencement of erection activities of particular equipment / system. The erection manual should contain the following as a minimum. a) b) c) d) Erection strategy Sequence of erection Erection instructions Critical checks and permissible deviation / tolerances

e) f) g) h) i) j) k) l)

List of tool, tackles etc. Bills of Materials Procedure for erection Procedure for initial checking after erection Procedure for testing and acceptance norms Procedure / Check list for pre-commissioning activities Procedure / Check list for commissioning of the system Safety precautions to be followed in electrical supply distribution during erection.

1.0 2. 0 3.0
4.0

Owner Project Title Location Power station site Elevation above Mean Seal Level (MSL) Latitude /Longitude Nearest Railway station Nearest Town Distance from Nearest State Highway Nearest Airport Nearest Sea Port Road Approach Seismic data Seismic intensity Zone Importance factor Temperature Maximum / Minimum temperature Daily maximum mean temperature Daily minimum mean temperature Maximum Dry bulb temperature Minimum Dry bulb temperature Wet Bulb Temperature Design temperature for elec equipment/device/System Relative Humidity Monthly Maximum Relative Humidity Maximum mean Relative Humidity Monthly minimum Relative Humidity Minimum mean Relative Humidity Design relative humidity for Electrical equipment/Device/System Rain fall Max. recorded Average Annual rain fall Period of Monsoon (Avg) Showers FFL + 224.5 m TG hall 1 9 5 8 ' N/ 7 9 1 8 'E Tadali Railway Station of Warora Branch of Central Railway and the distance is about 3.0 KM Chandrapur (Maharashtra), India, 3.0 km 0.5 Km from SH-264 Nagpur Visakhapatnam (East coast) NH-3&NH-6, and SH-264 AsperIS-1893. II 1.75 for tanks 48.3 0C and 2.8 0C 42.8 0 C

4.1 5. 0
6.0 7.0 8.0 9.0

10.0 11.0
(a ) (b ) (c) 12. 0 (a) (b) (c) (d) (e) (f) (g) 13. 0 (a) (b) (c) (d)

12.8 C
33.8 0C 21.3 0C 29 0C 50 C

14.0
(a ) (b ) (c)

84% 65% 21% 46%


95% 1276.5mm.

15.0 16.0 17.0 17.1 17.2 17.3 17.4

Wind data Maximum wind speed Climatic conditions Auxiliary power supply AC Motors above 160 kW AC Motors 0.18 kW to including 160 kW AC Motors Below 0.18 kW Plant lighting, utility power sockets, space heating panels and space heating of motors of rating 30kW and above Control Circuit of local panels (like compressor control, crane control, etc.) and 415 V switchgear outgoing feeder modules controls. For control of switchgear, switchyard equipment, DC emergency drives, DC emergency lights, switchyard and generator protection panels, etc. For Instrumentation and Control

44 m/s.

Unless otherwise specified, All auxiliary equipment to be supplied against this specification shall be suitable for operation on the following supply 6.6kV, 3 phase, resistance earthed) 400V, 3 earthed) phase, 3 4 wire, wire, AC AC supply (Medium

supply (Effectively

240V, 1 Phase, AC supply (Effectively earthed) 240V, 1 Phase, AC supply (Effectively earthed)

17.5

240V, 1 Phase, AC supply system (Derived from 415/240V step down transformer)

17.6

220V DC Supply : UPS supply 240V AC, Any other AC or DC voltage required shall be derived from the same.

17.7 17.8 17.9 (a) (b) (c) 17.10

Unless otherwise specified all electrical system shall be designed for the following voltage and frequency variations: AC system Voltage variations Frequency variation Combined Voltage and Frequency Variation DC system a) Voltage variation (220 V) + 10% to- 15% 1% 10% + 5% to - 5% 10%

17.11 18.0

UPS Electrical Voltage levels a. EHV System

400000 V ()10% , 3 phase, 50 Hz (+)5% to (-)5%, solidly grounded system.

b. c.

MV System LV System

6600 V ()10% volts, 3 phase, 50 Hz (+)5% to (-)5%, low resistance grounded system. 415 V ()10% volts, 3 phase, 50 Hz (+)5% to (-)5%, solidly grounded system. 230 V ()10% volts, 1 phase, 50 Hz. 240 V ()10% volts, 1 phase, 50 Hz 10% (Absolute sum) 220 (+)10% to (-) 15% volts, ungrounded system 230 volts ()10% volts, 1 phase, 50 Hz system 6.6 kV, 3 phase, 50 Hz low resistance grounded system 415 Volt, 3 phase, 50 Hz Solidly earthed 240 Volt, 1 phase, 50 Hz 415 Volt, 3 phase, 50 Hz

d. Control Voltage e. f. Auxiliary supply for lighting Combined voltage & frequency variation

g. DC Voltage h. UPS Voltage 19.0 Electric Equipment Voltage Rating a. b. c. d. For motors above 160 kW For motors from 0.18 upto 160 kW For motors less than 0.18 For all MOV motors Fault Level

20.0 a. b. c.

400,000 volts system 6.6 kV system 415 volts system

40 kA for 1 (One) second 40 kA for 3 (Three) second. 50 kA for one second

ANNEX-1.2 BILL OF MATERIAL System :


ITEM: PIPE

Instrument Air system

SL.No. 1 150 168.30

MATERIAL Mild Steel -IS 1239 Part 1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Medium Grade 720

ENDS BW

REMARKS

100

114.30

Medium Grade

120

BW

50

60.32

Heavy Grade

470

Threaded

One end of pipe to be provided with Threaded full coupling threaded. One end of pipe to be provided with Threaded full coupling threaded. One end of pipe to be provided with Threaded full coupling threaded.

25

33.40

Heavy Grade

550

Threaded

15

21.34

Heavy Grade

Threaded

ITEM : 90 ELBOW 1.5D

SL.No. 1 150 168.30

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Medium Grade 9

ENDS BW

REMARKS

100

114.30

Medium Grade

16

BW

50

60.32

Heavy Grade

Threaded

25

33.40

Heavy Grade

28

Threaded

ITEM: EQUAL TEE

SL.No. 1 150 168.30

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Medium Grade 4

ENDS BW

REMARKS

100

114.30

Medium Grade

BW

50

60.32

Heavy Grade

Threaded

25

33.40

Heavy Grade

Threaded

ITEM: CONCENTRIC REDUCER

SL.No. 1 150X100 168.30X114.30

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Medium Grade 2

ENDS BW

REMARKS

100X50

114.30X60.32

Medium Grade

BW

100X25

114.30X33.40

Heavy Grade

BW

50X25

60.32X33.40

Heavy Grade

Threaded

ITEM : UN EQUAL TEE

SL.No. 1 2 3 4 5 6

MATERIAL

ENDS
Medium Grade

REMARKS

150X100 168.30 X114.30 100X50 100X25 50X25 50X15 25X15


114.30X60.3 114.30X33.40 60.30X33.40 60.30X21.34 33.40X21.34

Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised

8 2 2 3 4 8

BW BW BW Threaded Threaded Threaded

Medium Grade

Medium Grade

Heavy Grade

Heavy Grade

Heavy Grade

ITEM : HALF COUPLING

SL.No. 1 Note: 15 21.34

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised A 105, Galvanised Heavy Grade / 3000# 2

ENDS Threaded

REMARKS

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, thickness and Quantity details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

System :
ITEM: PIPE

Service Air system

SL.No. 1 80 88.90

MATERIAL Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Mild Steel -IS 1239 Part1, ERW, Galvanised Medium Grade 500

ENDS BW

REMARKS

65

73.02

Heavy Grade

90

BW

50

60.32

Heavy Grade

435

Threaded

One end of pipe to be provided with Threaded full coupling threaded. One end of pipe to be provided with Threaded full coupling threaded. One end of pipe to be provided with Threaded full coupling threaded. One end of pipe to be provided with Threaded full coupling threaded.

40

48.26

Heavy Grade

450

Threaded

25

33.40

Heavy Grade

1550

Threaded

15

21.34

Heavy Grade

Threaded

ITEM: 90 ELBOW 1.5D

SL.No. 1 2 3 4 5 80 65 50 40 25 88.90 73.02 60.32 48.26 33.40

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Medium Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 16 8 6 7 40

ENDS BW BW Threaded Threaded Threaded

REMARKS

ITEM: EQUAL TEE

SL.No. 1 80 88.90

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Medium Grade 8

ENDS BW

REMARKS

65

73.02

Heavy Grade

BW

50

60.32

Heavy Grade

Threaded

40

48.26

Heavy Grade

Threaded

25

33.40

Heavy Grade

Threaded

ITEM : UN EQUAL TEE

SL.No. 1

MATERIAL

ENDS Medium Grade 2 BW

REMARKS

80X65 80X50 80X25 50X40 50X25 40X25 25X15

88.90 X 73.02

Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised

88.90 X 60.32

Medium Grade

BW

88.90 X 33.40

Medium Grade

BW

60.32 X 48.26

Heavy Grade

SW

60.32 X 33.40

Heavy Grade

SW

48.26 X 33.40

Heavy Grade

SW

33.4X21.34

Heavy Grade

SW

For Pressure I ndicator

ITEM: CONCENTRIC REDUCER

SL.No. NB 3 80X 40 OD in mm 88.90 X 48.26

MATERIAL THK. Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Medium Grade Nos. 2

ENDS BW

REMARKS

80X 50

88.90 X 60.32

Medium Grade

BW

50X 40

60.32 X 48.26

Heavy Grade

Threaded

50X 25

60.32 X 33.40

Heavy Grade

Threaded

50X 15

60.32X21.34

Heavy Grade

Threaded

For Pressure I ndicator

40X 25

48.26 X 33.40

Heavy Grade

Threaded

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, thickness and Quantity details have been indicated preliminary and which shall be finalised later. 3 Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

System - Potable Water System


ITEM : PIPE

SL.No. 1 200 219.08

MATERIAL IS 3589 Fabricated from IS 2062 Gr.B Mild Steel -IS 1239 Part 1, ERW, Galvanised Mild Steel -IS 1239 Part 1, ERW, Galvanise Mild Steel -IS 1239 Part 1, ERW, Galvanise Mild Steel -IS 1239 Part 1, ERW, Galvanise Mild Steel -IS 1239 Part 1, ERW, Galvanise Mild Steel -IS 1239 Part 1, ERW, Galvanise 4.5 50

ENDS BE

REMARKS

80

88.90

Heavy Grade Heavy I Grade Heavy I Grade Heavy I Grade Heavy I Grade Heavy I Grade

880

BW

65

73.02

1100

BW

50

60.32

Threaded

One end of pipe to be provided with full coupling threaded. One end of pipe to be provided with full coupling threaded. One end of pipe to be provided with full coupling threaded. One end of pipe to be provided with full coupling threaded.

40

48.26

500

Threaded

25

33.40

10

Threaded

15

21.34

Threaded

ITEM : 90 ELBOW 1.5D

SL.No.

MATERIAL

ENDS

REMARKS

200

219.08

A 234 Gr.WPB

4.5

BW

2 3 4 5 6

80 65 50 40 25

88.90 73.02 60.32 48.26 33.40

Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade

14 23 24 27 5

BW BW Threaded Threaded Threaded

ITEM : 45 ELBOW 1.5D

SL.No. 1 65 73.02

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Heavy Grade 2

ENDS BW

REMARKS

ITEM : EQUAL TEE

SL.No. 1 2 3 4 5 6 200 80 65 50 40 25 219.08 88.90 73.02 60.32 48.26 33.40

MATERIAL A 234 Gr.WPB Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised 4.5 Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 2 9 2 3 2 5

ENDS BW BW BW Threaded Threaded Threaded

REMARKS

ITEM : CONCENTRIC REDUCER

SL.No. 1 2 3 4

MATERIAL

ENDS Heavy Grade Heavy Grade Heavy Grade Heavy Grade 3 7 4 11 BW BW BW Threaded

REMARKS

80X65 80X50 65X50 50X40

88.9X73.02 88.9X60.32 73.02 X 60.32 60.32 X 48.26

Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised Mild Steel -IS 1239 Part 2, Galvanised

ITEM : END CAP

SL.No. 1 Note: 25 33.40

MATERIAL Mild Steel -IS 1239 Part 2, Galvanised Heavy Grade 5

ENDS Threaded

REMARKS End Cap for Drain and Ven

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

System :
ITEM : PIPE

Service water system

SL.No. 1 2
3 200 100 80

MATERIAL 219.08 114.30 88.90 60.32 IS 3589 Fabricated from IS 2062 Gr.B Mild Steel -IS 1239 Part 1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW 4.5
Medium Grade Medium Grade Heavy Grade 700 350 800 30

ENDS BE BE BE
BW

REMARKS
-

50

40

48.26

Heavy Grade

800

Plain End

One end of pipe to be provide i with socket welded full coupling. One end of pipe to be provide i with socket welded full coupling.

25

33.40

Heavy Grade

10

Plain End

ITEM : 90 ELBOW 1.5D

SL.No. 1 2
3 200 100 80

MATERIAL 219.08 114.30 88.90 60.32 48.26 33.40 A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 4.5
Medium Grade Medium Grade Heavy Grade Heavy Grade Heavy Grade

ENDS 11 13 24 4 44 5 BW BW BW
BW SW SW

REMARKS

4 5
6

50 40 25

ITEM : 45 ELBOW 1.5D

SL.No. 1
80

MATERIAL 88.90 Mild Steel- IS 1239 Part 2


Medium Grade

ENDS 2 BW

REMARKS

ITEM : EQUAL TEE

SL.No. 1 2
3 200 100 80

MATERIAL 219.08 114.30 88.90 60.32 48.26 33.40 A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel - IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 3 4.5
Medium Grade Medium Grade Heavy Grade Heavy Grade Heavy Grade

ENDS 2 1 1
4 3

REMARKS

BW BW BW
BW SW SW

4 5
6

50 40 25

ITEM : UNEQUAL TEE

SL.No. 1 2 3 4 5

MATERIAL

ENDS 4.5 Medium Grade Medium Grade Medium Grade Medium Grade 6 1 2 1 8 BW BW BW BW BW

REMARKS

200X100 100X80 100X40 80X50 80X40

219.08X114.3 114.3X88.90 114.3X48.26 88.90X60.31 88.90X48.26

A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2

ITEM : CONCENTRIC REDUCER

SL.No. 1 2 3 4 5

MATERIAL

ENDS 4.5 Medium Grade Medium Grade Medium Grade Heavy G rade 3 2 3 4 1 BW BW BW BW SW

REMARKS

200X100 100X80 100X40 80X40 50x40

219.08X114.3 114.3X88.90 114.3X48.26 88.90X48.26 60.32X48.26

A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2

ITEM : HALF COUPLING SL.No. 1 25 33.40 MATERIAL Mild Steel -IS 1239 Part 2 / A 105 #3000 5 END SW REMARKS

ITEM : END CAP SL.No. 1 25 33.40 MATERIAL Mild Steel -IS 1239 Part 2 Heavy Grade 5 ENDS SW REMARKS End cap for vent and drain.

Note: 1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

System : Plant water system


ITEM : PIPE SL.No. 1 2 3 4 5 6 7 8 9 10 11 12 700 600 500 400 350 250 200 150 100 80 65 50 711.20 609.60 508.00 406.40 355.60 273.05 219.08 168.30 114.30 88.90 73.02 60.30 MATERIAL IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B Mild Steel -IS 1239 Part 1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW 7.1 6.3 6.3 6.3 5.6 5 4.5 Medium Grade i Medium Grade i Medium Grade i Heavy Grade Heavy Grade 106 248 31 16 10 648 677 632 23 85 67 25 END BE BE BE BE BE BE BE BE BE BE BE Plain End REMARKS One end of pipe to be provide d with socket welded full coupling. One end of pipe to be provide d with socket welded full coupling. One end of pipe to be provide d with socket welded full coupling.

13

25

33.40

Heavy Grade

25

Plain End

14

15

21.34

Heavy Grade

25

Plain End

ITEM : 90 ELBOW 1.5D

SL.No. 1 2 3 4 5 6 7 8 9 700 600 500 400 350 250 200 150 100 711.20 609.60 508.00 406.40 355.60 273.05 219.08 168.30 114.30

MATERIAL Fabricated from IS 2062 Gr.B Fabricated from IS 2062 Gr.B Fabricated from IS 2062 Gr.B Fabricated from IS 2062 Gr.B Fabricated from IS 2062 Gr.B A 234 Gr.WPB A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 7.1 6.3 6.3 6.3 5.6 5 4.5
Medium Grade Medium Grade

END 5 12 6 6 2 26 19 29 7 BW BW BW BW BW BW BW BW BW

REMARKS Miter Bend Miter Bend Miter Bend Miter Bend Miter Bend

SL.No. 10 11 12 13 80 65 50 25 88.90 73.02 60.30 33.40

MATERIAL Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Medium Grade Medium Grade Heavy Grade Heavy Grade 15 31 10 15

END BW BW SW SW

REMARKS

ITEM: EQUAL TEE

SL.No. 1 2 3 4 250 100 80 65 273.05 114.30 88.90 73.02

MATERIAL A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 5 Medium Grade Medium Grade Medium Grade 1 6 6 5

END BW BW BW BW

REMARKS

ITEM: UNEQUAL TEE

SL.No. 1 2 3 4 5 600 X 400 250 X 200 200X150 150X100 100X80 609.60X406.40 273.05X219.08 219.08X168.30 168.30X114.30 114.30X88.90

MATERIAL Fabricated from IS 2062 Gr.B A 234 Gr.WPB A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 6.3 5 4.5 Medium Grade Medium Grade 1 1 2 1 1

END BW BW BW BW BW

REMARKS

ITEM : SORF FLANGE ( Header Flange) SL.No. 1 2 ITEM: GASKET SL.No. 1 2 80 65 MATERIAL CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) #150 #150 4 2 END
3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING

MATERIAL 80 65 A 105 A 105 #150 #150 4 2

END Flat face Flat face

REMARKS Flange Code ASMEB16.5 Flange Code ASMEB16.6

REMARKS

ITEM : BLIND FLANGE( Header Flange) SL.No. 1 2 ITEM: END CAP SL.No. 1 50 60.30 MATERIAL Mild Steel -IS 1239 Part 2 Mild Steel -IS 1239 Part 2 Heavy Grade 15 END Threaded REMARKS 80 65 MATERIAL A 105 A 105 #150 #150 4 2 END Flatface Flat face REMARKS Flange Code ASMEB16.5 Flange Code ASMEB16.5

25

33.40

Heavy Grade

25

Threaded

ITEM HALF COUPLING SL.No. 1 50 60.30 MATERIAL Mild Steel -IS 1239 Part 2 / A 105 Mild Steel -IS 1239 Part 2 / A 105 Mild Steel -IS 1239 Part 2 / A 105 #3000 15 END SW REMARKS

25

33.40

#3000

25

SW

15

33.40

#3000

30

SW

ITEM DISHED END COVER

SL.NO. 1 700 711.20

MATERIAL Fabricated from IS 2062 Gr.B

SCH/ THK. 7.1

QTYIN Nos. 1

END BW

REMARKS Torispherical

Note: 1 Pipe length, Pipe size and Pipe thickness details have been indicated preliminary and which shall be finalised later. 2 No Fittings, Fitting size and thickness details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

System :
ITEM : PIPE

DM Feed water system

SL.No. 1 50 60.30

MATERIAL A312TP304, ERW 40 35

END Plain End

REMARKS One end of pipe to be provide with socket welded full coupling. One end of pipe to be provide with socket welded full coupling. One end of pipe to be provide with socket welded full coupling.

