Chapter D, Annex.a, HYd

KUDREMUKH IRON ORE COMPANY LTD MANGALORE PELLET PLANT INSTALLATION OF ADDITIONAL TWO BALL MILLS AT MANGALORE
CHAPTER D, ANNEXURE - A PIPING INCLUDING PUMP BOX, CYCLONES, SLURRY PUMPS. 1.00 GENERAL Iron ore of (-) 1mm size as undersize of sizing screen is to be collected and sent to the existing slurry storage tanks. Oversize material of +1mm to 10mm has to be taken to Ball mill for grinding. After grinding, the materials will be fed to hydro cyclones for separation. Slurry pipes interconnecting Ball mill, hydro cyclone, sizing screen, and slurry storage tanks are to be erected as per the drawings supplied by the Owner/Engineer. Process water needs to be added at various locations of the screening and grinding section. Layout of proposed interconnection of slurry pipes and process water pipes are shown in the following drawings, which are enclosed: Sl.No. 1. 2. 3. 4. 2.00 Drawing Number MEC/A3/S/1966E/01/S3/01 MEC/A3/S/1966E/01/S3/02 M-1120-K10 MEC/A3/S/1966E/01/S3/03 Title Slurry and Process Water piping layout General arrangement of pump box Kreb Cyclone GA drawing Layout of process water pumps
SCOPE OF WORK The scope work of the Tenderer consists of following parts:-
PARTI: MANUFACTURE / FABRICATION & SUPPLY OF RUBBER LINED PUMP BOXES, PIPES (UNLINED/LINED), VALVES, VICTAULIC COUPLINGS, FLANGES, SUPPORTS AND ASSOCIATED FITTINGS. This part of the specification covers preparation of fabrication drawings, procurement of plates, manufacture / fabrication, testing, rubber lining, and transportation to place of erection of 2 nos. of pump boxes. Procurement of plates, victaulic couplings, flanges, pipes and foundation bolts required for the pump boxes is under Tenderers scope of supply.
MEC/1966E/01/36/S03 Rev. 0 2005 MECON Ltd. All rights reserved.
Page No. D Ann A / 1 of 31
Details of pump boxes are indicated in the enclosed tender drawings. For fabrication of pump boxes and specification, Please refer Annexure-A-4 of this chapter. This part of the specification also includes supply of pipes (unlined/lined), valves, supports and associated fittings as per specification furnished in Annexure-A-5 of this chapter (Please also refer attached data sheet). Tenderer shall arrange supply of standard / non-standard rubber lined/unlined pipes and fittings. Non-standard rubber lined pipes (R/L) are required to suit the slurry piping between various equipment. PART-II: DISMANTLING OF EQUIPMENT & PIPING AT KUDREMUKH SITE, TRANSPORTATION TO MANGALORE, SAFE CUSTODY / STORAGE. ERECTION, TESTING & COMMISSIONING OF PUMP BOXES, HYDRO CYCLONES, PUMPSETS, PIPES (UNLINED/LINED), VALVES AND ASSOCIATED FITTINGS. This part of the specification covers dismantling of equipment / piping at Kudremukh site and transport to Mangalore including safe custody / storage. This part also covers erection, testing and commissioning of pump sets, pipes (unlined / lined), valves, pump boxes, hydro cyclones and associated fittings for process piping, service piping and work incidental there as shown in the tender Drg.Nos.MEC/S/1966E/01/S3/01,02 and as per details specified therein. The following materials are to be dismantled from Kudremukh site and transported to Mangalore unless otherwise specified:1. Pump with motor and base frame. (2 sets.) 2. Cyclones with supporting structure.(2 sets.) 3. Pump boxes at discharge of Ball mill ( 2 Nos.) 4. Piping including fittings and valves. 1 Lot
PART-III: PREPARATION OF WORKING DRAWINGS FOR ROUTING OF PIPELINE INCLUDING FABRICATION DRAWINGS FOR PUMP BOX. OWNER/ENGINEER will provide detailed schematic drawings along with detailed / typical drawings of supports, hangers, etc. The drawings will include the estimated bill of materials. Based on the schematic drawings / GA drawings, Tenderer shall prepare working drawings / fabrication drawings, which shall be approved by the OWNER/ENGINEER. Any isometric drawings required by the TENDERER for their own work or to meet any statutory requirements shall be arranged by the TENDERER at no extra cost. Tenderer shall erect the pipeline as per site conditions. PART-IV: ERECTION OF OWNER SUPPLIED PUMPSETS. Process water pump house is being constructed by KIOCL, adjacent to existing cooling pond. Tenderer shall install 4 nos. of process water pumps along with 1 no. of sump pump in the process water pump house. Pumps shall be supplied to tenderer as free issue items for erection. Erection of pumps shall be complete with the erection of necessary pipes, valves, and fittings. C.I. sluice gate shall also be installed in the pump house. 2 nos.of GIW make slurry pumps shall be supplied to the tenderer as free issue items by KIOCL. Tenderer shall erect the same adjacent to the pump boxes, below the sizing screens. In addition to this, two slurry pumps are to be dismantled from Kudremukh and transported to Mangalore site. These pumps shall be erected adjacent to Ball mill pump boxes. 3.00 3.01 3.02 3.03 WORKS INCLUDED Dismantling of equipment /piping as per the instructions of owner. Transportation to Mangalore site and safe custody. Erection of equipment / pipes, valves, victaulic couplings and fittings in compliance with the schematic drawings (supplied by the owner) / working drawings prepared by the tenderer. Fabrication of pipe specials like tees, bends, reducers, pipe supports etc, wherever necessary i.e. in case, the same are not supplied by OWNER/ENGINEER, so as to install and fix the pipes as per the approved drawings (Please refer Annexure A1).
