LPG Blending Facilities - List of Documents For Tender

LPG Blending facilities List of documents for Tender
1, Scope of work
8122-03-DA-001
2, Sub vendor list
8122-03-DA-001 VL, 8122-01-DA-001 VL
3, Engg Specifications
25ES205/94-r1
8122-03-ES-001
8122-12-DA-001
8122-12-DA-002
25ES201
25ES202
02ES042/97
02ES023/97
8122-01-PS-002DV
Fabrication and Erection of steel piping

Spec for GRP piping
Spec for Cement Mortar lining
Spec for Pipeline concrete coating
Erection of Static equipments
Erection of Machinery items
Spec for Cold Insulation
Spec for Painting
Standard Spec for Deluge Valves
4, Data Sheets of Fire equipments

8122-01-DA-FH100 Hydrant assembly
8122-01-DA-FH101 Water Monitor
8122-01-DA-FH102 Spray nozzles
8122-01-DA-FH103 Hose box
8122-01-DA-FH104 Deluge valve system
5, Layouts
8122-03-OP-00001
8122-03-UP-00001
8122-03-UP-00002
8122-03-UP-00003
8122-03-KP-00001
8122-03-KP-00002
8122-03-KP-00003
8122-03-KP-00004
8122-03-KP-00005
8122-03-KP-00006
8122-01-ZM-00001
Overall plot plan

Unit plot plan Coastal terminal area
Unit plot plan Heat Exchanger area
Unit plot plan Sea Water Pump house
Piping Key plan
Piping Key plan
Piping Key plan
Piping Key plan
Piping Key plan
Piping Key plan
Piping routing of Fire hydrant
6, Isometrics
8122-03-IS-001 to 016 Piping Isometric drawings 16 Nos
7, Schedule of Items of work 8122-03-SW-001
8122 03 DA 001R0
Page 1 of 6
PIPING
DEPARTEMNT
Supply, Fabrication, Erection, Testing and Commissioning of Piping and Equipments
Introduction
M/s Hindustan Petroleum Corporation Ltd (HPCL) proposes to install an Online Blending Facility at
their Mangalore terminal for blending of Propane and Butane unloaded from the ship. For this purpose
they have requested additional area (appr 3 acres) adjacent to their Coastal terminal which is 1 km away
from the NMPT jetty.
The Online Blending facility shall include one LPG Heater, 3 nos Sea water pumps, one Static Mixer, 2
nos LPG Booster pumps and connected piping and instruments. The LPG Booster pumps will be located
in the new Pump house being constructed at HPCL Terminal whereas all other equipments will be
located in the NMPT jetty area. The Sea water pumps shall be located in the existing fire water pump
house after relocating the existing Jockey pumps.
This tender specification covers the fabrication, erection, testing and commissioning of the LTCS and CS
piping systems and supply, fabrication, erection, testing and commissioning of the GI & GRP piping
systems, supply and erection of Fire fighting equipments and Erection of Equipments
The major piping systems in the plant are
1, LPG system Carbon steel, Class 300
2, Propane, Butane system Low Temp Carbon steel, Class 300
3, Sea water system Glass reinforced plastic (GRP), Class 150
4, Fire water system Cement lined Carbon steel, Class 150 & Galvanised Iron, Class 150
A, Scope of work - Piping
The scope of the Contractor includes
1, Fabrication and Erection of CS & LTCS piping
2, Supply, fabrication and erection of GI & GRP piping
3, Fabrication and Erection of Cement lined CS piping
4, Testing & commissioning
5, Supply/Application of Painting
6, Supply/Installation of Cold Insulation
7, Dismantling of existing piping
PRPD. BY : GSP
CHKD. BY : KPM
APPRD. BY: KAK
ISSUED ON: 16-10-2009
FACT ENGINEERING AND DESIGN ORGANISATION
PIPING
DEPARTEMNT
8122-03-DA-002R0
Fabrication and Erection of Piping
Page 2 of 6
8, Tie in connections with the existing systems

9, Supply/erection of Structural supports etc
10, Supply and Erection of Fire fighting equipments
The details of the above are given below
1
Fabrication and Erection of CS and LTCS piping
The Fabrication and Erection of piping shall be done strictly as per drawings, codes, standards, Engg
specification 25ES205 94/R1( Fabrication and Erection of Steel piping) and instructions from the
Engineer in charge in a professional way. All the tools, tackles, consumables, manpower etc, required for
the work, shall be arranged by the Contractor.
The following codes/standards shall apply
a, ASME B31.3 Process piping
b, OISD 144 LPG Installations
c, OISD 158 Recommended Practices on Storage and handling of Bulk LPG
d, OISD 214 Cross country LPG pipelines
2
Supply, fabrication and erection of GI & GRP piping
GI & GRP materials including pipes, fittings, flanges, gaskets, fasteners, CI/Bronze valves etc are
included in the scope of the Contractor. These items shall be procured from the Sub Vendor list attached
to the tender. If any item is required for which vendor list is not given, the Contractor shall get prior
approval from the Owner/ Consultant before procuring the item.
The general specification of the GRP items ( 8122-ES 03 001) is attached. The Contractor shall
forward their procurement data sheets/specifications to Owner/Consultant for their review
All transportation, loading/unloading, handling, follow up with the supplier etc are included in the scope.
The items shall be despatched from the suppliers works only after inspection by Owner/ Consultant or
after getting clearance from them.
For all items procured by the Contractor, 6 copies of Manufacturers Test Certificates for all mandatory
tests shall be furnished by the Contractor.
PIPING
DEPARTEMNT
8122-03-DA-002R0
The Fabrication and Erection of piping shall be done
Page 3 of 6
strictly as per drawings, codes,
specifications/standards and instructions from the Engineer in charge in a professional way. The
installation of GRP piping shall be as per AWWA Manual M45 Fibreglass pipe Design. All the tools,
tackles, consumables, manpower etc, required for the work, shall be arranged by the Contractor.
The required gaskets and fasteners (galvanized) shall be supplied by the contractor although there are no
separate rates for theses items. Branch connections shall also be made by the Contractor at no extra cost.
For GI piping, all the threaded joints shall be seal welded after hydro static pressure testing.
3
Fabrication and Erection of Cement lined piping