25

33.40

A312TP304,ERW

40

10

Plain End

15

21.30

A312TP304, ERW

40

16

Plain End

ITEM : 90 ELBOW

SL.No. 1 2 50 25 60.30 33.40

MATERIAL A182Gr.F304 A182Gr.F304 #3000 #3000 6 8

END SW SW

REMARKS

ITEM : HALF COUPLING

SL.No. 1 2 ITEM : END CAP SL.No. 1 25 33.40 25 15 33.40 21.30

MATERIAL A182Gr.F304 A182Gr.F304 #3000 #3000 14 30

END SW SW

REMARKS

MATERIAL A182Gr.F304 #3000 14

END NPT

REMARKS

Note: 1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. 3 10% Margin has been considered for all piping & all Fittings.

ITEM : PIPE SL.No. 1 400 406.40 MATERIAL END 5S 35 BE REMARKS -

A312TP304, ERW

250

273.00

A312TP304, ERW

10S

70

BE

200

219.10

A312TP304, ERW

10S

40

BE

150

168.30

A312TP304, ERW

10S

710

BE

100

114.30

A312TP304, ERW

10S

435

BE

80

88.90

A312TP304, ERW

10S

20

BE

ITEM: 90 ELBOW 1.5D

SL.No. 1 2 3 4 5 6 400 250 200 150 100 80 406.40 273.00 219.10 168.30 114.30 88.90

MATERIAL A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 5S 10S 10S 10S 10S 10S 6 9 10 67 30 12

END BW BW BW BW BW BW

REMARKS

ITEM : EQUAL TEE

SL.No. 1 2 3 4 400 200 150 100 406.40 219.10 168.30 114.30

MATERIAL A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 5S 10S 10S 10S 2 2 2 1

END BW BW BW BW

REMARKS

ITEM : UNEQUAL TEE

SL.No. NB 1 2 3 4 400 X 250 250 X 200 250X150 150 X 100 OD in mm 406.40 X 273.00 273.00 X219.10 273.00X168.30 168.30X114.30

MATERIAL THK. A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 5S 10S 10S 10S Nos.(Rev. 0A) 8 2 1 15

END

REMARKS

BW BW BW BW

ITEM : CONCENTRIC REDUCER

SL.No. 1 2

MATERIAL

END 10S 10S 7 2 BW BW

REMARKS -

250X150 100X50

273.00X168.30 114.30X60.3

A 403 Gr. WP304 A 403 Gr. WP304

ITEM : SOFF FLANGE ( Header Flange) SL.No. 1 2 3 400 250 200 MATERIAL END #150 #150 #150 2 1 2 Flat face Flat face Flat face REMARKS Flange Code ASME B16.5 Flange Code ASME B16.5 Flange Code ASME B16.5

A182Gr. F304 A182Gr. F304 A182Gr. F304

150

A182Gr. F304

#150

Flat face

Flange Code ASME B16.5

ITEM : BLIND FLANGE SL.No. 1 2 3 4 ITEM : GASKET SL.No. 1 400 MATERIAL CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) #150 2 END
3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING

MATERIAL 400 250 200 150 -

END #150 #150 #150 #150 2 1 2 4 Flat face Flat face Flat face Flat face

REMARKS Flange Code ASME B16.5 Flange Code ASME B16.5 Flange Code ASME B16.5 Flange Code ASME B16.5

A182Gr. F304 A182Gr. F304 A182Gr. F304 A182Gr. F304

REMARKS -

2 3 4 Note:

250 200 150

#150 #150 #150

1 2 4

5 Pipe size,Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 6 Fitting size, thickness and Quantity details have been indicated preliminary and wh ch shall be finalised later. 7 Flow transmitter flange details shall be covered in next revision. 8 10% Margin has been considered for all piping & all Fittings.

System : Effluent System


ITEM: PIPE SL.No. 1 2 3 4 300 150 65 50 323.80 168.30 88.90 60.32 MATERIAL IS 3589 Fabricated from IS 2062 Gr.B Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW 6.3 Heavy Grade Heavy Grade Heavy Grade 1400 745 2290 1800 ENDS BE BE BE Plain End One end of pipe to be provided with socket welded full coupling. One end of pipe to be provided with socket welded full coupling. One end of pipe to be provided with socket welded full coupling. REMARKS -

40

48.26

Heavy Grade

5319

Plain End

25

33.40

Heavy Grade

25

Plain End

ITEM: 90 ELBOW 1.5D

SL.No. 1 2 3 4 5 6 300 150 65 50 40 25 323.80 168.30 88.90 60.32 48.26 33.40

MATERIAL A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 6.3 Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 20 30 30 30 30 20

ENDS BW BW BW SW SW SW

REMARKS

ITEM: EQUAL TEE

SL.No. 2 3 4 5 6 150 65 50 40 25 168.30 88.90 60.32 48.26 33.40

MATERIAL Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 3 Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 5 5 5 5 5

ENDS BW BW SW SW SW

REMARKS

ITEM: HALF COUPLING

SL.No. 1 25 33.40

MATERIAL Mild Steel -IS 1239 Part 2 / A 105 #3000 25

END SW

REMARKS -

ITEM: END CAP SL.No. 1 25 33.40 MATERIAL Mild Steel -IS 1239 Part2 Heavy Grade 25 ENDS SW REMARKS End cap for vent and drain.

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. , Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

ANNEX-1.3 PIPING CLASSIFICATION


PIPING CLASSIFICATION Corrosion Allowance -1 mm Instrument Air Distribution System NON IBR Hydrotest Pressure Factor -1.5 Service Air Distribution System CHART 1

Description
Instrument Air Distribution Lines Pipes Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness (mm) Standard End type Material Flanges Material End Type /Facing /Class Standard Bolts / Nuts Type Material /Class Standard Gaskets Type Material /Class Standard Fittings End type Class / Thick Standard Material 15 21.34 3.2

Design Press. (bar g )


10.5 20 26.67 3.2 25 33.4 4

Design Temp. C
50 32 42.16 4 40 48.26 4 50 60.32 4.5

Description
Service Air Distribution Lines 65 73.02 4.5 80 88.9 4.8 100 114.3 5.4

Design Pres. (bar g )


10.5 150 168.3 5.4

Design Temp. C
50

IS-1239 ( Part -I) THREADED END/ BUTTWELD Mild Steel - IS 1239 (Heavy Grade / Medium Grade ), ERW, Galvanised ASTMA105, Galvanised THREADED END / RAISED FACE /Class 150 ASMEB16.5 FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.) BOLTS A193Gr. B7, Galvanised & NUTS A194 Gr. 2H, Galvanised/Class 150 ASMEB 16.5/ASMEB 18.2.1 /ASME B 18.2.2/ASME B1.1 3MM THICKNESS SELF CENTERING FLAT RING CNAF (Compressed Non asbestos fibre) / Class 150 ASME B16.21 THREADED END//BUTTWELD TO MATCH PIPE THICKNESS IS-1239 (Part- 2 ) Mild Steel IS -1239, Galvanised

Note: 1. * - Pressure & Temperature have been indicated preliminary and subject to change. 2.

Pipe thickness details have been indicated preliminary and subject to change.

PIPING CLASSIFICATION Corrosion Allowance -1 mm Potable Water System Description Plant Potable Water Pump suction lines Plant Potable Water Pump discharge lines Potable Water Distribution lines Pipes Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness (mm) Standard End type Material Flanges Material End Type /Facing /Class Standard Bolts / Nuts Type Material /Class Standard Gaskets Type Material /Class Standard Fittings End type Class / Thick Standard Material THREADED END TO MATCH PIPE THICKNESS IS-1239 (Part-2) Mild Steel IS-1239, Galvanised 15 21.34 3.2 20 26.67 3.2 Design Press. (bar g ) 3.5 12 3.6 25 33.4 4 32 42.16 4 40 48.26 4 Design Temp. C 50 50 50 50 60.32 4.5 65 73.02 4.5 80 88.9 4.8 100 114.3 5.4 150 168.3 5.4 200 Description Colony Potable Water Pump suction lines Colony Potable Water Pump discharge lines

NON IBR Hydrotest Pressure Factor -1.5 Potable Water System Design Pres. (bar g ) 3.5 10

CHART 2

Design Temp. C 50 50

219.08 6.3 IS-3589 BUTT WELDED END /BEVELED END WITH ZINC RICH ELECTRODE IS 3589 Fabricated from IS 2062 Gr.B , Galvanised

IS-1239 ( Part -I) THREADED END/ BUTT END Mild Steel IS 1239 (Heavy Grade), ERW, Galvanised ASTMA105, Galvanised THREADED END / FLAT FACE / Class 150 ASMEB16.5 FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.) BOLTS A193Gr. B7, Galvanised & NUTS A194 Gr. 2H, Galvanised/Class 150 ASMEB 16.5/ASMEB 18.2.1 /ASME B 18.2.2/ASME B1.1 3MM THICKNESS SELF CENTERING FLAT RING CNAF (Compressed Non asbestos fibre) / Class 150 ASME B16.21

BUTT WELDED END /BEVELED END WITH ZINC RICH ELECTRODE TO MATCH PIPE THICKNESS ASMEB 16.9 ASTM A 234 Gr. WPB, Galvanised

Note: 1. * - Pressure & Temperature have been indicated preliminary and subject to change. 2. Pipe thickness details have been indicated preliminary and subject to change.

PIPING CLASSIFICATION Corrosion Allowance - 0 mm DM Feed Water System Description DM Water Transfer Pump Suction line DM Water Transfer Pump Discharge lines Hot Well Make up Pump Suction lines Hot Well Make up Pump Discharge lines Design Press. ( Bar g ) 3.5 3.5 3.5 5.5 Design Temp. C 50 50 50 50 Description DM Cooling Water Make up Pump Suction lines DM Cooling Water Make up Pump Discharge lines Boiler Fill Pump Suction lines Boiler Fill Pump Discharge lines

NON IBR Hydrotest Pressure Factor -1.5 DM Feed Water System Design Press. ( Bar g 3.5 5.5 3.5 16.32

CHART 3

Design Temp. C 50 50 50 50

Pipes

Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness (mm) Standard End type Material

15 21.34

20 26.67

25 33.4 40

32 42.16

40 48.26

50 60.32

65 73.02

80 88.9

100 114.3 10S

150 168.3

200 219.08

250 273.05

400 406.40 5S

ASMEB36.19M PLAIN END BUTT WELDED END / BEVELED END STAINLESS STEEL ASTM A 312 TP 304, ERW ASTMA 182Gr.F304 SOCKET WELDED / FLAT FACE / Class 150 ASMEB16.5 FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.) ASTM A 193 Gr. B8M Cl.2 & A 194 Gr.B8M / Class 150 ASMEB 16.5/ASMEB 18.2.1 /ASME B 18.2.2/ASME B1.1 3MM THICKNESS SELF CENTERING FLAT RI NG CNAF (Compressed Non asbestos fibre) / Class 150 ASME B16.21 SOCKET WELDED END Class 3000 ASMEB 16.11 ASTMA 182 Gr. F304 BUTT WELDED END / BEVELED END TO MATCH PIPE THICKNESS ASMEB 16.9 ASTMA403Gr.WP304 SLIP ON / FLAT FACE / Class 150

Flanges

Material End Type /Facing /Class Standard

Bolts / Nuts

Type Material /Class Standard

Gaskets Type Material /Class Standard Fittings End type Class / Thick Standard Material

Note: 1. Design Pressure & Design Temperature have been indicated preliminary and subject to change. 2. Pipe thickness details have been indicated preliminary and subject to change.

PIPING CLASSIFICATION

NON IBR

CHART 4

Pipes

Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness Standard

15 21.34 3.2

20 26.67 3.2

25 33.40

32 42.16

40 48.26

50

65

80 88.90 4.8

100

150

200 219.08 6.30

250

300

350

400 406.4 0 6.30

450

500

600

700

800 812.80 7.10

1000 1016.0 0 10.00

1400 1422.40 12.00

1200

1800

2200 2224.00 12.00

2600 2624.00 12.00

60.32 73.02 4.5 4.5

114.30 168.30 5.4 5.4

273.05 323.80 355.60 6.30 6.30 6.30

457.20 508.00 609.60 711.20 6.30 6.30 6.30 6.30

1219.20 1824.00 10.00 12.00

I S - 12 39 ( Pa r t- I )

IS - 3589

AWWA C200 / AWWA M11

Material

Mild Steel - IS 1239 (Heavy Grade) , ERW

IS 3589 Fabricated from IS 2062 Gr.B

AWWA M11 Fabricated from IS 2062 Gr.B

Flanges End Type / Facing /Class Standard Bolts / Nuts SOCKET WELDED / FLAT FACE / Class 150 ASMEB16.5 SLIP ON/FLAT FACE/Class 150 SLIP ON/FLAT FACE / Class B or Class D AWWA C 207

Material / Class Standard

BOLTS A193Gr. B 7 &

NUTS A194 Gr. 2H/Class 150

ASME B 16.5 / ASME B 18.2.1 / ASME B 18.2.2 / ASME B1.1

Gaskets Material / Class Standard Fittings End type Class /Thick Standard Material SOCKET WELDED END TO MATCH PIPE THICKNESS IS 1239 (Part-2) Mild Stee - IS 1239 IS 1239 (Part-2) l Mild d Ste ! -IS 1239 ASME B 16.9 ASTM A 234 Gr. WPB CNAF (Compressed Non asbestos fibre ASMEB16.21 BUTT WELDED END / BEVELED END TO MATCH PIPE THICKNESS AWWA C 208 / BS 534 Fabricated From Mild Steel IS 2062 Gr.B /Class 150

Note: 1. * - Pressure & Temperature have been indicated preliminary and subject to change. 2. * * - Pressure details shall be provided later 3. Pipe thickness details have been indicated preliminary and subject to change. 4. Miter Bends shall be used for size 300NB and above. 5. Epoxy coating shall be provided above 500NB pipe size for CW Piping system, ACW Piping system and Raw Water System

SECTION - 2.0 DETAILED TECHNICAL SPECIFICATION


SECTION - 2.1 DETAILED TECHNICAL SPECIFICATION -FABRICATION, ERECTION, TESTING & COMMISSIONING
SECTION CONTENTS SHEET NO

2.1

TECHNICAL SPECIFICATION FOR ERECTION OF LP PIPING 14 23 06 05 05

2.2 2.3

TECHNICAL SPECIFICATION-WELDING PROCEDURE TECHNICAL SPECIFICATION - ERECTION OF BURIED PIPING TECHNICAL SPECIFICATION - HYDRO TEST PROCEDURE TECHNICAL SPECIFICATION - LP PIPING FLUSHING AND CLEANING PROCEDURE TECHNICAL SPECIFICATION-WRAPPING& COATING OF BURIED PIPING

2.4
2.5

2.6

06

SECTION - 2.1 TECHNICAL SPECIFICATION ERECTION OF LP PIPING


TABLE OF CONTENTS 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 INTENT OF SPECIFICATION.........................................................................................................3 CODES AND STANDARDS............................................................................................................3 SCOPE OF WORK.........................................................................................................................4 EXCLUSIONS.................................................................................................................................6 LAYOUT, CUTTING AND FITTING UP...........................................................................................6 ERECTION......................................................................................................................................9 BURIED PIPING............................................................................................................................10 INSTALLATION AND ASSEMBLY................................................................................................10 ERECTION OF VALVES...............................................................................................................11

10.0.0 ERECTION OF SUPPORTS.........................................................................................................12 11.0.0 ERECTION OF INSTRUMENTS...................................................................................................12 12.0.0 LINE MOUNTED FILTERS, SIMPLEX/DUPLEX FILTERS, MIXERS & FLEXIBLE HOSES........................................................................................................................................12 13.0.0 INSPECTION................................................................................................................................13 14.0.0 MATERIAL IDENTIFICATION.......................................................................................................13 15.0.0 HYDROTEST................................................................................................................................14 16.0.0 INSTRUMENT CONNECTIONS....................................................................................................14 17.0.0 RECORDS....................................................................................................................................14

SECTION 2.1 TECHNICAL SPECIFICATION ERECTION OF LP PIPING 1.0.0 INTENT OF SPECIFICATION This specification covers the minimum requirements and guidelines to be adhered by the Bidder for the Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Fabrication of Supports (Support material will be free issued by owner), Laying, Erection, inspection & testing atsite, cleaning & painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping, valves, supports and specialties etc. The LP piping Erection comprises the following: Instrument Air Distribution System Service Air Distribution System Service Water Distribution System Potable Water Distribution System. DM Feed Water System a) DM Water Transfer Pumps all suction, discharge and recirculation lines. b) Hot Well Make up Pumps all suction, discharge and recirculation lines. c) DM Cooling Water Make up Pumps suction, discharge and recirculation lines. d) Boiler Feed Pumps suction, discharge and recirculation lines (Condensate Make up line). Plant Water System -I a) Raw Water System. b) APH Wash pumps all suction and discharge lines. c) Ash Water Tank Fill pumps suction and discharge lines. d) Service Water Pumps suction and discharge lines e) DM plant pumps suction lines. f) AHS Seal Pumps suction lines.

Plant Water System - II a) b) Plant Potable Water pumps all suction and discharge lines. Colony Potable Water pumps all suction and discharge lines.

CW Blow down System. Wash Water System. Effluent System. Sludge Water system. All pipe line headers. All tanks external down comer pipe lines, over flow lines, vent pipe lines and draw of sump lines. DM Cooling Water Supply & Return Line for Main Plant compressor & Ash Handling compressor. SSF Backwash line.

2.0.0

CODES AND STANDARDS The erection and testing of piping, valves, specialities and flash vessels, shall comply with the requirements of latest edition of ASME B31.1. The following standards shall be followed in particular. ANSIB31.1 ANSI B 2.1 ANSI B16.9 ANSI B 16.20 ANSI B 16.25 IS:803 ASME BPVC Sec V ASME BPVC Sec VII ASME BPVC Sec IX MSS-SP-55 MSS-SP-53 MSS-SP-54 AWWA-M11 AWWA-C206 AWWA-C208 AWWA-C200 Power Piping Pipe threads Wrought steel Butt Welding Fittings. Ring joint gaskets and grooves for steel pipe flanges Butt welding ends Code for design, testing and erection of mild steel storage tanks. Non destructive Examination Pressure Vessels Welding and Brazing qualifications. Visual inspection & testing Magnetic particle testing Radiographic testing Steel Pipe - A guide for Design and Installation. Standard for Field Welding of Steel Water Pipe. Dimension for fabricated steel water pipe fittings. Standard for Steel Water Pipe 6 in.(150mm) and larger.