3.04
3.05 3.06 3.07 3.08
Installation of miscellaneous pipes, pipe fittings, victaulic couplings, valves, flanges, strainers, filters, hoses, clamps, gaskets, bolting, etc. Testing and commissioning of piping as per technical requirement (Please refer Annexure A2). Painting of pipes, followed by colour banding / line numbering. Making necessary openings for piping in the work already executed by others or relocating / enlarging to the required size of existing openings and making good the same after laying and testing the piping. Fabricating and installing as per OWNERs design, pipe hangers and all that is necessary to completely support all the piping components such as valves, traps, etc. The scope also includes but not limited to supply & erection of beam clamps, clevises, riser clamps, pipe clamps, spring hangers fabricated structural supports, guides and anchors, turn buckles, brackets, saddles, U-blots, flanges, bolts, nuts and rods. Also, supporting members required in addition to the existing building structure shall be supplied and installed. Erecting the pipes, valves and fittings in strict compliance with the schematic drawings. Deviations, if considered necessary, to suit the site conditions, could however be carried out in consultation with and prior approval of the OWNER. Executing as part of process and service piping the following work for instrumentation : i) ii) Install all in-line-items shown on the piping drawings such as control valves, flow meters, orifice plates, thermo wells, etc. Install all piping connections for instrumentation. This shall include couplings, flanges, pipes and valves etc. as shown on the drawings.
3.09
3.10
3.11
3.12
Welding, making of joints, connections to equipment, moving into position, properly assembling and aligning the various parts, providing necessary shimming and grouting. Cleaning, testing, flushing and rectifying the piping system. All valves shall be hydrostatically tested before installation to ensure that valves are in proper working condition.
3.13
3.14 3.15 4.00 4.01 Installing all adaptors necessary to connect to underground piping. Repairing / replacing the damage that might be caused to the existing structure/equipment during erection at no extra cost. ERECTION OF PUMPSETS The pump base frame shall be erected on prepared foundation and levelled with shims and wedges with the help of precision levels and other instruments. The pump, drive and coupling shall then be aligned and coupled. The method of alignment and tolerance for alignment shall be maintained as specified in the manufacturers instruction manual. Connection of suction and delivery pipes shall be made in such a manner that the connection to the pump flanges does not develop any undue stress and the weight of the pipes is not transmitted to the pump. During manual rotation, it shall be ensured that the shaft assembly moves freely and no noise develops from bearings. Before coupling the motor to the pump, it shall be ensured that the direction of rotation of the motor corresponds to that of the pump indicated by the manufacturer/ supplier. ERECTION OF PUMP BOXES Rubber lined pump boxes (4 nos.) of the following description shall be erected as per drawings/instruction of the site engineer:a. b. c. d. 5.02 5.03 5.04 5.05 3.528m dia. 3.528m dia. 4.028m dia. 3.528m dia. X X X X 4.0 m height. 4.5 m height 5.5 m height 5.5 m height
4.02
4.03
4.04 4.05
5.00 5.01
Item 5.01 (a) and (b) are to be dismantled from Kudremukh and transported to Mangalore for erection. Item 5.01 (c) and (d) are to be fabricated by the Tenderer as per approved drawings and the same shall be erected at Mangalore. Legs of the pump box shall be firmly fixed to the foundation and alignment of the pump suction shall be checked. Over flow of the pump box shall be directed towards the drain.
5.06 5.07
During erection care shall be taken not to damage the rubber-lined surfaces. Undersize and oversize collecting pump boxes located below the screen shall be suitably interconnected with the pump boxes already installed for Ball Mill No.1 by the other agency. ERECTION OF CYCLONES Cyclones (2 nos.) of KREBS Engineers make shall be dismantled and transported to Mangalore for erection at 12.5m level. KREBS Engineers make cyclone presently working with Ball mill no.10 of Kudremukh is a cluster of 5 cyclones as per drawing attached. This needs to be dismantled and transported to Mangalore for erection. KIOCL may identify one more KREBS Engineers make cyclone for dismantling, transportation and erection. This cyclone may be a cluster of 5 cyclones as per drawing or having a different arrangement with less than 5 nos. of cyclones. The exact details of the hydro cyclones to be installed will be intimated to the successful Tenderer. Cyclones shall be erected as per drawings / instructions of the site engineer. Supporting structure of cyclone shall be firmly fixed to the foundation and alignment of the under flow, overflow and feed pipes shall be checked. Under flow launder shall be erected as per drawing issued by the Consultant / OWNER. During erection care shall be taken not to damage the rubber-lined surfaces. APPLICABLE STANDARDS All work performed under this part of the specification shall conform to the building and safety codes, ordinances and the rules and regulations of any legal body having jurisdiction.
6.00 6.01 6.02
6.03 6.04 6.05 6.06 7.00
7.00
Inspection and testing of all installations covered by this part of the specification shall comply with the following specifications. i) ii) iii) Indian Standard Specification. National Building Code of India. Power piping code, ANSI B 31.1.
8.00 8.01 i)
WORKMANSHIP AND DESIGN General Pumps, Pipes, fittings, valves and piping accessories shall be handled in a manner to avoid damage to the material. Pipe shall not be rolled or dragged on the ground. Restraining ropes shall be used when lowering from skids. Belt sling shall be used when unloading from carriers by crane. All openings into piping shall be kept effectively closed until assembled in the system to avoid foreign matter entering into the system. All piping shall follow the general arrangement shown and shall be cut accurately to measurements established for the work by the TENDERER and shall be installed without springing or required by other limiting conditions. All piping within buildings shall be installed with adequate clearance for lighting, doors, windows and other openings. Overhead piping in buildings shall run in the most inconspicuous positions unless otherwise indicated. When piping is being installed, it shall be arranged in the straightest possible runs with minimum amount of fittings and the required clearances and supports. Piping shall run parallel to structural members, columns and other piping, unless otherwise shown in the drawings or directed by the OWNER. Flanges of the pipelines, fittings etc, must be so mounted that top bolt holes are symmetrical about the vertical axis of the flange. When several pipelines are laid, parallel flanged joints must be staggered. Welded and flanged joints should as far as possible be located at onethird span from supports. If support is situated right under the welded joints, this joint must be reinforced with a strap. Flanged and welded joints must be avoided in the middle of the span. Valves provided with spindles whose location is not indicated in the drawings must be installed in such a manner as to ensure their convenient operation from the floor or the nearest platform. After completion of piping work, openings provided in the walls for pipelines must be closed with bricks on mortar with 10-22 mm clearance between the brickwork and pipe. The clear space must be stuffed with felt or asbestos.
ii)
iii)
iv)
v)
8.02
Piping Fabrication Fabrication of piping such as layout, cutting, fitting up, bending and welding shall be in accordance with Annexure A-I - `Fabrication of Medium Carbon Steel Piping and Fittings'.
