Vol II of II - 20130513 - 130521 PDF

GAIL (INDIA) LIMITED
(A.GOVT OF INDIA UNDERTAKING)
INSTALLATION OF I.P. STATION AT ANKHI, GUJARAT ON 12

GANDHAR-DABKA PIPE LINE
TENDER FOR CONDENSATE RECOVERY SYSTEM

VOLUME II OF II - TECHNICAL
(BID DOCUMENT NO: 110398 B /WGI/GAIL/02-R0)
ETENDER NO. - 8000005361
INTERNATIONAL COMPETITIVE BIDDING
ISSUED DATE: 10.05.2013
ISSUED BY
TABLE OF CONTENTS
S.NO.
DOCUMENT TITLE
DOCUMENT NUMBER
NO. OF
SHEETS
1.0
MATERIAL REQUISITION (MR) FOR CONDENSATE

RECOVERY SYSTEM
11-0398B02-01-09-06-001
2.0
TECHNICAL SPECIFICATION OF CONDENSATE

RECOVERY SYSTEM
11-0398B02-01-09-02-002
10
3.0
PROCESS DESIGN BASIS OF CONDENSATE

RECOVERY SYSTEM
11-0398B02-01-09-04-003
4.0
DATA SHEET OF SLUG CATCHER
11-0398B02-01-09-03-004
5.0
DATA SHEET OF CONDENSATE TANK
11-0398B02-01-09-03-005
6.0
DATA SHEET OF PRESSURE GAUGE
11-0398B02-01-11-03-006
7.0
DATA SHEET OF PRESSURE SAFETY VALVE
11-0398B02-01-11-03-007
8.0
DATA SHEET OF LEVEL GAUGE
11-0398B02-01-11-03-008
9.0
DATA SHEET OF DP TYPE PRESSURE

TRANSMITTER
11-0398B02-01-11-03-009
10.0
DATA SHEET OF FLAME ARRESTOR
11-0398B02-01-11-03-010
11.0
DATA SHEET OF LEVEL TRANSMITTER
11-0398B02-01-11-03-011
10
12.0
TECHNICAL SPECIFICATION OF PRESSURE

GAUGE
11-0398B02-01-11-03-012
13.0
TECHNICAL SPECIFICATION OF PRESSURE

SAFETY VALVE
11-0398B02-01-11-02-013
14.0
TECHNICAL SPECIFICATION OF DP TYPE

PRESSURE TRANSMITTER
11-0398B02-01-11-02-014
14
15.0
TECHNICAL SPECIFICATION OF INSTRUMENT

VALVE & MANIFOLD
11-0398B02-01-11-02-015
Document No.
CONDENSATE RECOVERY
SYSTEM
SHEET 1 of 2
Rev
S.NO.
DOCUMENT TITLE
DOCUMENT NUMBER
NO. OF
SHEETS
16.0
QAP FOR SLUG CATCHER
11-0398B02-01-11-02-016
17.0
QAP FOR CONDENSATE TANK
11-0398B02-01-09-02-017
18.0
LIST OF RECOMMENDED VENDOR FOR

CONDENSATE RECOVERY SYSTEM
11-0398B02-01-09-02-018
19.0
THIRD PARTY INSPECTION AGENCY FOR

11-0398B02-01-11-02-019
20.0
TECHNICAL SPECIFICATION OF TUBES &

FITTINGS
11-0398B02-01-09-02-020
21.0
DATA SHEET OF SUMP PUMP (VERTICALLY

SUSPENDED VESSEL MOUNTED)
11-0398B02-01-11-02-021
22.0
TECHNICAL SPECIFICATION OF PAINTINGS
11-0398B02-01-11-03-022
23.0
P&ID OF CONDENSATE RECOVERY SYSTEM
11-0398B03-01-11-01-003,
SHEET 2 OF 3
24.0
DATA SHEET OF BALL VALVES
11-0398B02-01-11-03-024
25.0
TECHNICAL SPECIFICATION OF BALL VALVES
11-0398B02-01-11-03-025
16
26.0
SCHEMATIC GAD OF SLUG CATCHER
ANNEXURE-I
27.0
SCHEMATIC GAD OF CONDENSATE TANK
ANNEXURE-II
28.0
SCOPE OF PAINTING FOR VESSELS
ANNEXURE-III
Document No.
CONDENSATE RECOVERY
SYSTEM
SHEET 2 of 2
Rev
INSTALLATION OF IP STATION AT ANKHI

GUJARAT ON 12 GANDHAR-DABKA PIPELINE
MATERIAL REQUISITION FOR CONDENSATE RECOVERY

SYSTEM
DOCUMENT NO
11
0398B02
01
CLIENT JOB NO.
TOTAL SHEETS
09
06
001
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
TABLE OF CONTENT
1. SCOPE OF WORK
2. REMARKS
3. SPECIAL INSTRUCTIONS TO BIDDER
4. INFORMATION/ DOCUMENTS/ DRWGS TO BE SUBMITTED BY SUCCESSFUL BIDDER
MATERIAL REQUISITION FOR

Document No.
Rev
11-0398B02-01-09-06-001
SHEET 2 of 6
1.0
SCOPE OF WORK (SOW)
1.1 General
This Specification covers the requirement of scope of supply of Condensate Recovery System intended to
be used as intermediate separation system of LNG/RLNG to be located at ANKHI IP Station on 12
Gandhar-Dabka Pipeline Project.
The Condensate Recovery System consists of a Slug Catcher / Separator and a Condensate Storage Tank
fitted with Vertically Suspended vessel mounted Sump Pump.
1.2 SOW - PIPING/MECHANICAL
The scope of work covers the design, engineering, supply, procurement of material, manufacturing,
assembly at shop, inspection, testing, painting, shipment and supervision during erection & commissioning
of all equipments under Condensate Recovery System along with supply of all Valves and Accessories like
mating Flanges, Blind Flanges, Bolts/Studs, Nuts, Gaskets etc. as per P&I Diagram and documentation
requirements of all following items in accordance with the requirements of this Requisition.
This scope of piping/mechanical work excludes erection and installation of all above equipments and
associated civil, structural & interconnecting piping works for hook-up of Condensate Recovery System with
Metering Skid and Tap-off point.
1.3 SOW ELECTRICAL/INSTRUMENTATION
The scope of work includes supply, erection, installation and commissioning of all equipment mounted
Instrument items as per P&ID and supply of other balance instrument items as per P&ID and data provided
in the Tender to complete the work in all respects.
Supply, Installation, calibration, Loop checking (as required) and commissioning of all the Equipment
mounted Instrument items (Pressure Safety Valves, Temperature Gauge/Thermo-Well, Pressure
Gauges, Differential Pressure Transmitters, Level Transmitter, Level Gauge, Level switch-integrated
Magnetic level gauge, Flame Arrester etc.) shall be in the Equipment Vendors scope including the
supply of all the associated installation materials and consumables. Vendor to note that the supply and
installation of all the Instrumentation items in closed and open control loops shall include the supply of
Zener barriers/isolators wherever applicable.
Supply of Junction Boxes and Cable glands for all the Instrumentation shall be under Vendors scope.
Supply of the main piping Instrument items (like Pressure Gauges, Gas Actuated On-Off Valve, Gas
Filter-Regulator etc.) shall be under the Vendors scope and also including the supply of all the
associated installation materials and consumables.
Supply of small Logic Controller (preferably PLC to be installed at the rear of the existing metering
panel) to carry out Safety Interlock Logics along with all associated accessories and utilities (like
Intrinsically safe barriers, 110V UPS Power Supply and all the redundant power supplies/converters
etc.) shall be under the Vendors scope.
Supply of all the associated and required Cables (Single pair/Multi-pair, Single core/ Multi-core,
Individual shielded/Overall shielded, signal/control/ Power from Field up to the existing Panel in the
control room) shall be under the Vendors scope.
Grounding for shielded cables at a suitable location as instructed by GAIL Engineer-in-charge (During
commissioning)
All paints, primers as per painting specifications in the Tender by vendor

Document No.
Rev
11-0398B02-01-09-06-001
SHEET 3 of 6
Writing tags details for all the Instruments with paint.
Furnishing all the Drawing/Documents for review and approval as per tender document.
Mandatory Spares (10 % subject to minimum one no. for each type of instrument) and minimum 1 no.
commissioning spares required during commissioning shall be under the Vendors scope of supply.
This scope of electrical/instrumentation work excludes modifications (if at all necessary) for the existing
metering panel.
For commissioning of Condensate Recovery System, skilled engineers shall actually commission these
items at site.
1.4 DESCRIPTION OF EQUIPMENTS and/or SERVICES
ITEM
NO.
DESCRIPTION
1.0
Design, Engineering, Manufacturing, Supply, Testing at Works

and Supervision for Pre-Commissioning/Commissioning of Slug
Catcher / Separator suitable for operating flow rate of 0.1
MMSCMD at 33.54 Kg/cm2g operating pressure with Inlet &
Outlet flange of sizes 14 NB & 12 NB and of ANSI rating 600#
respectively along with separate Horizontal Cylindrical
Condensate Storage Tank of 10 KL capacity fitted with
Vertically Suspended Vessel mounted Sump Pump with normal
flow rate of 10.0 m3/hr.
TAG NO.
110398B02-SC-0101
(Slug Catcher /
Separator Skid)
and
110398B02-CT-0101
(Condensate Storage
Tank Skid)
QTY
01 Set
2.0
200% Gasket as Mandatory Spares for each Nozzle/Flange

Joint for all above equipments mentioned in Cl. No. 1.4.1.
3.0
100% Fasteners as Mandatory Spares for each Nozzle/Flange

Joint for all above equipments mentioned in Cl. No. 1.4.1.
2.0
REMARKS
2.1
Suppliers Compliance
Supplier shall submit his bid in full compliance with the requirements of this MR and attachments.
Bidder shall include the following statement in his bid:
We certify that our bid is fully complying with your enquiry dated ....... and referenced
,
Compliance with this material Requisition in any instance shall not relieve the Vendor of his
responsibility to meet the specified performance.
2.2
Compliance with Specification

The supplier shall be completely responsible for the design and engineering, materials, fabrication,
testing, inspection & transfer of above material to nominated delivery point strictly in accordance with
the MR & all attachments thereto.

Document No.
Rev
11-0398B02-01-09-06-001
SHEET 4 of 6
2.3
Suppliers Scope
Suppliers scope of work includes the equipment with all internals & accessories shown on the data
sheets, specifications and all unmentioned parts necessary for a satisfactory operation & testing except
those which are indicated to be out of Suppliers supply.
2.4
Inspection
Supplier shall submit with his bid a list of 3 well known international Third Party inspection Agencies as
per enclosed vendor list, which he intends to use for inspection. This agency will issue all relevant
certificates as per specification & codes.
Inspection shall also be performed by a designated Third Party Inspection agency and/or purchaser as
set out & specified in the codes & particular documents forming this MR.
3.0
SPECIAL INSTRUCTIONS TO BIDDERS
3.1
Bidder to note that no correspondence shall be entered into or entertained after the bid submission.
3.2
Bidder shall furnish quotation only in case he can supply material strictly as per this Material Requisition
and specification/data sheets forming part of Material Requisition.
3.3
If the offer contains any technical deviations or clarifications or stipulates any technical specifications
(even if in line with MR requirements) and does not include complete scope & technical/ performance
data required to be submitted with the offer, the offer shall be liable for rejection.
3.5
The submission of prices by the Bidder shall be construed to mean that he has confirmed compliance
with all technical specifications of the corresponding item(s).
3.6
Bidder must submit all documents as listed in checklist along with his offer.
3.7
Supplier must note that stage wise inspection for complete fabrication, testing including the raw
material inspection to be carried out.
3.8
Vendors for bought out items to be restricted to the approved vendor list attached with Bid document.
Approval of additional vendor if required, for all critical bought out items shall be obtained by the
supplier from the purchaser before placement of order. Credentials/ PTR of the additional vendor
proposed to be submitted by supplier for review and approval of Purchaser/ Purchasers representative.
3.9
All the equipments/materials shall be delivered at GAIL-Ankhi IP Station, Gujarat.
4.0
INFORMATION/ DOCUMENTS/ DRAWINGS TO BE SUBMITTED BY SUCCESSFUL BIDDER

Successful Bidder shall submit six copies unless noted otherwise, each of the following:
4.1
Inspection & test reports for all mandatory tests as per the applicable code as well as test reports for any
supplementary tests, in nicely bound volumes.
4.2
Material test certificates (physical property, chemical composition, make, heat treatment report, etc.) as
applicable for items in nicely bound volumes.
4.3
Statutory test certificates, as applicable.
4.4
Filled in Quality Assurance Plan (QAP) for Purchaser's/ Consultant's approval. These QAPs shall be
submitted in four copies with in 15 days from LOI/ FOI.
4.5
WPS & PQR, as required.

Document No.
Rev
11-0398B02-01-09-06-001
SHEET 5 of 6
4.6
Within two (2) weeks of placement of order, the detailed fabrication drawings along with process and
mechanical design calculations for Purchaser's/Consultant's approval.
4.7
Detailed completion schedule activity wise (Bar Chart), within one week of placement of order.
4.8
Weekly & fortnightly progress reports for all activities including procurement.
4.9
Purchase orders of bought out items soon after placement of order.
4.10
Manufacturer's drawings for bought out items, in 4 copies, for Purchaser's/Consultant's approval within 4
weeks.
4.11
Manufacturer related information for design of civil foundation & other matching items within 6 weeks of FOI
/ LOI.
4.12
All approved drawings / design calculation / maintenance / operating manual documents as well as
inspection and test reports for Owner's / Consultants reference / record in nicely category-wise bound
volumes separately.
4.13
A list of documents to be furnished along with supply.
4.14
Vendor to furnish filled up documents / formats as per Appendix 9 - Special instruction to Bidders along
with the offer.
Note:
All drawings, instructions, catalogues, etc., shall be in English language and all dimensions shall be metric
units.

Document No.
Rev
11-0398B02-01-09-06-001
SHEET 6 of 6

GUJARAT ON 12 GANDHAR-DABKA
PIPELINE
TECHNICAL SPECIFICATION OF
DOCUMENT NO
11
0398B02
01
CLIENT JOB NO.
TOTAL SHEETS
10
09
02
002
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
TABLE OF CONTENT
1.0
GENERAL ....................................................................................................................3
2.0
STANDARDS AND CODES ...........................................................................................3
3.0
SCOPE OF SUPPLY ......................................................................................................4
4.0
TECHNICAL REQUIREMENTS... ........................6
5.0
TESTING AND INSPECTION .........................................................................................7
6.0
TESTING AND INSPECTION .........................................................................................8
7.0
DOCUMENTATION ........................................................................................................8
8.0
NAME PLATE.. ...9
9.0
PROTECTION AND PAINTING ......................................................................................9
10.0
SHIPPING ...................................................................................................................10
11.0
REJECTION ..............................................................................................................110
12.0
INFORMATION TO BE SUPPLIED WITH TENDER .......................................................11
13.0
WARRANTY & DEFECT LIABILITY PERIOD.....11
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 2 of 10
1.0
GENERAL
This specification together with all data sheets and specifications enclosed covers the requirements
for design, engineering, procurement of material, manufacturing, assembly at shop, inspection,
testing, painting & supervision of installation and commissioning, shipment and documentation
requirements along with all the accessories.
In the event of any conflict between this specification, datasheets, related standards codes etc., the
more stringent shall apply.
1.1
Datasheet for Slug Catcher / Separator, Condensate Storage Tank, Pressure Gauge, Pressure Safety
Valve, Level Indicator etc. are enclosed.
However, this does not absolve the bidder of the responsibility for proper selection with respect to the
fluid & its operating conditions. Proper sizing & selection of Slug Catcher, pressure safety valves etc.
and accessories are bidders responsibility.
Sizing Calculation required for above items shall be submitted for Client/ consultant review.
Following information shall be furnished as a part of design & engineering:
Make, model and detail specification of all Equipments.

Fixing pressure drop across all Equipments.
Sizing of all Equipments, PSV etc..
Selection of ranges for Pressure Gauges etc.
Design performance characteristics of all Equipments.
Overall dimension of all Equipments.
Empty & Hydro Test Weight of all Equipments.
1.2
Bidder shall consider all the requirements of this specification along with those as per relevant
standards and shall assume total responsibility including all aspects of engineering, design, and
certification etc. for Slug Catcher.
1.5
Bidder to note that all the items of the Slug Catcher shall be procured from reputed bidders as per the
attached Bidder list.
1.6
Bidders quotations shall include the detailed specifications for all the items of Slug Catcher. The
bidder shall also offer data sheet / specification of any instruments / equipments required for safe and
efficient operation of the system.
1.7
All units of measurements in bidders specification sheets shall be same as those in attached data
sheets of Slug Catcher, pressure safety valves, pressure gauges.
1.8
Bidder shall enclose catalogues giving detailed technical specification and other information for Slug
Catcher, pressure safety valve, pressure gauges covered in the bid.
1.9
Bidder shall submit subsequent to award of contract the sizing details & specification of all the
instruments make and model etc. The relevant catalogue, technical literature shall also be furnished.
1.10
All drains/vents should be having provision for putting end cap and shall be complete with wire seal.
2.0
STANDARDS AND CODES

Following principal codes and standards (Latest Edition) and in accordance with the relevant Institute
of Gas Engineers (IGE) codes shall be followed for design, manufacture, testing etc. of the
equipments.
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 3 of 10
ASME Boiler and Pressure Vessel code

Section V
:
Non destructive examination
Section VIII
:
Pressure Vessel, Division-1
Section IX
:
Welding and brazing qualification
American National Standard Code
ANSI/ASME B 16.5
:
Flanges and Flange fittings
ANSI/ASME B31.8
:
Gas Transmission and Distribution Systems
ANSI/ASME B 16.20
:
Metallic gaskets for pipe flanges
ANSI/ASME B 1.20.1 :
Pipe threads general purpose (inch)
ANSI/ASME B 16.34
:
Valves flanged, threaded & welding ends
ANSI/ASME B 16.1
:
Forged Steel Fittings Socket Welded & Threaded
ANSI/ASME B 16.47
:
Large Diameter Steel Flanges
ANSI/ASME B 36.10
:
Welding & Seamless Wrought Steel Pipe
ANSI/ASME B 16.21
:
Design of Non-Metallic Gasket
ASME Sec-II & ASTM :
Material Specifications
American Petroleum Institute
API RP 520
:
API RP 521
API RP 550
API 6 D
API 527
:
:
:
:
Part -1 & 2, Design. and installation of pressure relieving system in

refineries
Guide for Pressure relief and Depressing Systems.
Manual on installation of refinery instrument and control system.
Specification for pipeline valves, end closures and swivels.
Commercial Seat Tightness of safety relief valves with Metal-to-Metal
seats.
British Standard Specifications

BS 449
:
Structural steel work
BS 1515
:
Materials of Slug Catcher.
Instrumentation
Instrumentation shall generally be in accordance with the applicable sections of the following principal
codes of practice (latest editions).
BS 1041
:
Code for temperature measurement.
BS 1042
:
Code for measurement of fluid flow in pipes.
BS 5501
:
Part-1, Electrical apparatus for potentially explosive atmospheres.
API RP 550
:
Manual on Installation of Refinery Instrument Control Systems.
API RP 521
:
Guide for Pressure relief & Depressurising Systems.
ISA A 5.1
:
Instrument Symbols & Identification
BS 2765
:
Thermowell.
For purpose of material selection, national code of the country of origin shall also be acceptable
provided the bidder specifically establishes, to the satisfaction of purchaser, the equivalence or
superiority of the proposed material with respect to those specified.
3.0
SCOPE OF SUPPLY
3.1
Bidders scope shall include but not limited to:i)
Slug Catcher Vessel along with necessary internals (with SS Mesh), internal and external
supports, lifting lugs and flanged connections at inlet, outlet, drain, vent and necessary nozzles
with flanges & blind flanges fitted with bolts, nuts and gaskets for other utility services and
instrumentations.
ii)
Supply of PSV, Pressure Gauges, Level Indicator and all other necessary instruments etc. as
per Instrumentation Data Sheets, P&I Diagram and relevant codes/standards.
iii)
Ladder, Access Platform and Holding Clamps/Cleats etc.
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 4 of 10
iv)
Anchor/Foundation bolts with nuts & washers and base plates.
v)
Protective coating & painting of equipments.
vi)
Documents as called for in bidder data requirements.
vii)
Recommended Spares for two years of Normal Operation :

Bidders shall furnish a separate price list of the recommended spares (exclusive of quoted price)
for two years of normal operation for the system along with Bid. However, the actual supply of
these recommended spares, if required, shall be as per Purchasers advice.
viii) Mandatory Spares :

200% Gasket for each Nozzle/Flange Joint for both Slug Catcher / Separator and Condensate
Storage Tank.
100% Fasteners for each Nozzle/Flange Joint for both Slug Catcher / Separator and Condensate
Storage Tank.
Prices for above spares shall be inclusive of quoted price.
ix)
Start-up & Commissioning Spares (In addition to Cl.3.1.viii) :

100% Gasket for each Nozzle/Flange Joint for both Slug Catcher / Separator and Condensate
Storage Tank.
Prices for above spares shall be inclusive of quoted price.
x)
Interconnecting piping, tubing, fittings, valves, instruments with fittings, necessary nozzles,
flanges, blind flanges (fitted with bolts, nuts, gaskets etc.) etc. as required for the installation of
Instruments.
xi)
List of special installation tools / spare parts as required for two years normal operation and
maintenance.
xii)
Any other item required to complete the Slug Catcher and condensate storage tank in all
respects as per technical specs mentioned in tender document.
3.2
The Slug Catcher and Condensate Storage Tank shall be completed in all respects, ready for
Installation and commissioning.
3.3
There shall be minimum work to be done at site. All field mounted instruments shall be supplied
loose to avoid damages during transportation of the Slug Catcher and condensate storage tank.
The details regarding Installation of Slug Catcher and condensate storage tank shall be clearly
described in the Installation Manual especially made for installation of condensate recovery
system.
3.4
All items in the Slug Catcher and condensate storage tank shall be properly supported to avoid
vibration. Special supports, if required, shall also be supplied by bidder.
3.5
All piping materials shall be as per piping material specification/codes specified. The piping fabrication
work shall confirm to the requirements of ANSI B31.3.
3.6
The Slug Catcher and condensate storage tank shall be sized considering ease of transportation.
3.7
All the instrument enclosures mounted in the field shall be weather proof / ex proof conforming to IP55/ NEMA 4/ NEMA 7 as a minimum.
3.8
The Slug Catcher and condensate storage tank shall be installed in accordance with local
government rules and regulations applying to such facilities. The bidder shall be responsible for
determining all applicable requirements and ensuring compliance.
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 5 of 10
3.9
The bidder shall read the specification in conjunction with following documents enclosed :
i)
P & lDs.
ii)
Data Sheets.
iii)
Technical Specifications.
3.10
Commissioning spares as required shall be included as part of the offer. A separate list should be
attached along with the bid.
3.11
Bidder shall quote separately for two years operation and maintenance spares for the condensate
recovery system as per the SOR.
3.12
The pressure safety valves as indicated shall be vented 3 meters above the highest point of working
platform with proper support, rain cap, bug screen.
3.13
Any soft material used in Slug Catcher and condensate storage tank shall be able to retain its
functional properties in inventory for minimum period of 3 years.
3.14
The allowable tolerance in the set pressure for the pressure safety valves shall be as per relevant
codes.
3.15
The pressure safety valves shall meet the seat tightness requirement as per API 527.
3.16
All materials to be used in construction of valves shall be suitable for Wet Natural Gas services.
3.17
All the calculations and units of measurement shall be metric standards only.
3.18
All the instruments mounted on the Slug Catcher and condensate storage tank shall be suitable for
installation in tropical hot and humid climate.
Temp range: 0 - 65 deg. C
Relative Humidity: 95 %
3.19
Flow direction shall be clearly marked on the Slug Catcher body.
3.20
Field mounted instruments shall be capable of working under high ambient temperature and
environmental condition without any degradation in accuracy and repeatability.
3.21
End connection details of Slug Catcher and condensate storage tank shall be as per data sheets.
3.22
a) Bidder shall take single point responsibility for the design, fabrication, assembly, testing and
Performance of the Slug Catcher and condensate storage tank.
b) The fabrication, assembly, testing and inspection works have to be carried out at Bidders works or
works designated by the Bidder. In case of Bidder designated works, the facility should have
established track record.
4.0
TECHNICAL REQUIREMENTS :
1)
The Slug Catcher shall be provided with internal Stainless Steel Mist Separator. However baffle
plates & partition wall etc. shall be at par with shell material. Fabrication of Slug Catcher shall
conform to all applicable ASME code requirements and will carry AMSE U Stamp (mandatory).
2)
Slug Catcher must withstand a hydro-test pressure of 83.2 kg/cm2 (g) for a holding period of at
least one hour without breaking or failure.
3)
Bidder shall submit back-up documents & calculation for sizing of the equipment together with all
supportive documents / Catalogues / Monographs etc. along with BID. The type, model and
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 6 of 10
MOC of Condensate Recovery System shall be selected based on process design basis, data
sheets and suppliers recommendations. No deviation in MOC will be allowed during Bidding.
4)
All nozzles / pipes on the main vessel shall be of seamless construction. All nozzles less than or
equal to 50 NB size shall be provided with two nos. 6.0mm thk. stiffeners at 90 degrees apart. All
nozzles from 65NB and above shall be provided with reinforcing pads.
5)
All flanges mounted on the vessels shall be WNRF type unless otherwise specified. Dimension
of flanges including shell flanges, nozzle flanges and blind flanges shall be as per ANSI B16.5
up to 24 (600mm) NB. Larger flanges shall be as per ANSI B16.47, Series-A.
6)
Pressure parts joined by butt welds shall be with full penetration welds. Where both side 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.
7)
Vessels shall be post weld heat treated, whenever it is required due to service requirement or
due to code requirements and no welding shall be permitted after post weld heat treatment is
completed.
8)
The Slug Catcher and condensate storage tank shall be provided with lifting and earthling lugs.
Fire proofing and insulation of support shall be provided if mentioned in data sheet.
9)
The piping items shall conform to specification and data sheets included in the Engineering
documents.
10) The Slug Catcher and condensate storage tank shall be supplied in single unit individually.
11) Piping material (pipes, fittings, flanges, etc.) for high point vents shall be supplied loose by
bidder to be installed and assembled at site.
12) Bidder shall submit general arrangement drawings for Slug Catcher and condensate storage
tank indicating the elevations of inlet and outlet flanges, overall dimensions along with the empty
and hydro test weights of the individual units.
13) Bidder shall furnish details of Slug Catcher and condensate storage tank foundation along with
load.
14) Bidders shall submit the sizing calculation of Pressure Safety Valve.
15)
Slug Catcher mounting configuration shall be Vertical (Above Ground) and that of for
condensate storage tank shall be horizontal (Under Ground).
16) Bidder to provide Load Calculation of all nozzles mentioning Allowable Forces, Moments &
Thermal Growth.
17) The followings are included in Bidders scope of work :
The necessary load data and foundation layout plan required for the design and construction
of foundation shall be provided by the bidder.
6.0
TESTING AND INSPECTION
6.1
Bidder shall submit Quality Assurance (QA) procedures before commencement of fabrication.
Approved QA procedures shall form the basis for equipment inspection. All materials and equipments
shall be factory tested before shipment in the presence of purchaser / its authorized inspection
agency. No material shall be transported to site until all required tests have been carried out and
equipment is certified as ready for shipment. Acceptance of equipment or the exemption of inspection
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 7 of 10
or tests thereof, shall in no way absolve supplier of the responsibility for delivering equipment meeting
the requirements of the specifications.
6.2
Testing at Bidders Works shall include but not limited to the following :
Non destructive tests such as radiography, dye penetration tests.
Hydrostatic test at 130% of design pressure for the vessel usually for 1 hour. Pressurize step
by step @ 25% each step and holding time of 10 min. Once reached 100%, hold for 1 hour.
Any other tests as per data sheet / standards / codes.
6.3
Extent of radiography shall be 100% for Slug Catcher only.
6.4
Bidder shall submit the following documents / certificates for review by the purchaser / its authorized
inspection agency before starting inspection. Supplier shall be responsible for testing and complete
integration of the system. Detailed procedures of test and inspection shall be submitted by the
supplier for review before order and mutually agreed upon.
1. Material test certificate, hydrostatic test certificate of pressure safety valves and for all piping /
valves of the Slug Catcher.
2. Calibration certificate for pressure safety valve for set pressure and all field instruments.
3. Seat tightness test certificate for pressure safety valves.
4. Test certificate for all field instruments such as PG etc.
5. Certificates from statutory body for field instruments being flame proof and weather proof.
6. Interconnecting piping material testing and NDT of welds as per PMS.
7. The vessel hydrostatic test certificate.
8. Leak test certificate of complete Slug Catcher with air/N2, if required.
9. Slug Catcher functional testing considering pressure regulation, limiting and safety characteristics.
6.5
For all above activities, labour, consumable, equipment and utilities as required shall be in bidders
scope.
7.0
DOCUMENTATION
Data requirement indicates detailed drawings, data and catalogues required from the bidder. The
required number of reproducible and prints should be dispatched to the address mentioned, adhering
to the time limits attached.
Final drawings from the bidder shall include dimensional details, weight, mounting details and any
other special requirements etc. for the Slug Catcher and condensate storage tank. All dimensions in
general shall be in millimeters. Bidder shall furnish all manuals necessary to test, operate and
maintain, the system.
8.0
NAME PLATE
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 8 of 10
Each equipment of condensate recovery system and all the instruments mounted on the equipment
body shall have a SS name plate attached firmly to it at a visible place furnishing the following
information:
Tag number as per Purchasers data sheets.
.Body sizes in inches and the valve Cv (for Pressure Safety valves).
Set pressure range (for Pressure Safety valves).
Flow range in MMSCMD.
Rating
Manufacturers Name & model number
9.0
PROTECTION AND PAINTING
9.1
All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside and outside to
remove scale, rust, dirt and other foreign materials by wire brushing and sand blasting as applicable.
Minimum acceptable standard in case of power tool cleaning shall be St. 3 and in case of blast
cleaning shall be Sa 2-1/2 as per Swedish Standard SIS 0055900.
9.2
Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials, insulated
surfaces of
equipment and pre-painted items shall not be painted.
9.3
Stainless steel surfaces both inside and outside shall be pickled and passivated.
9.4
Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
9.5
Depending on the environment, following primer and finish coats shall be applied.
1)
2)
3)
4)
Environment
Description
Normal Industrial
Surface Preparation
Primer
:
:
Sa 2-1/2
2 coats of red oxide zinc chromate each 25
micron thick
Finish coat
2 coats of synthetic enamel, each 25 micron

thick.
Surface Preparation
Primer
:
:
Sa 2-1/2
2 coats of epoxy zinc chromate each 35
micron thick
Finish coat
2 coats of epoxy high build paint, each 100

micron thick.
Surface Preparation
Primer
:
:
Sa 2-1/2
2 coats of high build chlorinated rubber zinc
phosphate each 50 micron thick
Finish coat
2 coats of chlorinated rubber paint, each 35

micron thick.
Surface Preparation
Sa 2-1/2
Finish coat
2 coats of heat resistant aluminium paint

suitable for specified temp, each 20 micron
thick.
Corrosive Industrial
Coastal & Marine
All Environment
(80-4000 C)
(All values refer to dry film thickness).
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 9 of 10
9.5.1
The Slug Catcher in carbon steel body shall be painted light gray (RAL 7038) and Interconnecting
piping shall be canary yellow, unless otherwise specified. However, the colour of finish coat shall be
confirmed to bidder after placement of order.
9.6
Bidder to ship supply of primer and the paint to permit on-site repair of shipping damage (if any) to the
factory coatings.
10.0
SHIPPING
10.1
All threaded and flanged opening shall be protected to prevent entry of foreign material.
10.2
All the field mounted instruments shall be supplied loose to avoid damages during transportation.
10.3
Condensate recovery system shall bear proper shipping markings.
10.4
Shipping details like gross wt., net wt., volume, dispatch point, mode of dispatch, mode of package
etc. for each equipment shall be provided with the offer.
11.0
REJECTION
Bidder shall make his offer in detail, with respect to every item of the Purchasers specification. Any
offer not conforming to this shall be summarily rejected.
12.0
INFORMATION TO BE SUPPLIED WITH TENDER

The Bidder shall provide at the time of tendering a complete detailed engineering package in
accordance with the bidder data requirement and shall include but not necessarily be limited to the
same.
13.0
WARRANTY& DEFECT LIABILITY PERIOD

The Bidder shall as required by the Engineer in charge and without additional cost to Owner (unless it
can be shown that defects and deficiencies have occurred through Owners negligence), amend repair
or replace with new materials any defects or deficiencies in terms of performance in the plant and/or
work which become apparent at any time or from time to time, within the period of twelve (12) months
occurring from the date of commissioning or 18 months from the date of arrival of the material at site,
whichever is earlier.
If the Bidder does not make good those defects or deficiencies in the plant and/or work within a
reasonable time of having been given prior written notice by the Engineer In charge to do so, the
Engineer In -charge may arrange for such defects or deficiencies to be remedied by others at the risk
and expenses of the Bidder, but without prejudice to any other rights which Owner has under the
Contract in respect of those defects or deficiencies.
Bidder shall note that they shall submit the offer with full details as desired in the tender document.
Bidder shall submit the enclosed CHECK LIST & TECHNICAL QUESTIONNAIRE duly filled in
along with sets of offers to avoid further queries and to ensure proper evaluation of offer. If these are
not complied with, offer is liable to be rejected.
CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-002
SHEET 10 of 10

