1574_07-vol-4-1-gts

TENDER DOCUMENT NIT No.: DLI/C&E/WI-665/284 FOR

Tender for ‘Design, Engineering, Supply , installation, testing & commissioning of ‘DUST SUPPRESSION PACKAGE AND ASSOCIATED WORKS’ for the project of “Augmentation of Raw Material Handling Receipt and Handling facilities with new OHP Part– B (Package- 061) of Bhilai Steel Plant, (SAIL)”.

VOLUME – 4

General Technical Specification of Bhilai Steel Plant, SAIL

ENGINEERING PROJECTS (INDIA) LIMITED (A GOVT. OF INDIA ENTERPRISE)

Core-3, Scope Complex, 7, Institutional Area, Lodhi Road, New Delhi-110003 TEL NO: 011-24361666 FAX NO. 011- 24363426

STEEL AUTHORITY OF INDIA LIMITED BHILAI STEEL PLANT

GENERAL SPECIFICATION FOR PREFFERED MAKES (GS – 13)

MECON LIMITED

RANCHI – 834002

No. MEC/S/1901/11/38/0/00/00/F1889/R2

JULY, 2007

General Technical Specification

CONTENTS SL. NO. 01

PREAMBLE

02

FLUID SYSTEM

2

03

VENTILATION, AIR CONDITIONING AND AIR

9

DESCRIPTION

PAGE NO. 1

POLLUTION CONTROL EQUIPMENT 04

HANDLING & HOISTING EQUIPMENT

11

05

REPAIR & MAINTENANCE FACILITIES

16

06

ELECTRICAL

17

07

INSTRUMENTATION

25

08

FIRE PROTECTION SYSTEM

30

09

BOF GCP EQUIPMENT

30

10

INFORMATION SYSTEM

32

11

FLUID SYSTEMS & PIPING ENGG

34

(LUBRICATION & HYDRAULICS)

© 2007 MECON Limited All rights reserved

Preferred Makes Page 1 of 1

GS-13

General Technical Specification 01.

PREAMBLE

This document “PREFERRED MAKES OF EQUIPMENT AND SUPPLIES” is a part of the tender specification for various packages of BHILAI STEEL PLANT. The makes of various equipment and supplies in respect of imported/indigenous equipment/components/materials are listed out in this document. It is essential that the equipment/component/materials to be supplied from imported/indigenous sources by the Tenderer will be of any one of the makes listed against that particular equipment/ component/material in this documents.. In case the Tenderer/ Contractor intends to substitute any particular make of equipment / components/ materials by a make other than that listed in this document, the Tenderer shall clearly bring out the same in his tender along with justification and indicate the alternative makes offered by him. It will be prerogative of the Purchaser to accept or reject the alternative makes so offered.



GS-13

General Technical Specification 01

FLUID SYSTEM

01.01

Water Supply Facilities Sl. No.

Item Description

1

Horizontal Centrifugal Pumps

:

Kirloskar Brothers, KSB, Beacon Weir, Khimline, Jyoti, Sintech, Ghaziabad.

2

Vertical Turbine Pumps

:

Kirloskar Brothers, Voltas, WPIL, Jyoti,

3

Vertical Wet Pit Type Pumps

:

SU Motors, Kishore Pumps, Kirloskar Brothers, KSB.

4

Submersible Pumps

:

KSB, SU Motors, Kirloskar Brothers, Kishore Pumps, Darling, Beacon Weir.

5

Slurry Pump

:

Akay, Sam Engg., MBE, KBL, KSB Pumps, WARMAN.

6

Dosing Pump

:

Shapo Tools, Asia LMI (Madras), Positive Metering Pumps, Toshniwal, Milton Roy India.

7

Cooling Towers

:

PCTPL, Shri Ram Tower Tech, Gammon, Himgiri, Southern Cooling Tower, BDT, GEA

8

Pressure Filters

:

Thermax, Ion-Exchange, Resin India, Driplex, Doshion, VA Tech Wabag, UEM, Aquatech

9

Sluice Gates

:

Jash Engineering, IVPL

10

Travelling Water Screen

:

Macmet, Triveni, Otokiln, Mecgale (Nagpur), General Mechanical

11

Sludge Scrapper

:

Triveni, Neo – Parisrutan, Mata India, Geomiller

12

Fire Hydrants

:

New Age Industries, Steelage Industires, ASCO, Strumech, Vijay Fire, Zenith

13

Basket Strainers

:

Filteration Engrs, J.N Marshall, Masturlal Fabrication , ARF Engg, Purolator Filters, ABB, Filters Mfd India

14

Duplex Strainers

:

Filteration Engrs., Otokiln, Superflo

15

Rubber Dismantling Joints

:

BDX, CORI Engineers, D.Wren,

16

Diesel Engine

17

Softening & DM Plant

18

R O Plants

19

Effluent Treatment Plant

:

20

Drinking water Treatment Plant

:

UEM India, VA Tech, GEA Energy Systems, Driplex Water Engg , Triveni,

21

Basalt Liners

:

DEMECH, Vidyut Green Bank, Enviro Abrasian, Garden


Manufacturers

: :

:

Cummins/Ashok Layland/Ruston Doshi / Resin India / Thermax / Thermax Cullinyan / VA Tech / Ion Exchange /Triveni / GEA Energy Systems/ Driplex Water Engg, Triveni, UEM India, VA Tech, GEA Energy Systems, Ion Exchange, Driplex Water Engg, Triveni, UEM India, VA Tech, GEA Energy Systems, Triveni,


GS-13

General Technical Specification Sl. No.

Item Description

22

Oil Skimmer

:

JVM Engg.

23

Plate Heat Exchangers

:

Alfalaval, GEA Ecoflex, IDMC

24

Surge Tanks

:

Anup Engg., Zenith Erectors, Haldia., Perfect Engg., Sakthi Hitech

25

C.I. Valves (gate, globe, NRV)

:

Kirloskar Brothers, Steam & Mining, IVPL, AV Valves, Shiv Durga, BDK, Fouress.

26

CS Valves (gate, NRV)

:

Audco, Fouress, BHEL, Sakhi, KSB, Steam & Mining, BDK, Kirloskar, Virgo

27

Plug Valves

:

Audco- L&T, Vass Ind., Xomox, Virgo, BDK, Steam & Mining.

28

Ball Valves

:

Audco, KSB, AL Saunders, Xomox, Virgo, BDK, Virgo ,

29

GM Valves

:

Leader, Steam & Mining, NECO, Upadhyay Valves, Kalpana Valves

30

Butterfly Valves (Manually & electrically operated)

31

Diaphragm Valves

32

Float Valve

33

Control Valve

34

Solenoid Valve

35

Air Release Valve

36

Pressure Reducing Valve

37

Strainer/Filter

38

Electric Actuators

39

Rotory Pneumatic Actuators

40

Hoses

41

Pipes a) MS/GI

Manufacturers Reach Ship Builders & Engg.

b) DI

:

: : : : : : : : : : : :

L&T, Fouress, Kirloskar Brothers, IVPL, VIRGO, AL Saunders, Steam & Mining, Keystone, BDK, XOMOX.

AL Saunders, Fluid System, BDK , Steam & Mining. Leader, IVPL, IM Engineers, Steam & Mining. BHEL, L&T, Fouress, IL, MIL Controls, NECO Scharbet, Darling Rotex, Sicmag, Scharder, NECO INDFOS, Eastern Pneumatic, Bluestar, AVCON, ASCO, Mercury Shiva Durga, IVPL, IM Engineers, Steam & Mining, Schroder Duncum, Fluid Line Valves. JNM, Fouress, Bestobell, IL, Mazda, Nirmal Ind., Forbes Marshal Otokiln, Superflo, Triveni Plenty, Filter Mfg. Ind., Purolator, Filteration Engineers Beacon Rotork, Auma, Marsh Engineers, Keystone, Limitorque, Antrieb, IL, Palghat AL Saunders, Xomox, EL-O-Matic, Virgo, L&T, Flocon, Precision Processing Equipt. Co. Aeroflox/Markwel/Senior Flexonics, Inalsa, Teksons SAIL/TATA/Jindal/Zenith/Man/SAW/Surindra/Welspun/Prak esh Electro Steel Casting

42

RCC Pipes & Fittings

:

SUR Industrial Pipes, Hind Ceramics, Indian Hume Pipes, Daya Cuncrching.

43

HDPE Pipes &

:

EMCO, KWH Heliplastic Polyolefins, Oriplast



GS-13


01.02

Item Description

Manufacturers

Fittings

44

PVC Pipes & Fittings

:

Oriplast, Finolex, Bharat Pipe & Fittings, Supreme Industries.

45

SS Pipes / SS Fittings

:

Heavy Metal Tubes, Nobel Tubes, Rajendra Mech. Ind., Vitrag, SAIL, Poonam Enterprises, N.L.Hazra, M.S.Fittings

46

Seamless, Stainless Steel Pipes/Tubes

:

Choksy Tubes, MJ Patel, Nagardas Kanji, Poonam Enterprises, Sandulk Asia, Noble Tubes, Allied Steel, SAIL, Maharastra Seamless (P) Ltd,

47

Fittings for the above Pipes/Tubes

:

EBY Ind., High-Tech, Hydro technic, Hydro-Air Engg., Project Toolings, Shivananda, M.J.Patel, Nobles Tubes, Allied Steel, Poonam Enterprises, N.L.Hazra, M.S.Fittings

48

Wrapping & Coating for pipes

:

Rustech Products, HOTACO, IWL, M P Tar Products

49

Chemical Dosing System

Hindustan Dorr Oliver, Chembonddrewtreat ltd., NALCO

Tellabs

Chemicals,

Valves For Fuel Gas, Steam, Nitrogen, LPG & Compressed Air Facilities Item Description

Manufacturers

C.I. Valves for Fuel Gas & Compressed Air (gate, globe, NRV)

:

Kirloskar Brothers, GM Dalui, Steam & Mining, H.Sarker, IVPL, AV Valves, Leader, Associated tooling, BDK, Kalpana Valves

CS, FS, SS Valves for Steam, Feed Water, & LPG (Gate, Globe, NRV)

:

L&T (Audco Div), Fouress, BHEL, KSB, GM Dalui, Leader, BDK, NECO, Associated Tooling, Hawa Egr., Vass Ind, Advance Valves, Kalpana Valves

CI, CS, SS & FS Plug Valves

:

Vass Ind., Xomox, Virgo, BDK, Leader, Steam and Mining, GM Dalui, H.Sarkar, Audco

Ball Valves

:

Audco, Vass Ind, KSB, BDK, Microfinish, Niton,AL Saunders, Xomox, Virgo, United Engineers, Steam & Mining, Hi-Tech B.Valves

GM Valves

:

Bombay Metals, GM Dalui, Leader, NECO, Kalpana Valves



GS-13


02.03

Butterfly Valves

:

Audco, Fouress, Kirloskar Brothers, IVPL, Inter Valve, Virgo, AL Saunders, Keystone, BDK, Leader, AVC Engg., Crowley & Ray, Xomox, Tyco, Hi-Tech.

Diaphragm Valves

:

AL Saunders, Fluid System, Leader, BDK, Xomox, Steam & Mining

Pressure Control Valve/Pressure Reducing Valve

:

JNM, Fouress, Bestobell, IL, Mazda, Nirmal Ind., Vanaz, Kosan Metal, Vass Ind., RK Control, Fluid Line, Forbes Marshal, Leader.

Large Diameter Goggle Valve

:

Audco, Fouress, Cimmco, L&T

Fabricated Gate Valves

:

Fouress, Cimmco, Kalpana Valves

Safety Relief Valve (Pressure relief Valves)

:

BHEL, Keystone, Bliss Anand, L&T (Audco Div.), Sempell, Fainger, Leser Valves (P) Ltd., IL, Anderson, Kosan.

BECO, Beekay, L&T,

Miscellaneous Gas Facility & Compressed Air Equipment Item Description

Manufacturers

Oxygen Acetylene & LPG Manifolds

:

Kamrup Industrial Gases, INOX, Titan Engg., BOC, Ramba Hydrogen, Asiatic Oxygen

SS Bellows Expansion Joints

:

Flexican, Flexatherm, SURR Ind., Pressel (Cuttack), BD Engr., Eludyne Engr., SPB, SEPL, PEBI, Lonestar, GBM Mfg., TI Flexible Tube.

Centrifugal Gas Booster

:

Andrew Yule, TLT, James Howden (U.K), Donkin (U.K), Hibhen

Twin Lobe Type Booster

:

Skoda, CKD Kompressors, MD Pneumatics, Demag Delavl, Bryan Donkin Sulzer, Oil & Gas Plant Engg., (Tuthill), Kay International



GS-13

General Technical Specification Gas/Air Compressors

:

Ingersoll Rand, Atlas Copco, KG Khosla, Kirloskar Pneumatic, Chicago Pneumatic, Mannesman Demag, Eliat, Cooper, Sulzor, Corken (USA)

Hoses

:

Flexican, Gaytri Industrial Corpn., Inalsa, Teksons, Sudeep Industries, Markwell

Valves for Oxygen Services: Item Description 1.

Manufacturers

Non-Ferrous: For Isolation

:

Bestobell (UK), ETH IRELAND (France), RT Orseal (UK), Truflo (Belgium), Worcestor Controls (UK),

Quick Sheet-off Valve

:

Bestobell (UK), ETH IRELAND (France), RT Orseal (UK), Truflo (Belgium), Worcestor Controls (UK), Moorco, SEBIM

:

SEVERN (UK), NELES SECK GLOKON (UK), IL (Palghat)

Solenoid Valve

:

AVCON, SEITZ, ROTEX, ASCO

Safety Relief Valve (SRV)

:

KUNKLE (USA), KEYSTONE (USA), BROADY (UK), MOORCO, SEBIM, IL (Palghat)

Pressure Regulators (Self regulating with pressure gauge)for Oxygen

:

ESAB, BOC, Speciality Gases, Kamrup Industrial Gases, Venaz Engineers, Nirmal Ind.

Stainless Steel (SS)

:

Precision Engg., BDK, Niton, Akay, Leader, Audco, Sakhi & Co., KSB

Pressure Control Valve (PCV) & Flow Control Valve (FCV)

2.

(manual)

POWER & ENERGY © 2007 MECON Limited All rights reserved


GS-13

General Technical Specification Item Description

Manufacturers

Air Drying Uuit

:

Chemech, Cleanair, Delair, Indcon, Mellcon, Mirch Mirex, Gasoenergy System Pune.

Condensate Pumps

:

KSB, BHEL, Kirloskar Brothers, Mather & Platt, Khimline, Sigma

Ejector

:

BHEL, Weigand, Newfield, Mazda

Trap & Strainer for Compressed Air & Steam

:

Uniklinger, ESCO, JNM, Dryton Greaves, Forbes Marshall, Hawa Engrs., Mazda

Electrical

:

AUMA India, Beacon Rotork Controls, Continental Profiles, Emtork Actuators, Limitorque

Pneumatic

:

Marsh Engg., Keystone, IL, Massoneilan, ELO-MATIC, Virgo, AL Saunder, L&T, Flocan

:

BHPV, Kaveri, Texmaco, Thermax, Babcock & Wicox, Parkair Engg., Rhine, Universal Heat Exchanger, Godrej, L&T, GEI Godavari, Patel Air Temp., Hindustan Radiaton

Control Valves

:

Blue Star, Fouress Engg., IL, JNM, Mazda, Forbes Marshall

Pressure Vessel & Tanks

:

Beekay Engg., BHPV, ISGEC, Kaveri Engg., TSL, Lloyds Steel, Mukand, Parkair Engg., Grasim Industries, Anup Thermal System, Texmaco, SV Tank, Grasim Industries, Hyderfuel Industries.

Thermal Insulation

:

Hyderapad Industries, Lloyds Insulation, Rockwool, Thermax Heat Tracers, U.P. Twiga Fibreglass.

Suction Filters

:

FMI, KAAF, L&T, Flakt, Autokiln Filter, GEC Alsthom, Filtration Engr., ARF Engg., ABB, Dyna Filter, Purolator Filters, GM Dalui

Actuators

Heat Exchanger (Shell & Tube Type)



GS-13

General Technical Specification 02.04

Pipes & Fittings Facilities.

for Water Supply, Gas Facilities, Steam and Compressed Air

Item Description

Manufacturers

SW/SAW, ERW/EFW MS Pipes

:

SAIL, BHEL, TISCO, Jindal, Ajanta, Zenith, Saw Pipes, Welspun, Man Industries, Surindra Engg., Maharastra Seamless, Indian Seamless, BST, Advance Steel, Good Luck, Indus Tubes, Mukat, Lloyds, Poonam Enterprises, Soor Neogi Koumar.

SS Pipes / SS Fittings

:

Heavy Metal Tubes, Nobel Tubes, Rajendra Mech. Ind., Sterling Supply Agency, Vitrag, SAIL, Poonam Enterprises, N.L.Hazra, M.S.Fittings

Seamless, Stainless Steel Pipes/Tubes

:

Amardeep Steel, Choksy Tubes, MJ Patel, Nagardas Kanji, Poonam Enterprises, Sandulk Asia, MEC Tubes, Nagardas & Kusai, Noble Tubes, Allied Steel, Kamlesh Tube, Menilal & Bro, Uday Tubes, SAIL, Maharastra Seamless (P) Ltd, Imperial Steel, Soor Neogi Koumar.

Fittings for the above Pipes/Tubes

:

EBY Ind., High-Tech, Hydro technic, HydroAir Engg., Project Toolings, Shivananda, M.J.Patel, Nagardas & Kusai, MEC Tubes, Nobles Tubes, Amardeep Steel, Allied Steel, Kamlesh Tube, Menilal & Bros, Poonam Enterprises, N.L.Hazra, M.S.Fittings

RCC Pipes & Fittings

:

SUR Industrial Pipes, Hind Ceramics, Indian Hume Pipes, Daya Cuncrching.

HDPE Pipes & Fittings

:

EMCO, KWH Heliplastic Polyolefins, Oriplast

PVC Pipes & Fittings

:

Oriplast, Finolex, Bharat Pipe & Fittings, Supreme Industries.



GS-13


VENTILATION, AIR CONDITIONING & AIR POLLUTION CONTROL EQUIPMENT Item Description

Manufacturers

Centrifugal fans for Ventilation

:

C.Doctor, EFE, AEROVENT, Flow Link, Andrew Yule, RIECO, ISEL, BATLIBOI, Flaktwood, REITZ, ACCEL, Dustven, INDFAN,

Centrigugal fans for Dedusting

:

BHEL, TLT, C.Doctor, Andrew Yule, RIECO, Batliboi, F.Harley, Flaktwood, REITZ, DUSTVEN, ISEL, INDFAN

Tube axial fans / Propeller Fans

:

C.Doctor, EFE, Flow Link, ALMONARD, ACCEL, KHAITAN, AEROVENT, ISEL, INDFAN

Panel filter for air

:

FMI, Clean Filter Industries, EFE, ACCEL, FILTRONIC, FLOWLINK, CADILLAC, C. DOCTOR

Air washer

:

C.Doctor, EFE, FLOW LINK, FHARLEY, ALSTOM, Dustven, BATLIBOI, FMI

Man coolers

:

C.Doctor, Ventura, LM KHAITAN, ALMONARD, FLOWLINK

Roof exhauster

:

C.Doctor, EFE, ACCEL, ALMONARD, FLOWLINK, INDFAN, AEROVENT

Window air conditioners

:

Fedders Lloyd, VOLTAS, Blue Star, ARCTIC, Carrier Aircon, LG, Samsung, HITACHI

Packaged air conditioners

:

VOLTAS, Blue Star, KIRLOSKAR, ACCEL, BATLIBOI, EMERSON, FEDDERS LLOYDS, ROOS TEMPKOOL, ROOTS COOLING



ENGINEERS, DUSTVEN,

GS-13

General Technical Specification Item Description

Manufacturers

Packaged chillers

:

VOLTAS, Blue Star, ALSTOM, Batliboi, ACCEL, FEDDERS LLOYD, KIRLOSKAR, PNEUMATIC

Air handling units

:

VOLTAS, BLUE STAR, ALSTOM, BATLIBOI, PATELS AIR TEMP, ROOTS COOLING

Cooling towers

:

PAHARPUR, MIHIR, ADVANCE, GAMMON INDIA, Southern Cooling Towers Ltd., SHRIRAM TOWER TECH.

Refrigerant compressors

:

VOLTAS, SHRIRAM, ACCEL, BLUE STAR, , Atlas Copco, Kirloskar, HITACHI

Cyclones

:

THERMAX, RIECO, ALSTOM, C.DOCTOR, F.HARLEY, Dustven, EFE

Multicyclones

:

THERMAX, ALSTOM, C. DOCTOR, BATLIBOI, RIECO, F.HARLEY, EFE

:

THERMAX, ALSTOM, ANDREW YULE, RIECO, C.DOCTOR. F.HARLEY, Dustven, BATLIBOI, FMI

:

ALSTOM, RIECO, THERMAX, VAI, Dustven, BATLIBOI

Wet scrubbers

:

ALSTOM, THERMAX, BATLIBOI, RIECO, C.DOCTOR, F.HARLEY, EFE, SOIL & ENVIRO SYSTEM

Venturi scrubbers

:

BATLIBOI, THERMAX, RIECO, ALSTOM, Dustven

Electrostatic precipitators

:

ANDREW YULE, VOLTAS, ABB, VAI

Bag filters 3

(Cap – 10,000 m /h to 3 80, 000 m /h) Bag filters 3

(Cap –Above 80,000 m /h)

Insulation

THERMAX,

TWIGA, LLOYDS, BAKELITE MALANPUR ENTECH

BHEL, HYLAM,

Valves for air conditioning

:

DANFOSS, HONEYWELL, BLUE STAR

Vibration isolators

:

DUNLOP, EMERALD

Centrifugal horizontal pumps

:

KSB, BEACON KIRLOSKAR

Horizontal split casing pumps

:

VOLTAS, BEACON KIRLOSKAR



WEIR, WEIR,

VOLTAS, KSB,

GS-13


HANDLING & HOISTING EQUIPMENT & COMPONENTS

04.01

Equipment

Item Description

Manufacturers

EOT Crane (Up to 10T capacity)

:

Armsel, Avon, FAFECO, Mukand, Anupam, Shivpra, Tubrofurguson

EOT Crane (Up to 50 T capacity)

:

HEC, Jessop, Mukand, Hyderabad Ind. Ltd., WMI, FAFECO, Unique, Anupam

EOT Crane (Above 50 T capacity)

:

Jessops, HEC, Mukand, FAFECO, Unique, WMI, .

Underslung Cranes (Upto 5t only) Electric Hoists

:

Armsel, Brady & Morris, Shivpra

:

Armsel, Shivpra,WH Brady, Brady & Morris, Grip Engrs., Hi-tech, Century Crane

Transfer Cars

:

HEC, L&T, Hyderabad Ind., Engrs, ELECON, TRF

Chain Pulley Blocks & hand operated travelling cranes. Shunting Winch

:

Armsel, Century Cranes, Brady & Morris, Light Lift Ind., Hi-tech, MR Engg. Lifting Equipment

:

Beekay, HEC, Armsel, Century Cranes, Nirmal Equipments, Mining & MH Equipment, Cyclo transmission

Jib Crane

:

Brady & Morris, Century Cranes, Hi-tech, Grip Engrs., Elite, Light Lifting, Armsel

Crawler Mounted Mobile Crane Excavator/ Shovel

:

TIL, Hyderabad Industries, TATA-P&H

:

TIL, HEC, Hyderabad Industries, BEML

Elevator/Lift

:

OTIS, OMEGA, Kone, ECE



WMI,

Mukand, Eqipt

GS-13


Mechanical Components/ Equipment Item Description

Manufacturers

Hooks

:

Herman Mohta, Free Trading Corporation, Steel Forgings & Engg..

Flexible / Geared coupling

:

Hicliff, Concord, Wellman, GBM, Alliance, New Allenbery Works,Elecon,

Wire rope

:

Bharat Wire Rope, Orion Ropes, Usha Martin

Bearings for Cranes

:

SKF, FAG

Bearings for other equipment

:

SKF, FAG, Tata Timken, Asian Bearings, NRB,MBM

Oil Seals

:

Vaco Oil Seals, Rubber Equipment & Engg. Sealjet India (Pune), Sealpack, Champion Seals

Lubrication Fittings

:

Lubcon, AFMC, Prakash, Lincoln

Lubricating Systems

:

AFMC, Prakash, Grindwell Norton, Lincoln Helios

Gear box

:

New Allenburry, Greaves Cotton, ELECON, Shanti Gears, Flender, AR Engg, Kirloskar,I.C.

Hydraulic Systems

:

Vickers Sperry, Yuken, Manesmann, Rexroth, Hugglands Denison-Parker

Hydraulic Coupling

:

Fluidomat, Ghatge Patil, VOITH, Prembrill

Centrifugal blowers Burners

: :

Recuperators

:

REITZ, Flaht Wood, James Howden (UK) Stein Heurtey, Techint, LOI, Weswan North American, Ecllpse, Hotwork Eastern Equipment, GEFFI (Germany) SAFMAT (France), North American Minnt. Co. Thermal Transfer Corporation (USA)



GS-13


Item Description

Manufacturers

Hydraulic Power/Cylinders

:

Rexroth, Vickers, Wipro, Veljan, Yuken, Oscar.

High Pressure Vane/Piston Pump

:

Vickers, Yuker, Rexroth, Hugglands, Denison

Crusher

:

Sayaji, HEC, McNally Bharat, TRF, ELECON

DCEM Brake

:

Track type Limit Switch

:

Electromag, BCH, Industries Syndicate, Storm Kraft, Speed-O-Control Electromag, BCH, Speed-O-Control, Jayshree, EP&C, Bengal Technocrats

Thruster Brake

:

Electromag, BCH, Speed-o-Control, Elite

Belt changing Device

:

Nilos, Shawalmex

Conveyor Belting

:

Northland Rubber

Vibrating Screen

:

IC, TRF, ELECON, McNally Bharat, L &T, HEC, Orien, Electromag, Hydrabad Industries

Vibratory Feeder

:

Electromag, IC, TRF, ELECON, McNally Bharat

Magnetic Separators

:

Electromag, WMI, Magnet Corporation, Electro magnetic Ind., Ericz, Sartorius, Hans Bockels, Krupp Forder, Technick ,L & T

Pneumatic Actuators

:

Prepec, Technomech, Nucon OSCAR Equipt, Veljan Hydair.

Electro Mechanical Actuators

:

PREPEC, Technomech, Pebco


Rubber,


Usha

Telehoist,

Phoenix-Yule,

Orien

Oriental

Engineers,

Industries,

GS-13


Item Description

Manufacturers

Rubber liner

:

TEGA, Kaveri

Polymer liner

:

TEGA, Kaveri

Polyethelene liner

:

Kaveri, Tega

Polyurethane liner

:

Kaveri, Tega

Cast Basalt liner

:

DECCAN, Enviro Abrasion

Belt Scraper/ Belt Cleaner

:

Belt Switches Bin Vibrator

: :

Hosch Equipment, Vinar IDC, Kaveri Macmet, Hindustan Udyog Ltd., Karam Chand Thapper, Cobit Engg, Elecon, TRF, Promac, BMH Concare Jayshree, PROTO CONTROL, EPC Electromag, Electromagnetic Industries, IC

Samplers

:

Prisector (UK), Ramsay Engg (USA), Eastmn Crusher, Advanced system sampling (P) Ltd.

Belt Vulcanisers

:

Shaw Almex, Nilos India, SV Dattar

Sector Gates, Diverter Gates, Rack and Pinion Gates etc.

:

Vinar, IDC, Macmet, TRF, Precision Processing, Moktali, Holtzman, Mining & Material, Chennai Radha,

Flexowel Conveyors

:

METSO, Flexowel

Drag Chain Conveyors

:

Moktali Engrs., TRF, Equipt Engrs, Redler India, Enviro Abrasion, Karam Chand Thapar,



GS-13


Item Description

Manufacturers

Bucket Elevator

:

Moktali, Golden Electrical, Hindustan Udyog, Vinar, Cobit, Shree Conveyor, IDC, Orien, Macmet, Elecon, TRF

Belt Feeder

:

Reclaimer

:

Vinar, IDC, HEC, Orien, Macmet, Elecon, TRF, Cobit Metso, L&T, Elecon, TRF, HEC

Stacker

:

Metso, L&T, Elecon, TRF, HEC

Stacker – CumReclaimer Wagon Tippler

:

Metso, L&T, Elecon, TRF, HEC

:

L&T, HEC, Elecon, TRF, Metso

Wagon Loader

:

L&T, HEC, Elecon, TRF, Metso

Belt Weigh Feeders & Weigh Hopper

:

Kistler – Morse, Sartorius Mechatronics, Transweigh, Avery, Jenson Nicholson

Belt Weigh Scale

:

Kistler-Morse, Transweigh, Avery, Sartorius Mechatronics, Jenson Nicholson

Conveyor belt pulleys

:

Elecon, TRF, McNally Bharat, Macmet, HEC

Conveyor Idlers

:

Elecon, TRF, McNally Bharat, Kali, Hindustan Udyog Ltd., Macmet

Pneumatic Handling Equipment

:

TTG, Scorpio

Front – end – loader

:

TIL, Hyderabad Industries Ltd.,

Fork-lift-truck

:

Godrej, Voltas, TIL



GS-13


05.