The existing cement lined Fire water headers are to be re routed as per drawing. Also the Jockey
pump discharge lines are to be hooked up with the existing Fire water header in the pump house.
Necessary sleeves for joining, fasteners ( Galvanised)/non metallic gaskets, cement, sand, steel etc for
cement lining are in the scope of the Contractor. Cement lining of new piping as well as repair of cement
lining of the existing piping (if any) as per Specification 8122-12-Da-001attached shall also be carried
out by the contractor at the quoted rate.
4
Testing and Commissioning
Necessary Tests and Inspection of the piping during fabrication/erection and after erection shall be
carried
out by the Contractor.
Radiographic/ Ultrasonic Inspection of 100% butt joints and DP testing of 100% fillet joints shall be
arranged by the Contractor.
After completion of the fabrication and erection, the piping shall be subjected to Hydrostatic pressure
Testing at 1.5 times the design pressure.
All the tools, tackles, consumables, manpower etc, required for the work, shall be arranged by the
Contractor
5
Supply and Application of Painting
All Carbon steel and LTCS piping shall be coated with 1coat of primer and Structurals shall be coated
with 2 coats of primer and 2 coats of finish paint as per Engg specification 02ES203/97. All materials,
PIPING
DEPARTEMNT
8122-03-DA-002R0
Page 4 of 6
tools/tackles, manpower, scaffolding etc shall be arranged by the Contractor. Sand/shot Blasting is not
envisaged.
The primer shall be of Two pack poly urethane holding primer ( 30 microns DFT) and the finish coats
shall be of High build poly urethane coating ( 60 microns total DFT).
6
Supply and Installation of Cold Insulation as per 02ES042/97
Pre formed Poly urethane Cold Insulation over the pipes/valves/flange joints etc shall be applied as per
drawings/specifications /standards and instructions from the Engineer in charge. For all items, 6 copies of
Manufacturers Test Certificates shall be furnished to HPCL.
All materials, tools/tackles, manpower, scaffolding etc shall be arranged by the Contractor.
The supply and installation of Permali blocks( treated teak wood blocks)/ High Density Poly Urethane
blocks at the location of supports is also in the scope of Contractor.
Providing 12 mm concrete coating over the insulated piping as per Specification 8122-12-DA-002
attached is also in the scope of the Contractor.
7
Dismantling of existing piping
For the hook up/ installation of new piping, some of the existing pipelines including fittings, valves,
flanges etc are to be dismantled. The dismantled piping is to be transported to the location specified by
the Owner
8
Tie in connections with the existing system

Necessary tie in connections for hooking up the new system with the existing system shall be carried
out by the Contractor. Draining, flushing, blinding, cold cutting, dismantling / boxing up of joints,
temporary connections and any other activity required for obtaining hot work permit are to be carried out
by the Contractor. Hook up at Loading arm area is with flange and no payment shall be made for this tie
in connection. (Payment shall be made for Fabrication and Erection only).
PIPING
DEPARTEMNT
8122-03-DA-002R0
Page 5 of 6
Structural supports etc
Necessary pipe supports shall be done by the Contractor. The structurals shall also be painted as per
specification. Supply of structurals and MS plates is also included in the Contractors scope. All
miscellaneous works required for the completion of the job are in the scope of the Contractor.
10 Supply and Erection of Fire Fighting Equipments
Supply and erection of Fire fighting equipments such as Deluge valves, Monitors, hydrants, Spray
nozzles, quartzoid bulbs etc are included in the Scope of Contractor including gaskets, fasteners etc.
Supply of these items shall be as per specification 8122-01-PS-002DV and Data sheets ( 8122-01-DAFH100, FH101, FH102 , FH103& FH 104) attached.
11
Free issue of Materials
The following materials, limited to the extent of actual usage, shall be issued to the Contractor free of
cost
Metallic pipes, fittings, flanges, gaskets/fasteners( only for CS/LTCS piping)
Valves ( except CI/ Bronze valves), Strainers, Static Mixer
12
Drawings
Construction issue isometric drawings shall be issued except for Fire water piping and for small
bore lines below 50NB.

The quantities indicated are approximate only. Contractor has to supply and erect as per actual
requirement.
B
1,
Scope of work Equipments

The following equipments are to be erected as per Engg specifications 25ES201 and 25ES202
1, LPG Booster Pump - Vertical, 2 Nos, 4Te weight, 1.2M x 1.2 Mx 5.5M appr. dimensions
2, Sea water pump Vertical, 3 Nos, 2.75Te weight, 1.5M x 1.5M x 12 m appr dimensions
3, Jockey pump Vertical, 2 Nos, 1Te weight, 1.2M x 1.2M x 12 M appr dimesions
4, LPG Heater Horizontal, 1 No, 10.5 Te weight, 953mm dia x 8300mm overall length
PIPING
DEPARTEMNT
8122-03-DA-002R0
Page 6 of 6
All equipment shall be erected as per the instructions specified in the Instruction Manual
supplied by equipment vendor. If suppliers engineers are available at site, erection of equipment
shall be as per their instructions.
Before taking over the foundation for erection, its dimensions, co-ordinates, orientation and
elevations shall be checked with relevant layout drawings. Location and size of the foundation
pockets shall also be checked. Serious deviations, if any, shall be reported to HPCL engineers at
site.
4,
Foundation surface may have to be dressed with a chisel to remove irregularities or to ensure
sufficient roughness. This shall be done by the erection contractor.
5,
Before placing the equipment over foundation, the foundation shall be washed clean.
6,
The equipment shall be thoroughly cleaned by compressed air or clothes to remove dust/dirt.
Foundation bolts are supplied along with the equipment. Erection contractor shall check whether
correct foundation bolts as per equipment drawings are supplied.
In case foundation bolts are not available with the equipment, bidder shall supply the same. Unit
rate (Per Kg basis) shall be quoted in the bid for supply of various sizes of foundation bolts.
Equipment and drivers shall be aligned at site by erection contractor. If the couplings are
supplied with pilot bores, boring of the couplings to suit shaft diameters and cutting keyways
shall be done by erection contractor. In case any error in holes on base plates are noted, this shall
be got rectified by the erection contractor. Filling lubricants shall be done by erection contractor.
Lubricants will be supplied by HPCL.
10
Shims, wedges, jack bolt pads, routing materials etc. required for erection shall be supplied by
erection contractor. Shims shall be of SS 304 material.
11
Leveling of equipment shall be done by precision tools.
12
All tools, tackles, labour and consumables for erection shall be supplied by the erection
contractor. Bidders shall visit the site and familiarize the site conditions before quoting.
TECHNICAL
PROCUREMENT
SPECIFICATION
8122 - 03 - DA - 001 VL
SUB VENDOR LIST - Piping
PAGE 1 OF 2 R 0
A)
GRP PIPES & FITTI GS
1.
2.
3.
4.
5.
6.
B)
M/s Shriram SEPL Composites, Chennai

M/s Amiantit, Goa
M/s Marketing Services Consortium, Coimbatore
M/s Sunrise Polymers & Industries, Vadodara
M/s Sangir Plastics P.Ltd., Mumbai.
M/s Balaji Fibre Reinforce, Vadodara
BRO ZE & CI VALVES
1.
2.
3.
4.
5.
C)
M/s Leader valves, Jallunder

M/s Brightech Valves, Ahmedabad
M/s Steel strong, Mumbai
M/s Flowsteer, Ahmedabad
M/s Easwar Engg, Chennai
METALLIC GASKETS
1.
2.
3.
4.
5.
6.
00FT024/94
D)
M/s IGP Engineers, Chennai

M/s Mechanical Packing Industries, Mumbai
M/s Spiraseal Gaskets, Chennai
M/s Gaskets India, Mumbai
M/s Unique, Mumbai
M/s Vicap, Chennai
BOLTS & UTS
1.
2.
3.
4.
5.
6.
7.
8.
M/s Echjay Industries, Mumbai