3.0.0

SCOPE OF WORK

The scope of work covered in this document include but not limited to the following. Supply and receipt of materials, unloading, handling, identification, Prefabrication including cold bending of pipes, erection of complete piping, valves and specialities, all field welding of pipes and fabrication of pipes, fittings & supports, heat treatment, prequalification of welding procedures and welders (WPS, PQR), NDT examinations as per ASME sec IX, flushing, Hydro testing, cleaning including steam blowing as per the specification given hereinafter. The quantity of piping and equipment to be fabricated, erected, installed and tested shall be as per the erection drawings. Erection of all rod hangers and supports including auxiliary structures as required. Execution of field engineering, modification during execution, hydro testing etc. The Tenderer shall supply all required piping / supports etc on take back basis after dismantling the same. Supply and application of coating and wrapping for all buried piping. Supply and application of grouting material including non-shrinkable cement and erection of grouting. Supply and application painting for above ground piping. Supply and application of cathodic protection for all buried piping. The Purchaser/Consultant will furnish isometric drawings for all LP lines above 2". Tenderer shall prepare isometrics for lines below 2" based on site routing and get the approval of the Purchaser/ Consultant during the time of erection. The Tenderer shall prepare the erection drawings for all LP piping lines. Providing all labour, material, consumables and equipment as necessary for fabrication, manufacture and testing at site as required.

Broad Guidelines for Erection and Installation of Low Pressure Piping All fittings like "T pieces, weld neck flanges, reducers, etc., shall be suitably matched with pipes for welding. The valves shall be checked, cleaned, or overhauled in full or in part before erection, after chemical cleaning, and during commissioning. Adjustments such as removal of ovailties in pipes, and opening or closing the fabricated bends of high-pressure piping to suit the layout shall be considered part of the work and the Contractor is required to carry out such work, which shall include specified heat treatment procedures, etc., wherever required. Certain adjustments in length may be necessary while erecting high-pressure pipelines and the Contractor shall remove the extra lengths / add extra lengths to suit the final layout after preparing edges afresh and adopting specified heat treatment procedures. Suspension for piping, pressure parts, etc., shall be supplied in running lengths which shall be cut to suitably sizes and adjusted as required. All the valves, lighting equipment, actuators, power cylinders. etc., shall be serviced and lubricated before erecting the same and also during precommissioning. Even after commissioning the equipment, if there are problems in the operation, these shall be attended to by the Contractor. Welding or jointing of extension spindle for valves to suit the site conditions and operational facility shall be part of erection work. All tubes and pipes shall be cleaned and blown with compressed air before erection. Bigger size pipes shall be cleaned with flexible wire brush, wherever necessary. Fine fittings, drain piping, oil systems, and other small bore piping have to be routed according to site conditions and hence shall be done only in position. As such, layout of small bore piping shall be done in accordance with site requirement. There is a possibility of slight change in routing the above pipelines even after completion of erection. Work shall also include fabrication of small bends at site from straight lengths to suit the site conditions. No temporary supports shall be welded on the pressure parts. Welding of temporary

supports, cleats, etc., on the building columns shall also be avoided. (a) All pipes shall be grouped wherever practicable and shall be routed to present a neat appearance. (b) The piping shall be arranged to provide clearance for the removal of equipment for maintenance and for easy access to valves, instruments, and other piping accessories required for operation and maintenance. (c) Piping shall be generally routed above ground but, where specifically indicated / approved, piping may be arranged in trenches or buried. (d) Overhead piping shall generally have a minimum overhead clearance of 2.3 meters above walkways and working areas and 6 metres above roadways. (e) Drains shall be provided at all low points and vents at high points in accordance with actual layout regardless of whether the same have been shown in the respective drawings or not. The pipelines shall be sloped towards the drain points. (f) For field run piping, the Contractor shall fabricate and erect all hangers and supports as required with due regard to general arrangement and layout of other pipes, hangers, cable trays, ducting, structural members etc. All drips and drains for piping and equipment whether shown on the drawings or not shall terminate on the ground floor at the station drain unless otherwise noted. Leading such drains to the station drainage is also the responsibility of the Contractor. 4.0.0 EXCLUSIONS Mechanical: Erection of Piping beyond battery limits. All valves their counter flanges along with fastener and gaskets. All specialties their counter flanges along with fastener and gaskets. All instruments with their accessories. Supply of pipes and fittings (other than fabricated from the plate material). Plate for fabricated pipe and fittings. Pipe Support materials.

Civil: All Civil Engineering works such as RCC foundation, buildings, roads, pipe racks/ pipe trenches etc. Making opening in the walls for routing of pipes Encasement for the buried piping.

5.0.0 LAYOUT, CUTTING AND FITTING UP 5.1.0 Cutting and fitting-up Pipes shall be cut to required length in accordance with piping layout drawings and/or spool drawings. Preparation of pipe ends shall preferably be done by any combination of turning and grinding. When oxygen or arc cutting is resorted to then the cut shall be reasonably smooth and true and all slag is cleaned from the flame cut surfaces. Preparation of butt welding joints shall be as per ASME B 31.1/as per enclosed figure elsewhere in this tender document, unless otherwise approved by the Engineer. The ends of piping com ponents to be joined shall be aligned as accurately as is practicable within existing tolerance on diameters, wall thickness and out-of-roundness. Internal radial misalignment exceeding 1.6 mm shall be taper trimmed as per enclosed figure elsewhere in this tender document, after getting approval from Engineer. 5.2.0 Branch Connections

Openings for branch connections shall preferably be made by drilling. Oxygen or arc cutting is acceptable only if the cut is reasonably smooth and true and all slag is cleaned from the flame cut surfaces. End preparation of branch and runner pipe shall be as per the relevant clause of ASME B31.1. Edge Preparation details for branch connection joints shall be subjected to approval of Consultant/ Purchaser.

5.3.0

Minimum Distance between Longitudinal Welds

The distance between two longitudinal weld shall be staggered suitably. 5.4.0 Flanged Connections Flange bolt holes shall straddle the established center-lines (horizontal or vertical) unless otherwise shown. 5.5.0 Threaded Connections Taper pipe threads shall be used in accordance with ANSI B.2.1 "Pipe Threads" for threaded pipe joints. 5.6.0 Bending Hot bending is not permitted except for non- pressure piping such as drain and vent lines. Cold bending is only permitted and no hot bending is envisaged at site. 5.7.0 Mitre Bends Mitre bends shall be fabricated in accordance with "Piping Standard Drawing" unless otherwise specified in piping GA drawing. Single cut mitre are not allowed. 5.8.0 Threaded Joints When threaded couplings or nipples are welded to the pipe spools, the thread must be checked for fit and roundness after welding. 5.9.0 Heat Tracing Wherever applicable pipes should be installed along with heat tracer pipes as per the details given in the piping layout drawings. Heat tracer pipes shall be of non-cementing type with the main pipe line. 5.10.0 Layout For laying out headers, tees, laterals and other irregular details, templates shall be used to ensure accurate cutting and proper fit-up. All cutting shall follow the outline of the template. Machine cut bevels to form the welding groove are preferred in carbon steel pipe. However, smooth, clean, slag free, flame cut bevels using flame bevel cutting machines.

All buried piping shall be as per the specification given in Section 2.4. 5.11.0 Dimensional Tolerances The dimension tolerances generally acceptable are as follows a. b. Face to face/center to face Lateral translation in any direction c. d. Rotation Out of alignment measured across the diameter e. i. : 1 mm : : 1.5 mm (max) 1 .5 deg (max) : 3 mm (max)

Flattening measured as difference between maximum and minimum OD at any Cross Section. For pipe with external

pressure ii. For pipe with internal pressure

3% (max)

8% (max)

Tenderer shall be responsible for working to the dimensions shown in the drawing. However, there may be slight variations due to minor variation in the location of equipment, insert etc. Field welds (F.W) to be provided to take care of these. An extra pipe length of 100 mm over and above the dimension shown in the drawing may be left on one side of the pipe at each end of field weld. During erection the pipe end with extra length of each field weld may be cut to obtain proper dimension. The Tenderer shall provide adequate number of field welds. Wherever omissions/ errors occur in drawings and bill of materials, it shall be the responsibility of the Tenderer to notify the Purchaser prior to fabrication and erection. 5.12.0 Pipe Joints Pipe joints shall be generally welded or as indicated in Piping drawings. In general, BW joints shall be used for 65 NB and above and SW/Threaded/BW joints shall be used for sizes 50 NB and below as specified in piping drawings. However, BW joints may be used after getting prior approval from Purchaser/Consultant in place of SW/Threaded connections in long runs of piping. This is applicable for non-galvanised piping and piping without lining. All welding shall be as per the welding procedure specified. Flanged joints shall be used at connections to vessels, equipment and where required for ease of erection and maintenance as indicated in drawing. 5.13.0 Piping Alignment The pipes to be jointed by welding shall be aligned correctly with the existing tolerances on diameters, wall thickness and out of roundness. The same alignment shall be preserved during welding. For the internal misalignment due to difference in wall thickness of the mating components exceeding 1.5 mm, the component with the higher wall thickness shall be internally machined ground so that the adjoining surfaces are approximately flushed. 5.14.0 Cleaning of Piping On completion of fabrication, all pipes and fittings shall be cleaned inside and outside by suitable means (Mechanical tools, wire brush etc.) before erection to ensure that assembly is free from all loose foreign material such as scale, sand, weld spatter particles, cutting chips etc. All field fabricated piping shall be cleaned at the conclusion of the fabrication. All burrs, welding circles and weld spatter shall be removed by any suitable means (mechanical tools, wire brush etc.) Field fabricated piping shall be blown out with compressed air at the termination of cleaning and capped. 5.15.0 Quality Control For Welding 5.15.1 Welding Machines 1. DC Machines only to be used. Inspection and Maintenance of Welding Machines. Welding machines shall be periodically inspected at least once a month for maintenance. This inspection and maintenance shall be done mainly for quality control purpose and shall be periodically recorded in a list showing the location and conditions of the welding machines being used. 5.15.2 Installation a) Location of welding machines and the switch boards to be connected with them shall be decided in consultation with Engineer to prevent them for disturbing other work as well as to prevent overloading of the switchboards, cables and electrical power sources. Proper earthing to be provided for welding machine. b) Electric cables, switches and connections for welding machines shall be carefully checked and repaired atleast once a month and before operating the welding machines. c) Portable power cables used with welding machines shall be carefully examined and

repaired as necessary every day. d) Proper earthing of the welding machines shall be ensured by the Tenderer. 5.16.0 Welding 5.16.1 General a) All welding and heat treatment shall be performed in accordance with the welding requirements detailed in ASME B31.1. b) No welding shall be done if there is impingement of any rain, or high winds on the weld area except when suitable protection or shield against the rain or wind is provided. c) Before welding, the ends shall be cleaned by wire brushing, filing or grinding. Each weldrun shall be cleaned of slag before the next run is deposited. d) Welding shall be done by certified welders only. Welding procedure and welder qualification records shall be maintained for reference of Purchaser/Consultant at any time. e) Welding at any joint shall be completed uninterrupted. If this cannot be followed for some reason, the weld shall be completely removed and a new joint shall be made. f) Welding shall be done by manual shielded metal arc process and TIG welding as applicable. Automatic or semi-automatic welding processes may be done only with the specific approval of Purchaser/ Consultant.

5.16.2 Welding Procedure For detailed welding procedure refer Section -2.3 enclosed along with this section. 6.0.0 ERECTION 6.1.0 All piping shall be routed and located as shown in piping drawings keeping in view the piping specifications. No deviations from the arrangement shown shall be permitted without the approval of the Engineer. 6.2.0 For erection of piping, use of davits, welding of temporary supports on adjacent equipment / structure, use of existing foundation or steel structure shall be allowed only after approval of Engineer-incharge. In each case, maximum allowable load and erection procedure shall be as directed by the Engineer-in-charge. 6.3.0 Location and design of pipe supports shown in support drawings should be strictly adhered to. Pipe supports have been designed and located to effectively sustain the piping system for weight and thermal offsets. 6.4.0 Erection and fabrication or supports i.e. restraints such as guides, stops and anchors must be made in such a manner that they will not over stress a line while protecting a weaker or more sensitive component e.g. turbine, pump compressor, vessel nozzles, etc. 6.5.0 Flanged connections at the pump, turbines, compressors and other equipment shall be made in such a way as not to induce any stresses due to misalignment, excessive gap etc. The final tightening shall be redone when the machines are aligned completely and specifically authorised by the Engineer. Pipes shall not be pulled and connected to equipment as well as during welding. Temporary protective covers shall be provided at all flanged connections of pumps, compressors, turbines and other similar equipment until the piping is finally connected. 6.6.0 Slopes specified for various lines in the drawings shall be maintained by the Tenderer. In case the Tenderer is unable to maintain the indicated slope he shall check the sagging of the pipe with a precision spirit level and maintain a difference in levels higher than that. Vents and drains are shown in the isometric of each line and these are intended for releasing the trapped air during hydrostatic test and draining out the test fluid after testing. Valved vents and drains are also shown wherever required. The Tenderer shall provide vent and drain connections even when these are not shown in the drawings and are found necessary by the Engineer. The details for the type of connections to be adopted shall be as per enclosed drawings. 6.7.0 After the piping is erected in final position, it shall be cleaned, tested for tightness and kept dry wherever instructed, as described in this specification. 7.0.0 BURIED PIPING

Buried piping shall be as per detailed procedure enclosed as Annexure-3.2.0 along with this section. 8.0.0 8.1.0 INSTALLATION AND ASSEMBLY General a) Installation and assembly of fabricated spool and piping components shall be made so that the completely installed piping system conforms to the requirements of relevant drawings and specifications. b) Care shall be taken to prevent damage to equipment nozzle caused by the weight and moment of fabricated spools or piping components. Permanent or suitable temporary pipe supports shall be installed prior to installation of such a piping. 8.2.0 Connection to Equipment Nozzles a) Faces of flanges and the bolt holes shall accord reasonably to those of equipment nozzle flanges. b) Lines connected to rotating machinery shall be aligned so as to meet the following requirements. i) Flange faces which connect piping to the primarily aligned machinery shall be strictly parallel with the clearance between them equal to the thickness of the gasket so that alignment of the machinery after tightening the flanges will be within the allowable tolerances specified. No load shall be transferred to the connected equipment. ii) Off-center of bolt holes shall be minimised so that the bolt can pass smoothly through the bolt holes. The alignment of the piping shall be checked after completion of piping fabrication with flanges disconnected and witnessed by the Engineer. 8.3.0 Installation of Spools and Piping Components a) Care shall be taken to protect/prevent tack welds at both weld ends from any damage caused by weight and the moment of piping components. b) For installation of angle, blow-down, check and needle valve, control valve and pressure relief valve, the direction of those shall conform to the flow direction shown on piping drawings. c) Direction of the pressure balancing hole for gate valves, if drilled, shall conform to piping drawings. d) Care shall be taken that the faces of companion flanges for flanged cast iron components shall be parallel with the required clearance for gasket thickness and that the flange bolts shall not be off-centre. 8.4.0 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 Bolting Procedure Anti galling compound shall be applied on all flanges bolts in order to prevent seizing. All flanged joints shall be fitted so that the faces of the flange meet evenly with the gasket, and then the bolts shall be tightened in a sequence to ensure uniform bolt stress. In bolting flanged joints, the bolt shall be tightened in a proper manner to compress the gasket to build up a compression suitable for the type of gasket used. Steel-to-cast iron flange joints shall be assembled with care to prevent damage of the cast iron flange. All bolts shall extend completely and uniformly through their nuts. Bolt loads shall be in accordance with the manufacturer's recommendation. 8.5.0 8.5.1 Threaded Piping Teflon seal tape shall be used for all threaded piping. No lead based component shall be used.

9.0.0 9.1.0

ERECTION OF VALVES Erection and testing of the valves shall be in accordance with the applicable standards.

9.2.0 Valve spindle positions are shown in the arrangement drawings and the Tenderer shall be required to follow them. He shall, however, bring it to the notice of the Engineer in case he encounters some difficulty in installing them. 9.3.0 Where practicable and except when otherwise shown on the drawings, valve stems shall be installed in a vertical direction and shall not be installed with stems below the horizontal. 9.4.0 For Safety valves, Pressure relief valves, Rupture discs and other safety devices against excess pressure the directives of the Appendix II of the code ANSI B 31.1. "Non mandatory rules for design and safety valve installations" shall apply. 9.5.0 All globe valves shall be installed with the pressure on the bottom of the disc.

9.6.0 Globe valve, check valve, control valves etc. shall be installed in the correct sequence and direction as shown in P&I diagram and piping drawings. 10.0.0 ERECTION OF SUPPORTS10.1.0 Welding Pipe supports which are welded to the pressurised pipe directly, shall be welded by qualified pipe welders. 10.2.0 Fabrication All supports shall be properly levelled and plumbed as per pipe support drawings. Shims and wedges may be employed for levelling and alignment of the supports on the grade. Rigid temporary wooden frames or other suitable devices may be used for supporting piping before installation of pipe supports. 10.3.0 Supports Permitting Pipe Movement Supports permitting pipe movement shall be assembled to allow the necessary movement pipes of as caused by thermal expansion and contraction in accordance with the piping drawing and stress analysis reports giving details of movements at individual support locations. 10.4.0 Bracing 10.4.1 The first nipple and valve of small connections including instrument connections to piping, vessel or equipment shall be braced if required. 10.4.2 For 2" and smaller piping, additional pipe supports may be installed to improve the stability of the piping after approval of the Engineer. 11.0.0 ERECTION OF INSTRUMENTS 11.1.0 All in-line instruments shall be installed only after final flushing of the line and when the line is ready for commissioning. 11.2.0 The limits of piping Tenderer are clearly shown in the drawings provided (such as upto first block valve, nozzle and flange, taps etc.). In addition to this, he shall install all the in-line instruments such as orifice flanges including orifice plates, with valves, venturi control valves, flow integrators, positive displacement meters with strainers, pressure relief/safety valves, rotameters, rupture/bursting discs etc. 11.3.0 For installation of all in-line instruments, reference may be made to relevant clause of the chapter for pressure testing inspection procedures. 11.4.0 Care shall be exercised and adequate precautions to be taken to avoid damage to the instruments while transportation, installation etc. protection cover shall be used at control valves, flow meter etc. to avoid contamination with dust and foreign matter. 12.0.0 LINE MOUNTED FILTERS, SIMPLEX/DUPLEX FILTERS, MIXERS & FLEXIBLE HOSES 12.1.0 Installation of line mounted filters with by-pass arrangements, or any other arrangements,any, if duplex filters, mixers, ejectors including installation of all types of supports will be done by the Tenderer as part of piping erection work. 12.2.0 Installation of temporary strainers as per requirements either during finishing or start-up, its cleaning and up-keeping shall be part of the piping erection work and no separate payment shall

be made on this account. 12.3.0 Flexible hoses shall be installed on the suction of naphtha and distillate unloading pump as indicated in relevant piping layout maintaining necessary slope.