8.03 i)
Pipe Joints Screwed: Pipe sealant with Teflon / Loctite or any equal shall be used to make-up screwed joints, and shall be applied to male threads only. Threaded parts shall be wiped clean of oil or grease using appropriate solvent if necessary and allowing proper time for drying before applying the sealant. Pipe shall be free from fins and burrs. Pipe ends shall be reamed or filed out to size of bore and all chips shall be removed. Screwed flanges shall be attached by screwing the pipe through the flange and the pipe and flange shall be refaced accurately.
ii) Welded: For making up welded joints, welding shall be performed by the manual shielded metallic arc process in accordance with the requirement specified in Annexure A-I of this specification. No stress relieving or radiograph inspection of welds will be required unless directed by the OWNER. iii) Bolted: For making up flanged joints, flange bolts, bolt studs and nuts with gaskets shall be used. Only sufficient torque to provide a leak free joint shall be applied to the nuts. iv) Victaulic coupling with bolts and nuts shall be used for rubber lined pipes. 8.04 Painting a) b) c) d) e) All the un-insulated pipelines shall be painted. The outside surface of all pipelines to be painted shall be thoroughly cleaned by wire brushing or emery paper to remove dust, mill scale, rust etc. Before painting, any grease or lubricant shall be removed and the surface of the pipe shall be perfectly dry. Painting shall be applied evenly so as to be free from sags, runs, crawls, or other defects. The outside surface of pipes shall be painted with two coats of Zinc based primer in alkaline medium and followed by two coats of
finish paints. The finish paints shall be either aluminium conforming to IS:2339-63 or synthetic enamel conforming to IS:2932-74 or chlorinated rubber. f) g) 8.05 Valves Valves shall be installed in locations accessible for operation and repair. Proper protection shall be provided to prevent injury or damage caused by escaping fluid from relief or safety valves if vented to the atmosphere. i) Gate Valves shall be installed with the stem horizontal or vertical (preferably vertical) with the wheel on the side of or above the pipe. Valves shall not be installed with the hand wheel below the pipe. Globe valves shall be installed with the stem horizontal on lines requiring drainage through the valve. Reducing fittings Reducing fittings shall be used for changes in pipe size. The use of bushings will not be permitted. 8.07 Eccentric reducers When installing eccentric reducers, orient the reducers to avoid trapping vapour in liquid lines or liquid in vapour lines. Unless otherwise shown, eccentric reducers shall be installed with straight side at the top of piping or connection. 8.08 Vents and drains Provide vents at high points in piping where air or gas pockets may occur (vents for use with hydrostatic test shall be plugged after completion of the test). Vents shall not be less than 15 mm in size. Provide drains at low points in piping. Complete drainage of all systems must be possible. Drains shall not be less than 15 mm for line sizes upto 150 mm, not less than 20 mm for 200 mm to 300 mm, not less than 25 mm for 350 mm to 600 mm. The colour code for the finish paint will be furnished by the OWNER in due course. The pipes shall be colour banded/line numbered for proper identifications as per the instructions of OWNER.
j) 8.06
8.09 Branch connections Branch connections in piping, unless otherwise indicated, may be made by use of the following: Flanged, butt welding, socket welding or screwed fittings, welding outlet fittings such as cast or forged nozzles, couplings of maximum size 50 mm or other approved adapters. Such welding outlet fittings shall be attached to the header or run by full penetration weld. 8.10 Branch lines Branch lines for compressed air shall be connected to the top or side of the main or header, unless indicated otherwise. 8.11 Slope of pipeline Unless otherwise indicated on the drawings, pipelines for various services shall be sloped as follows: Air piping shall be sloped down towards a drip leg or moisture trap so that condensate may be removed. A slope of at least 25-mm in 10 m shall be used. Water piping shall be sloped so that any part the system can be drained through a shut-off drain valve. 8.12 Unions or flanges shall be provided to facilitate dismantling of piping, valves and equipment and shall be installed not more than 30 m apart in pipelines located inside the building. Each valve connection shall have union or flanges however in certain piping systems where a totally leakproof system is required, dismantling points with unions, flanges etc., shall be minimum or even absent if so specified. Flashing for buildings Where pipes pass through building roofs and outside walls, proper flashing shall be provided and shall be made tight and water proof. Flashing shall be in accordance with specification of the manufacturer of the roof and/or wall systems. 8.14 Pipe supporting All piping shall be supported in a manner that will not put undue strain on pumps, tanks or other equipment.
8.13
9.00 9.01
INSPECTION, TESTS AND CLEANING All equipment, tests media and all apparatus necessary for the tests shall be furnished by the Tenderer. Tests shall be made in the presence of the OWNER. Copy of test results in writing shall be given to the OWNER. Pumps shall be tested at site in accordance with Annexure-A-3 and piping systems shall be tested in accordance with the applicable section of Annexure-A-2. Gauge and other apparatus which may be damaged by the test pressure shall be removed or isolated before the tests are made. Temperature of water used for testing shall not exceed 40 Deg.C. The required test pressure shall be maintained for a sufficient length of time to enable an inspection to be made of all joints and connections. All defects disclosed by the tests shall be rectified retested until they show no defect or weakness and are water and air tight. Correction of Defects Leaks in threaded pipe, which cannot be stopped by tightening threads, shall be repaired by replacing the defective fittings. Leaks in welded joints shall be repaired by welding. Peening to stop leaks is not permissible.
9.02
9.03
9.04
Cleaning of piping system i) ii) All excess bead, oil, grease and weld splattering shall be removed from the exposed surfaces of piping. Prior to testing, the system shall be cleaned of all dirt, scale, oil, grease, waste and other foreign substances by flushing with water. Temporary screens shall be installed in pipelines for the retention of tramp iron or other foreign material and in all cases immediately ahead of pumps suction entry. All such strainers shall be supplied by the Tenderer at no extra cost. After cleaning, all lines shall be blown down with air or water, as required to leave system in clean and operating condition before final charging of the system and before connection to equipment or other facilities. After completion of all testing and system cleaning, the baskets of all strainers shall be removed, thoroughly cleaned, replaced and shall be made ready for operation of the system. The temporary screens shall be removed after cleaning of the system.
iii)
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v) 9.05
Testing of all piping systems shall be carried out before the installation of the line equipment.
All necessary pipes, by-pass connections and pumping equipment etc., required for cleaning and testing of pipelines shall be provided by the Tenderer.
