SUBJECT

Study of existing waste water section, Basic Design & Detailed Engineering, Procurement, Supply, Fabrication, Third Party Inspection (TPI) as applicable, Expediting, Insurance, Transportation of all Equipment / Materials, piping in pre-fabricated condition, Providing site supervisory assistance for Construction and Erection of all , Mechanical, Electrical and Instrumentation Works, Design of civil foundations, Submission of foundation drawings to RCF for execution of civil foundations, Assembly and Installation, Testing, Pre-Commissioning, Commissioning, Performance Guarantee Test Run including total Revamped waste water section Design, engineering, supply, Providing site supervision assistance for all activities with Single Point Responsibility achieving all guarantee parameters.

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TECHNICAL Sl.No. Particulars 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Revamped waste water section Description Contractors Scope of Work Design Philosophy Process Performance & Guarantee Tests Instrumentation Mechanical - Static Equipment - Piping - Annexure -1 - Annexure -2 - Rotating Equipment - Annexure -1 Documentation Schedule Vendor List 4.0 5.0 Volume-3 Volume-4 3.3.3 Section 1.0 2.0 3.0 3.1 A 3.2 3.3 3.3.1 Volume-2 3.3.2 Volume-1 Volume

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TECHNICAL (VOLUME 1) SECTION 1.0 REVAMPED WASTE WATER SECTION DESCRIPTION

TABLE OF CONTENTS

SL. NO. 1.0 2.0 3.0

DESCRIPTION INTRODUCTION PLANT LOCATION PLANT CAPACITY & CONFIGURATION

PAGE NO. 3 3 3

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1. INTRODUCTION
Rashtriya Chemicals & Fertilizer Ltd. (RCF) is proposing to revamp the existing waste water treatment section of urea plant at RCF, Trombay. Scope of work of the Contractor shall include Study of existing waste water section, Basic Design and Detailed Engineering required for integrating modified waste water section into the existing set up, Procurement, Supply, Fabrication, Inspection by Third Party Inspection Agency (TPI) as applicable, Expediting, Insurance, Transportation of all equipment / materials, pre fabricated piping to work site, Providing site supervisory assistance for construction and erection of all mechanical, electrical and instrumentation, Testing, Pre-Commissioning, Commissioning, Training of Owners persons, Performance Guarantee Test Run (PGTR) including Total Revamped waste water section Management on single point responsibility basis.

2. PLANT LOCATION
The Trombay Fertilizer Complex of RCF is located in Chembur, Mumbai.

3. PLANT CAPACITY & CONFIGURATION

a) RCF Trombay Urea Plant is based on Snamprogetti process and has a design capacity of 1000 MT/day. The plant is currently achieving production of 1300 MT/Day. The hydrolyser in the Waste Water Section is being maintained at pressure of 18 kg/cm2 and temperature of 1900C, with indirect heating by 26 ata steam, passing through U tube bundle; generating 30-35 m3 effluent, having Ammonia and Urea contents of 150 ppm and 250 ppm respectively b) RCF intends to revamp the waste water treatment section to achieve the following: 1. To reduce NH3 and Urea content in the effluent quantity of 35 m3/hr. to 5.0 ppm and 3.0 ppm respectively, so that it can be used as Boiler Feed water, in our steam generation plant. 2. The working pressure of revamped Hydrolyser heater shall be maximum 25 kg/cm2 and temperature in the range of 225-2300C. Before submission of bid, the bidder shall visit , Urea Plant at RCF Trombay, to completely understand the site condition and present condition and performance of the waste water treatment section. Bidder shall be provided with the existing plot plan Page 3 of 208

of the urea plant, waste water section. Party to revamp the section, so as new equipment shall be accommodated in the existing waste water section layout. During any exigencies due to variation in climatic conditions etc. BIDDER shall indicate capacity of Utilities facilities provided and shall also furnish design margins considered for each unit. 3.1 Waste water treatment section & facilities under Contractors Scope Description 1.0 Revamp of Waste water treatment section for urea plant of 1300MTPD capacity Provision To be specified by Bidder Remarks Under Contractors scope

3.2

Power Supply and Distribution Power requirement shall be made available to the required drive motors..

3.3

Cooling Water System Contractor to tell the requirement of cooling water, the same shall be catered through existing cooling tower in the urea plant.

3.4

Process water Process water shall be made available at one point near the battery limit of the plant.

3.5

D.M. Water D.M.Water shall be made available at one point near the battery limit of the plant.

3.6

Instrument and Service Air System The instrument air shall be made available at one point near plant battery limit of the plant.

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TECHNICAL (VOLUME 1) SECTION 1.0

PERFORMANCE & GUARANTEE TESTS

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TABLE OF CONTENTS

SL. NO.

DESCRIPTION

SHEET NUMBER 7 7 7 8 8

A B C D E

PERFORMANCE GUARANTEES EVALUATION OF OFFER FAILURE IN PROCESS PERFORMANCE LIQUIDATED DAMAGES FOR FAILURE IN PROCESS PERFORMANCE MECHANICAL GUARANTEE

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A. PROCESS PERFORMANCE GUARANTEES: Guarantee Basis: After mechanical completion of revamped waste water section, the waste water section will be operated as per their instructions and the feed shall be admitted to the system, as per specified quantity/quality, pressure and temperature. The feed to the waste water treatment section, shall be 35m/hr., maximum. The feed to the waste water treatment section, shall have following composition: Ammonia 10.0% weight Carbon di oxide 1.0% weight Urea 1.0% weight

The guarantee test run shall be carried out for 7 consecutive days,to demonstrate the process conditions guaranteed by contractor, and the best 3 consecutive days readings shall be considered. Contractor shall guarantee that the treated water, at the outlet of the revamped waste water treatment section, shall have the following composition: Ammonia 5.0ppm Urea 3.0ppm

Parties offering more than 5.0ppm of ammonia and more than 3.0 ppmurea in treated water are liable to get rejected. B. Failure in Process Performance: Contractor shall pay Liquidated Damages as specified in D below, provided the GTR results are within the ranges as follows: i. Ammonia in the effluent in the revamped waste water unit is at the most 110% of the Guaranteed Value of 5.0 ppm. ii. Urea in the effluent in the revamped waste water unit is at the most 110% of the Guaranteed Value of 3.0 ppm. If the ammonia and urea content in the effluent exceeds their respective maximum permissible limit of 110%, of guaranteed ppm after the revamp, contractor shall rectify the problem so as to attain the effluent quality as per design, at their own risk and cost.

C. Damages for failure in Process Performance: i. For every 1% deviation above 5.0 ppm in Ammonia in the treated effluent in the revamped waste water unit, damages shall be levied @ 0.25% of the contract value, Page 7 of 208

subjected to maximum 2.50% corresponding to 10% deviation from the guaranteed 5.0 ppm. ii. For every 1% deviation above 3.0 ppm in Urea in the treated effluent in the revamped waste water unit, damages shall be levied @ 0.25% of the contract value, subjected to maximum 2.5% corresponding to 10% deviation from the guaranteed 3.0 ppm. Iii Compensation for non-commencement or delay in completion of work. Time shall be regarded as the essence of the contract and failure on the part of contractor to complete the work on the dates stipulated in the work order for completion of the respective works shall entitle RCF to recover damages a sum equivalent to the % of the value of the delayed job for each week/day or a part of week for which the contractor is in default and subject to a maximum of % as given in the table below.

Item Supply of materials:

Period 15 months

LD 0.5 % per week max 5 %

The contractual period for Supply part shall start from date of LOI/PO The contractual period for pre shutdown activities shall start from date of clearance given by RCF for start of pre shut down activities. For hook up RCF shall hand over the existing waste water section after stopping the plant to the contractor. Tentatively Shut down and hook up clearance shall be given on 01-04-14 D. Mechanical Guarantee: contractor shall guarantee for material supplied and workmanship for a period of 12 months from the date of successful guarantee test run or 24 months from the date of receipt of last supply, whichever is earlier.

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TECHNICAL (VOLUME 1) SECTION 2.0

CONTRACTORS SCOPE OF WORK
TABLE OF CONTENTS

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SL. NO. 1.0 2.0 3.0 4.0 5.0

DESCRIPTION CONTRACTORS GENERAL SCOPE OF WORK SCOPE OF BASIC ENGINEERING SERVICES SCOPE OF DETAILED ENGINEERING SERVICES PROCUREMENT INSPECTION & EXPEDITING

PAGE NO. 12 13 23 36 37

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1.0

CONTRACTORS SCOPE OF WORK

The scope of CONTRACTOR shall cover Study of existing waste water section, basic & detailed design/engineering for proposed revamp, manufacture, supply, interconnection, transportation, Providing site supervision assistance for erection and commissioning, Guarantee test run of waste water treatment section, including successful completion of Performance Tests. CONTRACTOR shall provide and be responsible for the tasks summarised below but not limited to the following: Study of existing waste water section, Basic Design for the proposed revamp Detailed Engineering HAZOP Study and implementation of its recommendations Compliance to Applicable Codes and Standards Drawings and Documents Drawing & Documents shall be made available for OWNERs review as listed below : Basic Engineering Specification of all Critical Equipment & Machinery Detail Engineering

Procurement and supply of all equipment, piping in pre-fabricated condition, spring supports, etc. Including structural material for piping supports. Spares (Commissioning and 2 years operational) and special maintenance tools Transportation of equipment at site. Providing site supervision assistance for Construction & Erection of all structural items, mechanical, electrical, &instrumentation works. However civil works shall be undertaken by RCF, contractor will design and submit required drawings for execution the same by RCF. Quality Assurance & Quality Control Inspection & Expediting Providing details and procedure of Insulation, for insulation of equipment and piping Providing details and procedure of Painting of newly supplied and erected piping/equipment/structures

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Providing site supervisor for supervision of work of Sub-contractors Submission of Technical Information Supporting for Mechanical completion in time Pre-commissioning Commissioning Performance guarantee Training of OWNERs Personnel Operating & Maintenance Manual Process Design & Basic Engineering

***Party shall give per diem rate for site supervisor for supervisory services at site, along with tentative schedule of days / time and nos. of site supervisor required ; for timely completion of above mentioned supervisory services.
Preparation of Process Design and Basic Engineering Package for the revamped waste water section shall include all basic technical details for clear understanding of waste water treatment section. Such technical information and the process design and basic engineering package shall be established in the English language and submitted. 1.1 Detailed engineering documents Complete Detailed engineering documents shall be supplied for process compliance 1.2 Review of P&I Diagram Review of P & I Diagram after HAZOP Study & incorporation of Hazop recommendations 1.3 Final checking Final Checking of the waste water treatment section after Mechanical completion before start of Commissioning. 1.4 Training Training of Owners Operating and Maintenance Personnel. 2.0 SCOPE OF BASIC ENGINEERING SERVICES ENGINEERING DESIGN SPECIFICATIONS The Engineering Design Specifications shall comprise of technical data and information required for the Detailed Design and Engineering, Procurement/supply Page 12 of 208

of Equipment and Material piping in fabricated condition, Pre-Commissioning, Start-up and Operation of the Process. It shall include, but not limited to the following: 2.1 General a) b) c) d) e) f) g) Basis of Design. Optimized Heat and Material Balance. Detailed Process Description. Piping and Instrumentation Diagrams (P & IDs). Basic control schemes and interlocking requirements to have safe and efficient operations. Battery Limit definitions and conditions for various streams coming to and leaving of each individual Process Unit. Specifications of the required utilities with allowable tolerances, giving minimum, normal and peak consumption figures with duration for individual Process Unit.

2.2

Basis of design Basis of Design shall include the following: a) b) c) d) e) f) Product Specifications. Battery Limit Conditions. Chemistry of all reactions involved in the each Process Unit. Units of Measurement Spare Philosophy Brief Instrumentation/Control Philosophy

2.3

Flow Diagrams And Process Description Required flow diagrams including necessary and sufficient information, data and detailed description, shall be provided. Contractor shall ensure the following minimum information in each of the drawing/documents as indicated below.

2.3.1

Process Flow Diagrams and Process Description Detailed process description (based on Process and Utility Flow Diagrams) shall be provided giving technical information which would determine optimum operating conditions and all expected alternative operations like Start-up& Normal operation Detailed process description shall be submitted together with first issue of the process flow diagrams.

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The process flow diagram shall contain at least the following information: All Process Equipment shall be shown diagrammatically marked with equipment numbers and titles. b) Duties of the Equipment. c) Operating temperature, Pressure, Total flow rates, Composition, Vapour and liquid flow rates content and composition. d) Process lines (marked with stream numbers) showing direction of flow . e) All lines essential for understanding the mass balance around each piece of equipment shall be shown. f) All figures should be given in SI metric system, (or) traditional units of measurement. Material and Heat Balance Sheets For each stream number shown on the Process Flow Diagrams, the material and heat balance shall be specified indicating the stream properties Flow rate, Composition, Phase, Temperature, Pressure, Operating and Standard specific gravity or density, Enthalpy, Specific heat, Viscosity, Molecular weight for gases and vapours and all other thermodynamic information and data as are used and applied in the Basic Design. 2.4 Utility Data and Summary List Utility data and summary list shall include Electrical power, Steam, Cooling water, Minimum, average and peak consumption figures for utilities shall be indicated as well. 2.5 Piping And Instrumentation Diagrams (P&IDs) These drawings shall show all Process Equipment and Piping, Instruments and control systems, for the revamped waste water treatment section. Number and sizes shall be indicated for Valves, Check valves and Safety valves. Utilities shall be shown entering or leaving the plant including distribution of each utility to all utility users/producers together with utility control systems specific to that user/producer. Definitions of Piping and Instrument Diagram symbols and abbreviations used shall be provided on legend sheets of P&IDs. Piping and instrumentation diagram shall include: All Process Equipment including installed stand-by equipment. Page 14 of 208 a)

Line size and line identification including material specifications for all lines. For inlet and outlet lines of safety valves only preliminary sizes will be given and final sizes will be shown in Detailed Engineering P&IDs. Insulation requirements of lines (Heat conservation, Process stabilization or "not insulated") shall be shown on the P&IDs. Equipment characteristic parameters dimension plus Design Temperature, Pressure and Material of Construction (MOC) shall be given at the bottom of the P&ID. Equipment title and number. All nozzles on columns, heat exchangers, vessels and tanks and all internals in vessels/columns shall be shown. Required line slope, relative location of equipment or special conditions such as required vertical loop dimensions, gravity lines with or without pockets, etc. Vents and drains required for process or operating reasons (not hydraulic testing). Tracing of lines and instruments, as applicable. Gas or liquid purging or flushing of control valves, instruments or relief valves, including their inlet and outlet isolating valves. All start-up, by-pass, shutdown and emergency lines and lines for anticipated alternative operations. All instruments required for proper operation of the Process Unit within scope. Instrumentation control loops including interlocks, sequence and emergency shutdown. Control valves response on air failure (fail safe philosophy shall be adopted in design). Instrument tag numbers. All details shall be consistent with the appropriate process flow diagram and other process documents. Process specific installation position of piping components (if applicable). Kind and item number of special components. Battery limits of Process Measuring and control signals transmission. Flow direction of signals when combining several measuring and control circuits Electrical consumers other than motors, if any. Kind of signal or specific representation of signalling lines, such as pneumatic, electric, hydraulic, function line, capillary tubing. Principal sparable connections (e.g.Flanges, Spectacle blinds). Sample connections. Size and set pressure of safety valves and their inlet and outlet isolating valves. Updating of P&I diagrams after design review and HAZOP study. 2.6 Equipment List

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a)

This list shall show the equipment title, duty, size, tag number, type and quantity of each equipment. Operating temperature and pressures, Design temperatures and pressures. Equipment characteristics, parameters or dimensions and material of construction.

b) c)

2.7

Equipment Data Sheets Specification sheets giving all Process and Mechanical design data required for designing the equipment, including turn down ratio. Further specific design information shall be as follows:

2.7.1

Pumps a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) Fluid Physical Properties. Minimum, Normal and Maximum flow rates. Sealing Requirements. Suction and Discharge conditions. Specific Design and Fabrication requirements. Operating and Design Temperature and Pressure, Physical and Thermodynamic Properties. Estimated Efficiency and Hydraulic Power. Flushing requirements. NPSH required. Materials of Construction (MOC). Corrosion allowance. Type and special features required. Type of Driver. Recommended RPM. Principal requirement for Operation Control. Estimated Shut-off Pressure. Estimated Power Consumption. Spares for Commissioning and 2 years operation.

2.7.2

Vessels, Columns and Internals Data sheet including standard process sketch and tray/packing specification shall be provided showing: a) b) c) d) Process gas /liquid loading. Maximum Operating Temperature and Pressure. Mechanical Design Temperature and Pressure. Pressure drop. Page 16 of 208

e) f) g) h) i) j) k) l) m) n) o) p) q) 2.7.3

Materials of Construction (MOC) and corrosion allowance. Diameter and height or length. Type of packing material, size, packing bed height. Number, size, rating and location of nozzles. High and low liquid levels Any Special surface finish requirement. Stress Relieving. Insulation Requirements. Details for Columns, including pressure drop Skirt height. Details of special internals such as Distributors, etc. Mist eliminators, Supports, Mesh or Packing, etc. spares for Commissioning and 2 years operation. Instrumentation requirements.

Heat Exchangers (all types) Data sheets giving all Process and Thermal Design of all heat exchangers with relevant sketches and drawings including but not limited to the following: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) Operating and Design Pressures and Temperatures (Inlet and Outlet). Surface areas. Heat load and Fouling factors. Limiting transfer rates where applicable Specific Design and Fabrication requirements. Tube and Baffle arrangement (if applicable). Permissible Pressure drop. Material of Construction (MOC). Corrosion allowances. Fluid Thermodynamic properties such as Specific heat, Thermal Conductivity, Density, Critical properties and etc. Any specific foundation requirement. Nozzle location (if applicable) and Gasket material. The Exchanger type and Configuration to be specified via relevant standard data sheet. Mean Metal Temperature of tube side component of the Shell & Tube heat exchanger (if applicable). For Tubular Exchangers, Vibration analysis to be indicated by Contractor. Instrumentation requirement. Spares for Commissioning and 2 years operation.

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2.8

Instrumentation The following documents shall be compiled in Engineering Design Specification:

2.8.1

Control philosophy description and drawing: explaining and showing the concept of DCS/PLC/ESDS, FGD, local panels and packages control system regarding design basis and monitoring/control, remote/local, master/slave, dedicated/shared systems aspects, start-up location, systems location and interconnection. Advanced control manual, if any: including all necessary information and details such as control strategies descriptions, mathematical analysis and equations with definition, range and scaling of parameters, flowcharts, diagrams to enable the detailed engineering Contractor to develop and implement the advanced/special control in DCS. Specification for Instrumentation. a) Cause and effect diagrams showing electrical and instrument interlocking and trip requirement. b) Sequence and interlock (normal and safety) description as well as simplified logic diagram/flowcharts according to IEC 6 1131.3.

2.8.2

2.8.3

2.8.4 2.8.5 2.8.6 2.8.7

Preliminary Alarm and Trip set points. List and Specification for Special Systems/Instruments and requirements. Electrical Power and Air Consumption for Instrumentation. Instrument index including Tag nos, Service, Process conditions, Type, Size, Range, Alarm/trip set points, P&IDs No., reference to other documents etc. DCS/PLC/ESDS I/O summary. Instrument data sheets providing the following information: a) Tag number b) Name c) Service d) Equipment or Line number e) P&IDs Number f) All data which is necessary for sizing, selection and specifying the instrument such as: Stream data in Minimum, Normal and Maximum or other Specific operating conditions (to ensure proper rangeability, reading and control). Sealing, Purging or Flushing requirements including any special process design considerations. Consideration and recommendation regarding, Corrosion/Erosion effect, Toxicity and Suspended particles of process medium. Page 18 of 208

2.8.8 2.8.9

 g) h) i) j)

Response time. Leakage class. Accuracy (according to process requirements).

Type of Instrument (Principle of Measurement code). Preliminary Size and Range. Material of Construction (MOC). Impulse line and Instrument Casing Heating/Insulation requirement. k) Detail of Safety Relief Valves with flow rate, set pressure and relieving conditions.

2.9

Electrical General Electrical specifications will provide sufficient information for Detailed Engineering and shall include the following: 1. Specifications of Normal and Emergency Power supply and Electrical installation. 2. Single Line Diagram (SLD) to be used as the basis for Detail Engineering. 3. Requirement of information for: a) Interlocking method with Instrumentation system. b) Electrical consumers with indication of Estimated Power Consumption except illumination. c) Consumers requiring Emergency Power Supply and duration of it. 4. Energy requirement of Process Unit in Kilowatt hours per ton of product and the total expected power (kW) requirement with details of high/medium voltage and low voltage loads. Lightning protection, where applicable.

5. 2.10

Piping
1. 2.

3. 4.

Piping lay-out plans shall be provided indicating the critical areas of piping including general arrangement of piping in plan view. General specification for piping material including pipe classifications according to process requirement for Process, Utility and Service lines included in entire Waste water treatment section. Typical Piping specifications (for each classification). Special Insulation requirements for critical piping.

2.11

Pipe Class Summary (Basic Piping Specification)

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A summary of piping class for all the process, utility and service lines for revamped/new piping of Waste water treatment section shall be provided. A standard process, utility and service lines summary shall include: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 2.12 Piping material specifications and ratings. Flange material and ratings. Design pressure and temperature. Gasket types and bolting. Corrosion allowances. Valve types, size, material and rating. Type of fluid. Fittings. Strainers. Expansion joints. Check valves.

Line List Line index keyed to line numbers on piping and instrument diagrams showing Line numbers, Line size, Class, Design and Operating data, Type of insulation, Flowing phase, Alternating condition (if any), test pressure, test fluid, insulation thickness etc. to be provided.

2.13

Design Calculations For the Process Units, Contractor shall provide to Owners engineers on a piecemeal basis, the input and output sheets of simulation for the following calculations: a) Design calculations for estimating chemicals requirements. b) Calculation sheets for items such as , vessels, columns, pump, control valves and relief valve loads sizing. c) Hydraulic design tabulations sheets including back-up data and calculation shall be provided for each individual loop. For this reason the design philosophy for line sizing shall be submitted as well. d) Design data developed for design of each item of equipment.

2.14

Insulation List And Specifications Contractor shall indicate the insulation requirements in each Process & Utilities Unit with its Engineering Specifications.

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2.15

Other Required Information a) Any other documents or data which are reasonable necessary to perform the detailed design, Procurement and construction, Pre-commissioning, Commissioning, Start-up and Operation of the waste water treatment section.

2.16

Contractors Engineering Design Specifications And Drawings Any specific Standard Specifications, Instructions and Procedures which Contractor deems necessary to be taken into account for Detailed engineering, Procurement, Design and Manufacturing of the equipment, Transportation and Erection, PreCommissioning, Commissioning, Start-up and Operation of the Waste water treatment section shall be pointed out and to be included in the Engineering Design Specifications.

2.17

Safety a) Contractor shall perform the Hazard and Operability studies (HAZOP) using PFD and P&ID together with Plot Plan and Equipment data sheets and Safetyrelated equipment checklist. During HAZOP meetings, Contractor shall report any accidents (if any) in the plant and the necessary precaution that the designer has adopted for rectifying the same. Any other Specific safety requirements.

2.18

HAZOP Study Report Contractor shall carry out HAZOP study and implement its recommendations during following stages and submit HAZOP Report for the approval of the Owner. a) Basic Design and Detailed Engineering. b) Plant Start-up and Commissioning.

3.0
3.1

SCOPE OF DETAILED ENGINEERING SERVICES

Introduction The minimum requirements for Detailed Design and Engineering of the Waste water treatment section shall be according to Standards, Specifications and Procedures. Contractor shall prepare/provide all the drawings and documents as detailed below. Designs and Specifications of all major Equipment, Piping, Mechanical parts, Instrumentation, Electrical items, Insulation, Painting and other bulk materials. This

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would minimize spare parts and facilitate operation and maintenance of the Waste water treatment section. 3.2 3.2.1 Drawings and Documentation General Contractor shall prepare/provide all such Drawings and Documentation which shall be necessary for performing the procurement of Equipment and Materials, Construction, Pre-commissioning, Commissioning and Operation of the Waste water treatment section. The above drawings and documentation shall include, but is not limited to the following: a) Equipment Layout : 1) Contractor shall prepare detailed layouts and plot plans for Process Unit included in the Waste water treatment section based on overall plot plan of the plant. Detail plot plant &Layout shall be prepared by Contractor and shall show Location of all buildings, Battery limits of Process Unit, considered in the scope of contractor. Routing of roads and Configuration of pipe racks. 2) Process Unit Detailed Plot Plan: Based on overall Plot Plan of the Complex, Contractor shall prepare/provide detailed plot plan for Process Unit included in the Waste water treatment section. Detailed plot plan shall be on scale and shall show exact location of each equipment with their Tag number, Interconnections between the equipment, Configuration of pipe racks, Access ways, Sewerage and Trenches inside the Process Unit, Package unit detailed layout (through vendor), battery limit connections all of the Process and Utility lines (Incoming and outgoing) etc. The Detailed Process Unit plot plan shall be prepared taking into account easy operation and maintenance of each individual equipment and accessories and parts included in the Process Unit.

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b)

Unit Limit Drawings

Contractor shall prepare the Process Unit limits drawings showing details of all over ground and underground interconnections at Battery limit (Process and Utility Incoming and Outgoing lines) for the Process Unit. c) Piping & Instrumentation Diagrams These drawings shall show all Process Equipment and Piping, Instruments and Control systems. Sizes shall be indicated for Valves, Check valves and Number and Size for safety valves. The extent of line tracing, as applicable, and the extent and type of insulation shall be shown. Such details as Steam out and Purge connections, Utilities shall be shown entering and leaving the Process Unit including distribution of each utility to all utility users and/or producers together with utility control systems specific to that user and/or producer. Definitions of Piping and Instrumentation symbols used shall be provided on a cover sheet for Process Unit P&I Diagrams. Piping and Instrumentation Diagrams shall include: All Process Equipment including installed stand-by equipment (when warehouse standby is available, a note shall be laid down for that specific equipment). Line size and Line identification for all lines. Insulation requirements of lines (Heat conservation, Personnel protection, Process stabilization). Equipment characteristic parameters or Dimensions plus Design Temperature and Pressure and Material of Construction (MOC). Equipment Title and Number. All nozzles on Columns, Vessels, Heat exchangers and Tanks and all internals in vessels/columns shall be shown. Required line slope, Relative location of equipment or special conditions such as required vertical loop dimensions, Gravity lines with or without pockets, etc. Vents and Drains required for process or operating reasons (not hydraulic testing). Gas or liquid purging or flushing of control valves, Instruments or relief valves. All Instruments required for proper operation of Process Unit. Instrumentation control loops including Interlocks, Sequence and Emergency shutdown. Control valves response on air failure. Instrument tag numbers. Page 23 of 208

All details shall be consistent with the appropriate Process Flow Diagram and other process documents. Process specific installation position of piping components. Kind and Item number of special components. Battery Limits and Limits of Process Unit. Measuring and Transmission of control signals. Flow direction of signals when combining several measuring and control circuits. Electrical consumers other than motors, such as heating systems. Kind of signal for specific representation of Signalling lines, such as Pneumatic, Electric, Hydraulic, Function line, Capillary tubing. Principal separable connections. Start-up, Normal and Emergency shutdown, Catalyst regeneration, Catalyst/Chemical/Resin loading, unloading and Emergency provisions which shall be necessary for safe operation of the Waste water treatment section. Alternative operations (all expected modes of operations) which shall be necessary for continuous operation of a Process Unit/Waste water treatment section, when other Process Units are having shutdown. Sample points and details of sampling. Details of Pump flushing, cooling water, Drains, Vents, etc. Piping shall be supplied by contractor in pre-fabricated condition along with all supports and material for supports. However piping, erection and box up shall be in owners scope. Contractor shall depute their site supervisor to ensure proper erection of the piping and equipments. 3.2.2. Equipment a. b. Engineering drawings and/or Specifications for each individual Equipment, Materials, etc. Equipment drawings and/or specifications for Towers, Heat exchangers (all types), Heaters, Tanks and Non-code vessels and Machinery such as Pumps, etc, containing sufficient information to enable equipment manufacturers to prepare detailed drawings for manufacturing of equipment. Equipment arrangement drawings. Detailed drawings and documents of equipment required for Proper erection, Pre-commissioning, Commissioning, Operation and Maintenance. Material requisitions containing all required Process and Engineering information and data and all necessary Standard Drawings and Specifications. Material requisitions shall be up to date with all relevant and required information. Stress analysis due to piping on equipment considering Temperature, Pressure and all other expected loads.

c. d. e.

f.

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g. Calculation result sheets of Vessel design (through manufacturer) and Calculation result of Thermal Stress of Piping, Structural design and so on. h. Equipment "Sketches and Data sheet" for Towers, Heat exchangers (all types), Tanks and Non-coded Vessels and Machinery such as, Pumps, etc. Such drawings shall contain sufficient information and data to enable equipment manufacturers to prepare shop fabrication drawings. i. Detail procedure for preservation of equipment during Short time and Long time of Non operation. j. Equipment List, containing at least the following information: 1. Item number (Tag number). Item descriptions including Duty, Design and Normal conditions. Overall dimensions of Equipment. Erection Weight of Equipment. Type of equipment and Material of Construction (MOC). Tangent to Tangent length (for Vessels). Absorption and Rate of Power Consumption. Type (s) of Driver(s). k. Performance curves for Pumps l. Revamped waste water section Engineering specifications for each Individual Equipment and/or Components including but not limited to Piping material and drawings, Electrical, Instrumentation, Insulation and Painting specifications incorporating of all requirements of Owner's and Contractor's standard drawings and specifications. m. However erection of equipments in owners scope. Contractor shall depute their site supervisor for all activities including erection of the piping and equipments.

3.2.3

Civil work, Structural work. a) Site preparation activities: 1. Preparation of general Site grading design drawings including specifications and procedures to perform all Site preparation activities including land development and to make Site ready for next steps (e.g. foundation works). Any engineering required to remove the existing facilities from the Site is included in contractors scope. 2. However erection of civil foundation work for new equipment or structure shall be in owners scope . Contractor shall Design and prepare construction drawings & specifications for all civil & steel structural works required to complete revamped waste water section as given in scope of works. Contractor shall Design and prepare construction drawings, specifications including procedures for construction of Pipe racks. b) Foundations, Concrete Structures and Paving:

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1. Contractor shall establish loading data for foundation and equipment supporting structures. 2. Piling specification design, Drawings and Construction procedures wherever required within the Waste water treatment section shall be performed by Contractor. 3. All required Drawings for foundations of all Equipment and Machinery, Structures, Pipe racks, etc and all foundation drawings, specifications and procedures required for proper and efficient construction shall be prepared by Contractor. 4. Loading data and Calculation results of foundation designs to be specified and submitted to Owner. 5. Contractor shall prepare Construction drawings specifications and procedures to build all reinforced concrete structures. Where supply of equipment requires the provision of items of civil engineering nature e.g. concrete sumps, Contractor shall undertake the design in accordance with vendor requirements. 6. Bills of quantities and specifications of materials for civil works (e.g. Reinforcing bars, Cements, Anchor bolts etc) 7. All detailed drawings, Specifications and Procedures required to perform all civil works of the Waste water treatment section. c) Structures: Contractor shall prepare and submit at least following documents / drawings on structure works. 1. Complete arrangement drawings for Steel structures with all member sizes, Plan and framing elevation, Typical sections, and Details for preparation of shop detailed drawings and Fabrication work. 2. Loading diagrams and calculation results for all structures. 3. Steel structure drawings for Equipment supports, Racks, Platforms, Ladders and stairways, etc with sufficient details required for preparation of shop detailed drawings and fabrication work. 4. Steel structure revamped waste water section engineering specifications and standard details for Hand rails, Equipment supports, Racks, Stairs, Cat ladders, Platforms, Fire proofing, etc. Page 26 of 208

5. Developing and designing special members of structural steel which may become necessary for handling or supporting of special equipment and items during manufacturing, transportation and construction of the Waste water treatment section. 6. Preparation of all required specification including Procedures, Standard and Specification for manufacturing and construction of structures. 7. Preparation of shop fabrication drawings. 3.2.4 Piping Contractor shall prepare at least the following documents / drawings for piping: 1. Piping design, Fabrication, Erection, Testing and Flushing specifications. 2. Piping materials classification and specifications for Process and various services in the Waste water treatment section and Contractors requirement considering Corrosion, Erosion, High Temperature and High Pressure, all expected special conditions and etc. 3. Piping arrangement for all pipes on the pipe racks included in the Waste water treatment section. 4. Cross-sectional drawings of all piping entering and leaving Process Unit Battery limits. 5. Layout drawings. 6. Isometric drawings, (except for long runs shown on plan drawings) of all Carbon steel, Alloy and Stainless steel, indicating all fittings and materials and referring to Sand blasting, Pre fabrication , Fabrication, Erection, Surface preparation, Painting and Insulation in accordance with the specifications and procedures. Test pressure and it's media shall also be specified. 7. Piping arrangement drawings for all underground piping included in the Waste water treatment section. 8. Detail drawings and specifications for under ground piping and its protection device. 9. Detail Piping arrangement drawings or Isometrics for Process, Utility, Instrument air and all other various services and Steam/Electric tracing in the Waste water treatment section. These shall cover requirements for Pre fabrication, Fabrication, Erection, Pre-commissioning, Commissioning, Page 27 of 208

Operation and Maintenance in accordance with the Approved for Construction P&IDs. 10. Detail drawings or catalogue drawings and specifications of Valves, Fittings, Traps, Safety valves, Control valves and all other piping components included in the Waste water treatment section. 11. Piping drawings for match lines (interconnections) at Battery Limit. 12. Detail piping drawings for Vent and Drains required for process and operating reasons in the Waste water treatment section including hydraulic testing. 13. Piping Drawings indicating location of required Supports, Anchors and guides, for all piping within the Waste water treatment section. 14. Steam tracing detail drawings and specifications. Such drawings shall contain all information, data and procedures required for Construction/Erection, Operation and Maintenance. 15. Flexibility calculations and Stress analysis results for all piping systems as set out under Revamped waste water section Specifications including piping supports, especially for those systems subject to High Temperatures/Pressures and other loadings. 16. Vessel trims and special support design. 17. Colour coding of painting for piping suitable from safety and operation point of view. 18. Initial, Intermediate and Final material take-off for all Piping materials, Components and items included in the Waste water treatment section. These take-offs shall cover all required Piping materials, Components and items of the Waste water treatment section, otherwise supplementary take-offs shall be performed up to complete fulfilment of the requirements. 19. Material requisitions for all Piping materials, Components. 20. Line lists showing complete line identification (Line size, Service, Unit No, P&ID No, Pipe class, Operating and Design Temperatures and Pressures, Type of Insulation and etc), Line extremities, Maximum Pressure, Maximum Temperature, Material flowing and its condition (Vapour, Liquid, Mixture), Quantity, test pressures, test fluids, insulation thickness etc. 21. All Design calculations result, information and data in respect of preliminary hydraulic design of the piping system and final or adjusted hydraulic design

Page 28 of 208

calculations, data, information and configurations of the Waste water treatment section. 22. Piping and all supports and structural material for support shall be supplied by contractor. Piping shall be in pre-fabricated condition. 3.2.5 Instrumentation Contractor shall prepare, but not limited to, the following drawings and documents: 1. Instrument index containing Tag nos, Service, Process conditions, Type, Size, Range, Alarm/trip set points, Manufacturer, Model No etc., P & ID No, reference to other documents etc. 2. Systems Architecture (Hardware configurations) drawings. 3. General specifications for Instruments, Control systems and accessories in respect of Engineering, Procurement, Manufacturing, Inspection, Construction and Operation. (One document for instrumentation overall practice and individual documents for further attachment to material requisitions). 4. 5. 6. 7. Sizing calculations. Instrument data sheets (for further attachment to material requisitions). Cause and Effect diagrams. Interlock and Sequence (ESDS and non ESDS) description and Logic diagrams / flow charts according to IEC 61131.3. 8. Alarm / trip set points. 9. Loop sketches. 10. Loop diagrams. 11. Instrument hook-up drawings with material requirements. 12. Instrument mounting drawings with material requirements. 13. Instrument Heat tracing drawings with material requirements. 14. Instrument Cable tray / Ladder / Trench layout. 15. Instrument location drawings (layouts) showing positions of Instruments, Junction boxes, Local panels, Cable routing, and Instrument air header take off valves and cables on trays / ladders and/or in trenches. 16. Control/Auxiliary/Analyser room layout, showing all necessary details including locations, cable entry and route, tray/trench details etc. 17. Front view drawings of Control panels/Consoles with dimensions. 18. Earthing layout for instrumentation system. 19. Data required for Instruments/System Configuration such as I/O summary, Host Connection, Diagrams, Flow charts, Mathematics, Graphics, Layouts, Grouping lists, Ranges, Scales, Parameters, Set points, Colour codes etc. 20. Instrument cable lists and schedules. 21. Material take off (MTO) lists.