CLIENT JOB NO.
TOTAL SHEETS
PROCESS DESIGN BASIS
DOCUMENT NO.
11
0398B02
01
09
04
003
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
AP
PR
TABLE OF CONTENT
PROCESS DATA........................................................................................................ 3
1
1.1
Gas composition.3
1.2
Battery Limit..................................................................................................................3
1.2.1
Data For Slug Catcher.................................................................................................3
1.2.2
Data For Condensate Storage Tank.............................................................................3

DESIGN BASIS.............................................................................................................3
2
2.1
Efficiency of Slug Catcher 98%...................................................................................3
2.2
Particle Size Removal in Slug Catcher 10 micron........................................................3
PROCESS DESCRIPTION ...........................................................................................4
SLUG CATCHER DATA SHEET...................................................................................5

4.1
Weir Plate.6
4.2
Mist Eliminator.6
4.3
Vortex Breaker (Condensate Outlet)6
RESTRICTION ORIFICE DATA SHEET.......................................................................6
CONDENSATE TANK DATA SHEET ...........................................................................7
Document No.
Rev
11- 0398B02- 01-09- 04- 003
SHEET 2 of 7
1.0
1.1
PROCESS DATA
Gas composition
Gas Constituent
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
n-Pentane
Hexane
CO2
N2
NCV kcal/m3
GCV kcal/m3
Sp. Gr. at 15oC
M.W.
1.2
Battery Limit
1.2.1
Data For Slug Catcher
1.2.2
2.0
v/v percent
73.79
8.24
8.81
2.21
2.01
0.61
0.47
0.44
3.34
0.08
10698.35
11772.21
0.8078
23.29
Operating Fluid
Gas Flow Rate (Norm/Design)
Operating Pressure (Norm/Design)
Operating Temperature (Norm/Design)
ANSI Pressure Rating Class
Natural Gas
0.1/0.12 MMSCMD
33.54/64 kg/cm2
25.33/65 oC
600 #
Corrosion Allowance
3.0 mm
Data For Condensate Storage Tank

Condensate Flow Rate (Norm/Design)
Operating Pressure (Norm/Design)
Operating Temperature(Norm/Design)
Inlet Flange (NB)
ANSI Pressure Rating Class
3.62/4.34 KL/day
Atmospheric/3.5 kg/cm2
Ambient/65 oC
4 Inch
150 #
Corrosion Allowance
3.0 mm
DESIGN BASIS
Efficiency of Slug Catcher
Particle Size Removal in Slug Catcher
98%
10 micron and above
Document No.
Rev
11- 0398B02- 01-09- 04- 003
SHEET 3 of 7
3.0
PROCESS DESCRIPTION
The GAIL is in the process of introducing a Condensate Recovery System at Intermediate Pigging
Station at Ankhi, Gujarat on 12 Gandhar-Dabka Pipeline. Natural Gas will be distributed from 12 NB
main pipe. From 12 NB Main Line, one line will go to Pig Receiver, another line will go to slug catcher.
Based on data collected from CASE-2 of Simulation Results, vide EIL Doc. No. 6921-04-41-TSR-10010, the Condensate Recovery System is proposed to collect 3620 litres of condensate per day for a
operating gas flow rate of 0.10 MMSCMD.
The proposed Condensate Recovery System consists of a Slug Catcher/ Separator, a Condensate
Recovery Tank fitted with Vertically Suspended Sump Pump. There will be two stage separations -Gas
and Solid contaminated condensate. Gas will be collected from top part of the slug catcher / Separator
and Condensate from bottom part of slug catcher and finally will be stored in underground Condensate
storage tank.
Document No.
Rev
11- 0398B02- 01-09- 04- 003
SHEET 4 of 7
PROCESS DATA SHEET OF SLUG CATCHER

General Characteristics
1
2
3
4
5
Type of Vessel
No. of Phases
Internal Diameter (mm)
Length (mm)
Mist Eliminator
Slug Catcher
2
1000
5000
Yes
6
7
8
9
10
11
12
13
Operating Conditions
Operating Pressure (kg/cm2 g)
Operating Temperature( Deg C)
Design Pressure (kg/cm2 g)
Design Temperature( Deg C)
Operating Flow Rate of Gas (MMSCMD)
Gas Density (kg/m3)
Molecular Weight (kg/kmol)
Actual Flow Rate of Liquid (kl/day)
33.54
25.33
64
65
0.1
Refer Process Data
Refer Process Data
3.62
28
29
30
Performance
Efficiency
Particle Size to be removed (m)
Slug Catcher Dimension( ASME VIII Div I)
Vessel ID (mm)
Vessel Length -TL/TL (mm)
Weir Plate Height (mm)
Weir Plate Distance from TTL (mm)
Condensate Liquid Level
Low Liquid Level LLL (mm)
Low Low Liquid Level LLLL (mm)
High Liquid Level HLL (mm)
High High Liquid Level HHLL (mm)
Normal Liquid Level NLL (mm)
Height of Gas Flow Region (mm)
Mix Flow Region (mm)
Condensate Section Dimensions
Vessel ID (mm)
Condensate Section Length (mm)
Hold up Time (minutes)
HHLL-HLLL (Minutes)
HLL-LLL (Minutes)
LLL-LLLL (Minutes)
31
32
33
Gas Inlet Nozzle (inch)

Gas Outlet Nozzle (Inch)
Liquid Outlet Nozzle (Inch)
14
15
16
17
18
19
20
21
22
23
24
25
26
27
98%
10 and above
1000
5000
200
3500
200
150
400
450
300
450
150
1000
1500
56.00
589.63
30.40
Nozzle Size
14
12
4
Document No.
Rev
11- 0398B02- 01-09- 04- 003
SHEET 5 of 7
PROCESS DATA SHEET OF WEIR PLATE

1
2
3
Type
Segment Height (mm)
Material of Construction
Fixed
200
SA 516 Gr.70 OR
SUPERIOR
PROCESS DATA SHEET OF MIST ELIMINATOR

1
2
3
4
Type
Thickness (mm)
Segment Height (mm)
Mesh Pad
150
500
SS316
PROCESS DATA SHEET OF VORTEX BREAKER (CONDENSATE OUTLET)

1
2
3
Type
Size (Inch)
Cross Type
4
SA 516 Gr.70 OR
SUPERIOR
PROCESS DATA SHEET OF RESTRICTION ORIFICE

1
2
3
4
5
6
7
8
9
10
11
Size (Inch)
Class (#)
No. of Phases
Type
Length (mm)
Service Fluid
Operating Temperature (oC)
Gas Density (kg/m3)
Gas Flow Rate (MMSCMD)
Condensate Flow Rate (MMSCMD)
4
600
1
Concentric
Refer Vendor Data
Hydrocarbon
Condensate
33.54
25.33
Refer Process Data
0.1
3.62
Document No.
Rev
11- 0398B02- 01-09- 04- 003
SHEET 6 of 7
PROCESS DATA SHEET OF CONDENSATE TANK
1
2
3
4
5
6
7
8
9
10
11
12
Type of Vessel
No. of Phases
Internal Diameter (mm)
Vessel Length - TL/TL (mm)
Volume (m3)
Operating Temperature (oC)
Design Pressure (kg/cm2 g)
Design Temperature( Deg C)
HLL (mm)
LLL (mm)
Hold Up Time (Days)
Condensate Tank
1
2000
5000
15.71
Atmospheric
Ambient
3.5
65.0
1800
200
7.4
Document No.
Rev
11- 0398B02- 01-09- 04- 003
SHEET 7 of 7
CLIENT :
QUANTITY
GAIL India Limited

01 No.
TAG NO. : 110398B02-SC-0101

Flow Rate : MMSCMD
Pressure : kg/cm 2g
S.No.
UNITS :
VESSEL TYPE
Horizontal, Cylindrical, Dished Ends, Skid Mounted, Above Ground
SERVICE
Natural Gas
Temperature : Deg. C
OPERATING CONDITION
FLOW RATE (MMSCMD) at 33.54 kg/cm2g Pressure - Norm / Design 0.1 / 0.12
SPECIFIC GRAVITY
GAS INLET / OUTLET SIZE (Inch NB)
14.0 / 12.0
OPERATING PRESSURE (kg/cm2g) - Norm / Design
33.54 / 64.0
0.8078
OPERATING TEMPERATURE (oC) - Norm / Design
25.33 / 65.0
CORROSION ALLOWANCE (mm)
3.0
ALLOWABLE PRESSURE DROP (kg/cm2g) - Clean / Dirty
0.1 / 0.3 (Max.)
MATERIAL OF CONSTRUCTION
10
SHELL / DISHED ENDS / REINFORCING PADS / BAFFLES /

PARTITION WALL ETC.
ASTM A516 GR.70 OR SUPERIOR
11
NOZZLE NECKS / FABRICATED NOZZLE NECKS
ASTM A106 GR.B / ASTM A516 GR.70 OR SUPERIOR
12
NOZZLE FLANGES / MANWAY & FABRICATED FLANGES
ASTM A105 / ASTM A516 GR.70 OR SUPERIOR
13
BOLTING
ASTM A193 GR.B7 & ASTM A194 GR.2H
14
FITTINGS
ASTM A234 GR.WPB
15
SKIRT / LEG SUPPORT
ASTM A516 GR.70 OR SUPERIOR
16
GASKET / O-RING
GRAFOIL FILLED SPIRAL WOUND WITH SS 316L METAL WINDING / BUNA-N
17
NAME PLATE / MIST SEPARATOR
SS 316 / SS 316
DESIGN & CONSTRUCTION

18
DESIGN CODE
ASME -SEC VIII, DIV-1, Latest Edition
19
DESIGN PRESSURE (kg/cm2g)
64.0
20
HYDROSTATIC TEST PRESSURE (kg/cm2g)
83.2
21
DESIGN TEMPERATURE (C)
65.0
22
MAKE / MODEL NO.
23
NAME OF MANUFACTURER
24
ANSI RATING OF FLANGES
600#
25
FACING OF FLANGES
125 AARH
26
TYPE OF FLANGES
WNRF
27
CONDENSATE OUTLET SIZE (Inch NB)
4.0
28
DRAIN SIZE (Inch NB)
2.0
29
PSV INLET CONNECTION SIZE (Inch NB)
2.0
30
MANWAY SIZE (Inch NB)
24.0
31
INSTRUMENTS CONNECTION SIZE (Inch NB)
As per P&I Diagram
32
WIND SPEED (m/s)
47.0
33
EARTH QUAKE ZONE / FACTOR AS PER IS-1893, 2002
Seismic Zone III, Zone Factor = 0.16
34
INSULATION (TYPE & THICKNESS)
35
PRODUCT TO BE REMOVED
Condensate (in liquid state contaminated with solid particles)
36
GAS COMPOSITION
As per Tender Specification
37
SURFACE PREPARATION & PAINTING
38
CONDENSATE FLOW RATE (kl/Day) - Norm / Design
3.62 / 4.34
39
PARTICLE SIZE TO BE REMOVED (micron)
40
EFFICIENCY OF SLUG CATCHER (%)
41
OVERALL LENGTH (mm)
42
OVERALL HEIGHT (mm)
43
VESSEL INSIDE DIA. (mm)
44
VESSEL WALL THICKNESS (mm)
45
DISHED END THICKNESS (mm)
46
SKIRT/SADDLE THICKNESS (mm)
47
EMPTY WEIGHT (kg)
48
OPERATING WEIGHT (kg)
49
HYDROTEST WEIGHT (kg)
50
INSULATION CLEATS
51
LIFTING LUGS
Yes
52
ANCHOR / FOUNDATION BOLTS & NUTS
Yes
53
BLIND FLANGES, BOLTS, NUTS & GASKETS FOR DRAIN, VENT,

UTILITY CONNECTIONS ETC.
Yes
54
LADDER & PLATFORM WITH HOLDING CLEATS & FASTENERS
Yes
55
PRESSURE SAFETY VALVE
Yes
56
LEVEL INDICATOR CUM TRANSMITTER
Yes
57
DRAIN, VENT & UTILITY CONNECTION VALVES
As per P&I Diagram
58
DIFFERENTIAL PRESSURE INDICATOR CUM TRANSMITTER
Yes
DIMENSION & WEIGHT
ACCESSORIES
DATA SHEET OF
SLUG CATCHER / SEPARATOR
DOCUMENT NO.
REV.
11-0398B02-01-09-03-004
SHEET 1 OF 2
CLIENT :
QUANTITY
GAIL India Limited

01 No.
TAG NO. : 110398B02-SC-0101

S.No.
UNITS :
Flow Rate : MMSCMD
Pressure : kg/cm 2g
INSPECTION & TESTING

59
60
61
62
FULL (100%)
AS PER CODE
YES
YES
RADIOGRAPHY
PWHT
HYDROTESTING
DP / MP TEST
NOTES :
1. ( * ) BIDDER TO SPECIFY.
2. ALL CS MATERIALS SHALL BE OF FULLY KILLED QUALITY.
3. FLANGES SHALL CONFORM TO ASME B16.5
4. GASKETS SHALL CONFORM TO ASME B16.20.
5. TAG NOS. SHALL BE PRECEDED BY "398B02" FOR ALL EQUIPMENTS / INSTRUMENTS I.E. FOR PRESSURE INDICATOR "PI-XXXX" SHALL BE READ AS
"398B02-PI-XXXX".
6. BIDDER TO PROVIDE LOAD CALCULATIONS OF ALL NOZZLES MENTIONING ALLOWABLE FORCES, MOMENTS AND THERMAL GROWTH.
7. BIDDER SHALL SIZE THE PRESSURE RELIEF VALVE FOR FIRE SAFE.
8. VESSEL SHALL BE PROVIDED WITH INLET & OUTLET NOZZLE, MIST SEPARATOR, SUITABLE BAFFLES / INTERNALS, DRAIN & VENT CONNECTIONS,
PRESSURE SAFETY VALVE, LEVEL INDICATOR CUM TRANSMITTER, DIFFERENTIAL PRESSURE INDICATOR CUM TRANSMITTER AND OTHER
INSTRUMENTATIONS AS MENTIONED IN P&I DIAGRAM OF SLUG CATCHER (SEE ANNEXURE-I).
9. VENTING SIZE CALCULATION SHALL BE AS PER API-2000 (LATEST EDITION).
DATA SHEET OF
SLUG CATCHER / SEPARATOR
DOCUMENT NO.
REV.
11-0398B02-01-09-03-004
SHEET 2 OF 2
CLIENT :
QUANTITY
GAIL India Limited
INSTALLATION OF IP STATION AT ANKHI GUJARAT

ON 12 GANDHAR-DABKA PIPELINE
01 No.
TAG NO. : 110398BO2-CT-0101

S.No.
UNITS :
Flow Rate : KL/Day
Pressure : kg/cm g
OPERATING CONDITION
1
2
3
4
5
6
7
8
VESSEL TYPE
SERVICE
CONDENSATE FLOW RATE (kl/Day) - Norm / Design
SPECIFIC GRAVITY (Assumed)
INLET SIZE (Inch NB)
OPERATING PRESSURE (kg/cm 2g) - Norm / Design
OPERATING TEMPERATURE (oC) - Norm / Design
CORROSION ALLOWANCE (mm)
Horizontal, Cylindrical, Dished Ends, Skid Mounted, Under Ground, Buried

Liquid Condensate (separated from Wet Natural Gas)
3.62 / 4.34
0.8078
4.0
Atmospheric / 3.5
Ambient / 65.0
3.0
MATERIAL OF CONSTRUCTION
10
11
12
13
14
15
16
SHELL / DISHED ENDS / REINFORCING PADS / BAFFLES /

PARTITION WALL ETC.
NOZZLE NECKS / FABRICATED NOZZLE NECKS
NOZZLE FLANGES / MANWAY & FABRICATED FLANGES
BOLTING
FITTINGS
SKIRT / LEG SUPPORT
GASKET
NAME PLATE
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
DESIGN CODE
DESIGN PRESSURE (kg/cm 2g)
HYDROSTATIC TEST PRESSURE (kg/cm2g)
DESIGN TEMPERATURE (C)
MAKE / MODEL
NAME OF MANUFACTURER
FLANGE RATING
FLANGE FACING
FLANGE TYPE
INLET SIZE (INCH NB)
DRAIN SIZE (INCH NB)
PSV CONNECTION SIZE (INCH NB)
MANWAY SIZE (INCH NB)
INSTRUMENTS CONNECTION SIZE (INCH NB)
WIND SPEED (m/s)
EARTH QUAKE ZONE / FACTOR AS PER IS-1893, 2002
INSULATION (TYPE & THICKNESS)
PRODUCT TO BE REMOVED
Gas Composition
SURFACE PREPARATION & PAINTING
37
38
39
40
41
42
43
44
45
OVERALL LENGTH (mm)

OVERALL HEIGHT (mm)
VESSEL INSIDE DIA. (mm)
VESSEL WALL THICKNESS (mm)
DISHED END THICKNESS (mm)
SKIRT/SADDLE THICKNESS (mm)
EMPTY WEIGHT (kg)
OPERATING WEIGHT (kg)
HYDROTEST WEIGHT (kg)
46
47
48
INSULATION CLEATS
LIFTING LUGS
ANCHOR / FOUNDATION BOLTS & NUTS
BLIND FLANGES, BOLTS, NUTS & GASKETS FOR DRAIN &
VENT / UTILITY CONNECTIONS
*
Yes
Yes
INTERNAL LADDER
LEVEL SWITCH
DRAIN, VENT & UTILITY CONNECTION VALVES ETC.
PRESSURE INDICATOR
Yes
Yes
As per P&I Diagram
Yes
ASTM A516 GR.70

ASTM A106 GR.B
ASTM A105 / ASTM A516 GR.70
ASTM A193 GR.B7 & ASTM A194 GR.2H
ASTM A234 GR.WPB
IS 2062 GR.B
SPIRAL WOUND WITH SS 316L METAL WINDING
SS 316
DESIGN & CONSTRUCTION

ASME -SEC VIII, DIV-1 (Latest Edition)
3.5
4.55
65.0
*
*
CLASS 150#
125 AARH
WNRF
4.0
2.0
*
24.0
As per P&I Diagram
47.0
Seismic Zone III, Zone Factor = 0.16
*
Condensate (inliquid contaminated with solid particles)
DIMENSION & WEIGHT

*
*
*
*
*
*
*
*
*
ACCESSORIES
49
50
51
52
53
Yes
DATA SHEET
OF
CONDENSATE
STORAGE TANK
Page 1 of 2
DOCUMENT NO.
REV.
11-0398B02-01-09-03-005
SHEET 1 OF 2
CLIENT :
QUANTITY
GAIL India Limited
INSTALLATION OF IP STATION AT ANKHI GUJARAT

ON 12 GANDHAR-DABKA PIPELINE
01 No.
TAG NO. : 110398BO2-CT-0101

S.No.
UNITS :
Flow Rate : KL/Day
Pressure : kg/cm g
INSPECTION & TESTING

54
55
56
57
AS PER CODE
AS PER CODE
YES
YES
RADIOGRAPHY
PWHT
HYDROTESTING
DP / MP TEST
NOTES :
1. ( * ) BIDDER TO SPECIFY.
2. ALL CS MATERIALS SHALL BE OF FULLY KILLED QUALITY.
3. FLANGES SHALL CONFORM TO ASME B16.5
4. GASKETS SHALL CONFORM TO ASME B16.20.
5. TAG NOS. SHALL BE PRECEDED BY "398B02" FOR ALL EQUIPMENTS / INSTRUMENTS I.E. FOR PRESSURE INDICATOR "PI-XXXX" SHALL BE READ AS
"398B02-PI-XXXX".
6. BIDDER TO PROVIDE LOAD CALCULATIONS OF ALL NOZZLES MENTIONING ALLOWABLE FORCES, MOMENTS AND THERMAL GROWTH.
7. VESSEL SHALL BE PROVIDED WITH INLET & OUTLET NOZZLE, SUITABLE INTERNALS, DRAIN & VENT CONNECTIONS, LEVEL SWITCH, PRESSURE
INDICATOR AND OTHER INSTRUMENTATIONS AS MENTIONED IN P&I DIAGRAM OF CONDENSATE TANK (SEE ANNEXURE-II).
8. VENTING SIZE CALCULATION SHALL BE AS PER API-2000 (LATEST EDITION).
DATA SHEET
OF
CONDENSATE
STORAGE TANK
Page 2 of 2
DOCUMENT NO.
REV.
11-0398B02-01-09-03-005
SHEET 2 OF 2
CLIENT:
GAIL India Limited
QUANTITY:
One no. each
INSTALLATION OF IP STATION AT ANKHI GUJARAT ON

12 GANDHAR-DABKA PIPELINE
TAG NO. : PI-0101, PI-0102 & PI-0103

1
Type
Direct
Wetted Parts Material
Mounting
Local
Other Material
Dial Size
150 mm
Process Connection
Colour
White with black inscription
Size & rating
Case Material
SS 316
Facing & finish
Bezel Ring
Beyonnet type SS 316
Capillary Material
Window Material
Shatterproof glass
Armour Flexible Material
Enclosure
WP to IP 65 as per IEC 60529/IS 2147
Capillary Length
Pressure Element
Bourdon
Flushing/filling connection with
10
Element Material
SS 316
17 Over range protection
130 % of FSD
11
Socket Material
SS 316
18 Blow out protection
Yes
12
Accuracy
"+/-" 1% of FSD
19 Options
13
Zero Adjustment
Micropointer
a)
Scrubber
b)
Syphon
14
Connection
3/4" NPT(M)
c)
Gauge Saver
d)
Liquid filled casing
Bottom
e)
Vaccum protection
f)
Solid front
g)
Two valve manifold
Connection location
15
Movement
SS 316
16
Diaphagram Seat
Rigid
Yes
Type
PRESSURE
S.NO.
TAG NO.
TEMPERATURE
RANGE
SERVICE
OP.
MAX.
DES.
OP.
OPTIONS
MAX. DES.
Natural gas
e,f,g
* Vendor to furnish
NOTES:1)
Process data shall be as per Design Basis
2)
At the time of approval of DS, supplier shall furnish DS with catalogues
DATA SHEET OF PRESSURE GAUGE
DOCUMENT NO.
Rev.
11-0398B02-01-11-03-006
SHEET 1 OF 1
CLIENT:
GAIL India Limited
QUANTITY:
One no. each
INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12 GANDHAR-DABKA PIPELINE
Tag Number
Line Number
Vessel No.
110398B02-SC-0101
Safety / Relief
Safety Relief
Full nozzle full lift / Mod. Nozzle
Full nozzle full lift
Bonnet type
Closed
Conv./Bellows/Pilot Operated
PSV-0101
Schedule
NA
GENERAL
VALVE
Conventional
Size & Rating
2" NB , 600#
Facing & finish
RF, 125 AARH
10 Outlet Conn
Size & Rating
3" NB , 600#
11
Facing & finish
Inlet Conn.
RF, 125 AARH

Yes
12 Cap Over Adj. Bolt

Screwed/bolted
13
Bolted
14 Lifting Gear - Type

15 Test Gag
Yes
16
17
MATERIAL
18 Body & Bonnet
ASTM A351 CF8M
19 Nozzle & Disc
SS 316
20 Spring
SS 304
21 Belows
22
23
24 Resilient Seat Seal
25
OPTIONS
26
API
27 Code
BASIS
28
29
30 Fluid
State
Wet Natural Gas
Gas
33.54 kg/sq.cm g
31 Corrosive Constituent
32 Required Flow Capacity
SERVICE
CONDITIONS
33 Mol. Wt.
S.G at Rel. Temp.
34 Optg. Pressure
Normal
33.54 kg/sq.cm g
35 Optg. Temp.
Rel.Temp.
o
25.33 C
0.8078
36 Valve Discharges to
Atmosphere
37 Back Press
Variable
Const. or Variable
38 Set pressure
39 Cold bend test pressure
40 % Over Pressure
% Blow Down
41 Cp/Cv
Compress. factor
42 Viscosity @ Rel. temp
20%
mPas(cP)
43 Vess. Wall Temp
Surf.Area-m2
44 Min. & Max. pressure
As per Technical Specification
45 Max. flow capacity
*
*
46 Calculated Area cm2

47 Sel. Area cm2
ORIFICE
NOTES :-
Orifice Design
48 No. of valves reqd. for capacity
49 Total Area-cm2
50 Actual flow capacity
51 Model No.
52 IBR Certification
No
53 Manufacturer
*' Vendor to furnish
Process Data shall be as per Design Basis
At the time of approval of DS, supplier shall furnish DS with catalogues.
DATA SHEET OF PRESSURE SAFETY VALVE
DOCUMENT NO.
Rev.
11-0398B02-01-11-03-007
SHEET 1 OF 1
INSTALLATION OF IP STATION AT ANKHI, GUJARAT ON 12

GANDHAR- DABKA PIPELINE
DATA SHEET
FOR
LEVEL GAUGE ON SLUG CATCHER
07.05.13
ISSUED FOR TENDER
AS
AD
AD
A
REV
20.04.13
DATE
ISSUED FOR IDC

DESCRIPTION
AS
PREP
AD
CHK
AD
APPR

DATASHEET
GENERAL
Tag Number
LG-0101
Quantity
P&ID NO.
11-0398B03-01-11-01-003, Sheet 2 of 3
Equipment No.
110398B02-SC-0101
Location
Field
Hazardous Area Classification
Zone-1, Gas Group IIA/IIB, T3
Electrical Certification
EExd
Enclosure Protection
Weather-proof to IP-65
Tank Type
Closed
Function
Local Indication
SERVICE CONDITIONS
FLUID HANDLED
LIQUID CONDENSATE (from Wet Natural Gas)
OPERATING TEMPERATURE (Min /

Norm )
5.0 0C / 25.33 0C
OPERATING PRESSURE (Min / Norm)
~ / 33.54 kg/cm2 g
DESIGN PRESSURE
64.0 kg/cm2 g
DESIGN TEMPERATURE
0 0C to 65.0 0C
SPECIFIC GRAVITY
0.8078
VESSEL DETAILS
Length TL/TL : 5 meter
VESSEL DIMENSIONS
Inside Diameter : 1 meter
VESSEL UNDERGROUND / ABOVEGROUND
Above Ground
DOCUMENT NO.
REV.
110398B02-01-11-03-008
DATASHEET FOR LEVEL GAUGE

DETAIL OF GAUGE
Type
Corrosion-Resistant Magnetic float-type Level

Gauge
Measuring Principle
Differential Hydrostatic Pressure
Design Pressure Limit
64.0 Kg/cm2
Design Temperature Limit
0 0C to 65.0 0C
Process Connection
2 , ANSI 600#, FF, FLANGED
Vent Connection
1 NPT (M) , Plugged
Drain Connection and Valve
1 Flanged Ball valve
Mounting
Side / Side
Measuring Range Min / Max.
50 mm (from the bottom) to 500 mm (from the

bottom)
Indicator Type
Magnetic Bi-Colour roller
Scale
0-100 %
Accuracy
<10 % of visibility
DETAILS FOR MATERIAL OF CONSTRUCTION

Float
SS / Ti
Float Chamber
Wetted Parts
Stud / Nut
Stainless Steel
SS
SS-316
All Flanges/ Nozzle
SS
DOCUMENT NO.
REV.
110398B02-01-11-03-008

Gasket
PTFE
Vent/Drain Plug
SS-316 or better
Drain Valve
CS or better
Mounting Arrangements
Stainless Steel
Indication Scale
Acrylic/Plastic
MISCELLENEOUS
Consumable Item to be supplied with LG
Each level Gauge shall be shipped with two

flange gaskets as applicable and 16 sets of nuts &
Bolts with Gaskets as applicable. ( 8 sets for
mounting and 8 sets shall be for O&M
requirements)
Document
Test Certificate + Operation Manual

CERTIFICATION
Calibration
Required
Certification for use in hazardous area
Required
PURCHASE
Manufacturer
VTA
Model Number
VTA
1. NA:- Not applicable, VTA:- Vendor To Advice

2. CCOE Certification is required for all the Tags.
DOCUMENT NO.
REV.
110398B02-01-11-03-008
CLIENT:
GAIL India Limited
INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12

GANDHAR-DABKA PIPELINE
QUANTITY: One no. each

TAG NO. : DPT-0101
Function
Transmission & Indication
Other Material
Type
2 Wire, Electronic smart transmitter with

HART protocol of latest version
Process Connection
Case
Mfr. Std.
Size & Rating
Mounting
Yoke
Facing & finish
Elec. Area Class.
IEC Zone 1, Gr. II A/IIB, Temp. class T3
Capillary Material
Enclosure
WP to IP 65 as per IEC 60529
Armour Flexible
Intrinsically Safe
Yes
Armour flexible material
Power Supply
24 V DC
Cable Entry
1/2 " NPT(F) with SS plug
20 Fill Fluid
Silicone Oil
100% of span
Capillary Length
10
Accuracy
"+/-" 0.075% of span (Note 1)
Zero Suppression &

21
Elevation
11
Repeatability
40:1 or better
22 Zero & span adjustment
Continuously adjustable externally,

non interactive type
PTFE
12
Transmitter Output
4-20mA DC
23 Adapter "O" ring
13
Load Driving Capability
600 ohms at 24 V DC
24 Body Rating
14
Service
Natural Gas
25 Over Range Protection
15
Element
Diaphagram
26 Options
16
Body Materials
SS 316
a) Intrinsically safe output meter :- Yes (LCD in Engg. Unit)
17
Element Materials
SS 316 L
b) Air Filler Regulator
18
Process Connection
3/4" NPT (F) thru flange adapter with plug.
c) Mounting Accessories suitable for 2" NB pipe :- Yes
MEASURING UNIT
MISCELLANEOUS
Process Connection Location Bottom
d) 2 Valve manifold:- Yes

27 Model
Diaphagram Seat
19
Yes
Wetted Parts Material
DIFF. RANGE
S.NO.
TAG NO.
SPAN
SET
ZERO ZERO
PRESSURE
ELEV. SUPP.
mm
mm
MAX. DES.
H2O
H2O
TEMP.
MAX.
SERVICE
OPTIONS
Natural Gas
a),c),d)
DES.
* Vendor to furnish
NOTES:1)
Accuracy includes the combined effect of repeatability, linearity, hysterisis etc.
2)
Operating principle of transmitters shall be capacitance / peizo resistance
3)
Process data shall be as per Design Basis
4)
HP side of DPT shall be connected with process point terminal
5)
At the time of approval of DS, Supplier shall furnish DS with catalogues
& LP shall be open to atmosphere.
DATA SHEET OF
DP TYPE PRESSURE TRANSMITTER
DOCUMENT NO.
Rev.
11-0398B02-01-11-03-009
SHEET 1 OF 1

DATA SHEET
FOR
FLAME ARRESTORS
07.05.13
ISSUED FOR TENDER
AS
AD
AD
A
REV
20.04.13
DATE
ISSUED FOR IDC

DESCRIPTION
AS
PREP
AD
CHK
AD
APPR

FLAME ARRESTOR :
GENERAL
Tag No
FA 0101
Type:
Online/ End of line (located in vertical position)
Quantity:
1 No.
Location:
Field, on Tag: 110398B02-CT-0101
Nominal Size:
4"
Sheeting Pack Data:
End connection and Rating :
Flanged ,150 # WNRF ANSI B16.5
Body Material:
ASTM A216 WCB or ASTM A105
Flange Material
ASTM A105
Laminar Pack Material
Stainless Steel AISI 304 (Note-1)

VESSEL DETAILS
Length TL/TL : 5 meter
VESSEL DIMENSIONS
Inside Diameter : 2.0 meter
VESSEL UNDERGROUND /
ABOVEGROUND
Under Ground
SERVICE CONDITIONS
Fluid Conveyed:
LIQUID CONDENSATE (for Wet Natural Gas)
Operating Conditions :
Temperature = Ambient, Pressure = Atmospheric
Design Conditions:
Temperature = 65.0 C, Pressure = 3.5 kg/cm2g

DOCUMENT NO.
REV.
DATASHEET FOR FLAME ARRESTOR

110398B02-01-11-03-010

Specific Gravity
Refer Process Data
Available Pressure Drop
100 MM H2O (max.) (Note-1)
Gas Composition:
Refer Process Design Basis

PURCHASE
(Note-2)
Vendor
NOTES:
1. Bidder to specify/ Confirm
2. Successful bidder to specify or confirm
3. Each piece to be identified with own marking.
4. Laminar pack material shall be removable.
5. When submitting the offer, bidder to submit assembly drawing with overall
dimensions and list of materials to be used.
DOCUMENT NO.
REV.
DATASHEET FOR FLAME ARRESTOR

110398B02-01-11-03-010
INSTALLATION OF IP STATION AT ANKHI, GUJARAT ON

12 GANDHAR- DABKA PIPELINE
DATA SHEET
FOR
LEVEL TRANSMITTER
07.05.13
ISSUED FOR TENDER
AS
AD
AD
A
REV
20.04.13
DATE
ISSUED FOR IDC

DESCRIPTION
AS
PREP
AD
CHK
AD
APPR

TABLE OF CONTENTS
1.0 LEVEL TRANSMITTER FOR SLUG CATCHER : ........................................................................... 3

2.0 LEVEL TRANSMITTER FOR CONDENSATE STORAGE TANK :..... Error! Bookmark not defined.
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.