10.00 UNDERGROUND PIPING 10.01 Scope of Work The Tenderer shall furnish all materials and labour necessary to install underground piping in accordance with the following specifications and the working drawings. Excavation and backfilling shall be done as specified elsewhere. 10.02 Codes and Specifications Laying of underground piping shall conform to this specification, drawings, and where not otherwise specified, It shall conform to standard practices in common use as approved by the OWNER. All items of labour and material not specified in detail on the drawings, but incidental to or necessary for the complete installation of the piping systems or reasonably implied in connection therewith, shall be furnished and installed as if called for in detail by the specification or drawings. Tenderer shall furnish all caps, lagging, supports etc. to identify, maintain in "as laid" condition, and to provide access to the buried or embedded piping at a later date. 10.03 Handling The Tenderer shall perform repair work on all pipes that might be damaged during transportation and handling. Unloading operations shall be performed in such a manner not to damage OWNER's property. Pipes shall be unloaded from the trucks and lowered to the ground by means of suitable equipment. Extreme care must be exercised in unloading coated pipe from the truck so that the coating is not damaged. No pipe shall be strung except where the path has been cleared. The Tenderer shall string the pipes in such a manner as to leave gaps across the route where directed by the OWNER to facilitate the movement of vehicles or equipment.
10.04 Protective Coating Underground MS pipes shall be wrapped with 4 mm thick polyethylene corrosion protection tape and the same shall conform to IS : 10221 1982 (Code of practice for coating and wrapping of under ground MS pipelines) / AWWA C 203 and as per the following procedure : Polymeric protection tape shall incorporate a centre core of approx. 100 micron HDPE film. It shall have a second centre core of textile fabric to give mechanical strength and dimensional stability to the tape. 3 layers of polymeric based coal tar, rubber and other polymers shall be interleaved between the above centre cores. All the seven layers shall be calendered together to create the above protection tape. The pipe shall be initially wire brushed to remove all foreign matter. Primer shall be applied over the pipe at 150 gm/sq.m. The primer shall be allowed to dry until the solvent evaporates and the surface becomes tacky. Polymeric tape (4mm) shall then be wound around the pipe in spiral fashion and bonded completely to the pipe by thermo-fusion process. The overlaps shall be sealed by the same thermo-fusion process. Holiday test shall be conducted over the coated surface. Overlap of at least 72mm shall be ensured while wrapping the tape over the pipe. 10.05 Excavation for Trenches i) Trench excavation shall be classified as excavation required for installation of pressure pipe and similar works. Trench excavation shall include the removal of all material including the haul of excess material to a disposal area and usable material to a stock-pile area all upto a distance of one (1) kilometre.
ii) Excavation in both common and rock material shall be carried out to the lines and grades shown on the drawings, unless otherwise specified. In the event that a trench is constructed to a width or depth greater than that permitted above, through Tenderer's error, the Tenderer shall furnish free of extra cost necessary material, labour and equipment to correct such errors as decided by the OWNER. iii) Shoring and bracing shall be used to support the sides of trenches wherever necessary to protect life, and limbs of the workers. When closed sheeting is required, it shall be so driven as to prevent adjacent soil from entering the trenches either below or through. Sheeting and
bracing shall be removed after they have served their purpose, unless otherwise specified in writing by the OWNER. 10.06 Disposal Excavation materials deemed suitable by the OWNER for any purpose shall be stockpiled in required quantities in the vicinity of the excavation sites involved, with the approval of OWNER. Unsuitable or excess excavation material and debris shall be transported to spoil areas, as defined and approved by the OWNER. Material shall be end dumped and graded at these areas. 10.07 Back Fill Back-fill shall contain no ashes, rubbish, combustible or decomposable material, nor any other material which the OWNER deems unsuitable for this purpose. If the excavated material is deemed unsuitable by the OWNER for use as back-fill, the Tenderer shall back-fill the trench with material approved by OWNER which shall be obtained from locations to be specified. Granulated material under ground, and to 300 mm above underground pipe shall be considered as bedding. The remainder of back-filling required to fill the trench shall be completed by the Tenderer. Authorisation shall be obtained from the OWNER before proceeding with such back-fill. Compaction shall be done as specified at no extra cost. 10.08 Bedding Prior to the lowering and laying of pipe in any trench or excavation, the Tenderer shall back-fill and compact the bottom of the trench or excavation to provide an acceptable bed for placing the pipe. 10.09 Installation Pipes shall be laid to line and levels as shown in drawings.
ANNEXURE - AI FABRICATION OF MEDIUM CARBON STEEL PIPING AND FITTINGS 1.00 1.01 i) WELDING General All welding including the proposed procedure and the qualification of welders and welding operators, shall be done according to Power Piping Code ANSI B 31.1 and ASME section IX or approved equivalent.
ii) No welding shall start until the proposed procedure has been approved by the OWNER. iii) Welding shall be made by machine or manual shielded metallic arc process. Direct current shall be used exclusively with the base material on the negative side of the line. Electrodes used shall be an approved all position rod type ( of Ador / ESAB make only). Flux coated rods shall be kept dry, and open electrode containers shall be protected against moisture. Electrodes that show sign of deterioration or damage shall not be used. iv) Details of welding techniques such as number of beads and layers, angle of surfaces to be welded, weld gap at base, backing ring, electrode diameters and average current values, etc., are subject to the approval of the OWNER. v) The Tenderer shall furnish each welder with a steel stencil for marking the weld, so that the work of each welder may be identified. Each welder shall stencil each weld made by him with the stencil assigned. Each welder's certificate of qualification not older than 6 months shall be on file at the work site and shall be made available to the OWNER. In the event of a welder leaving the job his stencil will be voided and not duplicated if another welder is employed. This shall be done in addition to stamping of welds. Welders working close to inflammable materials shall be provided with fire extinguishers and shall observe all necessary fire preventions precautions, such as using shields as required, to avoid fire hazards and heat damage to adjacent structures. 1.02 i) End Preparation Piping for socket welded fittings shall be saw cut, square to the axis of the pipe and reamed Individual length of pipes shall be jointed by couplings
or unions. A minimum gap of 1/16" between the end of the pipe and the bottom of the socket shall be provided before welding. ii) Piping for butt-welded run shall be supplied with ends bevelled by machining. Any pipe and fitting ends requiring bevelling for welding shall also be machined. If machining is impracticable, ends may be prepared by grinding or by flame cutting and consequent grinding back 4 mm prior to welding. Butt welding preparation which meet the procedure qualification is acceptable. Each joint shall be internally swabbed and be free from scale, surface cracks, oil, grease, oxides or other foreign matter before welding. iii) Where backing rings are used, they shall be accurately fitted and welded to the upstream inside side of the pipe. Weld slag and splatter shall be removed prior to assembling the pipe. iv) The ends of the pipe-to-pipe, pipe-to-fitting and fitting-to-fitting joints shall be aligned as accurately as is practical within the existing commercial tolerance on pipe diameters, wall thickness, and out-of-roundness. Alignment shall provide the most favourable conditions for the deposition of the root bead. This alignment must be preserved during welding. In cases, where ends of unequal internal diameter are abutted and the internal misalignment exceeds 2 mm they shall be internally teamed to equal each other. 1.03 i) Welding Technique Welding may be performed with the pipes in a fixed position or by rolling, providing that proper alignment is maintained by the use of supports, skids, welding rolls or structural framework. The entire root pass shall be made with the pipes in a stationary position and movement of the pipes during this time must be kept to the absolute minimum. When using external clamps, the root beads must be uniformly spaced around the circumference of the pipe and shall have an accumulated length of not less than 50% of the circumference before removal of the clamps.