Page 29 of 208

22. Material requisitions, Bid evaluations and Purchase orders for Instruments/Systems and bulk materials. 23. Instrument JB Diagram/Connection. 24. Vendors technical drawings, Catalogues and Documents including Installation, Operation, Calibration, Configuration, Programming and Maintenance manuals for Instruments/Systems with illustrated parts lists. 25. Instruments/Systems configuration documents including Device Description/ Capability files, Software details, Source and application programs etc. 26. Panels/Consoles/Cabinets internal layout. 27. Panels/Consoles/Cabinets Interconnection block diagram with cable nos. 28. Power supply distribution drawings. 29. Interfacing diagrams/Philosophy between control systems and MCC. 30. Termination and Wiring diagrams as well as hardware configuration for construction and trouble shooting purposes. 31. Spare parts lists and filled SPIR forms. 32. Tests, inspections and QC certificates and reports. 33. UPS Power consumption for Instruments. 34. Connection between Auxiliary and HMI Interface. 3.2.6 Electrical Contractor shall prepare/provide, but is not limited to the following documents for electrical works: 1. Schematic One-Line Diagrams of Instrument power supply. 2. Load summary and analysis. 3. Lightning protection system design, layout and general specifications indicating any special requirement in the entire Plant. 4. Motor schedule showing Service, Number (Normal Operation and Stand by), Number of poles, Output capacity, Type, Classification and remarks indicating any special requirement. 5. Physical location of Grounding electrodes, equipment to be grounded and wiring layouts as well as their installation details. 3.2.7 Insulation Contractor shall prepare the following detailed documents as minimum requirements on insulations. 1. Insulation specification for each vessel, tower, drum, heat exchanger, pipelines and so on indicating operating and design temperatures, type of insulation, Page 30 of 208

service, thickness of insulation and insulation specifications including type and number of tracers all required drawings and procedures for construction/erection of insulation to be provided. 2. Wrapping requirements and specifications shall be provided in detail. 3. Design calculations result in respect of insulation of piping and equipment.

3.2.8

Painting Contractor shall prepare the following documents as minimum requirements on painting: 1. Methods and procedures of Surface preparation in detail. 2. Methods and procedures of painting of Equipment and Material in the manufacturer workshop and at Site in detail.

3.2.9

Vendor Drawings & Documents Contractor shall provide at least the following vendor documents: 1. Certified drawings for all equipment to be approved by Contractor. Vendor drawings shall include Foundation loading plans, General arrangement and detailed drawings. 2. Construction Installation and operation instructions to be issued at least eight weeks prior to shipping of respective items, equipment, etc. 3. Equipment dossier for Pressure Vessels, Columns, Drums, Silos and Heat exchangers, including Design Calculations, Welding procedures, Welding qualifications, Material Test Certificates, Inspection certificates, etc. 4. Recommended spare parts list for Pre-Commissioning, Commissioning and 2 years operation. 5. Performance test certificates for all rotating equipment, for tests carried out at the manufacturer's shop. All inspection reports with necessary and sufficient information for all of the Equipment, Machinery and Materials to be submitted to Owner at right time to be reviewed and commented or Approved (wherever applicable) by Owner. 6. Special measures to protect the Bearings, Shafts, Gears and other parts of rotating machines during Transportation, Storage at Site and against emergency (partial or total) shutdowns of the Waste water treatment section, or as a result of a cut-off of steam or electric power, due to lack of oil or cooling water. 7. Electrical and Instrument diagrams, wherever applicable.

Page 31 of 208

3.3

Heat Transfer Equipment Data The thermal and mechanical design information to be provided by Contractor shall at least include but is not limited to the following:

3.3.1

Shell and Tube Exchangers including Double Pipe Exchangers if any, (Process Information to be provided for each shell) 1. Exchanger type and its Duty in design condition and different modes of operations including Shell and Tube side Inlet and Outlet Temperatures. 2. Total Gross and Effective Heat Transfer Surfaces. 3. Out side diameter, Wall thickness, Pitch type, Configuration and Length of tubes. 4. Number of tubes and passes. 5. Shell and tube side flow rates (design and in different modes of operations) and required physical and thermodynamic data for the fluids flowing in both sides. 6. Shell pass configuration, inside diameter and length of the shell. 7. Type of shell side baffling, number of shell side baffles, baffle cut and baffle orientation. 8. Number, location and size of nozzle connections, tube sheet thickness, number and size of bolts. 9. Calculated and allowable pressure drops (shell side and tube side). 10. Heat transfer coefficients in shell and tube side as well as overall heat transfer coefficient. 11. Calculation result sheets for all and any individual exchangers. 12. Specific requirement, if any. 13. Fouling factor, on both sides.

3.3.2

Shell and Tube Exchangers- Mechanical Design Information Mechanical Design Information, overall dimensions, diameters and elevations of exchanger and its supports and connections, scanting thickness of all major parts with following details. 1. 2. 3. 4. Tube sheet layout and general arrangement drawings with sufficient details. Design and operating pressure and temperatures. Nozzle diameters and flange ratings. Weight of equipment empty and filled with water. Materials of construction of shell, tubes, tube sheet and other parts including corrosion allowances, shell wall thickness, tube sheet thickness, number and size of bolts. The weight of removable tube bundles. Insulation requirements, thickness, type and materials as well as painting materials and surface preparation. Any special requirements (e.g. seal welding). Page 32 of 208

5. 6. 7.

8. 3.4

Any special manufacturing procedures to be followed by vendor.

Drawings And Documents Issued For Construction Contractor shall provide, construction drawing/document stamped as "APPROVED for Construction" and shall be signed by a responsible person to confirm that the drawings/documents are certified in all respects and in all details. Drawings and documents issued by Contractor for construction purposes shall be sufficient from all respects and shall be so detailed in order to perform and execute all activities satisfactorily for construction/erection, pre-commissioning, commissioning and all modes of operations of the Waste water treatment section, Machinery and Materials included in the Waste water treatment section. Contractor shall also provide complete set of technical procedures and specifications for satisfactory performance of the installation/construction/erection, precommissioning, commissioning and all modes of operations of all of the Equipment, Machinery and Materials included in the Waste water treatment section.

3.5 3.5.1

Selection of Equipment and Materials General Design Contractor shall carry out design and select Equipment and Materials (in accordance to the procedures specified in the Contract) which reflect up-to-date proven and established technology. Prototype designs shall not be acceptable.

3.5.2

Standardization Contractor shall give close consideration to the need for standardization to restrict and minimize the number of types and sizes of the similar equipment, machinery, materials, parts, components and items in the Waste water treatment section such as electric motors, machinery, control valves and/or some of their parts, accessories and components such as mechanical seals and so on, in order to simplify maintenance and reduce spares requirements for the inventory at site.

3.6 3.6.1

Welding Procedures Classification 1. Class A Weldments are defined as follows: a. All alloy steel weldments b. All alloy clad weldments. Page 33 of 208

c. All dissimilar metals weldments. d. All non-ferrous metal weldments. e. All weldments for operating temperatures below 0 C. f. All air fin exchanger header weldments. g. Carbon steel weldments over 30 mm thickness. h. Field fabricated tank weldments over 12 mm thickness. i. Exchanger tube to tube sheet welds. j. All main seam weldments on field fabricated vessels. 2. Class B weldments are defined as follows: a. All field or shop fabricated piping. b. Welding of pressure parts. c. Welding non-pressure parts to pressure parts. d. Other standard weldments governed by a code of practice which calls for qualification of welding procedure and welders. 3.6.2 Documentation All welding Basic and procedures, specifications and shall be properly and fully documented. 3.7 Operating Manual Contractor shall supply detailed Operation, Safety and Laboratory manual for all waste water treatment section. The operation manual shall include detailed description of Pre-Commissioning; Commissioning, initial startup, Normal Operation, Shut Down and Emergency & Safety procedures .It shall also include suggested Log Sheets for recording plant operation and analytical data. The Laboratory Manual shall include detailed description of analytical procedures, collection of samples, frequency of analysis etc. along with quality control for raw materials, intermediate and finished product. The manual shall include list of laboratory instruments/equipments and list of chemicals with their specifications. 4.0 PROCUREMENT Contractors scope includes ordering, all import formalities, fabrication/purchase of equipment and materials, port clearance, packaging and transportation to site. Items requiring covered storage and air-conditioning storage is to be highlighted along with the bid. Items contemplated for fabrication at site to be submitted along with Page 34 of 208

the bid although both these aspects would be covered under the Contractors responsibility. Vendor manuals relating to installation, operation and maintenance and test certificates should be necessarily sent along with equipment. Please also refer Final Documentation Submission requirement spelt out in this Tender Document, in this regard. Before ordering, clearances for technical portion would be taken from OWNER in respect of the critical equipments (special equipments) comprising of mechanical static and rotary equipments, electrical and instrumentation items. For instrumentation items, other equipment and materials can be ordered without referring to PMC as long as ordering is in accordance with datasheets, drawings, standards, specifications. Any ordered items which do not conform to the contractual requirement identified at any stage of the revamped waste water section shall be rejected. Replacement/modification time/cost implication arising out of this shall be to the Contractors account. Whenever clearances are to be taken, it would be necessary to submit details of technically acceptable offer. Procurement of spares for two years operation as per spare part philosophy detailed in the scope of supply. Commissioning spares are also in the Contractors scope. 5.0 INSPECTION & EXPEDITING The Contractor is required to organise a proper inspection and expediting system so as to ensure timely delivery of all the items/equipment meeting the specified quality criteria. This function has to be carried out by appropriate deployment of qualified personnel who have wide experience in their respective fields. Inspection of all items supplied under this contract shall be carried out by independent third party inspection agencies like Llyods/ BV/ TUV/ PDIL. The cost of third party inspection shall be borne by the Contractor.

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TECHNICAL (VOLUME 1) SECTION 3.1

DESIGN PHILOSOPHY - PROCESS
TABLE OF CONTENTS

SL. NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 GENERAL

DESCRIPTION

SHEET NUMBER 39 40 41 42 42 42 43 43

DESIGN PRESSURE DESIGN TEMPERATURE CORROSION ALLOWANCE HEAT EXCHANGERS PUMPS PRESSURE RELIEF VALVES COLUMNS & VESSELS

Page 36 of 208

1.0

GENERAL
The waste water treatment section shall be designed to operate in a smooth trouble free and sustained manner within a range of 40% of normal capacity to 100% of rated capacity. Equipment and machinery shall be so designed & supplied that the

WASTE WATER TREATMENT SECTION can operate on a trouble free sustained basis for at least two years without major overhaul or inspection. All design shall conform with the latest edition of the applicable sections of governing codes or standard practices. In addition, the following state/local Codes/laws shall supplement.

a) b) c)

Pressure Vessels/ Formed ends Electricity Safety

ASME, Section VIII, DIV.I / Indian Standard IS 4049. Indian Electricity Rules. Relevant Indian Standard

1.1

System of Measurements The system of measurement shall be Metric as follows: Parameter Temperature Pressure - absolute Pressure - gauge Flow (liquid) Flow (gas) Flow (steam) Length, Level Time 9.0 Heat 12.0 Power Fouling resistance Pipe size / diameter Mass Liquid relative density Liquid density Vapor flowing density draft Preferred Units C kg/cm abs kg/cm g m/hr. 1.0 m/hr. 3.0 g/hr. 5.0 m 7.0 hr. 10.0 cal 13.0 W m hr C / kcal Inches (in) kg sp gr TC/15.6C kg/m3 kg/m3 mm of WC Page 37 of 208 Alternative Units

kg/hr. 2.0 g/hr. 4.0 6.0 8.0 sec, min 11.0 Cal 14.0 mm

Parameter Storage tank pressure Vacuum Standard vapor Standard liquid Thermal conductivity Heat Transfer coefficient Entropy Heat rate Viscosity Kinematic Viscosity

Preferred Units mm of WC mm of Hg, mm WC Nm3/hr at 0C & 1.033 kg/cm2a m3/hr at 15.6C kcal/hr-m-C kcal/hr-m2-C kcal/kg 106kcal/hr or MM kcal/hr cP cSt

Alternative Units

Gcal

2.0
2.1

DESIGN PRESSURE
General Rule Design pressure of Process Static Equipment shall be based on the maximum Operating Pressure. Malfunction and Equipment failure shall be taken into consideration by safety devices. Design pressure shall be selected from the list below. Alternatively Contractor shall select the design pressures as recommended by the process licensor. For max operating pressure below 2 kg/cm2 g use 3.5 kg/cm2 g For max operating pressure between 2 kg/cm2g and 15 kg/cm2g use Max. Operating Pressure + 1.5 kg/cm2 For Max. Operating Pressure between 15 kg/cm2 g and 100 kg/cm2 g use Max. Operating pressure x 110 %

a) b)

c)

2.3

Complete Systems Several pieces of Equipment protected by the same relief valve shall have a design pressure of at least the set pressure of the relief valve.

2.4

Equipment on the Discharge of a Pump Equipment which may have to bear the shut-off pressure of a pump shall have a design pressure equal to or higher than the shut-off pressure. Page 38 of 208

2.5

Thin walled Tanks and Vessels Atmospheric thin walled tanks and vessels shall have a design pressure equal to the highest pressure imposed upon discharge of the pressure relief device.

The design pressure for vacuum shall be equal to the lowest pressure imposed upon suction of the vacuum relief device.

3.0

DESIGN TEMPERATURE
Design temperature for process equipment shall be whichever is higher: a)
For equipment operating above ambient temperature shall be minimum 150C higher than maximum operating temperature.

b)

Boiling temperature at design pressure of process medium inside, if applicable. Design temperature shall be rounded up to full 5C steps. Design minimum temperature shall be specified only if the minimum operating temperature is below 0 C. Design minimum temperature shall be 5 C less than the minimum operating temperature. Special attention shall be given to low boiling liquids.

c) d)

e) For piping, design temperature shall be determined according to ASME B 31.3.

4.0

CORROSION ALLOWANCE
Materials of construction and corrosion allowance for all Equipment and machinery shall be for a design life of 20 years (except for heat exchanger tubes). However, minimum corrosion allowance for carbon steel (including 0.5 Mo alloy steels) shall be: Pressure Vessels and other applicable Equipment Storage Tanks Piping Removable parts or internals (on each side in Contract with operating fluid) For stainless steel/titanium Carbon steel with epoxy resin coating Page 39 of 208 3 mm 1.5 mm 1.5 mm 0.75 mm 0 mm 3 mm

5.0

HEAT EXCHANGERS
In general heat exchangers shall be designed to 110 % of their operating duty/flow. Large heat exchangers shall be split into two or more shells for easy operation and maintenance. As far as possible AES type of exchangers shall not be used.

6.0

PUMPS
Normally pumps shall be designed to 110 % of their maximum required flow rate in worst case of operation. The shut-off pressure shall be estimated according to the following criteria whichever is higher: a) Differential head at rated flow x 120 % + LH (level high) suction static head + max operating pressure suction side. Differential head of pump at rated flow + LHH (level high high) suction static head + design pressure suction side x 120 %. No over design shall be applied to the rated pressure.

b)

BFW pumps shall be designed for 120% of their maximum required flow rate in worst case of operation.

7.0

PRESSURE RELIEF VALVES

Pressure relief valves shall be supplied with locked open isolating valves. Pressure relief valves for operational failure shall have installed spares. The set pressure of pressure relief valves shall be equal to the design pressure of the equipment. All safety valves will have bypass with exception of safety valves which are only for fire cases and if there is more than one safety valve.

8.0 8.1

COLUMNS AND VESSELS

Nozzle a) Minimum size 3/4" (for S.S shall be 1 inch). b) Nozzle rating according to once of connected piping for instrument min. Class 150 ANSI rating. Page 40 of 208

8.2

Manhole a) b) Manhole size 24 (*) Manhole installation for Tray Tower

8.3

Hand hole or Inspection hole a) b) Preferable Size 8 inches Minimum Size 6 inches

8.4

Vent and Drain Vent and drain for vessels will normally be provided at the minimum length on overhead or bottom line in accordance with the following table: Volume or diameter of vessel (m3 or mm) V < 75 or D <= 4,500 75 < V <= 220 4,500 < D <= 6,000 220 < V <= 420 or D > 6,000 V > 420 Vent diameter (inches) 2 3 4 6 Drain diameter (inches) 2 3 4 4

Note: Vent and drain connections are not necessarily located on vessels.

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TECHNICAL (VOLUME 1) SECTION 3.2 DESIGN PHILOSOPHY INSTRUMENTATION

Page 42 of 208

CONTENTS
SECTION NUMBER 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 DESCRIPTION Instrumentation And Controls Scope Design Basis Instrumentation Control And Design Philosophy Instrumentation Code And Practices Field Instruments Primary Differential Procedures Other Flow Meters Level Instruments Level Gauge Glass Pressure Instruments Temperature Instruments Control Valves Pressure Relieving Devices Switches And Solenoid Valves Package Unit Instruments Noise Immunity Of Electronic Instruments Process Connection, Piping And Installation Electrical Supply, Classification And Instrument Wiring SHEET NUMBER 47 47 47 49 50 53 55 55 57 57 57 59 60 62 64 65 66 66 67

LIST OF ATTACHMENTS

ATTACHMENT NUMBER Annexure-1 Annexure-2

DESCRIPTION

NUMBER OF SHEETS

Instrument Accuracies Instrument Process Connections

69 70

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1.0 2.0
2.1

INSTRUMENTATION AND CONTROLS SCOPE

This section outlines the general requirements and specifications for Instrumentation and Control System for the REVAMPED WASTE WATER SECTION. The Instrumentation and Control System shall consist of but not limited to the following: All Field Instruments including control valves and safety valves

2.2

The Contractors scope for all the above facilities shall cover design, engineering, procurement, installation, testing, calibration and commissioning etc. as detailed below: a) Preparation of general specification for Instruments

b) Sizing of flow instruments, control valves, pressure relief valves etc., and preparation of Technical data sheets for all Instruments. c) Invitation of offers, technical and commercial evaluation of offers and placement of orders on final approval from the OWNER.

d) Preparation of engineering and construction documents like functional schematics, I/O list for both DCS and ESDS System, logic diagrams for interlocks as per ISA 5.2 with functional descriptions, configuration diagram, control room layout, electrical load list, cable schedule, instrument index, layout drawings, loop diagrams, primary and secondary sketches and bill of materials. f) Co-ordination with all instrumentation vendors and package vendors for obtaining sufficient information in the form of documents, drawings for engineering and approval from OWNER.

h) Preparation of specification for erection materials like cables, cable trays, pipe & pipe fittings, air tubing, junction boxes, air distribution pots etc. i) Site supervision of construction, erection, testing and commissioning activities of field instrumentation and control room instrumentation activities. In case of contradiction / conflict among documents, Bidder shall refer to Owner for clarification. However, most stringent specification shall be followed with Owners approval. Owner decision shall be considered as final.

3.0
3.1

DESIGN BASIS
Instrumentation for the proposed Revamped waste water section is to provide a highly reliable and comprehensive control and monitoring system. To facilitate this well proven technique shall be adopted for measurement and control.

Page 44 of 208

Local indicators, start /stop switches, emergency stop switches shall also be provided near package units/rotating machines where local start up of the equipment is advisable. 3.2 GENERAL NOTES TO BE FOLLOWED
a)

Universal Hart Protocol with Latest Revision shall be used in all cases. All logics shall be implemented in Central DCSDIs/DOs from MCC to DCS shall be with relays only.

b)

In ESDS wherever consequence of nuisance trips, e.g. production loss, are envisaged, a 2 out of 3 sensor philosophy shall be used. The philosophy shall be applicable for temperature sensors also with separate thermo wells for each sensor. Minimum 4 nos loop calibrators shall be provided. All limit switches shall be proximity sensor type. Test Instruments shall be provided. The execution of instrumentation shall be as per area Zone 2, group IIC, T6, EExib and Protection Electrical / Electronic instruments Sensors; RTD, T/C, etc. Local Gauges; PG, etc. Pneumatic instruments Solenoid valves Local Panel / Skid Mounted Panels IP 67 IP 65 IP 55 IP 54 IP 67 IP 55

c) d) e) f)

EMC compatibility and electrical safety as per latest IEC standard.

g) h)

Instrument air header, pipes and distributors shall be SS 304 only. Instrument air headers, pipes and distributors shall be of S.S. Instrument air manifold shall be used for supplying instrument air to control valves and other instruments. These shall be with 12 nos. of tapings and be with NPT (F), SS 304 valves. From the nearby air manifold, instrument air shall be supplied to the control valves. For the purpose, all tubing shall be used shall be of SS316, 6mm, 10mm, 1/2 OD, seamless tubes, laid in perforated aluminium trays. All intermediate fittings shall be double compression, SS316 MOC, Swaglok make only. Jucnction Boxes: Flame proof type approved for Ex-d IIC/T6 as per CENELEC. Weatherproof to IP 67 as minimum. Suitable armoured, pair/overall shielded, tinned copper conductor FRLS PVC cables between field sensors and control room. Spare Parts List shall be provided as per ATTACHMENT-II. The instrument power/signal and control cables shall be ATC, multistrands Page 45 of 208

i) j) k) l)

(max. 7 strands), screened/armoured/FRLS etc.

m) n) o) p)

Field junction box shall be made of die-cast aluminium and epoxy painted. Signal Category wise segregation shall be used. Destination based segregation shall be used. pH and conductivity meters shall be 2 wires, 24 V DC, SMART with HART protocol with local display and electrode/sensors shall be without preamplifier and the pre-amplifier shall be part of transmitter. Separate JBs for mV, DI, DO, AI, AO,RTD Junction Boxes shall be segregated signal wise and voltage rating wise. There shall be separate JBs for control related and interlock related signals. Broadly speaking following categories shall be maintained:-

q)

a. Analog Input JB b. Analog Output JB c. Discrete Input JB d.

r)

Discrete Output JB To the extent possible the Field Instrument Signal Distribution Junction-Box wise should be such that the signals terminated from individual Junction Box shall be terminated in the same DCS I/O module, i.e., signals from one junction box SHALL NOT be terminated in different I/O modules. All spare cable cores shall be terminated in the Junction box, at the marshalling panel end Connectivity from Upstream redundant device to downstream redundant device shall be through redundant device or cable.

s) t) u)

The transmitter selection shall be such that the operating maximum upper limit shall be around 70% of the total measurement range of the transmitter All Contacts shall be Gold Plated 2 SPDT. No Direct Process Switches (Pressure / Level/ Flow / Temp.) shall be used. Only Smart Transmitters shall be used.

4.0
4.1

INSTRUMENTATION CONTROL AND DESIGN PHILOSOPHY

Design and installation of instrumentation shall comply with codes and recommendations listed in item 5.0. All product flow shall be measured with accuracies of +/- 0.15% Execution type for all field transmitters in hazardous area shall be intrinsic safe. Flame / ex. proof enclosures shall be provided where intrinsic certifications are not available. All field transmitters for pressure, d/p, level and flow shall be microprocessor based SMART transmitters with UNIVERSAL HART protocol with latest revision Page 46 of 208

4.2 4.10

4.12

4.14 4.15 4.17

Hart management System is required. Dedicated sensors / transmitters shall be used for Emergency Shut Down System. Instrument air headers, pipes, tubes and air distribution pots shall be of stainless steel. Cable trays shall be of perforated anodised aluminium. Impulse pipes for process shall be in accordance with piping specifications. The minimum air supply for instruments at anywhere in the battery limit shall be designed for 4 kg/cm2g All pipe and pipe fittings used in steam and boiler feed water services shall be supplied with International Boiler Regulation Certificate. Multi Cable Transit (MCT) of Roxtec make only shall be used for leak proof sealing for cable entry to control room(s). All equipment/materials supply shall include spares required for 2 years operation and consumable for commissioning.

4.18

4.19

4.20

4.21

5.0

INSTRUMENTATION CODE AND PRACTICES IEC 13 Diagrams, Charts and Tables, Preparation of Logic Diagrams IEC 534 Industrial - Process Control Valves IEC 584 Thermocouples IEC 605 Equipment Reliability Testing elements IEC 611-12 Part 12Graphical Symbols for Diagrams. Binary Logic IEC 654 IEC 751 IEC 801 IEC 848 IEC 902 Definitions ISA S-5 .1 ISA S-5.2 ISA S-5 3 Measurement and Control equipment Industrial Platinum Resistance Thermometer Sensor Electromagnetic Compatibility for Industrial Process Measurement and Control Eqpt. Preparation of Function Charts for Control Systems Industrial Measurement and Control Terms and Instrumentation Symbols and Identification Binary Logic Diagrams for Process Operation Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Symbols

Page 47 of 208

ISA-S20 Instrumentation specification formats ANSI/ISA S 5.1 Process Instrumentation Terminology ANSI/ ISA S71.04 Environmental conditions ANSI/ ISA S75.01 Control Valve Equations ANSI/ ISA S75.02 Control Valve Procedure Capacity Test ANSI/ ISA S75.03 Face-to-Face Dimensions for Flanged Globe Style Control Valve Bodies ANSI/ Quality Control Standard for Control Valve Seat FCI 70.02 Leakage BS 6020 Instruments for the Detection of Combustible Gases DIN 3582 Screwed Plugs, Tapped Holes, with Whitworth Part 2Pipe Threads: General Outlay of Types DIN 43760 Measurement Standard for RTD. DIN 19243 Measurement and Control Electrical Sensors, Electrical Position Sensors and Signal Converters used for intrinsically safe twowire DC System. EN-50-014/020 Electrical Apparatus for Potentially Explosive Atmospheres EN 54 Part I Components of Automatic Fire Detection System Introduction. EN 54 Part 5 Heat sensitive Detectors - Point Detectors containing a Static Element. ISO 3511.1 Process Measurement Control Functions and Instrumentation Representation Part I: ISO 3511.2 Instrumentation Basic requirements. Process Measurement Control Functions and Representation

Part 2: Extension of Basic Requirements. ISO 3511.4 Process Measurement Control Functions and Instrumentation Representation Part 4: Basic Symbol for Process Computer, Interface and shared Display/Control System.

ISO 4200 Plain End Steel Tubes, Welded and Seamless-General Table of Dimensions and Masses per unit Length.
Page 48 of 208

ISO 5167

Measurement of Fluid by Means of Orifice Plates Nozzles andVenturi Tubes Inserted in Circular cross-section Conduits Running Full. Sizing, selection and Installation of Pressure relieving devices in Refineries Guide for Pressure Relieving and Depressuring System Venting Atmospheric and low pressure storage tanks Accessory equipment for liquid meters Manual of

API RP 520

API RP 521 API RP 2000 API- Chapter 5.4:

Chapter 6.2 Loading rack and tank truck metering system Chapter 6.6: Pipeline Metering Systems Measurement Chapter 12: Calculation of Standards Petroleum Quantities12.1 &12.2 Part 1 and 2 API-RP-550 Manual on Installation of refinery Instruments Part I and control System ANSI - B 16.104 Control Valve seat leakage ISA related to the analyser shelter shall be flame proof conforming to the area classification. The gas sample conditioning unit shall be installed outside the shelter. For O2 analysis in flue gas, vertical in situ mounting type zirconium probe for reformer top and horizontal type for HRU flue gas duct shall be used if not otherwise stated. All liquid analysers shall be of intrinsic safe design suitable for execution class specified for the area. Liquid Analyser, sampling conditioning unit and other accessories shall be mounted on a rack suitable for field mounting. pH, conductivity shall be installed preferably in a bypass line to facilitate maintenance of the analyser. Sox and Nox analyser cabinets shall be located just below the stack. If the area is unsafe purging with nitrogen /air shall be provided and shall conform to the hazardous area classifications. Analysers performance quality shall be in line with the following as a minimum: -S 75.01 Control Valve sizing ISA S 18.1 Specifications and guides for the use of general Annunciators. IEC 529 Environmental Protection of equipment
Page 49 of 208

ANSI B 2.1 ANSI B 16.5 IEC 79.11/ IEC-79.14 IS 2148 6.0 6.1

Pipe threads Steel pipe flanges, flanged valves and fittings Intrinsic safety code and practice International Boiler Regulation Flameproof enclosure of electrical apparatus

FIELD INSTRUMENTS pH & Conductivity Meter

All pH and Conductivity analysers shall be micro-processor based suitable for execution class specified for the area. The Analyser, sample conditioning unit and other accessories shall be mounted on a rack suitable for field mounting. pH, conductivity shall be installed preferably in a bypass line to facilitate maintenance of the analyser. The pH responsive electrode shall be solid state or dual membrane type. The electrodes shall be shock proof and screened with metal foil. The reference electrode shall be of diffusion type. The conductivity measurement shall be toroidal sensor type. Ultrasonic cleaning arrangement shall be provided for the probes. Temperature compensation shall be provided for the measurements. Accuracy for pH and Conductivity Analysers shall be as under: pH Conductivity 0.1% of full scale 0.5% of full scale

6.2 6.2.1

Flow Instruments Flow Transmitters

D/P cells shall have measuring method on the floating capacitance technology. The signal transmitter shall normally be a 2-wire system and shall be capable of delivering rated current into external load of at least 600 ohms when powered with 24 V d.c. Protection against short circuit and reverse voltage shall be provided. Bodies shall normally be in stainless steel with Hastelloy C/ Equivalent internals. Integral 3- valve manifold similar to AGCO make model 4A shall be used for mounting transmitters on manifold for ease of maintenance. Material of manifold in general shall be SS316L but may vary depending upon service. Digital output indication shall be preferable on the integral output meter with the transmitter. All flow transmitters shall have sq. root extraction function. Pressure elements in austenitic stainless steel are a requirement in hydrogen services. The transmitter shall be furnished with an output meter or gauge with a sq. Page 50 of 208

root scale. Smart type transmitters will be used with Hart V protocol. Overall accuracy for SMART transmitters shall be +/- 0.075% or better. Process connection size shall be 1/2 NPT through oval flanges.

All field transmitters shall be 2 wire types, 24 Volt DC, SMART with HART protocol, and shall be equipped with Local LCD type digital indicator. 2 pipe mounting, SS304 MOC brackets, Accuracy 0.075% of Span , Rangeability 1:100, Local Display configurable, SS MOC, Double Compression SS cable glands, EExib IIC/T6, IP67, Wetted MOC SS316L, SS316L MOC Manifold, Housing Die-Cast Aluminium .Epoxy Painted, Universal Hart Protocol with Latest Revision is required.

6.2.2 Rotameter
Rotameters or variable area meters may be used in pipe sizes from 1 1/2 and smaller. The meter shall be selected for normal flow at 50 to 60% of the span. In applications with toxic or inflammable fluids, glass tubes must not be used except for low pressure analyser sample flows. They may be used for severe corrosive services and of fluid of high viscosity. The metal tube meters shall be of stainless steel, PTFE lined or any other suitable lining for the service. The Indicator assembly shall be magnetically coupled and mounted with rotameter body. Transmitters or Indicators on float extension are not recommended except for cryogenic services. The switch assembly shall be of proximity type. All rotametres shall be metal tube type. The rotameter transmitters shall have 4-20 mA output at 24V d.c. power on two wire system.

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7.0 7.1

PRIMARY DIFFERENTIAL PRODUCERS Orifice Plates

Orifice plates of the square edged concentric type shall be specified except where unsatisfactory for the application. Materials of orifice plate shall normally be AISI 316 unless special materials are required for the service. The maximum ratio of orifice to inside pipe diameter of 0.70 and minimum ratio of 0.25. Orifice plates dimensions and calculations shall be in accordance with ISO 51671980.

7.2

Nozzles
ISA 1932 Nozzles may be used in high and medium pressure steam and BFW piping. Materials for nozzle element shall normally be AISI 316 steel unless special materials are required for the service. Dimensions and calculations shall be in accordance with ISO 5167-1980. Generally branch pipe is required with the nozzle the same shall be machined from higher schedule pipe than the one used for the service or forged branch pipe shall be used if higher schedule pipe is not available. The branch pipe bore shall be same as that of nozzle ID and shall have mirror finish.

7.3

Venturi Tubes
Venturi Tubes or nozzles as per ISO 5167-1980 or similar type elements may be used to measure the flow of low pressure gases or liquids where loss of pressure is an important consideration.

7.4

Pitot Elements
Pitot Elements of the averaging type may be used where high accuracy is not required or the pipe diameter is too large for acceptable orifice plate design. Use of annubars shall be limited to combustion air, flue gas raw water and fresh water services unless specifically indicated. The annubars shall be extraction type with ball valves and pipe fittings required for installation. The connection size shall be 1 1/2 NPT. For rating 1500# and above the process connection size shall be 2 flanged.

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7.5

Local Flow Indicator

Motion balance (Barton cell type) type differential pressure indicator shall be used for local flow indication. Body and internals shall be of 316 SS. Process connection shall be 1/2 NPT (F). 3-valve manifold with 1/2 NPT connection shall be used with the meter.

8.0 8.1

OTHER FLOW METERS Mass Flowmeter

Coriolis type mass flow meter with local digital display of flow shall be used to measure the process flow where high accuracy is required. Normal accuracy for mass flowmeters shall be 0.15% of span. The sensing element shall be straight/Utube, material 316 in general.

8.2 8.3

Vortex Meter No vortex meters shall be used. Ultrasonic Flowmeter

Ultrasonic flow meters (non- insertion probes preferred) based on the time-offlight method shall be used. Meters based on the Doppler principle are less accurate and shall not be used. Ultrasonic flow meters shall be considered for large turn downs and where pressure drop is not permitted. Upstream and downstream straight lengths shall be as per standard.

8.4

Electro-Magnetic Flowmeter
Electromagnetic flowmeter with ceramic lining shall be used for the measurement of flow with high accuracy for highly viscous and corrosive services and also for cooling water.

8.5

Guided Wave Radar Displacer type level instrument shall be avoided and guided wave radar type shall be used in their place if suitable to process condition. Ultrasonic / Radar type Instrument shall be used for large liquid storage tanks. Guided Wave Radar type level instruments, where used, shall be external type with side / side connections and rotatable transmitter head. Vent and drain valves shall be provided. Guided Wave Radar Level transmitter shall be applicable for liquids or slurries, hydrocarbons too water- based media. In absence of dielectric constant for the process fluid, Bidder shall confirm the suitability of Guided Wave radar Level Transmitter for such applications and Bidder shall suggest the suitable Page 53 of 208 model for

the same. Bidder shall suggest the suitable model for Interface applications like oil on water, Hydrocarbon on water, etc. Electronics shall be capable of measuring upper liquid and interface level simultaneously. Selection shall be available for analog output signal from level transmitter corresponding to upper liquid or Interface. Process connections shall normally be 2 flanged with side-side connections.

9.0 9.1 10.0 10.1

LEVEL INSTRUMENTS Displacement type level sensors shall not be used. LEVEL GAUGE GLASS Gauge Glasses
Glass gauges shall be avoided and magnetic type level gauges shall be used if suitable to process condition. If unavoidable Gauge Glasses shall normally be reflex type for all process services, except for boiler drums bicolour types shall be used, and in corrosive services. Where transparent gauges with glass protection and illuminators shall be used, Illuminators shall be explosion-proof in hazardous areas. Gauge glass columns will not exceed 1500 mm. Transparent type gauge glasses (double glass) will be used for services in which a level may not be distinguishable, such as interface services, between different liquids, where mica shields are required and fluids of high viscosity or high solid content. Level gauges shall be supplied with a pair of off-set shut off valves with ball check. For cold services where temperature is below 0 deg C a non-frosting gauge will be used. Glass tube level gauges shall be avoided.

10.2

Seal Diaphragm type Level Transmitter Smart DP transmitter with teflon lined hastelloy C shall be used for level measurement in corrosive services. The scale shall be linear.

11.0
11.1

PRESSURE INSTRUMENTS
Pressure Transmitters Pressure Transmitters and differential pressure transmitters shall be modern inherent motion-free type of the floating differential capacitance principle. Bodies shall Page 54 of 208

normally be in stainless steel with Hastelloy C Equivalent. Pressure elements in austenitic stainless steel is requirement in hydrogen services. Two valve integral manifold of SS316L material in general shall be used with pressure transmitters. The signal transmission should normally be a 2-wire system and shall be capable of delivering rated current into external load of atleast 600 ohms when powered with 24 V d.c. Protection against short circuit and reverse voltage shall be provided. The transmitter shall be furnished with a digital output meter or gauge with a sq. root scale. Smart type transmitters will be used with Hart V protocol. Overall accuracy for SMART transmitters shall be +/- 0.075% or better. Process connection size shall be 1/2 NPT. All field transmitters shall be 2 wire type, 24 Volt DC, SMART with HART protocol, and shall be equipped with Local LCD type digital indicator. 2 pipe mounting, SS304 MOC brackets, Accuracy 0.075% of Span , Rangebility 1:100, Local Display configurable, SS MOC, Double Compression SS cable glands, EExib IIc/T6, IP67, Wetted MOC SS316L, SS316L MOC Manifold, Housing Die-Cast Aluminium .Epoxy Painted, Universal Hart Protocol with Latest Revision is required

11.2

Pressure Gauges
Gauges for process and utility services shall be industrial SS Bourdon gauge/diaphragm or spring bellows type as per process requirement with the case in stainless steel. The gauge for 60 kg/cm2 above pressure shall preferably be a safety type with solid front where pointer and glass are partitioned off from the sensor by a solid disc. Pulsation dampeners shall be installed with the gauges where pulsating pressure occurs. Process connection shall be 1/2 NPT (M) bottom in general. Bezel rings shall be screw on pattern. Dial Size minimum 150mm Blow-out discs are required for all pressure gauges except for instrument air services. Vibration proof gauges or remote seal type shall be used if the surrounding environment is subject to vibration. Minimum accuracy for pressure gauges shall be +/- 1%

11.3

Pressure Switch
Pressure switches shall be used for alarm, interlock, sequence system and will have electric switches SPDT with hermetically sealed contacts rated for 0.5 amp, 24 V d.c. All such contacts shall be gold plated. Process connection shall be 1/2 NPT (M). The pressure switches shall have electrical connection size of 3/4 NPT (F) for cable gland termination. The cables shall be terminated in terminal strips and flying Page 55 of 208

leads shall be avoided. Sensor and all wetted parts material as a minimum shall be 316 SS. Casing material shall either be stainless steel or die cast aluminium. Sensor shall normally be bourdon but special elements such as diaphragms and bellows can be selected where they are more suitable for the service than bourdon tubes.