REPAIR & MAINTENANCE FACILITIES Item Description

Manufacturers

Centre Lathe

:

HMT, Mysore Kirloskar, HEC

Universal Milling m/c

:

HMT, BFW, Batliboi

Shaper

:

PAL, P&B, Loyal

Radial Drilling m/c

:

HMT, Batliboi, Kerry Jost, HEC

Horizontal Boring m/c

:

HMT, HEC, PAL

Submerged Arc Welding Set

:

Advani, ESAB, ADOR, Mogora, COSMIC

Welding Rectifier

:

Advani, ESAB, ADOR, Mogora, COSMIC

Welding Transformer

:

Advani, ESAB, MEMCO

Universal Tool and Cutter Grinding m/c

:

HMT, Praga, Batliboi

Hydraulic Press

:

BEMCO, P&B, Centerprise

Cast Iron Plate

:

Jash, Madras Gauge, P&B

Power Hacksaw

:

ITL, P&B, EIFCO

Column Drilling m/c

:

HMT, Thakoor, Kerry Jost, EIFCO, Batliboi

Bench Drilling m/c

:

Accuax, EIFCO, P&B, Thakoor

Double-ended Pedestal Grinder

:

Grind Tools, GECO, AMC, P&B

Cylindrical Grinder

:

HMT, Mysore Kirloskar, ELP

Tools & Tackles

:

P&B, Mekaster, Centerprise, Ally

Measuring Tools and Gauges

:

P&B, Bombay Tools

Garage Equipment

:

ELGI, USHA, WAP, P&B

Oiling & Greasing

:

ELGI, P&B



GS-13


ELECTRICAL

The list of acceptable makes for various electrical and automation equipment is given below. A ) POWER DISTRIBUTION EQUIPMENT SL. NO.

EQUIPMENT

PREFERRED MAKES

TRANSFORMERS

1. a)

DISTRIBUTION TRANSFORMER (OIL TYPE) (11 or 6.6/0.433 KV)

ABB / AREVA / / CGL / BHEL / BHARAT BIJLEE / VOLT AMP/ KIRLOSKAR /INTRA VIDYUT /

b)

DRY TYPE TRANSFORMER

INTRA VIDYUT / VOLTAMP / KEC

2.

11kV / 6.6KV ISOLATOR

A BOND STRAND / S&S,MADRAS / HIVELM / SIEMENS / DREISCHER-PANICKER.

3.

415V SWITCHBOARD

SIEMENS / L&T / GE POWER / SCHNEIDER

4.

LT BUSDUCT

STARDRIVE / C&S / PCE / ECC / BRIGHT ENGINEERS/ VIDHYUT CONTROL

5.

BATTERY a)

NICKEL - CADMIUM

AMCO / HBL NIFE

b)

VALVE REGULATED LEAD ACID MAINTENANCE FREE BATTERY (VRLA)

HBL NIFE / AMARARAJA / EXIDE

c)

BATTERY ( PLANTE)

HBL NIFE / AMARARAJA / EXIDE

6.

BATTERY CHARGER/ DCDB

CHHABI / HBL NIFE/ CALDYNE / AMARA RAJA / KIRLOSKAR

7.

PROTECTIVE RELAYS

AREVA / ABB / SIEMENS/ER

8.

AUXILIARY RELAYS

ABB / ER / SIEMENS / AREVA

9.

HEAT SRINKABLE CABLE JOINTING KITS/ STRAIGHT THROUGH JOINTS (H.T)

RAYCHEM / DENSON / M-SEAL

10.

METER (ANALOGUE TYPE)

IMP / AE / MECO / SECURE METERS / CONZERV / L&T / RISHAV

11.

CURRENT TRANSFORMERS

ABB / SILKANS / INSTRANS / PRAGATI / IMP/ AE / KAPPA / PRAYOG / SIEMENS / L&T

12.

POTENTIAL TRANSFORMER

ABB / BHEL / SILKANS / PRAGATI / IMP / KAPPA / PRAYOG /SIEMENS / ABB / INDOCOIL / PRECISION



GS-13

General Technical Specification SL. NO.

EQUIPMENT

PREFERRED MAKES

13.

11KV/ 6.6KV CABLES

ASIAN CABLES (RPG) / CCI / UNIVERSAL / NICCO / POLYCAB / HAVELLS

14.

DIGITAL TYPE MULTIFUNCTION METER

CONSERVE / L&T / SECURE / ER / RISHAV

B ) LT PANELS , DRIVES , AUTOMATION & CONTROL ACCESSORIES. SL.NO. 1.

SUB GROUP

MAKES

MCC (NON DRAW OUT) POWER DISTRIBUTION BOARD (PDB) CONTROL DESK &POST

HINDUSTAN CONTROL / POWER & PROTECTION / ECC / VENUS / BCH / HAVELLS / GEMCO

4.

LOCAL CONTROL STATION (LCS)

HINDUSTAN CONTROL / POWER & PROTECTION / ECC / VENUS / BCH / HAVELLS / GEMCO

5.

LIGHTING DISTRIBUTION BOARD MLDB, SLDB

HINDUSTAN CONTROL / POWER & PROTECTION / ECC / VENUS / GEPC / BCH

6.

VVVF AC DRIVE

ABB / ROCKWELL AUTOMATION / SIEMENS / VACON / SCHNEIDER / L&T

7.

SOFT STARTER

ROCKWELL AUTOMATION / ABB / SCHNEIDER / SIEMENS

8.

PROGRAMMABLE LOGIC CONTROLER (PLC)

ABB ( 800 XA) / GE-FANUC ( PAC Rx7i) / ROCKWELL AUTOMATION (CONTROLOGIX) / SIEMENS (S7 SERIES)

9.

UNINTERRUPTED POWER SUPPLY (UPS) LT AC MOTOR (SQ. CAGE)

TATA LIBERT (EMERSON) / GE / FUJI / DB ELECTRONICS

ALSTOM / KEC / CGL / SIEMENS

12.

LT AC MOTORS (CRANE DUTY) HT AC MOTOR

13.

LT AC GEARED

KIRLOSKAR ELECTRIC / POWERBUILD / NEW ALLEN

2. 3.

10. 11.


SCHNEIDER / L&T / SIEMENS / GEPOWER HINDUSTAN CONTROL / VENUS / SIEMENS / ABB / L&T / GEPC / HAVELLS

ABB / BHARAT BIJLEE / CGL / KIRLOSKAR ELECTRIC ALSTOM / SIEMENS

BHEL / ABB / CGL / SIEMENS / KIRLOSKAR ELECTRIC / ALSTOM / WEG / GE


GS-13

General Technical Specification SL.NO.

14. 15. 16. 17. 18. 19. 20. 21. 22.

SUB GROUP

MAKES

MOTOR

BERRY / IEC / AUMA

FLAME PROOF LT SQUIRREL CAGE AC MOTOR SLIPRING MOTOR (OTHER THAN CRANE DUTY) LT AC VVVF MOTORS FOR ROLLER TABLE APPLICATION STALL TORQUE MOTOR ACTUATOR

ALSTOM / BHARAT BIJLE / ABB / CGL KIRLOSKAR ELECTRIC / SIEMENS

MOTOR PROTECTION CIRCUIT BREAKER (MPCB) MOULDED CASE CIRCUIT BREAKERS (MCCB) MINIATURE CIRCUIT BREAKER (MCB)

CGL / ALSTOM / SIEMENS / KIRLOSKAR ELECT CO. SIEMENS / ABB / KIRLOSKAR ELECT CO. / ALSTOM / CGL DEMAG AUMA / ROTORK / LIMITORQUE SCHNEIDER / ABB / L&T / GEPOWER / SIEMENS SIEMENS / ABB / L&T / GEPOWER / SCHNEIDER HAVELLS / MDS LEGRAND / SCHNEIDER / STANDARD / GEPOWER / HAGAR (L & T) / ABB / SIEMENS

EARTH LEAKAE CIRCUIT BREAKER.(ELCB) HRC FUSES

HAVELLS / MDS LEGRAND / SCHNEIDER / STANDARD / GEPOWER / HAGAR (L & T) / ABB / SIEMENS

VACUUM CONTACTOR (LT) AC POWER CONTACTORS

SIEMENS / L&T / ABB / SCHNIEDER

26.

CRANE DUTY POWER CONTACTORS

ABB / SCHNEIDER / L&T / SIEMENS / GEPOWER

27.

THERMAL OVER LOAD RELAY

ABB / C&S / BCH / L&T / SCHNEIDER/ GEPOWER / SIEMENS

28.

ELECTRONIC THERMAL OVERLOAD RELAY CONTROL SWITCHES / SELECTOR SWITCHES

FANOX / SAMWHA / MOELLER / LG / SPECHER & SCHUH

23. 24. 25.

29.


L&T / SIEMENS / BUSMAN / GEPOWER / INDO-ASIAN

ABB / L&T / SCHNEIDER / SIEMENS / GE POWER / BCH

ABB / ALSTOM / BCH / KAYCEE / GEPOWER / SIEMENS


GS-13


SUB GROUP

MAKES

30.

PUSH BUTTONS

BCH / L&T / SCHNEIDER / SIEMENS / GEPOWER

31.

TIMERS/TIME DELAY RELAY AUXILIARY RELAYS

ABB / BCH / L&T / GEPOWER / SIEMENS / EAPL ABB / BCH / L&T / SCHNEIDER / GEPOWER / SIEMENS

33.

MASTER CONTROLLER

EPCC (KAKKU) / SCHNIEDER / SIEMENS / STROMKRAFT / TELEMECHANIQUE

34.

LIMIT SWITCHES

BCH / EPCC (KAKKU) / AG MECHANIC / ESSEN GEPOWER / JAIBALAJI / SCHNEIDER / SIEMENS

35.

PULL CORD SWITCHES

EPCC (KAKKU) / AG MECHANIC / TELEMECHANIQUE / JAYSHREE ENTERPRISES / STROMKRAFT / PROTO CONTROL

36.

BELT SWAY SWITCH

EPCC (KAKKU) / AG MECHANIC / TELEMECH / JAYSHREE ENTERPRISES / STROMKRAFT / PROTO CONTROL

37.

GRAVITY TYPE LIMIT SWITCH ROTARY LIMIT SWITCH

EPCC (KAKKU) / STROMKRAFT / KAYCEE EPCC (KAKKU) / AG MECHANIC ENTERPRISE / SCHNEIDER / TELEMECH

39.

PROXIMITY &PHOTO ELECTRIC SENSORS

ROCKWELL / SCHNIEDER / SIEMENS/ OMRON / SICK / DELTA / LINE & LINDE / TELEMECHANIQUE

40.

PULSE ENCODER

HUBNER / HEIDENHEIN / ROCKWELL AUTOMATION (ALLEN BRADLEY) / LEONARD BAUR GERMANY / SICK (GERMANY)

41.

INDICATING LAMP LED TYPE

SIEMENS / L&T / BINAY / ESSEN / BCH / VAISHNO

42.

HOOTER / BUZZER / BELL / SIRENS SOLID STATE ANNUNCIATOR

EPCC (KAKKU) / KHERAJ

32.

38.

43.

ADVANI OERLIKON / AREVA / APLAB/ CONTROL & DYNAMICS / DIGICON INSTRUMENTATION LTD. / L&T / MINILEC

44.

TEMP. SCANNER

ADVANI OERLIKON / ECIL / INSTRUMENTATION LTD. / MASIBUS / PYROTECH / SIEMENS

45.

LAMPS

BAJAJ / CROMPTON GREAVES / GE LIGHTING / PHILIPS / OSRAM / SIGMA

46.

LIGHT FITTING (FIXTURES)

BAJAJ / CROMPTON GREAVES / GE LIGHTING / PHILIPS



GS-13


SUB GROUP

MAKES

47.

COMPLETE WITH ALL ACCESSORIES EXCEPT LAMP. LIGHTING WIRE (PVC)

48.

5A/15A PIANO SWITCH

ANCHOR / ELLORA / MDS LEGRAND / PRECISION / HAVELLS

49. 50.

FLAME PROOF LIGHT FITTING EXHAUST FANS

GOVAN / BALIGA / FLEXPRO / SUDHIR / CEAG / FCG / SIGMA CGL / KHAITAN / BAJAJ

51.

CEILLING FANS

CGL / KHAITAN / HAVELS

52.

PERSONAL COMPUTER LAP TOP/ NOTEBOOK

HP / DELL. / LENOVO / IBM

53. 54.

CCI / DELTON / FINOLEX / NICCO / UNIVERSAL

IBM / HP / LENOVO / DELL

HRC FUSE (SEMICONDUCTOR PROTECTION) ELECTRONIC WEIGHING SYSTEM

ABB / SARTORIOUS / SANMAR / SCHENK / TRANSWEIGH / KELK

56.

PVC POWER CABLES (LT)

CCI / UNIVERSAL / NICCO / RPG CABLES (ASIAN) / POLYCAB / FINOLEX / TORRENT / HAVELLS

57.

PVC CONTROL CABLES

58.

HEAT RESISTANT CABLES (EPR/CSP & SR) SCREENED CABLES & SPECIAL CABLES

CCI / LAPP / NICCO / RPG CABLES (ASIAN) / UNIVERSAL / POLY CAB / FINOLEX / TOSHNIWAL / DELTON CCI / LAPP / NICCO / RPG CABLES (ASIAN) / UNIVERSAL / TOSHNIWAL / DELTON

55.

59. 60.

BUSMANN / JE MULLER / FERRAZ / GEPOWER / SIEMENS

CCI / BELDEN / LAPP / FINOLEX / POLY CAB / NICCO / TOSHNIWAL / DELTON

CABLE TERMINATION KITS (XLPE) TERMINAL CONNECTOR

CONNECT WELL / ESSEN-DINKY / PHOENIX / WAGO / LAPP

62.

TRAILING CABLES

LAPP / CCI / UNIVERSAL / ASIAN / NICCO

63.

WELDING SOCKET

BCH / SCHNIDER / BEST & CROMPTON / GEPOWER / HAVELL / JAIBALAJI

64.

LIFTING MAGNETS

ELECTROMAG / EPCC (KAKKU) / STERLING MAGNETICS / SUPERLIFT

65.

POWERPACK FOR MAGNETS

ELECTROMAG / BCH / EPCC (KAKKU)

61.


MSEAL, 3M / RAYCHEM


GS-13


SUB GROUP

MAKES

66.

RESISTORS (CRANE)

BCH / ELECTROMAG / AMP CONTROL / EPCC / SIEMENS / RESITECH / NARKHEDGE

67.

LT CAPACITORS

GEPOWER / ABB / CGL / UNI STAR / BHEL

68.

CABLE REELING DRUM

BENGAL TECHNOCRAT, / ELECTRO ZAVOD / ELECTROMAG

69.

DC ELECTROMAGNETIC BRAKE ELECTRO MAGNETIC OVERLOAD RELAYS

BCH

71.

OIL DASH POT OVERLOAD RELAYS

KILBURN ELECTRICALS LTD / ELECTROGEAR

72.

CONTROL TRANSFORMERS

SIEMENS LTD. / INDCOIL MANUFACTURING CO. / INTRAVIDYUT / AUTOMATIC ELECTRIC LTD. (AE) / INDUSHREE / BHARTIA CUTLER-HAMMER LTD.

73.

CRANE CONTROL PANELS

HINDUSTAN CONTROL / ECC / VENUS / MEDITRON / EPCC

70.

BHARAT HEAVY ELECTRICALS LTD / BHARTIA CUTLER-HAMMER LTD / KILBURN ELECTRICALS LTD.

C) FIRE DETECTION & ALARM. (F.D.A) SYSTEM SL.NO . 1. 2. 3. 4. 5. 6. 7.

DEVICES

MAKES

INTELLIGENT DETECTORS ( PHOTO ELECTRIC, HEAT, THERMAL) UL /FM / APPROVED INTELLIGENT FIRE ALARM CONTEROL PANELS UL /FM / APPROVED ADDRESSABLE MANUAL CALL POINTS INCLUDING HAND SETS . UL /FM / APPROVED MONITOR MODULES UL /FM / APPROVED FAULT ISOLATION MODULE UL /FM / APPROVED CONTROL MODULES UL /FM / APPROVED UV FLAME DETECTORS UL /FM /APPROVED


SIMPLEX / NOTIFIER / EDWARDS -DO-DO-DO-DO-DOPATOL / DETRONICS / SPECTREX


GS-13


10.

BEAM DETECTORS UL /FM / APPROVED IR FLAME DETECTORS SOLAR BLIND EMBER, FIRE UL /FM / APPROVED ANALOG LINEAR HEAT SENSING CABLE

11.

A) WITH METAL BRAID STEEL/BRONZE, COPPER B) WITH NYLON BRAID UL /FM / APPROVED DIGITAL LINEAR HEAT SENSING CABLE

KIDDE / L.G.M / PATOL

A) WITH NYLON BRAID B) WITH METAL BRAID STEEL, BRONZE, COPPER . UL /FM / APPROVED CONTROL UNIT FOR DIGITAL LHS CABLE UL /FM / APPROVED VIDEO DISPLAY UNIT INCLUDING CPU, PC, MONITOR, PRINTER ETC.

DELL / HP / HCL / WIPRO / IBM COMPATIBLE.

9.

12

13 14

SIREN CABLES A: FOR DETECTOR CABLING (I) IMPORTED (II)

KIDDE / L.G.M / PATOL.

BELDON / SOUTHWEST / ALPHA

INDIGENOUS

POWER CABLE

16

SIGNAL CABLE

17

M.S.CONDUIT AS PER IS-9537-PART-II1981 GI CONDUITS ROAD CROSSING G.I PIPES


ODTI / PATOL / DET-TRONIX / SPECTREX

KHERAJ / BEMCO / TULU

15

18 19

EDWARDS / NOTIFIER / SIMPLEX

FINOLEX / DELTON / UNIVERSAL / NICCO / POLYCAB / FORTGLOSTER / HAVELLS FINOLEX / DELTON / UNIVERSAL / NICCO / POLYCAB / FORTGLOSTER / HAVELLS USHA BELTON / HCL / DELTON / VINDHYA TELELINK NICCO / BHARAT / ZENITH / BEC / CENTURY BEC / NICCO / ZENITH NICCO / TATA / JINDAL


GS-13


1. ELECTRONICS CORPORATION OF INDIA LTD, 2. TECHNICAL TRADE LINKS PVT. LTD. 3. GUNNEBO INDIA LTD., 4. MATHER & PLATT PUMPS (I) LTD. 5. M/S AGNICE FIRE PROTECTION LIMITED. 20

F.D.A SYSTEM SUPPLIERS

6. M/S TECHNICO (INDIA) PVT. LIMITED. 7. NOTIFIER. 8. SIEMENS. 9. TECHNO FIRE. 10. NEW FIRE. 11. TYCO FIRE & SECURITY.

21

ELECTRONIC PRIVATE AUTOMATIC BRANCH TELEPHONE EXCHANGE (EPABX) SUPPLIERS

1. M/S INDIAN TELEPHONE INDUSTRIES LIMITED. 2. M/S AVAYA GLOBAL CONNECT LIMITED. 3. M/S SIEMENS LIMITED. 4. M/S ALCATEL. 5. M/S B.P.L TELECOM PVT. LIMITED. 6. M/S CROMPTION GREAVES LIMITED. 7. ERICSSON. 1. M/S E.C.I.L. 2. M/S NELCO LIMITED.

22

C.C.T.V SYSTEM SUPPLIERS

3. M/S DATAMATICS INFORMATION TECHNOLOGY LIMITED. 4. M/S PHILIPS/BOSCH 5. M/S PELCO



GS-13


23

LOUD SPEAKER TALK BACK(LSTB) / LOUD SPEAKER INTERCOMMUNICATION(LSIS) SYSTEMS SUPPLIERS

1. M/S POWER SYSTEMS. 2. PHI-AUDIOCOM. 3.M/S MOTAWANE PRIVATE LIMITED

1. DELTON CABLES. 24

TELEPHONE CABLE SUPPLIERS

2. TELE-LINK NICCO. 3. FINOLEX.

25 26

07.

FIBRE OPTIC (F.O) CABLE.

MOLEX/LUCENT/AMPHINOL/BIRLA ERRICSSON/OPTEL.

V.H.F SYSTEM

MOTORALA/ YEASU/SIMOCO/ADINO

INSTRUMENTATION

Sl. No.

ITEM DESCRIPTION

PREFERRED MAKES

A.

Field Instruments:

1.

Pressure / Differential Pressure gauge

:

2.

Pressure switches.

:

3.

Pressure / Differential Pressure Transmitters

:

Emerson (Rosemount), Chemtrols (Fuji), Honeywell, Yokogawa, Siemens , ABB

4.

Temperature gauges

:

WIKA, Manometer India, A.N. Instruments, General instruments, Waaree instruments, GE gauges, Walchandnagar, Precision Industries.

5.

Thermocouple & RTD / thermowell

:

General Instruments, Nagman Instruments, Toshniwal

/


Differential

Pressure

WIKA, Manometer India, A.N. Instruments, Precision Industries, General Instruments, Waaree instruments, Forbes Marshall, Walchandnagar (Tiwac) , Hirlekar (DP gauge) Ifm. WIKA, Kasturba (Orion-Ashcroft),Switzer, Indfoss, Vasutech,


GS-13


ITEM DESCRIPTION

PREFERRED MAKES Industries, Tempsens, Pyro-electric Instruments, Industrial Instrumentation, Altop, Waree, Detriv.

6.

Temperature Switch

:

WIKA, Manometer India, A.N.Instruments, Instruments, Indfoss, Switzer, Vasutech.

7.

Temperature transmitter

:

Emerson (Rosemount), Yokogawa, Honeywell, Siemens, Fuji (Chemtrols,) , ABB

8.

Rotameters

:

Krohne-Marshall, Instrumentation engineers, Eureka instruments. Chemtrols, Rota Instruments.

9.

Orifice Plate & flanges Assembly/ Venturi , Flow nozzle

:

Engineering Specialities, Micro-precision, Hydropneumatics, Chemtrols-Samil, Instrumentation ltd,

10.

DP type Flow / Level Transmitters

:

Emerson (Rosemount), Chemtrols (Fuji), Honeywell, Yokogawa, Siemens , ABB

11.

Flow Switch

:

Ifm. , Krohne-Marshall, Switzer, Levcon, D.K. Instruments,

12.

Electromagnetic flow meter

:

Yokogawa, Emerson (Rosemount), Krohne-Marshall, Endress & Hauser, ABB.

13.

Vortex Flow meter

:

Emerson(Rosemount), Krohne -Marshall, Yokogawa, Vortex Instruments

14.

Mass (coriolis) flow meter

Emerson (Rosemount) , Yokogawa, Krohne –Marshall, ABB, Endress & Hauser, Rockwin.

15.

Level gauge (magnetic & reflex type)

Chemtrol, Levcon Instruments, Pratolina Instruments, Waaree Instruments, Forbes Marshall, Techtrol, Sigma, Asian Industrial Valves & Instruments.

16.

Level Switch (Conductivity type)

:

Chemtrol (Vega), Endress & Hauser, Switzer Instruments, SB Electro-mechanical, Techtrol, Nivo Controls, LevelTech

17.

Level Switch (Capacitance/RF type)

:

Chemtrol (Vega), Endress & Hauser, Switzer Instruments, SB Electro-mechanical, Techtrol, Nivo Controls, LevelTech

18.

Level Switch (Tuning fork/ Rod type)

:

Chemtrol (Vega), Endress & Hauser, S.B. Electromechanical, ,Nivo Controls

19.

Level Switch (Float type)

:

Emerson,Trac, Chemtrols, Forbes Marshall, D K Instruments, Levcon Instruments, Techtrol , V-Automat, Warree



GS-13

General

Trac,


ITEM DESCRIPTION

PREFERRED MAKES

20.

Level Switch/ Transmitter (Displacer type)

:

Emerson, Chemtrols (Eckard), Trac, D K Instruments, Levcon Instruments,

21.

Level Switch/ Transmitter (Ultrasonic type)

:

Chemtrol (Vega) , Endress & Hauser, Krohne Marshall, Siemens (Miltronics) ,Toshbro controls (Enraf)

22.

Level Switch/ Transmitter (Radar type)

:

Chemtrol (Vega) , Emerson (Rosemount), , Endress & Hauser ,Toshbro controls (Enraf), Krohne- Marshall

23.

Level Switch/ Transmitter (Nucleonic type)

:

Concord International (Dr. Berthold), Emerson (Kay Ray), ECIL.

24.

Level switch (Electro- mech type)

:

Nivo Controls, mechanicals.

25.

Control valve

:

Fisher-Xomox ,Instrumentation Ltd, Dresser Industries (Masoneilan) , Valtek, Samson Controls(Globe type), Forbes Marshall ( Arca ), ABB, Fouress, Tyco valves (Keystone- Butterfly), MIL Controls, Dembla

26.

Electrical Actuator

:

Auma, Limitorque, Marsh, Instrumentation Ltd

Endress

&

Hauser,

S.B.

Electro-

( Bernard), Rotork, Keystone. 27.

Pneumatic Actuator

:

Fisher-Xomox , Instrumentation Ltd., Dresser Industries (Masoneilan), Valtek, Samson Controls, ABB, MIL Controls, Forbes Marshall (Arca), Keystone, Virgo, Habonim Vaas..

28.

Electro-hydraulic actuator

:

Reineke, Askania

29.

Self- regulating pressure control valve

:

Samson Controls, Nirmal Industries, Forbes Marshall, Instrumentation Ltd.

30.

I/P converters

:

Shreyas-Barton, Fisher –Xomox, Forbes Marshall (Moore products), Marsh-Bellofram, MIL controls, ABB, Watson – Smith.

31.

Pneumatic Positioner,

:

Instrumentation Ltd., Fisher-Xomox , Dresser Industries (Masoneilan), Samson Controls, Forbes Marshall ( Arca), ABB, Fouress, MIL,

32.

Electro- pneumatic positioner

33.

Solenoid Valve


Fisher-Xomox, ,Siemens, Dresser Industries (Masoneilan), Samson Controls, Instrumentation Ltd., Forbes Marshall (Arca), ABB, Fouress, MIL controls. :

Burkert, Herion, Rotex, Schrader-Schovill, Jucomatic, Avcon, .Asco


GS-13

General Technical Specification Sl. No. 34. B.

ITEM DESCRIPTION Air filter regulator

PREFERRED MAKES :

Shavo-Norgren, Schovill.

Marsh-Bellofram,

Placka,

Schrader-

Control room Instrumentation

1.

Distributed Control System (DCS)

:

Yokogawa (CS 3000), Honeywell (Experion +C 300), ABB (AC 800 XA), Emerson (Delta V), Siemens (PCS 7+ S7400H).

2.

Programmable Logic Controllers.

:

Refer Electrical list.

3.

Digital Indicator

:

Pyrotech Electronics, Lectrotek, Chino-Laxsons, Micro systems, Master Electronics, Masibus Instruments, Ranutrol, Honeywell.

4.

Bargraph Indicator

:

Chino-Laxsons , Masibus Instruments , Pyrotech Electronics, Lectrotek, Teletherm. Ranutrol

5.

Recorders (Chart Less)

:

Eurotherm, Yokogawa, Siemens, ABB.

6.

Microprocessor based controller

:

Yokogawa, Siemens, Honeywell, Eurotherm, Fuji, ABB, Forbes Marshall,Toshiba

7.

Digital scanners

:

Lectrotek, Micro systems, Master Electronics, MB controls, Masibus Instruments, Procon.

8.

DC Power Supply Unit

:

Aplab, Elnova,Siemens, Phoenix, Schneider,

9.

IS Interface/Zenner Barrier

10.

Signal isolators

:

Pepperl & Fuchs, MTL, Stahl, Yokogawa, Forbes Marshall (Protech), Chino-Laxsons, Phoenix

11.