12.4.0 Bolts, Nuts 12.4.1 During erection of the piping, the Tenderer shall install proper number and size of bolts and nuts as per drawings and specifications. 12.4.2 Grease and Graphite shall be supplied by the Tenderer. 12.4.3 All bolts shall extend completely through their nuts. Only bolts of adequate length, required die, specified material and machining quality shall be used. The number, material shall be readable for all the same side. Hexagonal bolt heads shall be all at the same side with horizontal flanges at the top. Threaded ends with machine bolts shall protrude adequately through the nuts. Bolts/stud threads and compressed asbestos gaskets shall be treated with graphite oil before assembly or as per the specification. 13.0.0 INSPECTION 13.1.0 General 13.1.1 Purchaser's/Consultant's inspector shall have free access to all places where the work is being done or any other place concerned with the work. 13.1.2 Purchaser is entitled to send his own inspector or his representative to field where prefabrication and erection of pipe lines are being done, with the following functions but not limited to: i. To check that the execution of welding and welding equipment used on the job are suitable and conform to relevant standards.

ii. To supervise welding procedure qualification, iii. To supervise welder performance qualification. iv To check whether welding is conforming to relevant specification and the procedure followed and is in accordance with good pipeline construction practice.

v. To check any other activity to ensure quality of work. 13.1.3 Tenderer shall notify inspection dates sufficiently in advance with all facilities necessary for carrying out his work at no extra cost to the Purchaser. 13.1.4 Approval from the Purchaser's inspector shall not relieve the Tenderer partially or fully of his responsibilities and guarantees under this Work order. 13.2.0 Details of inspection and defect acceptance norms its repair and removal shall be as per this tender document.

14.0.0 MATERIAL IDENTIFICATION Specification of all materials shall be as per the relevant piping drawings and piping service sections. 14.1.0 Material Check a) All the materials before usage the materials shall be identified by means of stencil and/or colour identification or other marking. 14.2.0 Thickness and Pressure Temperature Rating a) Thickness and pressure temperature rating of piping components to be used shall be checked by stencil or other marking and measurement referring to the material shown on piping drawing and piping service classes. b) Markings on pipe stencilled by manufacturer shall be left until final use of the pipe and be transferred by painting on to the length to be cut off prior to cutting. 15.0.0 HYDROTEST Hydrotest shall be as per Section 2.5 of this tender document. 16.0.0 INSTRUMENT CONNECTIONS

16.1.0 Stubs with root valves shall be provided for all pressure connections and half couplings shall be provided forthermowells. 17.0.0 RECORDS Fabrication details and results of inspection of piping shall be recorded on the piping drawings for records.

SECTION - 2.2 TECHNICAL SPECIFICATION WELDING PROCEDURE


TABLE OF COTNENTS 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 INTENT OF SPECIFICATION........................................................................................................3 APPLICABLE CODES AND STANDARDS....................................................................................4 BASE METAL.................................................................................................................................4 GENERAL STORAGE OF WELDING CONSUMABLES.................................................................4 EQUIPMENT AND ACCESSORIES...............................................................................................5 WELDING PROCESS.....................................................................................................................5 EDGE PREPARATION..................................................................................................................5 ALIGNMENT& SPACING..............................................................................................................6 WELDING TECHNIQUE.................................................................................................................7

10.0.0 WELDING PROCEDURE QUALIFICATION....................................................................................8 11.0.0 WELDER'S QUALIFICATION.........................................................................................................8 12.0.0 WELD HEAT TREATMENT PROCEDURES...................................................................................8 13.0.0 INSPECTION AND TESTING.........................................................................................................9 14.0.0 SAFETY REQUIREMENTS..........................................................................................................13 ANNEX- A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS...............................................15 ANNEX-B: FORMAT FOR PROCEDURE QUALIFICATION RECORD...................................................17 ANNEX - C : FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR QUALIFICATION TESTS......................................................................................................19 ANNEX - D : FORMAT FOR STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION..................................................................................................................20 ANNEX-E: RADIOGRAPHIC TECHNIQUE LOG.....................................................................................21 ANNEX- F: WELDER'S IDENTIFICATION CARD....................................................................................22 ANNEX-G: LIST OF APPROVED ELECTRODE MANUFACTURER.......................................................23 SECTION 2.2 TECHHNICAL SPECIFICATION - WELDING PROCEDURE 1.0.0 INTENT OF SPECIFICATION This specification shall be followed for the fabrication of all types of welded joints of carbon steel / mild steel LP piping system within the battery limits of the plant. Instrument Air Distribution System Service Air Distribution System

Service Water Distribution System Potable Water Distribution System. DM Feed Water System a) DM Water Transfer Pumps all suction, discharge and recirculation lines. b) Hot Well Make up Pumps all suction, discharge and recirculation lines. c) DM Cooling Water Make up Pumps suction, discharge and recirculation lines. d) Boiler Feed Pumps suction, discharge and recirculation lines (Condensate Make up line).

Plant Water System -I a) Raw Water System. b) APH Wash pumps all suction and discharge lines. c) Ash Water Tank Fill pumps suction and discharge lines. d) Service Water Pumps suction and discharge lines e) DM plant pumps suction lines. f) AHS Seal Pumps suction lines.

Plant Water System - II a) b) Plant Potable Water pumps all suction and discharge lines. Colony Potable Water pumps all suction and discharge lines.

CW Blow down System. Wash Water System. Effluent System. Sludge Water system. All pipe line headers. All tanks external down comer pipe lines, over flow lines, vent pipe lines and draw of sump lines. DM Cooling Water Supply & Return Line for Main Plant compressor & Ash Handling compressor.

(Instrument Air System / Service Air System / Potable water system pipes (upto 150NB) are of threaded ends, hence it will not come under the purview of this document). The welded pipe joints shall include the following:a. b. c. d. e. f. All pipe joints of the longitudinal and circumferential butt welded and socket welded types. Attachments of forgings, flanges and other supports to pipes. Welded manifold headers and other sub-assemblies. Welded branch connections with or without reinforcing pads. Joints in welded / fabricated piping components. The attachments of smaller connections for vents, drain drips and other instrument tappings.

Any approval granted by the Engineer-in-Charge or Owner's inspector, shall not relieve the Contractor of his responsibilities and guarantee. 2.0.0 APPLICABLE CODES AND STANDARDS

All welding works, equipments for welding heat treatment other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the following acceptable standards and procedures unless otherwise specified in the welding specification chart. In case of conflicting requirements, the requirements mentioned in welding specification chart/Technical notes shall be applicable. Since this section covers welding procedure for LP piping all IBR related procedure may be ignored. ANSIB31.1 ANSI B16.9 IBR Power piping Wrought steel Butt Welding Fittings Indian Boiler Regulations

In addition, the following codes and specifications referred in the relevant code of fabrication shall be followed for the welding qualifications, consumable qualifications and non-destructive test procedures. ASME BPVC Sec.IX ASME BPVC Sec.V ASME Sec.II Part C IS: 2825 MSS-SP-55 MSS-SP-53 MSS-SP-54 3.0.0 BASE METAL Welding and Brazing Qualifications Non destructive examination Material specifications; welding rods, electrodes and filler metals. Code for Unfired Pressure Vessels Visual inspection and testing Magnetic particle testing Radiographic testing

Base metal shall be as detailed in Welding Specification chart. 4.0.0 GENERAL STORAGE OF WELDING CONSUMABLES The welding electrodes and filler wires supplied shall confirm to the class specified in the welding specification chart. Electrode qualification test record have to submitted in the enclosed format. Batch test certificates has to be submitted from the electrode manufactures, giving details of physical and chemical tests carried out has to be submitted by them. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. Welding rods shall be stored indoors free from moisture. The package of the welding rods shall not be opened until immediately buffer use. Drying of welding rods Welding rods shall be baked in a heating cabinet in accordance with the manufacturer's recommendation. Welding rods not consumed in a day shall be baked by the same method with only two rebakings permitted. Portable ovens shall be utilized to maintain a temperature of 80C at actual site locations. Handling of welding rods being used During welding work welding rods shall not be laid down directly on the ground or any other humid place to ensure that rods are not damaged by moisture. 5.0.0 EQUIPMENT AND ACCESSORIES

5.1.0 All the equipments for performing the heat treatment, including transformers, thermo-couples, pyrometers, automatic temperature recorders with suitable calibration certifications shall be provided duly approved by Engineer. 5.2.0 The make & type of radiographic equipments, radiographic films, and all the equipments/materials required for carrying out the dye-penetrant/magnetic particle test shall be subjected to approval of Engineer in charge. All statutory regulations shall be adhered to (including qualification of personnel) for radiographic equipments & personnel.

6.0.0

WELDING PROCESS

6.1.0 Welding of various materials under this specification shall be carried out at site using one or more of the following processes with the approval of the Engineer-in-charge. Shielded Metal Arc Welding Process (SMAW) Gas Tungsten Arc Welding Process (GTAW) 6.2.0 The welding processes to be employed are given in the Welding Specification Chart. Any deviation desired shall be done through the consent of the Engineer-in-charge. 6.3.0 Automatic and semi-automatic welding processes shall be employed only with the approval of the Engineer-in-charge. The welding procedure adopted and consumables used shall be specifically approved. 6.4.0 A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-incharge. 7.0.0 EDGE PREPARATION

7.1.0 The edges to be welded shall be prepared to meet the joint design requirements by any of the following methods recommended. Edge shall conform to B31.1 a) Carbon Steel Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides shall be removed by chipping or grinding. b) Low Alloy Steels (containing upto 2/4% Chromium) (Not applicable for LP piping) Gas cutting, machining or grinding, methods shall be used. After gas cutting, machining or grinding shall be carried out on the cut surface. c) High alloy steels, cupro-nickel, nickel alloys, and aluminium alloys: Plasma cutting, machining or grinding methods shall be used. After plasma cutting, cut surfaces shall be machined or ground smooth. 7.2.0 7.2.1 Cleaning The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth and other foreign matter. The ends shall be completely dry before the welding commences. On completion of each run, craters, welding irregularities, slag etc., shall be removed by grinding and chiseling. Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and the grinding wheels used for grinding stainless steel shall be of a suitable type. Suitable grinding wheels and wire brushes should be used for carbon steels and stainless steels. ALIGNMENT & SPACING

7.2.2

8.0.0

8.1.0 Components to be welded shall be aligned and spaced as per the requirements laid down in applicable code. Special care must be taken to ensure proper fitting and alignment when the welding is performed by GTAW process. Flame heating for adjustment and correction of ends is not permitted unless specifically approved by the Engineer-in-charge. 8.2.0 A wire spacer of suitable diameter may be used to maintain the weld root opening while tacking, but it must be removed after tack welding and before laying the root bead. 8.3.0 For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured position in with the aid of couplers, yokes and 'C clamps, to maintain perfect alignment. Yokes shall be detached after the completion of weld, without causing any surface irregularity. Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the Engineer-in-charge. 8.4.0 Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified welders. Since the tack welds become part of the final weldment they shall be executed carefully and shall be free from defects. Defective tack welds must be removed prior to the actual welding of the joints. 8.5.0 Tacks should be equally spaced. Minimum number of tacks shall be

2 tacks - for 2/4" and smaller dia pipes 4 tacks - for 3" to 12" dia pipes 6" tacks - for 14" and larger dia pipes. 8.6.0 Engineer-in-charge shall check and approve the fit-up and alignment of pipe joint prior to the commencement of welding. 8.7.0 8.7.1 8.7.2 8.7.3 8.7.4 Dimensional tolerances generally acceptable are as follows. Face to Face/Center to Face Lateral translation in any direction Rotation Out or alignment measured across the diameter 9.0.0 WELDING TECHNIQUE 9.1.0 Root Pass a) Root pass shall be made with electrodes/filler wires recommended in the welding specification chart. For fillet welding shall be done with consumables recommended for filler passes. The preferable size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.25 mm (10 SWG). b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal. c) The root pass of butt joints should be executed so as to achieve full penetration with complete fusion of the root edges. Weld projection inside the pipe shall not exceed 1.6 mm. d) Any deviation desired from the recommended welding technique and electrodes indicated in the welding specification chart should be adopted only after obtaining approval of the Engineer-in-charge. e) Welding shall be uninterrupted. f) While the welding is in progress care should be taken to avoid any kind of movement of the components, shocks, vibrations and stresses to prevent occurrence of weld cracks. : 1 mm : : : 3mm (Max) 1.5 mm (Max) 1.5degMax

9.2.0

g) Penning shall not be used. Joint completion a) Joint shall be completed using the class of electrodes, recommended in the Welding Specification Chart. Size of the electrode shall not exceed 4 mm in diameter for stainless steels and alloy steels used for low temperature applications. b) Two weld beads shall not be started at the same point in different layers. c) Butt joints shall be completed with a cover layer that would effect good fusion at the joint edges and a gradual notch free surface. d) Each weld joint should have a workman like finish. e) Weld identification work shall be stamped clearly at each joint, just adjacent to the weld. Metal stamping shall not be used as a standard. Suitable paint shall be used on thin wall pipes for identification. f) No painting shall be done until the weld joint has been approved.

9.3.0

g) All welded joints are subjected to acceptance by Engineer-in-charge. Dissimilar Welds Where welds are to be produced between carbon steels and alloy steels, preheat and postweld Heat Treatment requirements shall be to those specified for corresponding alloy steels and electrodes shall correspond to AWS E-7016 / 7018 type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatment shall be those specified for higher alloy steel and electrodes used shall correspond to those specified for steel of lower alloy content.

For carbon steel or alloy steel to stainless welds, use of electrodes E-309/E-310/E NiCr Fe-2 shall be made. The welding procedure, electrodes/filler wires to be used shall be approved by the Engineer-in-charge. Following shall be generally adopted to ensure proper welding: i) Relation of welding rods matches with parent material, ii) Preheating to the required value of the parent material before welding, iii) Quality & brand of the welding rods approved by owner, iv) Overhead welding should be avoided to the extent possible. 10.0.0 WELDING PROCEDURE QUALIFICATION Welding procedure qualification shall be carried out in accordance with the relevant requirements of ASME Sec.IX latest edition or other applicable codes and the job requirements. The welding procedure specifications in format as per enclosed Annex - A should be submitted. Purchaser's inspector will review, check and approve the welding procedure submitted and shall release the procedure for qualification tests. A complete set of test results in format as per enclosed Annex - B shall be submitted to the Purchaser's inspector for his approval immediately after completing the procedure qualification test. Standard tests as specified in the code shall be carried out in all cases. In addition to these tests, other tests like macro/micro examination, hardness tests, dye penetrant examination, charpy V-notch and U-notch impact tests etc. shall be carried out on specimens depending upon the type of base material, operating conditions and requirements laid down in the detailed drawings and specifications. 11.0.0 WELDER'S QUALIFICATION 11.1.0 Welders shall be qualified in accordance with the ASME Section - IX or other applicable codes. The Purchaser's inspector shall witness the test and certify the qualification of each welder separately. Only those welders who have been approved by the Engineer in charge shall be employed for welding. The welder qualification test reports shall be submitted in the format enclosed as Annex - C and obtain express approval before commencement of the work. 11.2.0 The welders shall always have in their possession the identification card as shown in enclosed Annex- F and shall produce it on demand by the Engineer in charge. 11.3.0 No welder shall be permitted to work without the possession of identity card duly certified by the inspector. 11.4.0 If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder. 12.0.0 WELD HEAT TREATMENT PROCEDURES 12.1.0 Preheating 12.1.1 No welding shall be performed without preheating the joint to 10C (50F) when ambient temperature is 10C and below. 12.1.2 Preheating requirements for the various materials shall be as per the welding specification chart attached. 12.1.3 Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with neutral flame may also be carried when permitted by the Engineer-in-charge. 12.1.4 Preheating shall extend uniformly to atleast three times the thickness of the joint, but not less than 50 mm, on both sides of the weld. 12.1.5 Preheating temperature shall be maintained over the whole length of the joint during welding. Temperature indicating crayons or other temperature indicating devices shall be provided to check the temperature. 12.2.0 Postweld Heat Treatment 12.2.1 Post weld Heat Treatment, wherever required for joints between pipes, pipes and fittings, pipe body and supports shall be carried out as per the welding specification chart, applicable codes standards and the instructions of the Engineer-in-charge. 12.2.2 The details of the post weld Heat Treatment procedure (as per Annex - D attached), that is proposed to adopt for each of the materials/assembly/part involved shall be submitted for the approval of the engineer - in - charge well before carrying our actual heat treatment.

12.2.3 While carrying out local post weld Heat Treatment, technique of application of heat must ensure uniform temperature attainment at all points of the portion being heat treated. Care shall be taken to ensure that width of heated band over which specified post weld Heat Treatment temperature attained complies with relevant applicable standards/codes. 12.2.4 Throughout the cycle of Heat Treatment, the portion outside the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at the exposed surface or pipe. 12.2.5 The temperature attained by the portion under heat treatment shall be recorded by means of thermocouple pyrometers. Adequate number of thermocouples should be attached to the pipe directly at equally spaced location along the periphery of the pipe joint. The minimum number of thermocouples attached per joint shall be 1 upto 6" dia, 2 upto 10" dia and 3 for 12" dia and above. However the Engineer-in-charge can increase the required minimum number of thermocouples to be attached if found necessary. 12.2.6 Automatic temperature recorders which have been suitably calibrated should be employed. The calibration chart of each recorder should be submitted to the Engineer-in-charge prior to starting the Heat Treatment operations and his approval should be obtained. 12.2.7 Immediately on completion of the Heat Treatment, the post weld Heat Treatment Charts/records alongwith the hardness test results on the weld joints, wherever required as per the welding specification chart, shall be submitted to Engineer-in-charge for his approval. 12.2.8 Each joint shall bear an identification number which shall be maintained in the piping sketch. The joint identification number should appear on the corresponding post weld heat Treatment Charts. The chart containing the identification numbers and piping sketch shall be submitted to the Engineer-in-charge in suitable folders. 13.0.0 INSPECTION AND TESTING 13.1.0 General 13.1.1 Purchaser's/Consultant's inspector shall have free access to all places where the work is being done or any other place concerned with the work. i. To check that the execution of welding and welding equipment used on the job are suitable and conform to relevant standards.

ii. To supervise welding procedure qualification, iii. To supervise welder performance qualification. iv. To check whether welding is conforming to relevant specification and the procedure followed is in accordance with good pipeline construction practice.

v. To check any other activity to ensure quality of work. 13.1.2 Inspection dates shall be notified sufficiently in advance with all facilities necessary for carrying out his work at no extra cost to the Purchaser. 13.1.3 Approval from the Purchaser's inspector shall not relieve the Tenderer partially or fully of his responsibilities and guarantees under this work order. 13.2.0 Visual Inspection 13.2.1 Inspection of all welds shall be carried out as per ASME - B31.1. Finished welds shall be visually inspected for parallel and axial misalignment of the work, cracks, incomplete penetration, under cut on surface, weld reinforcement and lack of fusion, unrepaired burnthrough, dimensions, and other surface defects. 13.2.2 Inspection before welding a) Dimension and orientation of spool assembly and installed spool and/or piping components shall be checked with the piping drawings. b) Width of root space, bevel angle and alignment of components shall also be checked on each joint fitted up. c) Surfaces to be welded shall be checked to assure that they are clean and free from foreign material such as grease, oil, paint, scale, or others for a distance of at least 25 mm from the bevel ends.