11.4

Diaphragm seal
Teflon lined hastelloy C Diaphragm seals shall be provided where plugging of the element may occur due to congealing and high viscous fluids or where suitable sensor material is not available in highly corrosive services. The seal supporting flange material shall be 316 SS teflon lined.

12.0 12.1

TEMPERATURE INSTRUMENTS Thermocouples

No Thermocouples shall be used.

12.2

Resistance Temperature Probes

Resistance Temperature Probes shall be considered for applications where very narrow spans and high accuracy are required as well as low temperature service. They shall be 6mm (1.4) stainless steel sheath type similar to the thermocouples and with a Pt 100 ohms (0 degree C) element. The sensors shall be duplex type and shall be spring loaded for vibration proof. The elements shall conform to DIN 43760 or IEC 751.

12.3

Thermometers
Thermometers shall normally be bi-metallic, heavy duty, weatherproof (IP 55), adjustable angle connected type with 150 mm dial as a minimum, and dials of smaller size may be used for auxiliary services on machinery. Liquid filled indicators will be used only where indication is required to be remote Case and stem shall be in stainless steel. Dials shall be of white, non-rusting metal with black figures. For local temperature control upto a maximum scale range of 540 deg C, liquid Page 56 of 208

filled sensors with capillary extension shall be used. Filled system instruments when used shall be fully compensated for ambient temperature variations. Capillary shall be SS armoured and length of which will not generally exceed 4 mtrs.

12.4

Thermowells
Flanged thermowells shall be of 1 1/2 size. Screwed thermowells shall be of 1 NPT (M). Flanges rating, facing and material shall be in accordance with the equipment or piping standard. Thermowell material in general shall be of AISI 316 SS. but special materials like Hastelloy C, Alloy 20, and Uranus B6 shall be provided in special services like , slurry etc.

13.0

CONTROL VALVES
Valve types shall be selected, pneumatic diaphragm /piston operated globe, ball or butterfly shall be selected taking into account such factors as piping, operating and design conditions, fluid being handled, tangibility required, allowable leakage, noise and other special requirements. The valves shall have smart electropneumatic positioners. Seat Leakage shall be chosen in accordance with process demands and safe operation of the plant and in accordance with AISI B16.104-1976. However, in general, the globe valves used shall be of class IV leakage minimum as per ANSI B6.104 in general.. For vent services the leakage class shall be class V or VI depending upon process requirement. Safety shutoff valves must not be used in throttling service during normal operation. Noise abating devices shall be provided with valves where noise level at the outlet of valve at a distance of 1 metre all around is more than 85 DBA for valve which have operating times of 5 minutes or more in general and which are only working during start up and in upset conditions. For continuous operation the allowable sound level shall be 85 dBA. All noise abating plates, expanders, flanges, gaskets, studs & nuts shall be in the scope of valve manufacturer. The noise abating plates Page 57 of 208

shall be of wafer design for easy removal for maintenance. Source treatment for noise shall be preferred over path treatment and for high noise vent applications DRAG type trim shall be specified. All valve bodies shall be cast or forged. Stainless steel bodies shall be acceptable in place of alloy steel bodies, if not available, for low temperature application. On line replaceable trims shall be considered for all high pressure valves of buttweld or socket weld connections. Split body design for ball valves acceptable where top entry ball design has not been considered for economical reasons. Mufflers shall be provided on ball valve vent air lines for noise suppression. Spring loaded seat and hard chrome plated ball shall be a standard feature for ball valves, in general. All valve actuators shall be selected for a minimum operating air pressure of 4.0 kg/cm2g. The actuators shall be diaphragm or piston actuators in general. Diaphragm actuators with single or concentric multi-springs shall be used. Volume tank with airlock relay, booster relays shall be avoided as far as possible. Rotary rack and pinion pneumatic actuators may be used with ball and butterfly valves for on-off services. In general, if otherwise not specified in the valve data sheet the time for full travel shall not exceed 10 seconds. Wherever handwheel is required with a valve the same shall be side mounted type. All split range functions for valve operations shall be carried out in DCS and split range provision in valve positioners shall not be necessary. Butterfly valve bodies shall be of wafer design. Lug type body shall be considered for size above 12. Face to face dimensions shall conform to ANSI B 16.10 and ANSI B 16.47 wherever applicable. Butterfly valves shall be used for high flow, low pressure drop below 10 kg/cm2g. Non destructive test like radiography, ultrasonic, die penetration and magnetic particle shall be carried out for cast and forged bodies conforming to procedures laid Page 58 of 208

down in ANSI B16.34. Radiography or ultrasonic test, if not specifically mentioned in the data sheet, shall be carried out for cast or forged bodied of rating 900 lb. or above. Valve bonnets shall be in general of bolted bonnet design as per ASME B 13.3 par 307.2 with minimum four bolts. Smart E/P positioners with position transmitter along with valve signature software to be provided for all control valves Actuator sizing shall be done at 4 Kg/cm2. Handwheel (Side-mounted) for all regulating control valves to be provided By-pass valve provision shall be as per process licensor requirement. All regulating control valves to be provided with side mounted hand wheels. The control valve % opening shall be at minimum flow 10-20%, for normal flow 50 to 70%, for maximum flow 75 to 85%. All on off application valve shall be fixed with necessary limit switches.

14.0 14.1

PRESSURE RELIEVING DEVICES Pressure Relieving Devices

All Pressure Relieving Devices shall be sized in accordance with applicable local and national code requirements. Formulas shall be in accordance with API RP 520, 1990 and ASME Codes section I and VIII. Percent Overpressure and Accumulation used in calculation of sizes of relieving devices shall be: Overpressure 3% Steam services where ASME Power Boiler Code applies. 10% Gas or Vapour service. 15% For liquids and pump discharge lines with 6% system accumulation (Power Boiler Code) and with 10% system accumulation (Pressure Vessel Code) 21% Fire exposure on unfired pressure vessels.

Page 59 of 208

10% 10% 16% -

Liquids for thermal relief of pipelines or vessels Accumulation Gas , Vapour and liquid where ASME Pressure Vessel Code applies Gas , Vapour and liquid where ASME Pressure Vessel Code applies and the system is protected by means of multiple valves.

14.2

Nomenclature
Nomenclature used shall be in accordance with API RP 520.

14.3

Safety and Relief Valves

Safety and Relief Valves shall normally be direct spring loaded type. Balanced bellows valves shall normally be furnished for relief into closed flare and slowdown systems, if the developed back-pressure exceeds 10% of the set pressure. Bellows shall also be specified where leakage of gas from the seals are not permitted during normal plant operation. Steam jacketing may be considered necessary to keep some valves and lines warm at all the times to avoid the solidification of the lading fluid. Full nozzle types of valves shall be specified for sizes 1 or above. Test gags shall be furnished on all safety and relief valves. Test gags shall be removed and transferred to Owners possession after testing, clearly labelled with the tag number of the valve. Lifting levers shall be furnished for exposed spring bonnets on valves on steam and hot water services, on air valves and hot water service valves with closed bonnets Bonnet construction shall be plain closed bonnet for toxic and inflammable gases as well as vapour and liquids. Exposed bonnet shall be specified for steam service and in Boiler feed water service above 200C. Bonnet extension shall be used above 400C Springs shall be of carbon steel for normal process operating temperature of (-) 25C to 200C and tungsten alloy or high temp. alloy steel above 200C. Stainless steel spring may be used for services below (-) 25C. Carbon steel is permitted above 200C for open bonnets. Blowdown shall be in between 5% to 7%. For steam services under Power Boiler Code as per ASME the blowdown shall be 3% - 4% All connections shall be flanged in general with facing and rating in accordance with the piping specification or API 526 whichever is higher. Page 60 of 208

Centre to Centre dimensions shall be in accordance with API 526

14.4

Rupture Discs
Rupture discs may be used in lieu of or in combination with safety and relief valves, wherever applicable or required. For disc rupture trip or alarm disc shall be with bursting sensors.

14.5

Pressure and Vacuum Relief Valves

Pressure and Vacuum Relief valves for storage tanks shall normally be of the weight loaded or pilot operated type, and sized in accordance with API RP-2000 Tank Venting Code or Local Codes if they govern.

14.6

Thermal Relief Valves

For thermal relief of accumulated liquids in pipelines and vessels 1 x 2 size valves shall be used in general.

14.7

Centre-to-Face
Centre-to-face dimensions shall be in accordance with API 526.

15.0 15.1

SWITCHES AND SOLENOID VALVES Level Switches

Level Switches shall normally be the external float cage type. Body material and rating shall conform to piping specifications. Internal trim shall be stainless steel unless other materials are required for service.

15.2

Pressure Switches Refer details in item 1.10.3

15.3

Temperature Switches
Temperature switches mounted in the control room and in the local panels shall be thermocouple actuated and be completely adjustable. They shall have cold junction compensation. Page 61 of 208

15.4

Flow Switches
Flow switches for direct operation by process fluids may be of the rotameter for low accuracy requirements. Orifice plate and differential pressure type transmitter shall be used for high accuracy requirements and the switch shall be an electric analogue switch. For alarm purpose, the switching shall be through DCS software.

15.5

Solenoid Valves
Solenoid valves shall normally be used to actuate other instruments/valves connected directly to the process. The SOVs shall be direct acting type. Protective enclosure shall be IP 65 and the coil insulation suitable for continuous operation in 85 degree C ambient temperature (max. surface temperature in sun) for outdoor service. Body materials shall normally be stainless steel. Solenoid valves will be powered by 115V +/- 10%, AC 50 Hz +/- 3% insulation class H and orifice size 9 mm. The d.c. solenoids shall not have in built rectifier to operate with A.C voltage. The d.c. solenoids shall be used as an alternative to A/C solenoids only for low current intrinsic safe operations All solenoid valves shall be fitted with 1/2 NPT (F) SS cable gland connection.

16.0
16.1

PACKAGE UNIT INSTRUMENTS

Instruments and controls for Critical Compressors, blowers and their respective drives shall be in general Electronic microprocessor based system. All Controls including extraction control, speed control and discharge pressure control shall be done from central control room. However there shall be a local start-up control panel for each machine .The control system shall be supplied as complete system and only the utilities like power supply, water, and instrument air shall be provided at the battery limit of the compressors. Vendors scope supply includes: All instruments for safe and efficient running of the machine. The supply shall include control valves, suction and discharge auto block valves, relief valves, shut off valves, solenoids, speed indicators, transmitters, electronic governors, pressure and temperature gauges, switches, sensors etc. Gauge Board to be located near each machine with local gauges mounted on it. All instrument erection materials such as cables, pipes, pipe fittings, supports, trays, conduits, junction boxes etc.

16.2 16.2.1

16.2.3 16.2.4

Page 62 of 208

16.2.5 16.2.6 16.2.7 16.2.8 16.2.9

Tools for service calibration and maintenance. Spares parts for 2 year Operations. Consumables for one year. Engineering documentation. Commissioning spares, wherever applicable, shall be supplied along with the main item.

17.0

NOISE IMMUNITY OF ELECTRONIC INSTRUMENTS

The electronic Instruments shall have a susceptibility of less than 0.5% of span for a frequency range of 20 - 200 Mhz in a field strength of 20 Volts/metre

17.1

Pneumatic Transmission Tubing

Pneumatic transmission tubing for local transmission shall be 6mm OD stainless steel tubing with stainless fittings.

17.2

Instrument Air
Instrument air required is available at 6.5 kg/cm2g and max.70 deg C. However, the air pressure can be down to 4.5 kg/cm2g for remote consumers. Design pressure is 10 kg/cm2g. Dew point is -40 degree C at line pressure. Air Distribution Headers shall be as SS 304.

18.0

PROCESS CONNECTION, PIPING AND INSTALLATION

REFER ANNEXURE III

18.1

First tapping points for all pressure, d/p signals shall be 3/4. Mechanical piping scope shall be upto 1st isolation valve(s). Subsequent reduction to 1/2 size and impulse piping and connection shall be under the scope of instrumentation.

18.2

Wherever diaphragm seals have been used, the vessel or piping nozzle shall be 3 flanged. Flange rating shall conform to piping index.

Page 63 of 208

18.3 All vessel or piping nozzles for temperature instruments shall be 1 1/2 flanged or 1 NPT (F) threaded.

19.0

ELECTRICAL SUPPLY, CLASSIFICATION AND INSTRUMENT WIRING Electrical Supply

The electrical supply will be as follows: Distributed Control System, trip system, and Control Room Instruments : 115V AC Solenoid Valves Field-mounted Transmitters and switches Safety Circuits : 115V DC : 24V d.c.intrinsic safe

19.1

: 115 V AC

Where 24V DC is needed, it will be generated by local rectifier units, which are part foreseen.of the instrumentation supply. The power supply to these units shall be taken from the UPS. Where 24V DC are used for Safety Circuits, the rectifier units shall be duplicated and with high reliability and form apart of ESDS vendor. A separate instrument earthing system apart from the power supply protective earthing system is

19.2

Electrical Classification
The area classification is Zone 2 which is analogous to the American Division 2 classification. Electrical instrument equipment shall be designed for and supplied as intrinsic safe certified. Analysers, solenoid valves and other equipment that can not be classified intrinsic safe shall be exproof in accordance with the above mentioned electrical specification. Page 64 of 208

Separate trays shall be used for multiconductor cables for thermocouple wiring, 420mA wiring and alarm system and power circuits, which also will ensure the required segregation between high and low energy level circuits.

19.3

Electronic Instrument Signal Wiring

Electronic Instrument Signal Wiring shall be twisted pairs - 15 twists or more per meter. Conductors shall be1.5mm2 for one and two pairs and 1.0 mm2 for multiconductor cable and shall be stranded, annealed tinned copper. Insulation shall have a minimum radial thickness of 0.25mm. Insulation of core to core shall withstand a r.m.s. AC test voltage of min. 2000V. All cables shall be galvanised steel wire armoured under the PVC outer cover of a flame retardant, low smoke type (FRLS) in accordance with IES 227. Multi pairs shall be shielded with common aluminium mylar tape with tinned copper drain wire. The temperature rating shall be min. 85 degree C. Each core shall be colour coded and/or numbered.

19.4

Cables and Multicore Cables for Solenoids etc.

Cables and multicore cables for such items as solenoid valves and flame detectors shall normally have a conductor size of 1.5 mm2, however, conductor sizes for power cables shall be co-ordinated with the Electrical Group to avoid too many different cable types.

19.5

Thermocouple Extension Wires

Thermocouple Extension Wires shall be twisted pairs - 15 twists or more per meter. Conductors shall be 1.5 mm2 for one and two pairs and 1.0 mm2 for multiconductor cables. Conductors shall be solid and shall be matched and calibrated to ANSI C 96.1. All cables shall be galvanised steel wire armoured under the outer FRLS PVC cover. Individual pair cables and the individual pairs in multicore cables shall be shielded with aluminium-mylar tape with tinned copper drain wire; Multicore cables shall also have a similar common shield. Standard insulation is PVC with minimum temperature rating of 85 degree C. Each core shall be colour coded and numbered.

Page 65 of 208

ANNEXURE -1 INSTRUMENT ACCURACIES

The instrument reference accuracies shall be as per the table below. Any deviation shall have prior approval of the Owner.

Page 66 of 208

ANNEXURE -2

Page 67 of 208

Page 68 of 208

TECHNICAL (VOLUME 2) SECTION 3.3.1

DESIGN PHILOSOPHY STATIC EQUIPMENTS

CONTENT SL.NO. 1.0 2.0 3.0 4.0 5.0 6.0 General Equipment Design Basis Special Requirements Spare Parts Documentation Schedule Vendor List DESCRIPTION SHEET NO. 73 81 85 89 89 89

LIST OF ATTACHMENTS

ATTACHMENT NUMBER

DESCRIPTION Calculation method Dynamic wind analysis (guidelines) For vertical equipment Inspection (Guidelines)

NUMBER OF SHEETS

Annexure - 1

90

Annexure - 2

91

Page 69 of 208

1.0
1.1 1.1.1

GENERAL
Scope This document defines the design philosophy to be applied to the design of various types of static equipment i.e. Pressure Vessels, Heat Exchangers, Columns, Storage Tanks and Vessel Internals for the Waste water treatment section located at RCF, TROMBAY, MUMBAI. The complete design, material of construction/fabrication (shop/site as applicable), inspection, testing, painting, supply, transportation and erection of equipment etc. at revamped waste water section site shall conform to the specifications, drawings and internationally accepted codes / standards duly accepted by the Owner. In addition, all statutory rules & regulations shall also be complied with. Codes and Standards The equipment shall be designed & constructed as per the latest edition of the following codes and standards: Code ASME Section VIII Div 1 TEMA R / API 660 HEI API RP 2000 API 2550 API 605 ASME Section II A&B/ASTM ASME Section II PART C ASME SEC II PART D ASME Section V ASME Section IX NACE ASME B 16.5 ASME B 16.47 ASME B 16.20 ANSI IS: 875 (Latest)/SITE DATA Description Rules for construction of Unfired Pressure Vessels Standards of Tubular Exchangers Manufacturer's Association / For Shell & Tube Heat Exchanger Heat Exchanger Institute standards for steam surface condensers and steam jet ejectors Venting Atmospheric and Low pressure storage Tanks Method for measurement and calibration of upright cylindrical Tanks Metallic gaskets for raised face pipe flanges & flanged Connections(Double jacketed corrugated &Spiral wound) Materials Specifications Specification for welding rod, electrode & filler metal Properties Non-destructive Examination Welding Qualification National Association of Corrosion Engineers For flanges For large diameter flanges For gaskets Pipes, Flanges, Fittings and Valves For wind load consideration

1.1.2

1.2 1.2.1

IS: 1893 (Part 4):2005 / SITE For seismic design consideration DATA

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Notes: 1. Contractor may select DIN, BS or any other well known international materials as substituted materials to ASTM/ASME ones, if they are equivalent or superior to ASTM / ASME ones. The chemical & mechanical properties of such equivalent or superior offered materials preferably comparison w.r.t. ASTM materials shall be furnished along the bid. Contractor shall also submit the references of past supplies of similar type of equipment w.r.t. the proposed materials offered by them in their bid. 2. Process licensors guidelines / standards may be adopted complying minimum requirements of this design philosophy of static equipment. Details of such selected guidelines/standards along with the list shall be furnished in the bid. 3. Specifications of all critical equipments including those specified by the process licensor shall be furnished in the technical bid. 1.3 Regulations Besides codes & standards, Contractor shall follow National Laws and Regulations such as Indian Boiler Regulation and Department of Explosives, Nagpur, Central Pollution Control Board (CPCB) India together with Local by Laws for the state including statutory requirements as applicable. Static and Mobile Pressure Vessel (SMPV) rules as applicable shall also be complied with.

Publications: WRC Bulletin # 107 Local Stresses in Spherical & Cylindrical Shells due to External Loadings. WRC Bulletin # 297 Local Stresses in Cylindrical Shells due to External Loadings on Nozzles 1.4 1.4.1 1.5 1.5.1 Site Conditions Climatic and other site conditions as defined elsewhere. Operating Duty Service shall be twenty-four (24) hours per day, seven (7) days per week, and fifty-two (52) weeks per year. The equipment design life shall be 20 years. Design Documentation Detailed design calculations considering different loadings shall be made as per code/standards and the additional requirements as mentioned below:-

1.6 1.6.1

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1.6.2

Contractor shall consider the interfaces with other engineering disciplines w.r.t. Piping Layout/Location Drawings Civil / Structural Drawings P & IDs Materials Piping and Equipment Layout Hazardous Area Classification

1.6.3

Design philosophy of other disciplines shall be observed and shall be relevant to the extent applicable. Civil/Structural Design Criteria Piping Design Criteria Process Design Criteria Electrical and Instrumentation Design Criteria

1.7 1.7.1

Safety Safety standards and features which are inherent in the specific mechanical equipment design codes, standards and regulations are applicable to this criterion. Job Hazard and Operability [HAZOP] as per ISO-18001 & Factory Act shall be done during design stage the equipment. Safety features to be incorporated into the design include, but are not limited to, the following features for equipment: Ladder cages Safety chain across platform access Step-off platforms with Hand Railing where necessary Platform grating with adequate thickness Toe plates

1.7.2

1.8 1.8.1

Equipment Fabrication Equipment design shall be based on maximizing shop fabrication and assembly where deemed practical. The Contractor shall comply in all respects with the provision of the applicable codes / standards and specification during fabrication. For equipment fabricated in multi-wall / multilayer construction, special fabrication requirements as per ASME Sec-VIII Div.2 Article F-8 shall be complied with. Impact test, when required as per code and specifications, shall be carried out on parent metal, weld and HAZ. Production Control coupons, when required as per code and specifications, shall be subjected to all tests like impact, inter granular corrosion test etc., in addition to

1.8.2

1.8.3

1.8.4

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mechanical test as required. In case of heat treated equipment test coupons shall be given similar heat treatment as for the equipment. 1.8.5 Due provisions must be kept for venting out entrapped gases during welding of pads, flanges and liner plates etc. In case of equipment involving site assembly/fabrication the entire site job including loading & unloading at site, fabrication, radiography, heat treatment, Inspection & testing etc. shall be included in the scope of supply. All nozzle connections up to DN 200 size shall be made of seamless pipes. For sizes above DN 200 nozzles connection may be rolled from plates with full radiography of welds. Welding (Required For supply of material) 1.8.8 All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG welding is preferred. Gas or Carbon arc welding shall not be used. Welding electrodes of composition similar to Internals material shall be used except austenitic electrodes of higher chromium and nickel content such as AWS A5.4, ASME SFA 5.4 class E309 and E310 may be used for 12-Cr stainless steel. For dissimilar material welding, electrode composition shall be similar to nobler material being welded. Following electrodes shall be used unless specified otherwise: E 7018 E 308 E 308L E 309MoL for all CS materials for all SS 304 to SS 304 for all SS 304L to SS 304L for SS 410S to SS 410S, SS to CS, SS 410S to SS 304, 304L, 316, 3l6L for all SS316 for all SS316L

1.8.6

1.8.7

1.8.9 1.8.10

E 316 E 316L 1.8.11

Welding wherever specified, is to be done by qualified and approved welders using the suitable fillers and fluxes recommended for the materials in the fabrication drawings. For welding the stud on tray decks and support beams, use of stud welding gun with suitable flux is acceptable. In manually welding of studs, care should be taken to minimize the weld spatter and the outside diameter of the weld so that it should not foul with tray deck or washer. For stud welding, proper welding procedure shall be established. Torque required for welding failure shall be higher than the torque required for failure of the stud. A proposed Welding Procedure Specification (WPS) shall be submitted to Page 73 of 208

1.8.12

approved inspection agency for approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which shall be witnessed by approved inspection agency. On acceptance of all tests as per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be submitted. Production welding shall start only after approval of final WPS/PQR and qualification of welders as per ASME Section IX, approved inspection agency may accept previously qualified WPS/PQR at his sole discretion. 1.8.13 1.8.13.1 Miscellaneous All parts fabricated shall be smooth, true, clean and free from burrs, grease and dents. Openings for passage of workman must have exposed edges rounded. All support rings, bolting bars, beams support brackets and other components which are integral and therefore welded to the column shell inside, shall be supplied and installed by column fabricator. Total draw-off trays shall be designed for zero leakage construction and may be seal welded (if required) at site to attain zero leakage.

1.8.13.2

1.8.13.3

1.8.13.4 Seal welds shall have a throat thickness at least equal to the specified corrosion allowance. 1.8.13.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble caps, valves etc.) shall be pickled and passivated. Pickling and Passivation shall be as per ASTM 380. All parts shall be fabricated in accordance with good shop practice and in uniformity so that all corresponding parts will be inter-changeable.

1.8.13.6

1.10

Material of Construction The minimum requirement of the materials shall be as per the plant equipment metallurgy covered under specific process design guidelines. However superior materials as per the recommendation of Process Licensors may be selected which shall be indicated in the Bid by the Contractor.

1.10.1

All materials, whatsoever, required to complete the supplies shall be procured by Contractor and all such materials shall be covered with due identifiable material test certificate. Materials used in low temperature service shall be impact tested (charpy V) if required as per design code & specification. Impact test & energy value shall be in accordance with code requirement, unless specified otherwise. For coarse grained & high tensile materials in carbon steels ( UTS>45 Kg/mm2) & low alloy steel, guaranteed impact strength shall be ensured at a temperature 15 0 C below envisaged hydraulic test temperature as a precaution against brittle fracture during hydraulic test. Page 74 of 208

1.10.2

1.10.3

1.10.4

Heat Treatment Heat treatment of formed parts shall be carried out as per following:

For Carbon Steel

a. Cold formed dished ends or knuckles upto 16 mm nominal thickness shall be stress relieved. b. Cold formed dished ends or knuckles above 16 mm nominal thickness shall be normalised.
For Low alloy Steel:

c. Cold Formed Dish-ends or Knuckles shall be stress relieved. General d. Hot formed dished ends or similar parts, which have not been uniformly heated in the normalising range in the final stages of manufacture shall be normalised. e. When the completed vessel involves post weld heat treatment, heat treatment recommended in (a) above shall not be applicable. f. Vessels in caustic service, Amine or Sour gas service shall be stress relieved. 1.10.5 All CS & LAS materials including forging used for pressure parts shall be procured in fully killed and normalized condition. CS & LAS materials above 50 mm thickness shall be vacuum degassed except for plate ring flanges. All SS plates shall be hot rolled & solution annealed and pickled as per SA 480. All plates above 50 mm thickness shall be examined by UT as per ASTM-A435 at mills for both at surface & edges. Cladded plates shall be supplied as per ASTM A264 material specification. All clad plate shall be UT examined at the steel works in accordance with ASTM A578 level S8. All forgings except for flanges as per ANSI shall be UT tested as per ASTM A 388 for the thickness greater than 100mm and shall be procured in normalized / annealed condition. Acceptance standards shall be as per AM 203.2 of ASME Section VIII Div. 2. In case any defect is found, no repair by welding shall be allowed. All forgings including nozzle flanges shall be examined for surface defects by MP/PT testing after machining as per ASTM A 275. Tube sheet and Girth flanges shall not have any segmental weld joint. Page 75 of 208

1.10.6 1.10.7

1.10.8

1.10.9

1.10.10

1.10.11

1.10.12

Unless more restrictive prescription given by material specification the max. content for carbon steel used for fabrication as shown by ladle analysis shall be 0.23% for plates, pipes & tubes 0.25% for forging. Acceptable limit of copper and copper alloys shall be as per material specification and service requirement. Girth flanges must be made in one piece. Segmental butt-weld construction shall not be accepted. Top portion of skirt (min. 500 mm height) welded to the bottom dished head shall be of same material as that of shell /head for LAS & SS materials. a) Gaskets for all medium except cooling water shall be SS spiral wound type with external & internal guide rings shall be used. CAF gaskets are not acceptable. b) Gaskets used for high pressure shall be of the following type: - Ring Joint - Double conical with graphite tape - Diaphragm gasket - Lip seal Gasket

1.10.13

1.10.14

1.10.15

1.10.16

1.10.17

All directly welded external/internal attachments shall be of same materials as that of equipment, unless specified otherwise. Quality Assurance& Control The quality assurance shall be as per the approved procedures, test methods & facilities to be developed by the Contractor to ensure that the supplied equipment shall be of highest quality. The quality control shall mean that all the tests , measurements, checks & calibration which are to be carried out may be compared with the actual specified characteristics of the equipments/unit /system. Quality Assurance (QA) shall mean the organizational set up, procedures as well as test methods and facilities developed by Contractor in order to assure that Equipment leaving Contractors shop are of the highest possible quality i.e. either equal to or better than the requirement specified. Quality Control (QC), shall mean all the tests, measurement, checks and calibration which are to be carried out in Contractors shop in order to compare the actual characteristics of the equipment/unit/system with the specified ones, along with furnishing of the relevant documentation (certificates/records) containing the data or result of these activities. Contractor shall submit a comprehensive description (manual) of QA/QC measures contemplated by him for implementation with regard to this specification. It is contractual obligation of the Contractor to develop and implement adequate QA/QC systems.

1.11 1.11.1

1.11.2

1.11.3

1.11.4

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1.11.5

QA/QC system shall cover all products and services required for the equipment as per scope of work including job sub contracted by the Contractor. EQUIPMENT DESIGN BASIS General Design pressure is normally specified at the top of vertical vessel or at the highest point of horizontal vessel. The design pressure at any lower point shall be determined by adding the maximum operating liquid head and any pressure gradient within the vessel. Wind forces shall be increased by 20% to cater for the effect of piping system, platforms and ladders etc. Vertical vessels with height/diameter ratio equal to or greater than 10 shall be analyzed for vibration due to vortex shedding when critical wind speed does not exceed 30m/s. For guidelines of Dynamic Wind Analysis refer Annexure-I. Forces and moments acting on nozzles shall be considered in the equipment design. The exact forces & moments shall be indicated after piping layout which shall be considered by equipment supplier with out any commercial implication to Owner. All Carbon Steel (CS) and Low-Alloy Steel (LAS) pressure parts shall have 3 mm corrosion allowance unless specified otherwise. All internal CS & LAS parts shall have at least 1.0 mm Corrosion Allowance on either side. No corrosion allowance shall be considered for SS. In general, the recommendation of Process Licensor shall be adopted for construction. Design of supports and anchor bolts considering soil and importance factors shall be performed for compressive and tensile loading. In no case shall diameter of anchor bolts be less than M24 for skirt support and M16 for other type of support. Lifting lug shall be designed with shock factor 2. Bolt of size M52 and above shall be designed and spaced so as to permit tightening with a hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of approximately 1 bolt diameter, and shall be provided with threaded protection caps. Hex nuts shall have suitable holes for manual tightening. The requisite no. of hydraulic stud-tensioner device with necessary adopters/insertions based on varying sizes of studs shall be considered by Contractor as per mechanical design of the equipment. Inspection and Testing Equipment shall be inspected by TPIA (Lloyds/BV/TUV/PDIL). The Inspection and testing shall be in accordance with the relevant codes, standards, specifications, including mandatory NDT requirements indicated under Inspection and Testing clause 2.2.3 & Inspection guidelines (Annexure-2). All equipment & bought -out items shall be inspected during various stages of manufacturing Page 77 of 208

2.0 2.1 2.1.1

2.1.2

2.1.3

2.1.4

2.1.5

2.1.6 2.1.7

2.2 2.2.1

starting from identification of materials to final completion as per agreed QAP which shall be prepared by Contractor and shall duly approved by Owner/ Its authorised representative. In case of site fabricated/assembled equipment same inspection agency shall be responsible for inspection and testing at site. The guidelines for minimum inspection requirements are listed in Annexure-2& also defined under Inspection & Testing clause of the design philosophy. 2.2.2 All testing accessories, measuring instruments including NDT testing equipment, etc. shall be arranged by Contractor. The following NDT requirements are mandatory in addition to code /spec requirements: (applicable for supply) a) UT examination: i) All butt-welds in thickness greater than 50mm as supplement to radiography. ii) FPW of nozzle attachments of thk. above 50mm as supplement to radiography iii) Clad Plates and formed heads from clad plates in all thicknesses b) MP/PT examination i) All edges of plates and opening in shell of CS having thk. above 40mm and LAS/SS having thk. More than 25mm ii) Root and final layer of all butt welds iii) Fillet welds of 3.5% Ni & SS iv) Each layer of weld deposit in SS overlay v) Knuckle surfaces of dished ends, expansion bellows and pipe bends c) Radiography: i) All weld seams of formed head, if made in more than one segment shall be fully Radiographed after forming. ii) All the welded T- Joints shall be fully radiographed. iii) When spot radiography is specified all T-joints & min. 10% of total weld length excluding T-joints shall be radiographed iv) Radiography of welds in C- 1/2 Mo & Cr- Mo - Steel preferably is carried out after heat treatment d) Hardness test on welds of Cr-Mo, Materials after final heat treatment. The value shall not exceed to: i) ii) 2.2.4 215 HB for steel having Cr content less than 2% 240 HB for steel having Cr content more than 2%

2.2.3

All completed equipment shall be tested hydraulically as per the requirements of specification/codes in presence of the inspecting authority. Pneumatic test of completed equipment shall be carried out only when specially mentioned in the specification sheets. Chloride content in water used for testing shall not exceed 30 ppm for SS equipment and 40 ppm for CS and low alloy steel equipment. Page 78 of 208

Duration of test shall be 1 hour minimum. After hydro testing stainless steel vessels shall be dried thoroughly, immediately after draining to prevent the possibility of evaporation & concentration of chlorides. 2.2.5 When specified equipment shall be dispatched with N2 filling. In case of equipment assembled and welded at site, it shall be filled with N2 after testing at site. Dry Nitrogen shall be filled at a pressure of 0.5 Kg/cm2g and equipment shall be fitted with a pressure gauge and valve. Equipment under preview of statutory bodies shall be inspected during various stages of fabrication by their authorised inspecting agency. It is the responsibility of the Contractor to get the design calculations and fabrication drgs. approved by concerned statutory bodies before commencing fabrication. All raw materials shall be inspected at source and test certificates to enable proper identification shall be submitted. Unless otherwise stated gasket during testing shall be same as specified for operating conditions. After testing, gaskets used during testing shall be replaced by new gaskets. The temperature of test water shall comply with the construction code, but not less than 7 0C. After hydrostatic testing, the tightness of lining welds shall be tested by helium. The sensitivity of leak detection shall be as per ASME SEC V. Painting All external surfaces of shop fabricated equipment shall be painted in the vendors shop. For guidelines of painting refer Annexure-3. Pickling and Passivation All SS material shall be Pickled & Passivated as per following procedures: 2.4.1 Pickling Aqueous pickling solution shall be as follows: Nitric acid (Tech grade)-10 to 25% plus Hydrofluoric acid-1 to 8% (to be used only for stabilized SS grades). Temperature 50 to 60 C for 10% Nitric acid and 20 C for 25% Nitric acid. When size and shape of product permit, total immersion in the pickling solution is preferred. Where immersion is impractical, pickling may be accomplished by wetting the surface by i) Swabbing or spraying ii) Partial filling the item with pickling solution and rotating or rocking so that the entire surfaces receive the required chemical treatment. Page 79 of 208

2.2.6

2.2.7

2.2.8

2.2.9

2.2.10

2.3 2.3.1

2.4

The maximum period for which the pickling solution shall be allowed to remain on the surface is 30 minute. During pickling removal of oxides may be hastened by brushing with a hard fiber or SS wire brush. Over pickling shall be avoided. The pickling agent shall be washed off with plenty of water so as to leave no trace behind. 2.4.2 Passivation After pickling and water rinsing, an aqueous caustic permanganate solution containing NaOH 10 weight % and KMnO4 4 weight % shall be used for neutralizing pickling solution. This shall be followed by thorough water rinsing. Water used for pickling and washing shall not have chloride contents exceeding 30 ppm. 2.5 2.5.1 Insulation The equipment shall be insulated as defined in Piping Design philosophy. The contractor shall provide the details for carrying out the insulation work, which shall be undertaken by owner. Operability and Maintenance Equipment design and layout shall provide for ease of access, operability and maintenance. SPECIAL REQUIREMENTS Vessels Vessels shall conform to the requirements of ASME Section VIII Division 1 Pressure Vessels codes and Technical Specifications mentioned in the design criterion. Design of vessel skirt shall be based on seismic/wind/thermal considerations and fireproofing/insulation requirements. Head / Dished Ends Dished ends shall be of seamless construction. However, dished ends with one cordal weld seam are acceptable. In such cases, the cordal seam shall preferably be in the middle one third of the blank. Intermediate heat treatment, if considered necessary, shall be carried out by the Contractor.

2.6 2.6.1

3.0 3.1 3.1.1

3.1.2.1

3.1.2.2 a)

b) Whenever a dished end is made of more than two plates, it must have a crown plate. Whenever a nozzle or a manhole is positioned at the centre of the dished end, the crown plate should be larger than the nozzle / manhole reinforcing pad.