Annunciation system

:

IIC, Procon, Micro Systems & Controls, Minilec, Instrumentation Ltd, Lectrotek, Piri systems, Pyrotech Electronics, MB controls & Systems Semuda.

12.

Instrument Panels/ Control Desk

:

Rittal, Pyrotech, Radha Krishna Controls, Instrumentation Ltd.

13.

Instrumentation Cable


Chino-laxsons,

Honeywell,

Pepperl & Fuchs, MTL, Stahl

Universal Cables, Delton, Thermopads, KEI industries, Paramount Cables, Lapp cables, Cords cables, Uniflex cables, Brooks Cables, Elkay Telelinks, Rajnigandha, Special Cables, TCL Cables, Friends Cable, Daksha Cable, Crystal Cables, Udey Pyro-Cables, Elkay Telelinks, Fort Gloster Preferred Makes Page 28 of 37

GS-13


ITEM DESCRIPTION

PREFERRED MAKES

14.

Thermocouple Compensating Cable

C.

Analytical / Special Instruments

1.

Gas analysis Instruments

2.

Gas Detectors

3.

Calorific Value (CV) analyzers

:

Reineke, Union. Yokogawa

4.

Moisture Analyzers (Nucleonic)

:

Concord International (Dr. Berthold), Emerson (Analytical)

5.

ORP/PH/ Conductivity meter / Transmitter

:

Emerson (Analytical), Forbes Marshall (Polymetron), Yokogawa, ABB, Ion Exchange, Honeywell.

6.

Moisture Sensor & Transmitter

:

Invensys (Foxboro), Bartec, GE-Panametrics

7.

Flame Detector

:

Honeywell, Durag Instruments

8.

Vibration sensors & monitors

:

Bentley Nevada, Schenck -Avery, Josts Engineering (Bruel & Kjaer), SPM Instruments, , Mechanalysis India (IRD).

9.

Positive Displacement meter

:

Toshbro controls.(Bopp & Reuther), Forbes Marshall ( Moorco products), Liquid Controls, Emerson.

10.

Annubar / Flow tube

:

Emerson, Switzer Instruments.

11.

Infrared radiation pyrometer

:

Land, Chino-Laxsons, Toshniwal (Raytek), Ircon, Nagman (Wahl),

12.

Dip lance type Molten metal temperature measurement system T/C Tips

:

Ardee Enterprise ( Electronite) , Ferrotran

13.

Slag detection system

:

Elof Hanson (EMLI), Land.


:

Toshniwal Cables, General Instruments, Paramount Cables, Udey pyro-cables, Cords cables, Brooks, Daksha Cables, Friends Cable.

:

ABB (H&B), MSA, Emerson, Siemens, Chemtrols (Maihak), Forbes Marshall, Fuji, Beiler & lang (COMonitor), Honeywell, Yokogawa. Beiler & lang (CO-Monitor), Dragger, Oldham, Industrial Scientific Corporation, Detronics.

&


GS-13


ITEM DESCRIPTION

14.

SPM analyser

15.

SOx- NOx analyser

08.

PREFERRED MAKES Emerson, Yokogawa, Durag, ABB, Honeywell, Forbes Marshall (Codel). Forbes Marshall, Emerson, Yokogawa, ABB, Honeywell

FIRE PROTECTION SYSTEM

1.

Steel pipes

-

SAIL, ITC, JINDAL, Ajanta, Maharastra Seamless, Prakash Tubes Gujarat Steel tubes,

2.

Steel pipes fittings

-

Tube Bends, Jindal, Ajanta Shivananda, EBY Industries.

3.

Spray nozzles/Projectors -

4.

Deluge valves

-

Mather & Platt, ACE turnkey, Vijay Fire Protection System Ltd, HD Fire.

5.

Outside coating& Wrapping for pipes

-

Llyods/STP

6.

Quartzoid bulb detector

-

H.D. Fire Protect Co., Mather & Platt, Any other TAC approved make

7.

Diesel Engine

:

Kirloskar-Cummins, CromptonGreaves, Ashok Leyland

8.

Fire extinguishers

:

New Fire, VIPL, Zenith, ASCO Strumech

9.

Fixed fire protection system

-

New Age, Agnice, Vijay Industries& Project , Lloyds


Laxmi sprinklers, Reliable, Avon, Mather and Platt, HD Fire.


GS-13


10. 09.

Passive Fire protection

Insulation, Techno Fire Controls New Fire Engineers Llyod, 3M, Vijay System, Signum

BOF GCP EQUIPMENTS:Following equipment/supplies specific to BOF-Gas Cleaning Plant shall be manufactured by any of the following vendors listed below:-



GS-13


SL. NO.

EQUIPMENT

VENDOR/MANUFACTURER

1.

Hood, Stack and Lance sealing device

ISGEC, ACC-BABCOCK (ABL), BHPVL, L & T

2.

Hood traverse carriage, Stack inspection device, Hood bottom closure device

L&T, WMI CRANES, JESSOP, MUKAND

3.

Pressure vessels

ISGEC, ABL, BHPVL, TSL, KAVERI ENGG.

- Expansion vessel, Mixing drum, Make-up water tank, Sample cooler, Blow-down & drainage expansion tanks and Emergency spray vessel 4.

Additive feeding system

BEEKAY, SIMPLEX, MUKAND

5.

Gas holder

MICCO, SMS-DEMAG, CLAYTON – WALKER

6.

Fabricated gas ducts (Dia> 1200 mm), Trestles/Duct Supports, Flare stack structure Walkways/Accesses

BEEKAY, ROURKELA FABRICATION, BHARAT WEST – FALIA, SUBURBAN ENGG., KM UDYOG, OTTO, APV

7.

Electrostatic precipitator (wet type)

VOLTAS, OTTO, ORIENT, ANDREW YULE

8.

ID fan

NEU (France), JAMES HOWDEN (UK), ROTHEMUHLE (Germany), DONKIN (UK), FLAKTWOODS

9.

Centrifugal horizontal CW pumps

INGERSOLL, SULZER

Fabricated equipments

NHEC, BHPVL, KCP, BINNY ENGG. WORKS, ABL, ISGEC, OTTO

-

Stack cover plate, Saturator, Hydraulic seal Recycling tank, Convergent/Divergent ducts, Changeover device, Hydraulic nonreturn valve, Condensate seal pots, Sump cover



GS-13

General Technical Specification -

For

any

other

equipment/supplies

which

are

not

covered

above,

the

make/manufacturer’s name shall be mutually agreed between Purchaser /Consultant and the successful Tenderer.

10.

INFORMATION SYSTEM

Preferred Makes for Level-II automation

Server Computers

:

IBM/HP/SUN

Client Computers (PC)

:

IBM/Lenovo/HP-Compaq/DELL

Network Equipment • Active components • Passive components

: :

CISCO LUCENT/AMP

Application software including Process control models

:

Technology Supplier



GS-13


11. FLUID

SYSTEMS & PIPING ENGG (LUBRICATION & HYDRAULICS) PREFERRED MAKE OF ITEMS

SL. NO.

ITEM

1

Piston / Vane Pumps & Hydraulic Motors

2

Gear Pump

3

Screw Pump

4 5 6 7

Centrifugal Pump for Descaling System Piston Pump for Descaling System Centrifugal Pump (12 Bar & below) Submersible Type Sump Pump

8

Grease Lubrication System

9

Oil Lubrication System

10

Air Oil System

11

Air Controls

12

Hydraulic Proportional Valve

13 14 15 16

16.3

Hydraulic System Hydraulic Control Valve Hydraulic Servo Valve Manual Valves Manual Gate / Globe Valves with & without gear for High Pressure application Manual Gate / Globe Valves with & without for Low Pressure application (16 Bar and Low) Butterfly Valve

16.4

Ball Valve

16.5

Check Valve (Disc Type) –

16.1

16.2


MAKE Rexroth / Parker / Kawasaki / Eaton Del Pd Pumps (ROTODEL) / Tushaco / Rexroth / Parker / Alfa IMO / Allwiler / Nortek

AREA Hydraulics Hydraulics / Oil Lubrication Hydraulics / Oil Lubrication

KSB / Halberg / Wier

Descaling

Uraca / Wepuko / Hauhinco

Descaling

KSB / Kirloskar / Voltas / Mather & Platt / Beacon / Wier

Water

KSB / Flygt / Grundfos

Sump

Lincoln Helios / Bijur Delimon / Nortek Lincoln Helios / Shaan Lube Rebs / Dropsa / Bijur Delimon / Nortek Rotex, / Schrader Duncan / Shavo Norgren / Nucon / Ross / SMC / Rexroth / Parker Rexroth / Parker / Eaton / Yuken (Japan) Rexroth / Parker / Eaton / Yuken Rexroth / Parker / Eaton / Yuken Moog / Rexroth KSB / BHEL / AUDCO / BDK

Grease Oil Lubrication Air-Oil Lubrication Pneumatics

Hydraulics Oil Lubrication / Descaling

KSB / BHEL / VIRGO / AUDCO / BDK / Fouress / Akay AUDCO / VIRGO / BDK AUDCO / FOURESS / BDK / VIRGO / AUDCO / BDK / FOURESS Preferred Makes Page 34 of 37

GS-13

General Technical Specification SL. NO. 16.6 16.7 16.8 17

ITEM Low Pressure Check Valve ( Spring Loaded) – Low Pressure Check Valve (Spring Loaded) – High Pressure Check Valve (Disc Type) – High Pressure Control Valve for oil lubrication system

19

Spray Valve for Descaling System Air Release Valve

20

Air / Gas Safety Relief Valve

18

MAKE AUDCO / BDK / FOURESS AUDCO / BDK AUDCO / BDK Forbes Marshall / Samsung / Fisher / RK Controls / Nirmal Industrial Controls

Oil Lubrication

Hunt / Elwood

Descaling

Upadhyay / Steam & Mining / BDK Moorco / L & T / Fainger / Mankenberg

Water

L& T / Virgo / Rotex / AVCON

Oil Lubrication

Christie / Hydac / Parker / EPE

Hydraulics

Christie / Hydac / Parker / EPE

Hydraulics

WSR / BHPV / ISGEC

Descaling Hydraulics Hydraulics

25 26

Actuators for operating Valves Accumulator with safety shut off block Accumulator Charging Kit Accumulator for Descaling System Pressure Filter Return Filter

27

Basket Filter

28

Auto Back wash Filter

29

Basket Strainer for water

30

HP Compressor

Hydac / Pall / Internormen / Parker Hydac / Pall / Internormen / Parker Internormen / Hydac / Pall / Ball Filters Ball & Kirch, / Hydac / Fluid engineering Superflo / Hydac / EPE / Internormen / Multitex Ingersoll Rand / Aerotechnic Coltri

31

Heat Exchanger

Alfa Laval / Indswep / Tranter

32

Level Indicator Switch

Sigma / Levcon / Shridhan / Magnetrol / Buhler / Tectral / WEKA / Peneberthy / Kobold

33

Pressure Gauge & Temperature Gauge

A.N. Instruments / H.Guru / Wika / Forbes Marshal / Stauff / Hydac / kobold

34

Pressure Switch

Rexroth / Switzer / Hydac / Parker / Dadfoss (Indfoss) / Kobold

35

Differential Pressure

Fisher Rosemount / Forbes

21 22 23 24


AREA


Descaling

Oil Lubrication Descaling / Water Hydraulics / Oil Lubrication Descaling Hydraulics / Oil Lubrication Hydraulics / Oil Lubrication / Descaling Hydraulics / Oil Lubrication / Descaling / Utility Services Hydraulics / Oil Lubrication / Descaling Descaling GS-13


ITEM Transmitter

36

Thermostat

37

Differential Pressure Gauge cum Switch

38

Pressure Transmitter

39

Temperature Transmitter

39

Flow Switch

40 41

Flowmeter cum Totaliser Pipes / Tubes

41.1

Carbon Steel Seamless Pipes / Tubes

41.2

Stainless Steel Seamless Pipes / Tubes

41.3

Carbon Steel ERW - SAW Pipes / Tubes

MAKE Marshall

Hydraulics / Oil Lubrication / Descaling Hydraulics / Oil Switzer / Danfoss / Indfoss / Hydac Lubrication / Descaling Hydac / Forbes Marshall Hydraulics Hydac / Forbes Marshall / Kobold / Johnson Control / Switzer / Hydac / Stauff / Verma Trafag / Johnson Control / Kobold

Forbes Marshall / Stauff / Kobold / Rockwin / SMC / HYLOC / Flow Mon Rockwin / Forbes Marshall Jindal / Ratnamani / Maharashtra Seamless / MJ Patel / Indian Seamless / Gandhi Special Tubes / BHEL Jindal / Choksi Tubes / Ratnamani / MJ Patel Maharashtra Seamless / MJ Patel / Gandhi Special Tubes / SAIL / Jindal Saw / Ratnamani / Surya Roshni / MAN / Wellspun Hyd-air / Hyloc Hydoitechnic / MS Fittings / NL Hazra / Project Tooling Systems / Tube Bend / Parker / AVIT / Zest Technologies

42

Pipes / Tubes Fittings

43

Clamps (Polypropylene Clamp, U-Bolts)

Project Tooling Systems / Stauff / Hydair

44

Hose with end fittings

Hydrokrimp / Indo-industrial / Hydrolines / Superseals / Parker

45

Flanges

Echjay / NL Hazra / MS Fittings

46

SAE Flange

AVIT / Parker / Hyloc / Stauff

47

Electrical Heater

Escorts / Alco / Helios

48

Air Breathers

Internormen / Parker / Hydac

49

Portable Filter Unit

Internormen / Hydac / Rexroth /


AREA


Oil Lubrication / Descaling

Hydraulics / Oil Lubrication / Descaling

Hydraulics / Oil Lubrication / Descaling Hydraulics / Oil Lubrication / Descaling Hydraulics / Oil Lubrication / Descaling Hydraulics / Oil Lubrication / Descaling Hydraulics Hydraulics / Oil Lubrication Hydraulics / Oil Lubrication Hydraulics GS-13


ITEM

MAKE Parker PALL / Hydac / Internorman / Parker

50

Contamination Analysis Kit

51

Centrifuge

Alfa Laval / Westfalia

52

Vacuum Dehydrator

Filtervac / Pall / Parker / Nortek

53

Electrostatic Liquid Cleaner Mobile Motorised PumpMotor-Filter Unit for Oil Filling Chain Pulley Blocks & Hand Operating Traveling Cranes

KLEENTEK / Ferrocare PALL / Hydac / Internorman / Parker

56

Spray Nozzles

Lechler / Spraying system

57 58

Nitrogen Booster Station Water in Oil detector

59

Lubricating oil

60

Hydraulic oil

61

Flushing Oil

62

Grease

63

Expansion Joint

Hydac / Parker IMA / Parker / UCC Indian oil / HP / BP / Castrol / Mobil Exxon Indian oil / HP / BP / Castrol / Mobile Exxon Indian oil / HP / BP / Castrol / Mobile Exxon Indian oil / HP / BP / Castrol / Balmer Lourie ESBI / STANFLEX / ELAFLEX

54 55


Batliboi / Moris / WH Brady & Co.


AREA Hydraulics Hydraulics / Oil Lubrication Hydraulics / Oil Lubrication Hydraulics Hydraulics / Oil Lubrication Hydraulics / Oil Lubrication Descaling / Gear boxes Hydraulics

GS-13


GASES AND LIQUID FUELS

02.01.

REGULATIONS The entire interplant and in shop pipelines shall conform to the provisions of relevant Indian statutory regulations, wherever applicable, such as : -

Indian Safety Rules

-

Static & Mobile Pressure Vessels Rules

-

Indian Petroleum Regulations

-

Indian Explosives Manual

-

The Carbide of Calcium Rules

-

Indian Boiler Regulations

The Contractor shall have to obtain clearance/ approval of all the relevant drawings/ documents from such statutory bodies. 02.02.

PIPING LAYOUT General Routing and layout of piping system shall be as per good engineering practice. Following factors shall be taken into consideration while designing piping system. • • • • • •

All functional requirements shall be fully satisfied. Adequate clearance is provided for equipment and operating personnel. Easy access for operation and maintenance of piping component. Convenient supporting points for piping, equipment, valves, etc. Adequate flexibility for thermal expansion / movements. Aesthetics and neat appearance.

Pipe Laying for Fuel Gases, Industrial Gases, Liquid Fuels, Compressed Air and Steam 01.

The gas pipes installed along building wall should not cross window and door way.

02.

While laying high pressure gas pipes along the walls, the later should be fireproof. In doing so, the gas pipes should be laid along solid walls or above the windows of upper floors of plant buildings.

03.

When gas pipes are installed along external walls of buildings below window ways, installation of flange, thread joints and also installation of accessories is not allowed.

04.

Gas pipe may be laid along with pipes of water, steam, air, etc. and also with oxygen on a common support provided conditions stipulated under various clauses are followed.

05.

The following conditions shall be observed when installing gas pipes with other pipes :


Gases & Liquid Fluids Page 1 of 51

GS-02

General Technical Specification a)

Additional pipes on existing gas pipes will be allowed to be laid only with the permission of concerned plant personnel.

b)

In each case, the gas pipes and supporting structures shall be checked with due consideration for additional loads and practical state of the metal structure of gas pipes.

c)

When installing with pipes carrying corrosive fluids they shall be kept at least 500 mm below or by the side of the gas pipe at a distance of 500mm. If flange joints are provided on pipes carrying corrosive liquids, it is necessary to mount protective baffle plate against falling of corrosive liquids on gas pipes and their supports.

d)

The associated gas pipes at the places on gas pipes where valves and other devices are mounted, should be kept at a minimum 800 mm distance from the main pipe.

e)

Drainage of the associate pipes should be laid to one side at a distance so that condensate does not fall on gas pipes/ its accessories, supporting structures and their elements, etc.

06.

The branch line should generally be installed outside building along roof wall. Branch line having diameter less than 500 mm may be laid inside shop building.

07.

Branch line from gas main entering into building through building wall should pass through casings. Internal clearance between casing and pipe should be suitably filled up, wherever required.

08.

Gas branch line from gas main passing through roof covering should have circular opening. For this purpose, a circular opening should be made on roof and a taper hood should be provided on the branch line above the roof for protection from rain.

09.

Shop headers (except headers of By-product Plant) should be mounted at a height having minimum ground clearance of 4500 mm, when laying them outside the building wall.

10.

Layout of gas consuming units in various shops possible to bring the gas pipes above ground.

11.

Gas pipes of coke oven, natural gas and also their mixtures with blast furnace gas may be installed in channels and casings, in the region of gas supply to furnace and other consuming units.

should be such that it is

The following conditions should be observed for this purpose : a)

Clearance between wall and bottom should be at least 400 mm, and for gas pipes of 200 mm and below clearances should not be less than the gas pipe diameter.

b)

Installation of flanges, threaded joints and accessories (except accessories for removal of condensate on a pipeline) is not allowed when it is laid in a channel. The number of welds on such gas pipes should be restricted to a minimum.



GS-02

General Technical Specification c)

Installation of gas pipes with air pipes to gas consumer units is allowed to be laid in channels.

d)

Channels with gas pipes should not cross other channels, In case, it is unavoidable, air tight tie-plate should be made and gas pipe should be placed in casing. Ends of casing should be taken out beyond the limit of tie-plate by 300 mm at both ends.

e)

Channels should have provisions for natural ventilation.

12.

Gas pipes in buildings should be located at places convenient for servicing, inspection and repair. It is not allowed to lay gas pipes at places where there are chances of damage due to shop transport.

13.

For gas lines installed in hot zone, it is recommended to provide protection against overheating of gas pipes.

14.

It is allowed to fasten gas pipes to frames of furnaces, boilers and other units provided these frames are checked for strength by calculations.

15.

Gas pipes are not allowed to pass through buildings producing or having materials liable to explode or burn and building of power distributing devices and substations and ventilation chambers and through buildings, in which gas pipe may be damaged by intensive corrosion.

16.

Gas pipes should not cross ventilation doors, air exhauster, flue pipes and also gas pipes should not be installed in insufficiently ventilated space and in underground buildings.

17.

Installation of high pressure gas pipes below main working platforms of shops is not permitted.

18.

Gas pipes along bridges should be made of seamless pipe and laid in the open at a horizontal distance of one metre from ends of pavements for passing of people and it should be within reach for servicing. Supporting elements of the bridge should be accordingly checked for loads from gas pipes. Laying of gas pipes in channels of bridges is not allowed. All welding joints of gas pipes in the area of their attachment to bridge should be radiographed.

19.

Gas pipes passing through walls, ceilings, and other structures of buildings of construction shall be encased in a steel pipe having inside dia at least 50 mm more than that of the oxygen pipe. The Gas pipe shall have no joints in the section at such crossings. The gap between the gas pipe and the outer pipe shall be filled with non/inflammable material, but allowing vertical and horizontal movement.

20.

The laying of moist fuel gas pipelines shall be as per IPPS: 1-06-014-95

21

Pressure pipe work for gases and liquid fuels generally shall be routed overhead. All overhead interplant pipe work to be routed such that they will have a minimum clearance of 6.0m between bottom of supporting structures / pipes and road / railway track. The pipelines laid over hot tracks shall have a minimum clearance of 10.0m. In case, protective shields are used in these places, this clearance may be reduced to 6.0m. Buried pipes, wherever laid, shall be provided with a minimum earth covering of 1200mm in areas subject to



GS-02

General Technical Specification temporary loads and minimum earth covering of 1000mm in areas not subject to temporary loads, unless otherwise specified. 22.

For the pipelines laid on roof, the distance from the external edge of the pipe to the roof shall be at least 0.5m.

23.

All shop headers, except for gravity fluids, shall be generally routed along columns in multiple rows at a height 4 to 6m above floor level. The connections to equipment shall be taken through suitable covered floor trenches for shops at ground floor and for basements, for elevated operating floors, the equipment pipe work connection may be taken below the floor level. All isolated single pipe connections to equipment shall be buried in the flooring / equipment foundations. Pipe work from basement and oil cellars to main equipment shall be routed in pipe tunnels / trenches with adequate spacing for easy maintenance. All pipe trenches shall be covered by chequered plate or by concrete slabs.

24.

The bleeder pipes for purging lines and other exhaust pipe work shall be routed upward along columns / gable ends and / or walls to a minimum height of 4,000mm above the roof level / platforms.

25.

For the gas pipelines laid along the building walls, the clearance between the gas pipelines and the wall shall be adopted so as to ensure the possibility for maintenance of the gas pipelines. The gas pipelines laid on the walls must not cross the window and door openings.

26.

Branch pipes from the headers to the building through walls and the roof shall be encased.

27.

Gas pipelines shall be earthed. When laid under the high voltage lines, a protective sheet guarding shall be provided above the gas pipelines. The guarding shall be earthed. The earthing resistance must be not over 10 ohm.

28.

Platforms, access ladders, hand railing, etc. shall be provided for operation and maintenance of valves, instruments and controls. Manholes and hatches shall be provided for access inside the gas pipelines.

29.

At all the places of regular maintenance (gate valves, throttle valves, orifice plates, hatches, manholes, bleeders, etc.) if located at a height of over 2.5m from the maintenance level, provision shall be made for stationary platforms with the railings and stairs / ladders.

30.

To ensure the condensate drainage, the gas pipelines shall be laid with a gradient of about 0.005 towards the water drains. Condensate drains shall be equipped with bleeders. Necessary water pipe work for condensate seal pot shall be provided.

31.

Flash back arrestors shall be provided in each section of the pipe work for acetylene and LP gas to prevent flame propagation or pressure surges. They may be of hydraulic / cartridge type flash back arrestors or back pressure valves.

32.

All branch pipes from main header shall be connected through a hydraulic arrestor.



GS-02


Shut-off globe valves shall be provided on both the inlet and outlet sides of the arrestor and unions shall be provided for repair or replacement, if required.

34.

Oxygen pipelines may be laid on either side of the fuel gas line as per the following norms.

Oxygen Pressure in Kg/cm2

Diameter of Oxygen pipe mm

Permissible gap in mm

Upto 0.1

Upto DN 500

300

Upto 0.1

Above 500

600

0.1 to 16

Upto 500

800

16 to 35

Upto 200

800

Continuous installation is not allowed if the oxygen pressure is more than 16 Kg/cm2 and diameter of pipe is more than 200mm and also if the oxygen pressure is more than 35 2 Kg/cm for any size. Minimum clearances of overhead oxygen pipelines (surface to surface) i) ii) iii) iv)

Explosion Hazardous shops Railway tracks Railway bridge and platform Roads

: : : :

3 meters clearance 3 meters 3 meters 1.5 meters upto embankment

v)

High voltage Transmission lines A. Parallel to pipelines B. Crossing the pipelines upto 20kv 35 to 150kv 220kv

: : :

10 meters 3meters 4 meters

: : :

10 meters 0.5 meters 1.0 meters.

vi) vii) 02.03.

To place of hot metal tapping and Source of open fire Insulated L.T cables Bare conductor L.T

DESIGN PARAMETERS Design pressure for various categories of piping shall be as follows : Low Pressure Fuel gas piping ( Up to 1500 mm WC MOP)

: 1.25 Times Maximum Operating Pressure : But not less than 2000 mmWC

All other gas piping

: 1.25 Times Maximum Operating Pressure

Steam piping

: 1.5 times Maximum Operating Pressure.

Design temperature for all fluids shall be maximum working temperature of fluid. In case of ambient temperature, design temperature may be taken as 60 deg C for piping exposed to sun and 45 deg C for indoor piping. © 2007 MECON Limited All rights reserved


GS-02


Flow rate for design purpose shall be taken as peak flow rate for the respective section. In case of branches to individual consumers, peak flow rate for the consumers shall be considered. For common branches and main headers, peak flow rate based on consumption pattern/ diversity factor may be used for pipe sizing. Future augmentation of flow rate for common piping shall also be taken into consideration for pipe sizing. 02.04.

SELECTION OF PIPE SIZE •

Pipelines shall be sized by limiting the gas velocity in the pipeline as per Table 02-01. Peak flow rate based on the distribution pattern shall be considered for sizing of pipes. Sizing shall be based on actual flow rate at worst combination of parameters i.e. lowest pressure and highest temperature. In case recommended velocity is dependant on diameter range, after initial sizing, velocity should be re-checked and if required size should be recalculated. Nearest higher standard pipe size shall be selected after calculation.

• • • •

For critical applications, pipe sizes should be re-checked after pressure drop calculations and availability of required pressure at consumer point. If required pipe size may be increased to meet the pressure drop criteria. TABLE 02-01 RECOMMENDED VELOCITIES IN CARBON STEEL PIPES A: Sl. No 1 2 3 4 5 6 7

Low Pressure Fuel Gases Nominal Pipe Dia – (mm) 20 – 80 100 - 250 300 – 500 600 – 800 900 – 1200 1300 – 2000 > 2000

Gas Velocity, m/sec (maximum) CO Gas, Mixed BF & BF & BOF Gas Natural Gas Corex Gas 2 2 2 3-4 4–5 4 –5 5-6 6–7 5–7 6–7 7–8 7-8 8 - 10 9 – 12 8 – 11 11 - 18 13 – 20 12 – 19 20 - 25 23 - 28 21 - 27

Remarks

B : Medium Pressure & High Pressure Gases Medium Nitrogen, Argon, Compressed Air, Instrument Air Oxygen LPG Acetylene Liquid Fuels


Pressure Range 2 (kgf/cm g) Up to 6 6 - 16 16 - 40 Up to 16 16 - 40 Up to 3 Up to 1.2 All Pressures

Gas Velocity, m/sec (maximum) 8 –10 12 – 16 Up to 20 12 8 8 8 1.5


Remarks See Note 1 See Note 2 Up to DN 25

GS-02

General Technical Specification C : FOR STEAM Sl. No 1 2 3 4 5

Fluid Condition SATURATED AT SUBATMOSPHERIC PRESSURE SATURATED AT 1 TO 7 2 Kgf/cm (g) SATURATED ABOVE 7 Kgf/cm2 (g) SUPERHEATED UPTO 7 2 Kgf/cm (g) SUPERHEATED ABOVE 2 7 TO 35 Kgf/cm (g)

Average Velocity, m/sec DN 50 to DN 200mm Up to DN 50mm DN 150mm and above 10 – 15 15 – 20 15 – 22

20 – 33

25 – 43

15 – 25

20 – 35

30 – 50

20 – 30

25 – 40

30 – 50

20 - 33

28 – 43

35 - 55

Remarks

Steam piping network comes under the purview of IBR and thickness calculation shall be carried-out as per stipulations indicated in IBR and approval of CIB shall be obtained. 02.05.