M/s Fasteners & Allied Products, Hubli
M/s Fasteners India Manufacturers, Mumbai
M/s Hardwin Fasteners, Mumbai
M/s Nagabhushanam Industries, Bangalore
M/s Pacific Forgings, Mumbai
M/s Vaibhav Industries, Mumbai
M/s Fix fit Fasteners, Kolkota
15.10.09
REV.NO.
DATE
FOR TENDER
DESCRIPTION
GSP
KPM
KAK
PREPARED
CHECKED
APPROVED
TECHNICAL
PROCUREMENT
SPECIFICATION
8122 - 03 - DA - 001 VL
SUB VENDOR LIST
PAGE 2 OF 2 R 0
E)
GI Pipes
1.
2.
3.
4.
5.
6.
00FT024/94
F)
M/s Ajanta Tubes, New Delhi

M/s CSK Tube Enterprise, Chennai
M/s Jindal, Mumbai
M/s Surya Tubes, New Delhi
M/s Sri Laxmi Metal Udyog, Bangalore
M/s Ridhi Steel& Tubes, Ahmedabad
GI & CS fittings& flanges
1.
2.
3.
4.
5.
6.
M/s Madras Engg works, Mumbai

M/s Teekay Tubes, Mumbai
M/s Metal Forge, Mumbai
M/s Super Forge, Mumabi
M/s Tube Products, Baroda
M/s Evergreen Hardwares, Bangalore
15.10.09
REV.NO.
DATE
FOR TENDER
DESCRIPTION
GSP
KPM
KAK
PREPARED
CHECKED
APPROVED
TECHNICAL
PROCUREMENT
SPECIFICATION
1
8122-01-DA 001 VL
SUB VENDOR LIST - Fire Fighting
PAGE
OF 1 R 0
Fire Hydrant
a. Zenith Fire Services
b. HD Fire Protect Company
c. New Age Industries
7.0 Saha Bhogilal & Jethlal Bros
Medium Velocity Water Spray Nozzles

a. HD Fire Protect Company
b. New Age Industries
c. Zenith Fire Services
d. Saha Bhogilal & Jethlal Bros
e. Kidde
Stand post type water monitors.

a. Zenith Fire Services
b. HD Fire Protect Company
c. New Age Industries
d. Deepak Safety Systems
Note:
For bought out items from vendors ,other than that indicated in Subvendor list , prior approval
from Purchaser shall be obtained.
16.11.09
First issue
REV NO
DATE
DESCRIPTION
KK
CRP
PREPARED
CHECKED
JK
APPROVED
iso2.sty
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF

STEEL PIPING
CONTENTS
1.0.0
2.0.0
3.0.0
4.0.0
5.0.0
6.0.0
GENERAL
FABRICATION
WELDING
HEAT TREATMENT
THREADED AND FLANGED JOINTS
PROTECTION & SIZE OF PREFABRICATED
PIPE SPOOLS
7.0.0 INSTALLATION OF PIPE SUPPORTS
8.0.0 PIPING INSTALLATION
9.0.0 TESTING AND INSPECTION
10.0.0 PRESSURE TEST AND OTHERS
11.0.0 APPENDICES
1.0.0
GENERAL
1.1.0
1.1.1
SCOPE
This specification covers the general requirements for fabrication and installation of steel
piping (including carbon steels, low-alloy steels,
and stainless steels) within petroleum refineries
and chemical plants.
When conflict occurs between this specification
and the piping drawings or the individual
specification, the order of precedence shall be
piping drawings, individual specification, and
this specification.
REFERENCES
The requirements contained in the latest editions of the following standards shall form a part
of this specification, in the manner and to the
extent indicated herein:
1. Indian Boiler Regulation (IBR)
2. ANSI B2.1, Pipe Threads
3. ANSI / ASME B31.3, Chemical Plant and
Petroleum Refinery Piping
4. ASME, Boiler and Pressure Vessel Code:
Section V- Non-destructive Examination,
Se c t i o n VI I I - D i v i s i o n 1 , U W- 5 1 Radiographic Examination of Welded Joint,
Section IX- Welding and Brazing Qualifications.
DEVIATIONS
When piping cannot be fabricated and installed
as shown on the piping drawings, or when it is
deemed to be more appropriate to fabricate and
to install the piping in a manner other than as
shown on the drawings, the FEDO Engineer /
Representative shall be consulted and the
piping shall be fabricated and installed in accordance with his instructions.
1.1.2
1.2.0
1.2.1
1.3.0
1.3.1
2.0.0
FABRICATION
2.1.0
2.1.1
MATERIAL CONTROL
Packages of piping materials delivered to the
jobsite shall be opened immediately, and the
quantities, specifications, sizes, and identifica-
PRPD. BY:
CHKD. BY:
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.2.0
2.2.1
2.2.2
2.2.3
2.3.0
2.3.1
23.2
2.3.3
25ES205 / 94 - R1
PAGE 1 OF 28
tion ( color identification and die stamp ) shall be

checked and recorded in the material ledger.
The materials shall be stored promptly and neatly in the designated warehouse or storage yard.
When the identification is inadequate, the
material shall be marked according to the colour
identification or an identification mark such as
die stamp shall be applied before storing the
material.
Piping materials shall be issued only upon
presentation of Material Issue Slips signed by
the FEDO Engineer / Representaive. Piping
materials shall be issued only against the
relevant isometrics.
Issued materials shall be indicated on the drawings or material use charts, etc., to prevent
duplication of issues.
Any surplus materials found on the job - site
shall be returned promptly to the warehouse or
storage yard.
When more material is needed as a result of
faulty fabrication or other similar reasons, the
FEDO engineer shall promptly be in formed of
the matter so that he can give further directions
and advice.
Special precautions shall be taken to keep
electrodes and gaskets dry during storage.
PRECAUTIONS FOR PREPARATI ON &
FABRICATION
When the location of piping connections by field
welding is not shown on the piping drawings,
consideration shall be given to preparation and
fabrication of piping materials so that the field
welding position is flat or horizontal as far as
possible.
The minimum clearance between the edges of
two adjacent welds shall exceed 25mm or 4
t imes the pipe n ominal wall t hickness,
whichever is greater.
When both welded pipes and piping components having a longitudi nal welded joint are
joined at the end, in the girth butt welds the
dimension between the longitudinal welded
joints shall exceed 5 times the nominal pipe wall
thickness of the thicker of those being joined. In
unavoidable circumstances when the dimension is less than 5 times, both longitudinal
welded joints in the girth butt welds shall be
examined by radiography over 100mm. In addition, Section 8.1 (14) shall be considered in
the preparation and fabrication.
CUTTING
Pipes shall be marked accurately and then cut
according to the dimensions shown in the piping
drawing or the dimensions most suitable for the
conditions of field installation.
When irregular cutting is required for single and
multiple branch connections and for curved and
mitred segments of pipe, the cutting shall be
performed by using a template.
In principle, pipes shall be cut mechanically with
a pipe cutter or a high speed cutter. When
cutting ss pipe using a high speed cutter, an
APPRD. BY:
ISSUED ON: 19 - 8 - 96
ENGINEERING
SPECIFICATION
2.3.4
2.4.0
2.4.1
2.4.2
2.4.3
2.4.4

STEEL PIPING
abrasive wheel for stainless steel shall be used.