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3.1.3

Vessel skirts for carbon steel vessels shall be designed from the same material as the shell or the head. Vessel skirts for other than carbon steel vessels shall be the same material as the shell or the head for the top 500mm. All skirt supported equipment shall be provided with templates. All nozzles above 24 NB shall comply with ASME B16.47 Series B. Local vessel stress calculations for external structural attachments, such as platform clips, pipe support clips and lifting lugs shall be performed. The minimum spacing between the hold down bolts on a vessel skirt shall be 5 times bolt diameter plus 150mm. For vessel hold down bolts, the bolt design stress shall be as per applicable code requirements. Vessels with skirts having eight or more anchor bolts shall be required to be supplied with an anchor bolt template. The template shall be an annulus 10mm (minimum) thickness and 150mm (Minimum) wide, with bolt holes equal to bolt diameter plus 3mm, stack drilled with the skirt base plate. Design of supports and anchor bolts considering soil & importance factors shall be performed for compressive & tensile loading. In no case, diameter of anchor bolts shall be less than M24 for skirt support & M16 for other type of support. The lifting lug shall be designed with shock factor 2. Maximum permissible deflection for tall vessels/columns when subjected to design wind loadings shall not exceed 0.005 x Vessel height. For guidelines of Dynamic Wind Analysis refer Annexure-I. For vessels, the minimum thickness of shell & heads, including corrosion allowance shall be as indicated below: S. No. 1 2 3 4 5 Shell Diameter (mm) ID < 500 501 < ID < 1200 1201 < ID <2000 2001 < ID < 2600 Thickness (Min.) mm CS / LAS HAS 5 3 5 6 8 10 4 5 6 8

3.1.4 3.1.5

3.1.6

3.1.7

3.1.8

3.1.9

3.1.10 3.1.11

3.1.12

ID > 2600 CS = Carbon Steel LAS = Low-Alloy Steel HAS = High-Alloy Steel 3.1.13 3.2

Vessel man-ways shall be shown on the data sheets. Internals Page 81 of 208

3.2.1

For Tray design worst of the following conditions shall be considered: a) For tray design minimum loads of 100 kg/m2 in active areas and 320 kg/m2 in down comer area shall be considered. b) For atmospheric, pre flash & vacuum distillation columns for trays under flash area uniform load of 500 kg/m2 shall be considered. This loading shall be applicable to first three trays above flash section. c) A concentrated live load of 150 kg at any point on the installed assembly independent of other design live loads. d) Maximum horizontal deflection at effective tray loading shall not exceed 1/900 of the span or 7 mm. whichever is less. e) Corrosion allowance shall be added to both sides of trays, support rings and other fixed internal non pressure parts.

3.2.2 3.2.3

All internal bolting shall be of corrosion resistant material. Support for packing and internal shall be designed for the worst condition. In the condition of packing liquid hold up of minimum 20% of packing volume shall be considered. Tray support beams shall have height not exceeding 20% of distance between trays for diameter up to 2400 mm and 15% of the distance between trays for higher diameters. Each tray shall be so designed as to ensure liquid tight construction. Each tray shall be provided with a man-way suitable for opening both from top and bottom unless otherwise specified. Minimum thickness of internals shall be as follows: S. No. 1. 2. 3. 4. 5. 6. Parts Chimney tray Tray decks partition, down comers, weirs pans etc. Tray support rings & bolting bars Bubble caps Valves for trays Non-integral main & secondary supporting beams CS &LAS (MM) 10 3.5 6.0 3.5 1.5 5.0 HAS (MM) 6 2.0 6.0 1.5 1.5 2.0

3.2.4

3.2.5

Note: - 1) All bolting size shall be minimum of M10. All nuts shall be hexagonal. 2) Allowable stress criterion for design of internals shall be as per ASME Section VIII Div. 1

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3.2.6

All internals shall be designed so that they can pass through the vessel man-way internal diameter. The Contractor shall meet the process and hydrodynamic guarantee of towers along with their internals. All instruments including of special instruments required to verify the above requirements shall be arranged by the Contractor. Shell and Tube Heat Exchangers Mean metal temperature of tube & shell be considered in the design of fixed tube sheet exchangers. Parts such as tubes, tube sheets, floating heads etc. which simultaneously come in contact with both shell side and tube side fluids, shall be designed considering pressure acting on one side only or the combination of pressures, whichever results in higher thickness of parts. Attachment of tube to tube sheet will be rolled and expanded, strength welded or seal welded as specified on data sheets. Process Shell and Tube Exchangers will comply with the requirements of ASME SEC VIII Div I & TEMA Class R. TEMA Class C may be used for auxiliary heat exchangers for rotating and packaged equipment exchangers. ASME Section VIII, Div. 1, Appendix S shall be considered mandatory for bolted flange connections. All tube sheet for the exchangers shall be designed as per ASME Sec VIII Div 1 & also comply the requirement of section UHX of ASME Code. Tube sheets in vertical exchangers shall be provided with drain and vent arrangement with threaded plug seal welded. Exchanger saddle and foundation design shall include additional loadings generated from bundle pulling. The load shall be 1.5 times the bundle weight. Channel girth flange design shall also include 75 percent of the external applied load referenced in paragraph 2.1.4 of this criterion. Shell side hot nozzles shall be located at the top of the shell at the channel end whenever possible. Lifting lugs for heads or bonnets shall be specified where frequent dismantling is required. Saddle wear plate material shall be the same as the shell material. Tube sheet and Girth flanges shall not have any segmental weld joint.

3.2.7

3.3 3.3.1

3.3.2

3.3.3

3.3.4

3.3.5

3.3.6

3.3.7

3.3.8

3.3.9

3.3.10

3.3.11

3.3.12 3.3.13

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3.3.14

All heat exchanger tubes shall be seamless, cold drawn and formed from single length. CS tubes shall be normalized. LAS tubes shall be normalized and tempered. The mean radius of U tubes shall be not less than 2xOD of tube. Thickness of 2 inner most rows will be higher than other rows with minimum difference of 2 gauges. For U tube bundle, the following requirements shall also be met: i) Each U tube shall be formed from a single straight length. ii) All U tubes shall be cold bent. iii) All C.S, C-Mo, Cr-Mo tubes shall be annealed after bending. iv) Bent portion of all U tubes shall be examined by PT and hardness check on four opposite points of bent portion shall be carried out. v) Unless otherwise specified, after bending each tube shall be tested hydraulically.

3.3.15

3.3.16

3.3.17 3.3.18

Expansion bellows shall be designed for min. 5000 cycle, as per TEMA. Tube to tube sheets joints shall be leak tested with air & soap solution at pressure of 2.0 kg/cm2 g wherever specified leak testing with halogen shall be carried out. All SS tubes shall be subjected to non-destructive examination like eddy current or ultrasonic test at mill. CS & LAS tubes shall also be subjected to such examination when design pressure exceeds 100 Kg/cm2g. Impingement plates shall be provided if required by TEMA or indicated as a part of Licensors requirement. For stack type of heat exchangers, nozzles shall be designed to carry the loads of shells after installation in operating conditions. Saddles shall be used for erection purpose only. For stack type Heat Exchangers, complete assembly shall be hydraulically tested as a single unit except when the test pressures for individual heat exchangers are different. Removable tube bundle shall be provided with pulling York and suitable sliding arrangement. SPARE PARTS Commissioning Spares All commissioning spares shall be included by Contractor in their scope of supply and shall be part of the main equipment Page 84 of 208

3.3.19

3.3.20

3.3.21

3.3.22

3.3.23

4.0 4.1 4.1.1

4.2 4.2.1 5.0 5.1 6.0

Spares for 2 Years Operation 2 years operation spares shall be supplied by the contractor as spare parts section DOCUMENTATION SCHEDULE Documents shall be submitted as per Documentation schedule section of ITB. VENDORS LIST All equipment shall be procured/fabricated as per approved vendor list. For Noncritical items, Contractor may include the name of local vendors. Any equipment for which vendor list is not enclosed, the Contractor may furnish a list of their proposed vendors along with their references for supply of similar type of equipment along with bid. However all the additional proposed vendors shall have well proven track record and shall be subjected to consultant/owners approval.

Page 85 of 208

ANNEXURE-1

CALCULATION METHOD DYNAMIC WIND ANALYSIS (GUIDELINES) FOR VERTICAL EQUIPMENT

Check of the towers for dynamic wind moments due to vortex shedding shall be performed based on following assumptions : Vcr = T6 Vcr D F St Re For f * D/St = Critical wind velocity = Outside diameter of tower = First natural frequency of tower considering foundation complete rigid (s-1) = Strouhol number, may be taken as 0.15 for Re > 106 and 0.2 for Re < 106 = Reynolds number at critical wind velocity Vcr < 30 m/s following shall be considered :

The tower shall be checked for additional moments due to vortex shedding in 2 cases. 1. 2. Operating condition Shut down condition

Dynamic wind moment shall be calculated as follows : Md = Pd * Ck * S * Pi/d * H Pd Ck = Wind pressure at critical velocity = 0.5 * den* (Vcr)2 = Crosswind ocillatory force coefficient may be taken as 0.5 + ( 4 - Log10 Re)/5.7 for Re < 106 and 0.17 for Re > 106 = The logarithmic decrement of damping. For towers with trays or packing it is estimated 0.035 = Surface on which dynamic wind forces are acting ( height * diameter) = Height from base ring of point of application for dynamic wind force = 3.14 = Density

d S H Pi Den

For tapered construction only the tip diameter shall be considered in calculation. Moments to be considered for dynamic wind :
Mres = ( Md 2 + Mst 2 = Static wind moment at critical wind velocity

Mst

Only if Mres exceeds moments due to static wind or earthquake moments, it shall be considered for equipment design.

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ANNEXURE-2

INSPECTION GUIDELINES
1.0 GENERAL The min. Inspection to be carried out by Authorized approved Inspection agency: 1.1 VESSELS a) All carbon steel plates shall be identified against mill-test certificates at the VENDOR'S works before commencement of fabrication. b) Establish that welding procedure and welders are qualified and welding electrodes are approved before commencement of fabrication. c) d) Check fit-up and witness chipping-back of welded seams. Wherever applicable, select spots for radiography, D.P and M.P Tests.

e) Witness any crack detection, hardness checks, ultrasonic tests etc. which may be specified. (Refer Note (1)) f) Review radiographs and in case it is unsatisfactory re-radiograph. (Refer Note (1)) g) Witness hydrostatic test.

h) Dimensionally check and carry out final internal and external inspection for quality of workmanship. i) Check that all material test certificates and, where applicable, heat treatment charts are in order. Ensure that VENDOR is familiar with the requirements regarding data books and ensure that the documentation is submitted without any delay. j) Check internal lining of reactors and vessels (if applicable) to specifications. k) Witness any further test recommended by Process Licenser/Inspection agency and/or OWNER. Note (1): X or Gamma rays

1.2

VESSEL INTERNALS a) b) Leak testing & Final inspection only is required. Check one tray of each diameter and type, mock assembled in the shop. Page 87 of 208

c)

Spot check for interchangeability of parts, where applicable.

d) Ensure that any uncommon down comers are fully assembled and offered along withtheir respective trays. e) Where new designs and/or new VENDORs are concerned, check that any applicable leakage tests have been carried out on prototype. f) the 1.3 Check that materials including welding electrodes are in accordance with requirements of the order and all applicable specifications and standards.

STORAGE TANKS a) Shell plates to be dimensionally checked (including diagonals for squareness) beforerolling to curvature. b) All shell plates to be inspected and dimensionally checked after rolling to curvature. c) Check material test certificates and ensure that all shell plates are clearly stamped with the cast and plate number, so that they can be identified against the relevant test certificates. d) e) f) Check material test certificates for roof and bottom plates. Select the spot radiographs, D.P & M.P test as per codes. Review the radiographs. (Note (1))

g) On completion of inspection of shell plates ensure that VENDOR provides a chart giving all plate numbers, tier by tier. h) Inspect fabrication of all fabricated fittings. This is to include checking of material test certificates also. i) j) k) Inspect tank gauging equipment. For shop fabricated tanks, witness hydrostatic tests to applicable standards. Check welding material electrodes.

Note (1) : X or Gamma rays

Page 88 of 208

1.4 1.4.1

HEAT TRANSFER EQUIPMENT SHELL AND TUBE EXCHANGERS a) All carbon steel plates shall be identified against mill test certificates at the VENDOR'S works before commencement of fabrication. b) Establish that welding procedure and welders are qualified before commencement of fabrication. c) d) Check fit-up and witness chipping-back of welded seams. Wherever applicable, select spots for radiography.

e) Witness any crack detection, hardness checks, ultrasonic tests etc. which are specified in drawing, specification, data sheet etc. f) g) Review radiographs. (Note (1)) Witness all hydrostatic tests on shell and tube sides.

h) Complete dimensional check for stacked units. This is to be carried out in the full assembly stage. i) Check that all material test certificates and where applicable, heat treatment charts are in order. Ensure that VENDOR is familiar with the requirements regarding data books and see that the documentation is submitted without any delay. j) Witness any further test recommended by Process Licensor/ Inspection agency and/or OWNER. Note (1) : X or Gamma rays

1.4.2

VACUUM EQUIPMENT, INCLUDING CONDENSERS a) Tests on ejectors to be witnessed.

b) Inspection and tests of condensers shall be done as for shell and tube exchangers as far as applicable in addition applicable codes and standards shall be taken into account. c) Check all material test certificates for tubes, plates etc.

d) Check and witness other tests as applicable as per the Tender documents as well as applicable codes and standards, for rotary equipment. Page 89 of 208

TECHNICAL (VOLUME 2) SECTION 3.3.2

DESIGN PHILOSOPHY - PIPING

Page 90 of 208

CONTENT
Sl. No 1.0 1.1 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 5.1.1 5.1.2 5.1.3 5.1.3.1 5.1.3.2 5.1.3.3 5.1.3.4 5.1.3.5 5.1.3.6 5.1.3.7 5.1.3.7.1 5.1.3.7.2 5.1.3.7.3 5.1.3.7.4 5.1.3.7.5 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.3 5.4 5.5 5.6 5.7 5.8 DESCRIPTION SCOPE APPLICABLE STANDARD & CODES DESIGN PHILOSOPHY GENERAL CODES, STANDARDS AND SUPPLEMENTARY SPECIFICATIONS GENERAL GENERAL DESIGN DESIGN DESIGN PHILOSOPHY / CRITERIA GENERAL EQUIPMENT LAYOUT Basis of Equipment Layout Development of Equipment Layout Plant Layout & Design guidelines General Pipe-rack / T-Post / Small Portals Towers and Vertical Vessels Horizontal Vessels Pumps Exchangers Clearance and Accessibility Crane Access & Tube bundle pulling Access to Pumps Access to lower items to grade (lowering Area) Layout & Access Requirements for Platforms ladders and Stairs Clearances UNIT PIPING Basis of Unit Piping Pipe Ways/Rack piping Column / Vessel Piping Control Valves Exchanger Piping Pump Piping Steam Header & Supply Lines / Steam and Condensate Systems Steam Tracing Piping in trenches Air System IN-LINE INSTRUMENTS Sample Connections VENTS AND DRAINS LINE STRAINERS Page 91 of 208 PAGE NO. 94 94 95 95 96 96 97 97 98 98 98 98 99 99 100 100 101 101 101 102 102 102 102 102 103 103 103 104 105 106 106 107 108 110 110 110 111 111 112

Sl. No 5.9 5.10 5.11.1 5.11.2 5.11.3 5.12 5.13 5.14 6.0 6.1 6.2 6.2.1 6.2.2 6.2.3 6.3 6.4 6.5 6.6 6.7 6.8 7.0 8.0 9.0 9.1 9.2 Annexure -A Annexure -B Annexure -C Annexure -D Annexure E

DESCRIPTION SPECTACLE BLINDS FLEXIBILITY ANALYSIS AND SUPPORTING Pipe Supporting Criteria & General Guidelines Stress Analysis Criteria & General Guidelines Method Of Analysis PERSONNEL PROTECTION MECHANICAL HANDLING GENERAL CRITERIA MATERIALS PIPING MATERIALS PIPE Wall Thickness Pipe Size Pipe Type FITTINGS FLANGES GASKETS VALVES TECHNICAL REQUIREMENT OF PIPING ITEMS NDT REQUIREMENTS THERMAL INSULATION OF PIPING, EQUIPMENT & VESSELS PAINTING WELDING APPLICABLE CODES & STANDARDS WELDING PROCESSES ACCESSIBILITY FOR VALVES AND INSTRUMENTS MAXIMUM SPACING OF GUIDES FOR VERTICAL & HORIZONTAL PIPES TECHNICAL REQUIREMENTS OF PIPING ITEMS CLEARANCES JOB SPECIFIC REQUIREMETS

PAGE NO. 112 112 112 114 114 116 116 116 116 117 118 118 119 119 119 120 120 121 121 121 122 122 122 122 122 124 125

126 134 136

Page 92 of 208

1.0

SCOPE The scope of this document is pertaining to the design philosophy, norms .and specific requirements which shall be adhered to by contractor or his associates and representatives during the course of the revamped waste water section in designing, procurement & construction of piping material.

1.1

Applicable Standard & Codes Standard No. Title

ASME/ANSI B1.1 Unified Inch Screw Threads (UN & UNR Thread Form) ASME/ANSI B1.20.1 Pipe Threads, General Purpose (Inch) ASME/ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings ASME/ANSI B16.9 Steel Butt-Welding Fittings ASME/ANSI B16.10 Face to Face and End to End Dimensions of Valves ASME/ANSI B16.11 Forged Fittings Socket Welded and Threaded ASME/ANSI B16.20 Metallic Gaskets for Pipe Flanges Ring Joint, Spiral Wound, and Jacketed. ASME/ANSI B16.21 Non-Metallic Flat Gaskets for Pipe Flanges ASME/ANSI B16.25 Butt-Welding Ends ASME/ANSI B16.34 Valves Flanged, Threaded Welding End. ASME/ANSI B16.47 Large Diameter Steel Flanges ASME/ANSI B31.1 Power Piping Code ASME/ANSI B31.3 Process Piping Code ASME/ANSI B31.5 Refrigeration Piping ASME/ANSI B36.10M Welded and Seamless Wrought Steel Pipe. ASME/ANSI B36.19M Stainless Steel Pipe API 6D Specification for Pipe Line Valves (Gate, Plug, Ball and Check Valves). API 6FA Fire Test for Valves. API 501 Specifications for Metallic Gaskets for Refinery Piping. API 598 Valve Inspections and Testing. API 599 Steel Plug Valves Flanged and Butt-weld ends API 600 Steel Gate Valves Flanged and Butt-weld ends API 601 Metallic gaskets for RF pipe flanges & flanged connections API 602 Compact Carbon Steel Gate Valves API 603 Class 150 Corrosion Resistant Flanged End gate valves. API 604 Ductile Iron gate valves flanged ends. API 606 Compact C.S. Gate Valve extended body. API 607 Fire Test for soft seated Ball Valve. API-608 Metal Ball Valves, Flanged, Threaded & BW Ends. API 609 Butterfly Valves, Lug type & Wafer type. AWWA C207-D Large Dia. Steel Flanges ( Ring Type). EJMA Expansion Joints Manufacture Association. Page 93 of 208

MSS SP 6 Standard Finishes for Contact Faces of Pipe Flanges and Connecting End Flanges of Valves and Fittings. MSS SP 25 Standard Marking System for Valves, Fittings, Flanges & Unions MSS SP 43 Wrought Stainless Steel Butt-weld Fitting MSS SP 44 Steel Pipe Line Flanges over 26"NB MSS SP 45 By-pass and Drain Connection. MSS SP 48 Steel Butt-Welding Fittings(26"& Larger) NACE MR0175-94 Sulphide Stress Cracking resistant Metallic Material NFPA National Fire Protection Association. ASTM A233 Welding electrodes (carbon steel) ASTM A298 Welding electrodes (stainless steel) ASTM A316 Welding electrodes (low alloy steel) ASTM C533 SPECIFICATION FOR CALCIUM SILICATE. ASTM C547 MINERAL FIBRE PERFORMED PIPE SECTION. ASTM C592 MINERAL FIBRE BLANKET INSULATION. FIRE PROTECTION NFPA 11A NFPA 12 NFPA 16,16A Sprinkler PAINTING ASTM A123 Specification for zinc (hot galvanised) coatings on products fabricated from rolled, pressed and forged steel shapes, plates, bars and strips ISO 8501-I Preparation of Steel Surfaces before application of Paints and Related Products. Medium and High-Expansion Foam Systems Carbon Dioxide Extinguishing Systems Deluge Foam-Water Systems and Foam-Water System

2.0
2.1 2.1.1

DESIGN PHILOSOPHY
GENERAL Design, Procurement, Supply of material, fabrication, inspection and testing shall be in accordance with latest edition of ASME B31.3,Process Piping code , except for boiler and steam generation which shall comply with power piping code ASME-B31.1.

Page 94 of 208

2.1.2

The dimensions, manufacturing tolerances and marking of ferrous and non ferrous piping components shall conform to the applicable standards .The design shall comply with all applicable codes, laws and statutory regulations prevailing in INDIA. The Contractor shall optimise this layout with the approval of the owner and include any changes resulting from HAZOP studies and taking into consideration the following : I) General site layout taking into account the topographical geo-technical aspect of the site and to allow for further expansion in future. Access for maintenance and fire appliances. The interdependency of units and buildings with each other within the complex. Safety escape routes for personnel based on emergency or disaster management plans in the event of environmental upset or fire. Suitable drainage system of Revamped waste water section site.

ii) iii)

iv)

v) 2.1.3

Material of construction shall be suitable for specified process duty (both normal and abnormal operations) and have a revamped waste water sectioned life and corrosion/ erosion allowance in excess of minimum life of the revamped waste water section. Piping materials specified in Piping materials specification shall be used for selection of material of construction of major services. All materials under steam service shall be supplied with proper certificates in prescribed forms.

3.0
3.1 3.1.1

CODES,STANDARDS AND SUPPLEMENTARY SPECIFICATIONS:

GENERAL The latest edition of codes listed in clause 1.1 shall be applicable for piping system design, materials, fabrication, manufacture, erection, construction and inspection etc. For any item not covered in the list of codes and standards Indian / International Standards / proven design may be finalized based on discussion with client. Where conflict occurs, the order of precedence shall be: a) b) c) Statutory Regulations National, International and Industry Standards and Codes of Practice. Technical Specifications

3.1.2

3.1.3

Standards, Codes and Supplementary Specifications for piping design shall be applied as follows: i) Process and utility piping to ASME B31.3 Process Piping Page 95 of 208

ii)

Sour service piping to NACE (National Association of Corrosion Engineers) specification MR0175. Plant layout and fire protection piping to Dangerous Goods Regulations andStorage and Handling of Flammable and Combustible Liquids, supplemented where required by NFPA (National Fire Protection Association) Code 30. Piping fabrication tolerances to ASME B31.3 and PFI (Pipe Fabrication Institute) practise ES-3. Colour coding for identification of piping material to PFI Practise ES-22. Pipe wall thicknesses shall be in accordance with ANSI B36.10 or B36.19. Identification of Pipe Contents.

iii)

iv)

v) vi)

4.0
4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6

GENERAL DESIGN
Design Flanges for process and utility piping shall be in accordance with ANSI B16.5 and ANSI B16.47. Wherever possible all purchased equipment shall be supplied with flanges that comply with ANSI B16.5. The minimum size of piping to be used in pipe-racks shall be 2 NB. With the exception of equipment connections the minimum size of piping shall be NPS. Pipe sizes 1 , 2 , 3 and 5 NPS shall not be used except as connections to purchased equipment. Threaded pipe nipples between headers and vent, drain and instrument isolation valves shall be Schedule 160 for CS and Schedule 80S for SS in the size range to 2 NPS. Piping 2 NPS and above shall be butt-welded, with the exception of galvanised pipe used for Instrument Air and similar service, which may be screwed up to 4 NPS. In Class 600 and higher pressure rating double block and bleed valves shall be used for systems open to atmosphere, such as vents and drains. Piping in hazardous service shall have vents, drains and bleeds routed to a safe location. Category M substances shall be vented to the flare system. When a line of one material specification is connected to a line of higher material specification, the connecting line shall be constructed of the higher material specification or pressure rating up to & including the first block valve. As a minimum, piping systems shall have isolation facilities as follows: ASME B31.3 Category M service and Normal service (Class 600 and above) shall have double block isolation valves with a downstream drop-out spool. ASME B31.3 Normal service (Class 150 and 300) shall have a valve and downstream spectacle blind. Page 96 of 208

4.1.7

4.1.8

4.1.9

4.1.10

ASME B31.3 Category D service shall have spectacle blind.

a valve and downstream

Generally, equipment shall have provision for isolation of piping to each equipment connection by means of valves and /or blinds as determined by service conditions. 4.1.11 Piping flexibility shall be achieved by the use of piping offsets and expansion loops whenever possible. Expansion joints shall not be used without the express written permission of the Owner.

5.0
5.1 5.1.1

DESIGN PHILOSOPHY / CRITERIA GENERAL

Equipment Layout Basis of Equipment Layout Equipment Layout shall be finalised based on the following data : a) b) c) d) Basis Site Plan (Issued for Bids) Wind Direction Overall Plot Plan Safety Distance and Specific Distance mentioned in Piping Design

5.1.2

Development of Equipment Layout The following aspects shall be considered during development of equipment layout. a) Process Requirement -Proper interconnection between equipment as per P&I Ds to achieve the intended process parameters. b) c) Economy of Piping material- Minimize the quantity of costly piping. Erection & Construction requirements: Erection scheme and schedule of all equipment must be considered during equipment layout to have smooth erection mainly in case of tall columns, heavy equipments like thick walled reactors, space for laying tall columns, approach roads for cranes / derricks for lifting the column or reactors and requirement of special foundation / pile etc. d) Operation and Maintenance Requirement - Overhead and side clearances for exchangers and pumps - Provision of exchangers tube bundle pulling area Page 97 of 208

- Horizontal & overhead clearances for easy movement of working personnel. - Crane approaches for air coolers/fired heaters. - Provision of monorail for pumps and exchangers - Provision of EOT crane for compressors. e) Similar equipment grouping - All columns, exchangers, pumps etc. should be grouped together for convenience of maintenance and safety wherever feasible. The technological structures should be interconnected for easy movement of operational personnel. U/G piping corridors for main headers should be marked in equipment layout for all under ground piping.

f)

g)

5.1.3 5.1.3.1

Plant Layout & Design guidelines General The plant layout shall be based on ensuring adequate access, to allow construction, inspection, maintenance and operation to be performed in a safe and efficient manner. The alignment of equipment and pipe shall offer an organised appearance. The layout shall be in accordance with, but not limited to the design practices described in this criteria. Where dynamic loading, limited pressure drop or other severe service condition apply, particular care shall be taken in routing pipe lines. Flushing connections shall be provided on all lines containing flammable or toxic material, slurries, and materials which solidify when the line is dead. Trolley beams, pipe davits, shall be provided with appropriate removable hoists mechanism for charging and discharging packing rings etc. Piping and all other services shall be arranged so as to permit ready access of Cranes for removal of Equipment for inspection and servicing. All utility and process piping shall be located above ground, and major lines shall be located in overhead pipe ways. 20% spare space shall be provided at each pipe rack level. The following lines may be buried providing they are adequately protected.

. i) ii) iii) iv) Cooling Water Lines 18" dia. and larger. Potable Water Lines. Firewater mains. Drain and sewer (oily and chemical) lines from catch basin to mains and manholes. Page 98 of 208

Lines that must be run below grade, and must be periodically inspected or replaced, shall be identified on the P & IDs; these lines must be placed in covered concrete trenches. Sleeper-ways shall not be used in process areas where they may block access for personnel and equipment. Fire protection system shall be provided as a closed loop with hydrants spaced as per Isolation valves with position indicators shall be provided to shut off sections without shutting off the entire system. Drip legs and dead ends shall be avoided, especially for piping where solids or fluids may congeal from corrosive condensate. Where sleeper ways are used the elevations shall be staggered to permit ease of crossing or change of direction at intersections. Flat turns may be used when entire sleeper ways change direction. Flat turns must not be used within pipe racks. Spacing and routing of piping shall be such that expanding/contracting lines (including insulation) will not clash with adjacent lines, structures, instruments and electrical equipment during warm up and cool down. Piping to be sloped shall be indicated on the P&I Ds. 5.1.3.2 Pipe-Rack/T-Post/Small Portals In general, equipment layout shall be prepared considering straight pipe rack, however other shapes like L / T / U / H / Z etc can also be considered based on area available. The width of the rack shall be 4M, 6M, 8M, 10M or 12M for single bay having four (4) tiers maximum. In general, the spacing between pipe rack portals (span) shall be taken as 8M for main rack. However it can be decreased to 6M depending on the size/number of the pumps to be housed below pipe rack. Intermediate Beams between two portals shall be provided to support smaller pipes <= 2". 20% extra space shall be provided on the pipe rack and portals on each tier for future expansion/modifications. Cantilever shall not be considered in 20% extra space. - Clearance beneath pipe rack shall be 3.8Mminimum. - Road clearance shall be 7M minimum for main and secondary roads. - Water lines more than 16" shall not be routed over rack. - T-Portal's width shall not be more than 2.5 meter and height shall not be less than.3.0 metre. 5.1.3.3 Towers and Vertical Vessels Towers and vertical vessels shall be arranged in a row with common centre line, decided by the largest vessels, placing 0.0. Of the equipment minimum 4M away from the pipe rack. A minimum clearance of 3M shall be allowed between tower shells, but in any case adjacent towers shall be checked so that platforms Page 99 of 208

do not overlap considering the deflection of towers (deflection of towers shall be considered minimum L/200 MM, WHERE, (L=height of tower). A minimum 100 mm horizontal gap shall also be provided between platforms of adjacent towers after deflection and that a minimum 900mm is left between tower plinths. Also the gap between vertical vessels shall allow full opening of manhole covers without restriction. Efforts shall be made to provide interconnecting platforms at suitable levels for adjacent towers and/or adjacent technological structure etc., Interconnections where ever feasible shall be done, after taking thermal expansions of towers into consideration. All level switches, LG s etc including their isolation valves shall be accessible from ladders or platforms. To handle heavy items (like relief valves, blinds etc.), davit of suitable capacity to lift higher weight of safety valves/ Blind/ Internals etc. is needed. The davit shall be on the side of the vessel away from the rack. The area at grade shall be kept clear for a dropout. Davit capacity shall be minimum 1 MT. Chemical vessels to be located close to the dosing point to the extent possible, specially corrosion inhibitors. 5.1.3.4 Horizontal Vessels The horizontal vessels shall be laid perpendicular to pipe rack and shall be placed minimum 4M away from the pipe rack. The clearance between horizontal vessel shells shall be minimum 2M or 1.0 M clear space whichever is higher. 5.1.3.5 Pumps Wherever practicable pumps shall be arranged in rows with the centre line of the discharge on a common line. In general, pumps shall be kept inside the pipe rack. However in case of smaller racks, pumps shall be kept on one side or outside the pipe rack to provide clear access under the rack as per clause 5.1.3.2. Pump foundation height shall be 200 mm above FFL (Finished Floor level). Gap between each pump foundation / and foundation of technical structure should be sufficient for easy removal of equipment after piping. Clearance between two adjacent pumps shall be such that clear 1.0M space is available. All pumps not open to sky with motor rating >= 45 KW shall be provided with monorail. No monorail should normally be provided for pumps outside rack and sufficient space below rack shall be available for pump maintenance. 5.1.3.6 Exchangers In most of the cases floating head of exchangers are placed on a line minimum 4M away from pipe rack. Shell and tube type exchangers may have a removable shell cover with flanged head. Tube pulling or rod cleaning area must be Page 100 of 208

allowed at the channel end. This shall be minimum the tube bundle length + 1.5M from the channel head. In case of vertical exchanger suitable platform shall be provided below the top flange of channel or bonnet. Minimum clearance in between two horizontal exchangers shall be 2M or 1.0M clear space whichever is higher. Like wise Heat Exchanger train should be suitably spaced such that shell/ tube inlet/outlet piping do not foul floating Head Covers creating maintenance problem. Hydra extractor is considered for exchanger bundle/ shell removal. Monorails to be provided for tube bundle removal only for exchangers not accessible to Hydro extractor. No special bundle removal arrangement will be provided for exchangers which are open to sky. Davit shall be provided for floating head cover for all exchangers. 5.1.3.7 5.1.3.7.1 Clearance and Accessibility Crane Access & Tube bundle pulling Equipment, structures shall be arranged to permit crane access to service air coolers, compressors and exchangers. All exchanger tube bundles shall be "jacked out" against shell. A clear space for tube bundle removal shall be provided. Dropout bay may be considered for exchangers at elevated structures. For high pressure exchangers, shell pulling on rails should be considered. 5.1.3.7.2 Access to Pumps Clear access of 3.8M vertically and 4.5M horizontally shall be provided centrally under main pipe rack for small mobile equipment to service pumps, wherever these are put under pipe ways with prior specific approval. Pumps outside rack shall be approachable by small cranes etc. from under the pipe rack. 5.1.3.7.3 Access to lower items to grade (lowering Area) Clear access shall be provided at grade on the access side for lowering external and internal fittings from tall elevated equipment by providing pipe davits.

5.1.3.7.4 Layout & Access Requirements for Platforms ladders and Stairs For providing platform ladder & staircase following guidelines shall be followed. Two means of access (i.e. two ladders or one ladder and one stair case) shall be provided at any elevated platform which serves three or more vessels & for B/L valves operating platform.

Page 101 of 208

Platforms, ladders and stairways shall be the minimum, consistent with access and safety requirements. Stairway for tanks to be provided on upstream of predominant wind direction. Platform at elevated structure a) Dual access (i.e. one staircase and one ladder) shall be provided at large elevated structure if any part of platform has more than 22.65M (75 ft) of travel. Air coolers shall have platforms with interconnected walk-ways provided to service valving, fan motors and instruments. Access requirements shall conform to paragraph (a) above. When fired heaters are located adjacent to one another, they shall have inter-connecting platforms on the upper and lower section. Interconnecting platforms between tower may be provided taking into consideration expansion of towers.

i)

b)

c)

ii)

Platforms with stair access shall be provided for: a) Location at which normal monitoring (once a day or more) is required or where samples are taken. Locations where vessels or equipment items need operator attention "such as compressors, heaters, boilers etc.

b)

iii)

Platforms with ladder access shall be provided for: a) Points which require occasional operating access including valves, spectacle blind and motor operated valves, heater stack sampling points. Man ways above grade on equipment.

b)

iv) Ladder location a) Wherever practicable, ladder shall be so arranged that users face equipment or platform rather than facing open space. Landings shall be staggered. No ladder shall be more than 8M in one

b) flight. 5.1.3.7.5

Clearances Minimum clearances shall be as indicated in Annexure D.

5.2

Unit Piping Page 102 of 208

5.2.1

Basis of Unit Piping Piping & Instrument Diagram Equipment layout Equipment Data sheet & Setting plan Line list Instrument Data sheet Structural & building drawings Topography of the plant Piping material specification Overall plot plan

The following objective shall be ascertained during piping layout. Proper access to all operating points including valves, and for all orifice tapping points and instruments in particular (refer Annexure-A). Proper access to interrelated operating points for specific purpose and for maintenance.

5.2.2 5.2.2.1

Pipe Ways/Rack piping Racks shall be designed to give the piping shortest possible run and to provide clear head rooms over main walkways, secondary walkways and platforms. Predominantly process lines are to be kept at lower tier and, utility & hot process lines on upper tier. Generally the top tier is to' be kept for Electrical (if not provided in underground trench as per electrical design basis) and Instrument cable trays. Cable tray laying to take care of necessary clearances for the fire proofing of structure. Generally the hot lines and cold lines shall be kept apart in different groups on a tier. Generally the bigger size lines shall be kept nearer to the column. Minimum spacing between adjacent lines shall be decided based on O.D of bigger size flange'(minimum rating 300# to be considered), O.D of the smaller pipe, individual insulation thickness and additional 25 mm clearance, preferably. Wherever even if flange is not appearing the minimum spacing shall be based on above basis only. ' Actual line spacing, especially at 'L' bend and loop locations, shall take care of thermal expansion / thermal contraction / non expansion of adjacent line. Non expansion / thermal contraction may stop the free expansion of the adjacent line at "L' bend location.

5.2.2.2

5.2.2.3

5.2.2.4

5.2.2.5 5.2.2.5

5.2.2.6

Page 103 of 208

5.2.2.7

Anchors on the racks are to be provided on the anchor bay if the concept of anchor bay is adopted. Otherwise anchors shall be distributed over two to three consecutive bays. Anchors shall be provided within unit on all hot lines leaving the unit. Process lines crossing units (within units or from unit to main pipe way) are normally provided with a block valve, spectacle blind and drain valve. Block valves are to be grouped and locations of block valves in vertical run of pipe are preferred. If the block valves have to be located in an overhead pipe way, staircase access to platform above the lines shall have to be provided. Provision of block valves, blinds etc. shall be as per Process Design Basis and P & IDs. All small bore piping shall be designed in a way so as to ensure adequate space for maintenance and operation. For small bore piping intermediate support shall be provided in between portals. Column / Vessel Piping Control Valves Piping from column shall drop or rise immediately upon leaving the nozzle and run parallel and as close as practicable to vessel. Re-boiler outlet piping shall be as short as possible with minimum bends. Piping shall be grouped as far as possible for the ease of supports and shall run on the rack side of the column. Manholes shall be kept on the road side of the column and approachable from the platform. Platform width shall be such that minimum 1.0 M space is available beyond manhole for movement. Piping shall be supported from cleats welded on the vessel as far as possible. Proper guides at intervals shall be provided for long vertical lines. Access platforms/ladders shall be provided along the column for valves and instruments. Minimum width of platform shall be 750mm clear. For ease of operation and maintenance, column and vessels which are grouped together, shall have their platforms at the same elevation interconnected by walkways wherever feasible. However each column \ vessel shall have an independent access also. Column vessel platforms should be designed in such a way so that all the nozzles should be approachable from platforms. Unless specifically indicated in P&IDs control valves shall preferably be kept at grade instead of platform. Piping intended for vacuum services shall be routed as short as possible, with minimum bends and flanged joints. Page 104 of 208

5.2.2.8 5.2.2.9

5.2.2.10

5.2.2.11

5.2.3 5.2.3.1

5.2.3.2

5.2.3.3

5.2.3.4 5.2.3.5 5.2.3.6

5.2.3.7

5.2.3.8

5.2.3.9

5.2.3.10

Piping support cleats shall be designed for safety valves considering impact loading during popping off. Exchanger Piping Exchanger piping shall not run in the way of built in or mobile handling facilities. Wrench clearance shall have to be provided at exchanger flanges. Piping shall be arranged so that they do not hinder removal of shell end and channel cover and withdrawal of tube bundle. Pump Piping Pump drives shall have clear access. Pump suction piping shall be as short as possible and shall be arranged with particular care to avoid vapor pockets. Reducers immediately connected to the pump suction shall be eccentric type flat side up to avoid the accumulation of gas pocket. For end suction pumps, elbows shall not be directly connected to the suction flange. A straight piece minimum 3 times the line size shall have to be provided at the suction nozzle. Pump discharge check valve if installed in vertical lines shall be fitted with a drain connection as close as possible downstream of the valve. When a suction vessel operates under vacuum, the vent connection of the pump has to be permanently connected to vapour space of the suction vessel to allow possible filling of the pump with liquid before it is started.