EXPANSION AND FLEXIBILITY. All Pipe work shall be designed to provide sufficient flexibility against thermal expansion to prevent development of undesirable forces and moments at points of connection to equipment, at anchorage or at guide points. As far as possible, flexibility shall be provided by planning route with change of direction or by the use of bends, loops or off-sets. Whenever self-compensation can not be achieved by pipe routing, provision for thermal expansion shall be made by providing expansion loops or expansion joints as per following criteria: •

U loops shall be provided for all low pressure fuel gas piping up to DN 300 size and high pressure piping for all sizes.

•

For high pressure piping, where U-loop is not possible, bellow type expansion joint shall be provided. Bellow type compensators shall also be provided in low pressure gas lines. While locating the expansion joints following guidelines should be followed:

•

Bellow compensators should be located preferably in the center of two fixed points.

•

U-Compensators should be located in between two fixed points with variation in pipe lengths in the ratio of 1:2 (max).

•

Gland Compensators should be smooth functioning.

•

Bellow and gland compensators shall have flanged connection with pipes


located near the fixed supports to facilitate


GS-02

General Technical Specification U-loop Compensator U-loops shall be provided in piping system using elbows/ bends as per piping material specification. U-loops shall be in horizontal plane and loops for many pipes running in parallel may be provided at same location parallel to each other. Loops shall be in the same plane as the pipe route. However, in some cases, where there may be obstruction due to other parallel pipes, U-loop plane may be raised to clear the pipes by providing bends. Loops in vertical plane can be provided in exceptional cases if horizontal loop is not possible due to layout considerations. Provision shall be made in piping for draining of condensate, venting, etc. Bellow Compensator Bellow type expansion joints shall be made from SS sheet and can be single or multi layer with number of convolutions. Loads due to Compensators Loads on anchor points due to bellow compensators shall be considered based on the feed back from supplier / manufacturer. 02.06.

VALVES AND MEASURING DEVICES Valves shall be provided on pipe work for isolation of pipe sections and equipment, control of pressure, flow and level of fluids, venting, draining, pressure relief, etc. They shall be suitable for the service conditions in all respects and located suitably considering ease of operation and maintenance. Generally the following practice shall be followed; -

Stop valves : On all pipelines both at the sources and consumers also in the branch pipes to individual buildings and shops with a nominal diameter of 100 mm and above (if required, for smaller diameter as well).

-

Isolating and by-pass valves for flow meters, filters, etc.

-

Check valve on all pipelines requiring unidirectional flow.

-

Quick action safety shut-off valve on fuel oil, gas/ air lines to furnaces and heaters as well as before each consumer or group of consumers.

-

Pressure regulating valves with isolating, by-pass and relief valves for all pressure reducing installations.

-

Manual drain valves at low points and manual vent valves at all high points of pipe work.

-

Regulating valves with integral pressure gauge for all oxygen outlet points, fuel gas outlet, etc.

-

All valves shall be provided with the operating handle/ lever/ wrench within easy reach. Where necessary, operating platforms shall be provided. Valves located in inaccessible locations such as basements, tunnels, etc. Shall have remote actuation by means of electric motors, solenoids, etc.



GS-02


02.07.

-

For fluid lines with working pressures over 16 atg, valves of diameter 300 mm and above shall be provided with by-pass arrangement, unless otherwise specified in technical specifications.

-

Shut-off valves of dia 500 mm and above as well as shut-off valves of all diameter with remote or automatic control shall be provided with electric drives.

-

To facilitate operation of manually operated valves, adequate gearing and handling arrangement shall be provided, wherever necessary

-

All gas branch pipes from the in shop collector to the consumers shall be provided with bleed valve arrangement comprising two gate valves in succession with a bleeder in between. After the second gate valve (upstream), a provision shall be made for installation of a blank flange.

-

Shop pipe work for all production and ancillary units shall have metering of flow and pressure at the battery limits.

-

Sectionalising of pipe work for fuel gases such as coke oven gas, blast furnace gas, mixed gas and converter gas will be provided to facilitate maintenance work. This may be achieved by water seals, goggle valves, spectacle blinds or patented gas tight isolators.

CONDENSATE DISPOSAL Fuel gases as well as other gasses contain moisture and other condensable impurities which get separated during fluid transportation through piping system, effective condensate removal system should be incorporated to prevent accumulation of condensate in pipes which otherwise may cause obstruction to proper gas flow and excess live load to the pipe/ structure. All piping for gasses containing moisture etc. like BF / Coke oven / BOF gas, Mixed gas, Compressed air, Steam & Natural gas are laid with gradient / slope. A slope of 5mm per meter run shall be provided for the above pipelines. In case of space constraint to accommodate slope, it may be reduced to 0.003 particularly for in shop piping. For straight length of pipeline, low / high points should be located generally at a distance 100 meters. However, in no case it should exceed 300 meters. Condensate drain points shall be provided at all low points. In case of low pressure gas lines, automatic drainage system though seal pots shall be provided. For compressed air lines and steam lines, automatic condensate / steam traps shall be provided. Condensate Drain Arrangement for Low Pressure Gases i)

Drainage shall be provided at all the low points of gas pipes carrying moist gases for condensate removal. Disposal of condensate shall be through seal pots/ condensate drain installations.

ii)

Distance between any two drain points of a gas pipe within a radius of 100 meters from gas cleaning plant should not exceed 60 meters.

iii)

Drainage system for outdoor gas networks should be located in open air with necessary accessibility for operation.

iv)

Pipes for condensate removal from inter shop gas pipes of blast furnace gas in a radius of 400 m from gas cleaning plant should be at least 80 mm diameter. For pipelines beyond 400 m and also for gas pipes for other moist gases, diameter of condensate removal pipes should not be less than 50 mm.



GS-02


v)

Separate seal pots shall be provided for different gasses.

vi)

Removal of condensate from branch line from inter shop gas pipe and inshop gas pipe should be carried out in separate condensate seal pots.

vii)

Minimum height of the water seal in the condensate seal pot shall exceed the maximum working pressure of gas by 500 mm, but this height in no case shall be lower than 2000 mm. If necessary, the height of water seal can be increased by adding more than one seal pot in series. However, number of such seal pots shall not exceed three. Further base plate of seal pot shall have minimum thickness of 16 mm. While installing common seal pot for a number of gas pipe, height of water seal should exceed by 500 mm the maximum working pressure in any of the connected gas pipe.

viii)

Design of condensate seal pots should ensure protection against leakage of harmful gases into building by providing vent of adequate height on the seal pot.

ix)

Condensate seal pot shall be provided with purging facilities.

x)

Installation of condensate seal pot for in shop gas network is allowed inside the buildings.

Condensate Drain Arrangement for Medium pressure High pressures gas

02.08.

i)

Condensate disposal for gases having higher line pressure have to be done by using adequate pressure seal pots.

ii)

In a high pressure seal pot the metallic float is utilized for disposal of condensate and prevent leakage of gas from the pot.

iii)

The seal pot should be air tight and wall thickness should be decided on the line test pressure.

iv)

Condensate coming out of seal pot should be discharged into phenolic sewerage line or in a reservoir provided locally.

STEAM TRAPS / MOISTURE TRAPSAt low points in steam & compressed air pipeline steam traps / moisture traps with strainer assembly will be provided to drain out the condensate. Selection of steam trap shall be as per IPSS: 1-06-039 – 02. Installation of steam traps shall be as per IPSS: 106-037

02.09.

PURGING SYSTEM System for feeding purge gas and venting of gas/ air from the piping system shall be provided for all fuel gas piping. Purging i)


Gas pipelines of blast furnace gas, coke oven gas, converter gas and mixed gas shall be equipped with nitrogen or steam pipe connection with isolation valve. The connection of nitrogen or steam pipeline to the gas pipeline shall be done by means of flexible hose which shall be connected only during the period of purging. Gases & Liquid Fluids Page 10 of 51

GS-02


02.10.

ii)

Location of purge gas inlet points and vents shall be such that entire section of piping can be purged with minimum dead space. Purging points shall be provided at low points.

iii)

Purging points shall not in any case be provided at bottom half of the gas mains.

iv)

Purge points for fuel gas pipes up to DN 950 mm shall be of minimum DN 25 mm same for pipes of DN 1000 mm & above shall be of minimum DN 50 mm.

BLEEDERS/ VENTS Bleeders shall be provided on all the gas handling devices and pipelines for purging and venting any section of the gas pipeline. The purging bleeders of pipelines carrying different fluids, separated by gate valves, are not allowed to be combined into one bleeders. The bleeders shall be taken above the gas pipeline or above roof of the building by at least 4 m, but not lower than 12 m from the ground level. Bleeders on shop roofs shall be located away from roof monitors. i)

Bleeder/vents shall be provided for purging / venting any section of the pipeline. Bleeders shall be located generally at all high points in the piping system. Bleeder / vents shall also be provided at down stream / upstream of isolating devices & U-seals.

ii)

All vents shall discharge at a safe height into atmosphere. The vents shall be above the operating floor / platform for vent valve or roof of the building 4m, but not lower than 8 meters from the ground level. In the presence of the aeration monitors on the roof of the building, the vents shall be located so as to eliminate the possibility of purged gas getting inside the premises.

iii)

On straight lengths bleeder/vent shall generally be provided at an interval of 100 meters.

iv)

All vents shall have T piece/cowl with bird screen preferably at the top. For isolation of bleeder/vent pipe flanged gate valve of rising stem type shall be provided. Sampling points (DN 25) below isolation valve with lubricated taper plug valve shall be provided in the line to monitor gas samples at the time of purging.

v)

Vent pipes of different gases shall not be connected through a common vent.

vi)

Recommended sizes of bleeder / vent pipes corresponding to gas pipe diameter are indicated in Table – 02.02. Table –02.02 RECOMMENDED SIZES OF BLEEDER / VENT PIPES DN (mm) 20 25 40 50 65 80 100 150


Bleeder pipe dia. DN (mm) Low Pressure Fuel gas Natural gas/Corex Gas 20 20 20 50 20 50 20 50 20 50 20 50 25 Gases & Liquid Fluids Page 11 of 51

GS-02

General Technical Specification DN (mm) 200 250 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1800 2000 2200 2400 2500 2800 3000 3200 3500 02.11.

Bleeder pipe dia. DN (mm) Low Pressure Fuel gas Natural gas/Corex Gas 50 25 50 25 50 25 80 50 80 50 80 50 100 80 100 80 100 80 150 100 150 100 150 100 150 150 150 150 200 150 200 200 250 250 250 250 250 250 300 300 -

VALVES AND ISOLATING DEVICES Isolating devices shall be provided in piping system for isolation of pipe sections as well as for isolation of all other mounted accessories for the purpose of operation and maintenance. They shall be suitable for the service conditions in all respects and located suitably considering ease of operation and maintenance. Isolation valves shall be provided at the following locations: • • • • •

On all pipe lines both at the source and at consumer ends On all branch pipes to individual buildings and shops On all bleeder / vent pipes, purge gas inlet points, drain points, sampling connections, etc. On all by-pass lines for large valve, regulators, filters, moisture traps etc. Instrumentation tapping points.

Selection of Isolating devices: The gas cut-off arrangement shall ensure the possibility of complete cut-off gas along with fast and safe operation. Gate valves with rising stem shall be used normally for isolation in piping system. Pipe work for fuel gases such as Blast Furnace Gas, Coke Oven Gas, Converter Gas, Mixed Gas with low operating pressure shall have some means of gas tight isolation of sections of the pipe work to facilitate maintenance work. These may be water seals, goggle valves, spectacle blinds, or gas tight isolators / slide plate valves, etc. Necessary water pipe work shall be provided for water seal.



GS-02

General Technical Specification For sections where the gas tight isolating device can not be provided, provision to insert blind flange at outlet of gate valve shall be made. Sectionalizing / isolation for purging of fuel gas lines may be done with Spectacle blinds. Gas tight butterfly valves may be used for isolation near consumption points requiring frequent and quick operation. These can be valves with gas tight seating or eccentric valves for gas tight isolation. Emergency quick shut off valves shall also be double eccentric butterfly valves. For fluid lines with working pressure over 16 kg/cm2 (g), valves of DN 300 and above shall be provided with by-pass arrangement or depressurisation arrangement for pipe sections. Selection of Actuators for Isolating devices: Manually operated shut-off gate valves of size DN 300 to DN 450 for low pressure lines shall have gear drive. For high pressure lines, gear operator shall be provided as per manufacturer’s recommendations for limiting the operating torque to acceptable limits. Gate Valves of size DN 500 and above shall be provided with electric actuators. Electric actuators for fuel gas lines shall be of flame proof design if located in gas zone/in shop. In the interplant area these actuators need not be flame proof. Position and torque limit switches shall be provided on actuators. Manual over ride shall also be available in actuators. Goggle valves shall have electrical actuators for disc/ plate movement and electro hydraulic drive for flange separation. Manual arrangement for valve operation shall also be provided with gear and chain operation from convenient location. The hydraulic power pack for the valve shall include one motorized pump and one manual pump. Encased design goggle valve with vent shall be used at locations closed to buildings. Electrically operated gate valves for gas pipelines of smaller diameter are recommended to be used only if they are incorporated in the automation scheme. All valves located remotely, requiring frequent operation and / or with automatic control shall be provided with electric drives, electro- pneumatic drive, solenoids etc. Check valves shall be used in piping system where unidirectional flow is required. For small size pipes below DN 50, lift check valves shall be used. For DN 50 and above, swing check valves or dual plate check valve shall be used. Lift check valves shall be used only in horizontal pipeline. It should not be used in vertical pipeline. For low pressure gas lines dual plate check valve will be used. The Pressure Regulating valve shall be of globe / needle type, with material specifications, dimensional standards etc. as per the relevant Piping Material Specification (PMS) for the service for which the valve is intended. 001

For Compressed Air Pressure regulators of sizes up to DN 50 shall be complete with a prefilter having 40 micron porous bronze filtering element in shatterproof plastic or glass container, pressure regulator and pressure relief arrangement to prevent overpressure at downstream of the regulator.



GS-02

General Technical Specification For higher sizes to meet larger flow rates, the pressure regulator shall be self actuating type as per manufacturer’s standards, but capable of meeting the service conditions and duty specified. 002

For Steam For sizes up to DN 50, pressure reducing valves of single seated diaphragm type having in-built strainer, with screwed ends up to DN 20 for PN 10 and below and flanged ends for higher sizes and for higher PN. Body of main and pilot valves shall be of carbon steel / alloy steel castings / forging, diaphragms shall be of stainless steel, internal springs of stainless steel and pressure adjustment springs of spring steel. For higher sizes to meet larger flow rates, the pressure reducing valves shall be as per manufactures standards, but capable of meeting the service conditions and duty specified.

003

For Other Gases For dry air, nitrogen and argon the pressure reducing valves shall be of stainless steel. For oxygen service, the valve shall be of bronze construction and shall be degreased and cleaned to meet the service requirements. For acetylene and LP gas services, the pressure regulators shall have material for the service. Pressure regulators for large diameter gas lines shall comprise butterfly type valves actuated by means of an oil hydraulic control system, which is actuated in turn by changes in the preset downstream pressure through impulse pipe work. Pressure Relief Valves These shall be spring loaded type and shall automatically open when the pressure on the pipelines, on which they are mounted, exceed preset values. The valves shall have end connections and materials specified for throttling valves in relevant PMS. Relief / Safety valves for steam service shall have IBR certification. Relief valves shall have hand wheel / wrench for adjustment of preset value of relief pressure. Pressure relief valves shall always be used on outlet lines from the pressure reducing valves. Pressure relief valves shall be designed for full flow rate from pressure regulators. Set pressure shall be 10 % higher than the maximum working pressure at outlet of regulator. Filters Filters will be installed in piping system before the pressure regulators/ control valves and at consumer points depending on nature of fluid and technological requirements. For small size pipes below DN 50, Y-type strainers with sintered/ wire mesh cartridge may be used. For higher sizes, straight line mounted filters with removable cartridge shall be used. Filter element can be of wire mesh, sintered material, woven fibers or other suitable type as per process requirement. Filtration area shall be at least 500% of the inlet cross section area.



GS-02

General Technical Specification Safety Shut-Off Valves These shall shut-off in case the pressure on the upstream side of the valve becomes less than preset values. The valves shall be of globe type for DN 50 and below and butterfly type for sizes above DN 50; the material shall be suitable for service conditions. The valves shall be actuated by electromagnetic or pneumatic device working in conjunction with pressure switches located on the pipelines being safeguarded and shall include all components required for its functioning. Electrical continuity Metallic electro static jumpers shall be provided at all locations on all flanged connections, in case of flammable gases and oxygen. This is to prevent accumulation of static electricity in pipe sections. Piping system shall be suitably earthed at a regular length of pipeline. Measuring and control devices Instrumentation and control devices shall be provided for monitoring the fluid distribution system, regulation of pressure and flow. Flow measurement shall be provided at battery limit of all production and consuming units, inlet/ outlet piping of storage installations, on surplus gas bleeder piping to flare system etc. When orifice plates are used, proper care shall be taken in piping layout for preventing accumulation of condensate by providing suitable slope or drain system. Requirement of straight length upstream and downstream of flow sensors shall be maintained as per instrumentation requirements. Normally the straight length recommended is 10 times pipe dia before inlet and 5 times pipe dia after outlet of device. Pressure measurement shall be provided at battery limits of production and consumer units, at outlet of storage systems, inlet and outlet of pressure regulators/ controllers, etc. Pressure and Flow Control valves shall be provided at gas mixing stations, main pressure regulating stations, flare stack piping, inlet/ outlet piping of storage installations (gas holders). For low pressure gas lines, butterfly type control valves shall be used. For high pressure gases, globe valves may be used. Sizing of control valves shall be based on flow rate and pressure parameters. 02.12.

HOSES & HOSE BOXES General purpose oxygen and propane shall be provided with necessary isolating valves, pressure control valves, Hoses & Hose boxes at each consumer points. Nipples along with quick coupling hoses shall be provided for steam, compressed air and Nitrogen for purging and other needs.

02.13.

SPECIAL CONSIDERATIONS FOR OXYGEN PIPING Filters should be installed in the oxygen pipeline system at the following points: a)

At the outlet of the oxygen plant.

b)

Upstream of components having soft seating in contact with the oxygen stream e.g. pressure regulator and control valves. Upstream of components that have moving parts in contract with the oxygen stream e.g. flow measuring and limiting devices.

c)

Provision shall be made for safe and easy access for frequent cleaning and / or replacement of the filter element. The larger capacity filters like (a) above should be provided with differential pressure gauge for monitoring the condition and providing © 2007 MECON Limited All rights reserved


GS-02

General Technical Specification indication for cleaning / replacement of the filter element. The filter bodies shall preferably be of copper alloy or stainless steel and filter element of copper alloy or glass cloth suitably earthed to the filter body with copper wires. Two (2) or more pressure relief valves should be provided downstream of each set of pressure reducing valves. One or more main relief valve(s) should be capable of discharging 100% of the full oxygen flow and limiting the pressure within the defined limits. The secondary relief valve should be sized to discharge the nominal leakage from the pressure reducing valves. The relief valves should be positioned as close as possible to the pressure reducing valves. The vent lines from the relief valves should be preferably of stainless steel or copper. Consideration should be given for providing small size pressure equalisation bypass isolation valves across large diameter isolation valves in large pipeline systems so as to ensure safe pressurization of the downstream pipeline. The bypass pipe work and valve should be of copper or copper alloy. Fire break sections may be installed in the oxygen pipeline to limit the propagation of combustion in a steel pipeline. Fire break sections may be introduced immediately downstream of the main isolation and throttling valves where the velocities can be high. The fire break section will be either a length of copper pipe having the same inside diameter as the main pipe with flanges fitted at the two ends which is installed between the steel pipes or a copper insert tube made from copper sheet / tube and inserted inside the steel pipe downstream of the valves. The copper insert tube is generally used in large diameter steel pipelines. In steel pipelines, care should be taken to install isolation valves on straight sections of the pipeline. Any pipeline component which is likely to cause a change in the flow pattern, like reducer, bend, tee or “Y” connection, orifice plate etc., should be at a distance of at least four diameters away from the valve. For cleaning of the gaseous oxygen pipelines after erection, provision for “pigging” will be provided for pipelines having diameters upto DN 200. However, if the pipeline is pickled and phosphated as per approved procedure, pigging of pipelines is not essential. The bends on these pipelines will have a radius of 5 DN. Extra care will be taken regarding cleanliness of large dia. pipeline (DN 250 and above) during installation. The bends for the larger dia. Pipes will have a radius of 3 DN. Gaseous oxygen pipe work shall preferably have butt welded pipe joints. To reduce safety hazards the number of components should be kept to a minimum compatible with the system requirements. Flange joints shall be used only for connection of the pipe to the system components on the pipe work. Threaded joints and couplings should be sparingly used. 02.14.

DESIGN CONSIDERATIONS Piping system shall be designed with high degree of reliability so that the systems perform the duty of fluid handling without structural or functional failure under most adverse condition of plant operation. All piping systems shall be designed with sufficient corrosion and stress margins to ensure a life time without failure, not less than the life of the plant. 7000 complete cycle of operation shall be considered for stress analysis purpose. Piping system shall not impose reactions on equipment terminals exceeding permissible limits even under adverse operating conditions. Personnel injury from discharge of hot fluids from drains, steam traps, hot pipes or exposures to pipe vibrations shall be guarded against. Piping coming under the purview of Indian Boiler Regulations (IBR) shall be designed in accordance with such regulations. The design criteria of piping coming under the purview of IBR shall have to be approved by "Chief Inspector of Boilers"



GS-02

General Technical Specification of the respective State prior to manufacture. All welding procedures, stress relieving procedures, inspection / testing / certificates and all other records shall have to be approved by Chief Inspector of Boilers in approved form. Pipes having nominal bore less than 15 mm, shall not be used. Design pressure of steam and all other service pipelines shall be considered as 1.2 times the 2 maximum expected pressure. However it shall not be less than 4.0 kg/cm gauge 2 for steam services and 3.5 kg/cm gauge for other services. Design temperature for steam services shall be as pr IBR and for other pipelines shall be 5 deg. above the maximum sustained service temperature expected. All the piping coming under the purview of IBR, shall be designed with the allowable design stresses as per IBR. For all other piping, the allowable design stress shall not be more than that specified in ANSI B 31.1 or BS:806 latest revision. Pipe thickness of all pipeline shall be taken as per the pipe thickness schedules. The design and stress analysis shall take into account the effect of internal/external pressures, thermal expansion, self weight of piping, support reactions, shock due to relieving devices, surge and water hammer, earth quake and wind effect, noise and vibrations, corrosion and erosion etc. and any other effects dictated by recommended engineering practices. Adequate flexibility shall be provided in the pipelines to keep stress and reactions in the system arising due to thermal expansion or other effects within limits. Where the piping terminates at an equipment or at the terminal point of a system, the reactions and thermal movement imposed by piping on the equipment or the system concerned shall be well within the limits specified. The flexibility analysis of steam, condensate and hot service media pipelines shall be furnished. 01. Pipes shall be sized for minimum pressure drops and considering the velocity limitation for various types of fluids. 02. Adequate flexibility shall be provided in the pipelines to keep stresses and reactions in the system arising due to thermal expansion or other effects within limits. Where the piping terminates at an equipment or at the terminal point of a system, the reactions and thermal movement imposed by piping on the equipment or the system concerned shall be well within the limits specified. 03. If cold springing of pipeline is used, care shall be taken in determining the location and amount of cold spring gap. Cold spring gap shall be located at points where the bending and torsional moments are minimum. Use of cold spring gaps less than 10mm shall not be acceptable and cold spring gaps above 100mm shall be avoided. All outdoor piping 0 exposed to sunlight carrying fluid at a temperature less than 80 C shall be designed 0 considering thermal expansion corresponding to 80 C and empty pipe as one of the operating conditions although not necessarily the worst. 04. All piping shall have butt welded connections with minimum of flanged joints for connection to vessels and equipment to facilitate erection and maintenance. All high pressure steam valves and accessories shall have welded connections. Standard fittings shall be used wherever practicable. Unless otherwise specified, for all welded lines with 0 pressure above 4 kg/cm2 g and / or temperature above 200 C, branch connections with branch sizes upto 25% of welded mains shall be made with special forged steel welded fittings.



GS-02

General Technical Specification 05. Bends for pipes for oxygen service shall have a radius of not less than three times the nominal pipe dia unless otherwise specified. 06. In general pipes having size 50mm and above, shall be joined by butt welding and 40mm & below by socket welding / screwed connection. Threaded joints shall have to be seal welded except for galvanized pipes where teflon sealing tapes shall be used. For galvanized pipeline, pipe joints which are to be made before galvanising shall be of welding type. Those joints which are to be made after galvanising shall be either flanged or screwed type. As far as practicable, whole fabricated piping assemblies shall be galvanized at a time in order to minimize the number of joints to be made after galvanising. 07. All pipelines shall be provided with drain connections, generally at the lowest point for removing accumulated condensate or water and line draining. The drain piping shall have drain pockets and isolation valves. Trap stations shall be provided where necessary. Lines shall be given proper slope towards the drain points. 08 Piping coming under the purview of Indian Boiler Regulations (IBR) shall be designed in accordance with such regulations. The design criteria of piping coming under the purview of IBR shall have to be approved by "Chief Inspector of Boilers" of the respective State prior to manufacture. All welding procedures, stress relieving procedures, inspection / testing / certificates and all other records shall have to be approved by Chief Inspector of Boilers in approved form. 09 Pipes having nominal bore less than 15 mm, shall not be used. Design pressure of steam and all other service pipelines shall be considered as 1.2 times the maximum expected pressure. However it shall not be less than 4.0 kg/cm2 gauge for steam services and 3.5 2 kg/cm gauge for other services. Design temperature for steam services shall be as pr IBR and for other pipelines shall be 5 deg. above the maximum sustained service temperature expected. 10 All the piping coming under the purview of IBR, shall be designed with the allowable design stresses as per IBR. For all other piping, the allowable design stress shall not be more than that specified in ANSI B 31.1 or BS:806 latest revision. Pipe thickness of all pipeline shall be taken as per the pipe thickness schedules. The design and stress analysis shall take into account the effect of internal/external pressures, thermal expansion, self weight of piping, support reactions, shock due to relieving devices, surge and water hammer, earth quake and wind effect, noise and vibrations, corrosion and erosion etc. and any other effects dictated by recommended engineering practices. 11 Adequate flexibility shall be provided in the pipelines to keep stress and reactions in the system arising due to thermal expansion or other effects within limits. Where the piping terminates at an equipment or at the terminal point of a system, the reactions and thermal movement imposed by piping on the equipment or the system concerned shall be well within the limits specified. 12 The flexibility analysis of steam, condensate and hot service media pipelines shall be furnished. 02.15

PIPE SUPPORTS, ANCHORS, RESTRAINTS -


In general pipe supports, restraints, braces or anchors shall be located at those points in the building or outdoor where provision has been made for the loads imposed. Loads at the supporting points or restraints shall be determined sufficiently early and provisions shall be made in the building or outdoor structures for pipe supports. The Tenderer shall locate, design, supply and erect all the


GS-02

General Technical Specification supplementary steel structures to properly secure and support all pipe hangers, supports, restraints, etc. -

Provision shall be made for support of piping which may be disconnected during maintenance work. All large pipes and all long pipes shall have at least two supports each arranged in such a way that any length of piping or valve may be removed without any additional supports being required.

-

Supports, guides and anchors shall be so designed that excessive heat is not transmitted to the building steel. Supporting steel shall be of structural quality. Perforated, strap, wire or chain shall not be used. Support components shall be connected to support steel by welding, bolting or clamps. Bolt holes shall be drilled and not gas cut. Structural steel work for supporting shall be designed on the basis of a maximum design stress of 1265 kg/cm2. Pipe attachments coming in direct 0 contact with pipes having surface temperature above 400 C shall be made of alloy steel. Use of insulating materials like asbestos between pipe clamp and pipe surface to meet the above temperature limitation shall not be permitted. The maximum spacing between two consecutive supports shall be not more than as specified. Pipe hangers and supports shall be capable of supporting the pipelines under all conditions of operation. They shall be capable of supporting the pipelines under all conditions of operation. They shall allow expansion and contraction without over stressing the piping system or overloading the terminal equipment due to variation in supporting effort. Rigid supports or hangers shall be permitted only for pipes with small movements. For hot lines, spring hangers shall be used. The maximum permissible load variation on the terminals of sensitive equipment between hot and cold conditions shall be limited to 6%. Variability in load between hot and cold conditions expressed as a percentage of the design load shall be taken as the criteria for spring selection for spring hangers. Variable spring hanger shall be set at cold conditions so that they take design load under operating condition after the designed thermal expansion has taken place. Spring shall be encased in suitable cages and the hangers shall be provided with spring locking arrangement, external load and movement indicator and turn buckles for load adjustment. All the rigid hangers shall be provided with turn buckles for vertical length adjustments. Hanger rods shall be subjected and designed for tensile loads. At locations of high axial or lateral movement, suitable arrangement shall be 0 provided to permit the swing. The swing from vertical position shall be within 4 . Double nuts and locknuts shall be used for hanger rods and bolts in all cases. Hangers shall be designed so that they can not become disengaged by movements of supported pipe.