13.2.3 Inspection During Welding Crack in tack welds, welding slag on inter passes, welding current conditions, and finish after back chipping shall be checked. 13.2.4 Inspection of Welds Bead appearance under cut, overlap, spatter, crater, reinforcement of weldment and size fillet of weld shall be checked. 13.3.0 Radiography 1. All piping above 51 kg/sq cm (g) shall have 100% Radiography. All alloy steel and SS welding shall have 100% Radiography. However, SS lines used for services like bearing lubrication oil supply shall be tested as per the instruction of Engineer-in-charge. 2. All other IBR piping (steam) shall be tested as per regulation 360 of IBR or Table-A whichever is higher. 3. Gamma ray with Iridium-192 source is acceptable for carrying out radiography. 4. Plate fabricated pipes & specials forCW/ RW/ CLW service shall have 10% radiography. 5. All fuel lines shall have minimum 50% radiography. 13.3.1 Radiographic Examination Radiographic examination shall be performed in accordance with the following requirements. 13.3.2 Random Examination a) Radiographic testing and acceptance shall be in accordance with MSS-SP-54. b) Random radiographic examination shall be applied to the entire circumference of a specified percentage of the girth butt welds as designated in Table A. c) The welds to be examined shall be selected to ensure that the work product of each individual welder is included. d) The extent of radiographic examination shall be as per Table-A. e) Conducting radiographic test outside the Purchaser's premises should be performed only on approval of Engineering - in - charge. 13.3.3 Identification of Radiographs Identification marks shall be marked on every radiograph and radiographs of repaired welds shall be marked separately. 13.4.0 Liquid Penetrant or Magnetic Particle Examination a) Socket welds in piping system shall be liquid penetrant or magnetic particle examined in accordance with Table A. b) All completed girth butt and socket welds of carbon steel to Austenitic steel shall be subjected to 100% liquid penetrant examination. c) Liquid penetrant or magnetic particle examination shall be performed in accordance with section V ASME code. d) All fuel lines shall have for 100% LP/MP tested on welded joints. TABLE - A PIPING WELDING DETAILS FOR ERECTION - NON IBR (LP IPING) SERVICES : COOLING WATER, CIRCULATING WATER, RAW WATER, CLARIFIED WATER, EFFLUENT LINES AND EXHAUST PIPING TO ATMOSPHERE Sl. No. Material Combination P.No. Gr. Specn. AWS Specification Gr. Root Further Run No. Run

Specn.

P.No

IS 3589/ IS 1239/ IS 2062


Note:

P1

Any combination

P1

E6013*

E6013*

WPS shall be qualified (PQR) by the respective quality department of erection groups (FQA) prior to welding.

13.5.0 Acceptance Standards The following acceptance standards shall be used unless otherwise specified. 13.5.1 X-Ray Acceptance Standard No cracks or lack of penetration are permitted. Elongated slag or tungsten inclusions with lengths greater than the following are not permitted: 1/2 in. for Tup to 3/4 in. 2/3 T for T from 3/4 in . to 2-1/4 in. 1-1/2 in. fort over2-1/4 in. where T is the thickness of the weld. Groups of slag inclusions in line that have an aggregate length greater than T in length of 6T are not permitted. The through thickness of slag inclusions shall not exceed 1/4 of the thickness of the thinner member being joined. Porosity in excess of that specified in the following table shall not be permitted. MAXIMUM PERMISSIBLE POROSITY IN 6 INCH LENGTH OF WELD

13.5.2 Magnetic Particle and Liquid penetrant Acceptance standards Linear MP and LP indications up to 1/2 T where T is the weld thickness or 1/4 inch in length, whichever is smaller, and which are not visible cracks, are acceptable. The cumulative length of linear magnetic particle or liquid penetrant indications shall not exceed T in any 12T length of weld. 13.5.3 Ultrasonic Acceptance Standards Indications are unacceptable if the amplitude exceeds the reference level established by the basic calibration block for ultrasonic examination of welds as stipulated in ASME Boiler and Pressure Vessel Code, section V, Article 5, and the lengths exceed the following: 1/2 in. for Tup to 3/4 in. 2/3T for T from 3/4 in. to 2-1/4 in. 1-1/2 in. for T over 2-1/4 in. where T is the thickness of weld. Where indications are interpreted as cracks or lack of penetration, they are unacceptable regardless of length. 13.5.4 Visual Acceptance Standards The visual acceptance standards shall be as follows: Cracks-None Linear Indications - None Undercuts - (Including Burnback)- None for component thickness up to 1/8 in. include. 1/32 in max. for component thickness over 1/8 in.

IV)

(inches) Less than 1/8 1/8 1/4 1/2 3/4 1

Pore t/4 1/32 1/16 1/8 3/16

Area 8(t/4) 0.088 0.030 0.060 0.090 0.120 0.240 0.360

Reinforcement - 1/16 in max. for component thickness up to 3/16 in include. 1/8 in max. for component of 3/16 in. max. for component thickness over 1/2 in. Appearance - Welds shall have a workmanship appearance with minimum variations in width and size of weld, and absence of sharp notches at undercuts and surface ripples. Spatter and projections from welding and any remaining tack welds shall be removed. All arc strikes in the base metal are unacceptable. Any blending in the base metal shall not exceed the undercut allowance. 13.6.0 Repair and removal of visual defects 13.6.1 Defects which are not within the acceptable limits shall be removed from the joint completely by chipping or grinding. 13.6.2 When the whole joint is found unacceptable, the weld and the ends of the joints shall be restored. 13.6.3 No repair shall be carried out without prior approval of the Engineer. 13.6.4 Traces of jigs removed, undercutting, craters and beads shall be ground and weld metal deposited. 13.6.5 Repairs of weld reinforcement and overlap shall be ground and weld metal deposited. 13.6.6 Repairs of weld reinforcement and overlap shall be ground smooth. Spatter and slag shall be removed by a hammer or a brush. A crack found visually shall be removed and examined by a magnetic particle or liquid penetrant test until assured no defect remains. 14.0.0 SAFETY REQUIREMENTS Utmost care shall be taken during welding and gas cutting process to avoid fire hazard. Oxygen & Acetylene gas cylinders shall be stored and maintained properly including its valves, regulators, etc. Gas cutting torches shall be lighted by means of friction lighter and not with matches. The welding sets shall be earthed properly and properly insulated cables shall be used for welding purposes. For carrying out welding work in plant area necessary work permit shall be obtained from the Engineer - in - charge and after ensuring from him that the environment is quite safe for welding purpose the work shall be commenced. The wearing of safety by the gas cutters, grinders and welders, such as handgloves, safety goggles, welding glass, helmet, etc. should be observed strictly. Overhead work While carrying out the work in elevated positions, care should be taken to ensure that tools and materials are not left in position from where they can fall on the persons below. No tools, tackles and materials shall be dropped from any height which may endanger anybody. While working on elevated position use of safety belt shall be ensured which has to be periodically checked for its suitability to provide safety. Wherever necessary ladder and scaffolding shall be used to carry out work at elevated positions. Scaffolding and ladders should be maintained in good conditions. ANNEX -A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS
QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boiler and pressure Vessel Code) Company Name ________________________________ Welding Procedure Specification No._ Revision No ________________________________

_By:_ Date

_Supporting PQR No (s)_

Welding Process (es)_

_Type(s)_ (Automatic, Manual, Machine, or semi-Auto)

JOINTS (QW-402) Joint Desiqn

Details.

(Refer to both backing and retainers.) | Metal I | Nonmetallic |

| Metal | Other

| Nonfusing

Sketches, Production Drawings, Weld Symbols or Written Description Should show the general arrangement or the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified (At the option of the Mfgr, sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g. for notch toughness procedures, for multiple process procedures, etc.)

* Base Metals (QW-403) P Nn Group No OR

Grmip No.

to P.No

OR Hhpm Analysis and Mpnh Prnp Thickness Range: Paso Mtar Fillet Other FILLER METALS 9QW-404 nrnnvo

Weld Metal Thickness Range : Groove Fillet Electrode-Flux (class) Flux Trade Name Consumable Insert

Other " Each base metal.filler metal combination should be recorded individually

POSITIONS (QW-405) Position (s) of Groove Welding Progression: Up Position (s) of Fillet

Down

QW-482 (Back) WPS No. Rev.

POSTWELD HEAT TREATMENT (QW-407) Temperature Range Time Range ___________________ __________________

PREHEAT (QW-406) Preheat Temp. Min. Interpass Temp. Max.

GAS (QW-408) Shielding Trailing

Percent Composition Gas (es) (Mixture)

Flow Rate

(Continuous or special heating where applicable should be recorded) Backing ELECTRICAL CHARACTERISTICS (QWCurrent AC or DC_______________Polarity Amps (Range) Volts (Range)

(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information maybe listed in a tabular form similar to that shown below.) Tungsten Electrode Size and Type ________________________________________________________ (Pure Tungsten, 2% Thoriated, etc.) Mode of Metal Transfer for GMAW (Spray arc, short circuiting arc, etc.) Electrode Wire feed speed range TECHNIQUE (QW-410) String or Weave Bead Orifice or Gas Cup Size ___________________ ___________________

Initial and Interpass Cleaning (Brushing, Grinding, etc.) Method of Back Gouging Oscillation Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Other Weld Layer (s) _______________

Process

Filler Metal Dia. Class

Type Polar

Current

Amp. Range

Volt Range

Travel Speed Range

Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch angle, Etc.

ANNEX - B : FORMAT FOR PROCEDURE QUALIFICATION RECORD


QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions used to Weld Test Coupon. Company Name Procedure Qualification Record No WPS No. _______________ Date

Welding Process (es) Types (Manual, Automatic, Semi-Auto)

JOINTS (QW-402) Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filter metal or process used)

BASE METALS 9QW-403) Material Spec P.No Thickness of Test Coupon to P.No.

POSTWELD HEAT TREATMENT (QW-407) Temperature

GAS (QW-408) Percent Composition Gas (es) Flow Rate

(Mixture)

FILLER METALS (QW-404) SFA specification ELECTRICAL CHARACTERISTICS (QW-409) Current Amps. Tungsten Electrode Size Volts

POSITION (QW-405) Position of Groove

TECHNIQUE (QW-410) Travel Speed

PREHEAT (QW-406) Preheat Temp

QW-483 (Back) Tensile Test (QW-150|

Specimen No.

Width

Thickness

Area

Ultimate Total Load Ib

Ultimate Unit Load Psi

Type of Failure & Location

Guided-Band Tests (QW-160)

Toughness Tests (QW-170)

Specimen No.

Notch Location

Area

Test Temp

Impact Values

Result________Satisfactory: Yes Macro - Results

No

Fillet-Weld Test (QW-180) Penetration into Parent Metal: Yes Other Tests

No

Type of Test Deposit analysis Other

Welder's Name Tests conducted by :

______________________________________________ Clock No. _________________________________________________________

______Stamp No.

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer

Date

By

(Detail of record of tests are illustrative only and may be modified to confirm to the type and number of tests required by the Code.)

ANNEX - C : FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR QUALIFICATION TESTS


QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW301, Section IX, ASME Boiler and Pressure Vessel Code Welder's name _________________________Clock number ________________________________Stamp no. ______

Welding process(es) used

___________________________________________Type____________________________ ________________________________

Identification of WPS followed by welder during welding of test coupon

Base material(s) welded____________________________________________________________________Thickness Manual or Semiautomatic Variables for Each process (QW-350) Backing (metal,weld metal, welded from both sides, flux, etc.) (QW-402) ASMEP.No. _____________toASMEP.no. (QW-403) () Plate () Pipe (enter diameter, if pipe) Filler metal specification (SFA):____________Classification (QW-404) Filler metal F-no. Consumable insert for GTAW or PAW Weld deposit thickness for each welding process Welding position (1G, %G, etc.) (QW-405) progression (uphill/downhill) Backing gas for GTAW, PAW, or GMAW; fuel gas for OFW (QW-408) GMAW transfer mode (QW-409) GTAW welding current type/polarity Machine Welding Variables for the process Used (QW-360) Direct/remote visual control Automatic voltage control (GTAW) Automatic joint tracking Welding position (1G, 5G, etc.) Consumable insert Backing (metal, weld metal, welded from both sides, flux, etc) Guided Bend Test Results Guided Bend Test Type () QW-462.2 (Side) Results () QW-462.3 (a) (Trans. R&F) Type () QW-462.3(b) (Long, R&F) Result Actual Values ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ Actual Values ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ Range Qualified _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ Range Qualified _________________ _________________ _________________ _________________ _________________ _________________

Radiographic test results (QW-304 and QW-305) _________________________________________________________________________________________ (For alternative qualification of groove welds by radiography) Fillet Weld Macro test fusion _____________Fracture test ________________________________Length and percent of defects ______________________________ ii __________________________Fillet leg size _________________in. X ____________in. Concavity/convexity_____________________ ii

Welding test conducted by Mechanical tests conducted by

__________________________________________________________ __________________________________________________________Laboratory test no. ________________________

We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Organization Date ______________________________________ By __________________________________________________________

ANNEX - D : FORMAT FOR STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION.


STRESS RELIEF/HEAT TREATMENT Name of the project PROCEDURE SPECIFICATION Specification

Name of the HeatTreater

1 General Details Name of the

Other Details Type of Heatinq : Induction

Elec.Res:/

Equipment: Name of the Assembly/Part Assembly/Part Drawinq No. Material

(Tick mark) Capacity (size)

Maximum Temp.CC)

Method of Temp.

Thickness

Atmosphere Control

3 Heat Treatment Cycle Details Charqinq Temp C

Rate of heatinq C/Hr Soakinq Temperature C Soakinq time, Hrs Rate of Coolinq 7Hr Mode of Coolinq

Other details, if any

Hardness test

A.S

C.S

ANNEX - E : RADIOGRAPHIC TECHNIQUE LOG RADIOGRAPHIC TECHNIQUE LOG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 18 Location Date of Testing Name of the Contractor and welder Material: Carbon steel/Alloy Steel/Stainless Steel Diameter & Thickness Type of Weld Joint Radiation Source Source strength Screen Screen thickness Focus film distance Limit of Film coverage Film type and make Exposure Time Processing Density Sensitivity Penetrameter thickness (Source Side) Penetrameter thickness (Film slide) Shim thickness Signature of Contractor with seal Approval of Inspector

ANNEX - F : WELDER'S IDENTIFICATION CARD WELDER'S IDENTIFICATION CARD

Name

Photograph

2 3 4 5 6 7 8 9

Identification Date of Testing Valid until Process Material Thickness Diameter F.No.

: : : : : : : :

10 11

Approval of welding Position

: :

Approved by:

Employee's Signature with seal

ANNEX - G : LIST OF APPROVED ELECTRODE MANUFACTURER LIST OF APPROVED ELECTRODES AND MANUFACTURERS
Accepted manufacturers of 6010, 7018 and 6013 electrodes are given below:Root - run - Philips (ESAB) 31 CS E6010

7016/7018
- Supercito - Advani Oerlikon - Philips 36 H - ESAB - Supertherm - D & H - Tenacito - Advani - Ferro Weld 2 - ESAB -Modi 7018-MODI 6013 - Overcord S, Oerlikon - Vordian Esab/IOL
ANNEX-A QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boiler and pressure Vessel Code) Company Name ______________________________ Welding Procedure Specification No._ Revision No _By:_ Date _ Date Supporting PQR No (s)_

Welding Process (es)_

_Type(s)_

(Automatic, Manual, Machine, or semi-Auto) JOINTS (QW-402) Joint Design Details.

(Refer to both backing and retainers.) |______| Metal |____| Nonfusing Metal |______| Nonmetallic | | Other Sketches, Production Drawings, Weld Symbols or Written Description Should show the general arrangement or the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified (At the option of the Mfgr., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g. for notch toughness procedures, for multiple process procedures, etc.)

* Base Metals (QW-403) P Nn Nn firnur OR

Grnup Nn

tn P No.

OR Chem. Analysis and Mech. Prop to Chem. Anaysis and Mech. Prop. Thickness Range: Base Metal: Fillet Pipe Dia. Range: Groove Other * FILLER METALS 9QW-404 Groove Fillet

Weld Metal Thickness Range : Groove

Other * Each base metal.filler metal combination should be recorded individually POSITIONS (QW-405) Position (s) of Groove Welding Progression: Up Position (s) of Fillet Down QW-482 (Back) WPS No. Rev.

POSTWELD HEAT TREATMENT (QW-407) Temperature Range Time Range _________________ _________________

PREHEAT (QW-406) Preheat Temp. Min.

GAS (QW-408) Shielding Trailing Backing

Percent Composition Gas (es) (Mixture)

Flow Rate

InterpassTemp. Max.

(Continuous or special heating where applicable should be recorded) ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC______________Polarity Amps (Range)

_________

_______________Volts (Range)__________

(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form similar to that shown below.) Tungsten Electrode Size and Type Mode of Metal Transfer for GMAW Electrode Wire feed speed range TECHNIQUE (QW-410) String or Weave Bead Orifice or Gas Cup Size __________________ __________________ (Pure Tungsten, 2% Thoriated, etc.) (Spray arc, short circuiting arc, etc.)

Initial and Interpass Cleaning (Brushing, Grinding, etc.) Method of Back Gouging Oscillation Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Other Weld Layer (s) Process Filler Metal Dia. Class Type Polar Current Amp. Range Volt Range Travel Speed Range Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch angle, Etc. ______________

\\

ANNEXURE B QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions used to Weld Test Coupon. Company Name

Date

Procedure Qualification Record No WPS No. \ Welding Process (es) Types (Manual, Automatic, Semi-Auto)

JOINTS (QW-402) Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filter metal or process used)

BASE METALS 9QW-403) Material Spec P.No Thickness of Test Coupon to P.No.

POSTWELD HEAT TREATMENT (QW-407) Temperature

GAS (QW-408) Percent Composition Gas (es) Flow Rate

(Mixture)

FILLER METALS (QW-404) SFA specification ELECTRICAL CHARACTERISTICS (QW-409) Current Amps. Tungsten Electrode Size Volts

POSITION (QW-405) Position of Groove

TECHNIQUE (QW-410) Travel Speed

PREHEAT (QW-406) Preheat Temp

QW-483 (Back) Tensile Test (QW-150)

Specimen No.

Width

Thickness

Area

Ultimate Total Load Ib

Ultimate Unit Load Psi

Type of Failure & Location

Guided-Band Tests (QW-160)

Toughness Tests (QW-170)

Specimen

Notch

Area

Test

Impact

Result_______Satisfactory: Yes Macro Results

No

Fillet-Weld Test (QW-180) Penetration into Parent Metal : Yes

No

Other Tests Type of Test Deposit analysis Other Clock No. Welder's Name Tests conducted by : _______________________________________ ________________________________________

______Stamp No.

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer

Date ______________________________________________________ By (Detail of record of tests are illustrative only and may be modified to confirm to the type and number of tests required by the Code.)