5.2.4 5.2.4.1

5.2.4.2 5.2.4.3

5.2.5 5.2.5.1 5.2.5.2

5.2.5.3

5.2.5.4

5.2.5.5

Unless otherwise specified Y -type strainers shall be used on pump suction piping for sizes 2" and above. Y-type strainers to be used for all sizes in steam services and for pump suction lines 1" and below. All small bore piping connected to pump (drain to OWS & CBD, seat and gland leak drain) shall have provision for break up flanges for removal of pumps. Piping shall be so arranged that forces and moments imposed on the pump nozzle do not exceed the allowable values. Pump discharge should preferably be routed away from the pump rather than towards the motor side. Pump cooling water connection shall be taken from the top of circulating cooling water header.

5.2.5.6

5.2.5.7

5.2.5.8

5.2.5.9

5.2.5.10

Page 105 of 208

5.2.6 5.2.6.1

Steam Header & Supply Lines / steam and Condensate Systems Steam piping shall be designed to have complete condensate removal. Drip legs shall be provided with steam traps at low points in the system. All steam and condensate branch connections shall be taken from the top of the header. Return exhaust steam / condensate lines shall connect to the top of the exhaust steam Condensate header. Where block valves have been installed in the main steam header such that condensate can collect either side of the valve when closed, a safe means of draining the condensate prior to opening the valve shall be provided. Steam header shall be located generally on the upper tier and at one end of the rack adjacent to columns. Branch lines from horizontal steam header, except condensate collection points, shall be connected to the top of the pipe header. Isolation valves (if provided) on the Branch line shall preferably be provided on the horizontal run and outside the pipe rack. All branch lines shall be drainable. Drip legs & steam traps shall be provided at all low points and dead ends of steam header. Drip legs at low points shall be closer to down stream riser and shall be provided to suit bidirectional flows, if applicable. All turbines on automatic control for start up shall be provided with a steam trap in the steam inlet line. All traps shall be provided with strainers if integral strainers are not provided. Steam traps discharging to atmosphere shall be connected to storm water drain/storm sewer, in case of open system. In case of condensate recovery, traps shall discharge into condensate header. Expansion loops are to be provided to take care of the expansions within units. Wherever condensate is to be drained, proper condensate draining facility shall be provided.

5.2.6.2

5.2.6.3

5.2.6.4

Page 106 of 208

5.2.7 5.2.7.1

Steam Tracing Tracers for the individual lines shall be supplied from manifolds when there are two or more connections. Steam supply headers shall be located on continuous platform along the rack. No steam supply station shall be located at grade. Standard module for steam distribution and condensate collection manifolds with integral glandless piston valve and thermostatic steam trap shall be used. Number of tracers shall be 4/8/12 and tracer size 0.5" to 0.75" depending upon the detail engineering requirement. 20% or minimum 2 no. tracer connections shall be kept spare for future use for both steam supply and condensate collection manifolds. All manifolds shall be installed in vertical position and manifold size shall be 3". For steam tracing balanced pressure thermostatic steam trap with 40 mesh strainer to be used. Manifolds shall be accessible from grade or from a platform. Pockets in steam tracers shall be avoided as far as possible. Tracers shall be limited to the following run length upstream of traps: Size of Length of tracer pipe (Meters) tracer Steam operating pressure 0.5" (Inch) 20 psig 30 50 psig 45 100 psig 60 150 psig 75 200 psig & above 90

5.2.7.2

5.2.7.3 5.2.7.4

5.2.7.5 5.2.7.6 5.2.7.7

Tracers shall generally be of 0.5". Tracers shall be of CS steel seamless pipe and valves on the steam tracing circuit including steam station block valve shall be glandless piston type construction. Heat transfer cement shall be applied in between main pipe and tracer pipe to improve heat transfer. Size of the lead line to manifold shall be as follows: Number of connections 2 3 4-6 7 -12 Size of Lead Line 3/4" 1" 11/2 2"

The lead line to manifold, manifold up to the block valves of individual tracer shall be carbon steel of IBR quality. Tracer lines shall be provided with break up flanges for main line flange joints and valves. All tracers shall have individual steam traps before condensate manifolds.

Page 107 of 208

Condensate manifold including the last valve on individual tracer shall be of carbon steel. All steam traps discharging to a closed system shall have a block valve upstream and downstream of the trap. A bypass globe valve shall be installed around the trap. Check valve shall be installed on the downstream of the steam trap near the condensate header in case discharging to a closed system. Number of tracers required on a line shall be as follows: Size of Line up to 4" 6" to 16" 18" to 24" 26" & above Steam Jacketing System A steam jacketed pipe consists of a product line which passes through the centre of a larger diameter steam line. The nominal size of the inner pipe (CORE) and outer pipe (JACKET) in inches shall be as per table below unless otherwise mentioned in revamped waste water section piping material specification (PMS) or P&ID. Core pipe 3/4" 1" 1-1/2" 2" 4" 6" 8" 10" Jacket pipe 1-1/2" 2" 3" 3" 6" 8" 10" 12" Steam feeder to jacket 0.5" 0.5" 0.5" 0.5" 0.75" 0.75" 0.75" 0.75" Number of Tracers 1 2 3 To Calculate

For jacketed lines using high pressure steam, actual calculations for core, jacket and feeder pipe shall be performed before finalization of sizing. Distance between steam inlet and condensate outlet shall be similar to steam tracing system. Baffle plates, flanged joints or end caps shall be used to discontinue one feed length from the next. Flanged jump over shall be used in case of a flanged joint. In case of discontinuous jacketing simple jump-over shall be employed. The length of jacket shall be 4 to 5 meters or as mentioned in job specification. Intermediate partial baffles shall be provided if a separate branch portion is to be heated from the main line stream.

Page 108 of 208

Steam inlet to jacket shall generally be provided from top of the pipe in case of horizontal lines. The jump over and condensate outlets shall be from the bottom. In case of vertical lines steam inlet shall be done at the topmost points and condensate outlet shall be done from the lowest possible points. Two consecutive Slipovers shall be 180 deg. apart. Each feed length shall be provided with individual trap before connecting to condensate recovery headers. Balanced pressure I bi-metallic type thermostatic steam traps with 40 mesh strainer shall be used in jacketing. To keep proper concentricity between core and jacket pipe internal guides (rods or flat bars) shall be provided at intervals depending on the size of the pipe. Wherever anchors are provided on jacket lines proper interconnection of jacket pipe and core pipe shall have to be provided with proper jump over for steam. 5.3 Piping in Trenches The following points to be considered in designing of trench pipes i) Piping located below grade, requiring inspection, servicing or provided with protective heating. Fire water lines/Process lines. Drain lines requiring gravity flow trenches. Sump for valves and trenches shall be provided. Suitable draining scheme for trenches shall be provided.

ii) iii) iv) v)

5.4 5.4.1 5.4.2

Air Systems Branch connections shall be taken from the top of the header. Low points shall be fitted with drains.

5.5 5.5.1

In-Line Instruments Liquid level controllers and level glasses shall be located so as to be accessible from grade, platform or permanent ladder. The level glass shall be readable from grade wherever possible.

Page 109 of 208

5.5.2

Relief valves shall be accessible. Relief valves with a centre line elevation over 4.5m above grade (expect in pipe racks) shall be accessible from a platform or permanent ladder. Relief valves that discharge to a closed system shall be installed higher than the collection header, with no pockets in the discharge line. Relief valves that discharge to atmosphere shall have tail-pipes extended to a minimum of 3.0 m above the nearest operating platform that is within a radius of 8m. Provide steam traps at pocketed low points and at dead ends of steam headers. Provide steam traps on excessively long runs of steam piping to ensure dry quality steam at destination. Steam traps located more than 4.5m above grade, except in pipe racks, shall be accessible from a platform. Control valves shall be accessible from grade or platforms. In general, the instruments or indicators showing the process variables shall be visible from the control valve. Orifice runs shall be located in the horizontal. Orifice flanges with a centre line elevation over 4.5m above grade, except in pipe racks, shall be accessible from a platform or permanent ladder. Orifice taps shall be located as follows: i) Air, Gas and steam Top vertical centreline (preferred) 45 degrees above horizontal centreline (alternate) Liquid Horizontal centreline (preferred) 45 degrees below horizontal centreline (alternate) iii) Tap orientation shall be shown on piping isometrics.

5.5.3

5.5.4

5.5.5

5.5.6

5.5.7

5.5.8

ii)

5.6 5.6.1

Sample Connections Sample connections shall be accessible from grade or platforms. In general, where liquid samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free running of the liquid before sampling.

5.7 5.7.1

Vents and Drains Valved bleeds shall be provided at control valve stations, level switches, level controllers, and gauge glasses.

Page 110 of 208

5.7.2 5.7.3

Process vents and drains shall be indicated on the P&IDs. Low-point hydrostatic drains and high-point hydrostatic vents shall be added as required; locations to be determined during the Design review. Line Strainers Provide temporary conical type strainers in 2 NB and above pump suction lines for use during start-up. Arrange piping to facilitate removal. Provide permanent Y-type strainers on 2 and smaller screwed or socket-weld pump suction piping. Spectacle Blinds Spectacle blinds shall be provided to isolate equipment. In hazardous service flanged drop-out spools shall be provided for safety purposes. Both shall be shown on the P&IDs. Spectacle blinds shall be accessible from grade or platforms. Blinds located in a pipe-rack are considered to be accessible. Blinds that weigh over 40kg shall be accessible by mobile equipment. Where this is not possible davits or hitching points shall be provided.

5.8 5.8.1

5.8.2

5.9 5.9.1

5.9.2

5.10 5.11.1

Flexibility Analysis And Supporting Pipe Supporting Criteria & General Guidelines. Piping system shall be properly supported taking into account the following points: 1. 2. 3. 4. 5. 6. Load of bare pipe + fluid + insulation (if any). Load of bare pipe + water fill. Load of valves and online equipment and instrument. Thermal loads during operation. Steam-out condition, if applicable. Wind loads for piping at higher elevation, e.g. transfer lines, column over head lines, flare headers, etc. Forced vibration due to pulsating flow. Vibration due to two phase flow. Loads due to internal pressure.

7. 8. 9.

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10.

Any external loads/concentrated loads and cold load of springs.

Support spacing shall be established based on revamped waste water section requirement. For piping on 'rack or sleeper, as a minimum, providing resting support on every grid of pipe rack / sleeper is mandatory. Depending on the pipe size, as a rule, guides shall be provided on straight run of pipes at intervals as specified in Annexure-B, unless specifically becomes non-viable due to flexibility problems. Additional supports, guides, anchors, special supports like spring supports and sway braces shall be provided after detailed analysis of piping system to restrict the forces experienced on nozzles of critical items like pumps, compressors, turbines, exchangers, etc. For lines which do not need any support otherwise but become unsupported by opening of flange, etc, during maintenance and thereby may transfer the total load on a small branch off, a permanent support shall be suitably provided which may be a spring support a/so. Bare pipes of size 14" and above on elevated structures shall be supported with pad or shoe. While bare pipes of size 6" and' above, on sleepers, corrosion pads shall be provided. Pads shall be provided for insulated pipes before welding the shoes for sizes 8"& above. Adequate stiffening shall be provided for the following : a) Lines in above 600# , b) c) Lines having two phase flow, lines having Pulsating flow such as discharge of reciprocating compressors & reciprocating pumps, all small bore branches of size 1.5" and below, e.g. vents, drain, orifice taps, pressure tappings, temperature tappings, sample connections, PSV inlet, TSV inlet etc.

d)

For pulsating flow lines detailed thermal and vibration analysis by analog study shall be done to decide on location of anchor supports and guides etc. Pulsating flow lines shall be as identified by licensor/owner. Wherever two phase flow in piping is expected, piping design shall be checked by dynamic analysis to prevent vibrations. As far as possible long trunnion types of supports (more than 0.5 metre) are to be avoided. In case long trunnion support is unavoidable in straight length of pipe, trunnion height to be restricted to 0.5m and balance height to be made up by providing extended structure. Piping passing through the technology structure or passing near the concrete column etc. should have adequate annular .space to avoid restriction of line Page 112 of 208

movement during thermal expansion. The gap should take care the thermal expansion along with insulation thickness. All pipes supports shall be so designed that there is no undue tension on equipment flanges. Flange joints should not move 'away from each other incase of un bolting of the joint. 5.11.2 5.11.2.1 Stress Analysis Criteria & General Guidelines Piping shall be analyzed for expansion, contraction, differential settlement, relief valve reaction and any other effects. - The design of piping system shall taken into account the different conditions expected during operation, startup, shut down, cold branch in case of standby pump, tracing, etc. - The use of expansion joints shall be considered only when space or pressure drop limitation does not permit pipe bends .Expansion joints of axial type shall generally be avoided. - Forces and moments due to weight, thermal loads and other imposed loads on the equipment nozzles must not exceed the allowed loads for the equipment. 5.11.3 Method of Analysis Following lines shall be considered critical and shall mandatorily require formal analysis. Other lines may also need analysis, if required. Static All process lines to and from fired heaters and steam generators All process lines to and from centrifugal compressors and blowers All lines to and from Turbines All pump lines and air cooler lines (6" & above and analysis temp> 65 deg C & less than -60 deg C) All other lines as below 4" to 6" analysis temp above 300 deg C & less than -100 deg .C 8" to 14" analysis temp above 150 deg C & less than. -80 deg C 16"& above analysis temp above 80 deg C & less than -80 deg C All lines 6 NB and above and design / analysis temp >65D that are connected to sensitive equipments (rotating equipment, , cold box etc). The package used for flexibility analysis shall be CEASER-II I AUTOPIPE I SIMPLEX I CAEPIPE. Only one of these packages shall be used & not a combination of the above packages. Page 113 of 208

Any other system / line that stress engineer /owner / owners representative feels necessary for stress check.

All lines shall be analyzed at design I analysis temperature. In the absence of analysis temperature, lines shall be analyzed at design temperature. However, in case of wide difference in design and operating temperature, temperature for analysis shall be established in process documents. (e.g. while doing the analysis of flare line or calculating expansion of long columns.) All non-critical lines may be analyzed using other methods. Special analysis methods shall be followed for lines involving pulsating flow such as those connected to reciprocating pumps & compressors which require acoustical plus analog study by approved agencies and shall require entire system analysis along with piping I equipments. Seismic All emergency service lines (e.g. fire water line) of diameter 8NB and above. All turn phase flow lines of diameter 12NB and above. All lines 900# and higher pressure class of diameter 16 NB and above. For those lines which do not come under any of the above three types, following criteria shall be considered w.r.t. the zero period acceleration (ZAP) of site specific earthquake response spectra.

For all elevations:- Pipe diameter 36NB and above. For elevations (highest point of piping):-Greater than equal to 35.0 M and pipe diameter > 16N.B. Wind analysis:- Wind analysis shall be done for all columns overhead lines, transfer lines, flare header and any other lines of size O/D 20NB and above (including insulation, if any) running above 10.0M height from HPP level. Dynamic analysis:- Dynamic analysis shall be performed by the contracts for all two phase flow lines in order to ensure that such lines are provided with proper supports and there shall be no vibrations in the lines during normal operations as well as during startup or any upset conditions. Piping system shall be stiff enough with fundamental frequency of piping system 8Hz or more. Actual densities shall be considered while carrying out static analysis. Dynamic analysis shall be preformed at design temperature and temperature 50C less than operating temperature .given in the line list. Line shall be safe in design condition with guides etc. as provided in dynamic analysis.

Page 114 of 208

5.12 5.13 5.13.1

PERSONNEL PROTECTION Mechanical Handling Handling facilities such as davits and monorails shall be provided on vessels over 10m in height where the weight of removable internal and/or external equipment is greater than 35 Kg. General Criteria Minimum diameter pipe for flanged thermo well connection Pump suction piping reducer to be installed top flat Minimum slope of piping requiring positive draining Spacing of instrument air take-offs along pipe rack headers Unless in vertical legs all reducers to be eccentric. Minimum clear width between adjacent vessels (insulation 1.2m thickness to be added) Minimum clear width of operating and servicing area around 1.5m compressors. Minimum truck access width. 3.5m Minimum clearance width between pumps and small vessels and 1m piping manifolds. Minimum clearance in front of inspection, clean out and man way 900mm opening. Minimum clear headroom under main pipe racks. 3.6m Minimum clear access width under main pipe racks. Minimum clear headroom under secondary pipe racks. 3m 2.6m 1:250 6m

5.14

4 INCH

6.0MATERIALS
Basic material selection of particular line depending on its service, temperature and corrosivity shall be as below. Material specification shall follow the requirements as specified in PMS as per Licensor's requirement. PMS shall generally follow the requirements given in this section.

Page 115 of 208

ii)

LP Steam & LP Condensate Medium pr. Steam (temp>425) High pr. Steam (temp.480C) Cooling Water. Above ground Cooling Water. Under ground Potable Water Process Water Demin. water Instrument Air (7 Kg / Cmg ) Service Air (8 Kg / Cmg 2) Dosing pipeline for Cooling Tower Chemical Defoaming agent Hydrazine / Morpholine etc. Liquid Effluent
2

A 106 Gr B SMLS A 33P11 A 335P11 C.S C.S C.S (GALVANISED) C.S SS316 SS 316 C.S SS 316

iii) iv) v) vi) vii) viii) ix)

x)

C.S/CI/SS316L( valves Alloy20 or equivalent

6.1 6.1.1

Piping Materials All materials for piping components shall conform to the relevant code and/or specification. All materials shall be new. All plate, sections, pipe, fittings, flanges, valves and special items shall have Material Test Certificates. All alloy materials shall have Material Certificates verifying the alloy content. All bolting and gasket material shall have Letters of Compliance as a minimum. All alloy bolting and gasketing shall have material Letters of Conformance verifying the alloy content. Fabricated piping items, such as spectacle blinds, shall be constructed from plate to Steel Plates for Boilers and Pressure Vessels ERW pipe and fittings shall only be used for category D service as defined by ASME B31.3. Category M and Normal Service piping as defined by ASME B31.3 shall use seamless or 100% radiographed EFW pipe and fittings. Page 116 of 208

6.1.2 6.1.3

6.1.4 6.1.5 6.1.6

6.1.7

6.1.8

6.1.9

6.1.10

Only piping materials listed in ASME B31.3 shall be used for Category M and Normal Service piping. For Category D utility piping, where scaling and impurities are to be avoided (such as instrument air, potable water and deluge water) hot dipped galvanised and threaded pipes and fittings may be used in sizes up to and including 4 NB. Galvanised piping shall not be used in environments containing acids or other corrosive commodities. In corrosive environments stainless steel piping material shall be used for such utility systems. F or services defined within ASME B31.3 as Category M, no socket welded or threaded construction or connections shall be used for process equipment piping systems. Construction shall be by butt-welding with a minimum 20% radiography. Flanged connections shall be minimised. All insulation and gaskets shall be asbestos free. Insulating flange sets shall be provided between dissimilar materials as required. Aluminium or copper alloys shall not be used for any component in the piping systems. The use of 1.25Cr-0.5Mo alloy shall be a minimum requirement for piping systems having a design temperature above 425C. The minimum corrosion allowance for any material, other than stainless steel, shall be not less than 1.0mm. For stainless steel it is zero. Pipe Wall Thickness Calculation of pipe thickness and branch reinforcement shall be based on requirements of ASME B31.3. Proper corrosion allowance and mill tolerance shall be considered to achieve the selected thickness. For carbon steel and low alloy steel pipes (except for steam tracing piping) minimum pipe thickness shall be: S 80 up to 1.5", STD for 2" and above. For stainless pipes minimum pipe thickness shall be 40S up to 2", 10S for above 2" The philosophy of minimum thickness/schedule is applicable for both seamless and welded pipes. The above mentioned minimum thickness/schedule criteria is not applicable to category -D classes, Firewater service and specification where welded API 5L pipes are being used.

6.1.11

6.1.12 6.1.13 6.1.14

6.1.15

6.1.16

6.2 6.2.1 6.2.1.1

6.2.1.2

6.2.1.3

6.2.1.4

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6.2.1.5

All welded pipes shall have uniform negative wall thickness tolerance of 12.5% for wall thickness calculations purpose. For thicknesses .exceeding minimum thickness/schedule criteria, Schedule XS shall be selected for CS & AS classes (for 2" & above). Intermediate schedules between STD & XS shall be ignored. Similarly for SS classes (2" & above) S10, S20, S30 & 40S may be selected beyond minimum thickness/schedule criteria. Up to sizes 48", D/t ratio shall be restricted to 100(max.) Where D is nominal dia. And t is nominal thickness. However for category-D classes D/t ratio may be taken as max.150 where t is minimum calculated thickness excluding Corrosion and Manufacturing allowance. Pipe Size Pipe sizes shall normally be 0.5", 0.75", 1.0", 1.5", 2.0", 3", 4", 6", 8", 10,12", 14", 16", 18",20",24",26",28,30",32,36",40",42,44",48",52",54,56",60",62,64", 72", 78", 80".

6.2.1.6

6.2.1.7

6.2.2

6.2.3

Pipe Type Material CS, LTCS, AS Seamless (except for Cat 'D' fluids & LP hydrocarbon in offsite ) SS Process lines SS Non process lines CS (Cat 'D' fluids) Size Up to 14" 16 and above Up to 6" 8 and above Up to 1.50" 2" & Above ALL sizes Type Seamless E.F.S.W Seamless E.F.S.W Seamless Welded Welded

6.3 6.3.1 6.3.2 6.3.3

Fittings Type of fittings shall be equivalent to pipe type. Thickness of fittings at ends to match pipe thickness for BW fittings. SW fittings shall be 3000#, 6000# and 9000# depending on the pipe thicknesses S80, S160 and above S160 respectively. All branch connections shall be as follows, unless specifically mentioned otherwise in PMS: Up to 1-1/2" NB O-Iets/ Tee 2" and above Tees/O-Ietsl Pipe to pipe with or without Reinforcement pad up to 600# rating. Only Teel Red tee/ o-loets above 600# rating. Page 118 of 208

6.3.4

6.3.5

Mitres shall be used in Category 'D' service above 6". For other than Category 'D' fluid in 150# and 300# Class mitres can be permitted for sizes 'above 48". Mitres to be designed as per ASME B31.3. However, use of mitres shall be minimum. Flanges Flanges shall be as follows. Rating 150 # Size Up to 1.50" 2" &above 2" & above Up to1.50" 2" & above All Type SW RF WN RF/LJ FF SO FFIWN RF SW RF WN RF WN RTJ. Remarks If non metallic gasket used. For SS LJ FF + Stub Ends If used in CAT 'D' service

6.4

300 #,600 # 900 #,1500 #

6.5

Gaskets Rating Material/ service Temperature Type (OC ) GASKET OR STRIP MATERIAL + FILLER MATERIAL/RTJ GASKET MATERIAL Graphite SS316+ Graphite

150 # 150 #

CS & SS Up to 371C (utilities) up to 371C CS

PLAIN Spiral wound

(other

150 # 300#&600 #

300#&600 #

utilities) AS (all services) CS (all services, except H2) AS (all services,

up to 371C

Spiral wound

SS316+ Graphite SS316+ Graphite

up to 427C Spiral wound

above 71C

Spiral wound

SS316+Grafoil

Page 119 of 208

exceptH2) 150 #,300 #, 600 # SS (other than utilities All Spiral wound SS316+Grafoil (where trim material isSS304/316)'SS316L+Grafoil (where trim material is SS304L1316L

300 #, CS 600 #,900 #, 1500#,2500# 300#, AS 600#,900# 1500#,2500# 300#, SS 1500#,2500# * only if RTJ PMS. 6.6 Valves Type a)

All

OCTAGONAL Soft Iron RTJ OCTAGONAL 5Cr-Alloy steel RTJ OCTAGONAL SS RTJ

All

All

SW Valves up to 1 inch 600# except ball & plug valves which shall be flanged for all sizes. Flanged cast valve above 1-1/2" for 150#, 300#, 600# B.W. Valves - 900# and above

b) c) 6.7

Technical Requirements Of Piping Items Over and above the requirements specified in clause 6.1 through 6.6, other technical requirement prescribed in Annexure "C" shall also be adhered to.

6.8

NDT Requirements Depending upon the severity of application, extent of NDT shall be decided. As a rule, all oxygen, NACE and any other lethal service shall have 100% radiography on weld joints in aII class ratings. Castings used in these services shall have 100% radiography. For high pressure applications, i e., 600# and upward 100% radiography on weld joints shall be employed. In 100% radiography classes any fillet welds employed shall have 100% DP/MP test in CS/AS classes and 100% DP test in SS classes. Cat. 'D' service does not require radiography.

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DP/MP test (for CS&AS) or 20%DP test (for SS). For fire water service, radiography shall be as per statutory requirement

7.0

THERMAL INSULATION OF PIPING, EQUIPMENT & VESSELS

Party to specify type of insulation required for piping/vessel/equipment/machines, so as to have minimum heat loss and also from the personnel protection point. Party to give insulation application procedure.

8.0

PAINTING
Party to specify type of paint required for protection of piping/vessel/equipment/machines. Party to give paint application procedure.

9.0
9.1

WELDING (Only for supply)

Applicable Codes & Standards All welding work, equipment for welding, heat treatment, other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the following accepted standards and procedures. a) Process Piping ASME: B31.3

In addition, the following codes and 'specifications referred in the code of fabrication shall be followed for the welding specifications, consumable qualifications and non destructive test procedures. i) ii) Welding and brazing Qualifications ASME BPV- Sec. IX. Non destructive examination ASME BPV Sec. V.

iii) Material specifications: Welding rods, electrodes and filler metals ASME BPV Sec II Part C. The additional requirements mentioned in this specification, over and above those obligatory as per codes, shall be followed wherever specified. 9.2 9.2.1 Welding Processes

Welding of various materials shall be carried out 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). Page 121 of 208

9.2.2

Automatic and semi-automatic welding processes shall be employed only with the express approval of the OWNER / Consultant. The welding procedure adopted and consumables used shall be specifically approved. 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 OWNER/ Consultant. For additional details "Welding Specification for Fabrication of Piping shall be referred.

9.2.3

9.2.4

Page 122 of 208

Annexure A ACCESSIBILITY FOR VALVES AND INSTRUMENTS

Valves, instruments, Centreline of item to be operated, equipment to be operated located less than 3.6 m above grade, 2.75 m above floor or platform or 1.8 m above wing platform

Exchanger heads Oper. Valves 2" & smaller Oper. Valves 3" & above Motor operated valves Control valves Relief valves 2" & smaller Relief valves 3" & above Block valves 2" & smaller Block valves 3" & above -

Nil -fixed ladder Platform Platform Platform Fixed ladder Platform Portable ladder Platform (note-1)

Centreline of item to be operated, located more than 3.6 m above grade, 2.75 m above floor or platform or 1.8 M above wing Platform Platform Fixed ladder Platform Platform Platform Fixed ladder Platform Platform Platform (note-1 ) Platform Fixed ladder Fixed ladder Platform Fixed ladder Platform Platform Platform Platform Platform

Battery limit valves Platform Pressure Fixed ladder if above 2.2 Instrument M height Temperature Fixed ladder if above 2.2 Instrument M height Sample points Platform Gauge glasses Fixed ladder Level controllers Platform Process blinds and spacers Portable ladder i platform 2" & smaller Process blinds and Platform Spacers 3" & above Manways/manholes Platform Platform Handholes/inspection holes

Nozzles(process} Platform Platform Vessel vents Portable ladder Fixed ladder Line drains & vents Portable ladder Portable ladder Orifice flanges Portable ladder Fixed ladder-(note 2) Note -1: block valves, if located, with centre lines 2.0 m above from the operating floor! Access shall be provided with portable platform or chain for operation of valves.

Page 123 of 208

Annexure-B MAXIMUM SPACING OF GUIDES FOR VERTICAL & HORIZONTAL PIPES NOM PIPE SIZE IN INCHES 1 1 2 3 4 6 8 10 12 14 16 18 20 24 26 & ABOVE NOTES:1. These spacings may be varied to suit column spacing of rack. The above spacing is for straight runs of pipe & does not include guides which are used for control of thermal movements, as decided by stress group. The guide spacings given in the above table are indicative only. VERTICALSPACING METRES 6.0 6.0 6.0 8.0 8.0 8.0 8.0 12.0 12.0 12.0 12.0 12.0 16.0 16.0 16.0 HORIZONTAL SPACING METRES 6.0 6.0 6.0 12.0 12.0 12.0 12.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0

2.

Page 124 of 208

Annexure C TECHNICAL REQUIREMENTS OF PIPING ITEMS 1.0 ENDS Unless otherwise specified in Piping Material Specification (PMS), the ends of piping items shall be to the following standards: SW/SCRD BW FLANGED THREADING : : : : ASME B 16.11 ASME B16.25 ASME B16.5 and ASME 816.47 SERIES 'B'/API-605 ASME/ANSI B1.20.1 (NPT, Taper threads)

2.0 2.1

ITEM SPECIFIC NOTES Pipes Unless specifically exempted, welded pipes shall be acceptable Only with longitudinal weld made employing automatic welding. Double seam 180 apart is allowed for sizes 36" and larger only. Galvanised Pipes shall be only Hot Dip galv. to ASTM A53.

2.2

Fittings - All fittings shall be seamless in construction unless otherwise specified. - All welded fittings shall be double welded. Inside weld revamped waste water sectionion shall not exceed 1.6mm, and the welds shall be ground smooth at least 25mm from the ends.

2.3

Valves Valves of Class 900 & above shall be pressure-seal type. Threaded and' seal welded or welded bonnet may be employed up to sizes 1-1/2". All flanged valves (except forged) shall have flanges integral with the valve body. Valve Castings/Forgings purchased shall be from Local approved foundries/forging shop. Yoke material shall be at least equal to body material. Forgings are acceptable in place of Castings but not vice-versa. No cast iron valves to be used in firewater or any other service. Valves in sea water service shall be with non ferrous trims and all wetted parts other than trims shall be epoxy coated.

2.3.1

Dimensions

Page 125 of 208

- Face-to-Face/End-to-End dimension shall be as per ANSI B16.10. In case the same is not covered under B16.10, the dimension shall be as per BS 2080/manufacturers Std.
- Generally the valves are hand wheel or lever operated. However, suitable gear

operator in enclosed gear box shall be provided for valves as follows :

Gate Valves: CL150 CL300 CL600 to 2500 Globe and Angle Valves: CL150 CL300 CL600 CL900 CL1500 & 2500 Ball Valves: CL150 to 300 CL600 CL900 to 1500 Butterfly Valves: CL150 to 600 Plug Valves: CL150 to 600

14NPS and larger 10NPS and larger 8NPS and larger

12NPS and larger 8NPS and larger 6 NPS and larger 4 NPS and larger 3 NPS and larger

8 NPS and larger 8NPS and larger 3 NPS and larger

8NPS and larger

6 NPS and larger

Spectacle blinds and paddle blinds/spacers shall be provided per the pressure class and size range divisions shown below: Spectacle Blind CL150 14NPS and below CL300 10 NPS and below CL600 8 NPS and below Paddle Blind/Spacer CL150 16NPS and above CL300 12NPS and above CL600 10NPS and above

- Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500 mm on each side. Effort to operate shall not exceed 35 kgf at hand wheel periphery. However, failing to meet the above requirement, vendor shall offer gear operation. - Quarter-turn valves shall have "open" position indicators with limit stops.

2.3.2

By-Pass Page 126 of 208

- A globe type valve (size as per ASME/ANSI B16.34) shall be provided as by-pass for the following sizes of gate valves : Class 150 300 600 900 1500 2500 Size 26" & above 16" & above 6" & above 4" & above 4" & above 3" & above

By-pass Piping, Fitting and Valves shall be of compatible material and design. Complete fillet welds for by-pass installation shall be DP/MP tested. NDT of by-pass valve shall be in line with main valve. 2.3.3 Radiography of Cast Valves - Quantity is considered for each size in each valve sheet. - Radiography procedure, areas of casting to be radio graphed, and the acceptance criteria shall be as per ASME/ANSI B16.34. - All valve castings shall be of radiographic quality. a) The minimum requirement of radiography for other than category 'D' service shall be as under: Class 150 150 300 300 600 900 & above Size UP TO 24 26" & above UP TO 16 18" & above All All qty. 5% 100% 10% 100% 100% 100%

Note: No radiography is (required for category 'D' service classes. b) Additional radiography requirement for casting sizes for special critical piping classes (Over and above the requirements covered in clause ( a) above) shall be as follows: i) For alloy steel & stainless steel castings Class 150# 150# Size up to 24" ABOVE 24" Qty. 10% 100%

Page 127 of 208

300# 300#

up to 16" ABOVE 16"

10% 100%

2.3.4

Ball/Plug/Butterfly Valves - Each valve shall be supplied with a lever/wrench except for gear operated/motor operated valves. - Soft-seated Ball, Plug & Butterfly valves shall be supplied with antistatic devices. - The ball of Ball valves shall not protrude outside the end flanges. - Ball valves shall be floating ball type / trunnion mounted type as per following: Class 150 300 Floating Ball 8" & below 4" & below .Trunnion Mounted 10" & above. 6" & above

600 & above 11/2" & below 2" & above - Use of soft seated ball/plug/butterfly valves shall be suitably selected based on temperatures handled. - Butterfly valves shall be suitable for throttling application. 2.3.5 Special Valves (Orbit. Y -body Globe, Jacketed, Valves of all types) - SPECIAL VALVES shall strictly follow the requirements of Valve data sheet, Process data sheet/Specialty data sheet. - Special Valves shall be made out of 100% radiographic casting/ 100% ultrasound forging. - Jacketed Valves shall be tested to 100% DP/ MP check on Jacket welding, 100% radiography test of valve body, 100% hydro test of Jacket. Strainer - Allowable pressure drop when specified shall be certified by vendor along with the offer. If asked specifically, vendor shall furnish pressure drop calculations. - All 2" & higher sized Y type strainers shall be provided with 3/4" threaded ,tap and solid threaded plug as drain connection. For less than 2", this shall be " size. - Bottom flange of Y-type strainer shall not have tapped hole. Full length standard size studs shall be used for joining blind flange. Page 128 of 208

2.4

- For fabricated strainers, all BW joints shall be fully radio graphed and fillet welds shall be 100% DP/MP checked. - All the strainers shall be hydrostatically tested at twice the design pressure. 2.5 Traps - Vendor shall also furnish the performance curve indicating the capacity hi mass/hour at various differential pressures across the trap. - Parts subject to wear and tear shall be suitably hardened. Traps shall function in horizontal as well as in vertical installation. - Traps shall have integral strainers. - All traps shall be hydrostatically tested to twice the design pressure. 2.6 Hoses - Manufacturer shall guarantee suitability of hoses for the service and working conditions specified in the requisition, if the material is not specified in the Material Requisition for any particular service. - All hoses shall be marked with service and working pressure at minimum two ends clearly. - Hoses shall be resistant to ageing, abrasion and suitable for outdoor installations. - Complete Hose assembly shall be tested at two times the design pressure

Steam hoses shall be subject to steam resistance test. Flexible hoses of Hydrogen reformer should be of SS 316L or equivalent to resist chloride corrosion.

2.7

Expansion Joints - The applicable codes are ASME B31.3 and EJMA (Expansion Joint Manufacturer's Association). - Bellows shall be formed from solution annealed sheet conforming to the latest ASTM Spec. Any longitudinal weld shall be 100% radiographed. The finished longitudinal weld must be of the same thickness and same surface finish as the parent material. - Circumferential welds are not permitted. Bellows are to be hydraulically or expansion (punched) formed. Rolled formed bellows are not acceptable. Noticeable punch or die marks resulting from expansion operation are not acceptable. Page 129 of 208

- No repairs of any kind are allowed on the bellows after forming. Deep scratches and dents are not acceptable. . - The out of roundness shall be limited to 3mm. This is the max. deviation between the max. & min. diameter. - The actual circumference of the welding end shall be maintained to 3mm of the theoretical circumference. - Apart from the usual requirements, the vendor shall also furnish a) b) c) 2.8 Design calculations to justify stiffness and fatigue life. Axial, lateral stiffness, angular stiffness, effective pressure thrust area. Installation/maintenance manual.