When pipe is of a large diameter, or when a pipe
cutter or a high speed cutter cannot be used the
following methods may be used.
a) Carbon Steel
Carbon steel pipe may be cut with automatic
or manual oxygen- acetylene gas apparatus. However, base metal with a carbon
content of more than 0.35% shall not be cut
with oxygen-acetylene gas apparatus.
b) Low-alloy steel pipe
Only when unavoidable, low-alloy steel pipe
may be cut with oxygen-acetylene gas apparatus pursuant to Subitem (a) above.
c) Stainless steel pipe
Only when unavoidable, stainless steel pipe
may be cut by plasma arc cutting or arc air
gouging. In this case, the pipe shall be
coated with spatter deposit prevention paint
to avoid adhesion of spatter.
END PREPARATION
Shape of Grooves
1. In principle, grooves for butt welding ends
shall be shaped in accordance with ANSI
B16.25 However, the grooves shall be in
accordence with the approved Procedure
Qalification Records(PQR).
2. Unless otherwise specified, the grooves
shall be in accordance with the requirements shown in Table below which conform
to ANSI B16.25.
PIPE WALL THICKNESS (t)
GROOVE
3 mm or less (stainless
steel) and
4mm or less (carbon steel
and low alloy steel)
Square groove
or slightly
bevelled
Over 4mm (but over 3mm

for stainless steel ) to 22mm
Single v groove
asper figure 1a
Over 22 mm
Double v groove
as per figure 1b
Shape of Internal Trimming and Misalignment

1. Radial misalignment at the joining ends of
piping components shall be such that full
penetration can be attained.
2. Where component ends have an internal
misalignment over 1.6mm, the thicker component with the wall extending internally
shall be trimmed internally to an angle less
than 300C as shown in Figure2. However,
such trimming shall not result in a finished
wall thickness less than the required minimum design thickness plus corrosion and
erosion allowances.
End Preparation method
In principle, the end preparation shall be performed by machine. However, when the
preparation is other than by machine, any
cracks, flaws, burrs or oxidation scale (rust)
shall be removed from the surface with a grinder.
Treatment after End Preparation
2.5.0
2.5.1
2.6.0
2.6.1
2.6.2
25ES205 / 94 - R1
PAGE 2 OF 28
When carbon or low-alloy steel pipes and piping

components with the ends prepared are to be
stored for an extended period, a groove face rust
preventive that will not damage the welding shall
be applied to the ends (Appendix I). The rust
preventive shall be removed prior to welding, as
far as possible.
BENDING
In principle, ready-made elbows shall be used
for bends of piping. However, when bends of a
large radius are required due to fluid characteristics or plant performance, the pipe may be
bent to shape.The procedure for bending shall
be as follows:
1. In principle, pipe shall be cold bent with a
pipe bender. However, when the pipe
bender cannot be used because of the large
pipe diameter, the pipe may be bent by
heating or by high frequency induction.Lowalloy and stainless steel pipes shall not be
bent by heating.
2. Pipe bends shall be made of one piece of
pipe with no welds at the bend.
3 The pipe shall be smooth on both the exterior and interior, and shall be bent so as
not to form any cuts, cracks, wrinkles, dents,
etc.
4 Flattening of a bend shall not exceed the
requirements shown in Section 2.8 figure 6.
5 The minimum bending radius shall be
greater than 1.5 times the nominal diameter
of pipe, unless otherwise specified on the
piping drawings or the individual specification.
6 Low-alloy and stainless steel pipe shall be
heat treated in accordance with the individual specification to relieve residual
stress and work hardening of the bend.
However, the heat treatment may not be
applied to austenitic stainless pipe or to
nickel-alloy steel pipe.
7. For carbon steelpipe of 25 NB and smaller,
steam tracing, or discharge-end piping of
vents, drains, etc., the pipe may be bent to
the required angle by heating with an
oxygen-acetylene gas torch. However,
precautions shall be taken to prevent
damage to the pipe by overheating and to
ensure that the roundness of the steel pipe
is maintained.
MITRE BENDS
Unless otherwise specified, mitre bends shall be
used for piping 350NB and larger. For piping of
300 NB and smaller, ready-made smooth elbows shall be used.
Mitre bends shall be fabricated as follows unless
otherwise stated in the piping drawings or the
individual drawings.
1 Mitre bends to be used at bends greater
than 450C shall consist of not less than three
segments. The minimum distance (l) between alternate segments of the mitre bend
shall be 4 times the pipe nominal wall thickness or 25mm, whichever is greater (Figure3)
25 ES205 / 94 - R1

STEEL PIPING
PAGE 3 OF 28
FIGURE 1 B
FIGURE 1 A
WHEN t > 22 mm
WHEN t - 4mm to 22 mm
33 1/2 2 1/2
R 3.2mm
37 2.5
19
10 1
1.6 0.8
ENGINEERING
SPECIFICATION
1.6 0.8
3.2 0.8
3.2 0.8
FIGURE 2
TRIMMING AND PERMITTED MISALIGNMENT
OVER 1.6 mm
THIS PORTION SHALL BE FINISHED
SMOOTHLY SO AS NOT TO HAVE A

SHARP EDGE, WHICH MAY HINDER
RADIOGRAPHIC EXAMINATION
30 MAX
FIGURE 3
SHAPES OF MITRE BENDS
15
30
1.5 D
30
1.5 D
FIGURE 4
ANGLE OF MITRE BENDS
ENGINEERING
SPECIFICATION
2
3

STEEL PIPING
The radius of the mitre bend shall be greater

than the nominal diameter of the pipe.
The maximum mitre angle ( of Figure 4) of
each segment shall be as follows:
When design pressure is
8kgf / cm2G or less
: 22030
2.7.7
When design pressure is 28

kgf / cm2 G or less
: 15000
2.7.8
When design pressure exceeds 28 kgf / cm2G
: 11 015
The segments shall be neatly cut so that