ANNEX -C
QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW-301, Section IX, ASME Boiler and Pressure Vessel Code Welder's name ________________________Clock number _______________________________Stamp no. ______

Welding process(es) used

_________________________________________Type__________________________ ______________________________

Identification of WPS followed by welder during welding of test coupon

Base material(s) welded_________________________________________________________________Thickness Manual or Semiautomatic Variables for Each process (QW-350) Backing (metal,weld metal, welded from both sides, flux, etc.) (QW-402) ASME P.No. ____________to ASME P.no. (QW-403) () Plate () Pipe (enter diameter, if pipe) Filler metal specification (SFA):___________Classification (QW-404) Filler metal F-no. Consumable insert for GTAW or PAW Weld deposit thickness for each welding process Welding position (1G, %G, etc.) (QW-405) progression (uphill/downhill) Backing gas for GTAW, PAW, or GMAW; fuel gas for OFW (QW-408) GMAW transfer mode (QW-409) GTAW welding current type/polarity Machine Welding Variables for the process Used (QW-360) Direct/remote visual control Automatic voltage control (GTAW) Automatic joint tracking Welding position (1G, 5G, etc.) Consumable insert Backing (metal, weld metal, welded from both sides, flux, etc) Guided Bend Test Results Guided Bend Test Type () QW-462.2 (Side) Results () QW-462.3 (a) (Trans. R&F) Type () QW-462.3(b) (Long, R&F) Result Actual Values _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ Actual Values _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ Range Qualified ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ Range Qualified ________________ ________________ ________________ ________________ ________________ ________________

Radiographic test results (QW-304 and QW-305) ____________________________________________________________________________________________________________________________ (For alternative qualification of groove welds by radiography) Fillet Weld in. Macro test fusion in. ____________Fracture test ______________________________Length and percent of defects _____________________________

________________________Fillet leg size

________________in.X ___________in. Concavity/convexity____________________

Welding test conducted by Mechanical tests conducted by

________________________________________________________ ________________________________________________________Laboratory test no.

____________________________________________________________________________________ We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Organization ______________________________________________________________________

Date ____________________________________ ANNEX-D

By

STRESS RELIEF/HEAT TREATMENT PROCEDURE SPECIFICATION Name of the project Name of the Heat Treater General Details Name of the Equipment: Name of the Assembly/Part Assembly/Part Drawing No. Material Thickness 3 Heat Treatment Cycle Details Charging Temp C Rate of heating C/Hr ____ ____ Specification Reference No. Other Details Type of Heating : Capacity (size) Maximum Temp.(C) Method of Temp. Measurement Atmosphere Control Elec.Res:/ Induction (Tick mark)

Soaking Temperature C_____ Soaking time, Hrs Rate of Cooling /Hr Mode of Cooling 4 Other details, if any 5 Hardness test A.S C.S ____ ____ ____

ANNEX-E

RADIOGRAPHIC TECHNIQUE LOG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 18 Location Date of Testing Name of the Contractor and welder Material: Carbon steel/Alloy Steel/Stainless Steel Diameter & Thickness Type of Weld Joint Radiation Source Source strength Screen Screen thickness Focus film distance Limit of Film coverage Film type and make Exposure Time Processing Density Sensitivity Penetrameter thickness (Source Side) Penetrameter thickness (Film slide) Shim thickness Signature of Contractor with seal

Approval of Inspector

WELDER'S IDENTIFICATION CARD

Name

Photograph

2 3 4 5 6 7 8 9 10 11

Identification Date of Testing Valid until Process Material Thickness Diameter F.No. Approval of welding Position

Approved by:

Employee's Signature with seal

ANNEX -G
LIST OF APPROVED ELECTRODES AND MANUFACTURERS

Accepted manufacturers of 6010, 7018 and 6013 electrodes are given below:Root - run - Philips (ESAB) 31 CS E6010

7016/7018
- Supercito - Advani Oerlikon

- Philips 36 H - ESAB
-Supertherm - D& H - Tenacito - Advani - Ferro Weld 2 - ESAB -Modi 7018-MODI

6013

- Overcord S, Oerlikon -Vordian Esab/IOL

TECHNICAL SPECIFICATION -ERECTION OF BURIED PIPING


TABLE OF CONTENTS 1.0.0 INTENT OF SPECIFICATION ................................................................................................................................................................ 3 2.0.0 CODES & STANDARDS ................................................................................................................................................................. 3 3.0.0 EXCAVATION FOR PIPE TRENCHES ................................................................................................................................................................. 3 4.0.0 LAYING OF UNDERGROUND PIPING ................................................................................................................................................................. 4 5.0.0 VENT AND DRAINING ................................................................................................................................................................. 5 6.0.0 RECORDS ................................................................................................................................................................. 6 7.0.0 BACKFILLING ................................................................................................................................................................. 6 8.0.0 CLEAN UP OF SURROUNDINGS ................................................................................................................................................................. 6 SECTION-2.3 TECHNICAL SPECIFICATION ERECTION OF BURIED PIPING 1.0.0 INTENT OF SPECIFICATION This specification covers the minimum requirements and guidelines to be adhered by the bidder for the erection of complete underground piping of LP piping which includes excavation, laying and backfilling of buried pipe. 2.0.0 CODES & STANDARDS Piping design, reinforcement of branch connection, materials, and fabrication Flanges: rating, facing, and drilling for 24 inches (609 mm) and smaller Flanges: rating, facing, and drilling for larger than 24 inches (609 mm) Pipe specification Field applied external coatings for underground piping Repair of damaged field applied coatings for underground piping Dimensional checks Steel structure painting council, (SP-I solvent cleaning and SP-10 near white blast cleaning). Recommended Practice, High Voltage Electrical Inspection of pipeline coating prior to Installation.

AWWA C200 and AWWA M11 ANSI B16.5, Class 150 or AWWA C207 Class B, D, or E as indicated in the specification AWWA C207, Class B, D or E as indicated in the specification AWWA C200 / IS 3589 / IS 1239 /ANSI B31.1 3.0.0 EXCAVATION FOR PIPE TRENCHES

AWWA C203/IS 10221 AWWA C209, Section 3.4 AWWA C200, C208 and other applicable AWWA standards SPC-SPI&SP10 NACE RP-02-74

3.1.0 The trench shall be cut true to the line leveled with the help of sight rails provided at every 30M, at change of direction, gradient and at any suitable distance as directed by the owner's project manager. 3.2.0 If the trench is excavated below the required level indicated in the drawing, the extra depth shall be filled with concrete or approved equivalent material as directed by the owner's project manager at no extra cost to Owner. 3.3.0 The trench shall be excavated so as to provide an average cover of 1000 mm or equal to the diameter of the largest pipe to be laid in the trench unless otherwise shown in drawings. The minimum average cover will be reckoned from top of the pipe of the largest diameter to be laid in the trench, to the finished grade. The width of the trench, shall be sufficient to give free working space on each side of the pipe. The free working space shall conform to IS: 783. Generally it shall not be less than 150 mm on either side or 1/3 of dia of pipe whichever is greater.

3.4.0

No excavated material shall be deposited within 1.5 meters from the excavated trench.

3.5.0 In case of road cutting, all material i.e. metal, bricks, etc. shall be taken out carefully and kept separately for reuse and road work shall be redone upto the original level prior to cutting the road with the excavated road materials after laying & testing of the pipeline within 10 days from the date of starting the work at the cost of the Bidder. The Bidder shall provide suitable signs and barricades to prevent accidents. He shall also provide reasonable by pass at his own cost when a road is cut for laying pipeline. The dykes etc. affected due to laying of the pipes, shall be redone conforming to the original specifications by the Bidder at his own cost. 3.6.0 During excavation if some obstacle is met with, same shall be reported to the owner's project manager and dealt with as instructed by him. 3.7.0 The Bidder shall dewater, shore or do whatever might be required to excavate the trench, install the pipe in it and backfill the trench, in accordance with the specifications at no extra cost to the Owner. Dewatering shall be done in advance of the laying of the pipe to allow adequate inspection of padding of the bottom if required and dewatering shall be continued throughout during laying of the pipe and backfilling of the trench. 3.8.0 In muddy/slushy ground, the bed shall be provided with a layer of a sand or lean concrete as directed by the owner's project manager. 3.9.0 The trench shall follow the gradient of pipeline as specified in the drawing. The Bidder shall keep the trench in good condition, until the pipe is laid and tested. No extra claim shall be entertained due to its caving or setting down either before or after the pipe is laid. All materials to shore the trench in order to prevent caving are to be furnished and removed by the Bidder at no extra cost to the Owner. 3.10.0 In case pipe is lowered in caved trench and back-filled before being inspected by the owner's project manager, the Bidder shall re-excavate the trench for inspection and backfill it at his own cost. 4.0.0 4.1.0 LAYING OF UNDERGROUND PIPING General After prefabrication, coating and wrapping and trenching the Tenderer shall lay the underground piping in accordance with the following clauses and as per the approved piping arrangement drawings. The Tenderer shall be responsible for correct layout and gradient of the line. Errors, if any, shall be rectified by the Tenderer at his own cost. 4.2.0 Lowering & Laying The pipes shall be lowered either by mechanical methods or by hand when the trench is ready and bottom of the trench is graded as per required pipe laying conditions and specifications. 4.2.1 By machine The shop coated pipe, already transported to the pipe laying site/convenient length of pipe assembly coated and wrapped near the trench after hydrostatic testing shall be placed on clean square cut skids suitably spaced so as to keep the pipe away from touching the ground. The pipe may be lowered down in the trench by the launcher cranes, with sufficient care to protect the coating and wrapping of the pipeline. Bare cables, chains hooks etc. shall not be permitted to come in contact with the coating. At tie in welds and other places, the Tenderer shall clean, prime, coat and wrap manually. Also short sections of pipelines which are impracticable to shop treat may be hand treated but only on the prior written approval of the Engineer-in-charge. 4.2.2 By Hand The pipe may be lowered with the help of tripods and chain pulleys blocks into the trench immediately after the coating and wrapping. However if in the opinion of the Engineer-incharge that the temperature condition do not allow direct lowering, then the pipe shall be set down on clean square cut skids. The skids shall be so spaced as to keep the pipe away from touching the ground. 4.3.0 4.3.1 Method & Time of lowering pipe Under favorable temperature, conditions and using methods which will not damage coating the pipe may be lowered into the trench.

4.2.0

Pipe previously set on skids, because of unfavorable temperature conditions shall be lowered into the trench normally in the cool of the morning and only when the temperature of the pipe is below the softening point of the coating materials. All skid marks and other places of damages shall be thoroughly examined to ensure proper patching where necessary, before the pipe is finally lowered into the trench. Handling of Coated Pipes Coated pipes shall not be placed in trench until cave in plugs, hard clods, stones, skids, welding rods etc. have been removed there from. Where the trench has a hard or jagged bottom sufficient fine dirt or sand shall be placed therein, before the pipe is lowered. Coated pipe shall not be handled or moved by means of cable or chains or by prying with skids or bars. It shall be tied and lowered by using lowering in belts of a standard width and designs for the size of pipe being handled. Coated pipe shall not be dragged along the ground or otherwise handled in a manner that will be detrimental to the coating. Lining up & Welding The ends of the pipe line shall be kept securely closed to prevent entry of any foreign material/ moisture after lowering into the trench. Before making joints the pipe shall be carefully laid so as to be perfectly aligned in both plan and profile and the end closures provided shall be removed. Tie-in shall be made in the coolness of the morning or when the ambient temperature is not exceeding 29C or softening temperature of the coating material whichever is less. All beveling, aligning and welding shall be in accordance with the welding specifications. Free access shall be provided for the welding of the circumferential joints by increasing the width and depth of the trench at these points. There should be no obstruction to the welder from any side so that a good welded joint is obtained. VENT AND DRAINING

4.3.0

4.4.0 4.4.1

4.4.2

4.4.3

4.5.0 4.5.1 4.5.2 4.5.3

4.5.4

5.0.0

5.1.0 All lines and equipment shall be completely drained after the hydrostatic test of a system has been completed. High point vents shall be open to prevent excessive vacuum and permit complete draining. 5.2.0 If it becomes necessary to leave a system filled with the testing medium from any abnormal length of time, suitable arrangement such as venting shall be made to provide for possible liquid expansion with change in ambient temperature. 6.0.0 RECORDS

6.1.0 Records in triplicate shall be made by the Tenderer for each piping system as follows: 6.2.0 In case of underground piping, layouts giving actual elevations of pipeline as laid.

6.3.0 Test certificates containing date of test, identification of the piping system, date of flushing & approval by Purchaser's Inspector. 7.0.0 BACKFILLING

7.1.0 Aftertesting and inspection of the pipeline to the entire satisfaction of the Engineer-in-charge, the trench shall be backfilled with the same material as the pipe bed above the top of the pipe. No trench shall be backfilled without the approval of Engineer-in-charge. 7.2.0 Backfilling with the excavated material shall be done in layers of 100 mm, well watered and rammed to avoid any settling afterwards. 7.3.0 The Tenderer shall place soil over the trench to such a height as to provide adequately for future settlement of the trench backfill. If due to exigencies of the work, some portion of the pipeline is backfilled without approval of the Engineer-in-charge, the Engineer-in-charge shall have the right to order uncovering of the pipe for examination and the cost of such uncovering shall be borne by the Tenderer.

7.4.0

The backfill material shall be free from stone pieces.

7.5.0 Surplus excavated soil or rubbish material shall be removed by the Tenderer at his own cost to a place designated by the Engineer-in-charge. 7.6.0 When the trench has been dug through roads all backfill shall be thoroughly compacted. In certain cases, special compaction methods may be required by the Engineer-in-charge. This shall be done by the Tenderer at no extra cost to the Purchaser. 7.7.0 When the trench has been dug through unlined ditches the backfill shall be thoroughly compacted in 150 mm layers for a distance of 1.50 m beyond the outside banks of the ditch on either side. The banks of the ditch shall also be compacted in 150 mm layers at no extra cost to the Purchaser. 7.8.0 After the roads have been already graded, if they are trenched or otherwise disturbed by the Tenderer during laying of the pipelines. The Tenderer shall restore the road to its original level and condition. In the event, the Tenderer is required to place extra fill, gravel, or other special material it shall be borne by him without any extra cost to the Purchaser. 8.0.0 CLEAN UP OF SURROUNDINGS As soon as the backfill is completed, the Tenderer shall immediately clean up the adjoining area by removing all surplus and defective material and dispose of all refuse such as spurs, sheet iron, broken skids etc. to the complete satisfaction of the Engineer-in-charge. Exclusions: CIVIL: 1. Excavation and backfilling. 2. Valve and drain pits. 3. PCC, RCC, supports for buried pipes.

SECTION - 2.4 TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE


TABLE OF CONTENTS 1.0.0 2.0.0 3.0.0 4.0.0 GENERAL.........................................................................................................................3 CODES AND STANDARDS...............................................................................................3 LINE CHECKS BEFORE PRESSURE TEST......................................................................3 TESTING...........................................................................................................................4 S E CT I O N - 2 .4 TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE 1.0.0 GENERAL This specification covers the general requirements related to the hydrotesting of LP piping system. 2.0.0 2.1.0 3.0.0 3.1.0 CODES AND STANDARDS The Hydrotest of piping, valves and specialties comply with the requirements of latest edition the ANSI / Indian Standard or relevant standards. LINE CHECKS BEFORE PRESSURE TEST General After completion of the fabrication and installation works and prior to pressure test, line checks shall be carried out for all works to ensure that the works have been performed properly and that the quality of work is adequate. 3.2.0 Check Points

This shall include the following confirmation of overall and individual workmanship, but not be limited to these items: a) Lines and components i) ii) iii) iv) v) vi) vii) viii) ix) x) Piping layout is in accordance with the applicable drawings including P&I diagrams. Size, dimension, rating and material specification are in accordance with the applicable drawings. Bend, tee, reducer and other fittings are in accordance with the applicable drawings. Drain, vent, thermal expansion, header and other components are in accordance with applicable drawings. Valve, flange, blind, etc. are in accordance with applicable drawings and flange connection is properly made with correct use of bolts and gaskets. Orientation and direction of piping components are in compliance with piping drawings. Tightness and projection of flange bolts are adequate. Thread connections are not damaged and free from weld spatter, slag etc. All shipping and erection stoppers, welding jigs and temporary support attachments are removed. Welding quality and other workmanship complies with the applicable specifications.

xi) Applicable examination or inspection and the heat treatment (if applicable) has been satisfactorily completed and accepted. xii) Piping (including all components and attachments) is sufficiently cleaned, xiii) Slope is maintained as indicated in relevant drawings, b) Pipe Supports i) All pipe supports such as anchors, guided restraints, bands, hangers, etc. are to permit free expansion and contraction of piping in the specified direction and are assembled as indicated on support drawings. ii) Spring supports are to be properly set in cold position with setting pins.

iii) Enough and adequate temporary supports are to be provided wherever necessary to keep the piping stable. iv) Supports, guides and anchors for piping shall be fabricated and provided as shown in the drawings. No anchors on piping shall be used except at locations shown in the drawings. The pipe shall be secured firmly at anchor supports. v) Fabrication and erection of supporting elements and structural fixtures wherever required and pointed out by the Engineer-in-charge, whether indicated in drawing or not to prevent vibrations, excess sag etc. shall be carried out by the Contractor. vi) Spring hangers shall be erected with springs locked in cold set position. The tie rods shall be selected that the pipe center line with slope can be maintained in cold position. The springs shall be released after hydrotesting and before passing steam. When the hanger are released they shall be checked for cold set values and if there is any disturbance, the series of hangers nearby shall be adjusted using the turn buckle to activate the cold set load in all hangers. 4.0.0 4.1.0 4.1.1 4.1.2 TESTING General All pipes shall be tested for leakage to a hydrostatic test pressure of 1.5 times the design pressure. The testing shall be carried out in convenient sections as approved by Owner/Owner's Engineer.

4.1.3

If some defect is noticed during the hydrostatic testing, the same shall be brought to the notice of Owner/Owner's Engineer. Joints, if leaking shall be rectified as per welding specifications and instructions of Owner/Owner's Engineer at no extra cost. If leakage is on the threaded joints, necessary inert chemical bonding material shall be applied to arrest the leak. The Owner /Owner's Engineer shall be notified in advance by Contractor of all testing. The hydrostatic testing / flushing of all piping shall be carried out by the Contractor at his own cost. Contractor shall make his own arrangements for flushing at suitable points as per the instructions of the Owner /Owner's Engineer. Any extra work / modification on this account shall be done by the Contractor at his own cost. Test Medium Soft water shall generally be used as the testing medium for the hydrostatic testing of piping system. In situation where water cannot be used air is used as a testing medium. Air testing shall be carried as per ASME B31.1 or relevant Indian standard. Cleaning All systems shall be cleaned and flushed free of all dirt, debris and loose foreign material after testing Flushing and Pressure Test a) The piping system shall be sufficiently flushed with the pressure test medium in the presence of Owner/Owner's Engineer. b) Care shall be taken during flushing that no foreign material can enter into equipment which is connected to the test section. c) After flushing and testing, water shall be drawn off by opening all drain valves and vents. The piping system shall be dried internally to the satisfaction of the Owner /Owner's Engineer.

4.1.4 4.1.5

4.2.0 4.2.1 4.2.2

4.3.0 4.3.1 4.3.2

4.4.0 4.4.1

Temporary Blinds Open ends of piping systems such as at pumps or wherever equipment has been removed or disconnected prior to hydrostatic testing or at termination point of piping branch connections shall be blinded off by temporary blind flange made our of M.S. plate of suitable thickness. Venting All piping system and equipment shall be properly vented to remove air from the system during filling. Pressurizing Pressure shall be applied by means of a suitable test pump which shall not be connected to the system until it is ready to test. A pressure gauge shall be provided at the pump discharge for guidance in bringing the system upto pressure. The pump shall be attended to constantly during the test by authorized operator. The pump shall be disconnected immediately after the test pressure is reached. The test pressure is to be maintained for sufficient time to permit complete inspection of the system under test. Test shall be considered complete only when approval is given by Owner / Owner's Engineer.