Supports & Spring Assemblies - The Material, Design, Manufacture and Fabrication shall be generally as per MSSSP-58/ MSS-SP-89 and/or BS 3974. - Testing of springs shall be as per BS1726.

2.9

Stud, Bolts, Nuts and Jack Screws - All bolting shall be as per ASME/ANSI 818.2.1 for Studs, M/C Bolts and Jack screws, and ASME/ANSI B18.2.2 for nuts. - Threads shall be unified (UNC for; 1" dia and 8UN for> 1" dia) as per ANSI B1.1 with class 2A fit for Studs, M/C Bolts and jack screws, and class 2B fit for nuts. - Stud bolts shall be threaded full length with two heavy hex nuts. Length tolerance shall be in accordance with the requirement of table F2 of Annexure F of ASME B16.5 - The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot forged process. - The length of the studs/ bolts should be such that minimum two threads should be out of the nut on either side. - All the stud bolt should have metallurgical certificates in case of Alloy/ SS metallurgy with identified color marking at the stud ends/ bolt side face. - In corrosive atmosphere like Acid chemical storage area, cooling towers area, where SS flanges are provided, fasteners should also be SS.

Page 130 of 208

- Heads of jack screws and M/C bolts shall be heavy hexagonal type. Jack screw end shall be rounded. - Wherever bolt tensioning is specified stud bolt length shall be longer by minimum one diameter do suit bolt tensioner . Excess threads shall be protected by a threaded cap.

3.0

INSPECTION & TESTING: - All items and their parts shall be subjected to all mandatory as well as supplementary (wherever specified) tests and checks called for in the respective codes/standards/data sheets. - The examining personnel shall have the requisite qualification and experience. - Client and its authorized representative reserve the right to vet and suggest changes in vendor's procedures. - Vendor's works and facilities shall be accessible to the Clients Representative at all reasonable times. - Test reports for all mandatory as well as' supplementary tests wherever specified shall be furnished.

4.0

POSITIVE MATERIAL IDENTIFICATION (PMI) - All alloy steel, and higher alloyed piping material shall be subjected to PMI inspection. - Extent and procedure of PMI shall be as per "Specification for Positive Material identification (PMI) at vendor's work". Similar specification shall be developed by contractor for site inspection and submitted to Client/PMC for approval.

5.0

MARKING - All items shall be marked (stamped/etched) in accordance with the applicable code/standard/specification. In addition, the item code, if available, shall also be marked. - For ease of identification, the colour of painted strip (wherever required) shall be as per the applicable standard. .' - Paint or ink for marking shall not contain any harmful metal or metal salts which can cause corrosive attack either ordinarily or in service. - Special items/smaller items shall have attached corrosion resistant tag providing salient features. . Page 131 of 208

5.1

Dispatch - All items shall be dry, clean and free from moisture, dirt and loose foreign material of all kinds. - All items shall be protected from rust, corrosion, and mechanical damage during transportation, shipment and storage. - Rust preventive on machined surfaces to be welded shall not be harmful to welding and shall be easily removable with a petroleum solvent. - Ends shall be suitably protected, and the protectors shall be securely and tightly attached. - Each variety and size of item shall be supplied in separate packaging marked with the purchase order no., item code (if available),. and the salient specifications. - Carbon steel, LTCS and low alloy steel valves shall be painted with one coat of inorganic zinc silicate primer.

Page 132 of 208

Annexure D CLEARANCES Minimum clearances for piping, equipment, structures, platforms, and supports shall be in accordance with the following table: Item Roads Description Headroom for primary access roads (from the crown) Width of primary access roads excluding shoulders. Headroom for secondary roads (from the crown) Width of secondary roads excluding shoulders. Clearance from edge of road shoulders to platforms, equipment, pipe associated with equipment, or similar features. at Horizontal clearances for equipment maintenance by hydraulic crane (12t capacity) Vertical clearance for equipment maintenance by hydraulic crane (12t capacity) Horizontal clearance for fork lift and similar equipment (2500 kgs capacity) Vertical clearance for fork lift and similar equipment (2500 kgs capacity) Horizontal clearances for equipment maintenance by portable manual equipment (A-frames, hand trucks, dollies or similar equipment) Vertical clearances for equipment maintenance by portable manual equipment (A-frames, hand trucks, dollies or similar equipment) Horizontal clearance (not necessarily in a straight line) Headroom (except for handwheels) Minimum width Headroom from stairwell treads. Minimum clearance around any obstruction on the platform. Headroom Maximum vertical distance between platforms Minimum toe clearance behind a ladder. Minimum handrail clearance. Minimum maintenance space required between flanges of exchangers or other equipment arranged in pairs. Minimum maintenance space required for structural members or pipe. Clearance from edge of road shoulder (the extreme revamped waste water sectionion) Horizontal clearance from hydrocarbon equipment (shell to shell) Exception: Reactors or equipment in alloy systems shall be located for the most economical piping arrangement. Clearance from edge of road to heater shell. Page 133 of 208

6.5m 6m 4.2m 3m 1.5m** 3m 3.6m 2.4m 2.4m 1m

Maintenance Grade

Aisles

2.4m 750mm 2.2m 750mm 2.2m 500mm 2.2m 6m 210mm 100mm 500mm 300mm 1.5m 15m

Walkways Platforms

Equipment

Fired Equipment

3m

Item

Description Clearance between the outside of the handwheel and any Valve Hand wheels obstruction. Clearance between the outside diameter of the flange and the Pipe (aboveground) outside diameter of pipe insulation. Clearance between the outside diameter of the pipe, flange or insulation and a structural member. Clearance between the outside diameter of the flange and the outside diameter of bare pipe. Minimum distance from underside of pipe to grade or platform. Control Valve Arrangement Centreline of control valve above grade or platform. Minimum centreline of control valve from face of column or wall. Where process conditions require steam or hydrocarbon vapours to be discharged to atmosphere at a safe location, the tail pipe shall terminate as below: Distance above nearest operating platform. Within radius of nearest operating platform. ** Verify conformance with local regulations. * With full consideration of thermal movements

25mm* 25mm* 50mm* 25mm* 300mm 450mm 600mm

3m 7.5m

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Annexure-E JOB SPECIFIC REQUIREMETS NOTE:- THE JOB SPECIFIC REQUIREMENTS GIVEN AS UNDER SHALL BE CONSIDERED FINAL IN CASE OF ANY CONFLICT WITH THE MAIN BODY OF DESIGN BASIS.

Sl No 1 2

ITEM Equipment spacing (ISBL) Minimum pipe rack width 4m/ 6m/8m/10m/12m in single bay Spare capacity on Rack Cooling water lines

Job Requirement As per Piping Design basis. 10M for Main Rack 4M/ 6M/ 8M for Sub Racks.

Remarks.

3 4

6 7

Minimum height sleeper due maintenance requirement Fin-fan cooler location Location of pumps: -In units

Provision of 20 %( at the beginning) for future modifications. Generally on rack up to 16" Underground above 16"(ln specific cases, lower sizes may also go Under ground depending on layout) of 300mm with pavement below pipe way. to

On pipe rack and/or As per Equipment technological structure Layout. - Inside pipe rack as far as possible with concrete slab. - For, smaller width (4M, 6M & 8M) rack, pumps shall be outside or on one side of rack portal.

Requirements of monorail Required for motorrating45KWand above on pumps: -under pipe for all pumps. rackIshed None - Open area Requirement for exchanger bundle removal Hydro extractor a) Hydro extractor Where Hydro extractor mobility is b) Monorail & chain difficult in running plant. pulley block

However, required head Room for installing monorail at later stage shall also be kept in Technical Structures.

Page 135 of 208

10

11 12

13

14

15 16

Battery limit valves operation a) At grade. b) At elevated Platform. Pipe way road crossing Safety shower/eye wash. (in case of chemical/ catalyst handling system.) Connectivity of all platforms at higher elevations for tall columns(ie., between columns &technological structure and between columns & rack). Compressor/blower house for ISBL as well as OSBL a) location b) Maintenance requirement Instrument Air Drier Shed Insulation material a) Hot /Tracing/safety b) Electrical tracing Painting system Method of surface preparation a) Mechanical tools b) Blast cleaning Sand blasting! grit blasting Painting of SS pipes below insulation

Elevated platform provided at Battery Iimit.

Overhead pipe bridges Required.

At B/L with access.

Yes.

Adjacent columns/ technological Structures/ rack must be connected at minimum two locations.

a) b)

Under shed E.O.T.

None As per process design basis.

17 18

-Blast Cleaning

19 20

Grit Blasting -Whenever painting is not specified, Aluminium/ SS foil as per piping design basis shall be used.

21 22 23

Specific colour coding -requirements. Usage of asbestos NO gasket. Provision for high Flexibility of piping. settlement in tank farm: a) Usage of dresser coupling in tank farms. b) Flexibility of piping. Page 136 of 208

24

Steam tracing type

Standard module for. steam distribution and condensate collection manifolds with integral glandless piston valve & trap and carbon steel tracer pipe. Client agreed vendor List.

25 26 27

Bulk Material Engineering mode Drawing

Electronic 3-D MODELS, CAPABLE OF MODEL REVIEW AND WALKTHROUGH,

28 29 30 31 32

Specific software package for engineering drawings o AutoCAD and AP-ISO o PDS with Isogen o AutoPlant Designer with Isogen or AP-ISO o PDMS with Isogen o AutoCAD Material Control System Item Coding system Stress analysis package

--

33

34 35 36 37

-CEASER II/ AUTOPIPE / SIMPLEX / CAEPIPE. Access to nozzles of Platforms for all columns Nozzles. Staircase / Ladders for Ladders for tall column/reactors. columns/staircases "for reactors Provision of breakup Wherever necessary. flanges for removal of tube bundles of heat exchangers. Height of pipe support 150 mm from FGL pedestals Mandatory Bulk Material As per mandatory spares. Escalation Cathodic Protection of -Tankage and U/G Piping Cast iron valves Cast Iron Valves not to be used. Page 137 of 208

38 39 40 41 42

Pump Suction strainers Two phase flow line analysis Connectivity of the technological structure Usage of check valves. Traps on steam lines.

Y -type strainers. Both static and dynamic analysis required. Technological structure to be Interconnected. Wafer dual plate and swing check valves, Unless specifically called for in process Thermodynamic for line traps and Thermostatic for steam

Page 138 of 208

TECHNICAL (VOLUME 2) SECTION 3.3.3

DESIGN PHILOSOPHY ROTATING EQUIPMENTS
CONTENT
SL. NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Scope Design Philosophy For Machinery Design Requirements Inspection And Testing Spares Painting Vendor List Contractor/ Vendor Documentation DESCRPTION SHEET NO 152 152 154 156 156 156 156 157

LIST OF ATTACHMENTS ATTACHMENT NUMBER Annexure - 1 DESCRIPTION NUMBER OF SHEETS 158

Inspection & Testing Guide Lines Rotating Equipment

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1.0
1.1 1.1.1

SCOPE
General This Philosophy covers the requirements for the design, fabrication, installation, inspection & testing, painting, transportation and supply of rotating equipments for RCF- Trombay, waste water treatment section revamp. In addition, all statutory rules & regulations shall also be complied with.

1.1.2

2.0
2.1

DESIGN PHILOSOPHY FOR MACHINERY

Codes and Standards The latest edition of codes and standards as listed below shall be followed for design and manufacturing of different machinery items. Generally the manufacturer will comply with these codes and standards as indicated therein with minor deviations that are normally adopted by manufacturer and are reasonably accepted as per good engineering practice. A list of such deviations, if any, shall be furnished by the Contractor along with offer. Code API 610 ANSI/ ASME B 73.1 M International Standard API 614 API 671 API 674 API 682 Description Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industry Horizontal, End Suction centrifugal Pumps for Chemical Process Horizontal Centrifugal Pumps for Clear Cold Water Lubrication, Shaft-Sealing, and Control Oil System for Petroleum, Chemical and Gas Industry Services Special Purpose Coupling for Refinery Services, Petrochemical and Gas Industry Positive Displacement Pumps-Reciprocating Shaft sealing Systems for Centrifugal and Rotary Pumps.

ISO / DIN Centrifugal Pumps for smaller size & Non Critical Services. International HVAC Standard,ASHRAE Performance Testing (ASME Codes) PTC 8.2 Centrifugal Pump

Page 140 of 208

2.2

Design Life All equipment shall be designed for a minimum service life of 20 years and at least 3 years of uninterrupted operation under normal operating conditions. This requirement excludes specialised components requiring periodic maintenance and replacement.

2.3

Essential Revamped waste water section Reference Documents The following documents shall be observed, and relevant aspects incorporated into specifications and datasheets: Hazardous Area Classification Electrical and Instrumentation Design Criteria

2.4

Regulations Besides codes & standards, Contractor shall follow National Laws and Regulations together with Local by Laws for the state including statutory requirements as applicable.

2.5

Site Conditions Site conditions shall be as defined elsewhere.

2.6

Material of Construction The API guideline may be adapted to the extent applicable. Use of equivalent & superior material may be selected & shall be furnished with the offer along with chemical composition.

2.7 2.7.1

Quality Assurance & Control The quality assurance shall be as per the approved procedures, test methods & facilities to be developed by the Contractor to ensure that the supplied equipment shall be of highest quality. The quality control shall mean that all the tests, measurements, checks & calibration which are to be carried out may be compared with the actual specified characteristics of the equipments/unit /system.

Page 141 of 208

2.7.2

Quality Assurance (QA) shall mean the organizational set up, procedures as well as test methods and facilities developed by Contractor in order to assure that The Machines & Associated auxiliaries leaving Contractors shop are of the highest possible quality i.e. either equal to or better than the requirement specified. Quality Control (QC), shall mean all the tests, measurement, checks and calibration which are to be carried out in Contractors shop in order to compare the actual characteristics of the equipment/unit/system with the specified ones, along with furnishing of the relevant documentation (certificates/records) containing the data or result of these activities. Contractor shall submit a comprehensive description (manual) of QA/QC measures contemplated by him for implementation with regard to this specification. It is contractual obligation of the Contractor to develop and implement adequate QA/QC systems. QA/QC system shall cover all products and services required for the complete machine unit as per scope of work including job sub contracted by the Contractor.

2.7.3

2.7.4

2.7.5

3.0
3.1 3.1.1

DESIGN REQUIREMENTS
General All machines shall be directly coupled to their prime movers. If not, specifically mentioned, the drivers shall have rated output at least 10% greater than the power requirement at design operating condition of the driven equipment. All process pumps shall have Mechanical Seals. Single seals will be used in most cases, however, for ignitable or hazardous fluids, double, or Inside Wet and Outside Dry running seals will be used. Special tools and wrenches required for installation and maintenance shall be provided. Contractors have to submit the reference list for similar equipments models (minimum 2 nos.) supplied in past for similar duty conditions. Reference list must contain at least the following: Fluid handled Capacity, Suction Pressure, Discharge Pressure, Model No., Power consumption, Client Name, Address, and Year of supply.

3.1.2

3.1.3

3.1.4

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3.2

Centrifugal Pumps The process pumps shall be designed as per API 610, 10th edition. The pumps shall be of robust design to ensure long service life and minimum maintenance requirement. The pumps shall be designed for easy access for inspection and maintenance. All continuously running pumps shall have a spare pump. In addition to codes & standards, following points shall also be applicable:

3.2.1

All pumps shall have continuously rising head curve from any specified operating point to shut off point. Pumps running in parallel shall have equal head rise to shut off point. All pumps shall be designed for 20% overload. The pumps should have stable operating characteristics. The pump head at shut off shall be approximately 110% of head at rated capacity and not exceeding 120%. Best efficiency point shall be as close as possible to normal operating point. Impellers of multistage pumps shall be secured positively against axial movement. For multistage pumps, a lateral critical speed analysis shall be carried out. Pumps with centre line support shall be provided for pumps handling fluids of operating temperature more than 1770C. The maximum calculated axial load shall not in any operating condition exceed 50% of bearing manufacturer's load rating. Metastream type of coupling shall be provided. Coupling guard shall be nonsparking for pumps located in hazardous area. Mechanical seal of John crane / ESSIL / Flowserve / Burgmann make only shall be provided. Only balanced mechanical seal shall be used. For pumps with forced lubrication system, the lubrication system shall be designed as per API 610.

3.2.2 3.2.3

3.2.4 3.2.5 3.2.6 3.2.7

3.2.8

3.2.9

3.2.10

3.2.11

3.3

Reciprocating Pump / Metering pumps Reciprocating pump shall be designed as per API 674 and metering pump shall be designed as per API 675.

3.3.1

The metering pumps shall be suitable for continuous capacity variation from 0 to 100%. The capacity variation should be possible while the pumps are working. All continuously running pumps shall have a spare pump. Page 143 of 208

3.3.2

4.0

INSPECTION & TESTING

Machines shall be inspected by Third Party Inspection Agency (Lloyds/BV/TUV/PDIL). The Inspection and testing shall be in accordance with the all relevant codes, standards, specifications, including the minimum guide line given in Annexure I (ATTACHED).

4.1

All testing accessories, measuring instruments including NDT testing equipment, etc. shall be arranged by Contractor. DM water shall be used for hydro testing of the equipment which shall be supplied by client on chargeable basis. In general, following tests shall be conducted for all rotating equipments: Material test Non-destructive test Hydrostatic test for all the pressure containing parts Dynamic balancing of rotor NPSHR test for pumps Performance Test The tests required to be conducted and witnessed shall be specified in the equipment data sheet.

4.2

5.0
5.1

SPARES
All erection & commissioning spares shall be supplied by Contractor & cost shall be included in the cost of main equipment. 2 years operation spares shall be supplied by the contractor as per ITB.

5.2

6.0
6.1

PAINTING
All exterior non-stainless steel surfaces subject to atmospheric corrosion with the exception of machined surfaces shall be epoxy painted. All exterior machined surfaces shall be coated with suitable rust preventives.

6.2

7.0

VENDORS LIST
All equipment shall be procured/fabricated as per approved vendor list. Any equipment for which vendor list is not enclosed, the Contractor may furnish a list of proposed vendors along with their references for supply of similar type of Page 144 of 208

equipment along with bid. However all proposed additional sub-vendor shall have well proven track record and shall be subjected to consultant / owners approval.

8.0

CONTRACTOR/VENDOR DOCUMENTATION:
Drawings & Documents of machinery items shall be as per ITB.

Page 145 of 208

Annexure-1 INSPECTION & TESTING GUIDE LINES 1.0 SCOPE This document covers the minimum guide lines for the Inspection & Testing for the rotating Equipments. All rotating Equipments shall be inspected by Third Party Inspection Agency (Lloyds/BV/TUV/PDIL). The Inspection and testing shall be in accordance with the all relevant codes, standards, and specifications as specified in Specification sheet. 2.0 2.1 2.2 2.3 2.4 2.5 2.6 PUMPS Pump casings to be identified against foundry test certificates and thickness checked to conform to approved drawings. Witness hydrostatic test on casings. Dynamic balancing of rotor Witness running tests on pumps including N.P.S.H. where applicable. Non- destructive test Strip inspection of pumps on completion of running tests. Wearing surfaces to be checked and recorded. As a general principle, mechanical seals will not be dismantled after running tests. This necessity will be discussed on a case to case basis if abnormal noise or temperature has need records during testing. All materials to be checked against test certificates or VENDOR'S bill of materials. Final inspection and dimensional check of pump Heat run or standard abbreviated tests, as specified, to be witnessed on electric motor drives. Final inspection and dimensional check to be carried out on motor drivers. Check all test certificates.

2.7 2.8 2.9 2.10

Page 146 of 208

TECHNICAL VOLUME - 3 SECTION 4.0 DOCUMENTATION SCHEDULE

TABLE OF CONTENTS

SL. NO. 1.0 2.0 3.0 4.0

DESCRIPTION DRAWINGS & DOCUMENTS CATEGORY OF DOCUMENTS PROCEDURE LIST OF DRAWINGS & DOCUMENTS

SHEET NUMBER 160 162 165 165

Page 147 of 208

1.0

DRAWINGS & DOCUMENTS This chapter details out various drawings and documents to be generated at various stages during the course of execution of the Revamped waste water section by the Contractor for different revamped waste water section activities. Categorization of the documents/ drawings for review/ information/ records of PMC and the review/ approval requirements of the Owner/ PMC along with routing of the documents/ drawings will be conveyed separately as a philosophy.

The efficient handling of drawings and documents to be prepared by the Contractor under the contract is the key to the timely completion of the waste water treatment section. The Contractor undertakes to ensure that all drawings and documents to be submitted by him to the Owner/ PMC shall be of professional quality and conforming to the contractual requirements. The Contractor also undertakes to institute a formal drawing control system which will be documented and submitted to the Owner/PMC for review or approval.

Compliance of this chapter on drawings and documents is mandatory and is non-negotiable. The drawings / documents are to be generated by the Contractor at various stages of the revamped waste water section covering different activities. The drawings / documents generated will be in the category of Approval/ Review/ Information. The list of drawings and documents required is enclosed; however, the categorisation for the drawings/ documents will be informed separately. However, this will in no way relieve the Contractor of responsibility to conform to drawings, standards, specification, codes and contractual requirements / obligations. The Contractor shall prepare the drawing numbering procedure and submit to Owner/ PMC for approval. Each Drawing submitted by the Contractor shall be clearly

marked with the name of the Owner, PMC with revision number & date. It should contain the minimum following details: a. Size of Drawing. b. Discipline of Engineering for which the drawing is issued.

Page 148 of 208

c. Discipline wise segregation of numbering sequence for example: 100 Series for Process. 200 Series for Mechanical etc. For drawing, data sheet and all graphic works AutoCAD 2003/ 2007 and for all texts, MS Word Package 2003/2007 shall be used. Soft Copies of all calculations & Drawings shall be made available by the Contractor for PMC review/records. Line List, Data Sheet & spread sheets shall be provided in MS Excel & all text items shall be in MS Word. All other documents like presentations etc. and other data shall be in MS Office; the required operating system for Data Exchange shall be at least Windows. All documents before forwarding to Owner/PMC will have to be vetted in detail by the Contractor/duly approved engineering sub-contractor appointed by the Contractor. Document received without vetting will be returned. The review by the PMC/Owner shall not be construed by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these specifications and drawings. Each drawing submitted by the Contractor shall be clearly marked with the name of the Owner, Unit Designation, Specifications, Title, Specification number and the name of the Revamped waste water section with Revision number and date. If standards, catalogue pages are to be submitted, the applicable items shall be indicated therein. All titles, noting, markings and writings on the drawings shall be in English. All the dimensions should be in metric units. Upon receiving comments on Drawings & Documents by the Contractor, the subsequent submission should give compliance report, separately on each of the comments, document-wise. Comments given by PMC/Owner to be discussed and finalised within agreed schedule. The schedule of submission of the Drawings & Documents shall be in accordance with revamped waste water section plans only. The detailed list under different category, document-wise, shall be prepared by the Contractor for approval of Owner/PMC. This activity is to be completed within one month of Fax of Intent. Sequence of submission of drawing is essential for proper review of documents and timely completion of the revamped waste water section is to be adhered. In case sequence is not maintained, the documents submitted will not be reviewed by Owner/ Page 149 of 208

PMC and responsibility of timely execution of plant shall be to the Contractor's account. 2.0 CATEGORY OF DOCUMENTS Category Description Action by Owner/ PMC Contractor can continue to progress with the work. This drawings or documents will be retained with Owner/PMC for information only. Records/ Information Owner/ PMC reserves the right to advise the Contractor of any comments (deviations from the contract) at any time and the contractor is liable to respond to satisfy that the work being done is in accordance with the contract; deviations, if any will be bidder's risk and cost. Owner/PMC will review and advise the

Contractor of any Comments on Contractors Drawings / documents within specified schedule (ie 2 weeks), from date of receipt in PMC office of Contractor's drawings/documents. The review period is defined as date of receipt of documents by PMC, to date of issue of comments by PMC. 2 Review This review period shall be valid only if submission of drawings is done by Contractor in accordance with approved drawings / documents schedule as indicated in ITB. In case of any nonconformity to the above by Contractor due to which the period of review extends beyond 2 weeks by the PMC, schedule delay, if any will have to be absorbed by the Contractor.

The documents falling under Review category will be returned with comments within specified time schedules subject to fulfilling other conditions enumerated. The information category document will be retained for information only but however Page 150 of 208

Owner/PMC reserves the right to comment at any stage of the Revamped waste water section, but not later than two weeks of receipt. Where clearance of Owner/ PMC is required for ordering of equipment materials, enquiry documents and one technically selected offer is to be submitted for review. The un-priced copies of purchase orders detailing both technical and commercial aspects for all items shall be submitted to PMC/ Owner within 15 days of issue of the same. Each purchase order forwarded should contain complete technical documents. It is obligatory for the Contractor to obtain acceptance on all the technical documents and accepted copy only to be forwarded to Owner / PMC. Any inaccuracies /omissions/inconsistencies noticed and brought to the notice of the Contractor at any stage of the revamped waste water section will be rectified/ replaced by Contractor without any cost & time implication to the Owner/ PMC. Detailed manufacturing schedules of fabricated/ manufactured items shall be submitted within one month of ordering, Status report for all the items in detail, will be submitted once in a month. Documents to Boiler Regulation authorities shall be submitted and getting the documents reviewed by PMC/Owner. To any other agencies, documents shall be submitted under intimation to PMC/Owner. As built drawings and documents will be generated within one month of completion of activities on respective items of work. As Built Drawings: Contractor will furnish reproducible and electronic files of all the drawings under their scope to Owner / PMC, certified as As-Built Issue by Third Party Inspection Agency (TPIA) for Vendor Items coming under Third Party Inspection / Contractor for all other drawings. Upon completion of identifiable units or components of the fabrication, construction and installation phase of the revamped waste water section the Contractor will complete all the related plans to the "as built' stage including all Vendor drawings and furnish Owner/PMC with the following: a. One complete set of all original tracings copies. Page 151 of 208

b. One complete set of reduced size (A3-297x420 mm) copies of all drawings. c. One set of CD for all documents/drawings/data d. All the as built drawings duly certified should be scanned and converted into electronic files made on magnetic/discs/optical long storage. e. All other revamped waste water section documents such as operating and maintenance manuals, manufacturers' Catalogues etc. shall also be scanned on magnetic/optical discs for safe storage and retrievals by the Owner when needed. f. 6 complete sets of full size prints of the drawings and 4 sets of reduced size prints. g. 6 complete bound sets of Manufacturer's specifications including design calculations. h. 6 complete sets in hard binders of the Manufacturers data book including certified prints and data for all items including test reports. Data Books shall be complete with index as tag numbers associated with Manufacturer's data shown. Equipment data shall include as a minimum requirement the principal and description of operation, drawings and dimensions, spare parts lists and unpriced purchase orders and bill of material. i. 6 bound copies each of the Spare Parts data books and the Lubricants inventory Schedule. j. 6 complete sets of field records shall be signed by both the Contractor's and Owner's Representative at the site. k. Original approvals and related drawings and documents from the statutory authority. l. Copies of correspondence with the statutory authorities. 3.0 PROCEDURE The procedure for compilation of final as-built documents / drawings shall be informed later. However the Procedure for routing the final / as built documents/ drawings to PMC / Owner shall be informed during the execution stage. 4.0 LIST OF DRAWINGS & DOCUMENTS Page 152 of 208

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val Y Y Y Y Y Y Y Y Y Y Y Y

For Information

Final/ Approved / As-built

A. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 B. 1.0

2.0

3.0

4.0

5.0 6.0

PROCESS Basis of Design Process Description Process Flow Diagram Raw Material & Utility Diagram for Normal and Rated Condition P&I Diagrams of Main plant, Utility requirement diagram Data sheet of all equipment and machinery Logic diagrams Instrumentation Control philosophy HAZOP Study and Compliance report Equipment Layout Operating Manual(including analytical manual) STATIC EQUIPMENTS Filled in Data Sheets of all equipment along with outline sketches showing thickness of main parts, thickness of insulation, weight (erection & operating) and anchorage details General arrangement for package items showing plan, elevation & end view Recommended spares for commissioning & 2 years operation Details of Tower internals including acid distributor, demister, i.e. make and model No., free volume, , surface area, and density of material and separation efficiency. Civil load data including details of foundation/anchor bolts Drawing list, design calculations & fabrication drgs a)Critical items (b)Non-critical items Page 153 of 208

Y Y Y Y Y Y N N Y N Y N

Y Y Y Y Y Y Y Y Y Y Y Y

N N

Y Y

Y Y

Sl. No.

Description

With Bid (Y/N)

7.0

8.0

Thermal, Mechanical & Structural Design calculations, Hydrodynamic calculation for Internals including fabrication drgs. of main equipment & Internals complying with the specifications and codes. Welding procedure and performance records approved by inspecting authority ( ** ) Specifications for Acid/Alkali cleaning Repair procedure for lining / cladding Operating/Maintenance manual for mechanical items wherever required Transportation drawing showing overall dimension, C.G. weight and handling instructions duly approved by appropriate authority Procedure for hydraulic test and heat treatment (** ) Procedure for tube to tube sheet joint (**) Procedure for repair of damaged tubes (**) Procedure for site jobs like assembly, heat treatment, testing ,application of painting & insulation etc. ( ** ) Records of NDT tests e.g. Radiography, Ultrasonic Testing(UT), Magnetic Particle / Penetrant Testing (MP/PT), hardness etc. ( ** ) Records of vacuum box test plumbness, roundness, peaking, banding etc. (**) Materials test certificates duly stamped by inspecting authority Page 154 of 208

For Review / Appro val Y

For Information

Final/ Approved / As-built

9.0 10.0 11.0

N N N

Y Y Y

Y Y Y

12.0

13.0 14.0 15.0 16.0

N N N N

Y Y Y Y

Y Y Y Y

17.0

18.0

19.0

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val -

For Information

Final/ Approved / As-built

20.0 21.0 22.0 23.0

( ** ) PWHT Charts (**) Mock-up test for Tube To Tube sheet joint (**) Test on production test coupons( ** ) Corrosion test reports including C, Cr, Ni, Mo and ferrite contents report of raw materials, weldments, HAZ etc. ( ** ) Hydraulic/pneumatic/HydroPneumatic test reports ( ** ) Strain gauge measurement ( ** ) Foundation settlement check record(**) Calibration report (**) All final As- built shop drgs. & design calculations duly certified by Third Party inspecting authority ( ** ) Records/ drawings, charts duly approved, signed and stamped by Statutory Authorities ( ** ) All Radiography films ( ** ) Mechanical Guarantee Certificate ( ** ) Inspectors final certificate ( ** ) Manual for package items like Cooling Tower, TG Set etc. PUMPS List of drawings / documents including drawing number, revision number, description and approval status Detailed manufacturing programme (Time bar chart ) Certified dimensional outline drawing Cross sectional drawing and bill of Page 155 of 208

N N N N

Y Y Y Y

24.0 25.0 26.0 27.0 28.0

N N N N N

Y Y Y Y Y

29.0

30.0 31.0 32.0 33.0 C. 1.0

N N N

Y Y Y

2.0 3.0 4.0

N Y N

Y Y Y

Y Y Y

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val Y Y

For Information

Final/ Approved / As-built

5.0 6.0

7.0

8.0

material Shaft seal drawing and bill of material Shaft coupling assembly drawing and bill of materials including allowable misalignment clearances, shaft bores & key ways dimensions with tolerances and the style of coupling guard Primary & auxiliary sealing schematic and bill of materials including seal fluid, fluid flows, pressure pipe and valve sizes, instrumentation, orifice sizes, and piping arrangement drawings Cooling or heating schematic and bill of materials including cooling & heating media, fluid flows, pressure, pipe and valve sizes, instrumentation, orifice sizes and piping arrangement drawings Lube oil schematic and bill of materials Lube oil system arrangement drawing including sizes, rating and location of all customer connections Lube oil component drawings data Electrical and instrumentation schematics, wiring diagrams and bill of materials Electrical and instrumentation arrangement drawing and list of components Performance curves Pump specification sheet with complete details in Performa enclosed with enquiry / order Certified foundation assembly drawing of pump with driver & all accessories mounted on base plate Page 156 of 208

N N

Y Y

9.0 10.0

N N

Y Y

Y Y

11.0 12.0

N N

Y Y

Y Y

13.0

14.0 15.0

Y Y

Y Y

Y Y

16.0

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val

For Information

Final/ Approved / As-built

with load diagram for foundation design (In case of motor being procured by purchaser, motor frame details will be supplied to vendor within 4 weeks.) 17.0 Engineering flow diagram showing: - Lubrication & sealing lines - Flushing / washing lines - Cooling / steam lines Reference list for pumps supplied in past for similar duty conditions. Reference list shall contain complete address of user, users purchase order number, brief specifications and date of commissioning Lube oil schedule Automatic recirculation valve assembly drawing, sectional drawing with bill of material Quality Assurance Plan. Material test certificates and Inspection & performance test report along with dispatch clearance certificates from inspector Instruction manuals describing installation, operation and maintenance procedures Spare parts recommendations and price list Parts catalogue complete with reference drawing nos. and sketches etc. PIPING Equipment layout drawing. Piping Layout drg. Quality control procedure & plan for piping system. Page 157 of 208 Y N Y Y

18.0

19.0 20.0

N Y

Y Y

21.0 22.0

N N

Y -

23.0

24.0 25.0

Y Y

Y Y

D. 1.0 2.0 3.0

Y Y

Y Y

Sl. No.

Description

With Bid (Y/N)

4.0 5.0

Filled in Valve Data Sheet. Design data and layout. Design basis Piping material specification

For Review / Appro val Y Y Y

For Information

Final/ Approved / As-built

Y Y Y

6.0

Issued for construction (IFC) Drawing. - Piping GA DRGS. - Isometrics - Piping supports, operating platforms drg. Y Y Y Y Y Y

7.0 8.0 9.0

Material Take-offs Material and Purchase Requisitions - Valves Design calculation / Documents. Flexibility Analysis of Piping Support and load data Y Y Y Y Y

10.0 11.0

Vendor Drawings Valves As Built Drgs - Piping GADs - Isometrics - All inspection, testing & NDT Records.

E. 1.0 2.0 3.0 4.0 5.0

CIVIL & STRUCTURALS Engineering specifications Design Criteria / Design philosophy Overall foundation layout drawings Design & drawings of foundation / structures for critical items All drawings & design calculations of major structures (steel/RCC), foundations (steel str cols, static equipments, machineries, pumps, stack) etc. Page 158 of 208 Y Y Y Y Y Y Y Y

Sl. No.

Description

With Bid (Y/N)

6.0

Structural layout drawings: Showing key plan wise Structural Sectional drawings, platforms, Ladders, Walkways & Staircases

For Review / Appro val Y

For Information

Final/ Approved / As-built

Page 159 of 208

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val -

For Information

Final/ Approved / As-built

J. 1.

2.

4. 5.

6.

14.

15. 16.

17. 19. 20.

21. 23. 24. 25. 26. 28. 29.

ELECTRICAL Load List indicating rated and absorbed power of loads and duty type (Continuous / Standby / Intermittent) at different voltages including emergency loads Load Data indicating normal, peak, starting and construction power requirement at various voltage levels Specification of all Electrical Equipment Filled in Specification Sheets and Technical Particulars of all equipment General arrangement and foundation drawings of all equipment List of controls, interlocks, indication & metering at various locations for all drives Characteristic curves for motor / relays etc. Design calculations (for equipment sizing, earthing, lighting, cables, bus ducts etc.) Earthing and lightning protection layout Catalogues for all bought out items Bill of Materials covering all electrical equipment and installation materials Installation operation and maintenance (Manual) Spare Parts list Test Certificates Guarantee Certificates Quality Assurance Plan & Formats Erection Drawings & Details Construction & Commissioning specification and procedure for all equipment Page 160 of 208

Y Y

Y Y

Y Y

N N

Y -

Y Y

N Y Y

Y Y -

Y Y

N Y N N N N Y

** ** ** Y -

Y Y Y

Y Y Y Y Y Y

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val Y

For Information

Final/ Approved / As-built

K. 1 2 3

INSTRUMENTATION Drawing & document schedule Instrument Index Instrument sizing calculations (control vales, safety valves & flow elements) Utility requirements Level sketches Material Requisition Purchase Requisition Vendor Drawings Functional Schematic Logic Diagrams as per ISA 75.2 Instrument loop drawings Control room layout Layout of equipment inside control room Power supply distribution Wiring diagram for panels Configuration diagram I/O assignment DCS graphics, report/log formats & other DCS docs. Instrument duct / tray layout Instrument cable schedule Instrument location plans Instrument installation drawings Bill of material for installation items Spare part list for : a. Mandatory Spares b. Start up & commissioning Y Y Y Y Y

Y Y Y

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

Y Y Y Y

25 26

Inspection & test procedures Complete catalogues with part list for all vendor supplied instruments, control etc. Page 161 of 208

Sl. No.