1.0 LEVEL TRANSMITTER FOR SLUG CATCHER :

DATASHEET
GENERAL
Tag Number
LT-0101
Quantity
1
11-0398B03-01-11-01-003, Sheet No. 2 of 3
P&ID NO.
Line & (Equipment No).
110398B02-SC-0101
Location
Field

EExd
Tank Type
Closed
Function
Indication (LCD) & Transmission

SERVICE CONDITIONS
FLUID HANDLED
LIQUID CONDENSATE (for Wet Natural

Gas)
OPERATING TEMPERATURE (min / max)
5 0C / 47.3 0C
OPERATING PRESSURE (min / max)
33.6 / 36 Kg/cm2
DESIGN PRESSURE
64 Kg/cm2
DESIGN TEMPERATURE (0C)
-200C to 65 0C
SPECIFIC GRAVITY
0.5976
VESSEL DETAILS
Length : 5 meters
VESSEL DIMENSIONS
Diameter : 1 meter
DATASHEET FOR LEVEL

TRANSMITTER
Above Ground
DOCUMENT NO.
110398B02-01-11-03-011
REV.

TRANSMITTER
Type
Electronic, SMART
Measuring Principle
Capacitance/RF Admittance
65 Kg/cm2
-200C to 65 0C

Sensing Probe
Rod-Type fully insulated
Process Connection
FLANGED (2 , ANSI 600#, RF)

Die Cast Aluminum with Epoxy Painted /
Stainless Steel Housing (SS316L)
Housing Material
Calibration Range Min / Max.
VTA
.Output Signal :
4-20 mA DC, 2 Wire
Protocol Compatibility: FIELDBUS / HART

compatibility
HART compatibility
Enclosure Class :
Weather Proof to IP 65 (as per EN60529)
Ex Approval / Certification
Explosion Proof (EExd)
Input Power supply
24V DC, 2 Wire

1/2 NPT (F) Electrical cable entry (2 nos.)
No. of Cable Entries and Size

(Note-2)
Design Life
Fault Diagnosis Call up
25 Years
Required (Preferably through 4-20 mA HART
digital signal)
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.

Shock Resistance
Applicable ( As per DIN EN 60068-2-27 / IEC

68-2-27)
Vibration Resistance

68-2-64)
Measuring Range
Accuracy
150 mm (from the Bottom) to 500 mm (from the

bottom)
+/- 1 % of full span (At calibration conditions)
Repeatability
+/- 0.1 % of the span

MOUNTING
Mounting
Flanged Top-Mounted on Tank
Mounting Bracket
NA
SENSING PROBE
Type
ROD TYPE
Basic Capacitance
<=20pF
Probe Insertion Length
VTA (Note- 4)
Probe Rod material
SS-316L
Probe Build-up compensation
Required
Probe Rod Insulation material
PFA or PTFE or FEP (in conformity with FDA)

OPTIONS
Integral Output Indicator
Required (Digital)
Technical Literature
Required
Tag Plate
SS Tag plate Required
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.

CERTIFICATION
Calibration
Required
Required
Others
SIL-2 certification
PURCHASE
Manufacturer
VTA
Model Number
VTA
1.
NA:- Not applicable, VTA:- Vendor To Advice
2. Vendor shall provide Plug: 1/2 inch NPT-M, (material-SS-316), ex-proof certified, for
plugging spare cable entry.
3. Vendor shall provide Cable Glands - Nickel plated brass, double compression type, Exproof certified with PVC shroud
4.
Vendor shall Calculate the Probe insertion length as per the below specification :
The total Insertion Length shall be calculated from the Tip of the Process connection upto
the bottom (minus 50 mm from the bottom of the closed vessel).
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.

1.0 LEVEL TRANSMITTER ON CONDENSATE TANK :

DATASHEET
GENERAL
Tag Number
LT-0102
Quantity
1
11-0398B03-01-11-01-003, Sheet No. 2 of 3
P&ID NO.
Line & (Equipment No).
110398B02-CT-0101
Location
Field

EExd
Tank Type
Closed
Function
Indication (LCD) & Transmission

SERVICE CONDITIONS
FLUID HANDLED
LIQUID CONDENSATE (for Wet Natural

Gas)
OPERATING TEMPERATURE (min / max)
5 0C / 47.3 0C
OPERATING PRESSURE (min / max)
ATM
DESIGN PRESSURE
3.5 Kg/cm2
DESIGN TEMPERATURE (0C)
-200C to 65 0C
SPECIFIC GRAVITY
0.5976
VESSEL DETAILS
Length : 4 meters
VESSEL DIMENSIONS
Diameter : 1.8 meter

DATASHEET FOR LEVEL

TRANSMITTER
Under Ground
DOCUMENT NO.
110398B02-01-11-03-011
REV.

TRANSMITTER
Type
Electronic, SMART
Measuring Principle
Capacitance/RF Admittance
3.5 Kg/cm2
-200C to 65 0C

Sensing Probe
Rod-Type fully insulated
Process Connection
FLANGED (2 , ANSI 150#, RF)

Die Cast Aluminum with Epoxy Painted /
Stainless Steel Housing (SS316L)
Housing Material
Calibration Range Min / Max.
VTA
.Output Signal :
4-20 mA DC, 2 Wire
Protocol Compatibility: FIELDBUS / HART

compatibility
HART compatibility
Enclosure Class :
Weather Proof to IP 65 (as per EN60529)
Ex Approval / Certification
Explosion Proof (EExd)
Input Power supply
24V DC, 2 Wire

1/2 NPT (F) Electrical cable entry (2 nos.)
No. of Cable Entries and Size

(Note-2)
Design Life
25 Years
Fault Diagnosis Call up
Required (Preferably through 4-20 mA HART

digital signal)
Shock Resistance

68-2-27)
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.

Vibration Resistance
Measuring Range
Accuracy

68-2-64)
200 mm (from the Bottom) to 450 mm (from the
bottom)
+/- 1 % of full span (At calibration conditions)
Repeatability
+/- 0.1 % of the span

MOUNTING
Mounting
Flanged Top-Mounted on Tank
Mounting Bracket
NA
SENSING PROBE
Type
ROD TYPE
Basic Capacitance
<=20pF
Probe Insertion Length
VTA (Note- 4)
Probe Rod material
SS-316L
Probe Build-up compensation
Required
Probe Rod Insulation material
PFA or PTFE or FEP (in conformity with FDA)

OPTIONS
Integral Output Indicator
Required (Digital)
Technical Literature
Required
Tag Plate
SS Tag plate Required
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.

CERTIFICATION
Calibration
Required
Required
Others
SIL-2 certification
PURCHASE
Manufacturer
VTA
Model Number
VTA
6.
NA:- Not applicable, VTA:- Vendor To Advice
7. Vendor shall provide Plug: 1/2 inch NPT-M, (material-SS-316), ex-proof certified, for
plugging spare cable entry.
8. Vendor shall provide Cable Glands - Nickel plated brass, double compression type, Exproof certified with PVC shroud
9.
Vendor shall Calculate the Probe insertion length as per the below specification :
The total Insertion Length shall be calculated from the Tip of the Process connection upto
the bottom (minus 50 mm from the bottom of the closed vessel).
DATASHEET FOR LEVEL

TRANSMITTER
DOCUMENT NO.
110398B02-01-11-03-011
REV.
INSTALLATION OF IP STATION AT ANKHI, GUJARAT

ON 12 GANDHAR- DABKA PIPELINE
TECHNICAL SPECIFICATION
FOR
PRESSURE GAUGE
DOCUMENT NO
11
0398B02
CLIENT JOB NO.

TOTAL SHEETS
01
09
11
02
012
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
CONTENTS
1.0
GENERAL
2.0
DESIGN AND CONSTRUCTION
3.0
NAME PLATE
4.0
INSPECTION AND TESTING

ANNEXURE-1 : MATERIAL OF CONSTRUCTION
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 2 of 9
1.0
GENERAL
1.1
Scope
1.1.1
This specification, together with the data sheets attached herewith covers the
requirements for the design, materials, nameplate marking, and inspection, testing and
shipping of pressure, differential pressure and vacuum gauges.
1.1.2
The related standards referred to herein and mentioned below shall be of the latest
editions prior to the date of the purchaser's enquiry:
ANSI/ASME
American National Standards Institution/American Society

of Mechanical Engineers.
B 1.20.1
Pipe Threads General Purpose (Inch)
B 16.5
Pipe Flanges and Flanged Fittings NPS'A through

NPS24
B 16.20
Metallic Gaskets for Pipe Flanges, Ring Joint, Spiral

wound and Jacketed.
EN10204
Inspection Documents For Metallic Products
IEC-60529
Degree of Protection Provided by Enclosures (IP Code)
IS-13947
Specification for Low Voltage Switchgears and Control

gears.
IS-3624
1.1.3
Specification for Pressure and Vacuum Gauges.
In the event of any conflict between this standard specification, data sheets, statutory
regulations, related standards, codes etc., the following order of priority shall govern:
a)
Statutory Regulations'
b)
Datasheets
c)
Standard Specification
d)
Codes and Standards

In addition to compliance to purchaser's specifications in totality, vendor's extent of
responsibility shall include the following:
a)
Purchaser's data sheets specify the type of pressure element. Unless

specifically indicated otherwise, alternate type of pressure elements shall also
be acceptable provided all the functional and performance requirements
specified in the respective data sheets are guaranteed by the vendor.
b)
Purchaser's data sheets indicate the minimum acceptable material of

construction for pressure element, movement etc. Alternate superior material of
construction shall also be acceptable provided vendor assumes complete
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 3 of 9
responsibility for the selected materials for their compatibility with the specified
fluid and its operating conditions.
1.2
Drawing and Data
1.2.1
Detailed drawings, data, catalogues and manuals required from the vendor are indicated
by the purchaser in vendor data requirement sheets. The required number of
reproducible, prints and soft copies shall be dispatched to the address mentioned,
adhering to the time limits indicated.
1.2.2
Final documentation consisting of design data, installation manual, operation and

maintenance manual etc., submitted by the vendor after placement of purchase, order
shall include the following, as a minimum:
a)
Specification sheet for each gauges, and its accessories.
b)
Certified drawings sheets for each gauges and its accessories, which shall
provide dimensional details, internal constructional details, end connection
details and materials of construction.
c)
Copy of type test certificates.
d)
Copy of the test certificates for all tests indicated in clause 4.0 of this
specification.
e)
Installation procedure for each gauge and its accessories.
f)
Calibration and maintenance procedures including replacement of internal parts

wherever applicable
2.0
2.1
Pressure Elements, Gauge Movement and Socket
2.1.1
The pressure element shall be an elastic element like bourdon tube, bellow, diaphragm etc
with material as specified in the data sheet.
2.1.2
In case of bourdon type of gauges, the size of the bourdon tube shall not be less than 75%
of the nominal diameter of the dial size.
2.1.3
Gauge construction shall ensure no leakage of process fluid from the sensor elements to
atmosphere and between the high pressure and low-pressure side (in case of differential
pressure gauges) under normal condition.
2.1.4
The gauge socket shall be in one piece and shall also serve as element anchorage in case
of bourdon tube type element, which shall be directly connected to the socket, without any
capillary or tube in between. For other types of elements, the anchorage may be integral
with the socket or connected with the socket using capillary tube with minimum bore of 3
millimetres.
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 4 of 9
2.1.5
Any joint in the process wetted system including joint between the element and the
anchorage/socket shall be welded type only.
2.1.6
Unless specified otherwise, the pressure gauges shall have an over-range protection of at
least 130% of maximum working pressure, as a minimum.
2.1.7
Data sheet indicates the minimum requirement of material of construction. Alternate

materials as specified in Annexure 1 to this specification shall also be acceptable subject to
meeting process conditions.
2.1.8
The gauge movement material shall be of stainless steel unless specified otherwise in the
data sheet. It shall be adjustable for calibration without dismantling the sensor unit. The
use of'S' link for calibration of span is not permitted.
2.1.9
Vendor shall ensure that the operating pressure falls in the middle 30% of the full working
range i.e. operating pressure shall fall between 35% and 65% of the range offered.
2.1.10
front case.
Pressure gauges with range as 0 to 100kg/cm2g and above shall have safety type solid
All gauges in oxygen and chlorine service shall be thoroughly degreased using reagents
like trichloro-ethylene or carbon tetrachloride. All connections shall be plugged after
degreasing process in order to avoid entrance of grease or oil particles.
2.2
Cases and Dials
2.2.1
Unless specified otherwise, the gauges shall be weather proof to IP 55 as per IEC 60529
/ IS 13947, as a minimum.
2.2.2
In general, dial markings and dial colour shall be as per IS 3624. Dials of gauges in
oxygen service shall additionally have the word 'OXYGEN' or 'CHLORINE' written in
black and 'USE NO OIL'written in red.
2.2.3
The gauge dial shall be made of a suitable metallic materials so that the finished dial
shall be capable of withstanding a dry heat of 85C for 10 hours and immersion in waterat 85C for 1 hour without cracking, blistering, warping or discoloration of the dial or paint
on the dial.
2.2.4
The pointer stops shall be provided at both ends of the scale to restrict the pointer motion
beyond 5% above the maximum of scale and less than 5% below the minimum of the
scale.
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 5 of 9
2.2.5
The dial cover shall be made out of shatter proof glass sheet of thickness 1.5 to 3mm for
gauges with dial size less than 100mm while minimum 3.0mm for gauges with dial size
100mm or greater.
2.2.6
All gauges shall be provided with a blow out device i.e. blow out disc of aperture not less
than 25mm for gauges with dial size 100mm and above, while 20mm for gauges with dial
size less than 100mm.
2.2.7
When safety type solid front types of gauges are specified, they shall consist of a solid
partition isolating the pressure element from the dial. In such gauges the total solid
partition disc area shall not be less than 75% of the cross sectional area of the inside of
the case surrounding the pressure element.
2.3
Diaphragm Seals
2.3.1
Unless otherwise indicated in purchaser's data sheets, gauges specified with diaphragm
seals shall have their diaphragms integral with the gauges.
2.3.2
Whenever diaphragm seal gauges are specified with capillary, the size of the capillary
shall be selected to ensure response time of the gauge better than 5 seconds.
2.3.3
The sealing liquid for diaphragm seal gauges shall be an inert liquid, compatible with the
process fluid and its temperature. For gauges in oxygen and chlorine service, the sealing
liquid shall be fluro lube or equivalent compatible with the specified service.
2.3.4
For diaphragm seal pressure gauges with flanged ends, the diaphragm shall be rated for
the maximum allowable pressure of the associated flange.
2.4
End Connection
2.4.1
Unless specified otherwise, the following shall govern;

a)
Threaded end connections shall be NPT as per ANSI / ASME B. 1.20.1.
b)
Flanged end connection shall be as per ANSI / ASME B. 16.5
c)
Ring joint flanges shall have octagonal grooves as per ANSI / ASME B16.20.
d)
Flange face shall be as per clauses 6.4.4.1, 6.4.4.2 and 6.4.4.3 of ANSI / ASME
B16.5. The face finish as specified in the data sheet shall be as follows;
2.5
125AARH
: 125 to 250 AARH
63 AARH
: 32 to 63 AARH
Performance Requirements
2.5.1
Unless otherwise specified, the accuracy which is inclusive of repeatability and hysteresis
of pressure gauges / differential pressure gauges shall meet the following performance
requirements:
a)
Direct pressure gauge :
1% of full scale
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 6 of 9
b)
Chemical seal type pressure gauge : 2% of full scale
c)
Differential pressure gauges :
2% of full scale
2.6
Accessories
2.6.1
Gauges shall be supplied with all accessories as specified in the data sheets pre-installed.
2.6.2
For flanged diaphragm seal gauges, spacer ring, isolation valve and plugs shall be
provided whenever specified.
Over Range Protector (OPV)
2.6.3
a)
Whenever the maximum pressure specified in the data sheet exceeds the over range
protection pressure, over range protector shall be supplied.
b)
In case of pressure gauges with diaphragm seal, the over-range protector shall be
installed between the seal and the gauge.
c)
The material of construction of over range protector shall be same as socket material,
as a material.
2.6.4
Snubber
a)
Whenever the service specified is pulsating type, snubber shall be supplied.
b)
The material of construction of snubber shall be same as socket material, as a minimum.
3.0
NAME PLATE
3.1
Each gauge shall have a stainless steel nameplate attached firmly to it at a visible place
either by riveting or screwed to the case, furnishing the following information:
a)
Tag number as per purchaser's data sheets.
b)
Vendor's name
c)
Model number and manufacturer's serial number.
d)
Range of the instrument.
e)
MAWP and maximum vaccum rating of element
4.0
4.1
Unless otherwise specified, purchaser reserves the right to test and inspect all the items at
the vendor's works inline with the inspection test plan for pressure, differential pressure
and vacuum gauges.
4.2
Vendor shall submit following test certificates and test reports for purchaser's review:
a)
Material test report as per EN10204 clause 2.2 for wetted parts like gauge socket
and sensing element and as per clause 3.IB for flanges and spacer rings of
diaphragm seal type pressure gauges.
b)
Type test report for enclosure.

FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 7 of 9
c)
Dimensional test report for all gauges.
d)
Performance test reports for all gauges including accuracy, repeatability, over
pressure and vacuum test (as applicable)
e)
Type test reports for shock test and endurance test as per IS-3624 for each type /
model.
f)
Type test report for influence of temperature for each type/model.
4.3
Witness Inspection
4.3.1
All pressure, differential pressure and vacuum gauges shall be offered for pre dispatch
inspection for following as a minimum:
a)
Physical dimensions verification and workmanship.
b)
Performance test including accuracy and repeatability, on representative samples

of each type/model number before and after over-pressure and vacuum test.
c)
Over-pressure and vacuum test (as applicable) shall be carried out on

representative samples of each type / model number without loss of their elastic
characteristics.
d)
Review of all certificates and test reports as indicated in clause 4.2 of this
specification.
4.3.2
In the event when the witness inspection is not carried out by purchaser, vendor shall
anyway complete the tests and the test documents for the same shall be submitted to
purchaser for scrutiny.
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 8 of 9
Item
S.No.
Specified Material of
Alternate Material of Construction
Construction
1.
Sensing Element
SS316
SS316L, SS316Ti
2.
Socket
SS316
SS316L, SS316Ti
SS304
SS304L, SS316
3.
Case
Cast Aluminum
SS316Ti, SS316L,SS
4.
Capillary
SS
SS304, SS316,
SS304L, SS316L,
SS316Ti
Diaphragm
SS316
SS316L, SS316Ti
SS
SS 302, SS 304, SS
304L, SS316,
SS316L, SS316Ti
. 5.
FOR
PRESSURE GAUGE
Document No.
Rev
11-0398B02-01-11-02-012
SHEET 9 of 9
INSTALLATION OF IP STATION AT ANKHI,

GUJARAT ON 12 GANDHAR- DABKA PIPELINE
TECHNICAL SPECIFICATION FOR

PRESSURE SAFETYF VALVE
DOCUMENT NO
11
0398B02
01
CLIENT JOB NO.
TOTAL SHEETS
11
02
013
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
TABLE OF CONTENTS
1.0
GENERAL ....................................................................................................................................... 3
2.0
DESIGN AND CONSTRUCTION..................................................................................................... 4
3.0
INSPECTION AND TESTING.......................................................................................................... 6

Document No.
Rev
11-0398B02-01-11-02-013
SHEET 2 of 7
1.0
1.1
GENERAL
Scope
1.1.1
This specification, together with the data sheets attached herewith covers the requirements for the
design, materials, fabrication, nameplate marking, inspection, testing and shipment of pressure relief
valves.
1.1.2
The related standards referred to herein and mentioned below shall be of the latest editions prior to
the date of the purchaser's enquiry: -
1.1.3
ANSI/ASME
American National Standards Institute/American Society for Mechanical

Engineers.
B 1.20.1
Pipe Threads General Purpose (Inch).
B 16.5
Pipe Flanges and Flanged Fittings NPS 1/2" through JSr PS 24
B 16.20
Ring Joint Gaskets and Grooves for Steel Pipe Flange
B 16.34
Valves- Flanged, Threaded and Welding End
ASME
American Society of Mechanical Engineers.
Sec-VIII
Boiler and Pressure Vessels Code Section VIII 'Pressure Vessels'
Sec-I
Boiler and Pressure Vessels Code. Section-! 'Power Boilers'
API
American Petroleum Institute
API 520
Sizing, Selection
Refineries.
Part I
Sizing & Selection
Part II
Installation
API 521
Guide for Pressure Relieving and Depressurizing Systems.
API 526
Flanged Steel Pressure Relief Valves
API 527
Seat Tightness of Pressure Relief Valves.
EN 10204
Inspection Documents For Metallic Products.
IBR
Indian Boiler Regulations
and
Installation
of Pressure
Relieving Devices
in
In the event of any conflict between this specification, data sheets, related standards, codes etc., the
following order of priority shall govern:
a)
b)
c)
d)
Statutory Regulations
Data Sheets
Codes and Standards

Document No.
Rev
11-0398B02-01-11-02-013
SHEET 3 of 7
1.1.4
In addition to compliance to purchaser's specifications in totality, vendor's extent of responsibility shall

include the following;
a) Technical data sheets indicate the type, size, relieving area etc. of the selected the valve.
However, vendor shall be responsible to size and select the proper valve with orifice relieving area
meeting the indicated operating conditions
b) Technical data sheets specify the minimum acceptable materials for body, bonnet, disc, nozzle,
spring, bellows etc.
1. 2
Drawing and Data
1.2.1
Detailed drawings, data, catalogues and manuals required from the vendor are indicated by the
purchaser in vendor data requirement sheets.
1.2.2
Final documentation consisting of design data, installation manual, operation and maintenance
manual etc. submitted by the vendor after placement of purchase order shall include the following as a
minimum:
a)
b)
c)
d)
e)
f)
Specification sheet for each pressure relief valve and its accessories
Certified drawing sheets for each pressure relief valve and accessories, which shall provide
dimensional details, internal construction details, end connection details, weight and material of
construction.
Copy of test certificates for all the tests indicated in clause 4.0 of this specification.
Installation procedure for Pressure relief valve and its accessories
Calibration and maintenance procedure including replacement of internals wherever applicable.
2.0
2.1
Valve Design
2.1.1
The definitions of various terminologies used in purchaser's data sheets are as per clause 1.2 of API
RP 520 part 1.
2.1.2
Unless specified otherwise, all pressure relief valves shall be full nozzle full lift type and all relief
valves in thermal safety application shall be modified nozzle type.
2.1.3
For flanged pressure relief valves, the valve inlet and outlet size, the orifice designation and
corresponding relieving area shall be as per API 526.
2.2
Valve Sizing
2.2.1
Sizing shall be carried out using the formulae mentioned in the following standards whenever the
sizing code mentioned in the purchaser's data sheets refers to these
Sizing Code
API
2.2.2
Standard
API RP 520 Part I
API RP 521
Discharge Co-efficient
For all valves in gas, vapour or steam service with design code as ASME Sec VIII or ASME Section I
discharge co-efficient of 0.975 as per API 520 shall be used.
2.2.3
For the selected orifice letter designation and inlet and outlet size of the pressure relief valve, relieving
area of the valve offered by vendor shall meet those in API-526.
2.3
Valve Construction
2.3.1
Body
Document No.
Rev
11-0398B02-01-11-02-013
SHEET 4 of 7
2.3.1.1 Unless otherwise mentioned, end connection details shall be as below: a)
Threaded end connections shall not be used.
b)
Flanged end connections shall be as per ANSI/ASME B 16.5.
c)
Flanged face finish shall be as per ANSI/ASME B 16.5.The face finish as specified in the data
sheets, shall be as follows;
125AARH
125to200AARH
63 AARH
32 to 63 AARH
2.3.1.2 For flanged valves, inlet and outlet sizes and ratings and centre to flange face dimensions shall
be in accordance with API-526. Dimensional tolerance shall be as mentioned therein.
2.3.1.3 Body drain with a plug shall be provided as a standard feature on every pressure relief valve.
2.3.1.4 For the pilot operated pressure relief valves, where vendor's standard model provides only semi
nozzle design (i.e. the body is part of the inlet flow path), body material shall be of the same material
as that of nozzle specified in purchaser's data sheets, as a minimum.
2.3.2
Trim
2.3.2.1 The term 'trim' covers all the parts of the valves exposed to and in contact with the process fluid
except for the body and bonnet assembly i.e. nozzle, disc, disc holder, stem etc.
2.3.2.2 Valves shall be of the full nozzle type of design with the exception as per clause 2.3.1.4 and valves in
thermal relief application.
2.3.2.3 Wherever stelliting of disc and nozzle has been specified, it stands for stelliting of the seat joint and
the entire disc contour, unless otherwise mentioned.
2.3.2.4 For high temperature application, the materials for the internals shall be selected to avoid galling.
2.3.2.5 Resilient seat, seals or o-rings wherever used shall be suitable for pressure and temperature
conditions specified.
2.3.2.6 Gaskets wherever used shall be metallic type. Gaskets with asbestos filler or with asbestos bearing
material shall not be used.
2.3.3
Bonnet and Spring
2.3.3.1 All valves shall be provided with a cap over the adjusting bolt. Cap shall be of either bolted type or
screwed type as specified in the purchaser's data sheets.
2.3.3.2 Lifting lever shall be provided whenever the fluid to be relieved is steam and air or water above 65C.
2.3.3.3 Valve spring shall be selected such that it can permit an adjustment of 5% of the set pressure, as a
minimum.
2.3.3.4 Carbon steel springs shall be made corrosion resistant through plating/coating as per manufacturer's
standard design or as specified in the purchaser's data sheets.
2.3.3.5 The allowable tolerance in set pressures are as below:
a)
0.14 kg/cm2 g for set pressure upto and including 5kg/cm2 g.
b)
3% for set pressure above 5kg/cm2 g.
2.3.3.6 Bonnet shall be of the closed type for all process applications in general. Open type bonnet shall be
used only for steam and non-hazardous/non-toxic fluids. For all steam applications under design code
1BR or ASME Section-I with open bonnet design, weather protection cover shall be provided.
Document No.
Rev
11-0398B02-01-11-02-013
SHEET 5 of 7
2.3.4
Pilot Design
2.3.4.1 For pilot operated valves, the pilot design shall be of inherently fail safe.
2.3.4.2 Unless specified otherwise, pilot shall be non-flowing type.
2.3.4.3 All accessories like back flow preventer, pilot filter etc. required for proper operation of pilot operated
valves as per indicated service conditions shall be included.
2.3.4.4 Material of construction of pilot shall be same as that of main valve nozzle as a minimum.
2.3.4.5 The o-ring and diaphragm material of pilot shall be suitable for the pressure and temperature
conditions specified in the data sheet.
NAMEPLATE
2.4
Each pressure relief valve shall have a stainless steel nameplate attached firmly to it at a visible place
furnishing the following information: a)
b)
c)
d)
e)
f)
g)
Tag number as per purchaser's data sheet.

Manufacturer's serial number and/or model number.
Manufacturer's name/trade mark.
Nominal flange size in inches and rating in pounds for both inlet and outlet.
Orifice letter designation.
Valve set pressure.
Cold bench test set pressure.
2.4.1
For the above, pressures shall be marked in the same units as those followed in purchaser's data
sheets.
3.0
3.1
Vendor shall submit the following test certificates and test reports for purchaser's review:a) Material test certificate as per clause 3.1B of EN10204 for each valve body and bonnet
castings/forging, nozzle and as per clause 2.2 for stem, disc etc.
b) Certificate of radiography/X-ray for valve castings as per following requirements;
i)
100% radiography shall be carried out for all valve castings with body rating of 600# and
above
or wherever specifically indicated for in the material requisition.
ii)
Radiography procedure shall be as per ANSI B 16.34 and acceptance criteria shall be as per
ANSI B 16.34 Annexure-B. Following area of pressure relief valve shall be radiographed
unless specified otherwise.
- Inlet flange neck
- Outlet flange neck
- Nozzle (in case of cast construction)
- Body/bonnet joint neck.
c) Dimensional, hydrostatic and functional test reports for all valves as per clause 4.3 and 4.4 of this
specification.
d) Type test certificate for blow-off and closing down pressure.
3.2
Hydrostatic Test

Document No.
Rev
11-0398B02-01-11-02-013
SHEET 6 of 7
3.2.1
Each Pressure relief valve body shall undergo hydrostatic test as per outlet flange ANSI rating.
However all the safety valves castings covered under IBR shall be tested as per IBR regulations.
There shall not be any visible leakage during this test.
3.2.2
For full nozzle type of pressure relief valve, nozzle shall undergo hydrostatic test as per inlet flange
ANSI rating. For Semi nozzle design, valve Inlet shall be tested after assembly as per Inlet flange
ANSI rating.
3.3
Functional Test
3.3.1
Cold bench set pressure test:

Pressure relief valve shall be tested for opening at specified set pressure. Testing of pressure relief
valves shall be with air or nitrogen, testing of thermal relief valves shall be with water.
3.3.2
Seat Leakage test

a) Whenever the specified set pressure is less than or equal to 420 kg/cm2g, the valve shall meet the
seat tightness requirements specified in API RP-527. The maximum permissible leakage rates
against various sizes shall be as specified therein. Whenever the specified set pressure exceeds
420 kg/cm2g, the vendor shall submit the leakage rates of valves for approval by the purchaser.
Where bubble tightness has been specified, there shall be no leakage or bubbles of air at the
specified percentage of set pressure.
b) Seat leakage test pressure shall be as per API RP 527 for all valves except for valves under IBR
or ASME Section-I design code and pilot operated pressure relief valves. For these valves seat
leakage shall be carried out at the following pressure;
i)
Valves Under IBR or ASME Section-I : 95% of Set Pressure
ii)
Pilot operated Pressure relief valves
Upto 3.5 Kg/cm2G

Above 3.5 Kg/cm2G
: 90% of set Pressure

: 95% of Set Pressure
-----------------------------------X----------------------------------------------------X------------------------------------------------

Document No.
Rev
11-0398B02-01-11-02-013
SHEET 7 of 7

FOR
DOCUMENT NO
11
0398B02
CLIENT JOB NO.

TOTAL SHEETS
01
14
11
02
014
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
CONTENTS
1.0
2.0
GENERAL
DESIGN AND
CONSTRUCTION
3.0
NAME PLATE
4.0
FOR
Document No.
Rev
11-0398B02-01-11-02-014
SHEET 2 of 14
1.0
General
1.1
Scope
1.1.2
This specification, together with the data sheets attached herewith forms the requirements for
the design, materials, nameplate marking, inspection, testing and shipping of
electronic/pneumatic instruments.
1.1.3
The related standards referred to herein and mentioned below shall be of the latest editions
prior to the date of the purchaser's enquiry:ANSI/ASME
American National Standards Institute / American Society of

Mechanical
Engineers
B 1.20.1
Pipe Threads General Purpose (Inch)
B 16.5
Pipe Flanges and Flanged Fittings NPS through NPS24
B 16.20
Metallic Gaskets for Pipe Flanges,Ring Joint, Spiral wound

and Jacketed.
BS-5760
Reliability of System, Equipments and Components
EN 10204
Inspection Documents For Metallic Products
IEC-60068
Environmental Testing
IEC-60079
Electrical Apparatus for Explosive Gas Atmosphere.
IEC-60529
Classification of Degree of Protection Provided by Enclosures.
IEC-61000-4
Electromagnetic Compatibility for Industrial Process Measurement

and
Control Equipment.
IEC-61158
Fieldbus Standard for use in Industrial Control System
IEC-61158-2
Physical layer specification and Service definition for Field bus
IEC 61508
Functional Safety of Electrical/Electronic/Programmable Electronic

Safety
related Systems.
IS-13497
Specification for Low Voltage Switch gears and Control gears.
IS-2148
Flame Proof Enclosures of Electrical Apparatus.
ISA
Instrumentation System and Automation Society
S 7.3
Quality Standard for Instrument Air
S 50.1
Compatibility of Analog Signals for Electronic

Industrial Process Instruments.
ITK-x.x
1.1.4
Interoperability Test Kit (latest version)
In the event of any conflict between this standard specification, job specification/data sheets,
Statutory regulations, related standards, codes etc. the following order of priority shall govern:
a)
FOR
Document No.
Rev
11-0398B02-01-11-02-014
SHEET 3 of 14
1.1.5
b)
c)
Data Sheets
d)
Codes and standards
In addition to compliance to purchasers specifications in totality, vendors extent of

responsibility shall include the following:
Purchasers data sheets specify the minimum acceptable material of
a)
construction of body, measuring element and accessories. Alternate superior

material of construction shall also be acceptable provided vendor assumes
complete responsibility for the selected materials for their compatibility with the
process fluid and its operating conditions.
Selection of suitable sealant liquid for diaphragm seal instruments compatible
b)
with the process fluid and its operating temperature.