ii) If the rolling technique is to be used after the root pass, the weld must consist of not less than two passes using the approved type and size of electrode, and the weld puddle shall be maintained at or near the top centre of the pipe. iii) Welds shall be full penetration, continuous and without defects. After deposition, each layer of weld shall be cleaned to remove slag, and scale by wire brushing or grinding then chipped, where necessary to prepare for proper deposition of the next layer. The weld reinforcement shall not be
less than 2 mm and not more than 4 mm above the normal surface of the joined sections. iv) The reinforcement shall be crowned at the centre and shall merge into the base material without excessive shoulder or undercut. All scale and slag shall be removed and the completed weld shall be thoroughly cleaned before final inspection. v) Welding shall not be carried out without adequate protection when the quality of the completed weld may be affected by the weather. The OWNER shall decide if protection against the weather is adequate. 1.04 i) Welding Inspection The work shall at any time be available for inspection to the OWNER. No weld shall be covered before the inspection has been carried out to the entire satisfaction of the OWNER. The OWNER reserves the right to reject welds upon visual inspection and / or upon evidence of defects detected by radiography. The latter shall be carried out only on written request by the OWNER. Joints in welded piping systems shall be radiographed if so requested by the OWNER. Radiographing shall be done by a reputed firm specialised in this field and approved by the OWNER. Films shall be identified and marked with the date and location of the weld. Poor films may be rejected and replacements called for. Cost towards the radiography test shall be born by the Tenderer. Spot dye penetration test shall be carried out, if considered necessary by the OWNER, on a maximum of 10% of total piping.
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iv) The work shall be rejected in case of: a) b) c) d) e) f) Failure to meet radiographic requirements or other code tests. Welding performed by unqualified persons. Welds not reasonably uniform in appearance. Evidence of peening. Presence of cracks or pinholes. Oxidation around welds.
g) h) i) j) k) 1.05 i) ii) Repair All welds found to be of poor or doubtful quality shall be cut out and replaced with satisfactory welds at Tenderer's expense. Defective welds may be repaired on the authority of the OWNER but any weld that shows evidence of having been repaired without authorization may be rejected. Repairs may be made to pin holes and undercutting in the final bead without authorization but must meet with the final approval of the OWNER. Before repairs are made, remove defects by chipping, grinding or flame gauging. Slag and scale shall be removed by wire brushing. FABRICATION All bends, tees, elbows and reducers up to 150 mm diameter will be supplied ready made by OWNER. All bends, tees and reducers and other fittings above 150 mm diameter shall be fabricated by the Tenderer out of OWNER supplied pipes, as per the power piping code, ANSI 31.1 or approved equivalent. Reinforcement pads, wherever required shall be provided by the Tenderer. Lack of fusion and/or incomplete penetration. The presence of porosity, slag inclusion or overlaps. Undercutting adjacent to completed welds or evidence of undercutting by grinding. Misalignment exceeding 2 mm. Any other fault at the discretion of the radiograph specialist.
iii) 2.00 2.01 2.02
ANNEXURE - A2 FIELD TESTING OF PIPING 1.00 1.01 GENERAL The Tenderer shall include and conduct field tests for all piping systems. These tests shall be made after installation is completed and before the systems are placed in service. Field tests procedure given in the code of practice issued by the Bureau of Indian Standard shall govern in so far as they exceed corresponding requirements of these specifications or cover omissions therein. All tests shall be performed as specified in the presence of the OWNER and must be accepted by him. The Tenderer shall conduct a preliminary test and repair or correct all faulty work before calling the OWNER to observe the test for acceptance of the systems. Disposal of testing media must be done with full consideration of flooding or damage to the piping, other installations or property of the OWNER and to safety of personnel. The method of disposal shall be approved by the OWNER. The Tenderer shall be liable for any damage resulting from field tests. In all cases, the hydrostatic or pneumatic tests pressure shall be maintained at least for 10 minutes and for such additional time as may be necessary to conduct the examination for leakage. PREPARATION OF TESTING No tests shall be performed until all anchors, hangers supports, test gauges, plugs, bulkheads, blanks, etc. are installed. Tests shall be made against bulkheads or blanks and not against closed valves except where permitted by the OWNER. Piping systems designed for air may be provided with additional temporary supports, if necessary, in order to support the extra weight of the test liquid.