Description

With Bid (Y/N)

For Review / Appro val

For Information

Final/ Approved / As-built

27 28 M. 1.0

Installation, operation & maintenance manuals As Built Drawings GENERAL Master Time Schedule/Network (PERT Network/ Barchart) showing all the activities Reference list for similar packages supplied and executed by the bidder with details. Detailed Painting & Insulation Specifications Complete Spare Part List for the whole package List of all construction equipments, tool-tackles & man power resources proposed to be used. Description and Catalogues of Auxiliary items Y -

Y Y Y Y

2.0

3.0 4.0 5.0

N Y Y

Y Y -

Y Y Y

6.0 Notes:

Final documentations including approved documentation from statutory design verifying authority shall be supplied in hard copies (6 sets) as well as soft copies in CD formats. Applicable software is MS Office 2000, Word, Access, and Excel. Document marked as (**) are to be approved by authorized Inspection Agency and Statutory Authorities as applicable. Bidder shall submit document in required number of sets as stated elsewhere in commercial part. This list indicates the minimum drawings and documents requirements. However vendor shall submit complete list of document & drawing schedule listing all drawings and documents to be submitted by them during the course of execution of the job. The schedule shall list all drawings and documents along with their number and expected date of submission.

LEGEND: Y - Yes, N - No

Page 162 of 208

TECHNICAL (VOLUME 4) SECTION 5.0

VENDOR LIST
TABLE OF CONTENTS

SL. NO. 1.0 1.1 1.2 1.3

DESCRIPTION Mechanical Static Equipments Rotating Eqipments Piping

SHEET NUMBER 176 176 180 187

2.0 3.0 4.0 5.0

Electrical Instrumentation Erection and Construction Contractors Prequalification Criteria for Additional Vendors

197 203 221 221

Page 163 of 208

1.0 MECHANICAL
1.1
Static Equipments Sl.No Vendors Name SITE FABRICATED TANKS AND NON CODED VESSELS G REngineering 1. 2. 3. 4. 5. 6. 7. Gansons Godrej &Boyce Indus Revamped waste water sections Ltd. Bridge & Roof Co. India Tube Mills and Metal Induatries Larson & Toubro Ltd. Country India India India India India India India India India India India India India India India India India India

Vijay Tanks and Vessels 8. Novatech Revamped waste water sections India Ltd 9. Lloyds Steel Induatries Ltd 10. Precsion Tanks and Vessel 11. TAS Engineering 12. Newton Engg and Chemicals Ltd. 13. Vessels in CS/AS/SS Pressure upto10 kg/cm2g BHEL 1. GR Engg Works Ltd 2. Gansons Ltd 3. Godrej & Boyce Mfg. Co. Ltd 4. GMM Pfaudler Limited 5. ISGEC, Yamunanagar 6. Multimax Engg Works Pvt. Ltd (CS/SS) 7. Grand PrixFAB(P) Ltd. 8. Patels Airtemp (India) Limited 9. The Anup Engg. Ltd 10. Vijay Tanks and Vessels Ltd. 11. Schoeller-Bleckmann Nitec GmbH 12. OLMI SPA 13. Doosan Mecatec co. Ltd. 14. Hundai Heavy Industries 15. Hanjung DCMCo. Ltd. 16. Vessels in CS/AS/SS Pressure 11 to 60 kg/cm2g BHEL 1. Page 164 of 208

India India India India Austria Italy Korea Korea South Korea India

BHPV Gansons Ltd Godrej & Boyce Mfg. Co. Ltd GR Engg Works Ltd Larsen & Toubro Ltd ISGEC, Yamunanagar ISGEC, Dahej Multimax Engg Works Pvt. Ltd (CS/SS) (Upto 30 KG/cm2g) The Anup Engg. Ltd 10. Patel Airtemp (India) Ltd. (CS/SS) 11. Hindustan Dorr-Oliver Ltd. (CS/SS) 12. Vijay Tanks and Vessels Ltd. 13. Schoeller-Bleckmann Nitec GmbH 14. Borsig Gmbh 15. Belleli Spa 16. FBMHudson Italiana 17. GE Power (Formerly Nuovo Pignone SPA) 18. Rolle S.P.A. 19. Hitachi Zosen 20. Kobe Steel Ltd 21. Mitsubishi Heavy Industries Ltd. 22. Mecanica De La Pena S.A. 23. Vessels in CS/AS/SS Pressure above 60 kg/cm2g BHEL 1. BHPV 2. Godrej & Boyce Mfg. Co. Ltd 3. Larsen & Toubro Ltd 4. ISGEC, Yamunanagar 5. ISGEC, Dahej Works 6. Schoeller-Bleckmann Nitec GmbH 7. ATB Acciaieria E Tubificio Di Brescia Sp 8. Belleli Spa 9. FBMHudson Italiana 10. GE Power (Formerly Nuovo Pignone SPA) 11. Olmi Spa 12. Kobe Steel Ltd 13. Mitsubishi Heavy Industries Ltd. 14. Kawasaki Heavy Industries Ltd. 15. Hundai Heavy Industries Ltd. 16. Borsig Gmbh 17. Page 165 of 208

Sl.No 2. 3. 4. 5. 6. 7. 8. 9.

Vendors Name

Country India India India India India India India

India India India India Austria Germany Italy Italy Italy Italy Japan Japan Japan Spain India India India India India India Austria Italy Italy Italy Italy Italy Japan Japan Japan Korea Germany

Sl.No Vendors Name Krupp Industries Technik 18. Thyssen Rheinstahl Technik Gmbh 19. Tall Columns BHPV 1. Godrej & Boyce Mfg. Co. Ltd 2. Larsen & Toubro Ltd 3. G.R. Engineering Works Ltd. 4. ISGEC, Yamunanagar 5. ISGEC, Dahej Works 6. Apparatebau Schweisstechnik Gmbh 7. Schoeller-Bleckmann Nitec GmbH 8. Belleli Spa 9. Hitachi Zosen 10. Kobe Steel Ltd. 11. Mitsubishi Heavy Industries Ltd. 12. Hundai Heavy Industries Ltd. 13. Doosan Heavy Industries 14. Mecanica De La Pena S.A. 15. Trays, Distributors & Internals Godrej & Boyce Mfg. Co. Ltd 1. Kevin Enterprises Pvt. Ltd 2. Sulzer India Ltd 3. Koch Glitsch Ind. Ltd. (Earlier topack) 4. Apparatebau Schweisstechnik Gmbh 5. B.S.L Industries 6. Mitsubishi Heavy Industries Ltd. 7. Raschig AG 8. Sulzer Chemtech Nederland B.V 9. Glitsh Italiana Spa 10. Koch Glitsch Italia SRL 11. Norton Chemical Process Products Corp. 12. Heat Exchangers Pressure upto 30 kg/cm2g BHPV 1. BHEL 2. Godrej & Boyce Mfg. Co. Ltd 3. Gansons LTD 4. Grasim industries 5. Indus revamped waste water sections ltd. 6. Hindustan Dorr-Oliver Ltd. (CS/SS) 7. Larsen & Toubro Ltd 8. ISGEC John Thompson 9. Page 166 of 208

Country Germany Germany India India India India India India Austria Austria Italy Japan Japan Japan Korea Korea Spain India India India India Austria France Japan Germany Netherland Italy Italy U.S.A India India India India India India India India India

Sl.No 10. 11. 12. 13.

Vendors Name Patel Airtemp (India) Ltd. The Anup Engg. Ltd. Gemini Engg Fab. Pvt. Ltd.
Precision Equipments Chennai) Pvt Ltd (Tubesheet Thk upto 150 mm thk.)

Country India India India

Apparatebau Schweisstechnik Gmbh 14. Schoeller-Bleckmann Nitec GmbH 15. Belleli s.p.a 16. Walter Tosto SPA 17. FBMHudson Italiana 18. GE power 19. Officiene Luigi Resta Spa 20. Olmi S.P.A 21. Rolle S.P.A. 22. Kawasaki heavy industries LTD. 23. Kobe steel limited 24. Mitsubishi Heavy Industries Ltd 25. Hitachi Zosen 26. Doosan mecatec co.ltd 27. Hundai heavey industries 28. Mechanica De La Pena S.A 29. Manning & lewis engineering Co., 30. Borsig Gmbh 31. Heat Exchangers Pressure Above 30 to 60 kg/cm2g BHPV 1. BHEL 2. Godrej & Boyce Mfg. Co. Ltd 3. Grasim industries 4. Larsen & Toubro Ltd 5. Hindustan Dorr-Oliver Ltd. (CS/SS) 6. Patel Airtemp (India) Ltd. 7. The Anup Engg. Ltd. 8. ISGEC, Yamunanagar 9. ISGEC, Dahej 10. Precision Equipments Chennai) Pvt Ltd (Tubesheet Thk 11. upto 150 mm thk.) Apparatebau Schweisstechnik Gmbh 12. Schoeller-Bleckmann Nitec GmbH 13. FBMHudson Italiana 14. Officiene Luigi Resta Spa 15. Rolle S.P.A. 16. Mitsubishi Heavy Industries Ltd 17. Page 167 of 208

Austria Austria Italy Italy Italy Italy Italy Italy Italy Japan Japan Japan Japan Korea Korea Spain U.S.A Germany India India India India India India India India India India India Austria Austria Italy Italy Italy Japan

Sl.No Vendors Name Hitachi Zosen 18. Heat Exchangers Pressure above 60 kg/cm2g BHPV 1. BHEL 2. Larsen & Toubro Ltd 3. ISGEC, Yamunanagar 4. ISGEC, Dahej 5. Officiene Luigi Resta Spa 6. Olmi Spa 7. Hundai Heavy Industries 8. Apparatebau Schweisstechnik Gmbh 9. DHondt S.A 10. Borsig Gmbh 11. Demisters Evergreen Industries 1. Haver Standard India Pvt Ltd. (Demister Pads with Grids) 2. Hein Lehmann (I) Ltd. 3. Mister Mesh Wire Products 4. Pace Engineering Industries 5.

Country Japan India India India India India Italy Italy Korea Austria Belgium Germany India India India India India

1.2

Rotating Equipments Sl.No Vendors Name Country

Pumps for HP BFW Service (Above 60 kg/cm2 discharge pressure) 1. Bharat Pumps and Compressors Ltd. 2. KSB Pumps Ltd (upto 190 kg/cm2 diff. pressure) 3. Sulzer Pumps India Limited (upto 960 mlc, 80 m3/hr) 4. KSB AG 5. Ebara Corporation 6. Shin Nippon Machinery Co. Ltd 7. Flowserve (IDP) Pumps for Chemicals/ Acid/ Alkali/ BFW/ Condensate Use 1. A.R Wilfley India Pvt. Ltd 2. Akay Industries Pvt. Ltd 3. Beacon Weir Ltd 4. Bharat pumps and Compressors Ltd 5. ITT Corporation India Ltd. (Formerly Gould Pumps Inc.) 6. Kirloskar Brothers Ltd. 7. Kirloskar Ebara pumps Ltd 8. Kishore pumps Pvt. Ltd 9. KSB Pumps Ltd 10. Microfinish Pumps Pvt. Ltd 11. Sulzer pumps India Ltd. (single stage only) Page 168 of 208

India India India Germany Japan Japan U.K India India India India India India India India India India India

12. Pumpen Fabrik Ernst Vogel 13. Ensival S.A 14. GE Power (Nuovo Pignone Spa) 15. Weir Gabbioneta SRL 16. Arai pump Mfg. Co. Ltd 17. Sanwa Hydrotech Corporation 18. Flowserve (IDP) 19. Labour pump Co. Ltd Pumps for Utility Services 1. Akay Industries Pvt. Limited 2. BDK Enginnering Industries Ltd 3. Beacon Weir Ltd 4. Best & Crompton Engg. Co. 5. Flowmore Pvt. Ltd. 6. Flowserve India Control Ltd. 7. Kirloskar Brothers Limited 8. Kirloskar Ebara Pumps Limited 9. Kishore Pumps Ltd 10. Microfinish Pumps Pvt. Ltd 11. SU Motors Pvt. Ltd 12. Sulzer Pumps India Ltd. Pumps for very low NPSH Requirements 1. Bharat pumps & compressors Ltd 2. ITT Corporation India Ltd. (Formerly Gould Pumps Inc.) 3. KSB Pumps Ltd. 4. Sulzer Pumps India Ltd 5. KSB Guinard 6. KSB AG 7. GE Power (Nuovo Pignone Spa) 8. Weir Gabbioneta SRL 9. Arai Pump Mfg. Co Ltd 10. Ebara Corporation 11. Nikkiso Sundstrand Co. ltd 12. Sanwa Hydritech Corporation (Only Horizontal pumps) 13. Hayward Tyler Ltd 14. Byron Jackson Pump Pumps for Misc. Service 1. A.R Wilfley India Pvt. Ltd 2. Bharat pumps and compressors Ltd 3. KSB Pumps Ltd. 4. Sulzer Pumps India Ltd 5. V.K Pumps Industries Pvt. Ltd 6. UT Pumps & system Pvt. Ltd 7. Lewa Herbertott Gmbh & Co 8. Uraca Pumpenfabrik Gmbh & Co 9. Dosapro Millton Roy 10. Peroni Pompe Spa (capacity = 95 m3/hr, pre = 306 kg/cm2) Page 169 of 208

Austria Belgium Italy Italy Japan Japan U.K U.K India India India India India India India India India India India India

India India India India Germany Germany Italy Italy Japan Japan Japan Japan U.K U.S.A India India India India India India Germany Germany Italy Italy

11. Nigata Worthington pumps 12. Nikkiso Co. Ltd. 13. Bran & Luebbe Ltd. Couplings 1. Elecon Engg. Co. Ltd (for flexible coupling) 2. Fenner India Ltd. (for flexible coupling) 3. HI-Cliff (for gear coupling) 4. John Crane Felxibox Ltd 5. Rathi transpower Pvt. Ltd 6. Rathi turboflex Pvt. Ltd 7. Unique Transmission (I) Pvt Ltd 8. Eagle Industries,Japan ARC Valves 1. Holter Regelarmeturen Gmbh & Co. KG (Hora) 2. Schroedahl 3. Schroeder 4. Tyco Engineering & Construction Pvt. Ltd 5. Yarway corporation Air Conditioning System 1. Air Conditioning Corp. Ltd 2. Blue Star Ltd. 3. Kirloskar Electric company Ltd. 4. Patels Air temp India Ltd. 5. Suvidha Engineers 6. Voltas Ltd. (Pumps &Revamped waste water sections Business Division)

Japan Japan U.K India India India India India India India Japan Germany Germany Germany Germany Japan India India India India India India

1.3

Piping Sl.No Vendors Name Country CS Welded Pipes To API 5L/IS1239/IS3589/A672/A671/A691 Welded (SAW/EFSW/Spiral) 1. Jindal Pipes Ltd. India 2. Ratnamani Metals & Tubes Ltd. India 3. SAIL India 4. Surya Roshini Ltd India 5. Phoceenne France 6. ETS Trouvay & Cauvin France 7. Mannesmann Handel AG Germany 8. Thyssen-Krupp Stahlunion GmbH Germany 9. Dalmine SPA Italy 10. Raccortubi SRL Italy 11. Kosei Sangyo Ltd Japan Page 170 of 208

Sl.No 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Vendors Name Marubeni Itochu Steel Mitsubishi Corporation Nippon Kokan Nippon Steel Corporation Nishitani & Co. Ltd. Nissho Iwai Corporation Okura & Co. Ltd. Sojitz Corporation Sumitomo Metal Industries Ltd. Hyundai Corporation British Steel Corporation Corus Tubes Limited SAW pipes USA, Inc EEW

26. EBK 27. Maharashtra Seamless Ltd., 28. Jindal Industries Ltd., 29. Indus Tubes 30 Advance Steel Tubes 31. Inox Tech 32. S.C.Ario SA 33. Jindal Saw Ltd., 34. PCK 35. Wanchi 36. EEW Korea 37. EEW Malaysia 38. Steel Flower Co. Ltd, 39. Canadoil 40. Lalit Pipe and Pipes 41. Husteel 42. Inox Steel 43. Baoji 44. Shunite Steel 45. KASCO CS/AS LT Seamless Pipes 1. BHEL 2. Jindal Saw Ltd. 3. Maharashtra Seamless Ltd. 4. Phoceenne Page 171 of 208

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Sl.No 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26

Vendors Name ETS Trouvay & Cauvin Mannesmann Handel AG Horst Kurvers GmbH Dalmine SPA Gam Raccordi S.P.A IBF Seamless Pipes SPA Raccortubi SRL Marubeni Itochu Steel Mitsubishi Corporation Nippon Steel Corporation Nishitani & Co. LTD. Nissho Iwai Corporation Okura & Co. Ltd. Sojitz Corporation Sumitomo Metal Industries Ltd. Hyundai Corporation AB Sandvik Steel Vomal International Limited Corus Tubes Limited British Steel Corporation Productos Tubulare Valcony

27 Arcelor Mittal Tubular Productos Roman 28. ISMT 29. TPCO 30. Chengdu CSST 31. Wuxi Erquan Special Steel Tube Co. Ltd., 32. Tenaris 33. V&M 34. Huta Batory 35. JFE 36. Heavy Metals 37. Sainest 38. Wyman Gordan 39. Xangzhou Lontrin 40. Jiangsu Huashun 41. Bao Steel 42. Hehgyang valin SS Seamless/ Welded Pipes 1. Jindal Saw Ltd. Page 172 of 208

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Sl.No 2.

Vendors Name Prakash Steelage Limited(0.5 to 20 welded & 0.25 to 8 smls (upto sch 40s)) 3. Rajendra Mechanical Industries Ltd. 4. Ratnamani Metals & Tubes Ltd. 5. ETS Trouvay & Cauvin 6. Phoceenne 7. Horst Kurvers GmbH 8. Mannesmann Handel AG 9. Thyssen-Krupp Stahlunion GmbH 10. Dalmine SPA 11. Gam Raccordi S.P.A 12. IBF Seamless Pipes SPA 13. Raccortubi SRL 14. Marubeni Itochu Steel 15. Mitsubishi Corporation 16. Nippon Steel Corporation 17. Nishitani & CO. LTD. 18. Nissho Iwai Corporation 19. Okura & Co. LTD. 20. Sojitz Corporation 21. Sumitomo Metal Industries LTD. 22. Ab Sandvik Steel 23. T.T.I. Tubacex Tubos Inoxidables, S.A. 24. Vomal International Limited 25. Corus Tubes Limited 26. British Steel Corporation 27. Hyundai Corporation 28 Productos Tubulare 29. Jiuli 30. Walsin 31. Zhejiang Jiuli Hi-tech Metals 32. LS Metal 33. H Butting 34. Rivit 35. Sosta 36. Huachang 37. Outokumpu 38. BSL 39. Productos Tubulare 40. LS Metal SS Seamless Tubes Page 173 of 208

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Sl.No 1.

Vendors Name Prakash Steelage Limited (0.25" to 4" (upto 5mm thickness)) 2. Ratnamani Metals & Tubes Ltd. SS Pipes Urea Grade 1. BHDT GMBH 2. Schoeller-Bleckmann Nitec GmbH 3. ETS Trouvay & Cauvin 4. Phoceenne 5. Horst Kurvers GmbH 6. Mannesmann handel AG 7. Thyssen-Krupp Stahlunion GmbH 8. IBF seamless pipes SPA 9. Dalmine SPA 10. Marubeni Itochu Steel 11. Mitsubishi Corporation 12. Nippon Steel Corporation 13. Nishitani & Co. Ltd. 14. Nissho Iwai Corporation 15. Okura & Co. Ltd. 16. Sojitz Corporation 17. Sumitomo Metal Industries Ltd. 18. Hyundai Corporation 19. T.T.I. - TUBACEX TUBOS INOXIDABLES, S.A. (" NB to 10" NB, wall thk.1.0 mm to 50.0) 20. Ab Sandvik Steel 21. British Steel Corporation 22. Corus Tubes Limited 23. Vomal International Limited 24. Productos Tubulare 25. Ratnamani 26. Jiuli 27. Walsin 28. Rajendra Mechanical Industries Ltd. 29. Rivit 30. H Butting 31. Trouvay Cauvin 32. Gemaco 33. Outokumpu 34. Butting 35. Inoxtech 36. BSL 37. Sosta Page 174 of 208

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Sl.No Vendors Name Pipe-Agents/Stockists & Traders (MVL)-Foreign Barthel Kesselrohre Boilertubs Gmbh 1. 2. Peeraj General Trading Co (Llc) Commerciale Tubi Acciaio Spa 3. 4. Sideco Spa 5. Technical Parts Company Igawara Indl. Services & Trading Pte Ltd 6. 7. Maradle PIPES PLUG LIMITED 8. Horst Kurvers Gmbh 9. Edgen Murray Fze 10. Dalmine Spa (Enquiry To Tenaris) 11. Van Leeuwen Buizen Fittings: SS Urea Grade 1. BHDT GMBH 2. ETS Trouvay & Cauvin 3. Phoceenne 4. Vallourec 5. Horst Kurvers GmbH 6. Mannesmann handel AG 7. Seikmann Anlagen-Technik GmbH. 8. Thyssen-Krupp Stahlunion GmbH 9. IBF seamless pipes SPA 10. Dalmine SPA 11. Ind Meccanica Bassi Luigi & C. SPA 12. Raccortubi SRL 13. Techno Forge SPA 14. Marubeni Itochu Steel 15. Nippon Steel Corporation 16. Nishitani & Co. Ltd. 17. Nissho Iwai Corporation 18. Okura & Co. Ltd. 19. Sojitz Corporation 20. Sumitomo Metal Industries Ltd. 21. Avesta Candvite Tube AD 22. Helens Energy 23. British Steel Corporation 24. Corus Tubes Limited 25. Eurotube Limited 26. Vomal International Limited 27. Essay Flow 28. Erane Page 175 of 208

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Austria France France France Germany Germany Germany Germany Italy Italy Italy Italy Italy Japan Japan Japan Japan Japan Japan Japan Sweden Sweden U.K. U.K. U.K. U.K. USA Austria

Sl.No Vendors Name 29. Flmag 30. Schulz 31. Tectubi 32. SKB 33. TKB 34. T K Corporation 35. Tube Products Incorporate 36. Gujarat Infrapipes Pvt. Ltd. 37. Sidharth & Gautam 38. Trouvay Cauvin 39. Genoyer 40. Butting 41. Inoxtech 42. Metal One 43. Outokumpu Fittings: CS/AS/SS Seamless &Forged / Welded 1 EBY Fasteners 2 EBY Industries 3 Flash Forge(P) Ltd. 4 Gujarat Infrapipes Pvt. Ltd. 5 IISCO Ltd. 6 Mardale Pipes Plus Ltd 7 Shivananda Pipe Fittings Ltd., 8 S & G Engineers (P) Ltd. 9 Teekay Tubes Private Limited 10 Tube Products Incorporate (CS/AS/SS) 11 Visvesaraya iron & steel Ltd. 12 BHDT GMBH 13 Phoceenne 14 ETS Trouvay & Cauvin 15 Vallourec 16 Seikmann Anlagen-Technik GMBH. 17 TPS-Technitube Rohrenwerke GMBH 18 Mannesmann Handel AG 19 Horst Kurvers GmbH 20 Dalmine SPA 21 Gam Raccordi S.P.A 22 IBF Seamless Pipes SPA 23 IND Meccanica Bassi Luigi & C. SPA 24 Mantovani SpA 25 Raccortubi Srl Page 176 of 208

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Sl.No 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

Vendors Name Techno Forge SPA Marubeni Itochu Steel Nippon Kokan Nishitani & co. Ltd. Nissho Iwai Corporation Okura & co. Ltd. Sojitz Corporation Sumitomo Metal Industries Ltd. Avesta Candvite Tube AD Helens Energy Haitima Corporation Corus Tubes Limited British Steel Corporation Eurotube Limited Vomal International Limited Bonney Forge CSA Fittings Vilmar (Genoyer Group) (HTAS Approved) Tectubi SKB TKB T K corporation Dee Development Engineers, Faridabad (Cs/As/Ss) Pk Tubes& Fittings Ltd., Gurgaon (Cs/Ss) Tube Turn India (Pvt.) Ltd, Navi Mumbai (Cs/As) (Seamless & Forged) Allied International S.R.L. Gerab National Enterprises Kaddas Oilfield Services & Trading

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54 Hebei Cangzhou Hengtong Tubing Co.Ltd., 55 APCO Fittings 56 Jianjyin Tianning Pipe Fittings 57 Jiangsu Huayang Fittings 58 Metal One 59 Outokumpu Forged Flanges 1. Ajay Forging Pvt. Ltd 2. Amforge Industries 3. Anandmayee Forgings PVT. LTD. 4. C D Engineering 5. Chaudhary Hammer Works (P) LTD. Page 177 of 208

Sl.No Vendors Name 6. Echjay Industries Ltd 7. Ferrous Alloys Forging Pvt. Ltd 8. Golden Iron & Steel Works 9. J.K Forgings 10. Kunj Forgings Pvt. Ltd.(Material CS/SS/AS) 11. Perfect Marketing (P) Ltd 12. Punjab Steel 13. R D Forge (A Unit Of R D Chemicals Pvt Ltd) 14. Sanghvi Forgings & Engineering Ltd 15. Sawan Engineers 16. Tube Bend (Calcutta) Pvt Ltd 17. Viraj, Tarapur 18. Phoceenne 19. ETS Trouvay & Cauvin 20. Horst Kurvers GmbH 21. I.S. International 22. Mantovani spa 23. Officine Nicola Galperti & Figlio S.P.A 24. Raccortubi Srl 25. Nichinan Sangyo CO. Ltd., 26. Nishitani & CO. Ltd. 27. Sojitz Corporation 28. Vomal International Limited 29. Paramount 30. Metal Forging 31. R N Gupta 32. Shree Ganesh Forgings Ltd., 33. Vilmar (Genoyer Group) 34. Galperti 35. Melesi 36. Gerab 37. Kaddas Oil Field 38. Ulma Forja S. Coop 39. ROC Master Flanges 40. Trouvay Cauvin Gate/ Globe/ Check Valves CS/SS/AS < 900 Lbs 1 Audco India Ltd 2 BDK Engg. Industries Ltd. (upto 2500#) 3 Bell-o-seal valves Pvt. Ltd (for zero leakage, hazardous fliuds.) 4 BHEL Page 178 of 208

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Sl.No 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Vendors Name Dewrance Macneill & Co. Ltd. Hi-tech Valves Pvt. Ltd(CS,<=800# size 1/2"-2", <=300# for size 2"-6) Kirloskar Brothers Ltd. (CS upto 12" size, 300#) KSB Pumps Ltd. L&T Ltd(1/2" to 24") Microfinish valves (P) ltd. Niton Valve Industries Pvt. Ltd. (Forging upto 800#, <= 1.5" size) NSSL Limited Oswal industries ltd. (150&300#(2"- 24"),600#(2"12"),800#(1.5"-2")) Venus pump & Engg. Works Babcock Borsig Espana, S.A. Velan INC. Pemto valve Cesare Bonetti Fasani S.P.A. GTC Italia, S.R.L. Mantovani SpA OMB S.P.A. Petrol Valves S.R.L Matsura H. P Machine Works Co.Ltd. Nishitani & CO. LTD. Sojitz Corporation Redpoint Alloys BV Walthan & weir Sufa Limited Bel Valves MSA A.S

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32 33 34 35 36 37 38 39 40

Neway Pankorea Newmans-Cameron Jiangshu Jiulong Valve Manufacturer Co. Ltd., Raymond FZV Boteli Orion Vitas Page 179 of 208

Sl.No Vendors Name 41 Valvospain Gate/ Globe/ Check Valves CS/SS/AS > =900 Lbs 1. Advance Valves (for dual plate check valves) 2. Audco India Limited (L&T Valves Divn.) 3. BHEL (Valves Division) 4. BDK Engineering Industries Ltd. (upto 2500#) 5. KSB Pumps Limited (Valves Divn) 6. Larsen & Toubro Limited (1/2" to 2") 7. Leader Valves Limited (1500 & 2500# upto 12",forging upto 2" 2500#) 8. Metropolitan Industries (size=200mm, ratings=2500 lb) 9. Micon Valves (India) Pvt. Ltd. 10. NSSL Limited 11. Oswal Industries Ltd. (1500 & 2500, 1/2" to 2" size) 12. Babcock Borsig Espana, S.A. 13. Velan Inc. 14. Valvitalia SPA 15. BFE Bonney Forge Valve Licensee 16. Cesare Bonetti 17. Fasani S.P.A. 18. GTC Italia, S.R.L. 19. OMB S.P.A. 20. Petrol Valves S.R.L 21. Valvitalia SpA 22. Matsura H. P Machine Works Co.Ltd. 23. NishitanI & Co. Ltd. 24. Sufa Limited 25. BEL Valves 26. Neway 27. Pankorea 28. Newmans-Cameron 29. Raymond 30. FZV 31. Boteli 32. Orion 33. Vitas 34. Valvospain 35. Poyam Ball Valves (Soft Seated) 1. Forward Alloys & Castings(upto 900#) 2. Guru industrial valves pvt. Ltd Page 180 of 208

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Sl.No 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Vendors Name JC valves & controls india pvt. Ltd. KSB Pumps Ltd. (CS upto 100DN,20 bar) Leader Valves Ltd. (casting upto 600# 6",forging upto800# 2") Micon valves (India) pvt. Ltd. Microfinish Valves (P) LTD. NSSL Limited Virgo Engineers Ltd. Viba Fluid Control (Upto 300 #) Xomox Sanmar Limited (Fisher Xomox) BHDT GMBH Velan INC. ETS Trouvay & Cauvin GTC Italia, S.R.L. Mantovani Spa Petrol Valves S.R.L Valvitalia Spa Metso Automation Haitima Corporation Neway Pankorea Newmans-Cameron

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24. Jiangshu Jiulong Valve Manufacturer Co. Ltd., 25.. Raymond 26. FZV 27. Boteli 28. Poyam 29. Valvospain Ball valves (Metal Seated) 1. Delval Flow Controls Private Limited 2. Guru Industrial Valves Pvt. Ltd. 3. JC valves & Controls India Pvt. Ltd. 4. Microfinish Valves (P) Ltd. 5. NSSL Limited (2" NB to 12" NB, Ratings:150# & 300# (Material: Cast CS/AS/SS)) 6. Alfa Valvole SRL 7. GE power (Nuovo Pignone SPA) 8. GTC Italia, S.R.L. 9. Petrol Valves S.R.L 10. Valvitalia Spa 11. Red point alloys Bv Page 181 of 208

Sl.No 12. 13. 14. 15. 16. 17. 18.

Vendors Name Metso Automation Orbit Valves PLC Aqua Valves Pvt. Ltd., Flowchem Neway Pankorea Newmans-Cameron

19. Raymond 20. FZV 21. Boteli 22. Orion 23. Ksb / Amri 24. Tomoe 25. Vanessa Butterfly Valves 1. Advance Valves (rubber lined and metal seated) 2. Audco India Limited (L&T Valves Divn.) 3. BDK Process Control Pvt Ltd. (upto 1600mm) 4. Chemtech Industrial Valves Pvt Ltd 5. Crawley & Ray (F&E) Pvt. Ltd. (40mm - 1000mm) 6. Delval Flow Controls Private Limited (2" NB to 24" NB; for Classes: 150#, 300#,) 7. Fisher-Xomox Sanmar Ltd. 8. Flocon systems pvt. Ltd. (CS upto 12" 150#) 9. Fouress Engineering (I) Ltd. 10. Hawa valves india pvt. Ltd. (CS upto 6", 150#) 11. Hi-tech butterfly valves India Pvt. Ltd (<300#,<30"(Teflon/Rubber) ,<72"(Metal) 12. Intervalve India Ltd. 13. Instrumentation Ltd. (palakkad) 14. JC valves & controls india pvt. Ltd. 15. L&T Ltd (1/2" to 24") 16. Leader Valves Ltd. (150 # upto 16") 17. Mather & Platt (India) Ltd. (A Subsidiary of WILO SE German (upto DN 1600,PN10) 18. Metropolitan Industries (size=2000mm) 19. Micon valves (India) Pvt. Ltd. 20. Venus Pumps & Engineering Works (upto 600NB,150#) 21. BHDT GMBH 22. Velan INC. 23. Griss Sapag Industrail Valves Page 182 of 208

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Sl.No 24. 25. 26. 27. 28. 29. 30.

Vendors Name

Adams Armaturen GTC Italia, S.R.L. Valvitalia Spa Haitima Corporation Weir valves & controls division. Leeds Valve Ltd Curtis Wright Flow Control Corpoaration (COPESVULCAN LTD) 31. Lear siegler meas. Ctrls. Corp 32. Tyco International INC.,U.S.A. 33. Emerson Process Mgt 34. Spx Valves & Controls 35. XOMOS (Crane Co) 36. Tomoe Plug Valves (Non Lubricated) 1. Audco India Ltd (L&T Valves Divn.) 2. BDK Process Control Pvt Ltd. 3. Chemtech Industrial Valves Pvt Ltd 4. Crawley & Ray (Founders & Engineers) Pvt. Ltd (DN 200) 5. Guru Industrial Valves pvt. Ltd 6. JC Valves & Controls India Pvt. Ltd. 7. L&T Ltd ( 1/2" to 24") 8. Leader Valves Ltd. (upto 300# upto 6") 9. Micon valves (India) Pvt. Ltd. 10. Xomox Sanmar Limited (Fisher Xomox) 11. O.M.S. Saleri Di Saleri P & Figli S.M.C. 12. Forbes Marshall 13. Serck Audco Piston Valves 1. Uniklinger 2. Spirax Marshall Steam Manifold, Steam Traps 1. Spirax Marshall 2. Uniklinger 3. Armstrong 4. Pennant Strainers 1. Bombay Chemical Equipment 2. Gujarat Otofilt 3. Spirax Marshall 4. Armstrong Page 183 of 208

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Sl.No Vendors Name 5. Grandprix Hoses 1. Gayatri Engg. 2. Aeroflex 3. Senior Asbestos/ Rubber Gaskets 1. Ferrolite Joinings (P) Ltd. 2. Gaskets (India) Pvt. Ltd 3. Goodrich gasket pvt. Ltd. (upto 24") 4. Hindustan Asbestos & Allied Products 5. Hindustan Composite Ltd. 6. IGP Engineers Limited 7. Madras Industrial Products(upto 48") 8. Mechanical Packing Industries Ltd., 9. Packings & Jointings (P) Ltd. 10. Perfect Marketing (P) Ltd, 11. Reinz Talbros Private Limited 12. Spiraseal gaskets pvt. Ltd. (CAF & Teflon) 13. Starflex sealing india Pvt. Ltd. 14. Metaflex Spirally Wound Gaskets 1. Gaskets (India) Pvt. Ltd 2. Goodrich gasket Pvt. Ltd. 3. IGP Engineers Limited 4. Madras Industrial Products 5. Packings & Jointings Pvt. Ltd 6. Perfect marketing (P) Ltd, 7. Prashant Engg Stores 8. Spiraseal gaskets pvt. Ltd. 9. Starflex sealing india pvt. Ltd. 10. Uniklinger Gaskets, Pune 11. Garlock Sealing systems Ltd., Pune 12. TEADIT gaskets, Mumbai 13. Metaflex Expansion Joints & Bellows 1. Cori Engineers PVT. Ltd. 2. D.Wren & Co. 3. Flexatherm Expanllow Pvt. Ltd 4. Flexican Bellows & Hoses Pvt. Ltd 5. Fluidyne Engg. (I) Pvt. Ltd 6. Keld Ellentoft India Pvt. Ltd Page 184 of 208

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Sl.No 7. 8. 9. 10. 11.