-

The supporting structures at each support points shall be designed for the highest of the following loads to take into account the extra load during hydraulic testing.

-

1.25 times the maximum load under operating condition

-

Weight of pipelines full of water (combined weight of pipe, insulation, valve attachment etc. plus weight of water)

-

Weight of pipeline full of water as above plus any cold reaction as anticipated.

-

Where the piping system is subjected to shock loads such as thrust imposed by the actuation of safety valves, hanger design shall include provision of shock absorbing



GS-02

General Technical Specification devices of approved design. Vibration control devices shall be part of piping system design. Outdoor piping shall be designed with due consideration to expansion resulting from exposure to sunlight and care shall be taken to prevent progressive movement of long pipelines. Outdoor piping may be supported on shoes, saddles or steel sections. Effect of support friction especially for large dia pipelines shall be considered and friction forces minimized by suitable arrangement. Piping inside the trenches shall be supported at intervals on steel sections and the arrangement shall permit easy maintenance.

-

02.16

VALVES AND SPECIALTIES -

All valves shall be of approved make and type. All valves shall be suitable for service condition i.e. flow, pressure and temperature under which they are required to operate. The valves for high and medium steam service shall have butt welded ends unless otherwise approved and the internal dia shall be same as that of the pipes to be joined.

-

All gate/ sluice, globe and needle valve shall be fitted with outside screwed spindles and bolted type glands and covers. Spindle glands shall be of the bridge type construction and screwed glands will not be accepted. All high pressure valves having nominal dia more than 150mm, shall have integral steam bypasses concede to the valve body by means of welded joints.

-

All gate/sluice, globe and needle valve shall be provided with hand wheel and position indicator. The face of each hand wheel shall be clearly marked with words “open” and “shut” with arrows to indicate the direction of rotation to which each refers. Arrangement limiting the travel of any valve in the “open” or “shut” position shall be provided exterior to the valve body. All globe valves shall be designed to prevent erosion of valve seats when the valves are operated partially opened. Valves which cannot be operated from the floor or walkways, shall be provided with suitable extension rods and linkages to facilitate operation from the floor or walkways. Chain operation will not be accepted for steam valves. Stems shall preferably be arranged vertically with gland at the top. In no circumstances must the gland be at the bottom. Valves shall not be installed in an inverted position. The design of valves shall be such that it will permit packing of glands under pressure. Where required, valve spindles shall be extended so that the hand wheel is at a height of about 1.0m above the level of the floor or platform from where the valves are to be operated. Where required, they shall be provided with head stocks and pedestals of rigid construction and where gears or bevel wheels are used, these shall be of cast steel or suitable grade cast iron with machine cut teeth.

-

Non return valves on all pumps discharges and steam line shall be of an approved non slamming type. Draining arrangement shall be made on both sides of the horizontal non-return valve where such a valve adjoins an isolating valve. Valve bodies shall be provided with removable access cover to enable the internal parts to be examined without removing the valves. Valves shall have a permanent “arrow” inscription on its body to indicate direction of flow.

-

Gate sluice valves for low pressure service shall be outside screw rising spindle type. For these valves wherever necessary, chain operator shall be provided to operate the valve from the floor or walkways. Larger size gate valves for low pressure applications shall be provided with bypass and draining arrangement and valves with dia more than 350mm shall be provided with gear operator.



GS-02


02.17

-

Valves in corrosive service shall be diaphragm or rubber lined type. Diaphragm shall be of reinforced rubber and rubber lining of body shall have minimum thickness of 3mm. Generally plug valves shall be used in compressed air line. Plug valves shall be supplied with wrench operator. Valves shall be of taper plug type.

-

For motor operated valve, a 415V, 3 phase, 50Hz reversible speed motor shall be furnished. Motor shall be capable of producing not less than 1.5 times the required operator torque. Each operator shall be equipped with two adjustable limit and torque switch for both open and closed position. The motor shall be of high torque low starting current. Each operator shall be provided with auxiliary hand wheel for manual operation. The hand wheel shall automatically disengage when the operator is energized.

-

Manual operator shall be of worm and gear type, having permanently lubricated, totally enclosed gearing with hand wheel diameter and gear ratio designed to meet the required operating torque. The operator shall be designed to hold the disc in any intermediate position between full opened & full closed without creeping and fluttering. Adjustable stop shall be built into the operator to prevent over travel in either direction. Operator shall be equipped with direct coupled position indicator and suitable locking device.

-

Pressure reducing valves shall be perfectly stable, quiet and vibration less in operation when reducing the pressure for any throughput up to maximum and shall be suitable for continuous use at operating temperature. Valves shall be designed to prevent erosion of the valve seats. Safety valves shall be direct spring loaded type and shall have a tight, positive and precision closing. All the safety valves shall be provided with manual lifting lever. Valves used for compressible fluids shall be of pop type. Safety valve shall be so constructed and adjusted to permit the fluid to escape without increasing the pressure beyond 10% above the set blow off pressure. Valve shall reset at a pressure not less than 2.5% and more than 5% of the set pressure.

-

The seat and disc of safety valves shall be of suitable material to resist erosion. The seat of valves shall be fastened to the body of valve in such away that there is no possibility of seat lifting.

FABRICATION AND INSTALLATION OF PIPE WORK -

Pipe joints shall be assembled with the inside of all pipes and fittings smooth, clean and free from burrs, scale, welding slag, sand and dirt. The inside edges of pipe and tubing shall be reamed after cutting to remove burrs. Screw threads shall conform to ANSI B 2.1 for taper pipe threads. All the threaded joints shall be made up with a lubricant or compound suitable for the service under which the piping is to be used.

-

Welded joints shall conform to “Code for pressure piping ANSI B31 1.0 (power piping) or approved equivalent, except where the welding of such joints is covered by other code requirements such as IBR, ASME pressure vessel and boiler code or approved equivalent.

-

Branches shall, in general, be formed by welding standard fittings. Pipe bends and tees shall be truly cylindrical and of uniform sections. Where permitted for certain services, elbows or branch connections may be formed from steel pipe. Unless otherwise agreed, slip-on welding flanges shall be used on pipe and for connection to low pressure equipment. Weld neck flanges shall be used for butt welding fittings as elbows, tees and reducers and for connection to high pressure equipment. Where class 125 ANSI flanges are bolted to 150 ANSI steel fittings, the 1.5mm raised face



GS-02

General Technical Specification on the steel flange shall be removed. When bolting such flanges, a full face gasket shall be used. Equipment terminal flanges, if consist of a different standard, a suitable companion flange shall have to be provided at the connecting points.

02.18

-

Flange drilling shall straddle the natural centre line of pipe. Faces of all flanges shall 0 be 90 to the longitudinal axis of the pipe to which they are attached. Slip-on flange when used, shall be welded in accordance with ANSI B31.1 or any other equivalent code. If distorted after welding, the flange shall be refaced. In all cases, flange faces, must be free from particles of weld metal. The flange face and the pipe projecting end shall then be machined to permit both pipe and flange to bear against.

-

All welding by the electric arc and gas welding process for pipe joints and fabrication shall be done by qualified welders and done according to appropriate IBR, ANSI code / regulations as applicable for welding, subject to accompanying code regulations and standards for filler metal, pressure, temperature and fluid carried. The ends of pipe and welding fittings shall be beveled according to the details shown in ANSI B31.1 or equivalent. All welds shall be made in such a manner that complete fusion and penetration are obtained without an excessive amount of filler metal beyond the root area. The reinforcement shall be applied in such a manner that it will have a smooth contour merging gradually with the surface of adjacent pipe and welded fittings.

THERMAL INSULATION OF PIPELINES Thermal Insulation The tenderer shall furnish heat insulation for all necessary equipment and piping to efficiently prevent abnormal heat loss from all exposed parts to limit surface temperature within 60 deg.C. Resin bonded mineral wool/slag wool, fiber glass, asbestos ropes and preformed pipe sections, mats/mattresses form of insulation conforming to IS:8183/IS:9842/IS:7413 will be acceptable. However, the grades shall be selected considering respective temperature. In case of using loose insulation, proper care shall be taken at site to get recommended density. Packing density of the insulation wool shall be 150 kg/m3. Insulated surface of all equipment, piping, valves and fittings shall be covered with aluminium sheet of 22 SWG (0.8 mm thick) held in place by self tapping screws of nickel plated type. Apart from the screw, joints shall be further sealed with a suitable sealing compound. All fastening materials such as clips, wires for field weld to the equipment, galvanised wire mesh, metal corner bead shall be provided. Where valves, pipes fittings, flanges, etc. occur, a clear space between end of covering and flange shall be left of sufficient length, to permit withdrawal of flange bolts without interference. Ends of the covering at those joints shall be leveled from the outside covering to the pipe and sealed. Flanges, valves bonnet, end flanges and fittings shall be effectively insulated. Valve & flange insulation covers shall be made in two halves so that these may be removed/refitted readily without interfering with the adjacent covering. Protrusions through the insulation which themselves do not require insulation such as pipe clamps, supports, small piping, instrument take-offs, etc. shall be covered to the same thickness as the adjacent insulation and be tightly sealed except at hanger rods. Ample provision shall be made to prevent damage of insulation due to thermal movement of the pipe or equipment. All the services to be insulated shall be cleaned of all foreign materials such as scale, rust and paint by use of steel wire brushes and steel scrapers. Anti corrosion painting (primer coat) shall be applied on hot surfaces before application of insulation



GS-02

General Technical Specification Thickness of Insulation Table for Insulation thickness Pipe size Insulation thickness in mm for various temperature ranges (outside dia) 1000C and below

Between 101 and 0 200 C




Above 5000C

Upto DN 50mm

25

50

50

75

100

100

DN 65 to DN 100mm

25

50

75

100

125

125

DN 125 & DN 150mm

50

75

75

100

125

150

DN 200 mm

50

75

75

125

125

150

DN 250 mm

50

75

100

125

150

150

DN 300 mm

50

75

100

125

150

150

Pipe size (outside dia)

Note: The metallic jacket over the insulation shall be galvanized steel sheet conforming to IS: 277 with following thicknesses: 02.19

Pipe sizes up to 300 mm OD Pipe sizes up to 300 mm OD equipment, flanges, valves

:

0.63 mm

:

0.80 mm

LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS Load Calculations Loads from the piping system are transferred to the pipe supports and connected equipment. Depending on the direction of application, loads shall be calculated under two major heads : • •

Vertical Loads Horizontal Loads Vertical load shall comprise of the following :

-

Platforms Condensate collected in pipeline Dust deposition on pipeline Valves, compensators & fittings Supports, ladders, etc. 2

-

Live load on platform shall be taken as 500 kg/m

-

Platform shall be provided at the following locations :

•

Location of valves

•

Location of compensators



GS-02

General Technical Specification •

Location of condensate drain installation

•

Water seals and tanks for water seals

•

Purging and vent connections

•

Manholes

•

Instruments

Following norms shall be followed for calculating the condensate load of gas mains: Sl. No.

Pipe Dia (mm)

Height of filling of pipe cross-section with condensate (mm)

Filling in cross – section (%)

1.

Upto 500

Full

100

2.

600 – 1400

500

88 – 35

3.

15oo and above

500 - 800

30 - 14

Condensate drain installation shall be located at approximately every 100 m length of the pipeline. Load due to dust deposition shall be as follows: -

50 Kg per m2 area on pipelines at a distance within 100 m from blast furnaces.

-

25 Kg per sq metre area on pipelines at a distance between 100 to 500 from blast furnaces.

Horizontal load along the axis of the pipeline shall comprise the following: -

Load due to thermal expansion

-

Load due to internal gas pressure

-

Load due to friction (sliding of pipes on supports)

Horizontal load transverse to the axis of the pipelines shall comprise the following: -

Load due to wind pressure

-

Load due to component of gas pressure at branch connections

-

Load due to component of force arising from thermal expansion or at change of axis in plan.

For calculating load due to thermal expansion the co-efficient of linear expansion for mild steel shall be taken as 0.012 mm/deg.c/ m. Internal gas pressure for coke oven and blast furnace gas shall be taken as 2000 mmWC (g) (Test pressure for the gas pipeline). Co-efficient of friction for steel to steel shall be taken as follows: Sliding support : 0.30 Roller support

: 0.10

Ball support

: 0.10

IS:875 shall be applicable for calculating the wind load on the stockades. IS:1873 shall be applicable for calculating seismic load.



GS-02


The pipeline stockades shall be designed to take all vertical (dead) as well as horizontal loads.

-

20% extra load (vertical and horizontal) shall be considered for the design of structural and civil work to accommodate future pipeline on the stockades.

Horizontal loads due to thermal expansion, internal pressure and friction shall be calculated by carrying out flexibility analysis on individual pipe. However, wherever possible, standard software package like CEASER-II may be used for carrying out flexibility analysis and calculations of loads transmitted to supports and nozzles of equipment to which piping is connected. 02.20

LOCATION OF PIPE SUPPORTS Supports for pipes shall be provided based on pipe layout. The unsupported span of pipeline between two supports shall be calculated on the following basis; I)

Maximum deflection in the span should not exceed 1/600 of length of the span.

II)

Maximum stress in pipe should not exceed the limit as per design codes.

III)

Maximum permissible spans are indicated below:

Maximum permissible spacing between pipe supports Nominal Pipe size, mm

Maximum span for Liquid service, m

Maximum span for other services, m

25

2.0

2.5

40

2.5

3.0

50

3.0

4.0

65

3.5

4.0

80

5.0

4.5

100

5.0

4.5

150

5.0

6.5

200

6.0

7.0

300

7.0

9.0

500

-

13.5

600

-

15

1000

-

18

1500 and above

-

24

In specific cases where span between two supports can not be provided as per the table, alternative arrangement for intermediate support using bridge between trestles or guy



GS-02

General Technical Specification rope supports may be considered. In exceptional cases where distance exceeds the limiting span, suitable stiffening of pipe section to prevent sagging may be considered. At sliding supports pipe saddle shall be allowed to rest on bearing plate for free movement. In case U-clamps are provided, clearance shall be maintained for pipe movement by providing two nuts on opposite sides. All intermediate supports shall be of sliding type. Anchor supports shall be located based on piping configuration and layout to provide adequate flexibility. Distance between two consecutive fixed supports in straight runs of pipe route should be approx 70 m. However, in special cases it may go up-to 100 m (max.). In no case it should exceed 100 m. However, for steam pipeline it should be limited to 60 m. For pipe dia. above 100 mm cold pull if any during erection may be given as per instructions of the respective drawings. To reduce friction force transmitted to supports, roller supports or anti friction pad supports can also be used. 02.21

FLEXIBILITY ANALYSIS Piping arrangement shall provide for flexibility of lines to take care of the thermal expansion, contraction and equipment settlement. Large reactions or moments at equipment connections shall be avoided . Expansion computation shall be made on the basis of a base temperature of 21.1deg C (70 deg F) and shall cover ( +ve, or –ve ) design temperature(s) as given. i)

Flexibility analysis shall meet the requirement of Code ASME B-31.3 (Latest Edition). Analysis shall consider stress intensification factors as per ASME B31.3.

ii)

Lines which shall be subjected to steam out conditions, shall be designed and analyzed at low –pressure steam design temperature of line whichever is more. Lines having negative design temperature shall be analyzed for both conditions separately.

iii)

Flexibility Analysis of lines shall be carried out using simplified methods or a comprehensive computer program. Comprehensive computer analysis shall be carried out for the piping for lines connected to equipment like vessels, pumps, filters, furnace, compressors or other strain sensitive equipment. The result of the analysis must satisfy the allowable loading on the nozzles of such equipment.

iv)

Piping shall be adequately supported for the weight of piping, water, attached unsupported components, wind, seismic, insulation and any other applicable forces. Care should be taken that these supports are adequate to prevent excessive stress, load or moments in either the piping or terminal nozzles of the equipment to which it is connected. Adequacy of supporting of lines having heavy valves shall be checked. The support shall be indicated in the piping General Arrangement Drawings and Isometrics as applicable.

v)

Safety valve manifolds and downstream of control valves shall be adequately supported to avoid vibrations.



GS-02

General Technical Specification vi)

The following factors shall be considered in the stress analysis -

vii)

Friction for lines >= 8” NB ; @ steel to steel = 0.3: ( Sliding friction), @ steel to Steel =0.1 (Rolling friction), Corrosion Allowance. Initial displacement of nozzles at design temperature(s). Transverse deflections =25 mm( maximum) Longitudinal expansion/contraction = 200 mm (maximum) Special care to be taken to check for expansion loops and shoe support lengths shall be finalized accordingly.

The following shall always be analyzed using comprehensive computer analysis: a) b) c) d) e)

All lines 4” and above and Design Temp.> 300 deg. C. All lines 8” and above and Design Temp. > 150 deg. C. Al l lines 16” and above and Design Temp. > 80 deg. C. All lines 6” and above and Design Temp. > deg. 65 C that are connected to rotating Equipment, Air Coolers or any other sensitive equipment. Any other system/line that stress engineer feels necessary for stress check.

The report shall comprise of the following: -

Basic input data and calculated conditions. Layout isometric and supports configuration. Load cases and calculated member stresses. Forces, moments and displacements reports. Spring hangers design parameters. Allowable Stress Range.

Additional requirements ( reinforcement pad etc.) WIND LOAD CALCULATION Wind pressure shall be taken as per IS : 875. In cyclone prone areas maximum wind pressure due to cyclonic wind pressure shall be taken. In case of multiple pipes, for each tier of pipes, largest pipe may be considered for calculating wind load. 02.22

PIPING MATERIAL SPECIFICATION SCOPE This PMS covers the various piping specification for process Metallurgical plants and its related industrial Installation.

and utility piping in

REFERRED CODES & STANDARDS All piping shall be designed in accordance with relevant latest codes and standards like B 31.1, B 31.3 and different IPSS (Inter plant standard for steel industry) Individual piping material specification has been designed to cover a set of services operating within fixed pressure and temperature.



GS-02

General Technical Specification PIPES Pipe dimension shall be in accordance with ANSI B36.10 : IS:1239, IS:3589 for carbon steel pipe and to B36.10/B36.19 for stainless steel pipe. Pipe made by acid Bessemer process shall not be acceptable. Pipes shall be made by open hearth, electric furnace or basic oxygen process. All pipe threads shall conform to ANSI B1.20.1 except where otherwise noted. FLANGES Flanges shall be in accordance with following codes except where otherwise noted. DN 15 to DN 600 (150 # - 600#)

ANSI/ANSI B16.5 / IS : 6392

Above DN 600 API 605 / ANSI B16.47 / MSS-SP-44/IS:6392/DIN etc. Flanges to MSS-SP-44 or any other std. like DIN, BS etc. may be specified to be made with equipment or valve flanges with corresponding bolting. Finish of steel flange faces shall conform to MSS-SP-6/ ASME B46.1/ASME B16.5. The interpretation shall be as follows : Serrated

:

250 – 500 Mu in AARH

Smooth (125 AARH)

:


For RTJ groves (32 AARH)

:


Bore of WN flanges shall match the ID of the attached pipe Bore of slip on flanges shall suit the pipe OD and its thickness. Dimensions of welded steel flanges for low pressure gas ( Pressure upto 1 kg/cm2) is indicated in Table 06.01 FITTINGS Forged steel socket welded and threaded fittings shall be in accordance with ANSI B 16.11 unless otherwise noted. Butt welded fittings shall be in accordance with ANSI B16.9 unless otherwise noted. Fabricated (site/factory) fittings shall conform to IPSS-06-020-95 unless otherwise specified. Fittings thickness and tolerance shall match pipe thickness and tolerance. Mitres and reducers fabricated from pipe may be used if specified in PMS. Same shall conform to IPSS:1-06-020-95. In no case, thickness of mitres and material shall be inferior to parent pipe. GASKETS Non metallic gasket shall conform to IS:2712. Spiral wound gaskets (SPR, WND) shall conform to API 601/B16.20. Ring type and spiral wound gasket shall be self aligning type.



GS-02

General Technical Specification BOLTING Dimensional std of Bolt/studs and nuts shall conform to B 18.2 / IS:1364-1992 unless otherwise noted. THREADS Threads for threaded pipes, fitting, flanges and valves shall be in accordance with B1.20.1 taper threads unless otherwise noted. 0

Upto 200 C threaded joints shall be made with 1” width PTEE joining tape. 0

Above 200 C threaded joints shall be seal welded with full strength fillet weld. All threaded joints irrespective of pressure and temperature on lines carrying toxic fluid shall be seal welded with a full strength fillet weld. VALVES Face to Face/End to End dimension of valves shall conform to B16.10 to the extent covered. For valves not covered in B16.10. reference shall be made to BS2080 and / or the manufacturer’s drawings. Flange / weld ends of the valve shall be as per the corresponding Flange/Fitting ends of the piping class, unless otherwise specified. Pressure temperature rating for flanges and butt welding end valves shall be as per ANSI B16.34 except for ball, plug & butterfly valves. For these valves refer TABLE FOR PRESSURE TEMP. RATING FOR BALL, PLUG AND BUTTERFLY VALVES Unless called-out specifically, valves shall be as per the following Standards.

Valve

Size DN mm

Rating

Des. Std.

Testing Std.

Gate

15 - 40

800/1500

API-602

API-598

Globe/Check

15 - 40

800/1500

BS – 5352

BS-6755 Pt-I

Gate

50 - 600

150/300/600

API-600

API-598

Gate

650 - 1050

150/300

BS-1414

BS-6755 Pt-I

Globe

50 – 200

150/300/600

BS-1873

BS-6755 Pt-I

Check

50 – 600

150/300/600

BS-1868

BS-6755 Pt-I

900/1500/2500#

B-16.34

API-598/ BS6755 Pt-I

Gate/Globe/Check Ball

15 – 400

BS-5351

BS-6755

Plug

15 – 300

API-599

API-598 /BS5353 BS-6755

Butterfly

80 & above

-

API-609/ BS5155 AWWA C504

API-1898/ BS-6755 Pt-I /AWWA

Diaphram

ALL

-

BS-5156

BS-6755 Pt-I



GS-02

General Technical Specification If not covered above, the valve shall be as per B16.34 and relevant MSS SP Standard DN 50mm and larger steel Gate, Globe & Check valves in Hydrocarbon and utility service shall have bolted bonnets. Pressure seal bonnets or covers shall be used for Class 900# and above to minimize bonnet leakage. However, valves with pressure seal bonnet shall have wall thickness & seal stem diameter as per API600. Welded bonnets or screwed & seal welded bonnets are acceptable for sizes lower than DN 50 for Class 900# & above. PIPING MATERIAL SPECIFICATION SERVICE :

BF Gas, CO Gas, BOF Gas, Corex gas & Mixed Gas

SERVICE CONDITIONS : Maximum Working Pressure 1500mmWC Minimum Working Pressure 50 mmWC

o

Temp 60 C Temp 5 oC

CORROSION ALLOWANCE : 2 m.m. Item

Size Range

Description ERW, PE; Sch Heavy

Dimension Standard IS : 1239 part-1

Material Specification IS:1239 - Black

Pipe

DN 15 to 40 DN 50 to 150

ERW, BE; Sch Heavy

IS : 1239 part-1

IS:1239 - Black

DN 200 to 350

ERW, BE; 6 mm Thk

IS : 3589

IS: 3589 Gr.330

DN 400 to 750

ERW/SWP,BE; 8 mm Thk

IS : 3589

IS: 3589 Gr.330

DN 800 to 3500

Fabricated – SWP, BE; 10mm Thk.

IS : 3589

IS : 2062, Gr.B

Plate shall have copper content of 0.25 to 0.35 % Fittings

Flanges #150

Gaskets

DN 15 to 40

SW /Screwed Fittings (Elbow R=1.5D)

IS : 1239 (P-2)

IS : 1239 (P-2) Black

DN 50 to 150

BW (Elbow R=1.5D)

IS : 1239 (P-2)

IS : 1239 (P-2) Black

DN 200 & above

IPSS-06-20

IS : 2062, Gr.B

Upto DN 150

Fabricated Miters bends & fittings from pipe / plate SORF; Serrated Finish

IS: 2062, Gr.B

DN 200 to 300

SORF; Serrated Finish

DN 400 & above

SORF; Serrated Finish

Upto DN 500

Gasket: Thk. 2 mm Ring Type CAF Asbestos rope graphite impingnated. 8mm

IS : 6392 Table - 5 IPSS:1-06-20 Table 3 IPSS:1-06-20 Table 3 As per Flange

Above DN 500



IS: 2062, Gr.B IS: 2062, Gr.B IS : 2712 Gr W/3

GS-02

General Technical Specification Item

Size Range

Description

Valves (Isolation)

DN 15 to 40

Gate valve; Screwed

DN 50 to 550

Gate valve; Flanged ; Rising stem Gate valve; Flanged; Rising stem

IS : 14846

Check valve SW – Lift Type #800 Check Valve Flanged swing check valve/ dual plate #150

BS 5352

DN 600 and above Non-return

DN 15 to 40 DN 50 and above

Throttling

DN 15 to 40 DN 50 to 300 DN 350 & above

Sampling

DN 15 / DN 25

Bolting

All

Piping Fabrication

Flanged Joints Pipes Joints Fabricated pipes

Globe valve SW / Screwed ; #800 Globe valve; Flanged ; Serrated Finish; #150 Butterfly valve WAF Type; #150 Screwed and lubricated, Tapered Plug valve Bolts Nuts

Dimension Standard API 602

Material Specification Body ASTM A105; Cr 13% Trim Body CI GR. FG 200; SS trim Body IS-2062, Gr. B, SS trim Body A105, 13% Cr Trim CI IS–210 Gr. FG 200

BS 1868 / API 594 IS:5312 part-1 BS: 5153 BS 5352 BS 1873 BS 5155/ API 594 BS: 5158

Body A105, 13% Cr Trim Body CI, 13% Cr Trim Body CI; 13% Cr Trim Body & PLUG : CI IS 210 FG 200

IS: 1364- 1992 IS: 1364- 1992

At valve/ equipment location and for sectionalising & Maintenance. To be kept minimum Butt Welded Fillet welding using semi bandage on each segment.

Temp Connections

DN 40 – Flanged set-on nozzle

Pressure Tapping

DN 20 – SW Half Coupling Nipple Sch 80 with Gate valve to Spec.

Vents

On lines >= DN 50 ; MEC std.

Drains

On lines >= DN 80, MEC Std.

PIPING MATERIAL SPECIFICATION SERVICE : LPG, Propane

SERVICE CONDITIONS : Maximum Operating Pressure 10 kgf /cm2 Minimum Operating Pressure Atm

Temp 60 oC o Temp 5 C

CORROSION ALLOWANCE : 1.5 mm.



GS-02

General Technical Specification Item Pipe

Fittings

Size Range DN 15 to 40

Seamless PE Sch. 80

Dimensional/ Design Standard B 36.10

DN 50 to 150

Seamless BE Sch.40

B36.10

DN 200 to 300

Seamless BE Sch.20

B36.10

DN 350

Seamless BE Sch.10

B36.10

DN 15 to 40

SW / Screwed Fittings # 3000 (Elbow R=1.5D) BW Fittings #150 (Elbow R=1.5D) Miter bends & fittings fabricated from pipe SW:RF : Serrated Finish; #150 SORF : Serrated Finish; #150 Gasket : Thk. 2.0 mm Ring type CAF Gate valve SW # 800

ANSI B 16.11

ASTM A106 GR.B, Seamless ASTM A106 GR.B, Seamless ASTM A106 GR.B, Seamless ASTM A 105

ANSI B16.9

ASTM A234 Gr WPB

IPSS-1-06-020

Same as parent pipe

B 16.5

ASTM A 105

B 16.5

ASTM A 105

B 16.21

IS : 2712 Gr W/3

API 602

Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A216 Gr.WCB 13% Cr. Trim

DN 50 to 150 DN 200 & above Flanges

DN 15 to 40 DN 50 & above

Gaskets

All sizes

Valves

DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200 DN 15 to 40 DN 50 to 600 DN 15 to 150

Description

Gate valve Flanged RF Serrated Finish # 150 Globe valve, SW # 800

API 600

Globe valve : Flanged RF Serrated # 150 finish Check valve SW # 800 Lift type Check valve flanged RF Serrated finish # 150 Ball valve flanged RF Serrated finish #150

BS 1873

ANSI B 16.5 SRF

ANSI B 16.5 SRF BS 1868 BS 5351

Material Carbon Steel ASTM A106 GR.B, Seamless

Bolting

All

Studs / Bolts Nuts

B 18.2 B 18.2

ASTM A193 Gr B7 ASTM A194 Gr 2H

Miscellan e-ous

DN 15 to 40

TRAP #150, THRMDNMC

MANF’ STD.