1.2
Drawing and Data
1.2.1
Detailed drawings, data, catalogues and manuals required from the vendor are indicated by
the purchaser in vendor data requirement sheets. The required number of reproducible, prints
and soft copies should be despatched to the address mentioned, adhering to the time limits
indicated.
1.2.2
Final documentation consisting of design data, installation manual, operation and maintenance
manual, etc submitted by the vendor after placement of purchase order shall include the
following, as a minimum;
a)
Specification sheet for each electronic/pneumatic instrument and their accessories.
b)
Certified drawing for each instrument, which shall provide dimensional detail, internal
construction and part list, material of construction etc.
c)
Calculations for integral orifice
d)
e)
Copy of the test certificates of all the tests indicated in clause 4.0 of this specification.
f)
Installation procedure for electronic/pneumatic instrument and its accessories.
g)
Calibration and maintenance procedures including replacement of its internal parts.
2.0
2.1
General Requirements
2.1.1
The type and material of construction of electronic/pneumatic instruments shall be as specified

in the purchasers data sheet.
FOR
Document No.
Rev
11-0398B02-01-11-02-014
SHEET 4 of 14
2.1.2
The range of instruments shall be selected by vendor base on the set range indicated in the
purchasers data sheet. Where no set range is indicated, vendor may select the same as per
the following guidelines;
a)
The set range shall be 1.1 times the maximum process value or 1.4 times the
operating process value whichever is higher rounded to the nearest ten.
b)
2.1.3
The set range shall preferably be in the middle third of the selected instrument range.
Except for instruments covered under clause 2.2.3.10 of this specification or specified
otherwise in purchasers data sheets, each instrument shall have an over-range protection of
at least 130% of specified range.
2.1.4
Measuring element in vacuum service shall have under range protection down to full vacuum,
without undergoing a change in calibration or permanent set.
2.1.5
Unless otherwise specified, diaphragm seal instrument shall meet the following requirements;
a)
Instruments shall have its diaphragm seal integral with the instrument and shall be
supplied with adaptor flange.
b)
When purchaser data sheets specify wafer seal type of instrument, vendor shall
include supply of studs, nuts and gasket as per the materials specified in the
purchasers data sheet. Refer Annexure 1 attached with this specification for stud
bolts, nuts and gasket material requirement.
c)
The sealant shall be an inert liquid, compatible with the process fluid and process
temperature indicated in the purchasers data sheets. In general, sealant shall be;
i)
DC 704 or equivalent for all diaphragm seal instruments except for oxygen
and chlorine.
ii)
Flouro-lube or equivalent for all diaphragm seal instruments in

oxygen and chlorine.
The requirement of spacer ring shall be as specified in purchasers data sheet. The
material of construction of spacer ring shall be 316 Stainless Steel, as a minimum
unless otherwise specified in the purchasers data sheets.
2.1.6
Wherever purchaser data sheet specified integral flow transmitter, vendor shall supply
complete assembly consisting of integral orifice, upstream and downstream meter
runs
with
end flanges.
a)
Three nos. of integral orifice plates shall be supplied i.e one is installed and two are
spares.
FOR
Document No.
Rev
11-0398B02-01-11-02-014
SHEET 5 of 14
b)
Unless otherwise specified, material of construction shall be 316 Stainless Steel for
integral
2.1.7
orifice and meter run with flanges.
The instrument enclosure shall be suitable for the area classification indicated in the
purchaser's data sheets. Unless otherwise specified, the enclosure shall meet the following
standards;
Weatherproof housing
IP-65 to IEC-60529/IS-13947.
Flameproof housing
Flameproof/ Ex (d) as per IEC-60079/IS-2148.
Flameproof housing shall also be made weatherproof.

2.1.8
Unless otherwise mentioned, end connection details shall be as below:a)
Threaded end connections shall be to NPT as per ANSI/ASME B 1.20.1.
b)
Flanged end connections shall be as per ANSI/ASME B 16.5.
c)
Grooves of ring-type joint flanges shall be octagonal as per ANSI B16.20.
d)
Flanged face finish shall be as per clauses 6.4.4.1, 6.4.4.2, and 6.4.4.3 of ANSI B
16.5. The face finish as specified in the data sheets shall be as follows: -
2.1.9
125 AARH
125 to 200 AARH
63 AARH
32 to 63 AARH
All electronic / pneumatic instruments in oxygen and chlorine service shall be thoroughly
degreased using reagents like trichloro-ethylene or carbon tetrachloride. End connection shall
be blinded / plugged after the degreasing process in order to avoid entrance of grease or oil
particles.
2.1.10
Electronic Instruments
2.1.10.1 All instruments shall be of state-of-the-art technology and shall be in compliance with the
electromagnetic compatibility requirements specified in IEC-61000-4 standard.
2.1.10.2 Plug-in circuit boards shall be designed and manufactured such that reverse insertion or
insertion of the wrong card is prevented.
2.1.10.3 Electronic instruments shall generally operate on nominal voltage of 24 V DC and shall be
protected against short circuit and reverse voltage. Transmission and output signal shall
generally be 4 to 20 mA DC for analog and smart transmitters. The display of integral output
meter shall be in engineering units for pressure, differential pressure and flow and 100% linear
for level.
2.1.10.4 Electronic transmitters with two-wire system shall be suitable for delivering rated current to an
external loop resistance of at least 600ohm when powered with 24 V DC.
2.1.10.5 Terminals for electrical connections shall be clearly identified, and polarity shall be
permanently marked.
2.1.10.6 Peak to peak ripple and total noise level in the analog output signal shall not exceed 0.25% of
the maximum signal.
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2.1.10.7 Power supply, signal isolation, ripple and noise requirements shall generally be as per ISA-S
50.1.
2.1.10.8 Electrical conduit entries shall have internal NPT threads.
2.1.11
Pneumatic Instruments.
2.1.11.1 All pneumatic connections shall be 1/4" NPT, unless otherwise specified.
2.1.11.2 All threaded connections shall be internal, unless otherwise specified.
2.1.11.3 The process input connections and pneumatic output and air supply connections etc. shall be
permanently stamped on the body at a suitable place.
2.1.11.4 Unless otherwise specified, pneumatic instruments shall operate on air supply of 1.4 kg/cm2g
and shall have transmission and output signal of 0.2 to 1.0 kg/cm2g.
2.1.11.5 Instrument air quality shall be as per ISA-S7.3 and shall be free from all corrosive,
hazardous, flammable and toxic contaminants.
2.2
Transmitters
2.2.1
Pneumatic Transmitters
2.2.1.1
Pneumatic blind transmitters shall be of the force-balance type and pneumatic indicating
transmitters of the motion balance type.
2.2.1.2
Transmitters shall have an accuracy of 0.5 % of span.
2.2.1.3
Transmitters shall be supplied with external zero and span adjustments.
2.2.2
Electronic Analog Transmitters
2.2.2.1
Electronic transmitters shall be of the two-wire dc current regulating type. They shall be
provided with integral output indicator. When specified, field mounted external output meters
shall be provided.
2.2.2.2
Electronic analog transmitters shall have an accuracy of 0..075 % of span.
2.2.2.3
Transmitters shall be supplied with external zero and span adjustments, Flameproof
transmitters shall also have their calibration adjustment from outside, without any need to
remove the cover.

2.2.2.4 Unless otherwise specified, the electronic transmitters shall be certified intrinsically safe.
2.2.3
2.2.3.1
Smart and Field bus based Transmitters

Smart and field bus based transmitters shall be two wire microprocessor based type. These
shall have a non-volatile memory, storing, complete sensor characterisation and configuration
data of the transmitter. All necessary signal conversions and output generation with the
required protocol shall be carried out in the transmitter electronics. Integral output meter with
LCD display shall be provided for all transmitters.
2.2.3.2 Transmitter shall also run complete diagnostic subroutines and shall provide diagnostic alarm
messages for sensor as well as transmitter healthiness. Field bus based transmitter in addition
shall have facility to detect plugged impulse lines, whenever specifically indicated in
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purchasers data sheets. In the event of detection failure, the output shall be driven to a
predefined value, which shall be field configurable.
2.2.3.3 The transmitters with field bus connectivity shall have built in control algorithm like
proportional, proportional-integral and proportional-integral-differential.
2.2.3.4 Whenever specifically indicated in purchasers data sheets, the meter electronics shall be
provided with in-built lightening and power supply surges. The transient protection shall meet
the requirements specified in IEC-60587.
2.2.3.5 The configuratinal data of the instruments shall be stored in a non-volatile memory such that
this remains unchanged because of power fluctuations or power off condition. In case vendor
standard instrument has battery backed RAM, vendor to ensure that battery drain alarm is
provided as diagnostic maintenance message.
2.2.3.6 Accuracy of transmitters, smart as well as field bus based, shall be as follows:
a)
For transmitter ranges of 760 mm WC and above, the accuracy shall be equal to or
better than 0.075% within a turndown of 1:10 of the offered span.
b)
For transmitters with ranges less than 760 mm WC the accuracy shall be equal to or
better than 0.15% within a turndown of 1:10 of the offered span.
c)
For all diaphragm seal transmitter with ranges 500 mm WC and above, the accuracy
shall be equal to or better than 0.25% within a turndown of 1:10 of the offered span.
d)
For all diaphragm seal transmitter with ranges less than 500 mm WC, the accuracy
shall be equal to or better than 0.5% within a turndown of 1:10 of the offered span.
The accuracy is defined as the combined effect of repeatability, linearity and hysteresis.
2.2.3.7
The stability of the transmitters shall be equal to or better than 0.1% of span for a period of
minimum 6 months, as a minimum.
2.2.3.8
Transmitter shall update the output at least 8 times a second unless otherwise specified.
2.2.3.9
Unless specified otherwise in purchasers specification, transmitter response time shall be as

follows:
a)
For transmitter range of 760 mm WC and above, the response time shall be equal to or 1
second.
The response time of the transmitter shall be considered as the sum of dead
time and 63.2% step
response time of the transmitter.
2.2.3.10 Unless specified otherwise, the over-range/static pressure protection of the transmitter shall
be as follows;
a)
For transmitter range between 1 kg/cmg and 100kg, the over range/static pressure
shall be 130 kg cmg.
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b)
For transmitter with ranges of 100 kg/ cmg and above, the over-range/static pressure
shall be 210 kg/cmg or 130% of maximum range whichever is higher.
c)
For transmitter range between 0.5 kg/cmg to 1.0 kg/ cmg, the over pressure/static
pressure shall be 70kg/cmg.
d)
For transmitters with ranges between 1000mm WC to 5000mm WC, the overrange/static pressure shall be 35kg/cmg.
e)
For transmitter with ranges less than 1000mm WC, over-range/static pressure shall be
1.0kg/cmg.
2.2.3.11
In the transmitter, the 'WRITE' option shall be protected through password.
2.2.3.12
Temperature transmitters shall meet the following requirements as a minimum:

a)
Temperature transmitter shall be universal type and shall be able to accept input from
resistance temperature detector (RTD) or thermocouple (T/C) of any type and range.
b)
Temperature transmitters shall be freely programmable i.e. element type and range
shall be programmable without any change in hardware / software.
c)
Temperature transmitter shall be remote mounted type, in general. Head mounted

transmitters shall be supplied when specifically indicated in purchasers data sheets.
d)
The accuracy of the temperature transmitter with RTD element shall be as follows:
-
For temperature range above 350c, the accuracy shall be equal to or better
than 0.075% of full scale.
For temperature range with ranges between 350c to 150c, the accuracy shall
be equal to or better than 0.15% of full scale.
For temperature range below 150c, the accuracy shall be equal to or better than
0.2% of full scale.
e)
The accuracy of temperature transmitter with cold junction compensation for

Thermocouple element shall be as follows;
2.2.3.13
For temperature above 350c, accuracy shall be 0.25% of range.
For temperature between 150c to 350c. accuracy shall be 0.5% of range.

When HART protocol is specified, the following features must be ensured;
a)
It shall allow multi masters (two for example, primary and secondary) for
configuration, calibration, diagnostics and maintenance. The primary could be the
control system or host computer and the secondary could be the hand-held
communicator.
b)
It shall be capable of implementing universal commands from either of these
locations.
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2.2.3.14
In addition to the requirements specified above, field bus based transmitter shall meet the
following requirements;
a)
All instruments must satisfy the requirements of the field bus registration laboratory
with applicable checkmark like foundation field bus, profibus PA, or as specified in the
purchasers data sheets.
b)
All instruments shall have two analog input blocks, as a minimum. In addition, when
specified the transmitter shall also have PID controller block.
c)
All instruments must be interoperable and shall have valid interoperability test
clearance like ITK latest version for foundation field bus or equivalent for profibus PA,
as applicable.
d)
The field bus instruments shall support peer to peer communication.
e)
Field bus instruments as offered shall not be polarity sensitive.
f)
The field bus instruments in hazardous area shall be certified as per entity concept or
shall be FISCO approved as per the requirements specified in the purchasers
specification.
2.4
Receivers
2.4.1
Pneumatic/electrical cables shall be such that they permit the instrument internals to be drawn
from its normal mounting position without affecting operation. Pneumatic connection points
shall seal automatically upon disconnection.
2.4.2
Electronic receivers shall be suitable for standard voltage inputs of 0.25 to 1.25 V, 1 to 5 V, 0
to 10 V dc. Any voltage receiver shall not alter the voltage drop across the conditioning
resistor by more than 0.1% of input range of maximum input voltage.
2.4.3
Recorder pens shall be easily replaceable.

Each recorder shall be supplied with chart-rolls and ink for six months continuous operation
2.5
Controllers
2.5.1
Automatic control stations including dedicated cascade control stations shall have switches to
transfer control from automatic to manual mode and vice-versa. The transfer shall be
procedureless and shall not produce any bump in the process under control during such a
2.5.2
transfer, the output signal shall not change by more than 1% of span.
Cascade control stations shall have a switch to select local or remote set point.
2.5.3
The control settings of the controller shall be readily adjustable from the front.
2.5.4
Controller action shall be easily reversible.
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2.5.5
Pneumatic automatic controller shall be easily removable, without disturbing the manual
control mechanism.
2.5.6
Electronic controller shall be easily removable, with the aid of a service station.
2.5.7
Local mounted pneumatic controllers shall be supplied with gauges for air supply pressure
and control signal. The gauges shall be integral with the instrument.
2.6
Accessories
2.6.1
Field HART Communicator:
2.6.1.1
It shall be possible to perform routine configuration, calibration, display process variable,

diagnostics etc. from a hand held portable communicator, which can be connected at any
location in the transmitter loop. It shall be possible to perform all the above functions online.
The loop function shall remain unaffected while communication is going on between
transmitter and the field communicator.
2.6.1.2
2.6.1.3
There should be no interruption on the output while communicating with the transmitter.
Field communicator shall meet the following requirements:
a)
Hand Held communicator shall be universal type and shall be compatible with all make
and models of HART transmitters, Smart positioners, instruments with all engineering
capability like calibration, diagnostics, configuration, inhibition of HART signal, etc.
b)
It shall be possible to connect the communicator at any of the following locations for
purpose of digital communication;
i)
Marshalling cabinet serving the transmitter, in safe area.
ii)
Junction box serving the transmitter, in hazardous area.
iii)
Directly at the transmitter, in hazardous area.Plug-in type connections shall be
provided with field communicator. Necessary interconnection shall be supplied by the

vendor.
c)
Offered communicator shall be dust-proof, certified intrinsically safe and suitable for
outdoor location. Carrying case shall be supplied with each communicator.
d)
When specified in data sheets, the software shall also be capable of configuring other
makes of transmitters.
e)
2.6. 2
They shall be battery powered with replaceable and rechargeable batteries.
Field Bus Tester
2.6.2.1 The field bus testers shall be able to determine the ability of the field bus wiring to carry field
bus signals. The field bus tester shall be capable of testing both signal and resistance of
2.6.2.2
There shall not be any interrruption on the output while communicating with the field bus
devices.
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2.6.2.3
The field bus tester shall meet all the requirements as specified in clause 2.6.3 (b), (c), (d)
and (e)
2.6. 3
Field Bus Configurator

The field bus configurator shall be centralised device like personal computer with hardware
and software for configuration and maintenance of field bus instrument.
2.6. 4
Remote output meter
2.6.4.1
Remote output meter shall be electronic with LCD display. The display shall be in actual
engineering units.
2.6.4.2
The indicator electronic shall be able to perform square root extraction for flow
measurement.
2.6.4.3
Offered indicators shall be certified Intrinsically safe, when used in hazardous area.
2.6.4.4
Power supply shall be loop powered with smart transmitter, unless otherwise specified.
2.6.4.5
Fieldbus based field indicator shall be able to indicate all signals available in the fieldbus
segment, selectively.
2.6. 5
Yoke mounted instruments shall be supplied with mounting bracket, U-bolt and nuts suitable
for mounting the instruments on a 50 mm (nominal bore) pipe stanchion (horizontal or
vertical).
2.6. 6
Air set
Air set, where provided, shall be a combination air filter regulator set with 5-micron filter
cartridge. It shall have a 50 mm diameter pressure gauge to indicate the regulated pressure.
Each air set shall be supplied with mounting bracket and bolts with nuts for surface
mounting.
2.6.7
Battery charger
Battery charger shall be supplied with all necessary accessories and shall operate at 230V
10%, 50Hz3Hz, unless otherwise specified.
3.0
3.1
NAMEPLATE
Each flush panel mounted instrument shall have the following information identified in the
front:-a)Tag number as per purchaser's data sheet.
b)
Reading coefficient, if any
c)
Pen colour, tag number-wise in the case of recorders.
d)
Each flush panel mounted instrument shall have a back nameplate permanently
fixed to it at
a visible place reporting the following information:
e)
Manufacturer's serial number or model number.
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f)
3.2
Surface mounted instruments need be provided with only one nameplate.

Local mounted instruments shall have a stainless steel nameplate attached firmly to it at a
visible place, furnishing the following information:
a)
Tag number as per purchaser's data sheets.
b)
Manufacturer's serial number and /or model number
c)
d)
Body material.
e)
Measuring element material.
f)
Range of measurement.
g)
Area classification in which the equipment can be used, this shall be to the same
code as per purchaser's data sheets.
4.0
4.1
Unless otherwise specified, purchaser reserves the right to test and inspect all the items at the
vendors works in line with the inspection test plan for electronic/pneumatic instruments.
4.2
Vendor shall submit the following test certificates and test reports for purchasers review: a) Material test report as per clause 3.1B of EN 10204 for body, flanges and spacer rings for
all transmitters and diaphragm seal transmitters
b) Material test report as per clause 2.2 of EN 10204 for sensing element
c) Hydrostatic test report as per clause 4.3.
d) Functional and calibration report for each instrument including accuracy, linearity,
hysteresis and repeatability.
e) Performance test report as per clause 4.4.
f) Response time of smart and fieldbus transmitters
g) Capability of smart and field bus based transmitters to accept multimasters for
configuration, calibration, diagnostics and maintenance.
h) Configuration, calibration and diagnostics check through hand held configurator / field
bus tester for smart and field bus based instruments.
i) Configuration, calibration and diagnostics check through field bus configurator for field
bus based instruments.
j) Interoperability test certificate as per clause 2.2.3.14c) for fieldbus transmitters
k) Certificate from statutory body for intrinsic safety/flameproof enclosures.
l) Functional test report for fieldbus tester
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4.3
Hydrostatic Test
4.3.1
All transmitters shall be hydrostatically tested at static pressure as per clause 2.2.3.10 for a
period of minimum 1 minute. After this test the transmitter shall not undergo a permanent set
from the original calibration.
4.4
Performance Test
4.4.1
All instruments shall meet the Accuracy performance characteristics stated in clause 2.2.3.6
after the instruments have been subjected to the following over-range conditions: a)
An air supply pressure of 2kg/cmg for all pneumatic instruments.
b)
Differential pressure transmitters subjected to a differential pressure in either direction

equal to the manufacturers pressure rating of the body.
4.5
Witness Inspection
4.5.1
Vendor shall offer all items for pre-despatch inspection. Following tests/checks shall be
carried out, as a minimum: a)
Physical dimensional checks and workmanship.
b)
Hydrostatic testing as per clause 4.3 of this specification on representative sample.
c)
Performance testing as per clause 4.4 of this specification on representative sample.
d)
Functional and calibration check on representative samples.
e)
Effect of power supply/air supply variation and load driving capability check on
representative samples.
f)
Response time check on representative samples for smart and fieldbus transmitters
g)
Capability of smart and field bus based transmitters to accept multimasters for
configuration, calibration, diagnostics and maintenance.
h)
Configuration, calibration and diagnostics check through hand held configurator /

field bus tester for smart and field bus based instruments.
i)
Configuration, calibration and diagnostics check through field bus configurator for
field bus based instruments.
j)
Review of all certificates and test reports as indicated in clause 4.2 of this specification.
k)
Functional checks on fieldbus tester
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FOR
INSTRUMENT VALVE & MANIFOLD
DOCUMENT NO
11
0398B02
CLIENT JOB NO.

TOTAL SHEETS
01
11
02
08
015
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
CONTENTS
1.0
GENERAL
2.0
3.0
NAME PLATE
4.0
ANNEXURE - 1: HYDROSTATIC TEST PRESSURES FOR INSTRUMENT VALVES AND MANIFOLDS.
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1.0
GENERAL
1.1
Scope
1.1.1
This standard specifications, together with the data sheets attached herewith, covers the
requirements for the design, materials, inspection, testing and shipping of instrument valves
and manifolds which includes the following types:
a)
Miniature instrument valves
b)
Instrument valve manifolds

c)
1.1.2
Instrument air valves
The related standards referred to herein and mentioned below shall be of the latest edition
prior to the date of purchaser's enquiry;
ASME/ANSI
American Society of Mechanical Engineers/ American National
Standards Institute
B 1.20.1
Pipe threads General Purpose (Inch)
B 16.11
Forged steel fittings-socket welding and threaded.
B 16.9
Factory made Wrought Steel Butt welding fittings.
B 16.34
Valves-Flanged. Threaded and welding end.
API-598
Valve Inspection and Testing
EN 10204
Inspection Documents for Metallic Products.
MSS
Manufacturers Standardization Society of the Valve and Fittings

Industry.
SP99
1.1.3.
Instrument Valves
In the event of any conflict between this standard specification, job specification/data sheets, statutory
regulations, related standards, codes etc. the following order of priority shall govern:
a)
b)
Data Sheets
c)
d)
Codes and Standards
1.2
Drawings and Data
1.2.1
Detailed drawings, data, catalogue and manuals etc. required from the vendor is indicated by the
purchaser in vendor data requirement sheets attached with material requisition. The required number
of reproducible, prints and soft copies shall be dispatched to the address mentioned in the material
requisition, adhering to the time limits indicated.
1.2.2
Final documentation consisting of design data, installation and maintenance manual etc. submitted by
the vendor after the placement of purchase order shall include the following, as a minimum:
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a)
Specification sheet for type of instrument valve and manifold.
b)
Certified dimensional details showing internal constructional details and material of

construction.
c)
d)
Copy of test certificates for all the tests indicated in clause 4.0 of this specification.
e)
Installation and maintenance procedures.
2.0
2.1
The instrument valves shall be of manufacturer proprietary design. However, the minimum
requirements specified herein must be complied.
2.2
Qualification tests (hydrostatic proof and burst tests) as per MSS SP-99 shall be conducted by vendor
for each design and size of valve to establish the cold working pressure (CW.P) rating.
2.3
For all valves and manifolds with body material of carbon steel/stainless steel, the valve trim material
shall be 316 Stainless Steel, as a minimum. Whenever body material is other than that specified
above, trim material should be same as body material as a minimum.
2.4
Unless otherwise specified, the valve packing material for all valves and manifolds shall be PTFE
only. The o-ring materials wherever used shall also be of PTFE.
2.5
The finishing and tolerances of parts like stem, piston, stem threading etc. of the offered valves and
manifolds shall be properly machined to avoid problems like galling.
2.6
The hand wheel material for all valves and manifolds shall be zinc/nickel plated carbon steel. Any other
material, if provided as per standard vendor design, shall also be acceptable.
2.7
Instrument Valves (Miniature)
2.7.1
The instrument valves shall be of globe pattern needle valves forged/ bar stock with inside screwed
bonnet, with back-seated blow out proof system.
2.7.2
Body material shall be 316 Stainless Steel unless otherwise specified.
2.7.3
The minimum cold working pressure (CWP) rating of the valve shall be as per Annexure 1 of this
specification, unless otherwise specified.
2.7.4
The end connection shall be ^"NPTF to ANSI B 1.20.1, unless otherwise specified.
2.7.5
Flow direction shall be marked on the body.
2.7.6
The valve dimensions shall be as follows:

a)
b)
End to end dimensions 76mm (approximately).

Height in fully open condition - 135mm maximum. These dimensions are indicative only.
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2.8
Valve Manifolds
2.8.1
3-Valve and 5-Valve manifolds:
2.8.1.1
3-Valve manifold
a)
3-Valve manifold shall be designed for direct coupling to differential pressure transmitters
having 2 bolt flanges with 54mm (2-1/8") centre-to-centre connections and 41.3mm (1 -5/8")
bolt-to-bolt distance.
b)
3-Valve manifold shall contain two main line block valves and an equalising bypass valve.
The valves shall be needle type. They shall use self-aligning 316 Stainless Steel ball seats,
unless otherwise specified.
2.8.1.2
5-Valve manifold
a)
5-Valve manifold shall be designed for direct coupling to differential pressure transmitters
having 2 bolt flanges with 54mm (2-1/8") centre-to-centre connections and 41.3mm (1-5/8")
bolt-to-bolt distance.
b)
5-Valve manifold shall contain two main line block valves and a combination double block
and bleed for the bypass line. The valve shall of needle type or special ball with bleed hole.
2.8.1.3
The flanges shall be integral part of manifold block.
2.8.1.4
The material of construction shall be 316 Stainless Steel, unless otherwise specified.
2.8.1.5
The minimum cold working pressure (CWP) rating of manifolds shall be as per Annexure 1 of this
2.8.1.6
The process connection shall be '/2"NPTF to ANSI B 1.20.1.
2.8.1.7
Wherever the manifolds are specified for stanchion mounting, these shall be supplied along with
mounting accessories. The bolts and nuts shall be alloy steel as per ASTM A 193 Gr B7 and ASTM
A194 Gr. 2H (Hot dip galvanized or zinc plated) respectively. Other accessories shall be zinc plated.
2.8.2
2.8.2.1
3 way 2 valve manifold for pressure gauges

The manifold shall be designed for use with pressure gauges with block and bleed valves. The
manifold body shall be either straight or angle type as specified in the data sheet.
2.8.2.2
The valve shall be a needle type.
2.8.2.3
The body material shall be 316 Stainless Steel, unless otherwise specified.
2.8.2.4
The minimum cold working pressure rating of the manifold shall be as per Annexure 1 of this
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2.8.2.5
The manifold shall have the following connections:

The inlet connection shall be 3/4" plain ends with a minimum of 100mm nipple extension
a)
suitable for socket weld or butt weld as per B 16.11/ Bl 6.9 as specified in the job
specifications
b)
The gauge connection shall be with union nut and tail piece threaded to 1/2"NPTF.
c)
The drain connection shall be W'NPTF.
2.9
Instrument Air Valves
2.9.1
Instrument Air Isolation Valves (Miniature)
2.9.1.1
The valves shall be full-bore ball type with forged body.

2.9.1.2
2.9.1.3
Body material shall be 316 Stainless Steel.
The minimum cold working pressure rating of instrument air isolation valves shall be as per Annexure
1 of this specification, unless specified otherwise.
2.9.1.4
The end connection shall be ^"NPTF to ANSI B 1.20.1, unless otherwise specified.
2.9.1.5
End to end dimensions shall be 70mm (approximately).
2.9.2
Instrument Air Needle Valves (Miniature)
2.9.2.1
The instrument valves shall be globe pattern-needle valves forged/bar stock with inside screwed
bonnet.
2.9.2.2
Body material shall be 316 Stainless Steel.
2.9.2.3
The minimum cold working pressure of Instrument Air Needle valves shall be as per Annexure 1
of this specification, unless otherwise specified.
2.9.2.4
The end connection shall be %" NPTF to ANSI Bl.20.1, unless otherwise specified.
2.9.2.5
Flow direction shall be marked on the body.
2.9.2.6
The valve dimensions shall be as follows:
2.10
a)
End to end dimensions - 54 mm (approximately).
b)
Height in fully open condition - 49 mm maximum. These dimensions are tentative only.
All instrument valves in oxygen and chloride service shall be thoroughly degreased using reagents like
trichloroethylene or carbon tetrachloride. End connection shall be plugged after degreasing process in
order to avoid entrance of grease or oil particles.
3.0
NAME PLATE
3.1
Following information shall be punched on the body of each of these items;

a)
Material of construction to the same standards as in purchaser's data sheets.
b)
Cold working pressure of each item to the same standards as in purchaser's data sheets.
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c)
Manufacturer's identification and model number.
d)
Flow direction (if applicable)
e)
Material of construction.
4.0
4.1
Unless otherwise specified, purchaser reserves the right to test and inspect all the items at vendor's
works, inline with the inspection test plan for instrument valve and manifolds.
4.2
a)
Material test certificates as per clause 3. IB of EN 10204 for body and bonnet and as per
clause 2.2 for other parts.
b)
Dimensional test report.
c)
Pressure test report as per clause 4.3 of this specification.
d)
Hydrostatic proof and burst tests as per MSS-SP-99 for each design and size of valve.
4.3
Pressure Test Requirements
4.3.1
Each valve and manifold shall be subjected to hydrostatic pressure test at ambient temperature for
both seat and shell leakage at test pressures given in Annexure-1 of this specification. During and
after the hydrostatic test there shall not be any visible leakage.
4.3.2
Pneumatic Test
Each valve and manifold shall be subjected to pneumatic test for both shell and seat leakage at 7.0
kg/cm2g with testing medium as air at ambient temperature. There shall not be any visible leakage
when immersed in water or coated with a leak detection solution.
4.4
Witness Inspection
4.4.1
All valves and manifolds shall be offered for pre-dispatch inspection for following, as a
minimum:
a)
Physical dimensional verification and workmanship.
b)
Pressure test as per clause 4.3 of this specification on representative samples.
c)
4.4.2
In the event, when witness inspection is not carried out by purchaser, the tests shall anyway
be completed by the vendor and documents for the same shall be submitted to purchaser for
scrutiny.
FOR
Document No.
Rev
11-0398B02-01-11-02-015
SHEET 7 of 8
HYDROSTATIC TEST PRESSURES FOR INSTRUMENT VALVES AND MANIFOLDS

SL.NO.
ITEM
1.
Instrument
Valves
(Miniature
A)
B)
2.
4.
MIN. COLD
WORKING
PRESSURE
HYDROSTATIC
TEST PRESSURE
FOR SEAT
LEAKAGE
SHELL
LEAKAGE
TEST
<600#
>900#to<1500#
102kg/cmzg
253kg/cm2g
112kg/cmzg
278kg/cm2g
153kg/ cmzg
383kg/cm2g
<600#
>900#to<
1500#
102kg/ cm2g
253kg/cm2g
112kg/cmzg
278kg/cm2g
153kg/ cm2g
383kg/cm2g
27kg/cm2g
30kg/cm2g
41kg/cmzg
27kg/cm2g
30kg/cm2g
41kg/cmzg
Instrument
Valve
A)
B)
3.
LINE
PRESSURE
Instrument
Air Isolation
Valves
Instrument
Air Needle
Valves
FOR
Document No.
Rev
11-0398B02-01-11-02-015
SHEET 8 of 8
PROJECT:INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12 GANDHARDABKA PIPELINE

CLIENT: GAS AUTHORITY OF INDIA LTD.
QUALITY ASSURANCE PLAN OF

SLUG CATCHER
CONSULTANT: WOOD GROUP KENNY

QAP No.: 11-0398B02-01-09-02-016
Rev. 0
Page No. 1 of 3
INSPECTION BY
SR. NO.
DESCRIPTION
Review of Quality Plan
CHARACTERISTIC
CLASS
Sequence of check points
Major
Marking of Hold/Review/Witness Pts.
Major
TYPE OF CHECK
Review
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE NORMS
100%
Contractual
Doc/ Drgs.
Contractual
Doc/ Drgs.
FORMAT OF
RECORDS
TPI
CONSULTANT/
OWNER
Internal
Reports
Approval of Drwg & Design Calculations
Code Requirements
Major
Review
100%
Design code
Design code
Internal Reports
Review of WPS/ PQR/ WPQ
Code Requirements/ Coverage to
Major
Review
100%
Design code
Design code
Internal Reports
Major
Review
100%
Material Spec.
Material Spec.
Internal Reports
all weld joints

INCOMING MATERIAL IDENTIFICATION OF BOUGHTOUT ITEMS
4
Material Identification & Allocation of all
Verification of TC with material
Pressure Parts
spec.and Drwg.
W/R
Coorelation of TC with Material
Major
Visual
100%
Test Certificate
Test Certificate
Internal Reports
Dimensions
Major
Measurement
Sample
Drawing/ TC
Drawing/ TC
Internal Reports
Major
Review of TC
100%
Code
Code
Internal Reports
Major
Visual
100%
Hard Punching
Hard Punching
Internal Reports
Hydrotest/ NDE/ Impact Test of