Vendors Name Lonestar Industries Metallic Bellows (India) Pvt. Ltd Prashant Engg Stores Standard Precision Bellows Tuboflex

Country India India India India Germany

2.0 ELECTRICAL
GENERATOR BHEL 1. ASEA BROWN BOVERI 2. ALSTOM 3. MAN TURBO 4. SIEMENS 5. PETER BROTHERHOOD 6. MHI 7. Diesel Generator set BHEL (Electrical Machines Divn.) 8. Caterpillar 9. Cummins India Limited 10. Garden Reach Shipbuilders & Engineers Ltd. 11. Jeevan Diesel & Electricals Ltd. 12. Sudhir Gensets Ltd. 13. Wartsilla India Ltd. 14. Mitsubishi Corporation 15. 9. Toyo Elect.Mfg. Co. Ltd. 10. Asea Brown Boveri 11. Toyo Denky Power systems Pvt Ltd. 12. Jeumont Eletcric Induction Motors-LV(415V) (Safe Area) Ansaldo Robicon Siemens AG BHEL (Electrical Machines Divn.) Elgi Electric Industries Ltd. Asea Brown Boveri Ltd. Siemens Ltd. Toshiba Corporation General Electric co. Fuji Electric Systems Co. Ltd. 10. Crompton Greaves Ltd. 11 Kirloskar Induction motors-LV (415V) (For Hazardous Area) 1. Asea Brown Boveri Ltd. 2. Crompton Greaves Ltd. 3. Bharat Bijlee Ltd. 4. Siemens AG. Page 185 of 208 INDIA ARAB EGYPT GERMANY GERMANY U.K. JAPAN India India India India India India India Japan Japan Sweden India

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5. Kirloskar Electric Company Ltd. 6. Mitsubishi Corporation 7. Toshiba Corporation 8. General Electric co. 9. Fuji Electric Systems Co. Ltd. 10. Loher 11. Leroy Somer 12. Reliance (Rockwell) Induction Motors-HV (11KV) (For Safe / Hazardous Area) 1. BHEL (Electrical Machines Divn.) 2. Crompton Greaves Ltd. 3. Jyoti Ltd. 4. Kirloskar Electric Co. Ltd. 5. Fuji Electric Systems Co. Ltd. 6. Jeumont Industries 7. Toshiba Corporation 8. Mitsubishi Corporation 9. Peebles Electric Machines 10. Westinghouse Electric Corporation 11. Loher HT(11KV ) Power Cables 1. Cable Corporation of India Ltd 2. Ravin Cables Limited 3. RPG Cables Limited 4. KEI industries ltd. 5. NICCO Corporation Limited. 6. Torrent Cables Limited. 7. Universal Cables Ltd. 8. Diamond 9. Uniflex LT(1.1KV) Power Cables 1. Cable Corporation of Iindia Ltd. 2. Plaza Cable Industries Ltd. 3. Ravin Cables Limited. 4. RPG Cables Limited. 5. Delton Cables Ltd. 6. Finolex Cables Ltd 7. KEI Industries Ltd. 8. Torrent Cables Limited. 9. Radiant Cables Pvt. Limited 10. Industrial Cables (I) limited. 11. NICCO Corporation Limited. 12. Universal Cables Ltd. 13. Polycab 14. Cords cable LT(1.1KV) Control Cables 1. Cable Corporation of India Ltd. 2. Plaza Cable Industries Ltd. Page 186 of 208

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3. Ravin Cables Limited. 4. RPG Cables Limited. 5. Delton Cables Ltd. 6. Finolex Cables Ltd. 7. KEI Industries Ltd. 8. Cords Cable Industries Limited. 9. Radiant Cables Pvt. Limited. 10. NICCO Corporation Limited. 11. Universal Cables Ltd. 12. Polycab 13. Cords cable 14. Miracle cables HV Switchboard 1. ABB Ltd. 2. AREVA 3. Crompton Greaves Ltd. 4. BHEL (Electrical Machines Divn.) 5. Siemens Ltd. 6. Lotus Powergear Pvt. Ltd. 7. Schnieder Switchboards-LV(415V) (MCC/PCC/PMCC) 1. Larsen & Tubro. 2. Control & Switchgear Co. Ltd. 3. Interlec [for ASPB/ LDB/SDBs only] 4. Spaceage Switchgears Ltd. 5. Crompton Greaves Ltd. 6. GE Power Control India Ltd. 7. Elecmech Corporation. [for ASPB/ LDB/SDBs only] 8. AREVA. 9. Siemens Ltd. UPS System 1. Emerson Network Power Pvt. Ltd. 2. DB Power Electronic Pvt. Limited [Chloride brand only] 3. GE Power Controls India Pvt. Ltd. 4. Asea Brown Boveri Ltd. 5. AEG Telefunken AG. 6. Westinghouse Electric Corporation 7. General Electric Corporation 8. Piller [PCI ltd] 9. Gutor Battery Charger 1. Automatic Electric Ltd. 2. AMCO Power System Ltd. 3. Universal Industrial Products 4. Caldyne Automatics. 5. DB Power [Chloride brand] Page 187 of 208

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6. HBL Power Systems Battery (Ni-CAD/ Plante) 1. Japan Fuji Electric International Corporation. 2. Hitachi Limited Japan 3. High Energy Batteries Limited India 4. AMCO Power System ltd. India 5. HBL Power Systems India 6. Exide Transformers-Distribution 11KV/433V India 1. AREVA. 2. Crompton Greaves Ltd India 3. Kanohar Electricals Pvt. Limited India 4. Bharat Bijlee Ltd India 5. Voltas Ltd. (Pumps &Revamped waste water sections India Business Div.) 6. Indcoil Transformers Pvt. Ltd. India 7. Voltamp Transformers Ltd. India 8. EMCO Control & Relay Panel 1. India AREVA. 2. Asea Brown Boveri Ltd. India 3. Control & Switchgear Co. Ltd. India 4. Elecmech Corporation India 5. Larsen & Tubro Ltd. (El. ProductS Divn. ) India 6. Siemens Ltd. India 7. Lotus Powergear Pvt. Ltd. India HT Cable Jointing Kits 1. Birla 3M Ltd. India 2. Cable Corporation of India Ltd. India 3. India Mahindra Engineering & Chemical. 4. Raychem RPG. India 5. Poshya & Co. India Dry Type Transformers 1. Indcoil Transformers Pvt. Ltd. India 2. Putomatic Electric Ltd. India 3. Kalpa Electrical Pvt. Ltd. India 4. IMP Power Ltd. India 5. Shepherd Transformer Ltd. India Flameproof Local Control Station, Junction Box, Lighting Fitting, Plug, Socket, Hand Lamp, Accessories Lighting, Distribution Board & Control Panel. 1. FCG Flame Proof Control Gears Pvt. Ltd. India 2. Baliga Ltg. Eqt. Ltd. India 3. Sudhir Switchgear. India 4. Flameproof Equipment Pvt. Ltd. India 5. Flexpro Electricals Pvt. Ltd. India 6. R. Stahl India/Germany 7. Cooper Crouse-Hinds -8. Bartec Page 188 of 208

Street /Flood Lighting Fixtures 1. India Crompton Greaves Ltd 2. Philips India 3. Bajaj Electricals India 4. Wipro Lighting India 5. Havells India Ltd. India 6. Spaceage Switchgears Ltd. India Hose Proof Industrial Lighting Fixtures India 1. Bajaj Electricals 2. Crompton Greaves Ltd India 3. Philips India Ltd. India 4. Spaceage Switchgears Ltd India 5. Wipro Lighting India Hose Proof Local Control Station / Industrial Type SW. Socket & Plug 1. India Baliga. 2. Flameproof Equipment Pvt. Limited. India 3. FCG Power Industries. India 4. FCG Flameproof Control Gears. India Cable Trays 1. India Globe Electrical Industries 2. Metalite Industries India 3. Stealite Engineering Ltd. India 4. Rukmani Electrical Components Pvt. Ltd India 5. Parekh Engineering Company India 6. Sadhana Engineering Corporation India 7. UNIQUE STRUCTURAL Pvt.Ltd, Thane India HV/MV Bus Ducts 1. India Best & Crompton Engg. Co. 2. Powergear Limited India 3. Spaceage Switchegears Limited. India 4. Interlec India 5. Crompton Greaves Ltd.(HV Bus Duct) India 6. Globe Electrical Industries (MV Bus Duct) India Distribution Boards 1. Elecmech Corporation India 2. Intrelec India 3. Lotus Powergear Pvt. Ltd. India 4. Control & Switchgear Co. Ltd. India 5. Globe Electrical Industries India 6. Hindustan Control & Equipment Pvt. Ltd. India 7. Associated Switchgear &Revamped waste water India sections Ltd. 8. Reunion Electrical Manufacturers (P) Ltd. India 9. ABB Ltd India EPABX System 1. Crompton Greaves Ltd. India 2. Philips India Ltd. India 3. Indian Telephone Industries Ltd. India Page 189 of 208

4. Hakotronics Pvt. Ltd. 5. Motorola Singapore PTE Ltd. 6. Siemens Ltd. 7. Tata Telecom Ltd. Soft Starters 1. Kimo Electronics Pvt. Ltd. 2. Larsen & Toubro Ltd (El.Product Divn.) 3. Rockwell Automation India Ltd. 4. Innovative Technomics Pvt. Ltd. 5. Siemens Ltd. 6. Schnieder Telephone Exchange Equipments/ Paging Equipment / PA System A. Ammonia Plant 1. Neumann Gmbh Elektronik/ Laraon Engineers B. Urea Plant & Offsite facilities 1. Crompton Greaves Ltd. 2. Hakotronics Private Ltd. 3. Indian Telephone Industries Ltd. 4. Philips India. Ltd. 5. Tata Telecom Limited 6. Motorola Singapore Pte Ltd. 7. Motwane Programmable Logic Controller 1. Asia Brown Boveri Ltd. 2. Siemens Ltd. 3. Rockwell Automation. 4. Larsen & Toubro Ltd. (EL.Products Divn.) 5. Honeywell Earthing & Lightning Protection Material (Al/GI) Wire/Strip 1. Anand Electric Trading Co. 2. Bharti Exports 3. Control & Switchgear Co. Ltd. 4. Jayant Metal MFG Co. 5. Metalite Industries. 6. Premier Power Products (Calcutta) Pvt. Ltd. Capacitors 1. BHEL. 2. Crompton Greaves. 3. Shreem Capacitors Pvt . Ltd. 4. Universal Cables Ltd. 5. Baraon Power Chennai 6. Siemens / Epcos 7. ABB 8. Frako Protective Relays 1. AREVA. 2. Asea Brown Boveri Ltd. 3. Larsen & Toubro Ltd. (El. Products Divn.) Page 190 of 208

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India India India India

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Germany India India India

4. 5. 6.

Siemens Ltd. Easun Reyrolle Limited C & S Electric Ltd

India India India

3.0 INSTRUMENTATION
Vendors Name Sl.No. Gas Analysers (IR, Thermal Conductivity, Paramagnetic) 1. ABB Ltd (BU Analytical & Adv) 2. Chemtrols Enginnering Limited (Maihak Make) 3. Emerson Process Management (I) Pvt. Ltd 4. ABB 5. Maihak Aktiengesellschraft 6. Siemens AG 7. Emerson Process Management Singapore Ltd 8. Ametek Inc 9. M.S.A International pH, conductivity & ORP Analyser 1. Emerson Process Management (I) Pvt. Ltd 2. Yokogawa Electric Corporation 3. Emerson Process Management Singapore Ltd 4. Foxboro Far East Pte Ltd 5. ABB Process Analytics 6. Hach company Trace Analyser/ Ion Selective 1. Forbes Polymetron Pvt. Ltd 2. Zellweger SA 3. Bran & Luebbe Ltd 4. Hach company SOX/ NOX Analyser 1. ABB Ltd (BU Analytical & Adv) 2. Emerson Process Management (I) Pvt. Ltd 3. ABB 4. Sick AG 5. Siemens AG 6. Horiba Ltd. 7. Yokogawa Electric Corporation 8. Emerson Process Management Singapore Ltd 9. Lear Siegler Meas. Controls Corp. 10. M.S.A International 11. Thermo Environment Instruments Inc Page 191 of 208 Country India India India Germany Germany Germany Singapore U.S.A U.S.A India Japan Singapore Singapore U.K U.S.A India France U.K U.S.A India India Germany Germany Germany Japan Japan Singapore U.S.A U.S.A U.S.A

Vendors Name Sl.No. Mass Spectrometer 1. VG Gas Analysis Systems 2. ABB Inc. Analytical QMS 3. Orbital Science Corporation 4. Extrel 5. Themoscientific Gas Chromatograph 1. Applied Automation Inc 2. Foxbaro Far East Pte Ltd 3. ABB Process Analytics 4. Intromet International 5. Emerson Process Flue Gas Analyser (ZrO2 type) 1. ABB Ltd (BU Analytical & Adv) 2. Emerson Process Management (I) Pvt. Ltd 3. ABB 4. Ametek Inc H2S/ Total Sulphur Analysers 1. Barton Instrument Systems Limited System House Analysers 1. ABB Ltd (BU Analytical & Adv) 2. Chemtrols Enginnering Limited 3. Emerson Process Management (I) Pvt. Ltd 4. Intech Density Analysers 1. Emerson Process Management (I) Pvt. Ltd (coriolis type) 2. Bopp & Reuther Messtechnik Gmbh (coriolis type) 3. Solartron Mobrey Moisture Analysers 1. GE Panametrics 2. Ametek Inc Gas & Fire Detection System 1. Andrew Yule & Company Ltd. (Fire) 2. Honeywell Automation India Limited (Gas) 3. J B Boda And Brothers Pvt. Ltd. (Gas Make-International Sensor Technology) 4. Teledyne Fluid Systems (Gas) 5. General Monitors (Gas) Page 192 of 208

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Vendors Name Sl.No. Flow Element: Orifice/ Venturi/ Flow Nozzle 1. Baliga Lighting Equipments Limited (Only Orifice) 2. General Instruments Consortium (Only Orifice) 3. Instrumentation Ltd, Palakkad 4. Micro Precision Products Private Ltd. 5. Bopp & Reuther Messtechnik Gmbh 6. Technomatic Spa 7. ISA Controls Limited 8. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. Daniel Measurement & Control Control Engineers Emerson Process Management (I) Pvt. Ltd. Micro Precision Products Private Ltd. Technomatic Spa ISA Controls Limited Daniel Measurement & Control Instrumentation Engineers Pvt. Ltd. Krohne Marshall Pvt. Ltd. Pitot Tube/ Annubar

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Rotameters

Placka Instruments & Controls Pvt. Ltd. (Purge Rotameter India Only) Rota Instrumentation Krohne Rota Yokogawa Gmbh & Co. Kg Tokyo Keiso Co. Ltd. Yamatake Corporation Emerson Process Mgt Emerson Process Management (I) Pvt. Ltd. Bopp & Reuther Messtechnik Gmbh India Germany Germany Japan Japan U.S.A India Germany Germany U.S.A

Mass Flow Meter (Coriolis Type)

3. Yokogawa 4. Krohne 5. Schlumberger Resource Management Ltd. 6. Invensys Turbine Flow meter 1. Fmc Sanmar Ltd. 2. Abb 3. Bopp & Reuther Messtechnik Gmbh Page 193 of 208

India Germany Germany

Vendors Name Sl.No. 4. Instromet International N.V 5. Itochu Corporation (Rep.Kubota Corpn.) 6. Yamatake Corporation 7. Oval Asea Pacific Pte Ltd 8. Barton Instrument Systems Limited 9. Emerson Process Mgt 10. Emerson Process Mgt 11. Rockwell International Corpn. Vortex meter 1. Krohne Marshall Pvt. Ltd. 2. Yokogawa Limited 3. Abb 4. Bopp & Reuther Messtechnik Gmbh 5. Nuvotima 6. Krohne 7. Itochu Corporation (Rep.Kubota Corpn.) 8. Schlumberger Resource Management Ltd. 9. Wika PD Meter 1. Rockwin Flow Meters (I) Pvt. Ltd. 2. Bopp & Reuther Messtechnik Gmbh 3. Oval Asea Pacific Pte Ltd 4. Emerson Process Mgt 5. Schlumberger Resource Management Ltd. Magnetic Flow meter 1. Emerson Process Management (I) Pvt. Ltd. 2. Krohne Marshall Pvt. Ltd. 3. Bopp & Reuther Messtechnik Gmbh 4. Krohne 5. Yamatake Corporation Pressure Gauges 1. General Instruments Consortium, 2. Manometer (India) Pvt. Ltd 3. Precision Industries Ltd. (standard normal type) 4. Waaree Instruments Ltd. 5. Walchandnagar Industries Ltd. 6. Dresser Europe S.A 7. Wika Alexender Wiegard Gmbh & Co. 8. Spriano Spa Page 194 of 208

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Vendors Name Sl.No. 9. Nagano Keiki Seisakusho 10. Rueger SA 11. Budenberg Gauge Co. Ltd Vol. Seal Pr. Gauges 1. Dresser Europe S.A. 2. Wika Alexender Wiegand Gmbh & Co. 3. Spriano Spa 4. Nagano Keiki Seisakusho 5. Rueger Sa 6. Budenberg Gauge Co. Ltd. Local D/P Indicators 1. Switzer Instrument Co. 2. Barton Instrument Systems Limited 3. Delta Controls Ltd. Pressure & D/P Transmitters 1. Asea Brown Boveri Ltd. 2. Emerson Process Management (I) Pvt. Ltd. 3. Honeywell Automation India Limited 4. Yokogawa Limited 5. Asea Brown Boveri 6. Siemens Ag, Germany 7. Yamatake Corporation 8. Yokogawa Electric Corporation 9. Emerson Process Mgt Singapore Ltd 10. Honeywell Inc. Vol. Seal Pr./Dp Transmitter 1. Honeywell Automation India Limited 2. Yokogawa Limited 3. Abb Kent Tieghi S.P.A 4. Fuji Electric Systems Co., Ltd. 5. Yamatake Corporation 6. Yokogawa Electric Corporation 7. Emerson Process Mgt Singapore Ltd Pressure & D/P Switches Including Vol. Seal 1. Barksdale 2. Switzer Instrument Co., (Except Vol.Seal) 3. Nagano Keiki Seisakusho 4. Yamatake Corporation 5. Delta Controls Ltd. Page 195 of 208

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India Japan Japan U.K

Vendors Name Sl.No. 6. Sor Inc. 7. United Electric Controls Co. Transparent/ Reflex / Bicolor Mag.Level Gauges 1. Chemtrols Engineering Limited 2. Pune Techtrol Pvt.Ltd. (<=300# Rating Only) 3. Tecnomatic (India) Pvt. Ltd. 4. V-Automat & Inst. (P) Ltd., (Upto 300#) 5. Richard Klinger Ag 6. Cesare Bonetti 7. Technomatic Spa 8. Nihon Klingage Co. Ltd. 9. Clark-Reliance Corp. 10. Jerguson Gauge & Valve Co. 11. Tyco International Inc. Level Switches (Float & Displacer Type) 1. V-Automat & Inst. (P) Ltd., (Upto 300# , Non-Critical Service) 2. Magnetrol International N.V. 3. Isa Controls Limited 4. Kdg Mobrey Ltd. 5. Sor Inc. Displacer Type Level Transmitters 1. Fisher 2. Dresser Valve India Pvt Ltd (Rating <= 600#) 3. Magnetrol International N.V. (Lvdt) 4. Dresser Masoneilan 5. Foxboro Eckardt Gmbh 6. Parcol Spa (Pneumatic Transmission Only) Nucleonic Level Transmitter 1. Berthold Technologies Gmbh & Co.Kg 2. Endress + Hauser Gmbh & Co. 3. Kay Ray Capacitance Type Level Transmitter 1. Magnetrol International N.V 2. Endress + Hauser Gmbh & Co. 3. Krohne 4. Kdg Mobrey Ltd Tank Level Instruments 1. Endress + Hauser Gmbh & Co., (Non-Contact & Servo) Page 196 of 208

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Vendors Name Country Sl.No. 2. Krohne (Non-Contact Type) Germany 3. Tokyo Keiso Co. Ltd. Japan 4. Enraf Singapore Pte. Ltd. Singapore 5. L & J Technologies U.S.A Resitive Electrode Type Level Instrument 1. Clark-Reliance Corp U.S.A 2. Schlumberger Resource Management Ltd. U.S.A Special Level Switches (Vibration Fork/Rf Admittance) 1. Endress + Hauser Gmbh & Co. Germany 2. Sor Inc. U.S.A Temperature Elements (Thermocouple, Rtd) 1. Altop Industries Ltd. (Only Normal Type (Mi)) India 2. Detriv Instrumentation & Electronics Ltd (Only Normal India Type) 3. Detriv Instrumentation & Electronics Ltd (Only Normal India Type) 4. Eliend Engineering Pvt. Ltd. (Only Normal Type) India 5. General Instruments Consortium India 6. Industrial Instrumentation, (Only Normal Type) India 7. Sensycon ( M/S Degussa Ag ) Germany 8. W.C. Heraeus Gmbh Germany 9. Thermo Electric Co. Ltd. Holland 10. Okazaki Manufacturing Co. Japan 11. Yamatake Corporation Japan 12. Pyro Electric India Bimetallic Thermometer 1. Wika 2. Nuvofima 3. Krohne Marshall Pvt. Ltd. India 4. Waaree Instruments Ltd India 5. Technomatic Spa Italy 6. Nagano Keiki Seisakusho Japan 7. Rueger Sa Switzerland 8. Trend Instrument Inc. U.S.A Dial Thermometer (Hg In Steel/Glass) 1. Wika 2. Nuvofima 3. Waaree Instruments Ltd India 4. Walchandnagar Industries Ltd. India Page 197 of 208

Vendors Name Sl.No. Radiation Pyrometer 1. Siemens Ag, Germany 2. C.C.R. Technico 3. Chino Corpn. 4. Land Infrared 5. Wahl Instruments Gate/Plug Valves 1. Audco India Limited(L&T Valves Divn.) 2. Bhel (Valves Division) 3. Chemtrols Engineering Limited (Plug Valves) 4. Ksb Pumps Limited (Valves Divn) 5. Velan Inc. 6. Malbranque S.A. 7. Cesare Bonetti 8. Fasani S.P.A. 9. Petrol Valves S.R.L 10. Matsura H. P Machine Works Co.Ltd. 11. Bel Valves Globe / Angle Valves 1. Asea Brown Boveri Ltd.(Bu-Analytical&Adv (=<600# Upto 12" Size) 2. Dresser Valve India Pvt Ltd (Rating <= 600# , Size 3/4 To 6") 3.. Instrumentation Ltd. (Palakkad) (=<2500#,Except Slurry,Noise,Cavitatation) 4. Mil Controls Limited (=<600#,Except Slurry,Noise,Cavitation) 5. R K Engineering Ltd. (=<600#,6 except slurry,noise, 6cavitation) 6. Kent Introl 7.. Dresser Masoneilan (=<2500# ) 8. Arca-Regler Gmbh (=< 2500#) 9. Parcol Spa (=<2500#) 10. Nippon Fisher Co. Ltd. (=<2500#) 11. Yamatake Corporation (=<2500#) 12. Fisher Xomox (=< 2500#) 13. Abb (=< 2500#) 14. Flowserve (=<2500#) Ball Valves 1. Tyco Valves & Controls (I) Ltd (=< 150 #) Page 198 of 208

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Vendors Name Country Sl.No. 2. Kent Introl 3. GTC Italia,S.R.L (=<300#) Italy 4. Petrol Valves S.R.L Italy 5. Pibiviesse S.P.A. (Rating Upto 2500 #) Italy 6. Metso Automation (=<2500#) Singapore 7. Metso Automation (=<2500#) Singapore 8. Fisher Xomox Butterfly Valves 1. Instrumentation Ltd. (Palakkad) (=< 300#) India 2. Tyco Valves & Controls (I) Ltd (=< 150 #) India 3. Kent Introl 4. Parcol Spa (=< 2500#) Italy 5. Keystone (Upto 2500#) Singapore 6. Metso Automation (Upto 2500#) Singapore 7. Leeds Valve Ltd U.K 8. Fisher Xomox Saunders (Pinch) Valves 1. Bdk Engineering Industries Ltd. (Upto 150#) India 2. R K Engineering Pvt Ltd (Upto 150#) India 3. Crane Process Solenoid Valves 1. Asco (India) Limited India 2. Rotex Automation Ltd. India 3. IMI Norgren-Herion Fluidtronic Gmbh&Co. Germany 4. Alexender Controls Ltd. U.K 5. Asco Joucomatic Ltd. U.K Prds & Spray Nozzle,Vent Valves Upto 2500# 1. Cci Valve Technology Ab Sweden 2. Abb U.K 3. Control Components Inc. U.S.A 4. Spx Valves & Controls (Copes-Vulcan Ltd) U.S.A 5. ARCA(Forbes Marshall) (Mech. Spray Nozzle Type India Desuperheater Only) 6. EUR Control (BTG) Swedan Electric Actuator 1. Rotork Control (Deutschland) Gmbh Germany 2. Biffi Italia S.R.L Italy 3. Limitorque, U.S.A U.S.A Air Filter Regulator Page 199 of 208

Vendors Name Sl.No. 1. Asea Brown Boveri Ltd. 2. Divya Control Elements Pvt. Ltd. 3. Mil Controls Limited 4. Placka Instruments & Controls Pvt. Ltd. 5. Shavo Norgren (India) Pvt. Ltd. 6. Fairchild Limit/Proximity Switches 1. Osna Electronics Pvt. Ltd. (Intrinsically Safe Proximity Switches) 2. Pepperl + Fuch 3. Pepperl + Fuch 4. Pepperl + Fuchs Pte Ltd. 5. Honeywell Inc. Safety Valves & Thermal Relief Valves Upto 2500# 1. Fainger Leser Valves (P) Ltd. (Upto 600#, 1/2" To 6") 2. Instrumentation Ltd. (Palakkad) 3. Sebim Valves India Pvt. Ltd. (Upto 600#, Safety 4"X6",Th.Relief-3/4"X1") 4. Tyco Sanmar Ltd. 5. Sapag GEC Alshtom 6. BOPP& Reuther Messtechnik GMBH 7. Teledyne Fluid Systems 8. Dresser Valve & Controls 9. Parcol Spa 10. Tai Milano S.P.A 11. Itochu Corporation (Rep.Kubota Corpn.) 12. Crossby Valve & Engg. Company Ltd. 13. Farris 14. Dresser Industries Incorporated Vaccum Breakers 1. Braunschweiger Flammenfilter Gmbh 2. Parcol Spa 3. Tai Milano S.P.A 4. Itochu Corporation 5. Safety Systems Uk Ltd. 6. Whessoe Varec Limited Rupture Discs 1. Bs&B Safety Systems (India) Limited Page 200 of 208

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Vendors Name Sl.No. 2. Fike Europe 3. Sapag Gec Alsthom 4. Teledyne Fluid Systems 5. Continental Controls Inc. Control Panel 1. Asea Brown Boveri Ltd. 2. Electronics Corporation Of India Ltd 3. Industrial Control Appliances (P) Ltd., 4. Jaisun & Hutchisun Controls Ltd., 5. Pyrotech Electronics Pvt.Ltd. 6 United Electric Co. (Delhi) Pvt. Ltd. (Upto 10 Mtrs.) 7 Yokogawa Limited 8 Instromet International N.V Panel Access. ( Relay,Switch,Lamp,Terminal,Push Button) 1. Industrial controls and appliances(ICA) for OMRON relays 2. Larsen & Toubro Ltd.(Control& Automation (Lamp, Push Button) 3. Rockwell Automation India Ltd. (Relays) 4. Digitable Thielen Gmbh & Co 5. Phoenix Contact Gmbh & Co. 6. Siemens Ag, Germany (Lamp,Pushbutton,Contactors) 7. Stahl-Und Apparatebau Hans Leffer Gmbh (Lamp,Pushbutton) 8. Wago Kontakltechnik Gmbh 9. Weidmuler Ltd. 10. Omron Corporation (Relay) 11. Pepperl + Fuchs Pte Ltd. (Switch) Programable Logic Controller 1. Ge Fanuc Systems Prvitate Limited 2. Honeywell Automation India Limited (Safety System) 3. Larsen & Toubro Ltd.(Control& Automation (Non Failsafe) 4. Moore Controls Ltd. (Failsafe) 5. Rockwell Automation India Ltd. (Non Failsafe) 6 Siemens Ltd., (Non Failsafe) 7. Hima Paul Hildebrandt Gmbh + Co Kg (Failsafe) 8. Marconi Italiana (Non Failsafe) 9. Omron Corporation (Non Failsafe) 10. Triconex (Fault Tolerant Tmr) Page 201 of 208

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Vendors Name Sl.No. 11. Abb (Fault Tolerant Tmr) 12. Ge Fanuc Automation North America, Inc. (Fault Tolerant Tmr) 13. Emerson Process 14. Yokogawa Distributed Control System 1. Honeywell Automation India Limited 2. Yokogawa Limited 3. Siemens Ag, Germany 4. Invensys 5. Yokogawa Electric Corporation 6 Emerson Process Mgt Singapore Ltd 7. Bailey Controls Company 8. Honeywell Inc. Multiplexer / Remote I/O 1. Mtl Instrument Limited 2. Stahl-Und Apparatebau Hans Leffer Gmbh 3. M.T.L., U.K. Receiver Instruments (Indicator,Controller,Recorder) 1. Asea Brown Boveri Ltd. 2. Chino-Laxsons (India) Limited (Only Recorder) 3. Eurotherm Del India Limited 4. Honeywell Automation India Limited 5. Moore Controls Ltd. 6. Yokogawa Limited 7. Siemens Ag, Germany 8. Chino Corpn. 9. Yokogawa Electric Corporation 10. Heraeus Electro-Nite International N.V. 11. Honeywell Inc. Alarm Annunciator 1. Industrial Instruments & Controls 2. M.T.L., U.K. 3. Rochester Instrument Systems Ltd. 4. Riley Panalarm 5. Ronan Engg. Co. Barrier/Isolator/Trip Amplifier 1. MTL Instrument Limited 2. Digitable Thielen Gmbh & Co Page 202 of 208

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Vendors Name Sl.No. 3. Foxboro Eckardt Gmbh 4. Stahl-Und Apparatebau Hans Leffer Gmbh 5. Yokogawa Electric Corporation 6. Camille Bauer Ag 7. M.T.L., U.K. 8. Honeywell Inc. Temperature Scanner 1. Industrial Instrumentation Cctv / Access System 1. Honeywell Automation India Limited 2. Yokogawa Limited Miscellenous Items (Rtu / Scada Etc) 1. Asea Brown Boveri Ltd. (Scada,Rtu) 2. Emerson 3. Rockwell 4. Honeywell Machine Monitoring System 1. Bruel & Kjaer Gmbh 2. Skf Condition Monitoring Inc. 3. Bentley Neveda Llc Speed Indicator 1. Pepperl + Fuch 2. Shinkawa Electric Co. 3. Pepperl + Fuchs Pte Ltd. 4. Jacquet 5. Bentley Neveda Llc Anti Surge Controller 1. Compressor Control Corporation 2. Invensys Triconex 3. Dresser - Rand Co. Burner Management System 1. Durag Industrie Elektronik Gmbh & Co Kg 2. Siemens Ag, Germany 3. Mitsubishi Heavy Industries Ltd. 4. Omron Corporation 5. Yamatake Corporation 6. Honeywell Inc. Terminal Automation System 1. Asea Brown Boveri Ltd. Page 203 of 208

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Vendors Name Country Sl.No. 2. Emerson Process Management (I) Pvt. Ltd. India 3. Honeywell Automation India Limited India I/P Converter 1. Emerson Process Management (I) Pvt. Ltd. India 2. Emerson Process Management Ltd. U.S.A 3 Yokogawa Limited India 4. Yokogawa Electric Corporation Japan 5. Moore Products Company U.S.A. Instrument Power & Control Cables 1. Associated Cables Ltd. India 2. Associated Flexibles & Wires Pvt. Ltd. India 3. Cords Cable Industries Ltd. India 4. Delton Cables Ltd India 5. Insucon Cables & Conductors (P) Ltd. (For Smaller Non- India Critical Revamped waste water sections) 6. J K Cables Limited India 7. Kei Industries Limited India 8. Paramount Cable Corporation India 9. Thermopads Pvt. Ltd. India 10. Toshniwal Cables India Extension & Compensating Cables 1. Associated Cables Ltd. India 2. Associated Flexibles & Wires Pvt. Ltd. India 3. Cords Cable Industries Ltd. India 4. Delton Cables Ltd India 5. General Instruments Consortium, India 6. J K Cables Limited India 7. Kei Industries Limited India 8. Paramount Cable Corporation India 9. Thermopads Pvt. Ltd. India 10. Toshniwal Cables India Cable Trays & Accessories (Al./Gi) 1. 2. 3. 4. 5. 6. Globe Electrical Industries Indiana Engg Works Pvt Ltd Metalite Industries, Parekh Engineering Company Sadhana Engineering Corporation Steelite Engineering Limited India India India India India India

Multi Transit Inlet System Page 204 of 208

Vendors Name Sl.No. 1. Mct Brattberg Aktiebolag 2. 3. 1. 2. 3. 4. 1. Roxtec Ab Hawke International Baliga Lighting Equipments Limited Ceag Flameproof Control Gears Pvt.Ltd. Flameproof Equipments Pvt. Ltd. Stahl-Und Apparatebau Hans Leffer Gmbh Indian Tube Co(Tata Div. Of Tubes &Pipes)

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Junction Box & Cable Gland

CS Seamless Pipes 2. Ismt Limited 3. Maharashtra Seamless Ltd. 4. Ets Trouvay & Cauvin 5. Phoceenne 6. Horst Kurvers Gmbh 7. Mannesmann Handel Ag 8. Dalmine Spa 9. Ibf Seamless Pipes Spa 10. Marubeni Itochu Steel 11. Nippon Steel Corporation 12. Nissho Iwai Corporation 13. Okura & Co. Ltd. 14. Sojitz Corporation CS Seamless Pipes 15. Sumitomo Metal Industries Ltd. 16. Hyundai Corporation 17. Vomal International Limited SS Seamless Pipes 1. Choksi Tube Company Ltd. 2. Nuclear Fuel Complex 3. Rajendra Mechanical Industries Ltd. 4. Ratnamani Metals & Tubes Limited 5. Phoceenne 6. Tps-Technitube Rohrenwerke Gmbh 7. Dalmine Spa SS Tubes 1. Choksi Tube Company Ltd. 2. Nuclear Fuel Complex 3. Ratnamani Metals & Tubes Limited Page 205 of 208

Vendors Name Sl.No. 4. Itochu Corporation (Rep.Kubota Corpn.) 5. Nishitani & Co. Ltd. 6. Sumitomo Metal Industries Ltd. Pipe Fittings 1. Eby Industries 2. Excel Hydro-Pneumatics Pvt Ltd, 3. Micro Precision Products Private Ltd. 4. Precision Engineering Industries 5. Tecnomatic (India) Pvt. Ltd. 6. Cellier S.A. 7. Siemens Ag Pgi 8. Thyssen-Krupp Stahlunion Gmbh 9. Cesare Bonetti 10. Technomatic Spa 11. Sumitomo Metal Industries Ltd. 12. Dewrance & Co. Ltd. 13. Hopkinsons Limited 14. Thompson Valves Ltd. 15. Velan Engineering Co. Limited 16. Anderson Greenwood & Co. 17. Crane Company Intl. Sales Compression Fittings 1. Reliance Engg. & Electrical Corpn. 2. Swagelock Company/Creximco Instrument Miniature Valves 1. Audco India Limited(L&T Valves Divn.) 2. Bhel (Valves Division) 3. Chemtrols Engineering Limited 4. Excel Hydro-Pneumatics Pvt Ltd, 5. Ksb Pumps Limited (Valves Divn) 6. Tecnomatic (India) Pvt. Ltd. 7. Hyd Air Engineering Works,Lonavila 8.. Cellier S.A. 9. Bfe Bonney Forge Valve Licensee 10. Euromisure Cremona 11. Technomatic Spa 12. Kosei Sangyo Ltd 13. Sumitomo Metal Industries Ltd. 14. Dewrance & Co. Ltd. Page 206 of 208

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Vendors Name Sl.No. 15. Hopkinsons Limited 16. Velan Engineering Co. Limited 17. Anderson Greenwood & Co. 18. Crane Company Intl. Sales 19. Swagelock Company/Creximco Purge Rotameter 1. Instrumentation Engineers Pvt. Ltd. 2. Placka Instruments & Controls Pvt. Ltd. 3. Tokyo Kisho CS Seamless Pipes 1. Indian Tubwe Co.(Tatya Div. Of Tubes & |Pipes) 2. ISMT Ltd. 3. Maharashtra Seamless Ltd. 4. ETS Trouvay & Cauvin 5. Phoceenne 6. Horst Kurvers Gmbh 7. Mannesman Handel AG 8. Dalmine Spa 9. IBM Seamless Pipes Spa 10. Marubeni Itochu Steel 11. Nippon Steel Corporation 12. Nissho Iwai Corporation 13. Okura & Co. Ltd. 14. Sojitz Corporation 15. Sumitomo Metal Industries Ltd. 16. Hyundai Corporation 17. Vomal International Ltd.

Country U.K U.K U.S.A U.S.A U.S.A India India Japan India India India France France Germany Germany Italy Italy Japan Japan Japan Japan Japan Japan Korea U.K

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4.0

PREQUALIFICATION CRITERIA FOR ADDITIONAL VENDORS In addition to the above vendor list, Bidder may also consider Vendors meeting the following prequalification criteria, with respect to Past Performance / Experience: The bidder, during the last ten years, must have designed, manufactured (under third party inspection) and supplied at least two similar packages for similar duties and operating conditions and the same shall be operating satisfactorily after installation for at least TWO years. As a documentary proof, the bidder shall submit self attested photo copies of the following documentsCopy of Purchase Orders with full technical details of the equipment Certificate from user regarding satisfactory performance. The Bidder would be ultimately responsible for verifying the credentials, the quality of the equipment, machinery and timely supply.

4.1

5.2 In spite of serious follow up, verification of credentials of Vendors from China within limited time is very difficult. Given the critical nature of the job and very high degree of reliability, Chinese Vendors may be considered for this Revamped waste water section if they meet the criteria of having supplied, during the last 10 years, at least two similar plant equipments or machinery for similar duties and operating conditions provided that the referenced supplies were made to India. RCFs scope of work:Civil work execution, erection of equipment and piping hook-up, Painting(except equipment/machine painting) and insulation(as per given specification & procedures by party); Under the supervision of party supervisor. RCF shall provide following at the battery limit of the plant: Steam: Power: Cooling water: Instrument air: 26 ata/3.5 ata. 440 volts/3 ph/50 Hz. 3.5 kg/CM2. 6.5 kG/CM2.

Deviations and exclusions: The revamp of the waste water section shall be carried out as outlined in the previous documents. All the requirements of the scope of work by the bidder are required to be strictly followed. However if there is any minor deviation from the scope specified by RCF, the bidder shall spell it clearly in the technical offer.

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