BODY A105, TRIM 13% CR , S: SS304

DN 15 to 40

PERM. STR, SW, Y Type

MANF’ STD.

BODY A105: INT.SS 304

DN 50 to 350

PERM. STR, BW, T Type

MANF’ STD.

BODY A234WPB : INT SS 304

DN 400 to 600

PERM. STR, BW, T Type

MANF’ STD.

BODY A234WPBW: INT SS 304

Above DN 600

TEMP. STR, FF, CONE Type

MEC’ STD.

BODY A516GR. 70: INT SS 304



GS-02

General Technical Specification Item Piping Fabricatio n

Size Range Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Drains

Description

Dimensional/ Material Design Carbon Steel Standard At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec. Gate DN 40 – Flanged set-on nozzle On lines <= DN 40 ; MEC std. On lines <= DN 40 ; MEC std.

PIPING MATERIAL SPECIFICATION SERVICE : Fuel oil, LSHS 2

o

SERVICE CONDITIONS : Maximum working pressure 10 kg /cm (g) and temp 70 C Minimum working pressure 1 kg /cm2 (g) and temp 5o C CORROSION ALLOWANCE : 2 m.m.

Item

Size Range

Description

Pipe

DN 150 and below DN 200 to 450

ERW, Plain ends, Sch. – Medium ERW Pipe

DN 50 and below

Fabricated from pipes by cold bending with radius 3 DN / 3000 lbs forged carbon steel, SW Seamless BW elbow Sch40 Mitred bends with radius 1.5 DN 3000 lbs, forged carbon steel, SW Seamless BW, carbon steel Sch. – 40 / Fabricated

Pipe Fittings Bends

DN 65 to 200

Tees / Reducers

DN 250 and above DN 50 and below DN 65 and above

Screwed fittings Bolting Gaskets

DN 50 and above All sizes All sizes

Flanges

All sizes


Compressed asbestos, 1.5 mm thick Plate flanges made from

Dimensional/ Design Standard IS:1239 (part1)

IS:1239 – Black

IS: 1978 API 5L Gr.B

IS: 1978 API 5L Gr.B

ANSI B16.11

ASTM A 105

ANSI B 16.9 From parent pipe

ASTM A-234 Gr. WPB From parent pipe

ANSI B16.11

ASTM A105

ANSI B16.11

ASTM A-234 Gr. WPB IS:1239 – Black

IS:1239 (part II) IS:1367 IS:2712 IS:6392 (table 17)


Material Carbon Steel

IS:1367 IS:2712 Gr. 0/2 IS:2002 Gr. 2A GS-02


Valve Isolation

Size Range

carbon steel plates with bore to suit pipe OD DN 50 and below

DN 65 and above Throttling

DN 50 and below

DN 65 and above

Nonreturn

DN 50 and below

DN 65 and above

Filter Hose assembly

Description

DN 50 and below

DN 65 and above

Cast steel lubricated taper plug valve, screwed similar to AUDCO fig MW-32 / plug valve Cast steel lubricated taper plug valve, screwed similar to AUDCO flanged ends Forged steel globe valve with regular type discs, SS rising spindle, Screwed ends Cast steel globe valve with regulating type discs, SS renewable seat rings, outside screw with rising stem, flanged / globe valve Forged steel check valve, body and cap material, screwed ends / forged steel check valve Cast steel swing check valve with renewable seat rings, flanged generally, flanged / cast steel check valve. Self cleaning filter operating on the principle of edge filtration 15 m long hose with swivel SAE female coupling at both ends and adaptor at one end Flanged ends

Dimensional/ Design Standard


IS:10459

IS:10459

IS:23

IS:23 ASTM A105, ASTM A182, Gr. F6

IS:10605

IS:10605

IS:10989

IS:10989 BS 5153

Body and cap: ASTM A 105, Trim material: ASTM A 182, Gr. F6 IS:5312 (part1), BS 5153

IS: 635

IS: 635

IS: 635

IS: 635

PIPING MATERIAL SPECIFICATION SERVICE : MEDIUM PRESSURE NITROGEN , ARGON, & COMPRESSED AIR SERVICE CONDITIONS : Maximum Operating Pressure 10.5 kgf /cm2 Minimum Operating Pressure Atm

o

Temp 60 C o Temp 5 C

CORROSION ALLOWANCE : 1.5 m.m.



GS-02


Size Range

Description

Pipe

DN 15 to 40

Fittings

ERW, PE Sch. HEAVY

Dimensional/ Design Standard IS:1239 – part-1

IS:1239 BLACK

DN 50 to 150

ERW, BE Sch. HEAVY

IS:1239 – part-1

IS:1239 BLACK

DN 200 to 350

ERW, BE , THK 6.0mm

IS:3589

IS:3589 GR.330

DN 400 to 500

ERW, BE , THK 8.0mm

IS:3589

IS:3589 GR.330

DN 550 to 600 DN 650 & above

ERW BE Thk. 10.0mm ERW/ SAW, BE Thk. 10.0mm (min)

IS:3589 IS:3589

IS:3589 GR.330 IS:3589 GR.330

DN 15 to 40

SW / Screwed Fittings # 3000 (Elbow R=1.5D) BW Fittings #150 (Elbow R=1.5D)) Miter bends & fittings fabricated from pipe SW:RF : Serrated Finish #150 SORF : Serrated Finish #150

ANSI B 16.11

ASTM A 105

ANSI B16.9

ASTM A234 Gr WPB

IPSS-1-06-020

Same as parent pipe

B 16.5

ASTM A 105

IS:6392 Table-11

IS:2062 Grade B

B 16.21

IS : 2712 Gr W/3

API 602

Body ASTM A105 ; 13% CR Trim Body ASTM A216 Gr. WCB 13% Cr Trim Body ASTM A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body ASTM A105; 13% Cr Trim

DN 50 to 150 DN 200 & above Flanges



Gaskets

All sizes

Valves

DN 15 to 40

Gasket : Thk. 2.0 mm Ring type CAF Gate valve SW # 800

Isolation

DN 50 and above

Gate valve Flanged RF Serrated Finish # 150

API 600

DN 15 to 40

Globe valve, SW # 800

BS 5352

DN 50 and above DN 15 to 40

Globe valve : Flanged RF Serrated # 150 finish Check valve SW # 800 Lift type

BS 1873

DN 50 and above

Check valve flanged RF Serrated finish # 150

BS 1868

Bolting

All

Studs / Bolts Nuts

B 18.2 B 18.2

Miscellaneous

DN 15 to 40

TRAP #150, THRMDNMC

MANF’ STD.

BODY A105, TRIM 13% CR , S: SS304

DN 15 to 40

STRAINER, SW, Y Type

MANF’ STD.

DN 50 and above

STRAINER, BW, T Type

MANF’ STD.

BODY ASTM A105 : INT SS 304 BODY A234WPB : INT SS 304

Flanged Joints

At valve/ equipment location and for sectionalizing & maintenance To be kept minimum Butt Welded

Throttling

Non-Return

Piping Fabrication

Pipes Joints


BS 5352


Body ASTM A216 Gr.WCB 13% Cr Trim ASTM A307 Gr B ASTM A563Gr B

GS-02


Size Range Pressure Tapping

Description

Dimensional/ Material Design Carbon Steel Standard DN 20 – SW half coupling Sch 80 Nipple with Gate valve to spec.

Temp Connections Vents

DN 40 – Flanged set-on nozzle On lines <= DN 40 ; MEC std.

Drains

On lines <= DN 40 ; MEC std.

PIPING MATERIAL SPECIFICATION SERVICE : HIGH PRESSURE NITROGEN , ARGON SERVICE CONDITIONS : Maximum Operating Pressure 40 kgf /cm2 Minimum Operating Pressure 10.5 kgf /cm2


CORROSION ALLOWANCE : 1.5 mm. Item

Size Range

Description

Pipe

DN 15 to 40

Fittings

Seamless PE Sch. 80

Dimensional/ Design Standard B 36.10

ASTM A106 Gr.B

DN 50 to 150

Seamless BE Sch.40

B36.10

ASTM A106 Gr.B

DN 200 to 250

Seamless BE Sch.30

B36.10

ASTM A106 Gr.B

DN 300 to 350

Seamless BE Sch. Std.

B36.10

ASTM A106 Gr.B

DN 400 to 600

Seamless,

B36.10

ASTM A 106 Gr.B

DN 15 to 40

ANSI B 16.11

ASTM A 105

ANSI B16.9

ASTM A234 Gr WPB

ANSI B16.9

ASTM A234 Gr WPB

B 16.5

ASTM A 105

B 16.5

ASTM A 105

API 601

SS 304 SPR. WND + CA FIL Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim

Gaskets

All sizes

SW Fittings # 3000 (Elbow R = 1.5D) BW Fittings, Seamless (Elbow R = 1.5D) BW Fittings, Seamless (Elbow R = 1.5D) SW:RF : Serrated Finish #600 SW:RF : Serrated Finish #600 SPIRAL; THK. 4.4 mm

Valves

DN 15 to 40

Gate valve SW # 800

API 602

Isolation

DN 50 to 600

API 600

Throttling

DN 15 to 40

Gate valve Flanged RF Serrated Finish # 300 Globe valve, SW # 800

DN 50 to 350 DN 400 to 600 Flanges



BS 5352



GS-02


Nonreturn

Size Range

Description

DN 50 to 200

Globe valve : Flanged RF Body A216 Gr.WCB Serrated # 300 finish 13% Cr Trim Check valve SW # 800 lift BS 5352 Body A105; 13% Cr type Trim Check valve flanged RF BS 1868 Body A216 Gr.WCB Serrated finish # 300 13% Cr Trim Studs /Bolts B 18.2 ASTM A193 Gr B7 Nuts B 18.2 ASTM A194 Gr 2H At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.

DN 15 to 40 DN 50 to 600

Bolting

All

Piping Fabricatio n

Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Drains

Dimensional/ Design Standard BS 1873


DN 40 – Flanged set-on nozzle On lines <= DN 40 ; MEC std. On lines <= DN 40 ; MEC std.

PIPING MATERIAL SPECIFICATION SERVICE :

INSTRUMENT AIR

SERVICE CONDITIONS : Maximum Operating Pressure Up to 10.55 kgf /cm2 RATING

o

Temp 65 C

: # 150 Matching Companion Flanges of Valves & flow components as per corresponding rating.

CORROSION ALLOWANCE : NIL Item

Size Range

Description

Pipe

DN 15 to 40

ERW ; Screwed end HEAVY

Fittings

DN 15 to 40

Flanges

DN 15 to 40

Screwed Fittings # 3000 Screwed :RF : Serrated Finish #150 Blind Flanged RF : Serrated Finish #150

DN 15 to 40

DN 50 and above Gaskets

All sizes

Valves Isolation

DN 15 to 40


Dimensional/ Design Standard IS:1239, Portal

Material Carbon Steel IS:1239 (PART-I) GALV.

ANSI B 16.11

ASTM A 105 (GALV.)

B 16.5

ASTM A 105 (GALV.)

API 590

ASTM A 105 (GALV.)

Flange ; FF Serrated Finish #150 Gasket : Thk. 2.0 mm Ring type

B 16.5

ASTM A 105 (GALV.)

B 16.21

IS : 2712 Gr W/3

Gate valve SCRF; # 800

API 602

Body ASTM A105 ; 13% CR Trim


GS-02


Size Range

Description

Throttling

DN 15 to 40

Globe valve, SCRF; # 800

Nonreturn Bolting

DN 15 to 40

Check valve SCRF; # 800 Lift type M/C BOLT

B 18.2

Nuts

B 18.2

Piping Fabricatio n

All

Dimensional/ Design Standard BS 5352 BS 5352

Material Carbon Steel Body ASTM A105; 13% Cr Trim Body ASTM A105; 13% Cr Trim ASTM A307 Gr B (GALV) ASTM A563 Gr B, (GALV)

Flanged Joints Pipes Joints

Screwed Coupling

Temp. Conn.

Flanged Installation as MEC std.

Pressure Tapping Vents Drains

DN 20 – SW half coupling Nipple HEAVY with Gate valve to spec. MEC std. MEC std. PIPING MATERIAL SPECIFICATION

SERVICE :

LOW PRESSURE STEAM, MEDIUM PRESSURE STEAM, CONDENSATE & BOILER FEED WATER

SERVICE CONDITIONS : Maximum Operating Pressure 18 kgf /cm2

o

Temp 360 C

CORROSION ALLOWANCE : 1.5 m.m. Item

Size Range

Description

Pipe

DN 15 To 500

Carbon steel seamless pipe with bevel ends

Dimensional/ Design Standard ANSI B 36.10


ANSI B 16.11

ASTM A 105

ANSI B 16.9

ASTM A234 Gr. WPB, Sch 40

ANSI B 16.11

ASTMA 105

ASTM 106 GR.B or equivalent

Pipe Fittings Welded Fittings Bends

Below DN 50

DN 50 to 500

Tees / Reducers

Below DN 50


Bends fabricated from pipes by cold bending with 3D radius and socket welded ends, 3000# Forged carbon steel elbow, 3000# with socket welded ends. Bends fabricated from pipes by cold/hot bending with 3D radius, 3000# Forged seamless carbon steel LR elbow with butt welded ends, 3000# Forged carbon steel Tees / Reducers with socket welded ends


GS-02


Size Range

Description

DN 50 to 500

Forged seamless carbon steel Tees / Reducers with butt welded ends Bolts / studs / Nuts

Bolting

All sizes

Gaskets

All sizes All sizes

Flanges

All sizes

Compressed Asbestos Gaskets for condensate and LP stream Spiral wound SS304 with CA filler for MP stream SO/ WN / Blank flanges RF 125 AARH made from carbon steel plates / Forged carbon steel flanges

Dimensional/ Design Standard ANSI B 16.9

IS 2712 Gr W/3, 1.5 mm thick

Material Carbon Steel ASTM A234 Gr. WPB, Sch 40 Bolts / Studs ASTM A193 Gr B7. Nuts ASTM A194 Gr. 2H

ANSI B 16.5

IS 2002 Gr. 2A

ANSI B 16.5

A105 / A 234 Gr. WPB

API 602/BS 5352

Body / Bonnet to ASTM A105, Stem / trim SS to AISI 410 (13% Cr) Body / Bonnet to ASTM A216 Gr. WCB, Stem / Trim SS to AISI 410 (13% Cr) Body / Bonnet to ASTM A105, Stem / trim SS to AISI 410 (13% Cr) Body / Bonnet to ASTM A216 Gr WCB, Stem / Trim SS to AISI 410 (13% Cr%) Body / Disc / Cover to ASTM A105, Internals / Trim SS to AISI 410 (13% Cr) Body / Disc / Cover to ASTM A216, Grade WCB Internals / Trim SS to AISI 410 (13% Cr)

Valves Isolation

Below DN50

DN50 and above

Throttling

Below DN50

DN50 and above

Non return

Below DN50

DN50 and above

Strainer

Hose assembly


Forged carbon steel gate valve, Class 800/900 with rising stem and socket welded ends. Cast carbon steel gate valve, Class 150/300 (for MP steam) with rising stem and BW/ Flanged ends Forged carbon steel globe valve class 800/900 with rising stem and socket welded ends Cast carbon steel globe valve class 150 / 300 (for MP steam) with rising stem and BW / Flanged ends Forged carbon steel swing check / piston lift valve class 800/900 with socket welded ends. Cast carbon steel swing check valve Class 150/300 (for MP steam) with rising stem and BW / Flanged ends Strainer with cast steel body and brass strainers of 16 G sheet with 1.25 mm diameter perforation @ 20 per cm2 and SW / Flanged ends. Metallic hoses of 15 m length complete with screwed female swivel couplings at both the ends

API 600

BS 5352

BS 1873/ API 600

BS 1868

BS 1868

Manufacturer’s Standard

Manufacturer’s Standard


GS-02


Size Range

Description

Steam trap

50 and below

Thermodynamic steam trap with inbuilt strainer, Class 800/900 and SW ends

Dimensional/ Design Standard Manufacturer’s Standard

Material Carbon Steel Body / Cap / Plug A743 Gr CA 40

Note: 1. Class 150 for condensate and LP steam 2. Class 300 for MP steam 3. For feed water, schedule / thickness of pipe fittings and class ratings are to be selected by the tenderer based on pressure and temperature of feed water. PIPING MATERIAL SPECIFICATION SERVICE :

MEDIUM PRESSURE OXYGEN

SERVICE CONDITIONS : Maximum Operating Pressure 16 kgf /cm2

o

Temp 60 C

CORROSION ALLOWANCE : 2 m.m. Cleaning, Pickling, Passivation & Degreasing As Per IGC / IPSS code Item

Size Range

Description

Pipe

DN 6 to 10

Seamless Tube

DN 15 to 40

Seamless PE Sch. 80

B 36.10

DN 50 to 150

Seamless BE Sch.40

B36.10

ASTM A106 GR.B

DN 200 to 300

Seamless BE Sch.40

B36.10

ASTM A106 GR.B

DN 350 to 600

Seamless BE Sch.40

B36.10

ASTM A106 GR.B

DN 50 to 150

Copper Pipe

B36.10

Deoxidised non Arsenic Copper

DN 200 to 600

Copper Pipe

B36.10


DN 15 to 40

ANSI B 16.11

ASTM A 105

DN 50 and above

SW Fittings # 3000 BW Fittings

ANSI B16.9

ASTM A234 Gr WPB

SW:RF : Serrated Finish WNRF : Serrated Finish PTFE LOX GRADE

B 16.5 B 16.5 B16.21

ASTM A 105 ASTM A 105

Gaskets

DN 15 to 40 DN 50 above All sizes

Valves

DN 15 to 40

Ball valve class 800 for isolation purpose Flanged ends (class 300)

BS 5351

Body A182 GR. 304; /BRONZE ;13% Cr Trim / BRONZE

Fire Breaker

Fittings

Flanges




Material Carbon Steel Deoxidized nonArsenic Copper or Aluminum Carbon Steel, ASTM A106 GR.B

GS-02


Size Range

Description

DN 50 and above

Ball valve class 300 for isolation purpose Flanged ends (class 300) Globe valve class 800 for throttling purpose, flange end (class 300)

DN 15 to 40

DN 50 and above

Dimensional/ Design Standard API 600 BS 5352

Material Carbon Steel Body A351 GR. CF8; /BRONZE ;13% Cr Trim / BRONZE Body : Bronze Trim: Bronze

Globe valve class 300 for throttling purpose with flange end Check valve class 800 with flanged end class 300

BS 1873

Body : Bronze Trim: Bronze

BS 5352

DN 50 and above

Check valve class 300 with flanged end

BS 1868

DN 15 & Above

Ball valve flanged RF Serrated finish

BS 5351

Body A182 GR. 304; /BRONZE ;13% Cr Trim / BRONZE Body A351 GR. CF8; /BRONZE ;13% Cr Trim / BRONZE Body A351 GR.CF8 ; A182 GR. 304 Trim;PTFE Seat

DN 15 to 40

PIPING MATERIAL SPECIFICATION SERVICE :

HIGH PRESSURE OXYGEN

SERVICE CONDITIONS : Maximum Operating Pressure 40 kgf /cm2 Minimum Operating Pressure 16 kgf /cm2 RATING :


# 300 Matching Companion Flanges of Valves & flow components as per corresponding rating.

CORROSION ALLOWANCE : 2 m.m. Cleaning, Pickling, Passivation & Degreasing As Per IGC / IPSS code Item

Size Range

Description

Pipe

DN 6 to 10

Seamless tube

DN 15 to 40

Seamless PE Sch. 80

B 36.10

DN 50 to 150

Seamless BE Sch.40

B36.10

ASTM A106 GR.B

DN 200 to 250

Seamless BE Sch.40

B36.10

ASTM A106 GR.B




Material Carbon Steel Deoxidized nonArsenic copper or Aluminum Carbon Steel, ASTM A106 GR.B

GS-02


Fire Breaker

Fittings

Size Range

Description

DN 300 to 600

Seamless BE Sch.40

Dimensional/ Design Standard B36.10


DN 50 to 150

Copper Pipe

B36.10


DN 200 to 600

Copper Pipe

B36.10


DN 15 to 40

SW Fittings # 3000

ANSI B 16.11

ASTM A 105

ASTM A106 GR.B

DN 50 and above

BW Fittings

ANSI B16.9

ASTM A234 Gr WPB

Flanges

DN 15 to 40

SW:RF : Serrated Finish;

B 16.5

ASTM A 105

DN 50 and above All sizes

WNRF : Serrated Finish PTFE LOX GRADE

B 16.5 B16.21

ASTM A 105

Gaskets Valves

DN 15 to 40

Ball valve class 800 for isolation purpose flanged ends (class 300) Ball valve class 300 for isolation purpose flanged ends (class 300) Globe valve class 800 for throttling purpose, Flanged ends (class 300) Globe valve class 300 for throttling purpose, Flanged ends (class 300) Check valve class 800, with flanged ends (class 300)

BS 5351

Body A182 GR. 304; /BRONZE ;13% Cr Trim / BRONZE Body A351 GR. CF8; /BRONZE ; Trim:13% Cr / BRONZE Body: Bronze Trim: Bronze

Check valve class 300 with flanged ends

BS 1868

DN 50 and above DN 15 to 40 DN 50 and above DN 15 to 40 DN 50 and above

A)

API 600 BS 5352 BS 1873

Body: Bronze Trim: Bronze

BS 5352

Body A182 GR. 304; /BRONZE ;trim 13% Cr / BRONZE Body A351 GR. CF8; /BRONZE ; Trim:13% Cr / BRONZE

Erection of BF Gas, Cold Blast, Nitrogen, Instrument Air, Steam and LPG Pipelines 01

General

02

Before erection, the equipment, valves and other fittings to be mounted on pipelines/ equipment should be dismantled, (only if required), cleaned, oiled and reassembled. Glands shall be packed with suitable materials as per approved drawings.

-

All elements of the pipelines system shall be erected at site strictly as per the drawings approved by the / Consultant.

-

Any modification to be carried out at site, shall have the prior approval of / Consultant’s representatives.

-

While erecting, pipelines shall rest uniformly on each support. Yokes, if provided, shall not allow lateral movement of pipes.



GS-02


Matching faces of flanges shall be perpendicular to the axis of pipelines. Use of gaskets of unusual thickness to fill gap between flanges shall not be allowed.

-

For horizontal pipes, the flanges shall be erected such that top two bolt holes are displaced by half pitch from the vertical axis of the flange.

-

Flanges of adjoining pipes shall be located in staggered manner. Flanged joints shall be laid as close to the support as possible.

-

Bends for steam pipes shall have a radius of not less than times the nominal pipe dia unless otherwise specified.

-

In general pipes are to be joined by butt welding. However, steam service pipelines 40 mm & lower sizes shall be joined by socket welding.

-

For insulated pipe, steel protectors for the insulation shall be provided at points where the pipe is supported on rollers, slides or other equipment where contact with such members is required outside the insulation.

-

In case the location of spindle wheel of valves is not clearly shown in the erection drawings, the same shall be located in a manner as to facilitate easy operation from ground level of nearest operating platform.

-

For making pipe bends/ elbows at site using hot/ clod bending process, the decrease in the pipe thickness shall not be more than 15% of the pipe thickness.

-

After erection of pipelines, the holes made in the walls shall be covered with bricks & mortar. A gap of 10 to 20 mm shall be kept between wall and the pipe for the movement due to thermal expansion. The gap shall be filled with felt/ asbestos.

-

Holes made in the roof shall be covered with removable CGI sheets.

-

The trenches for pipes shall be covered with removable chequered plate covers/ concrete slabs as per the drawings.

-

All pipeline branches not connected to equipment shall be closed using blank flanges and gaskets.

03

Welding of pipelines

-

All pipelines shall be joined by welding. Flanged joints shall be used for connecting the pipe with equipment, valve or fitting.

-

Electric arc welding shall be used for joining pipes, support, structures, etc.

-

All manufactured pipes shall be joined by butt welding. Large dia pipes, fabricated from sheets, shall be joined by fillet welding using semi- bandages attached to each section being joined.

-

Welding shall be done by qualified welders. Code of practice as per relevant Indian Standards shall be followed for the welding procedure, use of electrodes, etc.

-

Proper edge preparation and preheating of edges to be welded, whenever required, shall be ensured before welding.

-

After every 50 butt welded joints of gas pipeline, one test sample shall be welded by the same welder. Tensile teat and bend test shall be performed as per IS :814 to check the strength of welding. Four test samples shall be made from the test piece, two each for tensile and bend test.



three

GS-02


Tensile strength shall not be less than 34 kg / mm2 and elongation less than 12 %.

-

Angle of bend at the appearance of first crack shall not be less than 70 deg.

-

Visual inspection shall be done for all welded joints to check for following possible defects :

-

Surface cracks on weld metal or parent metal.

-

Fusion or cuts at the joining of weld metal and parent metal.

-

Sponginess or porosity on the surface of weld.

-

Non-uniform thickness or distortion in case of fillet welds.

-

Deviation in the pipe axes or dimension of the joint.

-

All defective spots found shall be chipped off and re-welded.

-

For high pressure pipes, radiographic examination of welds shall be carried out as per IS : 2825.

04

Link lengths and tolerances

-

Straight sections of gas pipelines shall be manufactured as separate links and joined at site by butt welding.

-

Link lengths for pipes shall be as follows :

i)

ii)

a)

Up to 13 m : for pipes with dia 1400 mm or less.

b)

Up to 26 m : for pipes above 1400 mm dia.

Following tolerances are allowed :

For length of links : a)

+/- 3 mm for length up 1 m

b)

+/- 0.5 % for length more than 1 m, total deviation shall not exceed 10 mm for every 10 m or part thereof .

Deviation in the pipe axis from the straight line : Upto 0.12% of the link length but not more than 15mm for links with length more than 10 m. Deviation shall be checked by stretched cord.

iii)

For distance between the contacting surfaces from the geometrical axis for bends, tees, crosses and other pipe fittings. +/- 3 mm for distance upto 500 mm . +/- 0.5% or 10 mm maximum for distance more than 1 m. However, for BF gas and CO gas pipelines, the tolerance shall be limited to +/- 1.5 mm only.

iv)

Deviation of pipe axes at the joining point from the diametral plane of pipes: 2 mm, irrespective of link length.

v)

For distance between two adjacent connections on a pipe : +/- 2 mm for each length but not more than +/- 5 mm overall.

vi)

Distortion of the contacting surface of flange relative to the geometrical plane perpendicular to the pipe axis : 0.004 times the outer diameter of the flange at the periphery.



GS-02

General Technical Specification vii)

Tolerance for clearance between flanges and flange rings : Not more than 2 mm. 05

Erection of valves and fittings

-

Before erection, the valves, cocks and other fittings, to be mounted on pipelines, shall be dismantled, cleaned, oiled and reassembled. Glands shall be packed with suitable materials as per approved drawings.

-

All moving parts of the pipe fittings should move freely without jamming.

-

Valves shall be tested hydraulically for leakage by applying pressure on up stream side with valve in closed position.

-

Bolts & nuts shall be cleaned and lightly oiled.

-

Proper grades of gaskets shall be used for erection as per approved drawings.

Testing of BF Gas, Cold Blast, Nitrogen, Instrument Air, Steam and LPG pipelines -

Preliminary acceptance test for erected pipelines shall be carried out as follows :

a)

Checking of metal marked as per manufacturer’s certificate/ approved drawings.

b)

Checking of test result of mechanical tests for welding/ radiographic tests.

c)

Visual examination of welds.

d)

Dimensional checks as per the approved erection drawings.

e)

Checking of welded joints by chalk kerosene test.

-

In case defects are found by visual examination, these shall be rectified prior to leakage test.

-

Checking of proper installation of supports, expansion joints, valves and fittings.

-

The pipeline shall be cleaned from inside, all debris removed and pipeline blown with air to remove all dirt, rust particles, etc.