Plates / Pipes at Maker
Identification Stamp Transfer
5
Inspection of Machined & formed parts (Dish
Identification
Major
Visual
100%
Drawing
Drawing
Internal Reports
Ends/ Shell Plates/ End Plates/ Stubs/
Dimensions/ Profile
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Nozzles)
Min. Thickness/ Ovality
Major
Template
100%
Drawing/ Design
Drawing/ Design
Internal Reports
PT of knuckle/ Edge
Major
Visual
100%
LPE 01
LPE 01
Internal Reports
Heat Treatment
Major
Chart
100%
Design code
Design code
Internal Reports
INPROCESS INSPECTION
6
L Seam Set up for shells and Test Plates
Identification
Major
Visual
100%
Drawing/ IR
Drawing/ IR
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Weld Preparation
Major
Template
100%
Drawing
Drawing
Internal Reports
alignment/ Squareness
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Tack Weld Soundness
Major
PT
100%
Drawing
Drawing
Internal Reports
Major
Visual
100%
LPE 01
LPE 01
Internal Reports
Major
Visual
100%
FPAS-001
FPAS-001
Internal Reports
Major
RT
100%
Design code
Design code
Internal Reports
Production Test Coupon
Major
Impact Test
100%
Defect Removal
Major
PT
100%
Design code
Design code
Internal Reports
A. Welding of L Seam & Test Plates/ Pipes
Backchip & PT after 1st side
(above Parts)
Welding
Weld Size/ finish
Weld joint soundness of L-seam
& Test Plates
B. Repair: (if any)
Internal Reports
L Seam
Weld joint soundness
Major
RT
100%
Design code
Design code
Internal Reports
Set-up of Nozzle pipe to Flange
Squareness
Major
Measurement
100%
FPAS-001
FPAS-001
Internal Reports
Weld Preparation
Major
Template
100%
Drawing
Drawing
Internal Reports
Welding of Nozzle pipe to Flange
Weld size/ Reinforcement
Major
Template
100%
Drawing
Drawing
Internal Reports
Weld joint Soundness
Major
RT
100%
Design code
Design Code
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Pickling Passivation
Major
MTC
100%
Drawing
Drawing
Internal Reports
10
Inspection of Internals of HP Separator
REMARKS
PROJECT:INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12


SLUG CATCHER

QAP No.: 11-0398B02-01-09-02-016
Rev. 0
Page No. 2 of 3
INSPECTION BY
SR. NO.
11
12
13
DESCRIPTION
Welding of internals to HP Separator Shell
CHARACTERISTIC
CLASS
TYPE OF CHECK
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE NORMS
FORMAT OF
RECORDS
TPI
CONSULTANT/
OWNER
Test Plate to be
impact Tested &
Shall be
witnessed by
TPIA
Do
Repair RT to be
Reviewed
Weld size/ Reinforcement/ Finish
Major
Template/ Visual
100%
Drawing
Drawing
Internal Reports
Major
PT
100%
LPE01
LPE01
Internal Reports
C Seam set up for shells to Dish Ends
Identification
Major
Visual
100%
Drawing/ IR
Drawing/ IR
Internal Reports
& Test
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Plates
Weld preparation
Major
Template
100%
Drawing
Drawing
Internal Reports
Alignment/ Squareness
Major
Measurement
100%
Drg./ FPAS001
Drg./ FPAS001
Internal Reports
Tack Weld Soundness
Major
PT
100%
Drawing
Drawing
Internal Reports
A. Welding of C Seam (above parts) & Test
Backchip & PT after 1st side welding
Major
Visual
100%
LPE01
LPE01
Internal Reports
plates
Weld size/ finish
Major
Visual
100%
FPAS-001
FPAS-001
Internal Reports
Weld joint soundness of C seam
Major
RT
100%
Design Code
Design Code
Internal Reports
B. Repair: (if any) C Seam
Defect Removal
Major
PT
100%
Design Code
Design Code
Internal Reports
Major
RT
100%
Design Code
Design Code
Internal Reports
REMARKS
14
Heat Treatment of Test Plates + EQPT as per code Time/ Temperature Charts
Major
Visual
100%
Design Code
Design Code
Internal Reports
15
Testing of all Test Plates
Mech./ Physical Test Reports
Major
Visual
100%
Design Code
Design Code
Internal Reports
16
Inspection of Marking for Openings on Dish
Identification
Major
Visual
100%
IR/ Drawing
IR/ Drawing
Internal Reports
Ends/ Shelf
Layout
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Orientation
Major
Visual
100%
Drawing
Drawing
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Drawing
Internal Reports
Acc. Inspn. Rep.
Acc. Inspn. Rep.
Internal Reports
RW
W/R
W/R
W/R
W/R
17
Inspection after opening on shell/ Dish Ends
No. of holes
Major
Count
100%
A - Earlier Stage clearance review
Major
Review
100%
B - Opened Holes Orientation

Major
Visual
100%
Drawing
Drawing
Internal Reports
Major
Visual
100%
FPAS-001
Hard Stamping of
Insp.
Drawing
FPAS-001
Internal Reports
Quadrantwise
H - hole finish
18
19
20
21
I - Final Acceptance
Major
Visual
100%
Setup of studs, nozzles, sockets and
Orientation
Major
Visual
100%
connections with Shell / Dish End / Flange
Weld preparation
Major
Template
100%
Alignment
Major
Line thread
100%
Squareness
Major
Right angle
100%
Distance between connections
Major
Measurement
Tack Weld Soundness
Major
PT
Welding of Nozzles, & connections to Shell/
Weld size/ finish
Major
DESCRIPTION
Weld Soundness
Setup of Structurals Saddles & Attachments
Hard Stamping of Insp.
Internal Reports
Drawing
Internal Reports
Drawing/ Code
Drawing/ Code
Internal Reports
Drg / FPAS001
Drg / FPAS001
Internal Reports
Drg / FPAS001
Drg / FPAS001
Internal Reports
100%
Drg / FPAS001
Drg / FPAS001
Internal Reports
100%
LPE01
LPE01
Internal Reports
Visual
100%
Design Code
Design Code
Internal Reports
Major
RT/PT
100%
Design Code
Design Code
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Welding of Structurals Saddles &
Weld preparation
Weld size/ finish
Major
Major
Major
Template
Measurement
Visual
100%
100%
100%
Drawing
Drg./ FPAS001
Design Code
Drawing
Drg./ FPAS001
Design Code
Internal Reports
Internal Reports
Internal Reports
Attachments
Weld Soundness
Major
PT
Sample
Design Code
Design Code
Internal Reports
N.A.


SLUG CATCHER

QAP No.: 11-0398B02-01-09-02-016
Rev. 0
Page No. 3 of 3
INSPECTION BY
SR. NO.
22
DESCRIPTION
Full Welding Clearance
CHARACTERISTIC
CLASS
TYPE OF CHECK
QUANTUM
OF CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE NORMS
FORMAT OF
RECORDS
Overall Dimensions
Major
Measurement
100%
Drawing
Drawing
Squareness of Connections
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Distance Between Connections
Major
Measurement
100%
Drawing
Drawing
Internal Reports
RT Clearance/ U.T.
Major
Review of RT Rpts.
100%
Drawing
Drawing
Internal Reports
Code Punching Details
Major
Rub off
100%
Design Code
Design Code
Internal Reports
Pressure Gauge (2 Nos.)
Major
Review
100%
Valid Cert.
Valid Cert.
Internal Reports
Calibration
Major
Visual
100%
No leakage
No leakage
Internal Reports
Leakage
Major
Document Review
Major
Review
100%
Design Code
Design Code
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Surface Preparation
Major
Visual
100%
Free from scales etc
Internal Reports
TPI
CONSULTA
NT/
OWNER
W/R
W/R
W/R
W/R
Internal Reports
Final Inspection
23
24
25
Hydrostatic Testing
Final Inspection
100%
Internal Reports
Clearance for Assembly/ Dispatch (as
Painting finish
Major
Visual
100%
Drawing
Drawing
Internal Reports
applicable)
Capping/ Blanking of all opening
Major
Visual
100%
All Opening Protected
Internal Reports
Major
Visual
100%
Design Code
Design Code
Internal Reports
Legend
M
Manufacturer
Perform
Client
Review
TPI
Third Party Inspection Agency
Witness
For Approval
W/R
Witness for Test & Review of Certificates & Documents as per QAP
Hold
RW
Random Witness
NA
Not Applicable
REMARKS
PROJECT:INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12 GANDHARDABKA PIPELINE


CONDENSATE TANK

QAP No.: 11-0398B02-01-09-02-017
Rev. 0
Page No. 1 of 3
INSPECTION BY
SR. NO.
DESCRIPTION
Review of Quality Plan
CHARACTERISTIC
CLASS
Sequence of check points
Major
Marking of Hold/Review/Witness Pts.
Major
TYPE OF CHECK
Review
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE NORMS
100%
Contractual
Doc/ Drgs.
Contractual
Doc/ Drgs.
FORMAT OF
RECORDS
TPI
CONSULTANT/
OWNER
Internal
Reports
Approval of Drwg & Design Calculations
Code Requirements
Major
Review
100%
Design code
Design code
Internal Reports
Review of WPS/ PQR/ WPQ
Code Requirements/ Coverage to
Major
Review
100%
Design code
Design code
Internal Reports
Major
Review
100%
Material Spec.
Material Spec.
Internal Reports
all weld joints

INCOMING MATERIAL IDENTIFICATION OF BOUGHTOUT ITEMS
4
Material Identification & Allocation of all
Verification of TC with material
Pressure Parts
spec.and Drwg.
W/R
Coorelation of TC with Material
Major
Visual
100%
Test Certificate
Test Certificate
Internal Reports
Dimensions
Major
Measurement
Sample
Drawing/ TC
Drawing/ TC
Internal Reports
Major
Review of TC
100%
Code
Code
Internal Reports
Major
Visual
100%
Hard Punching
Hard Punching
Internal Reports
Hydrotest/ NDT of
Plates / Pipes at Maker
Identification Stamp Transfer
5
Inspection of Machined & formed parts (Dish
Identification
Major
Visual
100%
Drawing
Drawing
Internal Reports
Ends/ Shell Plates/ End Plates/ Stubs/
Dimensions/ Profile
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Nozzles)
Min. Thickness/ Ovality
Major
Template
100%
Drawing/ Design
Drawing/ Design
Internal Reports
PT of knuckle/ Edge
Major
Visual
100%
LPE 01
LPE 01
Internal Reports
Heat Treatment
Major
Chart
100%
Design code
Design code
Internal Reports
INPROCESS INSPECTION
6
L Seam Set up for shells and Test Plates
Identification
Major
Visual
100%
Drawing/ IR
Drawing/ IR
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Weld Preparation
Major
Template
100%
Drawing
Drawing
Internal Reports
alignment/ Squareness
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Tack Weld Soundness
Major
PT
100%
Drawing
Drawing
Internal Reports
Major
Visual
100%
LPE 01
LPE 01
Internal Reports
Major
Visual
100%
FPAS-001
FPAS-001
Internal Reports
Major
RT
100%
Design code
Design code
Internal Reports
Production Test Coupon
Major
Impact Test
100%
Defect Removal
Major
PT
100%
Design code
Design code
Internal Reports
A. Welding of L Seam & Test Plates/ Pipes
Backchip & PT after 1st side
(above Parts)
Welding
Weld Size/ finish
Weld joint soundness of L-seam
& Test Plates
B. Repair: (if any)
Internal Reports
L Seam
Major
RT
100%
Design code
Design code
Internal Reports
Set-up of Nozzle pipe to Flange
Squareness
Major
Measurement
100%
FPAS-001
FPAS-001
Internal Reports
Weld Preparation
Major
Template
100%
Drawing
Drawing
Internal Reports
Welding of Nozzle pipe to Flange
Weld size/ Reinforcement
Major
Template
100%
Drawing
Drawing
Internal Reports
Weld joint Soundness
Major
RT
100%
Design code
Design Code
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Pickling Passivation
Major
MTC
100%
Drawing
Drawing
Internal Reports
10
Inspection of Internals of HP Separator
REMARKS


CONDENSATE TANK

QAP No.: 11-0398B02-01-09-02-017
Rev. 0
Page No. 2 of 3
INSPECTION BY
SR. NO.
11
12
13
DESCRIPTION
Welding of internals to HP Separator Shell
CHARACTERISTIC
CLASS
TYPE OF CHECK
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE NORMS
FORMAT OF
RECORDS
TPI
CONSULTANT/
OWNER
Weld size/ Reinforcement/ Finish
Major
Template/ Visual
100%
Drawing
Drawing
Internal Reports
Major
PT
100%
LPE01
LPE01
Internal Reports
C Seam set up for shells to Dish Ends
Identification
Major
Visual
100%
Drawing/ IR
Drawing/ IR
Internal Reports
& Test
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Plates
Weld preparation
Major
Template
100%
Drawing
Drawing
Internal Reports
Major
Measurement
100%
Drg./ FPAS001
Drg./ FPAS001
Internal Reports
Tack Weld Soundness
Major
PT
100%
Drawing
Drawing
Internal Reports
A. Welding of C Seam (above parts) & Test
Backchip & PT after 1st side welding
Major
Visual
100%
LPE01
LPE01
Internal Reports
plates
Weld size/ finish
Major
Visual
100%
FPAS-001
FPAS-001
Internal Reports
Weld joint soundness of C seam
Major
RT
100%
Design Code
Design Code
Internal Reports
B. Repair: (if any) C Seam
Defect Removal
Major
PT
100%
Design Code
Design Code
Internal Reports
Major
RT
100%
Design Code
Design Code
Internal Reports
14
15
16
17
Heat Treatment of Test Plates + EQPT as per code Time/ Temperature Charts
Major
Visual
100%
Design Code
Design Code
Internal Reports
Testing of all Test Plates
Mech./ Physical Test Reports
Major
Visual
100%
Design Code
Design Code
Internal Reports
Inspection of Marking for Openings on Dish
Identification
Major
Visual
100%
IR/ Drawing
IR/ Drawing
Internal Reports
Ends/ Shelf
Layout
Major
Measurement
100%
Drawing
Drawing
Internal Reports
P
RW
W/R
W/R
W/R
W/R
Inspection after opening on shell/ Dish Ends
Orientation
Major
Visual
100%
Drawing
Drawing
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Drawing
Internal Reports
Acc. Inspn. Rep.
Acc. Inspn. Rep.
Internal Reports
No. of holes
Major
Count
100%
A - Earlier Stage clearance review
Major
Review
100%
B - Opened Holes Orientation

Major
Visual
100%
Drawing
Drawing
Internal Reports
Major
Visual
100%
FPAS-001
Hard Stamping of
Insp.
Drawing
FPAS-001
Internal Reports
Quadrantwise
H - hole finish
18
19
20
21
I - Final Acceptance
Major
Visual
100%
Setup of studs, nozzles, sockets and
Orientation
Major
Visual
100%
connections with Shell / Dish End / Flange
Weld preparation
Major
Template
100%
Alignment
Major
Line thread
100%
Squareness
Major
Right angle
100%
Distance between connections
Major
Measurement
Tack Weld Soundness
Major
PT
Welding of Nozzles, & connections to Shell/
Weld size/ finish
Major
DESCRIPTION
Weld Soundness
Setup of Structurals Saddles & Attachments
Hard Stamping of Insp.
Internal Reports
Drawing
Internal Reports
Drawing/ Code
Drawing/ Code
Internal Reports
Drg / FPAS001
Drg / FPAS001
Internal Reports
Drg / FPAS001
Drg / FPAS001
Internal Reports
100%
Drg / FPAS001
Drg / FPAS001
Internal Reports
100%
LPE01
LPE01
Internal Reports
Visual
100%
Design Code
Design Code
Internal Reports
Major
RT/PT
100%
Design Code
Design Code
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Welding of Structurals Saddles &
Weld preparation
Weld size/ finish
Major
Major
Major
Template
Measurement
Visual
100%
100%
100%
Drawing
Drg./ FPAS001
Design Code
Drawing
Drg./ FPAS001
Design Code
Internal Reports
Internal Reports
Internal Reports
Attachments
Weld Soundness
Major
PT
Sample
Design Code
Design Code
Internal Reports
REMARKS


CONDENSATE TANK

QAP No.: 11-0398B02-01-09-02-017
Rev. 0
Page No. 3 of 3
INSPECTION BY
SR. NO.
22
DESCRIPTION
Full Welding Clearance
CHARACTERISTIC
CLASS
TYPE OF CHECK
QUANTUM
OF CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE NORMS
FORMAT OF
RECORDS
Overall Dimensions
Major
Measurement
100%
Drawing
Drawing
Squareness of Connections
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Distance Between Connections
Major
Measurement
100%
Drawing
Drawing
Internal Reports
RT Clearance/ U.T.
Major
Review of RT Rpts.
100%
Drawing
Drawing
Internal Reports
Major
Rub off
100%
Design Code
Design Code
Internal Reports
Pressure Gauge (2 Nos.)
Major
Review
100%
Valid Cert.
Valid Cert.
Internal Reports
Calibration
Major
Visual
100%
No leakage
No leakage
Internal Reports
Leakage
Major
Document Review
Major
Review
100%
Design Code
Design Code
Internal Reports
Dimensions
Major
Measurement
100%
Drawing
Drawing
Internal Reports
Surface Preparation
Major
Visual
100%
Internal Reports
TPI
CONSULTA
NT/
OWNER
W/R
W/R
W/R
W/R
Internal Reports
Final Inspection
23
24
25
Hydrostatic Testing
Final Inspection
100%
Internal Reports
Clearance for Assembly/ Dispatch (as
Painting finish
Major
Visual
100%
Drawing
Drawing
Internal Reports
applicable)
Capping/ Blanking of all opening
Major
Visual
100%
Internal Reports
Major
Visual
100%
Design Code
Design Code
Internal Reports
Legend
M
Manufacturer
Perform
Client
Review
TPI
Third Party Inspection Agency
Witness
For Approval
W/R
Witness for Test & Review of Certificates & Documents as per QAP
Hold
RW
Random Witness
NA
Not Applicable
REMARKS
LIST OF RECOMMENDED VENDORS

S.NO
ITEM
NAME OF VENDOR
ADDRESS
Ishwardas Aggarwal & Sons (Trader)
39, Lalit House, 3rd floor, Sant

Tukaram Road,
Iron Market,
Mumbai - 400 009
M.J. Patel & company (Trader)
116, P.D. Mello Road, Near Camace

Bridge,
Mumbai - 400 009
Apex Tubes Pvt. Ltd (Manufacturer &

Trader)
Apex Tubes Pvt. Ltd.

1/6 B, Asaf Ali Road
New Delhi - 110 002
Steel Tube (India) (Trader)
526/36, Maulana Azad Road, 2nd

floor, Gulawadi Circle,
Mumbai - 400 004
Nagardas Kanji Shah (Trader)
176, Magazine street, darukhana,

Mazagaon, Mumbai 400 010
(022) 3721066)/
3724157
(022) 3781032
Jyoti Industries
P.B. No. 3081, 276/278, Samuel

street, 2nd floor, Vadgadi, Mumbai
400 003
(022) 3435091/92
(022) 3421 391
205, Magnanial Chambers, Baburao

(022)3430105,
Bobde Marg, Iron Market, Mumbai
3430107, 3434918
400 009
(022) 3414763
Station Piping (Seamless

Pipes) Trader
PHONE NO
FAX NO
QUALIFIED FOR SIZE
(+91)22-342 2566 (+91)22-342 3762
011 - 3236408
(+91)22-389 5908
(+91)22-3895906
(+91)22-381 2564
The Bengal Mill stores supply co

(Trader)
Radiant Engineering Co.
M-2, sundaram, sion college, Mumbai

40 022
(022) 409 2016,

409 6036
(022) 409 4822
Tianjin Pipe corporation
PO box 17537, Jebel Ali Free zone,

Dubai, U.A.E
97148833799
97148833899
10
Milsubihsi
11
Trub Chomulov
12
TENARIS
13
Valcvony
14
Vallurorec Maneshman Tubes Brazil
15
Virgo Engineers Ltd, Pune
Virgo Engineers, J/517, MIDC,

Bhosari, Pune - 411026
020 - 2747 4481
020-2747 0772
16
Steel Strong Valves (P) Ltd.
Plot No. R-241, TTC Industrial area,

MIDC, Rabale, New Bombay - 400
701
17
Flow Chem Industries
10, Navdurga Indl. Estate, Opp Forge

Blower, Naroda Road, Ahmedabad 25
18
Micro Finish Valves
B.D.K. Engineering Ltd.

Gokul Road, Hubli 580 030
upto 12" class 600
Hawa Valves (India) Pvt Ltd
4, Karmabhumi Industrial estate, opp.

Ajit Mill Police chowky. Rakhial Road,
Ahmedabad
Upto 8" class 600
20
L&T / Audco valves
Chennai
Upto 24" 600#
21
Cooper Cameron Valves

(singapore) Pte. Ltd
No.2, Gul Circle, Jurong Industrial

Estate, singapore - 629560
22
BOHMER Ball Valves
Gedulderweg, 95
45549 Sprockhovel
Germany
(+49) 2324 70010 (-49) 2324 700179
Upto 48" 600#
23
MSA
Hlucinska, 41
747 22 Doinin Benesov
Czech Republic
(+420) 553 881111 (+420) 553 651236
Upto 48" 600#
Document No.
Rev.
11-0398B02-01-09-02-018
19
BALL VALVES

FOR
Upto 24"
class 600
Upto 12" class
600 of split
body type
79 - 220 4773
0065 865 2887
79 - 220 1401
0065 861 7109
SHEET 1 of 8
upto 12" class 600
Upto 48" 600#

S.NO
ITEM
QUALIFIED FOR
SIZE
NAME OF VENDOR
ADDRESS
PHONE NO
FAX NO
24
RMA Maschinen - und Armalurenbau

Fulhaber & Truttenbach
Oststrasse, 17 77694 Kehl

Germany
(+49) 78 518680
(+49) 78 5186813
upto 30" 600#
25
SCHUCK ARMATUREN
(ex BORSIG)
Dailerstrasse 4-7 89555,

Steinheim Germany
(+49) 73 29 950 0 (+49) 73 29950161
upto 30" 600#
26
SUD ROBINETTERIE INDSUTRIE

(SRI)
279 -305, Bvd D, Casanova 13309

Marseille, France
(+33) 495 055050 (+33) 495 055070
upto 30" 600#
27
TORMENE GAS TECHNOLOGY

(VALVITALIA)
Via L. Campolongo, 97
35020 Due Carrare PD
ITALY
(+39) 059 919

9511
(+39) 049 9125455
upto 30" 600#
28
VIAR VALVOLE
Via L. Cadorna, 6 21041 Albizzate

VA ITALY
(+39) 0331 99
2985
(+39) 0331 992992
upto 30" 600#
29
BREDA ENERGIA SESTO

INDUSTRIA
Viale Sarca, 336 20126 Milano ITALY (+39) 0264 4771 (+39) 02 64477542
upto 30" 600#
30
FLOW CONTROL TECHNOLOGIES

(TYCO Flow Control)
23, Deuzieme avenue

13743 Vitrolles FRANCE
(+33) 442 103600

(+91) 11 647 1469
(+33)442103636
G39
(+91) 11 646 1550
upto 30" 600#
31
PETRO VALVES
Viale G Borri, 42 21053 Catellanza

VA ITALY
(+39) 0331 334

111
(+39) 0331 675830
upto 48" 600#
BALL VALVES
32
Contractor shall ensure that each valve manufacturer shall have valid API 6D license and in case of firm order the license shall be valid till complete execution of
supplies.
33
BIFI
Italy
34
Rotork Fluid System
Italy
CAMERON
Italy
36
PC Intertecnik
Germany
37
Bettis
Belgium
38
LEDEEN
Texas
39

79 - 220 4773
40
Shreeraj Industries
101, Samrudhi, Sattar Taluka

Society, Opp old high court lane,
Ahmedabad
79 - 2204773/
3623
41

MIDC, Rabale, New Bombay - 400
701
Upto 12" class

600 of split
body type
Ornate Valves Pvt. Ltd, Mumbai
104, Eric House 16th Road Chembur,

Mumbai - 400 071
upto 12" 600#
43
Micro Finish Valves

upto 12" class 600
44
L&T / Audco Valves
Chennai
Upto 24" 600#
45
Niton Valve Industries Pvt. Ltd
SD -115/116 Ghatkopar Industrial

Estate, L.B.S. marg
Ghatkopar (West)
Mumbai 400 086
46
L&T / Audco valves
Chennai
47
35
Gas Over Oil Actuators
42
Globe Valve
Check/ Non Return

Valve
022- 500 8315
79 - 220 1401
upto 12" 600#
022 - 5007654

MIDC, Rabale, New Bombay - 400 022 - 27699489/90 022 - 27695537
701
48
Micro Finish Valves

49


FOR
upto 12" 600#
Upto 24" 600#
Spring loaded type

upto 12" 600#
of split body type
upto 12" 600 #
79 - 220 4773
79 - 220 1401
upto 12" 600#

(lift type, wafer
type & Swing type)
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 2 of 8

S.NO
ITEM
NAME OF VENDOR
ADDRESS
PHONE NO
FAX NO
QUALIFIED FOR SIZE
Ornate Valves Pvt. Ltd, Mumbai
104, Eric House 16th Road Chembur,

Mumbai - 400 071
Arpita Enterprise
1201, GIDC Estate, Phase IV

Vithal Udyog Nagar
Anand 388 112
02692 - 36187
52
Niton valve Industries Pvt. Ltd
SD -115/116 Ghatkopar Industrial

Estate, L.B.S. marg
Ghatkopar (West)
Mumbai 400 086
022- 500 8315
022 - 5007654
53
FMC Sanmar Ltd
147, Karapakkam Village,

Chennai-600096
044-492-5455
044-492-6114
54
Protego Equipments Pvt. Ltd.
Navi Mumbai
Larsen & Tubro (Audco)
32, Sivaji Marg,Post Box 6223,Near

Moti Nagar, New Delhi
011-25931302
011-25438624
56
MEKASTER/sebim valves India Pvt. Ltd.
908, Ansal Bhawan,16 Kasturba

Gandhi Marg,New Delhi
011-23312110,23318360
011-23712155
57
TYCO SANMAR LTD
Chennai
58
RMG regal + GmbH,Germany
Germany
59
INTERFORGE
60
KURVERS Piping
Mark S Clarkelaan 13 a, Haven No.

M 512, 4761 RK Zevenbergen, The
Netherlands
"+31 168 33 43 44"
"+31 168 33 43 49"
Upto 30" class 600 fittings &

flow tee
61
MEREK Engineering
Premier estate, Leys road, Brockmoor

Brierley Hill, DY5 3UT West
midlands, UNITED KINGDOM
"+44 121 544 9938"
"+44 121 544 9132"

flow tee
62
PETROFIT
Unit 3 Rowan Court, Crystal Drive,

Smethwick, B66 1RB West Midlands,
UNITED KINGDOM
0121 544 9938
0121 544 9132

flow tee
63
PHOCEENINE (Groupe Genoyer)
Ten bergstraat 4, 2830 Wildebroek,

BELGIUM
"+32 3 860 73 70"
"+32 3 860 73 71"

flow tee
64
VAN LEEUWEN BUIZEN
Schaarbeeklei 189, 1800 Vilvoorde,

BELGIUM
"+32 2 255 40 00"
"+32 2 253 20 92"

flow tee
65
MS Fittings Mfg. Co. Pvt. Ltd.,

Kolkatta
M.S.FITTINGS MFG.
CO.(P)LTD.,H.O 17 WESTERN
STREET, KOLKATTA 13
033-2362902, 2362903
033-2252103
66
Ferrous Alloy Forgings(P) Ltd.
Ferro tubes & Forging Industries, C

1/129, GIDC Estate, vaghodia,
Baroda-391760
02668-62479
Pipe Fit Engineers
496/1 GIDC Industrial Estate,

Makarpura, Baroda-390010,
pipefit@pipefit.net
0265-2636 547/545
0265-2636 546
Upto 24"class 600
68
Teekay Tube
315/317, Navratan 69,P D Mello

Road Near Camac Bridge, Mumbai400009
"+91 22 342 3382-83,

91 22 343 7716
,345477, 3446975"
(022)349162
Upto 24"class 600
69
Alliance Fittings & forgings

, Navi Mumbai
Alliance fittings & forgings inc.,

A-468/469,T.T.C Industrial Area
022-2788 1333/1916
022-2788 1134/
5590 2273
Upto 12" Class 600
70
Swastik Lloyds Engineering Pvt. Ltd.,

Mumbai
Swastik Lloyds Engineering Pvt.

Ltd.,5 B Islam pura Street,
Mumbai-400004
022-3860222/23
022-7402779
Upto 12" Class 600
71
Steel Tubes (India)
526/36,Maulana Azad Road,2nd

Floor, (Gulawadi Circle), mumbai400004
022-3895908/
3822821
022-3895906
Upto 24"class 600
72
Eften Engineering Pvt. Ltd.
D1,Sipcot Industrial Park,

Irungaltukottai-602105, Tamil nadu
04111-256284,
256714
04111-256714
Upto 8"class 600
73
Dylan Belgie
Lerenveld 20, 2547 Lint, Belgium
32 3 488 4880
32 3 488 4880
Upto 30" class 600

fittings & flow tee
74
FBF
Dynamicalaan 4-8,
2610 Anlwerpen, Belgium
32 3 820 5880
32 3 828 2822
Upto 30" class 600

fittings & flow tee
75
Ferrostaal(Mangroup)
Hohenzollernstrasse 24, 45128

Essen, Germany
49 201 818 01
49 201 818 2822
Upto 30" class 600

fittings & flow tee
1
50
51
Check/ Non Return

Valve
55
upto 12" 600#

Lift & Swing type
upto 8" 600#
(wafer type)
Upto 24" 600#

(Lift & Swing Type)
Pressure Relief Valve
67
Pipe fittings (Elbows,

Tees,Reducers)
Grobe Strabe 14, 27356 Rotenburg,

Germany

FOR
"+49 4261 4081"
"+49 4261 3090"

flow tee
Upto 24"class 600
Upto 12"
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 3 of 8

S.NO
QUALIFIED FOR
SIZE
ITEM
NAME OF VENDOR
ADDRESS
PHONE NO
FAX NO
Pipe fittings (Elbows,

Tees,Reducers)
Sawan Engineers
201, Palace Plaza,lalbaug Road,

Near kashivishwanath
Temple,Baroda-390001, Email
:sawanengg@sify.com
0265-243 3003/553
8303
0265-243 5196
77
Ferrous Alloy
Forging(P) Ltd.
111,DLF Industrial
Estate,14th Mile stone,
Mathura Road
Faridaba-121003
78
Sanghvi Forging &

Engineering Ltd
Parvati chambers,Opp
Apsara cinema-pratap
Nagar Road,
Baroda-390004
0265-258 0644
/1658
0265 258 1125
upto 12" 600#
79
Sawan Engineers
201,Palace Plaza,
Lalbaug Road,Near
kashivishwanath
Temple, Baroada-390001
0265-2433003/
3096008
0265-2435196
upto 18" 600#
80
ECHJAY Forgings
Ltd.
Kanjur Village Road,

Kunjan Marg east
Mumbai- 400042
225782461
225782830
225784962
upto 30" 600#
81
Ms Fittings Mfg.Co.
Pvt.Ltd.Kolkata
Ms Fittings Mfg.Co.
Pvt.Ltd.Kolkata,
H.O.17 Westeren street,
Kolkata-13
033-2352902,
2362903
033-2252103
upto 24" 600#
82
Pipe Fit Engineers
496/1,GIDC,Indi.Estate
Makarpura,
Baroda-390010
0265-2636547
/545
0265-2636546
upto 24" 600#
83
Punjab Steel Works
38B, MayapurI Indl Area

Phase-1
New Delhi-110064
011-5130960
115137432
upto 24" 600#
84
Yokogawa
1
76
Flanges
85
86
Emerson Process Management
89
Swagelock
Instrument Fittings
including manifold,
needle valve etc
92
93
Honeywell Automation
ABB
88
91
upto 24" 600#
Invensys India
Pressure
/Level/Temeprature
transmitters
87
90
upto 24" class 600
Hamlet
Hoke
Parker
Impulse tubing
Sandvik
FOR
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 4 of 8

S.NO
ITEM
NAME OF VENDOR
94
Positronics
95
ICA
96
Instrumentation Panel
Pyrotech Controls
98
Enclotek
99
Daniel
100
RMG
Turbine Flow Meter
FMC
103
Instromet/Elster
MTL India Pvt. Ltd

Signal Repeater &
Isolator
105
FAX NO
A-273 Ansal chambers-1

3,Bhikaji cama place, New Delhi
011-26715408/6180
011-2671681
QUALIFIED FOR
SIZE
GE
102
104
PHONE NO
Rittal
97
101
ADDRESS
P&F
106
Concord
Indication Lamp
(Cluster LED type)
107
L&T
108
SITOP
109 24 V DC Power supply
Siemens
110
PHEONIX
111
Pyroelectric Instruments
112
General Instruments
RTD With Thermowell
113
ALTOP
114
A.N.Instruments
115
Roxtec
116
MCT
NEIMEX
117
Signet International
118
Flame Proof Control Gears Pvt. Ltd
119
Flame Proof Equiments Pvt. Ltd

Junction Box
120
Flex pro Electricals pvt. Ltd,Navsari
121
CEAG
FOR
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 5 of 8

S.NO
ITEM
122
NAME OF VENDOR
ADDRESS
PHONE NO
FAX NO
A-273 Ansal chambers-1

3,Bhikaji cama place, New Delhi
011-26715408/6180
011-2671681
QUALIFIED FOR
SIZE
IIC
Alarm Anunclator
123
Procon
124
KAYCEE
Selector Switch
125
SALZER
126
PECO
127
GD ENGG
128
R&M Energy Systems
129
Quick Open Closure
TD Williams
130
Peerless
131
Huber Yale
132
Pipeline Technologies UK
133
Honeywell
134
ABB
Digital Bar graph
Indicator
135
YOKOGAWA
136
MASIBUS
137
B.C.H.
138
Baliga
139
Switch Socket & Plugs
CGL
140
MDS
141
Delton
142
CORDS
143
KEI
Instrumentation Signal
Control Cable
144
Elkay Telelinks.
145
Polycabs Associate cables
146
MTL India Pvt. Ltd

Isolating Barrier
147
P&F
FOR
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 6 of 8

S.NO
ITEM
NAME OF VENDOR
148
Control switch Gear
149
Electromac
150
Cable Glands
Baliga
152
Flameproof Control Gear

Lugs
FAX NO
QUALIFIED FOR
SIZE
Dowells
154
IL Paighat
155
Fisher
156
PHONE NO
Commet
151
153
ADDRESS
Valtec
Control Valve
157
Dresser valves(India)
158
Arca Controls
159
Masoneilan
160
Daniel
161
ABB
Gas Chromatgraph
162
Instromet/Elster
163
RMG
164
Elemex
Terminal Block
165
Phoenix Contact(India) Pvt.Ltd.
166
PECO-FACET
167
FILTAN
168
VELCON
169
ACS
170
Filter Element / Cartridge
BURGESS MANNING
171
PALL
172
FILTERATE
173
DOLLINGER
174
DAHLMANN
FOR
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 7 of 8

S.NO
ITEM
NAME OF VENDOR
175
Grand Prix Engineering (P) Ltd.
176
Multitex Filtration Engineers Ltd.
177
Triveni Plenty Engg. Ltd.
178
Gas Tech
179
Flash Point
180
BGR Energy System
181
Slug Catcher /
Filter Separator /
Condensate Tank
ADDRESS
PHONE NO
FAX NO
ABB, Faridabad
182
Petromar Engineered Solutions Pvt.