1.02
1.03 1.04
1.05
1.06 1.07
2.00 2.01
2.02
2.03 Expansion joints shall be provided with restraints, if required during the test or shall be isolated from the test. Equipment, low pressure filling lines and other items not subjected to the test shall be disconnected or isolated with suitable means. Tests may be made through "open" valves if the test pressure does not exceed 1.5 times the primary service pressure rating of the valves, of if the valves with their closure are suitable for the proposed test pressure. HYDROSTATIC TEST Water shall be used for hydrostatic leak test; its temperature shall not exceed 40 deg.C. Unless otherwise specified or approved by the OWNER, hydrostatic tests shall be used for water, air or other liquid piping systems. All such systems, regardless of construction, shall be capable of withstanding without failure, leakage or permanent distortion, an internal hydrostatic test pressure of one and one-half (1 1/2) times the working pressure except that the test pressure shall, in no case, exceed the maximum test pressure of any component such as vessels, pumps or valves in the system, nor shall the pressure cause stresses in the piping system greater than 90% of its yield strength (0.2 percent offset) at test temperatures. Air vents shall be provided at all high points of the piping where the test will be conducted in order to purge air pockets while the piping system is filling. Examination for leakage should be made of all joints, connections and of all regions of high stress, such as around openings and sections where thickness of the pipe changes. Welded joints shall be subjected to hand hammer test while under test pressure. TEST EQUIPMENT For hydrostatic test, the Tenderer shall furnish the pumps, barrels, tanks, bulkheads, blanks, connections, test gauges and all other apparatus necessary for the test. The Tenderer shall furnish, install and dismantle (after the test) all temporary lines from the OWNER's water supply system to the system under test.
3.00 3.01 3.02
3.03
3.04
3.05 4.00 4.01
ANNEXURE-A3 FIELD TESTING OF PUMPS 1.00 Performance tests of pumps at site shall be conducted by the Tenderer after erection, to check the following: a) b) Mechanical soundness of equipment Power consumption of the motor with the help of test characteristic curves to compare the factory test results at site. The duration of performance tests shall be mutually decided at the time of testing.
ANNEXURE-A4 TECHNICAL SPECIFICATION FOR RUBBER LINED PUMP BOX 1.0 1.1 SCOPE This specification covers design, manufacture / fabrication of two numbers mild steel rubber lined tanks along with its associated accessories as specified. The scope of work shall also include, rubber lining, erection, testing, commissioning and painting (external) of the pump box. DESIGN AND CONSTRUCTION DETAILS The pump box shall be vertical, cylindrical non pressure type with mild steel welded construction and shall be designed as per IS: 803 1976. The tank shall be provided with sloping bottom inside the tank. The tank shall have a partition with over flow pipe connected to the chamber. Diameter of tank and thickness of shell shall be as per tender drawing. Bottom plate shall be 24mm thick and vacuum tested. Each shell course shall be of uniform height throughout longitudinal weld in any plate. Make up for the course width shall not be permitted. Shell plates in each course width shall be so arranged that all vertical joints be staggered having a minimum of 600mm stagger. The tank shall be properly constructed ensuring perfect vertical alignment. There shall not be any local bulging or depressions at any location of the tank. Qualified and experienced welders shall perform all welding. All welds shall be tight, leak proof and free from all defects like blowholes, slag inclusion and porosity etc. The welds shall be smooth, well reinforced giving a uniform weld surface throughout. 10% of welds shall be radiographed. All nozzles / pipes on the vessel shall be as per tender drawing. Pressure parts joined by butt welds shall be with full penetration welds. Where both sides welding is not accessible, root run by tungsten inert gas process or backing strip, shall be used to ensure full penetration. Backing strip if used, shall be removed after welding.
2.0 2.1
2.2 2.3
2.4
2.5
2.6 2.7
` 2.8
The shell sections, to the extent possible, shall be made out of a single plate with one longitudinal seam. Circumferntial weld shall be so located as to permit visual inspection with internals in position. Orientation of longitudinal seams and position of circumferential seams shall be clearly marked in the fabrication drawings. Branches, support and other attachments shall be located clear of weld joints; where this can not be provided, prior approval shall be obtained. All parts involving welding construction including internals shall have continuous welds unless otherwise stated. All welds shall be full penetration welds with back chipping and welding from the second side. For joints that are inaccessible for back chipping, the root run shall be carried out with TIG process. Single side welding with backing strips shall not be permitted. Due provisions must be kept for venting out entrapped gases during welding of pads, flanges and liner plates etc. Pads for supports and external cleats etc. shall be of same material as that of shell. All sharp corners shall be rounded off with smooth radius. Vessels shall be provided with lifting and earthing lugs. Detailed fabrication drawings shall be prepared by Tenderer and submitted for approval by consultant/owner.
2.9 2.10
2.11 2.12 2.13 2.14 2.15
3.0 TECHNICAL DATA SHEET SL.NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 14. 15. 3.1 DESCRIPTION No. of units Capacity (effective volume) Operating temperature Operating pressure Design pressure Material of construction Diameter and height Design Temperature Radiography Code of construction Hydro Test Pressure Test Temperature Shell Thickness Bottom plate Thickness List of nozzle connections : The size & other details of nozzles shall be as per the drawing enclosed. 4.0 4.01 INSPECTION AND TESTING OF PUMP BOXES: The pump box shall be subjected to stage wise expediting, inspection and testing at site by purchaser / consultant. Vendor shall submit Quality Assurance (QA) plan before commencement of fabrication. Approved QA plan and drawing shall form the basis for equipment inspection. Testing at site works/site shall include but not limited to the following : a) Bottom plate testing - Vaccum test. b) Non destructive tests such as radiography and dye penetration tests. c) Hydrostatic test - with water fill. d) Any other tests as per standards / codes. 4.03 All raw materials shall be inspected at source and to enable proper identification test certificates shall be submitted. UNIT No. Cu.m C Kg/cm(g) Mts C % Kg/cm (g) C mm mm 2 ~35 45 Atmospheric As per code Carbon Steel ASTM A-283 GRADE-C or equivalent As per tender drawing. 95 10 IS : 803 1976 Water fill Ambient 8.00 24 DATA
4.02
4.04 All equipment shall be inspected during various stages of manufacture starting from identification of raw materials to completion. The following NDT requirements are mandatory in addition to the requirements of code /specifications. Radiography a) Radiography when called for shall be applicable to all pressure welds i.e. longitudinal and circumferentials. b) When formed heads are made of welded plates / petal construction all the weld seams prior to forming and after forming shall be fully radiographed. All the weld T joints shall be radiographed. c) Any or all the tests, at purchasers option, shall be witnessed by purchaser / consultant. However, such inspection shall be regarded as check-up and in no way absolve the vendor of this responsibility. 5.0 PAINTING All exposed unfinished surfaces shall be thoroughly cleaned of all rust, oil, dirt, scale and foreign matter and shall be painted as indicated below: a) Internal: 6mm thk. Rubber lining. b) External: Two coats of high build chlorinated rubber zinc phosphate primer followed by finish paint of chlorinated rubber paint. 6.0 DATA, DRAWINGS AND INFORMATION TO BE SUBMITTED AFTER AWARD OF CONTRACT Following drawings/documents (as applicable) shall be furnished by the Tenderer for review/ reference / final approval. 1.0 2.0 3.0 4.0 5.0 Fabrication drawings with all auxiliaries. Commissioning and performance test procedure. Quality Assurance plan. (QAP) W.P.S. & P.Q.R as required. Test certificates. a) b) c) d) Material Test Certificates Hydrostatic test certificates Field leakage test report Any other test report.