Strength and leakage test for BF gas, Cold Blast, Nitrogen, Instrument air, Steam and LPG pipelines : Test fluid for BF gas, Cold blast and LPG shall be air and for Nitrogen, Instrument air & Steam service pipelines, test fluid shall be water. All mounted equipment / instruments, control valves, etc. on pipelines shall be temporarily replaced by spool pieces. End connection near equipment connection shall be temporarily disconnected and blanked. For BF gas, test pressure equivalent to 1.25 times the maximum operating pressure but 2 not less than 0.2 Kgf/cm (g) shall be applied using air as per the certified drawings and instructions of OWNER/ MECON for ascertaining the strength. For cold blast, compressed air, nitrogen & LPG test pressure shall be 1.25 times the maximum working pressure. For steam service pipelines test pressure shall be 1.5 times the maximum working pressure. a)

For BF gas, cold blast, compressed air, nitrogen & LPG pressure test shall be carried out by maintaining the test pressure indicated above for a minimum period of 1/2 hour. For steam pipes, the minimum duration shall also be 1/2 hour.



GS-02

General Technical Specification b) c) d)

During pneumatic test, pressure shall be gradually reduced to 1.1 times the operating pressure to check the leakage by soap solution. Test duration shall be minimum 2 hours. Soap solution shall be applied to the weld surfaces / flanges to check for any leakage. Any defect found shall be rectified after releasing the test pressure and after rectification of defects the test shall be repeated. During pneumatic tests of all gas pipelines pressure and temperature readings shall be taken at the beginning and end of the test. The percentage pressure drop (P) shall be calculated as follows : P = 100 (1 - P2 / P1 X T1/ T2) Where P1 and P2 are absolute pressure in the pipe at the beginning and end of test and T1 and T2 are absolute temperature at the beginning and end of the test.

e)

The maximum allowable pressure drop in all gas pipelines shall not exceed 1.0 % per hour for outdoor pipelines during pneumatic test. For pipeline subjected to hydro test, no leakage is permissible

1)

High pressure pipelines shall be tested as follows :

a)

Pipe sections shall be disconnected from the equipment using blank flanges.

b)

Vents shall be provided at high points for air release during pipe filling. The vents shall be plugged with threaded nipples after the tests.

c)

Tests shall be carried out before painting of the pipelines and before application of insulation.

d)

Pipe upto 300 mm diameter shall be tested hydraulically for strength by applying test pressure equivalent to 1.25 times the operating pressure. Test pressure shall be maintained for 30 minutes and then gradually reduced to the operating pressure. For steam pipelines test pressure shall be 1.5 times the working pressure and duration 2 hrs.

e)

Leakage from welded joints shall be checked by tapping with light hammer. No sweating should occur on the weld surface. Test shall be considered satisfactory if no visible leakage is found and pressure in pipeline remains steady.

f)

In case hydraulic testing is not feasible, test shall be carried out by compressed air. Leakage from joints shall be checked by soap solution.

g)

Test for tightness shall be carried out using compressed air at the operating pressure, the test pressure shall be held for 12 hours. The percentage pressure drop calculated as per formula given in para ( g ) of previous clause shall not exceed. Commissioning of BF gas, Cold Blast, Nitrogen, Instrument Air, Steam and LPG pipelines Pipelines shall be commissioned only after successful completion of preliminary acceptance test, strength tests and leakage tests. All valves and regulating devices shall be checked for smooth & proper operation. All safety relief valves shall be checked and set at required pressure setting. All instruments, interlocks, etc., shall be checked. Charging of BF Gas & LPG Pipelines shall be commissioned only after successful completion of acceptance tests, strength tests and leakage tests.



GS-02


Before charging the pipelines with fuel gas, the entire air from purged with nitrogen / Steam.

002

Before purging, all valves shall be set at required position, drain pots filled with water, all hatches & manholes closed. All bleeders except the ones used for venting the purge gas, shall be closed.

003

Discharge from the pipeline shall be through bleeder / vents only. The air / gas should not be discharged into the shop / furnace.

004

Completion of purging shall be determined by taking samples from the bleeders. When the oxygen content of two successive samples is less than 1%, the purging shall be deemed to be completed.

005

After purging is complete, the gas shall be gradually charged into the pipelines. The charging shall be done section wise gradually approaching the consumer end. -

the

pipeline

shall

be

The gas shall be discharged through bleeders only. Exhaust gas from bleeders can be set on fire.

Completion of filling shall be determined by taking samples from the bleeders. In case oxygen content of two successive samples is less than 1 % the gas blowing shall be deemed to be complete. All activities of gas pipe purging and charging shall be co-ordinated in presence of OWNER/ MECON, safety personnel, fire tenders, etc.

006 007

After charging the gas into the system, all isolating devices, instruments, controls, safety devices, condensate seal pots, etc. shall be again checked for proper operation. Charging of cold blast, nitrogen, Compressed Air

008

After pressure test, the nitrogen and instrument quality compressed air line / cold blast line shall be purged with nitrogen and dry air respectively for removal of moisture, dirt , etc. from the piping system.

009

Nitrogen, Instrument quality compressed air, cold blast shall be subsequently charged in the line by connecting with the existing network. Charging of Steam.

B)

010

After pressure test steam pipeline shall be depressurised and drained of water fully through drains/ by pass of steam traps. Subsequently, the pipeline shall be charged with steam slowly by crack opening the steam supply valve keeping all drain points open.

011

When steam is observed from all drain points and consumer ends then steam valve at the inlet to the system should be fully opened and all by pass valve on drains closed and isolation valve on steam traps are kept open.

Oxygen pipelines 01

General -

All work concerning oxygen pipeline system shall be done by persons of contractor well conversant with the oxygen service and having proven ability in the field.

-

All safety aspects with regards to selection of materials, erection procedure, degreasing, testing and commissioning procedures, cleanliness, etc. shall be kept in view by all personnel connected with the job.

-

Erection of pipes, fittings, instruments, etc. shall be done strictly as per the approved drawings. Any change proposed to be done at site shall have the approval of the Purchaser’s/ Consultant’s representatives.



GS-02


003

Routing of oxygen pipes -

Oxygen pipes can be laid along with other pipes on same stockades. Oxygen pipeline shall have independent support from the same stockade.

-

Clear distance of 300 mm shall be kept between oxygen pipe and any other pipe.

-

In-shop pipes can be laid along the wall and can be supported from building structures, crane girders etc. by independent brackets, hangers, etc.

-

Pipelines laid in trenches shall be covered with sand/ earth.

-

Oxygen pipeline shall not be laid in tunnel/ basements. In case, it is necessary to pass the pipeline through a tunnel, an encasing pipe shall be provided on oxygen line extending 1.0 m on both the ends of the tunnel.

-

A clearance of 500 mm shall be kept between oxygen pipe and electrical cables and in case of bare conductors, the clearance shall be 1000 mm.

-

Oxygen pipelines crossing the walls/ floors shall also have encasing pipe. The gap between the pipe and casing shall be filled with non-inflammable material allowing movement of the pipe.

-

Oxygen pipelines shall be effectively earthed, Jumpers of minimum 5 diameter shall be proved at all flanged joints.

Materials -

004

mm

All materials supplied for erection shall have manufacturer’s test certificates including materials test and hydraulic test reports.

Cleanliness -

All steel pipes & fittings shall be pickled at the manufacture’s works or at site prior to degreasing.

-

In case, pickling is done at manufacturer’s work, the ends of pipes shall be sealed/ plugged, and then pipes packed and tagged ‘pickled for oxygen service’ before despatch.

-

Pickling shall be done using HCL of 20% concentration (w/ w). After pickling, pipes shall be washed with water, neutralised with 0.25% NaOH solution and again washed with water.

-

Before erection, the pipes & fittings shall be visually inspected for presence of scales/ foreign matter like fillings, flux, corrosion products, dirt, wood and metal chips, threading compounds, sealants, tar asphalt, moisture, paint, chalk, etc.

-

The pipe work shall be thoroughly cleaned to ensure removal of all foreign matter.

-

Presence of grease or oil shall also be checked visually. Inside surface of pipes shall be checked by passing clean white cotton piece.

Hands, clothes and aprons of the workers doing erection job shall be clean and free of oil and grease. 005

Degreasing -

Before erection, all pipelines, fittings, valves, gaskets, packing material, instruments etc. shall be degreased using proper solvent like carbon tetrachloride or trichloroethylene. For initial degreasing detergent made by mixture of sodium hydroxide trisodium phosphate and calcium sodium silicate can be used.

-

The quality of the solvent used for degreasing shall application.



be checked before its

GS-02


006

007

-

The parts to be degreased should be cleaned and dried by blowing air.

-

Outer surface of pipes is degreased by wiping with cloth dipped in solvent and then dried till smell of solvent disappears.

-

For degreasing inner surface of pipes, pipe shall be plugged at one end, filled with solvent and closed at the other end. Pipe shall be kept in horizontal position, rotated about axis at least once in a minute. After continuing the process for about 15 minutes, the solvent shall be drained and pipe blown with dry oil free air or nitrogen for at least 5 minutes.

-

Drying after degreasing can also be done in open air for at least 24 hours.

-

Vapour degreasing method can also be applied for pipes.

-

For degreasing of valves, fittings and other components, the same shall be dismantled and parts dipped in solvent for 5 to 10 minutes. After degreasing, the parts shall be dried in open air till smell of solvent is eliminated.

-

Gaskets and packing material shall be degreased by dipping in solvent for 1.5 to 2 hours after which these shall be dried in open air for 24 hours.

-

Degreasing operation shall be done in open air.

-

The workers should use safety masks to prevent hazards due to inhaling of the solvent vapours. Solvent contact with skin shall also be avoided.

-

Safety aspects regarding handling of solvents shall be kept in mind during degreasing process.

Erection -

Erection of oxygen pipelines shall be done as per approved drawings and general guidelines for erection of pipelines.

-

Gas welding or electric arc welding shall be used for erection of pipelines. Welding shall be done by qualified welders.

-

Qualifying tests for welding, welding procedures and quality control etc. shall be generally as per IS: 2825, ‘ code of Practice for Unfired pressure Vessels’.

-

Radiographic examination of 100% welds for oxygen pipelines with working 2 pressure over 6 kgf/ cm (g) and OD above 76 mm shall carried out. Interpretation of radiographs shall be done by a competent agency like Lloyds Register of Shipping. Proper identification marking for welds and their corresponding radiographs shall be carried out by the contractor.

-

For pipelines having working pressure below 6 kgf/ cm (g), 40% welds shall be tested by radiography.

-

Cleanliness of personnel as well as tools and tackles shall be ensured.

2

Testing -

All erected pipelines shall be tested for strength and leakage using dry and oil free air or nitrogen.

-

Before testing, the pipeline shall be degreased by vapour degreasing method.

-

After degreasing, the pipelines shall be blown with dry and oil free nitrogen. During blowing, velocity in the pipeline shall not be less than 20 m/ sec.

-

Blowing shall be done for a period of at least 1 hour to remove all particles of dust, scale etc. from the system. Cleanliness shall be checked by holding a piece of white paper at the air outlet.



GS-02


After blowing, the line shall be pressurized up to 1.25 times the maximum working pressure using air/ nitrogen. The test pressure shall be held for 30 minutes during which the joints shall be lightly tapped with a wooden hammer of 1.5 kg weight.

-

Pressure shall be gradually reduced to the operating pressure and all joints checked by soap solution for leakage. If any leakage is detected, line shall be depressurized and defect rectified.

-

Leakage test for the pipeline system shall be done at operating pressure for a period of 24 hours. During this period, pressure and temperature readings shall be taken at an interval of 1 hour. Duplicate gauge with least count of 0.1 kg/ cm2 for pressure and 0.5 deg. C for temperature shall be used.

-

The percentage pressure drop (P) shall be calculated as follows :

P = 100 (1 – P2/ P1= * T1/ T2 ) Where P1 and P2 are pressure in the pipe at the beginning and end of test and T1 and T2 are absolute temperatures at the beginning and end of the tests.

008

009

-

Leakage of air / nitrogen determined by above formula shall not exceed 0.2% per hour.

-

After satisfactory completion of leakage test, the pipeline shall be isolated and 2 kept under pressure of 1.0 kg/ cm till the line is commissioned.

Commissioning -

Before charging the pipeline with oxygen, the line shall be blown with dry, oil free air/ nitrogen at a velocity of minimum 20 m/ s for a period of at least 8 hours. Cleanliness of outlet air shall be checked by holding a piece of white paper for 3 to 5 minute at air outlet. If dust particles are found on the paper, blowing shall be continued till paper test shows negative results.

-

After completion of blowing, oxygen shall be introduced gradually increasing the oxygen percentage in the pipe. The velocity of oxygen flow shall be limited to 10 m/ s till all air/ nitrogen is exhausted from the pipe.

-

Oxygen shall be vented through bleeders in open atmosphere at a safe place away from open flames/ fire. Minimum height of bleeder outlet shall be 2.5 m from ground/ platform level or shop roof.

-

After charging the line completely with oxygen, bleeder valves shall be closed and line may be put into service.

Safety -

Testing, cleaning and commissioning of oxygen pipelines shall be carried-out only in the presence of and with the permission of senior engineers of the and the Consultant.

-

The safety department of the shall be informed and their concurrence taken on all matters related to cleaning, testing and commissioning of oxygen pipe lines.

-

All first aid and fire fighting facilities should be readily available.

-

During testing of pipelines by air, the area shall be cordoned off and clear working placards shall be displayed.

-

All safety precautions shall be observed in storage and handling of solvents.

Passing and acceptance of pipelines Prior to passing and acceptance of pipelines for operation they shall be inspected with the view to check that all civil, structural, erection and special works are completed. © 2007 MECON Limited All rights reserved


GS-02


Before handing over the pipelines for operation, the Contractor shall provide the following technical documents. 001

Certificates of inspection, degreasing and testing of fittings, pipe joints and parts.

002

Certificate on the inspection of internal cleanliness of pipes.

003

Certificates on pipe, flanges, plugs and welding material.

004

Copies of the welder`s certificates.

005

Results of mechanical testing of samples.

006

Certificate on testing of pipelines for strength and leaks.

007

Principal scheme of pipelines with indications of welded butts and labels.



GS-02


G E N E R AL

01.01

This specification covers the materials, tools, facilities and quality requirement for surface preparation and painting of steel structures, equipment, piping, ducts, chutes, wood work etc.

01.02

This is only a general guideline of the painting scheme to be followed by the Tenderer. However, in case a specific painting procedure is stipulated in any tendering specification, then this general guideline shall be s u p e r c e d e d . A n y s p e c i a l c a s e w h i c h m a y a r i s e f r o m t im e t o t i m e s h a l l b e dealt with individually on the merit of each case

01.03

The term “painting” referred herein covers rust preventive, fungus/insects preventive and decorative coating along with surface protection of the following area but not limited to the areas indicated below. i) ii) iii) iv) v) vi)

Structural steel works Mechanical equipment Electrical equipment Instrumentation and control equipment. Pipe work O x yg e n p l a n t , e t c .

01.04

Surfaces made of asbestos, aluminum, brass, bronze, galvanized steel, s t a i n l e s s s t e e l , c a s t i r o n a n d o t h e r c o r r o s i o n r e s i s t a n t a l l o ys a n d r u b b e r / s yn t h e t i c p o l y m e r / f i b e r r e i n f o r c e m e n t p l a s t i c a n d b u r i e d p i p e w o r k are not required to be painted unless specified except for aesthetic purposes or for identification bands, wherever relevant.

01.05

T h e c o m p l e t e p a i n t s ys t e m f o r a n y i t e m i n c l u d e s t h e f o l l o w i n g b a s i c activities: i) ii) iii) iv)

Proper surface preparation Application of primer coats Application of intermediate coats Application of finished coats

All the above coats shall be of quality paint products and of approved m ak e . T h e s c o p e o f w o r k s h a l l a l s o i n c l u d e s u p p l y o f a l l p a i n t m a t e r i a l s a s per specification described herein. 01.06

I f t h e c o n t r a c t o r d e s i r e s t o a d o p t a l t e r n a t i v e p a i n t s ys t e m f o r a n y s p e c i f i c i t e m f o r a n i m p r o v e m e n t o r e q u i v a l e n t t o t h e s ys t e m s p e c i f i e d h e r e - i n o r as per recommendations of paint manufacturer, may do so subject to purchaser’s approval in advance.

02

S U R F AC E

02.01

Surface preparation required for paint application, shall be such as to clean the surface thoroughly of any material which will be conducive to premature failure of the paint substrates.


P R E P AR AT I O N

Painting Page 1 of 19

GS-09


All surfaces shall be cleaned of loose substances, and foreign materials, such as dirt, rust, scale, oil, grease, welding flux, etc. in order that the prime coat is rigidly anchored to the virgin metal surface. The surface preparation shall confirm to pictorial representation of surface quality g r a d e o f S we d i s h S t a n d a r d s I n s t i t u t i o n SIS – 055900 or equivalent standards such as SSPC – VIS – 1.67 or DIN 55928(Part 4) or BS 4232 or IS 1477 – 1971 (Part I)

02.03

The acceptable surface preparation quality / grade are described under e a c h p a i n t s ys t e m . T h e p r o c e d u r e s i n c l u d e s o l v e n t c l e a n i n g , h a n d t o o l cleaning, power tool cleaning, blast cleaning, wood surface cleaning, f l a m e c l e a n i n g a n d p i c k l i n g . T h i s wi l l e n s u r e s u r f a c e q u a l i t y a s r e q u i r e d by the specific primer paint. For ready reference surface preparation quality grade to be adopted in respect of SIS 055900 and DIN 55928 (part-4) is given in Annexure-01.

02.03.01

Solvent Cleaning T h e s u r f a c e s h a l l b e c l e a n e d b y w i p i n g , i m m e r s i o n , s p r a yi n g o r v a p o u r c o n t a c t i n g o f a s u i t a b l e s o l v e n t o r wa s h i n g wi t h a n e m u l s i o n o r a l k a l i n e solution to remove oil, grease, dirt, old paint, etc. Solvent cleaning shall n o t r e m o v e r u s t , s c a l e s , m i l l s c a l e s o r we l d f l u x . T h e r e f o r e , b e f o r e a p p l i c a t i o n o f p a i n t , s o l v e n t c l e a n i n g s h a l l b e f o l l o we d b y o t h e r c l e a n i n g procedures as stated in subsequent clauses.

02.03.02

Hand Tool Cleaning The surface shall be cleaned manually by vigorous wire brushing as per g r a d e S t - 2 q u a l i t y o f S we d i s h S t a n d a r d I n s t i t u t i o n S I S 0 5 5 9 0 0 a n d D I N 555928. This method effectively removes loosely adherent materials, but would not affect residues of rust or mill scales that are intact are firmly a d h e r e n t . F i n a l l y t h e s u r f a c e i s t o b e c l e a n e d wi t h a v a c u u m c l e a n e r o r with clean compressed air or with clean brush. After preparation the surface shall have a faint metallic shine. The appearance shall correspond to the prints designated St – 2.

02.03.03

Power Tool Cleaning The surface shall be cleaned by electric or pneumatic tools, such as brushes, sanding machines, disc abrasive grinder, rotar y disc scaler etc. t o S t – 3 q u a l i t y. T h e t o o l s s h a l l b e u s e d c a r e f u l l y t o p r e v e n t e x c e s s i v e roughening of surface and formation of ridges and burrs. This method will remove loosely adherent materials but would not affect residues of rust or mill scales that are firmly adherent and intact.

02.03.04

Blast Cleaning The surface shall be cleaned by impingement of abrasive materials, such as graded sand at high velocity created by clean and dr y compressed air blast as per the grade according to Swedish Standard Institution SIS 0 5 5 9 0 0 . T h i s m e t h o d wi l l r e m o v e l o o s e l y a d h e r e n t m a t e r i a l s a s w e l l a s adherent scales and mill scales. Prior to application of blast, heavy deposit of oil and grease are removed by solvent cleaning excessive



GS-09

General Technical Specification surface scales are removed by hand tools or power tool cleaning. The extent of removal of adherent scales is varied, depending on the application and are defined by the surface quality grades Sa1, Sa2, Sa2.5 and Sa3 in the order of increasing cleanliness. The blast cleaning is not recommended for sheet metal work. 02.03.05

Flame Cleaning T h e s u r f a c e i s c l e a n e d b y r a p i d h e a t i n g b y m e a n s o f o x ya c e t yl e n e f l a m e to loosen the adherent scales, followed immediately by wire brushing. T h i s m e t h o d w i l l r e m o v e l o o s e l y a d h e r e n t m a t e r i a l s a s we l l a s m o s t o f t h e a d h e r e n t s c a l e s a n d m i l l s c a l e s . I n o r d e r t o m i n i m i ze o r p r e v e n t d i s t o r t i o n f l a m e c u t t i n g s h a l l n o t b e u s e d o n m em b e r s h a v i n g t h i c k n e s s o f 6 m m a n d lower.

02.03.06

Pickling In this method the surface is cleaned of mill scales, rust or rust scales by c h e m i c a l r e a c t i o n o r e l e c t r o l ys i s o r b o t h .

03.

P AI N T AP P L I C AT I O N

03.01

Paints

03.01.01

Paint shall be applied in accordance with paint manufacturer’s r e c o m m e n d a t i o n s . T h e wo r k s h a l l g e n e r a l l y f o l l o w I S 1 4 7 7 – 1 9 7 1 ( P a r t I I ) for jobs carried out in India and SSPC-PA-1 or DIN 55928 or equivalent for jobs carried out outside India.

03.01.02

General compatibility between primer and finishing paints established by the paint manufacturer supplying the paints.

03.01.03

In the event of conflict between this general procedure on painting and the paint manufacturer’s specification, the same shall be immediately brought to the notice of the Purchaser. Generally in cases of such conflicts, manufacturer’s specifications/recommendations shall prevail.

03.01.04

B e f o r e b u yi n g t h e p a i n t i n b u l k , i t i s r e c o m m e n d e d t o o b t a i n s a m p l e o f paint and establish “Control Area of Painting”. On Control Area, surface preparation and painting shall be carried out.

03.01.05

If required, samples of paint shall be tested in laboratories to establish quality of paint with respect to: (i) (ii) (iii) (iv) (v) (vi)

03.01.06

shall

be

Viscosity Adhesion/Bond of paint in steel surfaces Adhesion/Simulated salt spray test. C h e m i c a l a n a l ys i s ( p e r c e n t a g e o f s o l i d s b y w e i g h t ) Normal wear resistance as encountered during handling & erection. Resistance against exposure to acid fumes, etc.

W h o l e q u a n t i t y o f p a i n t f o r a p a r t i c u l a r s ys t e m o f p a i n t s h a l l b e o b t a i n e d f r om t h e s a m e m a n u f a c t u r e r .



GS-09

General Technical Specification 03.01.07

The main Contractor shall be responsible for supply of paints and this responsibility shall not be passed on to the sub-contractor.

03.01.08

The painting material as delivered to the Contractor, must be in the manufacturer’s original container bearing thereon manufacturer’s name b r a n d a n d d e s c r i p t i o n . P a i n t / P a i n t i n g m a t e r i a l i n c o n t a i n e r s wi t h o u t l a b e l s or with illegible labels shall be rejected, removed from the area and shall not be used.

03.01.09

T h i n n e r s wh e r e v e r u s e d s h a l l b e t h o s e r e c o m m e n d e d b y t h e p a i n t manufacturers and shall be obtained in containers with manufacturer’s name and brand name of thinner legibly printed, failing which the thinner is liable to be rejected and shall not be used.

03.01.10

All paint containers shall be clearly labeled to show the paint identification, date of manufacture, batch number, special instruction, shelf life etc. The container shall be opened only at the time of use.

03.01.11

All paints shall be stored in accordance with the requirements of laid down procedure by the paint manufacturer.

03.01.12

All ingredients in a paint container shall be thoroughly mixed to break-up lumps and disperse pigments before use and during application to maintain homogeneity. The proposed make, quality and shade of the paint shall have the approval of the client.

03.01.13 03.01.14

The colour code of the finishing paint to be followed shall be intimated to the successful Tenderer after finalisaiton of order. The undercoat shall have different tint to distinguish the same from the finishing coat.

03.01.15

The Contractor shall furnish paint manufacturer’s test report or technical data sheet pertaining to the paint selected. The data sheet shall indicate a m o n g o t h e r t h i n g s t h e r e l e v a n t s t a n d a r d s , i f a n y, c o m p o s i t i o n i n we i g h t p e r c e n t o f p i g m e n t s , v e h i c l e s , a d d i t i v e s , d r y i n g t i m e , v i s c o s i t y, s p r e a d i n g rate, flash point, method of application, quality of surface preparation required, corrosion resistance properties and colour shades available.

03.01.16

For details of paint materials refer Annexure - 02

03.02

General

03.02.01

Each coat of paint shall be continuous, free of pores and of even film t h i c k n e s s wi t h o u t t h i n s p o t s .

03.02.02

Each coat of paint shall be sufficiently dr y before application of next coat.

03.02.03

Paint shall be applied at manufacturer’s recommended rates. The number of coats shall be such that the minimum dry film thickness specified is a c h i e v e d . T h e d r y f i l m t h i c k n e s s o f p a i n t e d s u r f a c e s s h a l l b e c h e c k e d wi t h ELCOMETER of measuring gauges to ensure application of specified DFT.



GS-09

General Technical Specification 03.02.04

Z i n c r i c h p r i m e r p a i n t s wh i c h h a v e b e e n e x p o s e d s e v e r a l m o n t h s b e f o r e finishing coat is applied shall be washed down thoroughly to remove soluble zinc salt deposits.

03.02.05

T h e m a c h i n e f i n i s h e d s u r f a c e s s h a l l b e c o a t e d w i t h wh i t e l e a d a n d t a l l o w before shipment or before being put out into the open air.

03.02.06

Areas which become inaccessible after assemble shall be painted before a s s e m b l y ( a f t e r o b t a i n i n g p a i n t i n g c l e a r a n c e f r om t h e i n s p e c t i n g a u t h o r i t y) after requisite surface cleaning as specified.

03.02.07

P a i n t s h a l l n o t b e a p p l i e d wh e n t h e a m b i e n t t e m p e r a t u r e i s 5 d e g C a n d below or 45 deg C and above. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and above unless the manufacturer’s recommendations permit. Applications of paint shall be o n l y b e s p r a yi n g o r b r u s h i n g a s p e r I S 4 8 6 – 1 9 8 3 a n d I S 4 8 7 – 1 9 8 5 .

03.02.08

Primer paint shall be applied not later than 2 – 3 hours after preparation of surface, unless specified otherwise.

03.02.09

Edges, corners, crevices, depressions, joints and welds shall receive special attention to ensure that they receive painting coats of the required thickness.

03.02.10

Surfaces which cannot be painted but require protection shall be given a coat of rust inhibitive grease according to IS 958 – 1975 or solvent deposited compound according to IS 1153 – 1975 or IS 1674 – 1960.

03.02.11

Surfaces in contact during shop assembly shall not be painted. Surfaces which will be inaccessible after assembly shall receive minimum two coats of specified primer.

03.02.12

Surfaces to be in contact with wood, brick or other masonr y shall be given one shop-coat of the specified primer.

03.03

Site/Field Painting

03.03.01

W herever shop primer painting is scratched, abraded or damaged, the surface shall be thoroughly cleaned using emery paper and power driven w i r e b r u s h w h e r e v e r wa r r a n t e d , a n d t o u c h e d u p w i t h c o r r e s p o n d i n g primer. Touching up paint shall be matched and blended to eliminate conspicuous marks.

03.03.02

If more than 50% of the painted surface of an item requires repair, the entire item shall be mechanically cleaned and new primer coats shall be applied followed by intermediate and finishing coats as per painting specification.

03.03.03

A l l f i e l d we l d e d a r e a s o n s h o p p a i n t e d i t e m s s h a l l b e m e c h a n i c a l l y cleaned (including the weld area proper, adjacent areas contaminated by w e l d s p a t t e r o r f u m e s a n d a r e a s wh e r e e x i s t i n g p r i m e r p a i n t i s b u r n t ) .



GS-09

General Technical Specification S u b s e q u e n t l y, n e w p r i m e r a n d f i n i s h i n g c o a t s o f p a i n t s h a l l b e a p p l i e d a s per painting specification. 03.03.04

T h e f i r s t c o a t o f f i n i s h p a i n t a t s i t e s h a l l b e a p p l i e d p r e f e r a b l e wi t h i n t h r e e months of the shop paint.

03.04

Structural

03.04.01

All fabricated steel structure, fabricated steel pipes, etc. shall have a m i n i m um o f t w o c o a t s o f p r i m e r p a i n t b e f o r e d i s p a t c h t o s i t e .