4.5.0 4.5.1

4.6.0 4.6.1

4.7.0 4.7.1

Test Gauges Contractor's own gauge shall be installed as close as possible to the lowest point in the system being tested. Calibration of test gauges shall be the responsibility of the Contractor.

SECTION - 2.5

TECHNICAL SPECIFICATION -LP PIPING FLUSHING AND CLEANING PROCEDURE


TABLE OF CONTENTS 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 INTENT OF SPECIFICATIONS..............................................................................................3 CODES AND STANDARDS...................................................................................................3 INSPECTION.........................................................................................................................3 CLEANING METHODS..........................................................................................................3 FLUSHING.............................................................................................................................5 SECTION - 2.5 TECHNICAL SPECIFICATION -LP PIPING FLUSHING AND CLEANING PROCEDURE 1.0.0 INTENT OF SPECIFICATIONS This specification covers the general requirements for inspection, cleaning & flushing of piping, valves and specialties for LP piping system. 2.0.0 CODES AND STANDARDS The following codes and standards shall be followed for the work covered by this contract in addition to the detailed specifications of the contract. Swedish standard Institution - SIS-05 5900-1967 (Surface preparation standards for painting steel surfaces). Steel structures (SSPC-SP). painting council, U.S.A. (Surface Preparation Specifications

British Standards Institution (Surface Finish of Blast cleaned steel for painting) BS-4232. National Association of Corrosion Engineers, U.S.A. (NACE). IS:1477-1971 (Part - I) - code of practice for painting of Ferrous metals in buildings (Part 1, pre-treatment). Various international standards equivalent to Swedish standard for surface preparation are given in Table-1. ASME B31.1 - power piping

The Contractor shall arrange, at his own cost, to keep a set of latest edition of the above standards and codes at site. 3.0.0 INSPECTION During various stages and after completion of fabrication and erection, the piping system shall be inspected by the Engineer-in-charge to ensure that : 4.0.0 4.1.0 Proper piping material has been used. Piping has been erected as per drawings and instructions of Engineer-in-charge. All supports have been installed correctly. Test preparations mentioned in this specification have been carried out.

CLEANING METHODS General The Piping components shall be mechanically and /or chemically cleaned during the following stages of the Contract. Cleaning in workshop Cleaning before painting and/or corrosion protection (application of prime coat)

Cleaning before erection and after installation.

Cleaning of fabricated component items shall be carried out after fabrication and final heat treatment or welding at manufacturer's works or at site, as appropriate. For cleaning in workshop and before painting mechanical cleaning as opposed to alternative chemical cleaning is the preferred method for works cleaning except where this is precluded by design or access considerations. Machined surfaces shall be protected during the cleaning operations. In the event of the surfaces not being cleaned to the purchaser's satisfaction, such parts of the cleaning procedures or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the contractor sole expense. For recleaning small areas, hand cleaning by wire brushing by puffing method may be permitted. Wire brushes of austenitic steel bristles shall only be used. Austenitic stainless steels, copper and aluminium alloys, cast iron, bimetallic and metallic/plastic items, and components fabricated by spot welding or riveting shall not be chemically cleaned. All weld areas shall be suitably stress relieved before chemical cleaning. 1Any cleaning work on piping shall be commenced only when erection activities are completed in all aspects and after the system tests have been completed and clearance for taking up painting work is given by the Engineer, who may, however, at his discretion authorise in writing, the taking up of surface preparation or painting work in any specific location, even prior to completion of system test. All tools, brushes, rollers, spray guns, blast material, tarpaulin sheets for covering the areas to be sandblasted ,hand power tools for cleaning and all equipment shall be arranged by the Contractor at the site in sufficient quantity at his own cost. 4.2.0 Mechanical Cleaning Mechanical cleaning shall preferably be carried out by abrasive blasting. The Purchaser is prepared to consider alternative methods provided they achieve the necessary surface condition. 4.3.0 Surface condition The Metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any other deleterious matter. Where metal surfaces are to be painted the surface profiles shall conform with the painting specification requirements. Where this does not apply surfaces shall have a surface texture not coarser than Grade 80 abrasive paper. 4.4.0 Abrasives Abrasives containing silica, silicates or slag residues shall not be used for water/steam side surfaces of plant except for cleaning sand castings, where hydro blasting with sand may be used. For austenitic materials only, abrasives containing 98% or more of aluminia, Al2 O3, shall be used. 4.5.0 Removal of abrasive and debris After cleaning, abrasive and debris shall be thoroughly removed from components. 4.6.0 Alternative Chemical Cleaning The procedure shall comprise both pretreatment and acidic treatment and preservation of the system applicable only for fuel oil system. 5.0.0 FLUSHING Flushing of all lines shall be done before pressure testing. Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign material.

Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure for air flushing the line / system will be pressurised by compressed air at the required pressure which shall be 50 psi maximum. The pressure shall then be released by quick opening of a valve, already in line or installed temporarily for this purpose. This procedure shall be repeated as many times as required till inside of the pipe is fully cleaned. In line instruments like control valves, orifice plates, rotometers, safety valves and other instruments like thermowells which may interfere with flushing instrument shall not be included in flushing circuit. From oil permanent strainers the screens / meshes shall be removed before flushing. Screen / meshes shall be reinstalled after flushing but before testing. During flushing temporary strainers shall be retained. These shall be removed, cleaned and reinstalled after flushing but before testing. In case on equipment such as column, vessel, exchanger etc. forms part of a piping circuit during flushing, this shall be done with the approval of Engineer-in-charge. However equipments thus included in the circuit, shall be completely drained and dried with compressed air, after flushing is completed. During flushing discharge of water / air shall be drained to the place directed by the Engineerin-charge. If necessary, proper temporary drainage shall be provided by the contractor. Care shall be taken during flushing so as not to damage / spoil work of other agencies. Precautions shall also be taken to prevent entry of water / foreign matter into equipments, electric motors, instruments electrical installations etc. in the vicinity of lines being flushed. The contractor shall carry out all the activities required before, during and after the flushing operation, arising because of flushing requirements, such as but not limited to the following: Dropping of valves, specials distance pieces, inline instruments and any other piping part before flushing. The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-in-charge. These flanges shall be provided with temporary gaskets at the time of flushing. After flushing is completed and approved the valve distance pieces, piping specials etc. shall be reinstalled by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where isolation is required during testing only temporary gaskets shall be provided. Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing done in standard format. Contractor shall submit procedure for flushing and cleaning in detail based on the above for Engineer's approval.

SECTION-2.6 TECHNICAL SPECIFICATION -WRAPPING & COATING OF BURIED PIPING


TABLE OF CONTENTS 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 INTENT OF SPECIFICATIONS..................................................................................3 CODES AND STANDARDS.......................................................................................3 COATING THICKNESS..............................................................................................3 TECHNICAL REQUIREMENT....................................................................................3 PROCEDURE FOR COATING AND WRAPPING.......................................................4 EXTENT OF APPLICATION.......................................................................................5 INSPECTION..............................................................................................................5 REFERENCE DOCUMENT.........................................................................................6 BOQ FOR COATING AND WRAPPING OF BURIED PIPELINES..............................6 SECTION-2.6

1.0.0

TECHNICAL SPECIFICATION - WRAPPING & COATING OF BURIED PIPING INTENT OF SPECIFICATIONS This specification covers the procedure for coating and wrapping of corrosion protection coating for buried pipes and fittings using polymeric protection prefabricated tape including, inspection and testing.

2.0.0

CODES AND STANDARDS a) b) c) d) AWWA C-203-91 AWWA standard for coal tar protective coatings and linings for steel water pipe lines enamels and Tape-Hot applied. SSPC-SPI & SP 10 Steel structure painting council, (SP-I solvent cleaning and SP-10 near white blast cleaning). NACE RP-02-74 Recommended Practice, High Voltage Electrical Inspection of pipeline coating prior to Installation. IS 10221 Code of practice for coating and wrapping of underground mild steel pipelines.

3.0.0

COATING THICKNESS The polymeric tape thickness is 2 mm and two layers shall be provided over the buried pipe.

4.0.0 TECHNICAL REQUIREMENT 4.1.0 General The coating and wrapping of pipes shall be from a polymeric corrosion protective tape with mix of coaltar, rubber & other polymers. 2 mm thick tape is used and two layers of 2mm thick are to be applied one over the above on the pipes. The sequence of coating and wrapping of pipes shall consist of following operations. i) Surface Preparation

ii) Application of First Layer of Primer iii) Application of first Layer of Membrane tape iv) Application of Second Layer of Primer v) Application of Second Layer of Membrane tape vi) Tape Coating of Field Joints All appurtenances and equipment to be used for cleaning, priming, coating and wrapping and testing shall be approved by the Engineer-in-charge. 4.2.0 Materials The materials required for application of anticorrosive polymeric tape are as below, a. Wire Brush to remove all foreign debris b.Coat of fibre, coal tar and solvent based primer of density 0.92 gms/cm3 and viscosity of 1000-2000 cps. @ 150 gms/sqm (Primer) recommended by tape manufacturer. c.Anticorrosive multilayered polymeric tape of 4 mm or 2 mm thick. Application should be with recommended over laps and in accordance with manufacturer's specification. d. The material shall confirm to ASTM / DIN codes. 5.0.0 PROCEDURE FOR COATING AND WRAPPING 5.1.0 Surface Preparation If the pipe surface is free from oil and grease then wire brush shall used to remove all foreign debris otherwise, all oil and grease on the pipe metal surface shall be thoroughly removed by flushing with a suitable solvent (such as xylene or 1,2,2 trichlorethane) and wiped with clean rags. The solvent cleaning shall be as per SSPC-SP-1. The degreased pipe metal surface shall be wire brushed / power brushed. The pipe surface after cleaning by wire brush shall be cleaned with dry cloth thoured. After being cleaned the pipe shall be protected from and be maintained free of oil, grease and dirt that might fall on the pipe before it has received its final coat. Preferably priming shall be done within four hours of completion of wire brushing. 5.2.0 Application of First Layer of Primer

Primer is to be applied on pipes immediately after cleaning. Primer is a cold applied primer and is applied by brush @ minimum 150 gms/sqm. After application, it is allowed to dry until the surface becomes tacky. This primer is applied so as to produce effective bond between metal and pipe coating membrane tape prior to application, primer shall be stirred in drums so that it is mixed properly. After application the primer coat shall be uniform and free from floods, runs, sags, drips, or bare spots. Any bare spots shall be recoated with an additional application of primer. All runs, sags, or drips shall be removed by scraping and cleaning, and the cleaned area shall be retouched or remedied by reblasting and repriming. Suitable measures shall be taken to protect the wet primed pipe from contact with rain, fog, mist, spray, dust or other foreign matter until tape is applied. The minimum and maximum drying times of the primer or the period of between application of primer and application of membrane tape shall be in accordance with instructions issued by the manufacturer. The cleaning and priming operation may be carried out in the Bidder's workshop or on site. The entire pipe length shall be cleaned but the ends of the pipes shall be left without coating and wrapping for a distance of 150 to 200 mm for joints, which shall be coated and wrapped manually on site after laying, field welding and testing the pipes. 5.3.0 Application of first Layer of Membrane tape (used for 2 mm thick tape application) After the surface is primed, membrane tape is applied over the pipe in spiral fashion under slight tension by thermofusion process. A LPG torch or other heat source is applied onto the inner face of the membrane tape till the polymeric mix attains a shiny appearance and tape compound is softened. The membrane tape is then adhered to the primed coated surface. Overlaps are maintained as per specifications with a minimum of 15 to 20 mm. The overlaps are doubly sealed by thermofusion on the exterior for additional security. 5.4.0 Application of Second Layer of Primer The second layer of primer is applied over the first layer of tape by brushing or spraying @ minimum 150 gms/sqm. The primer is allowed to dry for 15 minutes before commencement of application of second layer of tape. 5.5.0 Application of Second Layer of Membrane Tape (used for 2 mm thick tape application) Second layer of membrane tape is wound over the wet second layer of primer. This is a cold process, which does not involve thermofusing. Care is taken that the overlap of the second layer does not coincide with the overlap of the first layer. Once again overlaps are maintained at minimum 15 mm. However, overlaps are double sealed by thermofusion as for the first layer. 5.6.0 Tape Coating of Field Joints (common for all thickness of tape) Incase of site coated pipes the welded joints shall be coated. Primer shall be applied with brushes after cleaning the pipe thoroughly. The primer and tape coating materials shall be the same as used for yard coating the pipe. The welded field joints and uncoated areas shall be cleaned and dried in accordance with the procedure indicated above. Primer shall be applied on the clean area. Primer shall be applied on adjacent tape coating also. Over the primed surface tape shall be applied in accordance with above section. Tapes shall overlap the coating on each side of the field joint to form a continuous external coating free of defects. Overlaps on each side of the weld joints shall be 50 mm. No wrinkling in the wrapper shall be allowed. If coating and wrapping is found unsatisfactory to the Engineer-in-charge the same area shall be recoated and wrapped with above procedures. 6.0.0 EXTENT OF APPLICATION All buried piping of water and utility service shall be applied with above type of coating & wrapping method. Whenever buried pipe extents above the ground the coating of tape shall be applied as a minimum length of 500 mm above ground level. 7.0.0 INSPECTION 7.1.0 General

Contractor shall test the coating and any repair subsequently made to it. The testing shall be carried out prior to laying of pipes in the trench. 7.2.0 Holiday Detection i) All coated and wrapped pipes shall be subjected to a test with an electric holiday detector as specified in AWWA-C-203-91. ii) The holiday detector shall be supplied, correctly operated and always maintained in good working condition along with adequate supply of spare parts. Any delay caused by the incorrect functioning of the holiday detector will not be entertained. iii) The operating voltage of the detector shall be determined by NACE RP-02-74. iv) Any pipe having three (3) or more holidays shall be rejected. Similarly any pipe having any one holiday bigger than 0.1 square metre shall be rejected. Any defective places shall be plainly marked with chalk immediately after they are detected visually or by the holiday detector. v) For pipe with pre-fabricated tape, the test voltage which the pipe should pass with holiday detector kit at voltage 15 kV for 4 mm thickness coating. 7.3.0 Measuring coating thickness i) All pipes shall be tested for thickness as per AWWA-C-203-91.

ii) The thickness shall be measured by pushing the point of an approved pit depth gauge or microtester through the coating and wrappers. iii) The specified minimum thickness shall be present both at the pipe or any other point. 7.4.0 Testing and adhesion of the coating i) Atleast two tests a day shall be carried out on finished coating after 12 hours from completion of coating. The test shall be carried out as per AWWA-C-203-91 Sec.7.8 / IS 10221 Section B-3.3.1 / 3.3.3/3.3.3. ii) The areas where the coating has been removed for testing by the inspector shall be repaired by the CONTRACTOR at his own expense. 8.0.0 REFERENCE DOCUMENT For material of construction, handling and storage of coated pipes, lowering of pipes, trenching & backfilling refer Section - 2.3 Technical specifications - Erection of Buried piping. 9.0.0 BOQ FOR COATING AND WRAPPING OF BURIED PIPELINES Material: Anticorrosive 2 layered polymeric tape with primer required for the following length of pipe to be coated & wrapped. Pipe Size( NB) Buried Pipe Length (m)

Note: Pipe Size and Buried pipe length details will be provided during details engineering.

SECTION - 3 LIST OF TENDER DRAWINGS


SECTION - 3 LIST OF TENDER DRAWINGS
Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Drawing No. DP-00CE-01-003 DP-00SC-22-074 DP-00SC-22-074 DP-00GC-22-075 DP-00GH-22-072 DP-00PA-22-071 DP-00GH-22-073 DP-00GH-22-077 DP-00UE-01-002 DP-00GH-35-166 DP-00GB-35-167 DP-00GC-35-168 DP-00PA-35-169 DP-00GH-35-170 DP-00MM-35-171 DP-00GC-35-172 DP-00PA-35-173 DP-00GB-35-174 DP-00SC-35-176 Symbols& Legends P&ID for Instrument Air Distribution System P&ID for Service Air Distribution System P&ID for DM Feed Water System P&ID for Plant Water System P&ID for CW and ACW System P&ID for Potable Water Distribution System P&ID for Service Water Distribution System Plot Plan Piping Layout - Raw Water Pump House Area Piping Layout - Clarified Water Pump House Area (Will be submitted later) Piping Layout - DM Water System (Will be submitted later) Piping Layout - CW Make up Water System Piping Layout - Service & Potable Water System (Will be submitted later) Piping Layout - Service & Instrument air system( Will be submitted later) Piping Layout - DM Make up & Condensate System (Will be submitted later) Piping Layout - CW blow down system Piping Layout - Effluent collection to ETP (Will be submitted later) Piping Layout- Main Plant Air Compressor & Closed Cycle Cooling Water System (Will be submitted later) Piping Layout - Pipe rack Isometric - Raw water system (Will be submitted later) Isometric - DM water system (Will be submitted later) Isometric - CW makeup system (Will be submitted later) Isometric - CW blowdown system (Will be submitted later) Isometric - Service water system ( Will be submitted later) Isometric - Potable water system ( Will be Title

20 21 22 23 24 25 26

DP-00BQ-35-179 DP-00GH-31-190 DP-00GC-31-191 DP-00PA-31-192 DP-00PA-31-193 DP-00GH-31-194 DP-00GK-31-195

Sl.No. 27 28 29 30 31 NOTE:

Drawing No. submitted later) DP-00MM-31-196 DP-00MM-31-197 DP-00GH-31-198 DP-00GB-31-199 DP-197-39-210

Title Isometric - Instrument air system ( Will be submitted later) Isometric - Service Air system ( Will be submitted later) Isometric - Plant Water System submitted later) ( Will be

Isometric - Effluent collection system ( Will be submitted later) Piping support - Typical pipe supports (Will be submitted later)

The above list of drawings is tentative and indicative only. Final drawings will be furnished progressively to the bidder after the award of the contract.