ANNEXURE-A5 PIPING MATERIAL SPECIFICATION NO.1 ( Process water, cooling water, gland water & Make-up water pipes (PW-, CLW-,GW -,MW -) 1.0 DESIGN CONDITIONS Maximum pressure Maximum temperature 2.0 2.1 PIPE 50 mm and smaller: Carbon steel pipe,, black, welded, standard weight as per IS:1239 Part-I (Heavy) with threaded ends, except that pipe ends and end couplings shall be threaded as per IS:554. 80 mm, 100mm & 150 mm: Carbon steel pipe, black welded, beveled ends as per IS: 1239 Part-I (Heavy). 200 mm to 500 mm: Carbon steel pipe, black welded, beveled ends as per IS: 3589. (Thickness as per BOQ). PIPE JOINTS 50 MM and smaller: Threaded and coupled (threads as per IS:554) 80 mm and above: 4.0 4.1 4.2 PIPE FITTINGS 50 mm and smaller : Mild steel, as per IS:1239 (Part II) / IS:1879. 80 mm to 500 mm: Carbon Steel forged seamless fitting as per ASTM A 234 Gr. WPB. Dimensions as per ANSI B 16.9 (R=1.5d ) with Butt weld ends. FLANGES 80 mm and above: Carbon steel, Raised face, slip-on or plate flange or welding neck, bore to match the pipe as per class 1.0 of IS: 6392. 6.0 UNIONS 50 mm and smaller : Mild steel, screwed as per IS:1239 (Part II) / IS:1879 7.0 7.1 7.2 GASKETS 250 mm and smaller: 1.6 mm thick, flat ring, compressed asbestos, C grade as per IS: 2712. 300 mm and larger: 3.2 mm thick, flat ring, compressed asbestos, C grade as per IS: 2712. Butt-welded - 10 Kgf/cm2 - 65 C
2.2 2.3 3.0
5.0
PIPING MATERIAL SPECIFICATION No.2 Slurry Pipeline, Rubber lined 1.0 Design Conditions Maximum pressure: 10.5 Kgf/cm2 Maximum Temperature: 40 C 2.0 2.1 Pipe 250 mm and smaller: Carbon steel pipe, black, ER welded, (thickness as per BOQ) IS: 1978 with square cut ends, grooved for style-77 come along Victaulic coupling or approved equal. Lengths: Straight pipe in exact length of 6000 mm unless otherwise shown on the drawing. Grooving - Pipe end grooving shall be made according to victaulic specification or approved equal. Lining:- Pipe shall be lined with an abrasive resistant rubber of 6 to 6.35mm thick. Pipe Joint Victaulic coupling style 77 come along or approved equal. Pipe Fittings For all sizes: Victaulic full-flow, steel with ends grooved for Victaulic couplings. Lining :- Fitting shall be lined with an abrasive resistant rubber of 6.35mm thick. Flanges Carbon steel, flat face, slip-on boss flange or plate flange or Welding Neck, bore to match the pipe, class 1.0 as per IS: 6392. Gaskets Not used. Rubber lining parts provides seal. 0 Bolting for Flanged Connections Carbon steel as per IS: 1364.
2.2 2.3 2.4 3.0 3.1 4.0 4.1 4.2 5.0 5.1 6.0 7.0 7.1
1.0 a) b) c)
DATA SHEET FOR BUTTERFLY VALVES DESIGN PARTICULARS DOCUMENTATION TO BE SUBMITTED WITH Fluid to be handled water 6.0 OFFER Working pressure 5.0 to 8.0 kg/cm Type Wafer type conforming IS Catalogues/ literature 13095-1991/ BS: 5155 DOCUMENT TO BE SUBMITTED AFTER ORDER 7.0 Type of operation Size upto 200 mm NB lever operated / 250mm and above gear operated. 150 class 8.0 a) b) Cast DI Soft To be provided c) d) e) 9.0 GA & Cross sectional drawing with part number, material of construction and major dimensions for approval from OWNER/ consultant. DOCUMENTS TO BE SUBMITTED DURING INSPECTION TO OWNER/ CONSULTANT Hydro-test certificate Chemical Test Certificate Warranty Certificate Mechanical Test Certificate Approved QAP MARKING The valves shall be clearly and permanently marked with the following : a) b) c) d) e) 10.0 Manufacturers name and trade mark. Year of manufacture ISI / BS certification mark. Size of valve Rating/ class QUANTITY REQUIRED. As per schedule of items and quantities
d)
e) 2.0 a) b) c) d) 3.0 a) b) c) d) f) 4.0
Rating CONSTRUCTION MODE Body Disc Seat Hand lever/ gear
MATERIAL OF CONSTRUCTION Body Disc Shaft Seating ring/ seal retaining ring Cast iron IS: 210-1978, FG 200, Min Ductile (SG) iron to IS:1865 Gr. 450/10 Stainless steel IS: 6603-1972, 12 Cr 13 Stainless steel IS : 66031972, 04 Cr 18 Ni 10
Seat Elastomers, Grade : Nitrile TEST TO BE WITNESSED BY OWNER/ CONSULTANT Hydro test Body Seat Disc Strength As per IS: 13095/ BS : 5155 - do - do -
a)
5.0 a) b)
WORKMANSHIP FINISH & PAINT Workmanship Finish Good All burrs and sharp edges shall be removed and the inside surface should have smooth finish 1 coat of primer followed by 2 coats of enamel paint
c)
Paint
DATA SHEET FOR BALL VALVE 1.0 a) b) c) d) e) f) DESIGN PARTICULARS Fluid to be handled Filtered water Type Ball valve, three piece full bore Design standard BS 5351 Type of operation Lever operated Working pressure 2 to 6 Kg/cm End connection Suitable for socket welding as per ASME B 16.11 b) c) d) e) 6.0 a) 7.0 Year of manufacture Size Direction of flow Manufacturing standard DOCUMENTATION TO BE SUBMITTED WITH OFFER Catalogues/ literature DOCUMENTS TO BE SUBMITTED AFTER ORDER Cross sectional drawing with part number, material of construction and major dimensions for approval from Owner/ Consultant DOCUMENT TO BE SUBMITTED DURING INSPECTION TO OWNER / CONSULTANT Approved QAP Hydro-test certificate Chemical Test Certificate Warranty Certificate Mechanical Test Certificate QUANTITY REQUIRED. As per schedule of items and bill of quantities As per BS 6755 part-1 As per BS 6755 part-1
2.0 a)
MATERIAL OF CONSTRUCTION Body Carbon steel to ASTM A 105/ ASTM A 216 Gr. WCB. SS, AISI 316 a) b) c) d) f) 9.0
8.0
b) c) d) e) f) g) 3.0 a)
Ball
Seat PTFE Stem SS AISI 316 Body seal Graphite Gland packing PTFE Stem seal PTFE TESTS TO BE WITNESSED BY OWNER/ CONSULTANT Hydro test Body Seat
4.0 a) b)
WORKMANSHIP, FINISH & PAINT Workmanship Good Finish All burrs and sharp edges shall be removed and the inside surface should have smooth finish 1 coat of primer followed by 2 coats of enamel paint.