Ltd. (Formerly Ravi Techno Systems
Pvt. Ltd.)
183
Burgess Manning
184
Tormene Gas Technology
184
Taylor Forge Engineered Systems,

INC.
184
Indcon Projects & Equipments

Limited
New Delhi
185
Indus Projects Limited
Kolkata
186
Tata Projects Ltd.
22,Sarvodaya
Society,Nizampura,Baroda-390002
187
Indian Register of Shipping
188
Bax counsel Insepection Bureau Pvt.

Ltd.
189
Bureau VeritasQl
190
Germanischer Lloyd
304-305, Anna
Salai,Teyanampet,Chennai-600018
044-24320335
044-24328186
Velosi Certification
Serrvices,Mumbai
Velosi Certification
Services(I)Pvt.Ltd.,212,Shivkrupa
Complex Centre,Off Ghokhale
Road,Navpada Thane(W)400602
022-25376770
022-25426777
192
ABS Industrial Verification Ltd.,

Mumbai
404,Mayuresh Chambers,Sector11,CBD Belapur(E),Navi Mumbai400614
022-27578780 /1 /2 022-27578784 / 5
193
Certification Engineers International

Ltd.
EIL Bhavan,5th floor,1,Bhikaji Camma

Place,New Delhi-110066
011-26167539,
26102121
011-26101419
194
Dalal Mott MacDonald
501, Sakar -II, Ellisbridge,Ahemedabad380006
079-26575550
079-6575558
195
International Certification Systems
E-7,Chand Society, Juhu Road, Juhu,

Mumbai-4000049
022-26245747
022-226248167
196
SGS
SGS India Pvt. Ltd.,SGS

House,4B,A.S.Marg,Vikhroli
(W),Mumbai-400083
191
Third Party Inspection

Agency
QUALIFIED FOR
SIZE
0265-2392863
0265-2785952
303, Madhava,Bandra Kurla Complex, 022-26591526,022022-26591526

Bandra(E),Mumbai-400051
26590236
The Leela Galleria,5th floor,Andheri022-26956300
Kurla Road,Andheri(E),Mumbai-400059
022-26956309
022-25798421 to 28 022-25798431 to 33
NOTE: IF THE VENDOR WANTS TO GO TO ANY OTHER VENDOR OTHER THAN THOSE APPEARING IN APPROVED VENDOR LIST, HE HAS TO SUBMIT PTR &
FINANCIAL STATUS OF THE SAME FOR OWNER/CONSULTANT REVIEW BEFORE COMMENCING PROCUREMENT.

FOR
Document No.
Rev.
11-0398B02-01-09-02-018
SHEET 8 of 8
INSTALLATION OF IP STATION AT ANKHI,

GUJARAT ON 12 GANDHAR- DABKA PIPELINE
THIRD PARTY INSPECTION AGENCY FOR CONDENSATE

RECOVERY SYSTEM
DOCUMENT NO
11
0398B02
01
CLIENT JOB
NO.
TOTAL
SHEETS
09
02
04
019
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
TABLE OF CONTENT
1.0
INTRODUCTION ....................................................................................................... 3
2.0
SCOPE OF WORK .................................................................................................... 3
3.0
CO-ORDINATION FOR INSPECTION ........................................................................... 3
4.0
INVOLVEMENT OF TPIA ............................................................................................ 3
THIRD PART INSPECTION AGENCY

FOR CONDENSATE RECOVERY
SYSTEM
Document No.
Rev
11-0398B02-01-09-02-019
SHEET 2 of 4
1.0
INTRODUCTION
The objective is to specify the role of Third Party Inspection Agency (TPIA) appointed by
Supplier for supply items for carrying out inspection.
The Supplier will appoint an independent approved Third Party Inspection Agency (TPIA) whose role shall
be to witness, review and certify all quality related issues for supply of material. The TPIA shall ensure that
all quality related requirements during manufacturing are strictly followed as per Owner/Owners
representative specifications and approved documents. Owner shall appoint its TPIA for witness, review
and certification of all the construction activities.
2.0
SCOPE OF WORK
2.1
Role of TPIA for supply items

TPIA, as appointed by the Supplier from list to be provided, shall witness, review and certify all quality
related activities for supply of material. The extent of TPIA involvement as a minimum is indicated in the
various Quality Control Sheets attached with the tender document and shall be as per final approved
QA/QC procedures or as per codes and standards, wherever applicable.
2.2
Role of Owner / Owners representative for supply items

For supply items, Owner / Owners Representative reserves the right to carryout independent inspection /
audit of the plant during manufacturing. The extent of inspection shall be at the discretion of Owner I
Owners Representative. All costs related to the same (excluding travel expenses) shall be borne by
Supplier
2.3
The various Hold points involvement as mentioned in various QC sheets are indicative minimum.
However, actual involvement shall be decided by Owner/Owners Representative during review of
documents, and Supplier shall be bound by the same. Supplier shall also submit the calibration certificates
of all the equipment/instruments, which are part of manufacturing/Inspection & testing for TPIA review
TPIA shall also be responsible to check /witness the necessary calibration of such equipment/Instruments
during visit to suppliers works.
3.0
CO-ORDINATION FOR INSPECTION

Supplier on award of the Contract/LOl shall submit the detailed procurement schedules within fifteen (15)
days to Owner/Owners representative for their approval. The detail item wise Manufacturing schedule
indicating dates and location of manufacturer works shall be submitted by the Supplier within One (1)
week from the date of issue of their internal Indent /Purchase order to sub vendor.
The Supplier shall inform in writing minimum One (1) week in advance to inform the Owner/Owners
representative for Inspection Notice/Call. All coordination among Owner/Owners representative/TPIA and
Suppliers/ Vendors works shall be the responsibility of Supplier. In case the Supplier fails to honour its
inspection calls/notice, supplier has to reimburse all costs incurred by the Owner/Owners representative
at actual.
4.0
INVOLVEMENT OF TPIA
4.1
The Minimum requirements are indicated in the Quality Control Tables attached in tender document.
4.2
Mechanical
All bought out items required for execution activities for mechanical supply should satisfy the following
conditions:
All materials shall be of standard quality and shall be procured from renowned sources /
manufacturers approved by Owner/Owners representative.

SYSTEM
Document No.
Rev
11-0398B02-01-09-02-019
SHEET 3 of 4
4.3
All tests of the materials as specified by the relevant codes should be carried out by the supplier in
an approved laboratory and the test reports should be duly authenticated by the laboratory and
should be submitted to TPIA for his approval. If so desired by Owner/Owners representative, tests
shall be conducted in his presence or in presence of his authorized nominee.
Quality and acceptance of materials not covered under technical specifications shall be governed by
relevant codes.
The Supplier shall submit manufacturers test reports on quality and suitability of any material
procured from them and their recommendations on storages/application/workmanship etc. for the
intended use. Submission of manufacturers test reports does not restrict Owner/Owners
representative from asking fresh test results from an approved laboratory of the actual materials
supplied even from an approved manufacturer.
The Supplier shall furnish the QAP for all supply items for approval.
Instrumentation
All bought out items for required execution activities for Instrumentation works should satisfy the following
conditions:
Supplier shall furnish the quality assurance procedure for field instruments and cables for review of
Owner/Owners representative.
QAP will commence at the instigation of the requisition and follows through to equipment
acceptance, thereby ensuring total conformity to the specifications.
Type test certificates of similar equipment shall be provided.
Owner/Owners Representative shall carryout the inspection of erection of the equipment and
witness the testing and commissioning and approve the certificates.

SYSTEM
Document No.
Rev
11-0398B02-01-09-02-019
SHEET 4 of 4

FOR
TUBES & TUBE-FITTINGS
DOCUMENT NO
11
0398B02
CLIENT JOB NO.

TOTAL SHEETS
01
11
02
06
021
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APP
R
CONTENTS
1.0
GENERAL
2.0
3.0
NAME PLATE
4.0
ANNEXURES:
ANNEXURE - 1: HYDROSTATIC TEST PRESSURES FOR INSTRUMENT TUBE FITTINGS
FOR
Document No.
Rev
11-0398B02-01-11-02-020
SHEET 2 of 6
1.0
GENERAL
1.1
Scope
1.1.1
This standard specification, together with the data sheets attached herewith, covers the
requirements
for
the
design,
materials,
inspection,
testing
of
instrument
tube
fittings which includes the following types:
1.1.2
a)
Stainless steel compression fittings (for stainless steel tube)
b)
Brass compression fittings (for copper tube)
The related standards referred to herein and mentioned below shall be of the latest editions
prior to the date of the purchaser's enquiry: ANSI/ASME
American National Standards Institute/American Society of Mechanical

Engineers
1.1.3
B 1.20.1
Pipe Threads General Purpose (Inch).
B 16.11
Forged Steel Fittings - Socket Welding and Threaded.
BS-4368
Carbon and Stainless Steel Compression Couplings for Tubes.
EN 10204
Inspection Documents For Metallic Products.
IS-319
Specification for free cutting Brass Bars, Rods and Sections.
ISA
Instrumentation, Systems and Automation Society.
RP 42.1
Nomenclature for Instrument Tube Fittings.
In the event of any conflict between this standard specification, data sheets, statutory
regulations, related standards, codes etc., the following order of priority shall govern:
a)
b)
Data Sheets
c)
d)
Codes and Standards
2.0
2.1
Stainless Steel Tube Fittings
2.1.1
Nomenclature of all tube fittings shall be as per ISA RP 42.1.
2.1.2
Fittings shall be of flare less compression type having four-piece (for double compression type)
construction consisting of two ferrules, nut and body or three piece (compression type) construction
consisting of single ferrule, nut and body suitable for use on tubes of specified material for example
stainless steel tubes conforming to ASTM A269 TP 316L with hardness in the range of HRB 70 to 79.
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SHEET 3 of 6
2.1.3
All parts of the tube fittings shall be of 316 Stainless Steel unless specified otherwise.
2.1.4
Hardness of the ferrules shall be in the range of HRB 85-90 so as to ensure a hardness difference of
the order of 5 to 10 between tube and fittings for better sealing.
2.1.5
Nuts and ferrules of a particular size shall be interchangeable for each type.
2.1.6
Spanner hold shall be metric.
2.1.7
Threaded ends of fittings shall be NPT as per ANSI B 1.20.1.
2.1.8
Specific techniques like silver plating shall be used over threading in order to avoid jamming and
galling.
2.1.9
Ferrule finish and fitting finish shall be such that there is no abrasion/galling when the nut is tightened.
2.1.10
All instrument tube fittings in oxygen and chlorine service shall be thoroughly degreased using reagents
like trichloro-ethylene or carbon tetrachloride. End connection shall be plugged after degreasing
process in order to avoid entrance of grease or oil particles.
2.2
Copper Tube Fittings
2.2.1
Nomenclature of all tube fittings shall be as per ISA RP 42.1.
2.2.2
Fittings shall be of flare less compression type and of three-piece construction consisting of ferrule, nut
2.2.3
and body suitable for use on copper tubes conforming to ASTM B68 /B68M, hardness not exceeding
HRB 50.
2.2.4
All parts shall be manufactured from brass as per IS 319 bar stock and nickel plated.
2.2.5
For better grip, vendor shall maintain hardness difference between tube and ferrule and indicate the
same along with the offer.
Threaded ends of fittings shall be NPT as per ANSI
Spanner hold shall be metric.
3.0
NAMEPLATE
3.1
No separate nameplates are required on the fittings. However, manufacturer's name/trademark should
be punched on a visible place on the body of each fitting for easy identification.
4.0

4.1
Unless otherwise specified, purchaser reserves the right to test and inspect all items at vendor's works,
inline with the inspection test plan for instrument tube fittings.
4.2
4.2.1
Type test reports for following tests in accordance with BS-4368 Part IV:
a)
Hydrostatic proof pressure test.
b)
Minimum hydrostatic burst pressure test.
c)
Disassembly and reassembly test.
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d)
Minimum static gas pressure (vacuum) test.
e)
Maximum static gas pressure test.
f)
Hydraulic impulse and vibration test.
4.2.2
Material test certificates as per clause 3.1 B of EN 10204.
4.2.3
Routine test reports for following tests:

a)
Hydrostatic Test
Instrument tube fittings shall be hydrostatically tested at ambient temperature at test
pressures given in Annexure 1 of this specification. During and after the hydrostatic test, the
tube fittings shall not show any leakage or rupture.
b)
Pneumatic pressure test

The fittings shall be tested at 7 kg/cm2g of dry air. There shall not be any visible leakage
when immersed in water or coated with a leak detection solution.
c)
Disassembly and reassembly test.
d)
Hardness verification:
Hardness test shall be carried out on each rod used for machining ferrules. Vendor shall
ensure that after machining, the finished ferrules shall meet the required hardness given in
the specification.
e)
Dimensional test report
4.3
Witness Inspection
4.3.1
All fittings shall be offered for pre-dispatch inspection for the following as a minimum:
a)
Physical dimensional verification and workmanship on representative samples.
b)
Hydrostatic and pneumatic tests as per clause 4.2.3 of this specification on representative
samples.
4.3.2
c)
Hardness verification as per clause 4.2.3 of this specification.
d)
Disassembly and reassembly test on representative samples.
e)
In the event when no witness inspection is carried out by purchaser, vendor shall anyway complete the
tests and test reports for the same shall be submitted to purchaser for scrutiny.
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HYDROSTATIC TEST PRESSURES

FOR INSTRUMENT TUBE FITTINGS
Sr.
No.
Size of Tube
Fittings
Material
Line Pressure
Class
Hydrostatic Test Pressure
6mm and 1/2"
Stainless Steel
<600#
153 Kg/cmg
6mm and 1/2"
Stainless Steel
> 900# to
<1500#
383 Kg/cmg
6mm and 1/2"
Brass
FOR
80 Kg/cmg
Document No.
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SHEET 6 of 6
CLIENT
S.No.
UOM
GAIL India Limited
PROJECT NAME
Pressure : kg/cm2g
Flow Rate : MMSCMD
INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12"

GENERAL
1
2
Project
ARC-04
Job No.
Owner
M/s GAIL (India) Ltd.
Site
PMC
M/s Wood Group India Pvt. Ltd.
Unit
Item TAG No. 110398B02-SP-0101
Qty. Reqd.
Working
Applicable to
Proposal
Applicable Codes & Standards
Standby
One
Nil
Unit No.
Service
Sump Pump
Parallel Operations Reqd.
No
Driver
Electric Motor, Flame Proof
Driver Supplied & Mounted By
API 610, Latest Edition
Pump Manufacturar
OPERATING CONDITIONS
Capicity ( m3/hr): Min./ Nor./ Rated
10
Liquid Handled
Condensate
11
Pumping Temp.
Ambient
Discharge Pressure: Max./ Rated (kg/cm g)
12
Specific Gravity at P.T.
0.8078
Suction Pressure: Max./ Rated ( kg/cm2 g)
9.0/10.0/11.0
2
13
Vapour Pressure at P.T. ( kg/cm2 )
Diff. Pressure ( kg/cm2 g ) @Rated Capacity
14
Viscosity at P.T. ( cP)
Diff. Head (m) @ Rated Capacity
15
NPSH Available / Required (m)

MANUFACTURER'S SPECIFICATION
16
17
Pump Manufacturer
Model No.:
CONSTRUCTION
18
Bowl Head Calculations: (m)
19
Pump Type
20
Vertical Double Casing Type
Diff. Between min. liquid level/min
21
Casing Connections
Submerged level and bottem of Mounting
22
Line Shaft
Plate( whichever is higher)
23
Shaft Dia. (mm)
Diff. between Mounting plate level and
24
Spacing Between Shaft Guide Bushing
discharge. Flange centerline/top of flange
25
Coupling
Make
Friction losses in Suction Strainer
Type
Friction losses in Column/Discharge pipe
26
27
External Shaft Vertical Pump
Differential Head at Discharge Flange
Non Spark Guard
28
Line Shaft Coupling Type
29
Column Type
Total (Bowl) Differential Head (m)

PERFORMANCE
30
Column NB (mm)
31
Nozzles
32
Suction
33
Discharge
34
Imp. Dia (mm)
Max.
35
Guide Bushing
Material
36
Guide Bushing Lubrication
37
Driver Half cplg. Mounted by
38
Packing Type
39
Mech Seal
40
Make/Model
41
Mounting Plate
42
Mounting Plate Gasket
43
Moter Mounting Stool
44
Suction Strainer
45
Size
Size
ANSI Rating
No. of Column Segaments
Proposal Curve No.
Facing
Position
Visc. Corr. Factor
Submerged
NPSH Reqd. (water) (m)
Side
No. of Stages
Rated.
Co
Min.
Efficiency
No.
Rated BKW (0% Tol.) (kw)
CQ
CH
F/L Speed (rpm)
Max. BKW rtd.Imp. (m)

Rec. Driver Rating (kw)
No.of Rings
Hydrostatic Test pressure (kg/cm2 g)
API Code
Thrust ( kg) Up
Max. / Min.
Thrust (Kg) Down
Max. / Min.
Rotating Facing Coupling end
Type
WEIGHT DATA
Weight of the Pump (kg)
Make
Weight of The Mounting Plate (kg)
Mesh Size
Weight of the Mounting Stool (kg)
46
Foundation Bolts
Weight of the Driver (kg)
47
Mounting Bolts
Total Weight of the Pump Unit (kg)
DATA SHEET FOR SUMP PUMP

(VERTICALLY SUSPENDED VESSEL MOUNTED)
DOCUMENT NO.
REV.
11-0398B02-01-09-03-021
SHEET 1 OF 2
CLIENT
GAIL India Limited
PROJECT NAME
INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12"

INSPECTION & TESTS (EACH PUMP)
48
49
Witness
50
Shop Test/ Inspection
51
Material Certificates
52
Hydrostatic
53
Observe
Witness
Observe
NPSH Test
Dismantle Inspection & Reassembly after test
Unitisation/ dimentional check
Perfomance/Sound Level
Check for diection of rotation of pump & driver
54
Complete Unit Test
55
Materials Class (API 610):
56
Materials:
MOC
57
Casing / Barrel
Carbon Steel
(All interface connections shall be terminated with a flange block valve)
58
Impeller
Carbon Steel
Item Description
59
Inner Case Parts
Carbon Steel
Lantern Ring Inlet/Outlet
60
Sleeve Packed
61
Sleeve seal
62
Casing wear ring
H-BHN
Seal pot vent/drain
63
Impeller wear ring
50(min.)
Casing vent/drain
64
Shaft Driver
C.W. Inlet/Outlet
65
Shaft Intermedioate
Base plate drain (only flanged)
66
Shaft
67
Column
68
Mounting Plate
69
Discharge Plate
70
Throttle Bush
71
Driver suitable for end of curve operration with max. specific gravity.
72
First dry critical speed of pump assembly in vertical condition.
AUXILIARY PIPING INTERFACE CONNECTIONS
ASTM Grades
Rating
Facing
Ext. Seal flush fluid inlet/outlet

Seal Quench fluid inlet
SS 316 / 410
73
SITE AND UTILITY DATA
74
Location:
Indoor:
Heated:
Steam Inlet/outlet for Jacket
Under Roof:
75
Outdoor:
Unheated:
Grade:
76
Partial Side:
Mazzenine:
Other:
Group:
Division:
77
Size
Electrical Area Classification:
78
Class:
79
Winterisation Required:
Tropicallisation Required:
80
Site data:
81
Altitude (m):
82
Range of Ambient Temperature (oC): Min / Max
83
Relative Humidity (%) Min / Max
Barometer (kg/sq.cm g):
DATA SHEET FOR SUMP PUMP

(VERTICALLY SUSPENDED VESSEL MOUNTED)
DOCUMENT NO.
REV.
11-0398B02-01-09-03-021
SHEET 2 OF 2

12" GANDHAR-DABKA PIPELINE
CLIENT JOB NO.
TECHNICAL SPECIFICATION FOR PAINTING

TOTAL SHEETS
DOCUMENT NO
11
0398B02
01
09
27
02
022
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
TABLE OF CONTENT
1.0
GENERAL .............................................................................................................................. 3
2.0
CODES & STANDARDS ........................................................................................................ 3
3.0
CONDITIONS OF DELIVERY ................................................................................................ 4
4.0
COMPOSITION OF THE PAINT PRODUCTS USED............................................................. 4
5.0
IDENTIFICATION ................................................................................................................... 5
6.0
SURFACE PREPARATION STANDARDS ............................................................................ 6
7.0
PREPARATION OF THE SURFACES ................................................................................... 6
8.0
METALLISATION................................................................................................................. 10
9.0
CARRYING OUT THE PAINTWORK ................................................................................... 10
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1.0
GENERAL
1.1
These technical specifications shall be applicable for the work covered by the contract, and without
prejudice to the provisions of various codes of practice, standard specifications etc. It is understood that
contractor shall carry out the work in all respects with the best quality of materials and workmanship and
in accordance with the best engineering practice and instructions of Engineer-In-Charge.
Wherever it is stated in the specification that a specific material is to be supplied or a specific work is to
be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any
deviation from this standard without written deviation permit from appropriate authority will result in
rejection of job.
1.2
SCOPE
1.2.1
Scope of work covered in the specification shall include, without being limited to the following.
1.2.2
This specification defines the requirements for surface preparation, selection and application of primers
and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures,
external & internal protection of storage tanks for all services, MS Chimney without Refractory lining and
Flare lines etc. The items listed in the heading of tables of paint systems is indicative only, however, the
contractor is fully responsible for carrying out all the necessary painting, coating and lining on external
and internal surfaces as per the tender requirement.
1.2.3
Extent of Work
1.2.3.1 The following surfaces and materials shall require shop, pre-erection and field painting:
a. All uninsulated C.S. & A.S. equipment like columns, vessels, drums, storage tanks(both external &
internal surfaces), heat exchangers, pumps, compressors, electrical panels and motors etc.
b. All uninsulated carbon and low alloy piping, fittings and valves (including painting of identification
marks), furnace ducts and stacks.
c.
All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc.
e. Flare lines, external surfaces of MS chimney with or without refractory lining and internal surfaces of
MS chimney without refractory lining.
f.
Identification colour bands on all piping as required including insulated aluminium clad, galvanised,
SS and nonferrous piping.
g. Identification lettering/numbering on all painted surfaces of equipment/piping insulated aluminium

clad, galvanized, SS and non-ferrous piping.
h. Marking / identification signs on painted surfaces of equipment/piping including hazardous service.
i.
Supply of all primers, paints and all other materials required for painting (other than Owner supplied
materials)
j.
Over insulation surface of equipments and pipes wherever required.
k.
Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
l.
Painting of pre-erection/fabrication and Shop primer.
m. Repair work of damaged pre-erection/fabrication and shop primer and weld joints in the field/site
before and after erection as required.
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n. All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP plant.
1.2.3.2 The following surfaces and materials shall not require painting in general. However, if there is any
specific requirement by the owner, the same shall be painted as per the relevant specifications:
a. Uninsulated austenitic stainless steel.
b. Plastic and/or plastic coated materials
c. Non-ferrous materials like aluminum.
1.2.4
Documents
1.2.4.1 The contractor shall perform the work in accordance with the following documents issued to him for
execution of work.
a. Bill of quantities for piping, equipment, machinery and structures etc.
b. Piping Line List.
e. Painting specifications including special civil defence requirements.
1.2.5
Unless otherwise instructed, final painting on pre-erection/ shop primed pipes and equipments shall be
painted in the field, only after the mechanical completion, testing on systems are completed as well as
after completion of steam purging wherever required.
1.2.6
Changes and deviations required for any specific job due to clients requirement or otherwise shall be
referred to J P Kenny for deviation permit.
2.0
CODES & STANDARDS

Without prejudice to the specifications of the contract, the following codes and standards shall be
followed for the work covered by this contract.
3.0
IS: 5
Colors for ready mixed paints and enamels.
IS: 101
Methods of test for ready mixed paints and enamels,
IS: 161
Heat resistant paints.
IS: 2074
Specifications for ready mixed paint, red oxide zinc chrome priming.
IS: 2339
Aluminum paint for general purposes in dual container.
IS: 2379
Color code for identification of pipelines.
IS: 2932
Specification for enamel, synthetic, exterior (a) undercoating. (b) Finishing.
CONDITIONS OF DELIVERY
Packaging
Every recipient will be fitted with a hermetically-sealed lid with an opening that is sufficiently large to
allow the contents to be stirred: the outside and inside are protected against oxidation, and, the lid,
are marked with a strip of color identical to the contents.
4.0
COMPOSITION OF THE PAINT PRODUCTS USED

a) Quality
The composition and quality of the products may not differ from batch to batch. A batch is all of
the products of a specified manufacture. If the analyses of products bring to light that the
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SHEET 4 of 27
composition does not conform to the specifications of the paint manufacturer, the OWNER may
refuse to use this batch of products. The paint products must comply with the following
conditions
They must have the viscosity necessary for the described use and the established
condition: use of the brush - paint roller (spray gun only for special cases and in the
workshop)
b) Quality control - Sampling

While the works are in progress on the construction site, the OWNER may carry out sampling on
the paint being used for the purpose of checking conformity. The paint products must be made
available free of charge to the laboratory or the approved supervisory body in sufficient
quantities so that all the tests can be carried out on the same batch.
If analyses reveal a non-conformity in the composition of the products used (tolerance of + 3 %
of the dosage of every component), the OWNER may refuse application of the product under
consideration, halt the work and have the nonconforming product already applied removed.
Before proceeding the work, a product that does conform will be required. The only Purpose of
the analysis is to reveal any nonconformity of the composition of the products. Their purpose is
therefore not to assess the quality of the different components. The analyses concerned are not
acceptance tests of the products supplied and in no way affect the obligations of the contractor
specified in the contract towards the OWNER.
5.0
IDENTIFICATION
Every recipient will bear the following information:
Name of the manufacturer
Date and number of manufacture
Name of the product type
Batch no
Net weight of the produced or the contents of the recipient
Date of the expiry.
At the time of delivery, this packaging must bear labels in conformity with the legal stipulations in force.
Leaving the site after work
After completion of a job a general clean-up shall be carried out by the Contractor to remove all debris,
materials or irregularities that his work has brought to the site so that it is left tidy:
The restoration work includes among other things:
The removal of abrasives.
The removal of the different protective coverings.
The Contractor will make the required repairs to any damage after refitting the supports.
The removal of paint and cleaning of the stains on the floor.
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6.0
SURFACE PREPARATION STANDARDS

Following standards shall be followed for surface preparations:
1
Swedish Standard Institution- SIS-05 5900-1967
Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP)
British Standards Institution (Surface Finish of Blast-cleaned for Painting) BS-4232.
National Association of Corrosion Engineers. U.S.A. (NACE).
5.
IS-1477-1971 (Part-1) - Code of Practice for Painting of Ferrous metals in Buildings. (Part 1,
Pre-treatment)
a)
The contractor shall arrange, at his own cost to keep a set of latest edition of above
standards and codes at site.
b).
The paint manufacturer's instruction shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
Proper storage to avoid exposure as well as extremes of temperature.
Surface preparation prior to painting.
Mixing and thinning.
Application of paints and the recommended limit on time intervals between

coats.
c)
Any painting work (including surface preparation) on piping or equipment shall be

commenced only after the system tests have been completed and clearance for taking
up painting work is given by the OWNER, who may, however, at his discretion authorize
in writing, the taking up of surface preparation or painting work in any specific location,
even prior to completion of system test.
7.0
PREPARATION OF THE SURFACES
7.1
General Specifications
The cases that occur in practice on building sites, with regard to painted surfaces, can be broken down
as follows:
Material of which the oxide content disappears by natural oxidation.
Material that has already been covered with a layer of paint in the workshop.
Material that is covered with old paint layers that show different degrees of weathering.
Good preparation oldie surface is the best guarantee for good anti-corrosion protection.
Paintwork may never begin until the surface to be treated is dry and is independent of the base coat and
cleared of dirt, dust, rust, scale, grease, salt attack, cement powder, cement mud-scale, sand, oil, etc.
Based on the environmental conditions of coastal and saline nature, the Painting specification for station
pipes defines the complete requirements like:
Surface preparation standards like NACE etc.

Sand blasting process
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Color Codes for piping

Paint materials types and their DFT measurement.
Selection and application of paints on external surfaces.
The pipeline passes through the coastal and marine environment, the Table-4 of this specification to be
followed for the painting works.
The method of preparation of the surface will be implemented in accordance with the preparation
methods described below:
Cleaning (bright blast-cleaning);
Mechanical cleaning;
Manual derusting.
The Contractor should have the required material at his disposal to clean the surfaces to be coated
thoroughly in accordance with the preparation methods regardless of the form or the condition of such
surfaces. The cleaning devices that might be damaged during the surface preparation shall be screened
off by the Contractor.
7.2
Sandblasting
Before beginning cleaning by blasting, the person carrying out the work will take the following measures:
Clear the steel surface of oil and/or grease;
Ensure that each flange collar (section where the sealing is applied) is properly screened off
against the blasting and the subsequent works;
Check that no blasting grains can act into the pipes during this process. Any openings not
sealed off must be screened off;
Where there are valves, regulators and other devices, the manufacturer's identification plate will
be dismantled so that all surfaces can be treated. The plate will then be put back again.
Screen off all non-metal structures such as rubber where there is a filter;
With valves, operators and other devices, care should be taken to ensure that no metal filings or
paint get into the apparatus:
The OWNER reserves the right to carry out part or all of these works himself.
To prevent rust forming quickly as the result of humidity on the blasted surface, cleaning by blasting may
only be carried out when the temperature of the steel surface is at least 3C higher than the dew-point of
the ambient air.
Blasting may not be carried out if the relative degree of humidity exceeds 80%. The choice of the type of
blasting medium used depends on local circumstances such as the possible presence of gas and the
material to be blasted.
The abrasive to be used must conform to the local low i.e. it may contain no carbon and less than 1%
free silicon dioxide. The Sa 3 will always be requested and must at least reach Sa 2 during the initial
stage of the paintwork. For blasting followed by metallisation, the surface preparation degree to be
achieved is always Sa 3. The degree of cleanliness to be obtained will be inspected in accordance with
the Swedish standard SVENSK STANDARD ISO 8501-1-1988 SS 05.5900.
Sa 3: surface blasted down to the bare metal; when the surface is inspected with a magnifying
glass, scale, rust and foreign bodies must be completely removed and it should be possible to
raise a metallic -shine on the treated surface.
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Sa 2 1/2: blasted very carefully. Scale, rust and foreign bodies must be removed in such a way
that anything left behind will only be visible as nuances (shading) or strips.
The blast-cleaning will be carried out by means of compressed air free of water and oil.
After the blasting and before painting, the surface should be completely cleaned of blasting material and
so forth with a soft brush, a dry cloth or dry compressed air.
7.3
Mechanical cleaning
If sandblasting is not permitted or if the metal structures are not easily accessible for blasting or blasting
for one reason or another is technically unfeasible, mechanical derusting can be used instead. With
mechanical cleaning by means of chipping, rotating steel brushes and sanding discs, a degree of
cleanliness St. 3 should be reached.
St 3: removal of the old paint layers of which the adhesion leaves something to be desired and/or of
which the paint layer no longer fulfils the requirements.
If parts are present that are so corroded that St 3 is difficult to achieve, this should be notified to the
OWNER representative prior to the start of the works.
N.B:
St. 3 : means removal of every old paint layer. Retouching means local polishing with St. 3 or Sa 3
followed by application of the desired painting system.
After mechanical cleaning, the surface should be made dust-flee with a cloth or a so brush, washed with
an organic solvent and thoroughly dried off with a dry cloth (e.g. with 1.1.1. Trichoroethane such as
Solvethane, Chloroethene).
7.4
Manual Derusting
Manual derusting with the aid of scrapers. steel brushes, sandpaper etc. shall only be permitted in
exceptional cases for local repairs. Any deviation there from must be requested from the OWNER/
OWNERs Representative.
With manual derusting, a surface preparation degree St 3 must be obtained. The length of the handles
of the equipment used may not exceed 50 cm.
7.5
Preparation of a surface covered with a layer of paint in the workshop.