they will closely fit with each other when
assembled. Cutting and end preparation of
pipe shall be in accordance with the requirements (Sections 2.3 and 2.4)
5 When designing the shape of a groove, the
mitre angle shall be considered and the
shape of the groove shall be suitable for the
welding process used.
6 When assembling the mitre bend, the segments shall be laid out and tack welded on
a surface plate or other flat surface to keep
the centers of the segments aligned.
7 After welding is completed, the interior of the
pipe shall be inspected and any internal
weld protrusions shall be removed.
8 Welding and heat treatment shall be performed in accordance with the requirements
specified in Sections 3.0.0 and 4.0.0 of this
specification.
2.7.0. BRANCH CONNECTIONS
2.7.1 Branch connections shall be fabricated by assembling the fittings that have dimensions and
configurations shown in the piping drawings.Unless otherwise specified, branch connections
shall be made in accordance with Figure 5 and
as follows:
2.7.2 Branch connections, which are made by providing a hole in the main run pipe and inserting a
branch pipe or a coupling, shall be as follows:
a The hole provided in the main run pipe shall
conform to the requirements of Section 6.
b When the main run pipe is welded pipe, the
welds of branch connections shall be made
so as to avoid the welds of the main run
pipe.
2.7.3 Branch connections shall be made by means of
fully penetrated groove welds. The groove
welds shall be made in accordance with the
same welding procedure as for girth butt welds.
2.7.4 In no case shall scraps of metal resulting from
making the hole be left inside the pipe.
2.7.5 When making branch connections, a jig or a
metal fitting shall be attached to the main run
pipe to prevent distortion of the main run pipe or
bending of the branch pipe due to welding. The
material of the metal fitting shall be similar to the
main run pipe.
2.7.5 If reinforcement pads are used, unless otherwise specified, a 3.0mm dia vent hole shall be
provided (at the side and not at the crotch) in the
reinforcement pad to reveal leakage in the weld
2.8.0
2.8.1
2.8.2
2.9.0
2.9.1
25ES205 / 94 - R1
PAGE 4 OF 28
between branch and main run, and to provide

vent ing during welding and heat treatment
operations. If the reinforcement pad is made in
more than one piece, each piece shall be
provided with a vent hole.
The material of reinforcement pads shall be the
same as the main run pipe.
An examination of the welds joining reinforcement pad to the branch shall be made by FEDO
Engineer/ representative before installing the
reinforcement pad.
FABRICATION TOLERANCES
To avoid misalignment when joining a pipe or
fitting to a pipe, the pipe or fitting shall be turned
to check for any irregularities and shall be joined
correctly.
Unless otherwise specified, tolerances for
fabrication shall be in accordance with the requirements shown in Figure 6.
GALVANISED PIPING
Galvanised carbon steel piping shall be completly cold worked so as not to damage galvanised surfaces
3.0.0
WELDING SPECIFICATION
3.1.0
3.1.1
GENERAL
This specification shall be adopted to all welded
pipe joints of carbon steel, alloy steel and stainless steel piping system.
The welded pipe joints are defined as under:
1. All line joints of the longitudinal and circumferential butt welded and socket welded
type.
2. Attachments of castings, forgings, flanges
and other supporting attachments to pipes.
3. Welded manifold headers and other sub assemblies
4. Welded branch connections with or without
reinforcement pads.
5. Manufacture of welded / fabricated piping
components.
6. The attachment of smaller connections for
vents, drains, drips and other instrument
tappings.
All welding, and heat treatment, shall be in
accordance with the applicable codes and
specifications.
3.1.2
3.1.3
a.
codes for petroleum

refinery piping
ANSI B31.3
b.
Welding Qualifications.
ASME Sec. IX.
c.
Code of procedure for

metal arc welding of mild
steel (structural work only)
IS : 823
d.
The Indian Boiler Regulations
IBR
All codes referred shall be the latest editions. In

adition to the codes mentioned above, other
relevant international codes such relating to the
work, shall also be applicable. In case of conflicts between different codes or between codes
ENGINEERING
SPECIFICATION
3.2.0
3.2.1
and tender specifications the more stringent

shall be applicable.
INSPECTION & TESTING
General
1. The owners inspector shall have free access to all concerned places, where the
actual work is being performed. The contractor shall also provide the owners inspector all means and facilities necessary
for carrying out inspection.
2. The owner is entitled to depute his own
inspector to the field or shop where prefabrication and erection of pipe lines are
being done with ( but not limited to ) the
following functions :
a.
b.
c.
d.
e.
f.
b. To supervise welding procedure & welders

performance qualification tests.
c. To ensure that only qualified welders are
engaged for welding.
d. To check that shop / field welding is in conformity with the relevant specification and
codes of practice followed in pipe line construction.
g.
h.
i.
j.
e. To carry out Non Destructive Examination

of welds.
3.2.3
3. Contractor shall intimate sufficiently in advance the commencement of qualification

tests and welding work to enable the
owners inspector to be present to supervise
them.
Welding procedure qualification
Welding procedure qualification shall be carried
out in accordence with the job requirements and
relevant requirements laid down in the standard
ASME Sec. IX and other relevant applicable
codes. The contractor shall submit the welding
procedures in QW 482 format given in ASME
Sec. IX. immediately on receipt of work order.
Owners inspector will review, check and approve the welding procedure after conducting
the necessary tests. It shall be the responsibility
of the contractor to carry out the tests, at his
costs. All the necessary arrangements for the
procedure qualification i.e. supply of material for
assembly welding consumables, welding equipments, preparation of test coupons, welding,
heat treatment, machining of test specimen,
conducting N.D.T, mechanical & chemical test
and maintaining qualification records, shall be
by the contractor at his cost. He shall submit the
test results to the Engineer-in-charge in QW483 format given in ASME Sec. IX. for approval.
Welders Qualification
1. Welders qualification shall be in accordance with the relevent codes specified in
scope of work. Owners inspector shall witness the test and certify the qualification of
each welder. Contractor shall submit the
welder qualification report as per Format
before the commencement of work. It shall
be the responsibility of the contractor to
carry out the qualification tests of welders.
PAGE 7 OF 28
For piping covered by Indian Boiler Regulations, welders with valid IBR certificate,
qualified by Boiler Inspectors and acceptable to the local Boiler Authority shall only
be employed.
2. The welders shall always have in their possession the identification card as per Format
and shall produce it whenever demanded
by owners Inspector. It shall be the responsibility of the contractor to issue the identity
cards after duly certified by the Inspector.
3. The identity card shall contain the following
minimum details.
a. To check the quantity, consumables and

welding equipments used on the job
3.2.2
25ES205 / 94 - R1

STEEL PIPING
3.3.0
3.3.1
3.4.0
3.4.1
3.4.2
3.4.3
Name of Contractor
Name of welder
Stamp No.
Address
Recent passport size photograph
Details of qualifications
i
Welding process and P numbers
ii
Range of pipe diameters
iii Range of thickness
iv Welding positions
Date of qualification test
Period of validity
Signature of manufacturer
Signature of Engineer incharge
4. No welder shall be permitted to work without

the possession of identify card.
5. If a welder is found to perform a type of
welding or in a position for which he is not
qualified, he shall be debarred from doing
any further work. All such welds so performed shall be cut and redone at the expense of the Contractor.
6. Engineer-in-charge reserves the right to ask
the contractors to perform requalification
test at their cost for welders whose
workmanship technique etc. are found unsatisfactory during the execution of the job.
SELECTION OF WELDING MATERIALS
Selection of welding electrodes shall be as per
Appendix - II
Table - I : Selection of welding electrodes & rods
for joining similar materials except Aluminium
Table - II : Selection of welding electrodes & rods
for joining dissimilar materials except Aluminium
STORAGE AND ISSUE OF ELECTRODES
Electrodes shall be stored and issued as follows:
Electrodes shall be stored indoors free from
moisture as far as possible.
Electrodes shall be dried in a heating cabinet in
accordance with the manufacturers recommendation before welding.
Immediately after drying, electrode shall be
stored in a portable dryer, or in a heating cabinet
at the following temperature, and shall then be
used.
a.
Illumenite
: 70 - 1000C
ENGINEERING
SPECIFICATION
b.
3.4.4
3.4.5
3.4.6
3.4.7
3.5.0
3.5.1
3.5.2
3.6.0
3.6.1
3.6.2
Others