c) 5.0
Painting MARKING
a)
The Ball valve shall be clearly and permanently marked with the following : Manufacturers name and trade mark.
DATA SHEET FOR CAST IRON DUAL PLATE CHECK VALVE 1.0 a) b) DESIGN PARTICULARS Fluid to be handled Water Type Wafer type Dual plate check valve Working pressure Manufacturing standard Rating 6 Kg/cm API 594/ API 6D b) c) d) e) Year of manufacture Manufacturing standard certification mark and Direction of flow Size Rating
c) d)
7.0 DOCUMENTATION TO BE SUBMITTED WITH OFFER Catalogue/ literature 8.0 DOCUMENTS TO BE SUBMITTED AFTER ORDER GA & Cross sectional drawing with part number, material of construction and major dimensions for approval.
e) 2.0 a) b) c) 3.0 a)
ANSI 150
CONSTRUCTION MODE Body Cover Disc Body Cast Bolted With renewable liner 9.0 a) b) c) d) e) CI BS 1452 Gr. 220/ ASTM A 216 Gr. B/ IS : 210 Gr. GR 220/260 ASTM A 217 Gr. CA 15 BUNA-N SS 316 AISI SS 316 AISI SS 316 AISI SS 316 10.0
MATERIALS OF CONSTRUCTION
DOCUMENTS TO BE SUBMITTED DURING INSPECTION TO OWNER QAP Hydrotest certificate Chemical Test Certificate Warranty Certificate Mechanical test certificate QUANTITY REQUIRED As per Schedule of items and bill of quantities.
b) c) d) e) f) g) 4.0 a)
Plates Seal Spring Body bearing Plate bearing Spring bearing
TESTS TO BE WITNESSED BY OWNER/ CONSULTANT Hydro test Body Seat As per API 598 - do -
5.0 a) b)
WORKMANSHIP FINISH & PAINT Workmanship Finish Good All burrs and sharp edges shall be removed and the inside surface should have smooth finish 1 coat of primer followed by 2 coats of enamel paint
c) 6.0
Painting
MARKING The valves shall be clearly and permanently marked with the following : Manufacturers name and trade mark.
a)
DATA SHEET FOR COPPER ALLOY GLOBE VALVE 1.0 a) b) DESIGN PARTICULARS Fluid to be handled Type /class Water Solid wedge type confirming to IS:778:1984 class-2 6 Kg/cm Screwed ends. 4.0 a) TEST TO BE WITNESSED BY OWNER/ CONSULTANT Hydro test Body :1.6 MPa (gauge) for a test duration 2 min. Seat test:1.6Mpa for a duration 2 Min. WORKMANSHIP FINISH & PAINT Workmanship Finish : Good All burrs and sharp edges shall be removed and the inside surface should have smooth finish 1 coat of primer followed by 2 coats of enamel paint.
c) d) e) f) 2.0 a) b) c) d) e)
Working pressure End connection
5.0 a) b)
Accessories NA Rating /class 16 Kg/cm/Class-2 CONSTRUCTION MODE Body Copper alloy Bonnet Bolted Stem Wedge disc Hand wheel / lever Rising Solid To be provided
c) 6.0
Painting :
MARKING The valves shall be clearly and permanently marked with the following : Manufacturers name and trade mark. Year of manufacture ISI certification mark Nominal pressure of valve Size of valve
3.0 a)
MATERIAL OF CONSTRUCTION Body, bonnet, dome, Leaded Tin Bronze stool cover, wedge, LTB 2 of IS:318-1981 stuffing box, gland, thrust plate and cap Hand wheel Cast iron FG200 of IS:210-1978
a) b) c) d) e)
b)
c)
Stem
f) g) h) i)
Bolts Nuts Gasket Gland packing
7.0 DOCUMENTATION TO BE SUBMITTED WITH OFFER Catalogues/ Literature High tensile brass 8.0 DOCUMENTS TO BE SUBMITTED AFTER ORDER FHTB 1 and FHTB 2 of IS:6912-1973 GA & Cross sectional drawings with part number, Mild steel IS 1367material of construction and major dimensions 1967
and QAP for approval from OWNER/ Consultant.
-DOCompressed asbestos fiber Asbestos
9.0 DOCUMENTS TO BE SUBMITTED DURING INSPECTION TO OWNER a) Hydro test certificate
b) Chemical Test & Mechanical test Certificate c) Warranty Certificate 10.0 QUANTITIES REQUIRED As per schedule of items and quantities.

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KUDREMUKH IRON ORE COMPANY LTD MANGALORE PELLET PLANT INSTALLATION OF ADDITIONAL TWO BALL MILLS AT MANGALORE

MEC/1966E/01/36/S03 Rev. 0 2005 MECON Ltd. All rights reserved.

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3.05 3.06 3.07 3.08

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6.00 6.01 6.02

6.03 6.04 6.05 6.06 7.00

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iii) 2.00 2.01 2.02

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3.00 3.01 3.02

3.05 4.00 4.01

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2.11 2.12 2.13 2.14 2.15

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2.2 2.3 3.0

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