This layer is in general applied by the manufacturer, for example, on valves, regulators etc. Layers of
this kind will be checked for their proper adhesion in accordance with ASTM D 3359, method A
(Standard Test Method for measuring adhesion by tape test). The adhesion should be at least .
If the paint layer shows less adhesion or is incompatible with the rest of the system it should be
completely removed. If the paint layer is not removed, the Contractor accepts it in the state in which the
coating is found and the guarantee remains in force. The adhesion does not have to be examined if
system 63 has already been applied in the workshop on behalf of the OWNER.
The Contractor, who must provide for the protection on the construction site, must therefore obtain the
information regarding the treatment of the surface and the quality of the paint that was used and must,
moreover, examine the adhesion of the layer on the construction site, the percentage of damage and
weathering as well as the value of the preparation of the surface in the workshop together with the
thickness thereof that must be supplemented if necessary.
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a)
Galvanized surface
Galvanized surfaces, both old and new will be carefully roughened up. Every foreign body
(concrete splatters, chalk marks, grease and oil stains, etc.) will be removed. Thereafter, rub the
surfaces with abundant water and, if necessary, with cleaning products.
To this end, nylon brushes will be used for every kind of dirt as well as for removing zinc salt
residue. Thereafter, the surfaces will be treated in accordance with system 21. Where the zinc
layer is lacking, it will be derusted manually to a degree of cleanliness St 3, after which a primer
coat will be applied in accordance with system 22.
b)
Metallised surfaces treated with an impregnation layer
degrease with the desired degreasing product:
clean under high pressure or with a product prescribed by the paint supplier.
If the paint layer adheres well and is applied on a clean base, the painting system described may be
continued. If the percentage of damage and weathering does not exceed 5 % m. retouching may be
considered. These partial repairs will be carried out.
If on the other hand, the percentage of damage does exceed 5 %/m or if the layer applied in the
workshop comes loose the Contractor must draw the attention of the OWNER to this and carry out the
complete application system.
7.6
Preparation of surfaces covered with earlier paint layers that show different degrees of weathering.
If the surfaces do not show deep weathering limited to the spread of rust by small pitted areas or nonpenetrative rust in spots, it will very often be sufficient to clean the surfaces with abrasives or with an
abrasive disc, then to rub them down with steel wool, remove the dust and wash off. If thick rust
appears, in spots, scale rust and active rust canker, this should be removed with needle hammers or
stripped away directly by blasting, removing the dust and washing oft.
7.7
Preparation of concrete or cement plaster surfaces

Remove unsound paint layers and loose components with scrapers, blades or rotating steel brushes.
Thoroughly clean the entire surface with water containing ammonia. Thoroughly remove moss, algae
and fungal growths. Where these growths have been removed, treat the area with a fungicide in
accordance with the instructions for use.
Once the entire area is completely dry, brush off the dead residue of moss, algae and fungus with a hard
brush. In the case of reinforcement steel that has been laid bare, remove as rust, dust and grease as
possible and treat with a printer coat. When painting concrete surfaces, they must first be checked for
cracks. Cracks larger than 0.3 mm must be repaired with an appropriate system in accordance with the
type and extent of the repairs (e.g. injection with epoxy mortar). Repair damage such as cracks and
bursts to concrete parts with a two-component mortar or preferably with micro-mortars. Finally check the
alkalinity of the surface with the aid of litmus paper and neutralize it if necessary.
7.8
Use of solvents
It is sometimes necessary to use solvents when the surfaces to be painted are streaked with grease or
oil. In this case a suitable organic solvent should be applied. The operation should be carried out with
the aid of clean brushes or rags and clean solvent.
All the legal specifications in connection with solvents etc. must be adhered to. The OWNER/OWNER's
Representative will be informed in advance of any toxicity or flammability. All measures must be taken to
prevent any risk of fire and to nick out any possibility of poisoning (ventilation). The Contractor will
provide drip collectors to keep the environment free of pollution.
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7.9
Condition of the metal after stripping

The Contractor must call in a representative of the OWNER/OWNER's representative or of the Approved
supervisory Body responsible for checking the condition of the metal during stripping and informing the
OWNER/OWNER's representative immediately of any damage that he might have noticed.
7.10
Deep corrosion of the plates - rivets - bolts

Faulty welding
Fittings that appear to be dangerous because of their age.
Removing coating from surface pipelines
The Contractor must have the equipment necessary for the removal of asphalt from the pipe without
damaging the latter (scratching, impact, etc,). The Contractor undertakes to carry out the work in
accordance with an approved procedure.
8.0
METALLISATION
8.1
Applying the metallisation

Metallisation must be carried out in accordance with ISO 2063,
Metallisation is carried out as rapidly as possible after blasting in order to limit corrosion of the pipes
(max. 3 hours later). With metallisation, a surface preparation degree Sa 3 is compulsory. The
roughness of the blasted surfaces should be from 25 to 50 R Max.
The metallising is always carried out on dry parts in good weather conditions (maximum relative
humidity 80 %);
For metallisation, a wire composed of 85 % zinc and 15 % aluminum with a minimum

guaranteed degree of purity of 99.5 % is used (subject to other specifications). The application
thereof is always carried out in accordance with the conditions of the manufacturer and may at
all times be submitted to the OWNERs representative.
The sealant should be applied maximum 3 hours alter metallisation.
The sealant must be thinned and applied as per the present specifications. A visual inspection
whereby the sealant completely covers the metallisation will suffice here.
When evaluating the metallisation, a negative deviation from the minimum coating thickness, to
80 for 20% of the measurements will be permitted.
9.0
CARRYING OUT THE PAINTWORK
9.1
Conditions for carrying out paintwork

Painting may not be carried out in unsuitable conditions.
All preparatory work and painting may only he carried out in dry weather and at a minimum temperature
of 10C, except for special eases requested by the OWNER's Representative.
Unless otherwise stipulated in the specifications of the paint supplier, application of the paint is forbidden
if it is forecast that the temperature will fall to below 0C before the paint is dry. The temperature of-the
surface to be painted must be at least 3C higher than the dew point of the ambient air. Application of
the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or
condensation sets in.
The work must be stopped:
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If the temperature of the surface to be painted is higher than that described by the supplier.
In rain, snow, mist or fog or when the relative humidity is higher than 80 %.
Coats that have not yet dried and have been exposed to frost, mist, snow or rain and might thereby be
damaged must be removed after drying and the surfaces must be repainted at the expense of the
Contractor.
Working in direct sunlight or in hot weather must be avoided,
The first coat of paint must be applied maximum 3 hours after the preparation of the surface of the
relative humidity of the air is between 50% and 80%. This time span may be increased to 6 hours if the
relative humidity is less than 50%. In all cases, the preparation of the surface must exhibit degree Sa 3
and at the very least the appearance of degree Sa 2 at the time of painting.
The coats of paint may only be applied on carefully cleaned surfaces that must be dry and free of grease
and dust.
9.2
Special conditions
Painting may be carried out when the Contractor can be sure that the instructions of the paint supplier
have been scrupulously followed with regard to the parameters in the following (non-exhaustive) list:
Ambient temperature.
Surface temperature.
Relative humidity.
Dew point.
Drying times.
The Contractor must in this respect be able to produce the instructions for the paint on the site. The
OWNER/CONSULTANT will guarantee 100% supervision in this regard during the execution of the
work.
In addition, the paintwork may only be carried out to a minimum ambient temperature of 5C and/or to a
maximum relative degree of humidity of 85 %. Application of the paint is also not permitted if there is a
danger that the coat of paint will not be dry before dew or condensation sets in.
9.3
Paint Materials
Manufacturers shall furnish the characteristics of all paints indicating the suitability for the required
service conditions. Primer and finish coats shall be of class-I quality and shall conform to the following:
a)
Primer (P-1)
Red oxide Zinc Chromate Primer
Type and Composition
Single pack, Modified phenolic alkyd medium pigmented with

red oxide and zinc chromate.
Volume solids
30 - 35%
DFT
25 microns/coat (min)
Covering capacity
12-13 M/Lit/Coat
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b)
Primer (P-2)
High build chlorinated rubber zinc phosphate primer
c)
Single pack, Chlorinated rubber medium Plasticised with

unsaponifiable plasticiser pigmented with zinc phosphate
Volume solids
35- 40%
DFT
50 MICRONS/COAT (MIT)
Covering capacity
7-8 M/Lit/Coat
Primer (P-3)
High build zinc phosphate primer
d)
Single Pack, Synthetic medium, pigmented with zinc

phosphate.
Volume solids
40-45%
DFT
35-50 microns/coat
Covering capacity
10-12 M/Lit/Coat
Heat resistance
Upto 100 C (dry)
Primer (P-4)
Etch Primer / Wash Primer
e)
Two pack Poly vinyl butyral resin medium cured with

phosphoric acid solution pigmented with zinc tetroxy
chromate.
Volume solids
7-8%
DFT
8-10 microns/coat
Covering capacity
7-8 M/Lit/Coat
Primer (P-5)
Epoxy Zinc Chromate Primer
f)
Two pack, Polyamide cured epoxy resin medium pigmented

with zinc chromate.
Volume solids
40%(min)
DFT
Covering capacity
11-12 M/Lit/Coat
Primer (P-6)
Epoxy Zinc Phosphate Primer
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g)
Two pack, Polyamide cured Epoxy resin medium pigmented

with zinc phosphate.
Volume solids
40%
DFT
35 microns / coat (min)
Covering capacity
11-12 M/Lit/Coat
Primer (P-7)
Epoxy high build M10 Paint (Intermediate Coat)
h)
Type and composition
Two pack Poly Polyamide cured epoxy resin medium

pigmented with micaceous iron oxide. Volume solids 7- 8%
Volume Solids
50%
DFT
Covering capacity
5.0 M/Lit/Coat
Primer (P-8)
Epoxy Red Oxide zinc phosphate primer
i)
Two pack. Polyamine cured epoxy resin pigmented with Red

oxide and Zinc phosphate.
Volume solids
42%
DFT
Covering capacity
13-14 M/Lit/Coat
Primer (P-9)
Epoxy based tie coat (suitable for conventional alkyd based coating prior to application of acrylic
polyurethane epoxy finishing coat)
j)
Two pack, Polyamide cured epoxy resin medium

suitably pigmented.
Volume solids
50-60%
DFT
Covering capacity
10-12 M/Lit/Coat
Finish Coats (F-1)

Synthetic Enamel
Single pack, Alkyd medium pigmented with superior

quality water and weather resistant pigments
Volume solids
30-40%
DFT
20-25 microns/coat
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Covering capacity
k)
16-18 M/Lit/Coat
Finish coat (F-2)

Acrylic Polyurethane paint
l)
Two pack, Acrylic resin and iso-cyanate hardener

suitably pigmented.
Volume Solids
40% (min)
DFT
30-40 microns / coat
Covering Capacity
10-12 M/Lit/Coat
Finish Coat (F-3)

Chlorinated Rubber Paint
m)
Single pack, Plasticised chlorinated rubber medium with

chemical & weather resistant pigments.
Volume solids
30%
DFT
Covering capacity
1 0.0 M/Lit/Coat
Finish Coat (F-4)

High build chlorinated rubber M10 paint.
n)
Single pack Chlorinated rubber based high build pigmented with

micaceous iron oxide.
Volume solids
40-50%
DFT
65-75 microns/coat
Covering capacity
6.0-7.0 M/Lit/Coat
Finish coat (F-5)

Chemical Resistant Phenolic based Enamel
o)
Single pack phenolic medium suitably pigmented.
Volume solids
35-40%
DFT
25 microns/ coat
Covering capacity
15.0 M/Lit/Coat
Finish Coat (F-6)

Epoxy High Building Coating
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p)
Two pack. Polyamide cured epoxy resin medium suitably

pigmented.
Volume solids
60-65%
DFT
Covering capacity
6.0-6.5 M/Lit/Coat
Finish Coat (F-7)

High build Coal Tar Epoxy
q)
Two pack, Polyamine cured epoxy resin blended with Coal Tar.
Volume solids
65% (min)
DFT
100-125 microns/coat
Covering capacity
6.0-6.5 M/Lit/Coat
Finish Coat (F-8)

Self-priming epoxy high build coating (complete rust control coating)
r)
Two packs. Polyamide-amine cured epoxy resin suitably

pigmented. Capable of adhering to manually prepared surface
and old coatings.
Volume solids
65-80%
DFT
125-150 microns/coat
Covering capacity
4-5 M/Lit/Coat
Finish Coat (F-9)

Inorganic Zinc Silicate coating
s)
Two packs, self cured Ethyl silicate solvent based Inorganic Zinc
coating.
Volume solids
60% (min)
DFT
65-75 microns/coat
Covering capacity
8-9 M/Lit/Coat
Finish coat (F-10)

High build Black
Single pack. Reinforced bituminous composition phenol based

resin.
Volume solids
55-60%
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t)
DFT
Covering capacity
5.50-6.0 M/Lit/Coat
Finish Coat (F-11)

Heat Resistant Aluminium Paint Suitable up to 250C.
u)
Duel container (paste & medium). Heat resistant spec varnish

medium combined with aluminium flakes.
Volume solids
20-25%
DFT
Covering capacity
10-12 M/Lit/Coat
Finish Coat (F-12)

Heat Resistant Silicon Paint suitable up to 400 C.
v)
Single pack Silicone resin based with aluminium flakes.
Volume solids
20-25%
DFT
Covering capacity
10-12 M/Lit/Coat
Finish Coat (F-13)

Synthetic Rubber Based Aluminium Paint Suitable up to 150C.
Single Pack, Synthetic medium rubber medium combined with

leafing Aluminium,
DFT
25 microns/coat
Covering capacity
9.5 M/Lit/Coat
Notes
1
Covering capacity and DFT depends on method of application Covering capacity specified above
is theoretical. Allowing the losses during application, min specified DFT should be maintained.
2.
All paints shall be applied in accordance with manufacturer's instructions for surface preparation,
intervals, curing and application. The surface preparation quality and workmanship should be
ensured.
3.
Selected chlorinated rubber paint should have resistance to corrosive atmosphere and suitable
for marine environment,
All primers and finish coats should be cold cured and air-drying unless otherwise specified.
5.
Technical data sheets for all paints shall be supplied at the time of submission of quotations.
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6.
7.
In case of use of epoxy tie coat, manufacturer should demonstrate satisfactory test for inter coat
adhesion. In case of limited availability of epoxy tie coat (P-9) alternate system may be used
taking into the service requirement of the system.
In case of F-9, F-1 1 & F-1 2 Finish Coats, No Primer is required.
MANUFACTURERS
The paints shall conform to the specifications given above and Class-I quality in their products range of
any of the-following manufacturers:
i)
ii)
iii)
iv)
v)
vi)
Asian Paints (India) Ltd,

Bombay Paints
Berger Paints India ltd.
Gaodlass Nerolac Paints Ltd.
Jenson & Nicholson
Shalimar Paints
STORAGE
All paints and painting material shall be stored only in rooms to be provided by contractor and approved
by OWNER/ OWNER 's Representative for the purpose. AlI necessary precautions shall be taken to
prevent fire. The storage building shall preferably be separate from adjacent, building.
A signboard bearing the words given below shall be clearly displayed outside:
PAINT STORAGE No NAKED LIGHT highly -inflammable
COLOR CODE FOR PIPING:
i)
ii)
iii)
V)
VI)
VII)
VIII)
For identification of pipelines, the color code as per Table -1 shall be used.
The color code scheme is intended for identification of the individual group of the pipeline. The
system of color coding consists of a ground color and color bands superimposed on it.
Colors (Ground) as given in Table-2 shall be applied throughout the entire length of uninsulated
pipes, on the metal cladding & on surfaces. Ground color coating of minimum 2m length or of
adequate length not to he mistaken as color band shall be applied at places requiring color
bands. Color bands shall be applied as per approved procedure.
Line coating shall meet DIN 30670 standard for external coating and API 5L RP 2 for internal
coating.
The thickness for the epoxy should be 180 microns, adhesive 200 microns and balance should
be PE
The minimum coating thickness on weld seam shall be 3.2 mm and minimum coating thickness
on body should be 3.2.
Minimum thickness for liquid epoxy for internal coating should be 100 20 microns.
Max design temperature for coating should be considered +80 C
COLOR CODE:
A)
B)
C)
D)
E)
F)
G)
Ball Valve (Above Ground)

: Off White
Globe Valve (Above Ground)
: Oxford Blue-RAL 5005, IS-519941005
Check Valve(Above Ground)
: Oxford Blue-RAL 5005, IS-519941005
Launcher / Receiver
: Yellow Golden
Jib Crane / Trolley
: Yellow Golden
All underground valves shall have epoxy base coating after surface finish of SA 2.5
Valves and above ground pipes need to be properly blasted to achieve surface finish of Sa 2.5 before
the application of paints.
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IDENTIFICATION SIGN
i)
Colors of arrows shall be black or white and in contrast to the color on which they are
superimposed.
ii)
Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as
approved by OWNER.
iii)
Size of arrow shall be either of the following:
a)
Color Bands
Minimum width of color band shall be as per approved procedure.
b)
Whenever it is required by the OWNER to indicate that a pipeline carries a hazardous material,
a hazard marking of diagonal stripes of black and golden, yellow as per IS:2379 shall be painted
on the ground color.
IDENTIFICATION OF EQUIPMENT
All equipment shall be stenciled in black or white on each vessels, column, equipment, painting as per
approved procedure.
1.
All painting materials including primers and thinners brought to site by

contractor for application shall be procured directly from manufactures as per
specifications and shall be accompanied by manufacturer's test certificates Paint formulations
without certificates are not acceptable.
2.
The painting work shall be subject to inspection by OWNER/ OWNER's Representative at all
times. In particular, following stage wise inspection will be performed and contractor shall offer
the work for inspection and approval at every stage before proceeding with the next stage.
In addition to above record should include type of shop primer already applied on equipment e.g. Red
oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect noticed during the various stages of inspection shall be rectified by the contractor to the
entire satisfaction of OWNER/ OWNER's Representative before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work. Contractor shall be responsible for
making good any defects found during final inspection/guarantee period/defect liability period as defined
in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application
of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra
cost to OWNER.
PRIMER APPLICATION
i.
The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of
sand blasting. Holiday detectors and pinhole detector and protector whenever required for
checking in case of immerse conditions.
ii.
At the discretion of OWNER/ OWNER's Representative, contractor has to provide the paint
manufacturers expert technical service at site as and when required. For this service, there
should not be any extra cost to the OWNER.
iii.
Final Inspection shall include measurement of paint dry film thickness, check of finish and
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workmanship. The thickness should be measured at as many points/ locations as decided by

OWNER/ OWNER's Representative and shall be within +10% of the dry film thickness.
iv.
The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The OWNER shall have the right to test wet samples of paint
at random for quality of same. Batch test reports of the manufacturer's for each batch of paints
supplied shall be made available by the contractor.
PAINT SYSTEMS
The paint system should vary, with type of environment envisaged in and around the plants. The types
of environment as given below are considered for selection of paint system. The paint system is also
given for specific requirements.
a)
b)
c)
Normal Industrial Environment, Table-2

Corrosive industrial Environment, Table-3
Coastal & Marine Environment, Table-4
Notes 1.
Primers and finish coats for any particular paint systems shall be from same
manufacturer in order to ensure compatibility.
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Table 1
Colour Coding Scheme for Pipes and Equipments
SI. No.
Content
1
a) Plant Air
b) Instrument Air
2
a)
b)
c)
d)
e)
3
Charge Gas
Regeneration Gas
Residue Gas
LPG
Acetylene
Ground Color
COMPRESSED AIR
Sky Blue
Sky Blue
GASES
Canary Yellow
Canary Yellow
Canary Yellow
Canary Yellow
Canary Yellow
ALL EQUIPMENT
Light Grey
First Color
Band
Second Color
Band
Silver Grey
French Blue
Signal Red
White
White
Brilliant Green
Dark violet
Smoke Grey
Dark Violet
French Blue
White
-
a) Such as vessels. columns,

exchangers, etc. containing nonhazardous fluids.
b) All equipment containing hazardous Canary Yellow
fluids
c) Pipe carrying hazardous fluids
Bar is to be
replaced by
Hazardous
Marking as per
IS: 2379 Clause
7.1C
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Table 2
Normal Industrial Environment (Above Ground)
Sl. Description
No.
1.0
Temp.
Range
Surface
Preparation
Primer
Finish Coat
Total
DFT
Remarks
One coat F-4

65 microns/
coat (min)
Two coats F3, 30
Microns/coat
(min)
Two coats of
F-1, 20
microns/coat
(min)
175
Primer and
Finish coat
can be
applied at
ambient
temp.
90
Two coats of
F-13, 25
microns/coat
(min)
150
Three coats
of F-11, 20
microns/ coat
(min)
60
Three coats
of F-12, 20
microns/ coat
(min)
60
Paint
application
at ambient
temp. curing
at elevated
temp. during
start-up.
-do-
External surface of equipment's and piping.
1.1
-Do-
-10 to 20
SSPC-SP-3
One coat
P-2
50
microns /
coat
(min)
1.2
-Do-
21 to 60
SSPC-SP-6
1.3
-Do-
61 to 80
SSPC-SP-6
1.4
-Do-
81 to 250
SSPC-SP-6
Two
coats P1, 25
microns/
coat
(min.)
Two
coats P3, 50
microns/
coat
(min)
Covered
in Finish
coat
1.5
-Do-
251 to 400
SSPC-SP-10
Covered
in Finish
coat.
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Table- 3
Corrosive Industrial Environment (Above Ground)
SI. Description
No.
Temp.
Range
Surface
preparation
Primer
Finish Coat
1.0
External surface of un-insulated and other equipment
I.1
- do -
-10
20
to
SSPC-SP-3
1.2
- do -
21
80
to
SSPC-SP10
I.3
- do -
81
400
to
SSPC-SP-3
Two coat
P-2,
50
microns)
coat (min.)
Two coats
P-5,
35
microns /
coat (min.)
Covered
in
finish
coat
Two coat F3,

30
microns /
coat (min.)
Two coats
F- 6, 100
microns
coat (min.)
Three coats
F- 12, 20
Microns
/
coat (min.)
FOR PAINTING
Total
DFT
Remarks
160
Primer and paint

application at
ambient temp.
270
Paint application
at ambient temp.
60
Paint
application.
at ambient temp,
and curing at
250'C for 4
hours,
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Table 4
Coastal and Marine Environment (Above Ground)
SI.
No.
1.0
Description
Temp.
Range
Surface
Preparation
Primer
Finish Coat
Total
DFT
External surface of equipments and piping.
1.1
-do-
-10 to
60
SSPC-SP-3
Two coats
P-2, 50
micron/
coat (min)
Two coats F3, 30

Microns/coat
(min.)
160
SSPC-SP10
Two coats
P-5. 35
Microns.
coat
(Min.)
One coat
F-9, 83
Microns/
Coat(Min.)
Two coats of
F-6, 100
Microns/Coat
(min.)
270
85
1.2
do -
61
80
1.3
- do -
81 to
400
SSPC-SP-I0
1.4 - do -
i) Upto
80
SSPC-SP10
One coat
F-9, 6.5
microns /
coat (Min)
One coat of
F-2. 30
Microns/coat
(min.)
95
ii) 8l to
400
SSPC-SP10
-do-
-do-
85
1.9.4
Remarks
to
Primer and
Finish
coat
application
at Ambient
temp.
-do-
Paint
application
at Ambient
temp.
Primer
is
acting
as primer
cum finish
coat.
Paint
application
at ambient
temp.
Paint
application
at ambient
temp.
Primer
is
acting
as primer
cum
finish coat.
Precautions to be taken
Neither the environment of the site nor the marking labels of devices may be covered with paint and they
must be kept free of paint splashes. To this end, it is advisable to use removable masking tape.
Paint splashes, leaks, etc. on any adjacent installations such as measuring apparatus, valves, pipes.
sources of light, insulation, heat insulators, walls, concrete, etc, must immediately be wiped up and the
damage repaired before the paint is dry.
Otherwise, the OWNER will be obliged to have the cleaning carried out at the expense of the Contractor.
The paint recipient will only be opened at the time of use (unless otherwise specified by the
manufacturer).
The product will be mixed in the recipient with the aid of suitable tools and thus homogenized.
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1.9.5
Method of application
Normally, three methods of application will be used on the construction site for the paint products. i.e.
with a brush, with a roller or with a spray gun.
The brush method makes it possible to obtain good penetration of the paint over irregularities in the
metal.
Only this method will be used for application of the base coats, for retouching and for protrusions,
welded areas, riveted joints or bolted joints:
The roller method may be used on large flat surfaces for the intermediate and topcoats.
The spray gun method must be used in accordance with the instructions of the manufacturer and carried
out by qualified personnel.
The Contractor must guarantee that all safety measures have been taken for such work. The spray gun
method may only he used on site for places that arc difficult to reach with the brush. In this case, a
request must be made to the OWNER/ OWNER's Representative for a deviation.
All paintwork will be carried out with good brushes or rollers that are suitable for the type of paint being
used and for the form of the material to be painted and fitted with short handles. The maximum length of
the brush and roller handles will be 50 cm; longer handles may only be used for places that are
absolutely inaccessible. The maximum width of a brush will be 13 cm.
1.9.6
Application of the coating

Application of the paint will be carried out in accordance with best practice in order to obtain a
homogeneous and continuous layer. The OWNER or the Approved Supervisory body demands that
painting of a layer will only be started after acceptance by them of the surface preparation or of the
previous layer of paint.
The layers of paint must have a uniform thickness. They must he spread in such a way that all concave
parts are dried out and that the surface is completely covered and has a glossy appearance without
leaving brush marks and without exhibiting bubbles, foam, wrinkles, drips, craters, skins or gums that
arise from weathered paint,
Each layer must have the color stipulated in the tables of the present specifications, which clearly differs
from the previous layer, taking account of the Color of the top layer, all of which for the purpose of being
able to identify the number of coats and their order of sequence. If the color of the coats is not
mentioned in the tables the color difference in consecutive coats must, if possible, he at least 100 RAL.
The color of the top layer is given in the table.
The coating power should be such that the underlying layer is not visible. Only 1 layer per day may be
applied, unless otherwise specified by the OWNER or the Approved Supervisory Body.
The drying times prescribed by the paint manufacturer must be strictly observed in relation to the
environmental conditions before proceeding with the application of the next layer.
The dry coating thickness indicated in the description of the paint systems are minimum thickness. In
this connection, the Contractor is obliged to contact the paint manufacturer and conform to his
guidelines. The Contractor must respect the thickness specified by the supplier.
1.9.7
Transporting treated items

In the case of works being carried out in a workshop, the metal structures will be surrounded by
ventilated contraction film that prevents damage during transportation. This film may only be applied
after complete polymerization of the paint.
FOR PAINTING
Document No.
Rev
11-0398B02-01-09-02-022
SHEET 24 of 27
1.10
GROUND-LEVEL TRANSITION POINT
1.11
Polyester protection system

The Contractor will provide system 02 over the entire length of the pipes above ground and below
ground and up to a height of 20 cm and a depth of 40 cm. perpendicular to the ground level mark. In
each case, he must ensure that the jointing below the asphalt is in good condition and assures' faultless
adhesion. He will apply the following products over the entire surface area, prepared in accordance with
is Sa 3:
1)
The primer of system 01.
2)
Reinforced polyester 20 cm above the ground level marker and 5 cm on the asphalt cleaned
beforehand (application of reinforced polyester is carried out in accordance with the work
method prescribed by the manufacturer). Moreover, in the case of PE, in contrast to asphalt, he
will apply a polygon primer to PE immediately before applying the reinforced polyester.
3)
He will then apply the other coats of system 01a to the surface section and thus cover the
reinforced polyester with about 5 cm.
4)
For new constructions, the polygon primer will be applied to PE and then subsequently
processed as described under point 2.
1.11.1 USE OF SCAFFOLDING

Mounting, maintenance and dismantling of scaffolding for carrying out adaptation and/or paintwork to
surface gas pipes or gas transport installations in use;
1.12
The Contractor will specify the cost of scaffolding in the price list.
The supplementary rental price for delays attributable to the Contractor will be charged to him:
In his price quotation the Contractor should present the OWNER with diagrams of the scaffolding
that he intends to install for carrying out the works of the OWNER.
QUALITY CONTROLS AND GUARANTEE
1.12.1 The Contractor is responsible for checking the weather conditions to ascertain whether the paintwork
can be carried out within the technical specifications.
The Contractor should have the required calibrated monitoring apparatus for this purpose on site (with
calibration certificates). The personnel who will have to use this apparatus should have the training for
this purpose.
The OWNER or his representative and possibly the approved supervisory body indicated by the
OWNER will maintain supervision during the works and inspect the works with random checks. A daily
report will be drawn up in relation to the department that maintains supervision of these works.
The supplementary inspection and the supervision by the OWNER or the approved supervisory body do
not diminish in any way the liability of the Contractor. The proper execution of the work and the materials
used may be checked at any time.
1.12.2 Reference Surfaces
At the start of the works. the OWNER or the approved supervisory body will indicate a few surfaces that
the Contractor will prepare and cover in accordance with the recognized method of operation under the
inspection and to the satisfaction of all parties ; the OWNER or his representative, the approved
supervisory body. the contractor and possibly the paint manufacturer. These reference surfaces will
serve as a point of comparison for the good adhesion of the paint on the installations as a whole. The
FOR PAINTING
Document No.
Rev
11-0398B02-01-09-02-022
SHEET 25 of 27
parties will together work out a system for the identification of these surfaces in order to be able to
monitor the conditions of the coatings over time. If the paintwork on a section of the installations is in a
worse condition than the reference surfaces, the Contractor may be obliged to treat these parts again.
1.12.3 Measures to be taken in the event of a dispute
If on delivery of the works no agreement can be reached between the Contractor and the OWNER
regarding the conformity of the works to the requirements of these specifications, an Approved
Supervisory Body will he Called in. The Approved Supervisory Body will then carry out inspections' on
site whereby the following assessment criteria wilt be used:
The Swedish standards ISO 8501-1 1988 SS 05.5900 concerning the degree of cleanliness of
the areas derusted by blasting, by machine or by hand.
The wet film thickness of the paint will be measured in accordance with ISO 2808 or ASTM DI
212;
The dry layer thickness of the film will be measured electronically, will complete statistical
information. in accordance will, ISO 2808 or ASTM D 1186.
The thickness of each layer will he measured in accordance with ISO 2808. ASTM 4138 or DIN
50986.
Adhesion tests will be carried out in accordance with ISO 2409. ASTM 3359 or DIN 53151.
Traction tests will he carried out in conformity with ISO 4624 or ASTM D 4541.
The rugosity will be measured electronically in accordance with DIN 4768;
The non-porosity will be measured with a test tension depending on the type of coating, the
layer thickness and after consultation with the Paint manufacturer.
Any defects in the paint film may be inspected visually by means of a magnifying glass or
microscope. If necessary a photographic report may be drawn up in accordance with ASTM
Standard D 4121-82,
The final judgement of the Approved Supervisory Body is irrevocable and binding for the Contractor and
the OWNER. In the event of non-conformity of the works with the criteria of these specifications, all costs
arising from the inspection by the Approved Supervisory Body shall be borne by the Contractor.
1.12.4 Guarantee
a)
General Principles
The Contractor declares that he is aware of:
The maximum operating temperature of the surfaces to be covered.
The maximum permitted degree of humidity of the bearing surface.
The properties of the environment to which the surfaces to be covered are: subject.
FOR PAINTING
Document No.
Rev
11-0398B02-01-09-02-022
SHEET 26 of 27
b)
Summary of the Guarantee.

The contractor fully guarantees the following without reservation:
The observance of all stipulations of the specifications for paintwork regarding, among other
things:
o
o
o
The preparation of the surfaces.