STEEL PIPING
: 100 - 1500C
During welding, electrodes shall be kept in a

portable dryer or equivalent. The electrodes
shall not be laid down directly on the ground or
any other damp places.
Electrodes exposed to the atmosphere for more
than 4 hours shall be redried. However, only two
redryings are permitted.
When the days work has been completed, the
electrodes shall be collected and stored in a
heating cabinet at the temperature specified in
3.3.2 above.
Issue of electrodes shall be controlled by the
assigned person.
SURROUNDING CONDITIONS FOR WELDING
Welding shall not be performed under the following climatic conditions.
1. In the rain
2. In winds of 8 m/s or more
3. In snow
However, welding may be performed if the area
is fully protected from the inclement weather.
When the item to be welded is wet with rain or
covered with snow or ice, the snow or ice shall
be removed and the surface dried completely
before welding.
GENERAL FOR WELDING
Welding shall be performed in accordance with
welding procedure specification (WPS), which
has been approved by FEDO/Representative.
Before welding, the WPS shall be prepared
which has been qualified by the welding procedure qualification test based on the specification
for welding procedure qualification, according to
this specification and ASME Section IX.
As a general rule, welding for steel pipes shall
be performed as follows.
1. The welding process used shall be SMAW,
GTAW, or GMAW (MIG Welding). Any other
welding process may be used only when
approved by FEDO / Representative.
2. Preferably, the first layer of butt welded joint
shall be made by GTAW. For the first layer
on 3Cr. and higher low-alloy steel pipe, or
stainless steel, GTAW shall be performed
with back shielding gas such as argon.
3. The surface to be welded shall be cleaned
thoroughly and any paint, rust, scale, oil,
dust, moisture, or any other foreign matter
that would be detrimental shall be removed
at least within the extent of 50mm from the
groove end before welding.
4. The welding position shall be performed in
flat position as far as possible.
5. Full consideration shall be given to the welding progression to keep distortion to a minimum.
6. In multi-layer welding, before welding the
following layer, the surface of each layer
3.7.0
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
25ES205 / 94 - R1
PAGE 8 OF 28
shall be removed of any slag or other foreign

matter with a chipping hammer, a grinder, or
a wire brush. To prevent spatter adhering to
the base metal, a spatter deposit prevention
paint may be applied around the outside of
the groove. Wire brushes and abrasive
wheels shall be distinguished so that those
for stainless steel shall not be confused with
those for carbon steel or low-alloy steel.
Moreover, any arc starts, craters, or inferior
beads of each layer shall be removed
before the welding is continued.
7. Peening on the welds is prohibited.
8. Unless required, the external surfaces of
welds shall not be finished with a grinder or
any other tool. However, when finishing the
end of weld beads with a grinder, special
precautions shall be taken not to reduce the
thickness of base metal by over grinding.
9. Arc strike shall not be generated on the pipe
surface. Care shall be taken not to lay down
the electrode holder or move it around by
the electrode.
10. To prevent damage from sparks, care shall
be taken to ground the welding equipment
by strict use of ground clips and to ground
each piece of material.
11. When welding galvanized steel, the coating
shall be removed from the surface to be
welded, 50mm on either side.
12. For the joints of P-Number 5 materials,
when welding is unavoidably interrupted,
postheating shall be applied and the welds
shall be cooled gradually by the use of
insulation or other suitable materials. ( Para
4.3.0 ).
BUTT WELDS
When welding a pipe to a pipe, fitting, valve, etc.,
the components shall be placed on a revolv ing
stand, aligned accurately within the tolerances
specified in Section 2.8. of this specification by
the use of tack weld pieces (fit-up pieces), lineup clamps, etc., and shall then be welded.
Backing rings shall not be used unless otherwise specified.
The number of tack welds made shall be the
minimum required to secure the pipe, and a
minimum of three shall be made for pipes of 50
NB and larger.
When tack weld pieces are used for pipe
materials of stainless steel,the material of the
pieces shall be similar to that of the pipe. When
the pipe material is low-alloy steel, carbon steel
may be used for the pieces unless otherwise
specified.The welding for the tack weld pieces
shall be performed with electrodes equivalent to
those used for the base metal and shall be
performed by a welder or welding operator
qualified for fillet welds.
Tack welds, which are made directly at the root
of the joint, shall be made by a qualified welder
or welding operator specified in Section 3.2.3
and shall be made by the same welding procedure as the product welding. Tack welds that
are cracked or not fused properly shall be
removed.
ENGINEERING
SPECIFICATION
3.7.6
3.7.7.
3.7.8.
3.8.0
3.8.1
3.9.0
3.9.1
3.10.0
3.10.1
3.10.2
3.10.3
3.10.4

STEEL PIPING
Pieces for tack welds shall be removed with a

grinder. If a concave surface due to overgrinding, etc., is produced on the pipe, the repair
welding shall be performed in accordance with
WPS, which has been approved by FEDO Engineer / Representative. Any convex weld beads
formed on the pipe surface shall be removed.
When defects are found while removing tacks /
cleats they shall be fully removed, repaired by
welding, and a magnetic particle or liquid
penetration examination shall be performed to
confirm that there are no defects.
Internal weld protrusions of butt welds for orifice
flanges shall be finished smoothly to the pipe
inside diameters with a grinder.
The root pass of all buttwelds on pipe of size
less than 50NB shall be made in GTAW grove
only.
FILLET WELDS
Fillet welding shall be performed as follows:
1. Fillet welds shall be multi-layered and of
sufficient strength.
2. Fillet welds shall be as shown in Figures 7A
and 7B.
3. Fillet welds for socket welding flanges shall
be as shown in figure 7C.
4. Fillet welds for socket welding components
shall be as shown in figure 7D.
SEAL WELDS
Seal welding shall be performed as follows:
1. Threaded joints to be seal welded shall not
be coated with a compound or covered with
a seal. After any oil on the threads has been
fully removed, the threads of joint shall be
screwed in securely in accordance with
Section 5-1.0, and shall then be welded.
2. If threaded joints are seal welded, all exposed threads shall be covered by a seal
weld.
3. Seal welding shall be performed by a
qualified welder.
4. Electrodes of 3.2 mm dia or less shall be
used.
FLANGE ATTACHMENT WELDS
Flange attachment welding shall be performed
as fol lows:
Unless otherwise shown on the drawings, in
principle, flange bolt holes shall straddle the
established centerlines. The only exception is at
equipment flanges required for matching orientation.
When installing flanges, flange square or other
jig shall be used, and the center line of the pipe
and the perpendicular of the flange face shall be
within the tolerances specified in Section 2.8.
Joining welding neck flanges to the pipe shall be
performed in accordance with the requirements
of Section 3.7.
Front welding shall be performed on slip-on
flange joints except for pipes class less than
50NB (Figure 8). Care shall be taken so that the
weld reinforcement does not protrude on to the
25ES205 / 94 - R1
PAGE 9 OF 28
gasket contact face and that the gasket contact