03.04.02

Parts of steel structures embedded in concrete shall be given a protective coat of Portland cement slurry immediately after fabrication and after s u r f a c e s o f t h i s p a r t i s t h o r o u g h l y c l e a n e d f r om g r e a s e , r u s t , m i l l s c a l e s , etc. No paint shall be applied on this part.

03.04.03

All structures shall receive appropriate number of primer and finishing coats in order to achieve overall DFT as per design drawings/specification.

03.05

Hot Surfaces

03.05.01

Total DFT for heat resistant paints should not exceed 100 – 120 microns, otherwise flaking occurs (as per paint manufacturer’s recommendations).

03.05.02

Heat resistant paints should be applied by brush.

03.05.03

Primer coat should not be applied on the surfaces having temperature condition more that 120 deg C.

04

P AI N T I N G S C H E M E S F o r a c o m p l e t e p a i n t i n g s c h e m e o f a n y i t e m b e i n g p r i n t e d , a l l t yp e s o f p a i n t s a r e t o b e p r o c u r e d f r o m t h e s a m e m an u f a c t u r e r a s a p p r o v e d b y t h e purchaser.

04.01

Legend SP 2P1 1I1 2F1 DFT CRT-

Surface preparation quality as per SIS standard T wo ( 2 ) c o a t s o f P r i m e r p a i n t t yp e P 1 O n e ( 1 ) c o a t s o f I n t e r m e d i a t e p a i n t t yp e I 1 T wo ( 2 ) c o a t s o f F i n i s h p a i n t t yp e F 1 Dry Film Thickness in microns developed Clean and Retouch

T yp e o f p a i n t p r o d u c t s l i k e P 1 t o P 9 , I 1 t o I 4 a n d F 1 t o F 1 0 h a v e b e e n specified under Annexure-02. 04.02

The painting scheme to be followed for various structure/equipment exposed to different condition is briefly given in Annexure-03 for guidance to the tenderer.



GS-09


The colour code for different applications are indicated in Annexure-04. W herever colour codes are not specified, the same is to be mutually agreed between the Purchaser and Contractor.

05.

G U AR AN T E E

05.01

T h e C o n t r a c t o r s h a l l g u a r a n t e e t h a t t h e p h ys i c a l a n d c h e m i c a l p r o p e r t i e s of the paint materials conform with the specification of paint products.

05.02

The Contractor shall submit internal test reports from paint manufacturers regarding the quality of paint whenever asked by the Purchaser/Consultant.

05.03

Guarantee period shall commence from the date of completion of finishing coat of paint. The guarantee period will be indicated depending on the t yp e o f s u r f a c e p r e p a r a t i o n a n d s ys t e m o f p a i n t i n g . T o f u l f i l l t h i s obligations the Contractor may obtain from the painting manufacturer, guarantee for the performance of paint/painted surfaces.



GS-09

General Technical Specification Annexure-01

Surface Preparation Grade Sl. No. 1

Surface Preparation Blast cleaning to white metal Removal of all visible rusts, mill-scales, paint and foreign matters.

2

Sa 3

Sa 3

Sa 2.5

Sa 2.5

Sa 2

Sa 2

Sa 1

Sa 1

St 3

St 3

St 2

St 2

Blast cleaning to commercial quality: At least 2/3 of any section of the surface area is free from all rusts, mill-scales and visible residues.

4

DIN Std. Din 55928 (Part 4)

Blast cleaning to near white metal: 95% of any section of surface area is free from all rusts, mill-scales and visible residues.

3

Swedish Std SIS 055900

Brush-off blast cleaning: Removal of all loose mill-scales, rust and foreign matters etc.

5

Power tool cleaning: Very thorough scrapping and wire brushing to remove loose mill-scale, rust and foreign matters to have pronounced metallic shine.

6

Hand tool cleaning: Removal by hand brushing of loose mill-scale, loose rust and foreign matters.



GS-09

General Technical Specification Annexure - 02

P AI N T M AT E R I AL S 01.

P R I M E R P AI N T S ( P ) Primer paint products shall be applied only on dr y and clean surfaces.

01.01

P r i m e r P a i n t – P 1 ( P h e n o l i c – Al k y d B a s e d ) A s i n g l e p a c k a i r d r y i n g p h e n o l i c m o d i f i e d a l k yd c o m p o s i t i o n w i t h z i n c phosphate as a primer paint conforming generally to IS : 2074. Air drying time

01.02

-

About 60 minutes (touch dry)

-

Overnight (hard dry)

Dry film thickness (DFT)/Coat

-

40 microns (min)

Temperature resistance

-

Upto 100 C dry heat

Primer Paint – P2 (Chlororubber Based) A single pack air phosphate primer.

01.03

0

d r yi n g

high

build

chlorinated

rubber

based

Percent chlororubber

-

20 to 22 (% Chlorine above 65% in chlororubber)

Air drying time

-

About 15 minutes (touch dry) Overnight (hard dry)

DFT/ Coat

-

50 microns (min)


-

Up to 65 C dry heat

zinc

0

Primer Paint – P3 (PVC Copolymer Alkyd Based) Polyvinyl chloride (PVC)

-

Alkyd zinc phosphate – redoxide based primer

Ratio

:

PVC copolymer + alkyd resin (1:1)

Pigments

:

Zinc phosphate & Fillers

Air drying time

-

24 hours

DFT/Coat

-

80 microns


-

Upto 80 C dry heat



0

GS-09


Primer Paint – P4 (Epoxy Based) A t w o p a c k a i r d r yi n g E p o x y p o l ya m i d e r e s i n b a s e d r e d o x i d e - z i n c phosphate primer.

01.05

Epoxy content (% wt.)

-

15 to 18

Air drying time

-

About 30 minutes (touch dry) overnight (hard dry)

DFT/Coat

-

30 microns (min)


-

Upto 120 C dry heat

0

Primer Paint – P5 (Epoxy Based) A t w o p a c k a i r d r yi n g E p o x y p o l ya m i d e w i t h zi n c d u s t o f a t l e a s t 9 2 % z i n c dust on the dr y film

01.06

Epoxy content (% wt.)

-

8 to 10

Air drying time

-

Less than 10 minutes (touch dry) Less than 2 hours (hard dry)

DFT/Coat

-

40 microns (min)


-

Upto 300 C dry heat

0

Primer Paint – P6 (Poly – Vinyl Butyral Resin Based) A t w o p a c k a i r d r yi n g p o l yv i n yl b u t yr a l r e s i n b a s e d w a s h p r i m e r w i t h r u s t inhibitive pigments.

01.07

Air drying time

-

5 to 7 minutes (touch dry) 2 hours (hard dry)

DFT/Coat

-

8 microns


-

Upto 65 C dry heat

Application for

-

Galvanised iron, aluminium, light alloys etc. on which the adhesion of conventional paints are poor.

0

Primer Paint – P7 (Ethyl Zinc Silicate, EZS Based). A t wo p a c k h e a v y d u t y z i n c d u s t r i c h s i l i c a t e p r i m e r wh i c h p r o t e c t s t h e surface with just a single coat. T ota l s o l i ds ( 3 wt) De ns it y ( g / c c )


-

84 +/- 2 3. 0 7 + /- 0. 0 5


GS-09

General Technical Specification A ir dr yi n g t im e DF T / c o at T em per at ur e r es is t a nc e 01 . 08

-

T o t op c o a t 16 ho ur s 60 m ic r o ns Up to 45 0 d eg C dr y h e at

P ri m e r P a in t – P8 ( H i g h B u i ld Co al T a r Ep o x y) A t wo p ac k c o l d c ur ed H. B. ep ox y c o a l tar c o at i ng – no pr im er is r e qu ir e d.

01 . 09

M ix i n g r a ti o A ir dr yi n g t im e

-

DF T / C oa t

-

B as e : Ha r d e ner ( 4: 1b y v o l .) 48 ho ur s ( h ar d dr y) F u l l c ur e 7 d a ys 10 0 m ic r o ns

W o o d V a rn i sh - P 9 T r eat e d o il bas e d pr im er p igm e nt ed wi th s u it ab l e p i gm ents :

02 .

A ir dr yi n g t im e

-

16 ho ur s f or a pp l ic at i o n of to p c o at .

Co v er ag e

-

10 t o 1 4 s q . m /l it r e

INT E RM EDI AT E P AI N T S ( I) T hes e p a in ts s ha l l be ap p l ie d o v er p r im er c o ats as an i n ter m ed i a te l a yer t o pr o v i d e we a th er pr o of s ea l of pr im er c oa ts .

02 . 01

In t er m e d i at e P ain t - I I ( P h e n o l i c al k yd b a s e d ) A s i n g le p ac k hi g h b u il d p h en o l ic b as e d p a in t wit h m ic ac e o us i r on ox id e ( M 10) . A ir Dr yi n g T im e 2 d a ys ( ha r d d r y) DF T /C o at T em per at ur e r es is t a nc e Com pa t ib l e wi t h

02 . 02

-

4 to 6h o ur s ( to uc h dr y)

-

7 5 m ic r ons ( m in) Up to 10 0 d eg C d r y h e at P r im er P 1

-

In t er m e d i at e P ain t - I 2 ( Ch lo ro ru b b e r b a s ed ) A s i n gl e p ac k a ir dr yi n g h ig h b u i ld c h l or o b a s ed pa i nt wi th MIO . A ir Dr yi n g T im e DF T /C oa t T em per at ur e r es is t a nc e Com pa t ib l e wi t h

02 . 03

-

1 5 m i nu t es ( to uc h dr y) 24 ho ur s ( h ar d dr y) 70 m ic r o ns ( m i n ) U pt o 6 5 d eg C d r y h e at P r im er P 2, P 3 & P 4

In t er m e d i at e P ain t - I 3 ( P V C – Al k yd B a se d ) P VC C op l o ym er P igm e nts DF T /C oa t


-

Res i n 1 : 1 M ic ac e ous ir o n ox i d e ( MIO ) 80 m ic r o ns ( m i n)


GS-09

General Technical Specification T em per at ur e r es is t a nc e Com pa t ib l e wi t h 02 . 04

-

Up to 80 d e g C dr y h e a t Pr im er P2 & P 3

In t er m e d i at e p ai n t - I 4 A t wo p ac k a ir dr yi n g h ig h b u il d e p ox y r es in bas e d p ai n t wi t h MI O . A ir dr yi n g t im e DF T / c o at T em per at ur e r es is t a nc e Com pa t ib l e wi t h

03.

-

6 to 8 ho ur s ( t o uc h d r y) 7 d a ys ( f u l l c ur e) 10 0 m ic r o ns 0 Up t o 1 80 C dr y h ea t Pr im er P4 & P 5

F I N I S H P AI N T S ( F ) Finish paint costs shall be applied over primer coats and intermediate coats after proper cleaning and touch up of primed surface.

03.01

Finish Paint – F1 A s i n g l e p a c k a i r d r y i n g h i g h g l o s s p h e n o l i c a l k yd m o d i f i e d s yn t h e t i c enamel paint suitably pigmented.

03.02

Air drying time

-

3 to 4 hours (touch dry) 24 hours (hard dry)

DFT/Coat

-

25 microns (min)


-

Upto 100 C dry heat

Compatible with

-

Colour

-

Primer P1 Intermediate I1 Generally all shades

0

Finish Paint – F2 A s i n g l e p a c k a i r d r yi n g p o l yu r e t h a n e e n a m e l o f h i g h g l o s s a n d h a r d f i n i s h suitably pigmented. Air drying time

-

2 to 2 ½ hours (touch dry) 6 hours (hard dry)

DFT/Coat

-

30 microns (min)


-

Upto 100 C dry heat

Compatible with

-

Colour

-

Primer P1 & P8 and Intermediate I1 Generally all shades


0


GS-09


Finish Paint – F3 A t w o p a c k a i r d r yi n g b i t u m i n o u s a l u m i n u m p a i n t .

03.04

Air drying time

-

1 to 2 hours (touch dry) 21 hours (hard dry)

DFT/Coat

-

25 microns (min)


-

Upto 100 C dry heat

Compatible with

-

Primer P1 and Intermediate I1

Colour

-

Bright metallic

0

Finish Paint – F4 A r e a d y m i x e d o i l - a l k yd b a s e d s yn t h e t i c e n a m e l p a i n t o f h i g h g l o s s a n d hard wearing properties.

03.05

Air drying time

-

6 to 8 hours

Coverage

-

14 to 16 Sq. m /litre


-

Upto 60 C dry heat

Compatible with

-

P8

Colour

-

Generally all shades

0

Finish Paint – F5 A s i n g l e p a c k a i r d r yi n g p l a s t i c i z e d c h l o r o r u b b e r p a i n t s u i t a b l y p i g m e n t e d . Air drying time

-

30 minutes (touch dry) 24 hours (hard dry)

DFT/Coat

-

35 microns (min)


-

Upto 65 C dry heat

Compatible with

-

Colour

-

Primer P2 & P3, Intermediate I2 & I3 Nearly all shades except few.


0


GS-09


Finish Paint – F6 A P V C – C o p o l ym e r a l k yd b a s e d e n a m e l .

03.07

Density

-

1.17 + 0.05

Total solids (1 wt)

-

55 + 2

DFT/Coat

-

40 microns

Compatible with

-

P2 and P3

Finish Paint – F7 A t w o p a c k a i r d r yi n g e p o x y p o l ya m i d e e n a m e l s u i t a b l y p i g m e n t e d .

03.08

Air drying time

-

2 to 3 hours (touch dry) 7 days (full cure)

DFT/Coat

-

40 microns (min)


-

Up to 130 C dry heat

Compatible with

-

Primer P4 & P5, Intermediate I4

Colour

-

Generally all shades.

0

Finish Paint – F8 A s i n g l e p a c k s yn t h e t i c r u b b e r b a s e d a l u m i n i u m p a i n t . Air drying time

-

2 hours (touch dry) 24 hours (hard dry)

DFT/Coat

-

25 microns (min)


-

Upto 200 C dry heat

Compatible with

-

No Primer paint except primer P6 is applicable in case of non-ferrous substrate.

Colour

-

Smooth aluminium.


0


GS-09

General Technical Specification Annexure - 03

PAINTING SCHEME Sl. No. 1.0 1.1

1.2

Painting Scheme At Shop At Site

Description Steel Structures 0 (Temp. not exceeding 80 C) Technological steel structures for plant and equipment Indoor

SP – Sa 2.5 2P1

CRT 2F1

130

Outdoor

SP – Sa 2.5 2P1 1I1

CRT 2F1

205

SP – St-2 and/ or St-3 2P1

CRT

Fabricated steel structures at site for rung ladders, cat-ladders, gates, rolling shutters, etc. (Springs/rubbing surfaces excluded) - Indoor / Outdoor

1.3

SP – St-2 and/ or St-3 2P1

- Outdoor

SP- St2 and/ or St-3 2P1 1I1

130

CRT 2F1

130

CRT 2F1

205

Steel doors and windows - Indoor / outdoor

Sl. No. 2.0

2F1

Walkways, stairs, platforms etc. which are of wearing surface - Indoor

1.4

Total DFT (Refer Note-1)

SP–St-2 and / or St-3 2P1 1I1

2F2


Description MECHANICAL EQUIPMENT

2.1

Mechanical equipment 0 (Temp. not exceeding 80 C)

2.1.1

Static equipment like storage tanks, vessels, bins, bunkers, heat exchangers, coolers,


CRT


215 Total DFT

GS-09



Description cyclones, scrubbers, etc.

2.1.2

Sl. No. 3.0 3.1

- Indoor

SP – Sa 2.5 2P2/2P3

CRT 2F5/2F6

170/240

- Outdoor

SP – Sa 2.5 2P2/2P3+1I2/1I3

CRT 2F5/2F6

240/320

- Indoor

SP – Sa 2.5 2P3/2P4

CRT 2F6/2F7

240/140

- Outdoor

SP-Sa 2.5 2P3 + 1I3/1I4

CRT 2F6/2F7

320/340

Rotary/moving equipment and machineries like crushers, mills, vibratory screens, bin activators, blowers, fan, air/gas compressors, pumps, gear boxes, machine housings etc.


Description Pipe / Duct work (Overground)

SP – St2 and or St3 2P1 SP – St2 and / or St3 2P1 + 1I1

- Outdoor Insulated (hot) - Indoor/Outdoor

SP- St2 and/ or St3 1P1

Sl. No. 4.0 4.1

Total DFT

Non – insulated 0 (temperature up to 80 C) - Indoor

3.2

Total DFT

Oxygen Plant


2F1 CRT

130

2F1

205

Remove paint and insulate


Description

Outdoor steel structures

CRT

SP – St2 and / or St3


Total DFT

CRT

GS-09


Description

4.2

Rotary equipment like air compressors

5.0

Others

5.1

Standard mobile equipment like chasis of trucks, dumpers, crawler cranes bulldozers, railway rakes, chasis of slag cars, ladle cars, etc. Laboratory equipment like ovens, screens, magnetic stirrers, samplers, etc. Steel structures partly immersed in water

5.2 5.3

Painting Scheme At Shop At Site 2P1 + 1I1 2F3 Sa 2.5 CRT 2P4 2F7

Total DFT 205 140

As per manufacturer’s standards

Stove enamelling

CRT

SP – Sa 2.5

CRT

2P8

110

200

Notes: 1.

Painting scheme of all fabricated steel structures, fabricated pipe work, building s t r u c t u r e , c o n v e yo r g a l l e r i e s , p i p e t r e s t l e s e t c . i s i n d i c a t e d i n t h e T e c h n i c a l Specification of steel structures.

2.

Primer Paint Primer coat shall be suitable for intended temperature applications as per manufacturer’s recommendation. The primer selection shall be generally in line with the specification laid down in Annexure-02.

3.

Finish Paint I n c a s e o f A l u m i n i u m c l a d d i n g f i n a l p a i n t i n g wi l l n o t b e r e q u i r e d .



GS-09

General Technical Specification ANNEXURE - 04 COLOUR CODE The colour codes are mentioned for all the items including pipe work. Shades of finish coat of paint applied over respective item indicated below are tentative and subject to alteration as per Purchaser’s request or due to compatible paint system adopted. The service for which colour code/bands are not specified are to be mutully agreed for by the Purchaser & the Contractor. Sl. No. 1.

2.

Items Painted Structures Building frames including bracings, side girts, louvers etc. Crane girders Crane stops Gutters Fire escape platforms ladders, etc. General hand railing, top runners Rung ladders All members blocking passages for movement Trestles, towers and pipe bridges Conveyor gallery structures Steel chimneys Equipment and Machinery General indoor equipment General outdoor equipment Crane bridges, trolleys, hooks etc. and other mobile equipment Furnaces Tanks

Fire-fighting equipment 3.

Colour

Colour No. of IS:5

Aircraft grey

693

Azure blue Post office red Black bituminous aluminium Signal red Lemon yellow Lemon yellow Lemon yellow

104 538 537 355 355 355

Dark admiralty grey Aircraft grey Aluminium

632 693 -

Light grey Dark admiralty Base : Lemon yellow Stripes : Black (100 mm wide) Aluminium Base : Same as for general equipment Strips : Same shade as for piping around the tnk at half the tank height Signal red

631 632 355

537

Pipe work Colours shall be as given below. The base colour shall be applied throughout entire length except on surfaces of materials such as asbestos, aluminium, brass, bronze, galvanized steel, stainless steel and other corrosion resistant alloys and rubber / synthetic polymers. In such cases identification colour bands of at least 500mm width shall be provided near each branch, valve and at distances not exceeding 10m either as local colour coatings or coloured adhesive type of suitable material or label attached to the pipe work. Additional identification bands superimposed over the base colour shall be provided near each branch, valve and at distance not exceeding 10m. The bands shall be atleast 25mm wide except in care of double bands where the first band shall be about 100mm wide. Direction of flow shall be clearly marked on the pipelines at intervals not exceeding 10m and all branches and change of directions.



GS-09

General Technical Specification Service Sea or river water (untreated) Cooling water Boiler feed water Condensate Drinking water Industrial water Compressed air Instrument air Drainage Fuel oil Coke oven/BF gas/other fuel gases Argon Acetylene LP Gas (LPG)

Nitrogen Oxygen Non-acidic slurries Fire-fighting system Rain water down pipes Duct work

Colour Base – Sea green Band - White Base – Sea green Band - White Base – Sea green Base – Sea green Band – Light brown Base – Sea green First band - French blue Second band – Signal red Base – Sea green Band – Light orange Base – Sky blue Base – Sky blue Band – Light brown Base – Black Base – Light brown Band – Signal red Base – Canary yellow Band – Signal red Base – Canary yellow Band – French blue Base – Canary yellow Band – Dark violet Base – Canary yellow First band – Signal read Second band – Traffic green Base – Canary yellow Band – Black Base – Canary yellow Band – White Base – Sea green Band – White Base – Signal red Base – Sea green Band – Sky blue Base – Aluminium

217 217 166 217 217 410 217 166 537 217 557 101 101 410 410 537 309 537 309 166 309 796 309 537 267

Colour No. of IS:5

309 309 217 537 217 101 -

Note : For these services, hazard marking as per fig. 4C of IS:2379 shall also be provided.



GS-09

FORM NO. 11.20 (DQM) F-09, REV-0

ORDER NO. & DATE

QUALITY ASSURANCE PLAN FOR

SUB - CONTRACTOR ORDER NO. & DATE

STRUCTURAL & MECHANICAL EQUIPMENT

CONTRACTOR

QAP shall be submitted for each of the equipment separately w ith break up of assembly / sub-assembly & part/component or for group of equipment having same specification.

2

Use numerical codes as indicated for extent of inspection & tests and submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant and equipment.

3

Separate identification number w ith quantity for equipment shall be indicated w herever equipment having same specification belonging to different facilities are grouped together.

4

Code

MFG

:

PACKAGE NAME

Code Description 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

13. Heat Treatment 14. Pressure Test 15. Leakage test 16. Balancing 17. Vibration Test 18. Amplitude test

ABBREVIATIONS USED :

:

Description

1. Visual(Welding etc.) 2. Dimensional 3. Fitment & Alignment 4. Physical Test(Sample) 5. Chemical Test (Sample) 6. Ultrasonic Test 7. Magnetic Particle Test(MPT) 8. Radiography test 9. Dye Penetration Test 10. Metallographic Exam. 11. Welder's Qualification & Weld Procedure Test 12. Approval of Test and Repair Procedure

Weight in tonnes (T) must be indicated under column 5 for each item. Estimated w eights may be indicated w herever actual w eights are not available.

CONTR

PACKAGE NO.

CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :

INSTRUCTIONS FOR FILLING UP :

1

PROJECT

CONTRACTOR MANUFACTURER E Q U I P M E N T

Code

Sponge test Dust/Water Ingress test Friction Factor Test Adhesion Test Performance Test/ Characteristic curve No. Load/Free Running Test Load/Overload Test Measurement of speeds Accoustical test Geometrical Accuracy Repeatability and Positioning Accuracy Proving Test

Description 34. Internal Inspection report by Contractor 35. Hardness test 36. Spark test for Lining 37. Calibration 38. Safety device test 39. Ease of Maintenance 40. Thickness measurement

of Zinc coating

31. Surface Preparation 32. Manufacturer's Test Certificates for bought out items 33 IBR/Other statutory agencies' compliance certificate

D E T A I L S

Description (w ith equipment

Identification

No.

heading,place of use and

No.

No / M

INSPECTION AND TESTS

Quantity

3

4

Manufacturer's

Expected Sche-

T

Name and Address

dule of Final

5

6

brief specification) 1

2

for MECON ( Stamp & Signature )

D1. Approved GA draw ings D2. Information and other reference drg / stamped drgs released for manufacture D3. Relevant catalogues D4. Bill of Material/ item no./ identification. D5 Matchmark details D6 Line/Layout diagram D7 Approved erection procedures D8 Unpriced sub P.O.w ith specification and amendments if any D9. Calibration Certificate of all measuring instrument and gauges. D10. Ordering Specification

Raw Material and Inprocess Sl.

DOCUMENTS :

Test Certificates &

stage Inspection

Final Inspection / Test by

Inspn

MFR

CONTR

MECON

MFR

CONTR

MECON

7

8

9

10

11

12

13

For CONTRACTOR / SUB - CONTRACTOR (Stamp & Signature )

Acceptance Criteria

documents to be

Standards/IS/BS/

REMARKS/

submitted to MECON

ASME/Norms and

SAMPLING PLAN

Documents 14

15

( Q . A . P . NO. TO BE ALLOTTED BY MECON ) NO. / / / MSHEET : OF

16

REV.


CONTINUATION SHEET E Q U I P M E N T

D E T A I L S

INSPECTION AND TESTS Raw Material and Inprocess

Sl.


Identification

Quantity

No.


No.

No / M

3

4

Manufacturer's

Expected Sche-

T

Name and Address

dule of Final

5

6


2


Test Certificates &

stage Inspection


Inspn

MFR

CONTR

MECON

MFR

CONTR

MECON

7

8

9

10

11

12

13


Acceptance Criteria

documents to be

Standards/IS/BS/

REMARKS/

submitted to MECON

ASME/Norms and

SAMPLING PLAN

Documents 14

15

( Q . A . P . NO. TO BE ALLOTTED BY MECON ) NO. / / / MSHEET : OF

16

REV.


QUALITY ASSURANCE PLAN FOR ELECTRICAL EQUIPMENT

CONTRACTOR ORDER NO. & DATE SUB - CONTRACTOR

PROJECT PACKAGE NO. PACKAGE NAME

ORDER NO. & DATE CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :

INSTRUCTIONS FOR FILLING UP :

1

QAP shall be submitted for each of the equipment separately w ith break up of assembly / sub-assembly & part/component or for group of equipment having same specification.

2

Use numerical codes as indicated for extent of inspection & tests and submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant and equipment.

3

Separate identification number w ith quantity for equipment shall be indicated w herever equipment having same specification belonging to different facilities are grouped together.

4

Code

MFG

:

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

12. Routine test as per relevant IS/other standard. 13. Type tests as per relevant IS/ other standard.

ABBREVIATIONS USED :

:

Code Description

1. Visual 2. Dimensional 3. Fitment & Alignment 4. Physical Test(Sample) 5. Chemical Test (Sample) 6. Ultrasonic Test 7. Magnetic Particle Test(MPT) 8. Radiography test 9. Dye Penetration Test 10. Measurement of IR Value : a) Before HV Test b) After HV Test 11. High voltage test/Dielectric test.

Weight in tonnes (T) must be indicated under column 5 for each item. Estimated w eights may be indicated w herever actual w eights are not available.

CONTR

Description

CONTRACTOR

Code

Impalse Test. Partial Discharge Test. Heat run test/Temp. rise Test. Enclosure protection Test. Calibration. Noise & Vibration. Test Certificates for bought out components. Tank pressure Test. Paint shade verification. Short time rating. Operation & functional check. Overspeed Test.

DOCUMENTS : D1. Approved GA draw ings D2. Approved single line / schematic diagram. D3. Catalogues / Approved data sheet D4. Approved bill of materials. D5. Unpriced P.O. copy. D6. Calibration Certificate of all measuring instrument and gauges

26. Flame proof Test 27. Clearance and creepage distance. 28. Acceptance Tests as per relevant IS

MANUFACTURER E Q U I P M E N T

D E T A I L S


Sl.


Identification

No.


No.

No / M

Quantity

3

4

Manufacturer's

Expected Sche-

T

Name and Address

dule of Final

5

6


Description

2


Test Certificates &

stage Inspection


Inspn

MFR

CONTR

MECON

MFR

CONTR

MECON

7

8

9

10

11

12

13


Acceptance Criteria

documents to be

Standards/IS/BS/

REMARKS/

submitted to MECON

ASME/Norms and

SAMPLING PLAN

Documents 14

15

( Q . A . P . NO. TO BE ALLOTTED BY MECON ) NO. / / / ESHEET : OF

16

REV.


CONTINUATION SHEET E Q U I P M E N T

D E T A I L S


Sl.


Identification

Quantity

No.


No.

No / M

3

4

Manufacturer's

Expected Sche-

T

Name and Address

dule of Final

5

6


2


Test Certificates &

stage Inspection


Inspn

MFR

CONTR

MECON

MFR

CONTR

MECON

7

8

9

10

11

12

13


Acceptance Criteria

documents to be

Standards/IS/BS/

REMARKS/

submitted to MECON

ASME/Norms and

SAMPLING PLAN

Documents 14

15

( Q . A . P . NO. TO BE ALLOTTED BY MECON ) NO. / / / ESHEET : OF

16

REV.

1574_07-vol-4-1-gts

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