SECTION - 4 TECHNICAL DATA SHEETS & SCHEDULES


TABLE OF CONTENTS SCHEDULE 4.1
SCHEDULE 4.2 SCHEDULE 4.3 SCHEDULE 4.4 SCHEDULE 4.5 SCHEDULE 4.6 SCHEDULE 4.7 SCHEDULE 4.8 SCHEDULE 4.9 SCHEDULE 4.10 TECHNICAL DATA SHEET FOR LP PIPING - FABRICATION, ERECTION& COMMISSIONING.............................................................3 ERECTION/COMMISSIONING................................................................4 DEVIATION SCHEDULE - TECHNICAL...................................................5 DEVIATION SCHEDULE-COMMERCIAL..............................................6 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS....7 CONCURRENT COMMITMENTS OF THE BIDDER................................8 SCHEDULE OF SUB-CONTRACTOR......................................................9 PROPOSED SITE MANPOWER DEPLOYMENT...................................10 QUALITY ASSURANCE PLAN...............................................................11 UTILITY CONSUMPTION LIST..............................................................12 SECTION 4 TECHNICAL DATA SHEETS & SCHEDULES [Duly filled in by the Bidder] SCHEDULE 4.1 TECHNICAL DATA SHEET FOR LP PIPING FABRICATION, ERECTION & COMMISSIONING Bidder shall submit a detailed Technical data sheet for the following. 1. 2. 3. 4. 5. 6. Receipt of material from site stores, Handling at site. Fabrication of piping & fittings (above 300NB / the plate will be free issued by owner). Fabrication of Supports (structural material only by owner). Hume pipes / Encasement for Buried line. Wrapping and Coating for Buried piping. Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Site Supervision, Calibration and Commissioning at site for LP piping, valves, specialties and supports etc. SCHEDULE 4.2 ERECTION/COMMISSIONING We hereby confirm the completion schedule for the various milestone activities indicated below: Sl.No
1.0 2.0 3.0

Description Establishment of site office Mobilisation of site staff Delivery of Material at site from store (Completion)

Completion schedule from date of LOI in (months)

4.0

Fabrication of Pipes, Fittings and Flange etc. Piping erection (Completion) Testing Trial operation Commissioning / Performance Test and handing over

5.0 6.0 7.0 8.0

Note:

Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.
SIGNATURE OF BIDDER NAME ______

COMPANY SEAL

DESIGNATION_ DATE

SCHEDULE 4.3 DEVIATION SCHEDULE -TECHNICAL Sl.No. Tender References Cl.No./Page No./ Description as Section No. / specified Volume No. Deviation Taken Reasons for deviation taken

We confirm that above are the only deviations from the bid document. Notes: 1. 2. Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. Deviations to tender documents, if any, shall be indicated only in this schedule.

3.

Deviations listed elsewhere will be summarily rejected and shall be ignored.


SIGNATURE OF BIDDER NAME ______

COMPANY SEAL

DESIGNATION_ DATE

SCHEDULE 4.4 DEVIATION SCHEDULE COMMERCIAL Sl.No. Tender References Cl.No./Page No./ Description as specified Section No. / Volume No. Deviation Taken

We confirm that above are the only deviations from the bid document. Notes: 1. 2. 3. Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. Deviations to tender documents, if any, shall be indicated only in this schedule. Deviations listed elsewhere will be summarily rejected and shall be ignored.
SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.5 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS
Sl. No Full postal address of client & name of Officer-in-charge with Telex/Tel.No./ Fax No. 2 Description of the work (shall indicate parameters & major scope) Value of contract Date of commen Cement of work Schedule Completion Period Actual completion period Reasons for delay, if any Operating Hours Logged

Certified that documentary proof for above information is enclosed. Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.
SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.6 CONCURRENT COMMITMENTS OF THE BIDDER Sl. No Full postal address Description of Value of of client & name of the work (shall contract Officer-in-charge indicate with Telex/Tel.No./ parameters & Fax No. major scope)
2 3 4

Completion Time as stated in order

Date of % Expected commen- completion date of cement of as on date completion work

Certified that documentary proof for above information is enclosed. Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.
SIGNATURE OF BIDDER NAME COMPANY SEAL ______

DESIGNATION_ DATE

SCHEDULE 4.7 SCHEDULE OF SUB-CONTRACTOR Sl. No Equipment/ Item Sub-Vendor/SubContractor Place Experience Details

Note:

This statement shall be furnished section wise separately for each volume of the bid specification.
SIGNATURE OF BIDDER

NAME COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.8 PROPOSED SITE MANPOWER DEPLOYMENT The Bidder shall also indicate here in proposed site organisation for timely execution of work. It is understood that this will be augmented from time to time depending on the requirements for timely completion of work, as directed by the Engineer. Sl. No Designation of Personnel Qualification & Experience of Personnel No. of Personnel Remarks

Note:

Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.
SIGNATURE OF BIDDER NAME

COMPANY SEAL

DESIGNATION_ DATE _______

SCHEDULE 4.9 QUALITY ASSURANCE PLAN


SL. NO. COMPONENT CHARACTERISTIC CHECKED CLASSIFICATION TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENTS ACCEPTANCE NORM FORMAT OF RECORD
P 1 2 3 4 5 6 7 8 9

INSPECTION BY

REMARKS

W 10

V 11

LEGENDS : P-PERFORMANCE, W-WITNESS, V-VERIFY. SIGNATURE OF BIDDER COMPANY SEAL NAME DESIGNATION_ DATE SCHEDULE 4.10 UTILITY CONSUMPTION LIST
ITEM NO. No. Equipme Mode (KW) (NM 3/HR) (M3/HR)

kg/cm2 (g)
C I C I C I C

kg/cm2 (g)
I

Any items are not covered in the above table, Bidder shall include and give their details. C - Continuous I Intermittent SIGNATURE OF BIDDER COMPANY SEAL NAME DESIGNATION_ DATE

SECTION - 5 PRICE SCHEDULES (TO BE FILLED AND SUBMITTED BY THE BIDDER WITH OFFER)
TABLE OF CONTENTS SCHEDULE-5.1 SUMMARY OF PRICE PROPOSAL FABRICATION,

ERECTION, TESTING & COMMISSIONING.........................................3 SCHEDULE- 5.2 SCHEDULE OF PRICE FOR FABRICATION, ERECTION AND COMMISSIONING..................................................................................4 SCHEDULE - 5.3 PRICE BREAK-UP FOR SPECIAL TOOLS & TACKLES........................5 SECTION-5 PRICE SCHEDULES SCHEDULE-5.1 SUMMARY OF PRICE PROPOSAL - FABRICATION, ERECTION, TESTING & COMMISSIONING Details 1.0 Erection & Commissioning: Total lumpsum price towards 1. Receipt of material from site stores, Handling at site. 2. Fabrication of piping & fittings (above 300NB / The plate material will be free issued by owner). 3. Fabrication of Supports (structural material only by owner). 4. Hume pipe for buried line. 5. Wrapping and Coating for Buried piping. 6. Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Site Supervision, Calibration and Commissioning at site for LP piping, valves, specialties and supports etc. as detailed in the scope of work (as per Schedule 5.2 inclusive of all taxes and duties). Rs. in lakhs

TOTAL PRICE COMPANY SEAL SIGNATURE OF BIDDER NAME DESIGNATION _ DATE

SCHEDULE-5.2 SCHEDULE OF PRICE FOR FABRICATION, ERECTION AND COMMISSIONING SL.


1.0

DESCRIPTION Fabrication, Erection & Commissioning: Total lumpsum price towards 1. Receipt of material from site stores, Handling at site. 2. Fabrication of piping & fittings (above 300NB / The plate material will be free issued by owner). 3. Fabrication of Supports (Structural material will be free issued by owner). 4. Hume pipe for buried line. 5. Wrapping and Coating for Buried piping. 6. Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Site Supervision, Calibration and Commissioning at site for LP piping, valves, specialties and supports etc. as detailed in the scope of work.

BASIC PRICE

TAXES & DUTIES

INSURANCE

TOTAL PRICE

REMARKS

Note: Any items are not covered in the above table, Bidder shall include and give their details. COMPANY SEAL SIGNATURE OF BIDDER NAME DESIGNATION DATE PRICE BREAK-UP FOR SPECIAL TOOLS & TACKLES

Sl.

No.

DESCRIPTION OF THE EQUIPMENT/ ITEM

QTY.

UNIT PRICE EXWORKS (DULY PACKED) (4)

TOTAL PRICE EXWORKS (DULY PACKED) (5)=(3)x(4)

EXCISE DUTY (%)

SALES TAX %

OTHER CHARGES

INSURANCE CHARGES

TRANSPORT ATION CHARGES

TOTAL PRICE

(1)

(2)

(3)

(6)

(7)

(8)

(9)

(10)

(11)

GROSS TOTAL Note: Any items are not covered in the above table, Bidder shall include and give their details. SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION DATE

2x300 MW Chandrapur Thermal Power Project Technical Specification

load. The hoist hook shall be provided with safety locking arrangement to provide accidental unhooking. Provision shall be made for lubrication of all moving parts and bearings while the hoist is in service except where life lubricated bearings are used. All exposed bearings shall be suitably sealed or shielded. Bridge girder for the crane shall be of plate welded box type construction fabricated from tested steel plates. Box section shall be adequately reinforced by internal diaphragms and ribs. Box girder shall be provided with end plates for sealing. Diaphragms shall be provided to transmit the trolley wheel loads to the web piates. Trolley / crab runway rails shall be standard rail section as per IS:3443 or equivalent. The rails shall be accurately aligned, levelled and properly fixed to bridge girder. End stops and curved wheel stoppers on crab/ trolley runway rails on both end of each bridge girder shall be provided in approved construction. The rail section shall be sufficient to cover the whole runway length and shall be adequate for maximum permissible trolley travel. The trolley frame shall be built up from heavy steel sections welded together to form a rigid piece frame adequately braced to resist vertical, lateral and torsional strain and support all loads without undue deflection. Trolley frame shall be provided with equaliser sheaves and spring bumper at each side for safe operation of the crane assembly. Manually operated hoisis shall be of spur gear chain pulley block type. It shall be suspended from the trolley by a hook. The design of the hoist shall conform to IS:3832. The load hook shall be swivelling type fitted with a locking device. AN manually operated hoists, unless stated otherwise, shall be trolley suspended type. The trolley of hoists shall be manually operated. Electric hoist shall be electric wire rope trolley suspended type. The design, operation, testing of electric hoist shall conform to IS:3938 {Specification for electric wire rope hoist. 3.25. PAINTING PROTECTION 3.25.1. General The requirements for shop and field application of protective painting/coatings and linings are described in this clause. Each painting/coating system shall provide an optimum life expectancy of 10 years from the time of original painting, considering the corrosive saline atmosphere at project site. The optimum life of a painting/coating system shall be considered the time until first maintenance painting/touch up should occur before active rusting begins. Surfaces which are inaccessible after assembly shall be protected for the life of the equipment. The tables included at the end of this section provide recommendations for painttng/coating systems at various locations and substrates found in the power station. The Bidder shall review the life expectancy and exposure requirements and propose complete painting/coating systems for the Owner's considerations. Coating material and application shall conform to the regulations of the air quality management agency having jurisdiction. Materials shall contain not greater than 0.06 percent lead or chromium in the dried film. Ferrous metal surfaces shall be cleaned, prepared, and painted/coated in accordance with the painting/coating manufacturer's instructions and Steel Structures Painting Council Paint Application Specification No. 1 "Shop. Field, and Maintenance Painting." 3.25.2. Shop Coating Equipment manufacturers' standard painting/coating systems shall be applied in lieu of those specified provided the system complies with the life expectancy requirements. All primers shall contain rust inhibitors.

2x300 MW Chandrapur Thermal Power Project Surfaces to be painted shalt be filled to provide a uniform substrate and shall be prepared for painting in accordance with the appropriate surface preparation specifications. No paint shall be applied to surfaces within 75 mm of field welded connections. These surfaces shall be painted/coated wfth a consumable preservative and masked. 3.25.3. Mechanical Equipment Mechanical equipment includes pumps, compressors, valves, valve operators, external piping surfaces, pipe hangers, and other similar equipment etc. At the Bidder's option, the primer shall be applied in the shop and the finish coats shall be applied in the field. If equipment shall operate at temperatures above 60 C and shall not be insulated, a high temperature painting/coating system designed for the operating temperatures shad be applied. For those surfaces that shall be insulated, painting/coating system shall be applied that has been designed for application below thermal insulation. Steel plate pipes shall be lined with a two pack cold cured Isophthalic Polyester acrylic co-polymer glass flake filled coatings, both internally and externally to provide long term corrosion protection. Coating thickness for the internal of the pipeline shall be 1.0 mm average and for external shall be 0.5 mm average. The vertical water pumpsets surfaces particularly in respect of volute casing, suction elbow etc shall be lined with a two pack cold cured Isophthalic polyester acrylic copolymer with glass flake filled coating at 1.5 mm thickness for providing corrosion protection. The surface preparation shall be by light sand blasting. The internals of the large sized butterfly valves handling water shall be coated with a two pack cold cured Isopthalic polyester acrylic co-polymer with flake glass coating at thickness of 1.0 mm average. The external surfaces of the valves shall be applied with a base coat of two pack epoxy compound incorporating a rust converter, inhibitor and passivator with leafing platelets + top coat of polyamine cured high solids, two pack glass fiake filled epoxy with good gloss and chemical resistance . 3.25.4. Structural Steel and Miscellaneous Metals Structural steel and miscellaneous metals including steel fabricated items such as plates and shapes, ladders, handrails, stair stringers, ducts, equipment and pipe supports, and similar fabrications, shall be abrasive blast cleaned in accordance with SSPC-SP10, Near White Metal Blast Cleaning. Profile depth shall be 40 to 50 microns. The primer shall be inorganic zinc with a total of 85 percent zinc in the dried film applied to a minimum dry film thickness of 75 microns. The fabricated steel structures in contact with water shall be coated with a two pack cold cured Isopthalic Polyester acrylic co-polymer with flake glass. The coating thickness shall be 1.0 mm average. Metal Wall Panels Wall paneis shall be finished with a three coat system consisting of a urethane primer and two fluoropoiymer topcoats. The first topcoat shall be coloured and the second topcoat shali be clear. 3.25.5. Touch-up Paint Touch-up paint shall be provided for repair painting of at least 25 percent of shop finish painted equipment surfaces. The touch-up paint shall be the same type and colour as the shop applied material, Surface preparation and application instructions shad be provided.

3.25.6. RustPrevent ive Compo unds Ma chi ne d sur fac es an d oth er fer ro us sur fac es wh ich sh oul d not be co ate d, but ar e su bje ct to cor ros ion , i sh all be pr ote cte d wit h rus tpr ev ent ive co mp

ounds. Additional

protection shall be provided for equipment and materials which shall be exposed to the atmosphere for extended periods. Rust-preventive compounds shall be checked every two months while in transit and in site storage and renewed as required to maintain adequate protection. Rust-preventive compounds which are used to protect surfaces of equipment and piping that are exposed to feedwater or steam shall be completely water soluble. Machined surfaces of weld-end preparations shall be coated with consumable rustpreventive compounds which shall not affect the quality of the weld. 3.25.7. Galvanizing Structural steel members and steel assemblies particularly outdoor switchyard structures and metallic surfaces in the open atmosphere to be galvanized shad be pickled after completion of fabrication process. Pickling shall remove scale, rust, grease, and other impurities. Steel shall be hot-dip galvanized in accordance with ASTM A123 or equivalent. For bolted connections, where either member to be boltsd is galvanized, erection and structural bolts shall be galvanized in accordance with ASTM A153. 3.25.8. Field Paintings/Coatings and Linings All surfaces of erected equipment, piping, tanks, structures and building components shall be finish painted. Surfaces of connections, field weids, and damaged areas shall be cleaned, prepared, and primed before application of the finish system. The final topcoat for interior metai surfaces shall be a high solid polyamide epoxy applied to a minimum dry film thickness of 125 microns. The final topcoat for exterior metal surfaces shall be a high soiids aliphatic polyureihane applied to a minimum dry film thickness of 50 microns. Shop primers shall be touched up and barrier/universal coats shali be applied to a minimum dry film thickness of 50 microns to provide a suitable base for topcoat application. 3.25.9. Immersion Service Interior surfaces of shop fabricated and field erected tanks shall be cleaned and lined with materials designed for the specific application. Cleaning shall be in accordance with SSPC-SP5, White Metal Blast Cleaning. 3.25.10. Architectural Components Interior non-metallic architectural components, including concrete block/ cement plastered brick walls, in neutral environments shall be painted with low gloss water-borne materials. Finishes for metallic architectural components, including doors and frames, shall provide a smooth, semi-gioss, and durable surface.

3.25.11. Colours Co lou rs for th e ide ntif ica tio n of pip eli ne s, ve ntil ati on du cts , ele ctri cal co nd uit s, an d rel at ed se rvi ce s sh all be in ac co rd an ce wit h th e re qui re m en ts of

BS 1710 and its appendices. Pipelines shall be identified with the name of the fluid or gas and the direction of flow. Finish colour of mechanical equipment shall match the colour of the system of which it is a part. Finish colour of high temperature surfaces shall be deep grey. Finish colour of exterior surfaces of electrical cabinets and panels shall be light grey. Interior surfaces shall be gloss white. 3.25.12. Documentation

Engineering submittals shall identify the painting/coating and lining systems to be applied _______in the shop and the field. D^ta to be provided shall include the surfaces to be painted, the

painting/coating system manufacturer's name and product designation, the degree of surface preparation, dry film thickness of each coating, finish colour, and Material Safety and Data Sheets (MSDS). 3.26. PLANT LAYOUT This section describes the philosophy which shall be used in the development of the general arrangement drawings. Plot Plan drawing (LII-GEOE09043-G-00010-00), Genera! Arrangement drawings for different floors (LII-GEOE09043-203-W-102,103,104) and Cross-section drawings (LII-GEOE09043-203-W-101,) are attached with this specification as a guideline for the bidders. Bidders shall develop their recommended drawings based on the guidelines provided ensuring cost effectiveness, ease of operation and maintenance. 3.26.1. General The power plant shall make optimum use of land and facilities to minimize total life cycle costs but not at the cost of flexibility of maintenance and future expansion. Major external functional systems shall be so oriented that any maintenance work as well as subsequent construction work can be carried out without any interference and/or hindrance to the adjacent unit. The main power plant building shall be functionally subdivided into the turbine-generator area, steam generator area including Mill bay area, the auxiliary bay area, and the electrical equipment area. Similarly, unit control rooms shall be so located that turbine and steam generator areas of the units shall be easily accessible. Passenger-cumgoods-elevators shall be provided for each unit as indicated in the ground Moor plan drawing (LII-GEOE09043-203-W-103) The turbine generator floor levels shall be same for both the units and have the same EOT crane serving the TG of two units. 3.26.2. Equipment Arrangement The layout of the major equipment shall be shown on the bidder's general arrangement drawings to be enclosed with the bid indicating the overall internal arrangement of the plant building as well as the setting dimensions and orientation of all significant equipment. The overall building configuration including internal and external walls and column rows, floor outlines, stairways, access-ways and hatches, and major obstructions, such as the turbine foundation, shall be shown to determine that such items satisfy equipment installation, access, operation, and maintenance requirements even when other units are under construction/ operation and are inline with the layout enclosed with this specification. The optimum arrangement of equipment shall be determined by considering functional requirements, economy of piping and electrical cables, economy of equipment supports, installation and maintenance access requirements, ventilation requirements, and equipment generated noise and vibration level. Equipment location shall be determined keeping in mind the overhead Travelling Crane clearance & approach required. 3.26.3. Maintainability The primary objective shall be to maximize the generation of kilowatt-hours. To achieve this goal, a secondary objective shall be to minimise the complexity and time required for maintenance. The following general criteria shall be followed to achieve this objective:a) Equipment shall be of a low maintenance design and shall be easily maintainable. Special alloys shali be used which can withstand highly erosive coal S ash. b) Equipment shall be designed to be maintained in place, if possible, with minimum disassembly of surrounding equipment and minimum usage of temporary scaffolding