face is not damaged by welding. If the gasket
contact face is damaged,or weld reinforcement
protrudes onto the gasket contact face, such
defects shall be removed by polishing the gasket contact face.
3.10.5 When welding flange joints, care shall be taken
to handle the flanges carefully so that the gasket
contact face will not be damaged. The gasket
contact face shall not be in direct contact with
the ground, and grounding shall not be taken
directly from the gasket contact face.
3.10.6 In the case slip-on flanges which are to be heat
treated, and also require to be front welded,they
shall be provided with a 3mm dia vent hole at
the hub as shown in FIG.8.
4.0.0
HEAT TREATMENT
4.1.0
4.1.1
PREHEATING
Unless otherwise specified, the preheating applies to gas cutting and welding (all welds including butt welds, fillet welds, socket welds, repair
welds, tack welds, and seal welds of thread ed
joints ). Preheating shall be performed as follows:
1. Materials to be pre heated and preheating
temperature shall be in accordance with
relevant codes as a rule, but for steam lines
fallen under the purview of IBR, the same
shall be followed.
2. If the maximum specified carbon content is
more than 0.38, or if the material is under a
high degree of restraint (weld-all- around
such as pipe shoe), carbon steel shall be
preheated to a minimum of 800C and maintained at that temperature for surface welding.
3. When welding dissimilar metals, unless
o th er wise sp eci fied , the preh eatin g
temperature shall be that for the higher
grade steel
4. The width of the heated circumferential
band shall be 4 times the pipe nominal wall
thickness or 100mm, whichever is greater,
extending on both sides of the welds.
5. Heat shall be applied by the use of a gas
burner or a heating coil. The use of a gas
burner for cutting shall not be permitted
since it tends to heat locally.
Temperature measurements of preheating, interpass temperature, and postheating shall be
performed by a temperature crayon ( tempil
stick), thermocouple temperature indicator, etc.,
and it shall be confirmed that the specified
temperature is maintained.
INTERPASS TEMPERATURE
The following items shall be confirmed for interpass temperature:
1. Interpass temperature of the materials that
require to be preheated shall be the same
as the preheating temperature and shall be
maintained until welding has been completed.
2. Interpass temperature of austenitic stainless steel pipe shall not exceed 1500C.
4.1.6
4.2.0
4.2.1
ENGINEERING
SPECIFICATION
4.3.0
4.3.1
4.4.0
4.4.1
25ES205 / 94 - R1

STEEL PIPING
POSTHEATING
When postheating is required it shall be carried
out for more than 30 minutes within the temperature range of 300 to 4000C, and the material
shall be cooled gradually by the use of insulation, etc. However, when post weld heat treatment is performed immediately after welding,
post - heating is not necessary.
POST WELD HEAT TREATMENT
Procedure
Unless otherwise specified, post weld heat
treatment shall be performed in accordance with
the following procedure. However, post weld
heat treatment for dissimilar metals shall be in
accordance with the individual specification.
1. The requirements for heat treatment shall
be in accordance with applicable codes. But
for steam lines IBR shall be followed. Heat
treatment of welded joints between dissimilar ferritic metals shall be within the
temperature ranges for the higher grade
steel.
2. Al l th e m ach ine d surf aces sha ll be
protected adequately by the use of paint or
compound to prevent damage from scaling
during heat treatment.
3. In case of furnace heat treatment, all the
pipes shall be supported properly during
heat treatment to minimize warps and other
distortions.
4. In principle, after heat treatment has been
completed, neither rewelding nor reheating
shall be performed. However, if rewelding is
performed because of repairs, etc., heat
treatment shall be performed again.
5. If welding is intrrupted before completion or
the weldment is allowed to cool prior to heat
treatment, adequate heat treatment or controlled rate of cooling shall be applied to
ensure that no effects detrimental to the
piping shall result. The pre-heat temperature in the welding must be applied before
welding is resummed.
6. When heat treatment is performed, the holding temperature, holding time, rate of heating and cooling, and the hardness after heat
treatment required shall be recorded and
the records shall be submitted to FEDO
Engineer / Representative.
7. The measurement of heat treatment
temperature shall be performed by measuring the metal temperature by the use of a
thermocouple,or by other suitable methods.
Ho w e ve r, w he n t he h e at t r ea t me n t
temperature is measured by the furnace
temperature, the relation between the
temperature of metal and furnace shall be
considered.
8. A hardness test shall be performed in accordance with Section 9.4.0 to determine if
the heat treatment has been performed
satisfactorily.
9. Throughout the cycle of heat treatment, the
portion out side the heated band shall be
suitably wrapped under insulation so as to
avoid any harmful temperature gradient at
PAGE 11 OF 28
the exposed surface of pipe. For this purpose temperature at the exposed surface of
pipe should not be allowed to exceed
4000C.
10. All online pipe item ( eg. Valves, Instruments
etc. )within 500mm of the weld which is
beingheat treated, shall be dismantled prior
to commencement of heat treatment of
weld.
11. The no. of thermocouples to be used for the
monitoring of tempreature shall be as follows.( HAZ - Heat Affected Zone )
DIA OF
PIPE
NOS. OrientatIO
N(0)
LOCATION
15NB &
below
0 , 180
One on weld & one

in HAZ
200 to
500 NB
0 , 120 ,
240
one on weld & rest in

HAZ on either side
of weld
600 Nb &
above
& rest in
0 , 90 , two on weld
either side
180 , 270 HAZ on
of weld
4.4.2
Heating Methods
For heat treatment, application of heat in a
furnace is preferable, however, heat may be
applied locally by the following methods:
1. Heating by electrical resistance
This is a method where a programmed movable automatic heater applies heat by
means of nickel-chrome wire applied
around the welds. Special attention shall be
given to the following items:
a.
Protective measures shall be taken to

prevent damage to the pipe surface or injury to the workers due to a short circuit
of the lead wire, and to prevent persons
other than the operator entering the work
area.
b.
The width to be heated shall extend

25mm beyond the edges of the weld on
each side
c.
The width to be insulated shall extend at

least 150mm on each side of the weld.
d.
The heating and cooling rates above

3150C shall be determined by the following formula, but in no case shall the rate
exceed 2200C per hour.
25 x 220
( oC h)
wall thickness (mm)
2. Heating by gas burner

a.
This is a method where heat is applied

by a propane or butane gas burner. This
method shall not be used unless
specified by FEDO Engineer/ Representative.
5.0.0
THREADED AND FLANGED JOINTS
5.1.0
THREADED JOINTS
Threading of joints shall be as follows.
Taper pipe threads shall be as per ANSI B2.1,
5.1.1
ENGINEERING
SPECIFICATION

STEEL PIPING
ANSI Standard Taper Pipe Thread (NPT).