The thickness of each layer.
The total thickness of the covering.
The uniformity of the materials used.
The repair of all defects before delivery of the works.
The Contractor will carry out the requested repair work as promptly as possible.
FOR PAINTING
Document No.
Rev
11-0398B02-01-09-02-022
SHEET 27 of 27
CLIENT
SIZE/QUANTITY
GAIL (India) Limited
INSTALLATION OF IP STATION AT ANKHI GUJARAT ON 12

As per Table
GENERAL SPECIFICATION
Process Fluid
Design Temperature
Design Standard
NG
600# / 150#
ANSI Rating
0 to 65 deg C
API 6D
64 barg / 19 barg
Design Pressure
6A1 / 1A1
Piping Class
Size, inch (mm)
As per Table
Body Type
As per Table
End Connection Type

Flange Finish
As per Table
ANSI B16.5
Standard
125 AARH
Special Requirement
Locking Device Reqd
Yes
Vent, Drain & Sealant connection with

Anti Blow out Stem (Refer Technical
Specification of Ball Valve)
VALVE DESIGN CONDITIONS

Corrosion Allowance
Installation
Opening/Closing time
6.0 mm
Aboveground
Design Factor
0.5
Stem Ext Length, mm
N.A.
*
CONNECTING PIPE DETAILS
As per Table (see sheet no. 2 of 2)
Diameter, mm (inch)
Wall Thickness, mm/Sch
Out of Roundness
*
5 mm
VALVE OPERATION
Auto Actuation Reqd

Type of Actuator/Valve Operator

VALVE MATERIAL SPECIFICATION
PART DISCRIPTION
Body
Ball
Seat Rings
Seat Seal
Stem
MATERIAL OFFERED (Equivalent or

Higher)
MATERIAL SPECIFIED
ASTM A 216 Gr. WCB / ASTM A 234 Gr. WPB
ASTM A 216 Gr. WCB / ASTM A 234 Gr. WPB +
0.003" ENP
AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410
VITON AED O-RING
AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410
Stem Seal
PTFE / VITON
Stud Bolts
ASTM A 193 Gr. B7
Hex Nuts
ASTM A194 Gr. 2H
TESTING REQUIREMENT
Hydrostatic Test Pressure
Body: 96.0/28.5 barg
Air Test Pressure
Seat: 70.4/20.9 barg

7 bar
As per API 6D Latest Edition
Anti-Static Testing Requirement

Hardness Test
248 HV10
Yes (at 0 deg C)
Charpy Impact Test/ Temperature
DATA SHEET OF BALL VALVE
Document No.
Rev.
11-0398B02-01-08-03-024
SHEET 1 of 2
CLIENT
GAIL (India) Limited

KHERA COMPRESSOR STATION UPGRADATION PROJECT
SIZE/QUANTITY
Fire Safe Test
As per API 6FA

Suitable for Corrosive Industrial Environment (Refer Painting
Specification)
Valve Painting Specification

Manufacturer's Painting Specification Number
Notes
1. This Data Sheet Shall be read in conjunction with the Technical Specification, MTO (if any), PMS which are enclosed.
* To be filled by Vendor
Legend: FLGD - Both Ends Flanged, FBW - One End Flanged (U/S) Other End Butt Welded (D/S),
BW - Both Ends Butt Welded, XV - Gas Actuated Valve, HOV - Hydraulic Operated Valve,
AG - Above Ground, FB - Full Bore, TMBV - Trunion Mounted Ball Valve, # - ANSI Pressure Class/Rating,
NB - Nominal Bore/Size, SW - Both Ends Socket Welded, FL - Floated
Valve Table :
TAG NUMBERS
Size (inch)
Description
4" NB
TMBV, 600#, FLGD, FB,

AG
3 NOS.
2" NB
FL, 600#, FLGD, FB, AG
6 NOS.
2" NB
FL, 150#, FLGD, FB, AG
1 NO.
1" NB
FL, 1500#, SW, FB, AG
2 NOS.
3/4" NB
FL, 1500#, SW, FB, AG
4 NOS.
DATA SHEET OF BALL VALVE
QTY
Document No.
Rev.
11-0398B02-01-08-03-024
SHEET 2 of 2

FOR
BALL VALVES
DOCUMENT NO
11
0398B02
01
CLIENT JOB NO.
TOTAL SHEETS
16
08
02
025
07.05.13
ISSUED FOR TENDER
AS
AD
AD
20.04.13
ISSUED FOR IDC
AS
AD
AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
TABLE OF CONTENT
1.0
SCOPE .............................................................................................................................3
2.0
REFERENCE DOCUMENTS ...........................................................................................3
3.0
DEFINITIONS ...................................................................................................................4
4.0
INSTRUCTIONS ...............................................................................................................5
5.0
MATERIALS .....................................................................................................................5
6.0
DESIGN AND CONSTRUCTION ....................................................................................6
7.0
INSPECTION AND TESTS ...........................................................................................10
8.0
TEST CERTIFICATES ...................................................................................................12
9.0
PAINTING, MARKING AND SHIPMENT......................................................................12
10.0
SPARES AND ACCESSORIES....................................................................................13
11.0
DOCUMENTATION
13
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 2 of 16
1.0
SCOPE
This specification provides minimum requirement for design, manufacturing, Inspection, Testing and
supply of Carbon steel Ball Valves covering sizes NB through 36NB( 900mm) for ANSI pressure
classes # 150 through # 900 to be used in cross country Gas pipeline(onshore) and City Gas distribution
for handling non-sour hydrocarbon in liquid or gaseous phase.
2.0
REFERENCE DOCUMENTS
The following Standard includes provision which, through reference in this text constitute provision of this
Standard. Latest revision of this standard shall be used unless otherwise specified.
API 6D
Specification for Pipeline Valves.
API 605
Large Diameter Carbon steel Flanges.
API 6FA
Specification for Fire Test for Valves.
API 5L
Specification for Line Pipe.
API 1104
Specification for Welding Pipelines and related facilities.
ASME 16.10
Face to Face and End to End Dimensions of Valves
ASME 16.20
Metallic gasket for pipe flanges Ring joint or spiral wounds and
jacketed.
ASME 16.21
Non Metallic Gaskets for pipe flanges.
ASME B 16.5
Steel Pipe Flanges and Flanged Fittings.
ASME B 16.34
Valves - Flanged, Threaded and Welding Ends.
ASME B 16.5
Steel Pipe Flanges and Flanged Fittings.
ASME B 31.3
Process Piping.
ASME B 31.8
Gas Transmission and Distribution Piping Systems.
ASME Sec VIlI Div.I/Div.II :
Boiler and Pressure Vessel Code Rules for Construction of

Pressure Vessels.
ASTM A370
Standard Test Methods and Definitions for Mechanical Testing of Steel

Products.
ASTM B 733
Auto catalytic Nickel Phosphorous Coating on Metals.
BS 6755-1
Testing of Valves. Specification for production pressure testing

requirements.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 3 of 16
EN 1004511
Metallic products: Charpy Impact test test methods (U & V Notches)
BS 6755-2
Testing of Valves. Specification for fire type-testing requirement.
EN 10204
Metallic Materials Types of Inspection documents.
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 and Union.
MSS-SP-44
Steel Pipeline Flanges.
MSS-SP-53
Quality Std for Steel Casting & Forgings for Valves, Flanges & Fittings &
Other Piping Components Magnetic Particle Examination Method.
MSS-SP-55
Quality Standard for Steel casting of valves, Flanges, Fittings & other
Piping components (Visual Method)
MSS-SP-72
Ball Valves with Flanged or Butt welding ends for General Service.
ISO 5208
Industrial Valves Pressure Testing of Valves
ISO 10497
Testing of Valves fire type testing requirements.
ISO 13623
Petroleum & Natural Gas Industry pipeline transportation system.
ISO 14313
Petroleum & Natural Gas Industry. Pipeline transportation system

pipeline Valves
SSPC-VIS-1
Steel Structures Painting Council Visual Standard.
In case of contradiction the most stringent shall apply.

3.0 DEFINITIONS
Purchaser
: The Company which makes purchase order.
Manufacturer
: Manufacturer who receives the purchase order.
Shall
: This verbal form indicates requirements strictly to be followed in order to confirm to the
standards and from which no deviation is permitted.
Should
: This verbal form indicates that among several possibilities one is particularly suitable
without mentioning or excluding others or that a certain course of action is preferred
but not necessarily required.
May
: This verbal form indicates a course of action permissible within the limits of this
standard.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 4 of 16
Can
: This verbal form used for statements of possibility & capability, whether material,
physical or casual.
4.0
INSTRUCTIONS
4.1
Eventual Interpretations and deviations to this specification by the manufacturer shall be

requested by writing in his offer with detailed justification and approved by the purchaser or
purchasers representative before the eventual order to the manufacturer.
4.2
The specifications of the steel used shall be mentioned by the material manufacturer and all
potential sub contractors (such as forging plant, casting plant and fabrication unit etc) will be
described in the offer. After order no change will be accepted except for justified. In that case the
asked changes shall be supported by a technical file submitted to the purchaser and the
purchasers representative for approval.
4.3
The manufacturer shall provide a technical description of the manufacturing methods that might
influence the quality of material.
4.4
The purchaser/ purchasers representative keeps the right to audit the manufacturers and sub
contractors manufacturing and control methods. All costs for such an audit shall be borne by the
manufacturer except the wages, travel expenditure, lodging and boarding of the auditors
supported by the purchaser/ purchasers representative.
4.5
The purchaser/ purchasers representative shall have at any time free access to all parts of the
manufacturers facilities and to all his sub contractors involved in the order manufacturing.
4.6
A copy of ISO 9001 Certificate shall be included in the offer.
4.7
An approval of documents can never be considered as acceptance of deviations or relaxation to

requirements. A deviation is only possible after specific request to purchaser and purchasers
representative.
4.8
Purchaser/ purchasers representative may verify the control equipment of the manufacturer, its
calibration and the points at which it is located. If during the production certain problem arises,
the purchaser/ purchasers representative may demand supplementary tests.
5.0
MATERIALS
5.1
Material for major components of the valves shall be as indicated in Valve Data Sheet.
In addition, the material shall also meet the requirements specified herein. Other components
shall be as per Manufacturers standard (suitable for service conditions as indicated in valve data
sheet), which shall be subjected to approval by Purchaser / Purchasers representative.
5.2
Carbon steel used for the manufacture of valves shall be fully killed.
5.3
The carbon equivalent (CE) of valve end connections which are subject to further field welding
by Purchaser shall not exceed 0.45% on check analysis for each heat of steel used and shall be
calculated by the following formula:
CE = C + Mn +
6
5.4
Cr + Mo + V + Ni + Cu
5
15
The steel used shall be suitable for field welding to pipes, flanges or fittings manufactured under
ASTM 53, A 105, A 106, A 234, A 350, A 352, A 694, A 420, A 333, and
API 5L etc.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 5 of 16
5.5
When the ball of valve is manufactured out of C.S, it shall be subjected to 75m (0.003) thick
Electrolysis nickel plating as per ASTM B733 with following classification SC2, type II, class-2.
For Ball made of S.S material, ENP is not mandatory.
The hardness of plating shall be minimum 50 RC.
5.6
For valves specified to be used for Gas service or High Vapor Pressure (HVP) liquid service;
Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 7.5
for all pressure containing parts such as body, end flanges and welding ends as well as bolting
material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall
be conducted at 0C. The Charpy V-notch test specimen shall be taken in the direction of
principal grain flow and notched perpendicular to the original surface of plate or forging. The
minimum average absorbed energy per set of three specimens shall be 35 J with an individual
minimum per specimen of 27J. Test procedure shall conform to ASTM A 370 or ISO 148.
For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements
stated above are not applicable, unless required by the specified material standard as a
mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard
shall be complied with.
5.7
Valves shall be subjected to hardness test on base material for each heat for pressure containing
parts. A full thickness cross section shall be taken for this purpose and the maximum hardness
shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire
thickness.
6.0
6.1
a) Valve design shall be as per API 6D and suitable for the process conditions indicated in the
Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used
to design the valve body. Allowable stress requirements shall comply with the provisions of
ASME B31.3 and B31.8. In addition, corrosion allowance indicated in Valve Data Sheet shall
be considered in valve design. However, the minimum wall thickness shall not be less than the
minimum requirement of ASME B16.34.
b) Corrosion Allowance for all valves to be used in sweet gas services shall be considered nil.
c) The manufacturer shall have valid license to use API monogram on valves manufactured
as per API 6D.
6.2
Fully welded valves shall be used for main line aboveground/underground services. Other
aboveground valves may be of welded or bolted type with 2 piece/3 piece construction. Threaded
body joints shall not be accepted.
6.3
Ball shall be of single piece, solid type construction.
6.4
Valves shall be Full bore (FB). Full bore valves shall be suitable for the passage of all types of
pipeline scraper and inspection pigs on regular basis without causing damage to either the valve
component or the pig. The full bore valve shall provide an unobstructed profile for pigging
operations in either direction. Full bore valves shall be designed to minimize accumulation of
debris in the seat ring region to ensure that valve movement is not impeded.
6.5
Reduced bore valves shall be provided if specifically mentioned in data sheet. Valve body shall
be manufactured by casting or forging.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 6 of 16
6.6
All valves 4NB and above shall be trunion mounting type. Valves below 4 shall be floating type
unless specifically mentioned in data sheet otherwise.
6.7
Valve seats shall be with primary metal to metal contact. O - Rings or other seals if used for drip
tight sealing shall be encased in a suitable groove in such a manner that it can not be removed
from seat ring and there is no extrusion during opening or closing operation at maximum
differential pressure. The seat rings shall be designed so as to ensure sealing at low as well as
high differential pressures. Seat design with PTFE inserts is not acceptable.
6.8
All valves shall have two seating surfaces which in close position blocks the flow from both
ends. The cavity between the seating surfaces is vented through a bleed connection
provided on the body cavity i.e. the valves shall be Double Block & Bleed (DBB).
6.9
Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in
both open and closed positions.
6.10
All valves of nominal valve size 200 mm (8) NB & above shall have provision for secondary
sealant injection under full line pressure for seat and stem seals. All sealant injection connections
shall be provided with an internal Non-return valve. Valve design shall have a provision to
replace the sealant injection fitting under full line pressure.
6.11
All valves shall be provided with a vent and drain connection. These connections shall be welded
type as per Fig. 6.11 A/B. Body vent and drain shall be provided with valves (Ball or Plug type).
All these vents & drain connection shall be provided with isolation ball valve as shown in Fig
6.11 A/B. The end connection of vent & drain line to valve body or isolation valves shall be
welded type at underground location and threaded type for above ground location.
6.12
Valve design shall ensure repair of stem seals/packing under full line pressure.
6.13
a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt welded
as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged body valves shall
be integrally cast/ forged with the body of the valve. Face to face/end to end dimensions shall
conform to API 6D.
b) The length of butt welding ends shall be sufficient to allow welding and heat treatment without
damage of the internal parts of the valves.
c) Flanged end, if specified shall have dimensions as per ASME B 16.5 for valve sizes up to DN
600 mm (24) excluding DN 550 mm (22) and as per MSS-SP-44/ASME B16.47Series A for
Valve sizes DN 550 mm (22 inches) and for DN 650mm (26) and above. Flange face shall be
either raised face or ring joint type as indicated in Valve Data Sheet. In case of RTJ flanges,
the groove hardness shall be minimum 140 BHN. All flanged face shall have concentric
serration with 125 AARH finish.
d) Butt welding end preparation shall confirm to ASME B 16.25. Incase of difference in thickness
of valve body & mating pipelines, the bevel end of valve shall be as per ASME B 31.8 or
ASME B 31.4 as applicable. The end preparation shall take care of outside diameter of
connecting pipe, wall thickness, material grade, SMYS & Special chemistry of welded material
as indicated in the data sheet.
6.14
The temperature and pressure range of the valves shall be in accordance with the indicated
values on the relevant piping specification and valve data sheet.
6.15
Wall thickness of parts used for the welding connection with the line pipe shall meet the
following requirements:
a) The maximum allowable stress in the material of butt-weld connection for butt welding shall be
equal to 50% of the minimum yield strength guaranteed by the specification of steel used.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 7 of 16
b) The minimum wall thickness for butt welding connection must be greater than or equal to the
largest value of either the calculated minimum thickness of butt welding connections or the
nominal thickness of pipe as indicated on data sheet.
c) If the butt welding connections has a yield strength lower than the yield strength of the pipe to
which it is intended to be welded, the wall thickness in each zone of the butt welding
connection is at least equal to the specified pipe wall thickness times the ratio of minimum
yield strength guaranteed by the specification of the steel of the pipe to minimum yield strength
guaranteed by the specification of the steel of the butt welding connection.
d) The specified pipe wall thickness and grade with which the valve is intended to be used is
specified in the data sheet.
e) All valves under this specification shall be designed to withstand a field hydrostatic test
pressure with non corrosive water. After installation during 24 hours when the ball is partially
or fully open at a pressure level
P = 1.4 X MOP
P = hydrostatic test pressure (bar)
MOP = Maximum operating pressure at 38 C
6.16
Valve shall be provided with ball position indicator and stops of rugged construction at the fully
open and fully closed positions.
6.17
Valves of nominal size, DN 200 mm (8) and larger, shall be equipped with support foot and
lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot
shall be kept minimum. The lifting lugs shall be stamped with safe working load.
6.18
In order to avoid stress induced crack and soft seat damage during direct field welding operation
to valve body, all valves shall be supplied with welded pups at both ends which shall be
considered as an integral part of the valves and also the ID of the pup shall match with pipe ID.
The pup piece welding shall be carried out in controlled condition of temperature at
manufacturers workshop. Field welding of pup piece shall not be allowed. Material & length of
pup piece shall be as per Data sheet.
6.19
When indicated in Material Requisition, valves shall have locking devices to lock the valve
either in full open (LO) or full close (LC) positions. Locking devices shall be permanently
attached to the valve operator and shall not interfere with operation of the valve. Locking device
shall be such that the valve shall operate when the differential pressure across the valve
is 3bar.
6.20
Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high alloy
steel components in the assembly. Accordingly, Suitable insulation shall be provided as required.
6.21
The valve stem shall be capable of withstanding the maximum operating torque required to
operate the valve against the maximum differential pressure as per the appropriate class.
The combined stress shall not exceed the maximum allowable stresses specified in ASME
Section VIII, Division 1. The design shall take into account a safety factor of 1.5 based on the
maximum output torque of the operating mechanism. The valve Manufacturer shall guarantee
that the breakaway torque after long periods of non- movement can not exceed the normal
short term breakaway torque by a factor more than 1.25, and that the safety factor specified
above is not compromised.
6.22
The valve stem shall have anti-blowout feature with antistatic device conforming to BS 5351
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 8 of 16
6.23
When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions:
a) Valves provided with stem extension shall have water proof outer casing. The Length of
stem extension shall be as indicated on the Valve Data Sheet. The length indicated
corresponds to the distance between centerline of the valve opening and the centerline of
the rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a horizontal
shaft.
b) Manual override devices shall be provided on all valves
c)
Vent, drain and sealant connections shall be terminated adjacent to the valve operator by
means of suitable piping anchored to the valve body.
d) The stem extension shall be self relieving.

e) Outer casing of stem extension shall have 3/8 or 1/2 NPT plugs at the top and bottom, for
draining and filling with oil to prevent internal corrosion
6.24
Operating Devices
a) All valves of size > 12NB shall be manually operated & hydraulically actuated. In case of
manual operator, valve sizes, 100 mm (NPS 4) and below shall be wrench/ lever operated.
For Valves from 6 - 12 shall be gear operated.
Valve design shall be such that damage due to malfunctioning of the operator or its control
gear train or power cylinder and other damaged parts can be replaced without the valve cover
being removed.
b) The power actuator shall be in accordance with the Purchaser Specification issued for the
purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as
indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open
/full open to full close under maximum differential pressure corresponding to the valve rating.
For actuated valves, the actuators rated torque output shall be 1.25 times the break torque
required to operate the ball valve under the maximum differential pressure corresponding to
the Valve Class Rating.
c) For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, the total force
required to operate the valve does not exceed 350N. Manufacturer shall also indicate the
number of turns of hand wheel (In case of gear operators) required for operating the valve
from full open to full close position. The wrench length or hand wheel diameter shall be in
accordance with API 6D requirements. The manufacturer shall indicate the number of turns
of the hand wheel (for gear operators), required for operating the valve from fully open to the
fully closed position.
d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing
the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully encased
in water proof/splash proof enclosure and shall be filled with suitable grease.
6.25
Welding including repair welding of pressure retaining parts shall be as per welding
procedure qualification specified in ASME Section IX. The procedure qualification shall also
Include impact test and hardness test when required as per Clause 5.6, 5.7, 7.5 and 7.6 of this
specification and shall meet the requirements as specified therein.
6.26
The welders involved in welding shall be qualified in accordance with ASME Section IX.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 9 of 16
6.27
Repair by welding is not permitted for forged body valves. However repair by welding as per
ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat
treatment of casting is done. Repair welding procedure qualification shall also include impact test
and hardness test when required as per Clause 5.6, 5.7, 7.5 and 7.6 of this specification and
shall meet the requirements as specified therein.
6.28
The tolerance on internal diameter and out of roundness at the ends for welded ends valves
shall be as per connected pipe specification as indicated in the Valve Data Sheet.
6.29
When specified on the Valve Datasheet, Ball Valves shall be fire safe in accordance with
API 6FA, for which qualifying certificates, covering the range of items offered, shall be supplied
by the Manufacturer.
7.0
INSPECTION AND TESTS

The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests
shall be, but not limited to, the following:
7.1
The valve manufacturer must deliver a Certificate EN 10204 3.2 stating the quality, the
mechanical properties (yield strength, tensile strength, and impact test at 0 C), the chemical
analysis the process of manufacture and the marking (for ex: - heat number of material)
A new chemical analysis (upgradation) shall be done on specimen of valve in presence of TPIA.
7.2
All valves shall be visually inspected. The external and internal surfaces of the valves shall be
free from any arc strikes, gouges and other detrimental defects.
7.3
Dimensional check on all valves shall be carried out as per the Purchasers approved drawings.
7.4
Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.
7.5
Pressure containing parts of all valves such as body, bonnet, flange, welding ends and balls etc
shall be subjected to impact test on each heat of base material as per API 6D CL.7.5.
7.6
Notch toughness properties Charpy V: The standard impact test temperature is 0 C. The
average value per series of 3 test specimen shall be equal to 35 J/cm. The minimum value per
test specimen shall be equal to 35 J/cm; this value may drop to 27 J/cm per test specimen
per series.
7.7
Non Destructive Examination

a) Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer. All castings shall be wet magnetic particle inspected 100% of the internal
surfaces. Method and acceptance shall comply with MSS-SP-53.
b) Body castings of all valves shall be radio graphically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B 16.34. For all sizes, body casting
shall be subjected to 100% radiography.
c) All forgings shall be ultrasonically examined in accordance with the procedure and acceptance
standard of Annexure E of ASME B 16.34. All forgings shall be subjected to wet magnetic
particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with
MSS-SP-53.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 10 of 16
d) Bodies and bonnets made by welded assembly of segments of castings, forgings,

combinations thereof shall be examined, as applicable, by methods of 7.7 (b) for cast
components or 7.7 (c) for forged components and plates.
7.8
Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.3 or ASME B31.8 as applicable and API 1104.
7.9
a) All finished weld ends subject to welding in field shall be 100% ultrasonically tested for
lamination type defects for a distance of 50 mm from the end. Laminations shall not be
acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100% radio graphically
examined and acceptance criteria shall be as per ASME B16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet magnetic particle methods. All defects longer than 6.35 mm shall be rejected. Rejectable
defects must be removed. Weld repair of bevel surface is not permitted.
7.10
All valves shall be tested in compliance with the requirements of API 6D. During pressure
testing, valves shall not have sealant lines and other cavities filled with sealant, grease or
other foreign material. The drain, vent and sealant lines shall be either included in the
hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic
testing. The body cavity self-relieving feature meeting the requirements of clause 6.8 of this
specification shall also be checked.
7.11
A supplementary air seat test as per API 6D, Appendix C, Para C3.3 Type II shall be carried
out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is
allowed. Test pressure shall be held for at least 15 minutes.
7.12
Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6, API 6D
under hydraulic pressure equal to maximum differential pressure corresponding to the valve
rating. For manually operated valves, it shall be established that the force required to operate
the valve does not exceed the requirements stated in section 6.24 (c) of this specification.
7.13
Power actuated valves shall be tested after assembly of the valve and actuator, at the valve
Manufacturers works. At least five Open-Close-Open cycles without internal pressure and
five Open-Close-Open cycles with maximum differential pressure corresponding to the valve
rating shall be performed on the valve actuator assembly. The time for Full Open to Full
Close shall be recorded during testing. If required, the actuator shall be adjusted to ensure
that the opening and closing time is with in the limits stated in Valve Data Sheet. The Hand
operator provided on the actuator shall also be checked after the cyclic testing, for
satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the
same size, rating and the actuator model/type. In case, the tests do not meet the
requirements, retesting/rejection of the lot shall be decided by the Purchasers Inspector.
7.14
Subsequent to successful testing as specified in clause 7.10, 7.11, 7.12 and 7.13 above,
one(1) valve out of the total ordered quantity shall be randomly selected by the Company
Representative for cyclic testing as mentioned below:
a) The valve shall be subjected to at least 5 Open-Close-Open cycles with maximum
differential pressure corresponding to the valve rating.
b) Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 7.10 and 7.11.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 11 of 16
In case this valve fails to pass these tests, the valve shall be rejected and two more valves
shall be selected randomly and subjected to testing as indicated above. If both valves pass
these tests, all valves manufactured for the order (except the valve that failed) shall be
deemed acceptable. If either of the two valves fails to pass these tests, all valves shall be
rejected or each valve shall be tested at the option of manufacturer.
Previously carried out prototype test of similar nature shall not be considered acceptable in
place of this test.
7.15
Purchaser reserves the right to perform stage wise inspection and witness tests as indicated
in clauses 7.1 to 7.14 above at Manufacturers works prior to shipment. Manufacturer shall
give reasonable access and facilities required for inspection to the Purchaser. Purchaser or
Purchasers representative reserves the right to require additional testing at any time to
confirm or further investigate a suspected fault. The cost incurred shall be borne to
Manufacturer.
In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves .
Inspection and tests performed/witnessed by the Purchasers Inspector shall in no way
relieve the Manufacturers obligation to perform the required inspection and tests.
8.0
TEST CERTIFICATES
Manufacturer shall submit the following certificates:
a) Mill test certificates relevant to the chemical analysis and mechanical properties of the
materials used for the valve construction as per the relevant standards.
b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and
pressure of each test.
c) Test reports of radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 7.12, 7.13 and 7.14 of this
specification.
e) All other test reports and certificates as required by API 6D, this specification and data sheets.
The certificates shall be valid only when signed by Purchasers Inspector. Only those valves
which have been certified by Purchasers Inspector shall be dispatched from Manufacturers
works.
9.0
PAINTING, MARKING AND SHIPMENT
9.1
Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient
coats of corrosion resistant paint. Surface preparation shall be carried out by
shot
blasting to SP- 6 in accordance with Steel Structures Painting Council - Visual
Standard
SSPC-VIS-1. For the valves to be installed underground, when indicated
in Valve Data Sheet,
the external surfaces of buried portion of the valve shall be
painted with three coats of suitable
coal tar epoxy resin
with a minimum dry film
thickness of 300 microns.
9.2
All valves shall be marked as per API 6D. The units of marking shall be metric except
nominal diameter, which shall be in inches.
9.3
Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces,
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 12 of 16
securely attached to the valves. Bevel ends shall be protected with metallic or high impact
plastic bevel protectors.
9.4
All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
9.5
Packaging and shipping instructions shall be as per API 6D and procurement documentation.
All valves shall be transported with ball in the fully open condition.
9.6
On packages, following shall be marked legibly with suitable marking ink:

a) Order Number
b) Manufacturers Name
c) Valve size and rating
d) Tag Number
e) Serial Number
10.0
SPARES AND ACCESSORIES
10.1
Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning.
10.2
Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves.
10.3
Manufacturer shall quote for spares and accessories as per Material Requisition.
11.0
DOCUMENTATION
11.1
At the time of bidding, Manufacturer shall submit the following documents:

a)
Filled in Data Sheet
b)
General arrangement/assembly drawings showing all features and relative positions and
sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts
together with overall dimension.
c)
Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be furnished
complying with the requirement of Clause 6.7 of this specification.
d)
Reference list of similar ball valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating, service
etc.
e)
Torque curves for the power actuated valves along with the break torque and maximum
allowable stem torque. In addition, sizing criteria and torque calculations shall also be
submitted for power actuated valves.
f)
Clause wise list of deviations from this specification, if any.
g)
Descriptive technical catalogues of the manufacturer.
h)
Installation, Operational and Maintenance Manual.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 13 of 16
11.2
i)
Copy of valid API 6D Certificate.
j)
Details of support foot including dimensions and distance from valve centerline to bottom
of support foot.
Within three weeks of placement of order, the Manufacturer shall submit four copies of, but not
limited to, the following drawings, documents and specifications for Purchasers approval:
a)
Detailed sectional drawings showing all parts with reference numbers and material
specifications.
b)
Assembly drawings with overall dimensions and features. Drawing shall also indicate
the number of turns of hand wheel (in case of gear operators) required for operating the
valve from full open to full close position and the painting scheme. Complete dimensional
details of support foot (where applicable) shall be indicated in these drawings.
c)
Welding, heat treatment and testing procedures (Quality Assurance Plan).
d)
Details of corrosion resistant paint to be applied on the valves.
Manufacturing of valves shall commence only after approval of the above documents. Once the
approval has been given by Purchaser, any changes in design, material and method of
manufacture shall be notified to Purchaser whose approval in writing of all changes shall be
obtained before the valve is manufactured.
11.3
Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the
following:
a) Test certificates as per clause 8.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions including a list of
recommended spares for the valves.
11.4
CD containing all docs in 11.2 & 11.3 shall be submitted within 30 days from the approval date,
Manufacturer shall submit to Purchaser one reproducible and six copies of the approved
drawings, documents and specifications as listed in clause 11.2 above.
11.5
All documents shall be in English language only.
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 14 of 16
FIG - 6.11 A
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 15 of 16
FIG - 6.11 B
FOR
BALL VALVES
Document No.
Rev
11-0398B02-01-08-02-025
SHEET 16 of 16
GAIL (India) LIMITED

12" GANDHAR-DABKA PIPELINE
CLIENT
REFERENCE DOC.
TECHNICAL
SPECIFICATION FOR
PAINTING
11-0398B02-01-09-02-022
REFERENCE DOC. NO.
For Slag Catcher

Description
Item Code
Surface Finish :
SA 2.5
Qty.
Primer :
Internal
P-6
2 Coats
External
P-6
2 Coats
Finish Paint :
Internal
NIL
External
F-6
External Colour / Shade :
Light Grey (RAL 7035 or Equivalent)
2 Coats
For Condensate Tank

Description
Item Code
Surface Finish :
SA 2.5
Qty.
Primer :
Internal
P-6
2 Coats
External
P-6
2 Coats
Finish Paint :
Internal
NIL
External
F-7
External Colour / Shade :
Jet Black (RAL 9005 or Equivalent)
SCOPE OF PAINTING FOR VESSELS
2 Coats
Document No.
Rev.
ANNEXURE - III
SHEET 1 of 1

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GAIL (INDIA) LIMITED

(A.GOVT OF INDIA UNDERTAKING)

INSTALLATION OF I.P. STATION AT ANKHI, GUJARAT ON 12

TENDER FOR CONDENSATE RECOVERY SYSTEM

MATERIAL REQUISITION (MR) FOR CONDENSATE

TECHNICAL SPECIFICATION OF CONDENSATE

PROCESS DESIGN BASIS OF CONDENSATE

DATA SHEET OF SLUG CATCHER

DATA SHEET OF CONDENSATE TANK

DATA SHEET OF PRESSURE GAUGE

DATA SHEET OF PRESSURE SAFETY VALVE

DATA SHEET OF LEVEL GAUGE

DATA SHEET OF DP TYPE PRESSURE

DATA SHEET OF FLAME ARRESTOR

DATA SHEET OF LEVEL TRANSMITTER

TECHNICAL SPECIFICATION OF PRESSURE

TECHNICAL SPECIFICATION OF PRESSURE

TECHNICAL SPECIFICATION OF DP TYPE

TECHNICAL SPECIFICATION OF INSTRUMENT

QAP FOR SLUG CATCHER

QAP FOR CONDENSATE TANK

LIST OF RECOMMENDED VENDOR FOR

THIRD PARTY INSPECTION AGENCY FOR

TECHNICAL SPECIFICATION OF TUBES &

DATA SHEET OF SUMP PUMP (VERTICALLY

TECHNICAL SPECIFICATION OF PAINTINGS

P&ID OF CONDENSATE RECOVERY SYSTEM

DATA SHEET OF BALL VALVES

TECHNICAL SPECIFICATION OF BALL VALVES

SCHEMATIC GAD OF SLUG CATCHER

SCHEMATIC GAD OF CONDENSATE TANK

SCOPE OF PAINTING FOR VESSELS

INSTALLATION OF IP STATION AT ANKHI

MATERIAL REQUISITION FOR CONDENSATE RECOVERY

CLIENT JOB NO.

ISSUED FOR TENDER

ISSUED FOR IDC

3. SPECIAL INSTRUCTIONS TO BIDDER

4. INFORMATION/ DOCUMENTS/ DRWGS TO BE SUBMITTED BY SUCCESSFUL BIDDER

MATERIAL REQUISITION FOR

SCOPE OF WORK (SOW)

All paints, primers as per painting specifications in the Tender by vendor

MATERIAL REQUISITION FOR

Writing tags details for all the Instruments with paint.

Design, Engineering, Manufacturing, Supply, Testing at Works

200% Gasket as Mandatory Spares for each Nozzle/Flange

100% Fasteners as Mandatory Spares for each Nozzle/Flange

Compliance with Specification

MATERIAL REQUISITION FOR

SPECIAL INSTRUCTIONS TO BIDDERS

All the equipments/materials shall be delivered at GAIL-Ankhi IP Station, Gujarat.

INFORMATION/ DOCUMENTS/ DRAWINGS TO BE SUBMITTED BY SUCCESSFUL BIDDER

Statutory test certificates, as applicable.

WPS & PQR, as required.

MATERIAL REQUISITION FOR

Purchase orders of bought out items soon after placement of order.

A list of documents to be furnished along with supply.

MATERIAL REQUISITION FOR

INSTALLATION OF IP STATION AT ANKHI

CLIENT JOB NO.

ISSUED FOR TENDER

ISSUED FOR IDC

STANDARDS AND CODES ...........................................................................................3