Unless otherwise specified, when threading on
pipes of NPS 11/2 or smaller, the pipe thickness
shall be Schedule 80.
5.1.3 In principle, all threads shall be cut with a threading machine or lathe. When threading with hand
dies such as an oster or reed type, a lubricant
shall be used to avoid an irregularity of screw
thread or scratches due to coarse machining.
5.1.4 All the threads shall be cleaned thoroughly.
5.1.5 In principle, teflon seal tape shall be used for
threaded joints used in services of 1500C and
lower. Once the joints are screwed, they shall
not be unscrewed. Fillers such as hemp, jute,
lead scraps, and white paint shall not be used.
5.1.6 Seal welding of threaded joints shall be in accordance with Section 3.9
5.1.7 In no case shall threaded joints be made with a
length of engagement less than specified.
5.1.8 When pipe is screwed into a threaded flange,
the pipe end shall not extend beyond the gasket
contact face. If the pipe end protrudes even
slightly, the pipe end shall be ground off with a
grinder or a file so that the gasket contact face
is not scratched.
5.1.9 When screwing a pipe into a threaded bronze
valve, the pipe shall be gripped by a pipe vice
and the valve shall be screwed on by clutching
the end of the valve with a wrench. Threading
and screwing shall be carried out carefully so
that the pipe does not enter the valve too far and
damage the valve due to the threads being
overcut on the pipe.
5.1.10 Scraps of metal due to threading and oil used
for cutting shall be removed before screwing on
instrument air piping.
5.1.11 Any compound or lubricant used on the threads
shall be suitable for the service conditions, and
shall not react unfavourably with either the service fluid or piping material.
5.2.0 FLANGED JOINTS
Flanged joints shall be made as follows:
5.2.1 In principle, Class 125 and 250 flanges of valves
and other equipment made of gray cast iron
shall be of flat face with full contact area gaskets.
5.2.2 Steel to gray cast iron flanged joints shall be
assembled with care to prevent damage to the
cast iron flange.
5.2.3 Unless otherwise specified, gasket paste shall
be applied uniformly on the gasket contact face
of the flange when a metal jacketed gasket or a
metal gasket is used. However, when the flange
material is austenitic stainless steel, the use of
gasket paste shall be approved by FEDO Engineer / Representative. As the choice of paste
is limited by the fluid handled, the paste shall be
suitable for the service fluid. The gasket paste
shall be kept in a container with a lid and handled
with care to prevent entry of sand, dust or other
foreign matter.
5.2.4 For asbestos-sheet gasket, gasket paste may
not be applied.
5.2.5 For spiral-wound gaskets or ring-joint gaskets,
gasket paste shall not be applied.
5.2.6
5.1.2
5.2.7
5.2.8
5.2.9
5.2.10
5.2.11
5.2.12
5.2.13
5.2.14
5.2.15
25ES205 / 94 - R1
PAGE 12 OF 28
The thread and bearing surfaces of bolts and

nuts to be used on piping at temperatures of
2500C or higher shall be coated thinly and
uniformly with a lubricant to prevent them becoming burnt and stuck.
Lubricant shall not be applied to machine bolts
unless other wise specified.
Bolts shall be of material and length as
specified. In principle, all the bolts shall extend
2 or 3 threads through their nuts.
Flanges shall be tightened with a wrench or
spanner of the specified length and with a hammer if required, or with a torque wrench. Care
shall be taken so that the bolt is not tightened
excessively or unevenly.
As the tightening force varies according to the
flanges, gaskets, and bolts used, the tightness
shall be controlled with care. In particular, flanges of piping for low temperature and dangerous
services shall be tightened only with a torque
wrench. For large diameter bolts, the use of an
impact wrench with torque control or a power
machine ( hydraulic torque wrench ) is preferred.
Bolts of flanged joints shall be successively and
evenly tightened in a symmetrical pattern ( Appendix IV ).
Cast iron flanges of equipment such as pumps,
turbines, compressors, or other similar equipment shall be tightened carefully so that the
flange does not break.
The flange clearance with connections of
pumps, compressors, or other similar equipment, and ring-joint flanges shall be measured
by the use of a clearance gauge and the parallelism shall be checked, and then the bolts shall
be tightened evenly.
Ring-joint gaskets shall be ground with the
groove of the flange for a tight fit prior to installation. The grinding shall be performed by using
a compound (coarse, intermediate, or fine), and
red paste shall be applied to confirm the roughness of the contact face between the ring and
the groove of the flange. The paste shall be
removed completely before the ring is installed.
If the gasket contact face of the flange is
damaged, the defects shall be removed by
polishing evenly the gasket contact face, or the
flange shall be replaced.
6.0.0
PROTECTION OF PREFABRICATED PIPE

SPOOLS AND SIZE
6.1.0
PROTECTION OF PREFABRICATED PIPE

SPOOLS
All prefabricated pipe spools that have been
inspected shall be protected as follows until they
are installed in a plant.
1. All dust, rust, weld slags, or other foreign
matter in the pipe shall be removed carefully
by brushing or by flushing with compressed
air, or by other suitable means. After cleaning, all openings of austenitic stainless steel
shall be blanked.
2. Pipe spools to be stored temporarily shall
be laid on suitable sleepers and not directly
on the ground.
6.1.1
ENGINEERING
SPECIFICATION
6.1.2
6.1.3
6.2.0
6.2.1
6.2.2

STEEL PIPING
3. Pipe spools shall be marked with the area

number (major divisions such as offsite,
onsite), line number, and piece number.
After cleaning the pipe spool surface and
applying rust preven tive, it shall be marked
clearly with paint by the use of a stencil.
When specified, in showing the line number,
etc., a color code identification or tag plate
(die stamped to the sheet metal) for each
area shall be made, and it shall be attached
with coated iron wire. However, zinc coated
iron wire shall not be used for austenitic
stainless steel.
4. If hydrostatic test is performed, the water
shall be removed completely.
When prefabricated pipe spools are to be stored
for a long period of time or are to be shipped,
the pipe interior shall be checked to see that it
is clean, and the openings of pipe ends shall be
protected as follows:
1. When the pipe ends are prepared, the ends
shall be coated with rust preventive ( Appendix 1 ) and covered with a plastic cap, etc.
2. When the pipe ends are flanged, the gasket
contact face shall be coated with rust
preventive and be protected with a wooden
or plastic cover bolted on to the flange. In
case of a wooden cover, poly ethylene or
other suitable film shall be inserted between
the flange and the cover.
3. When the pipe ends are threaded, the
threads shall be coated with rust preventive
and threaded end connections shall be
covered with wooden or plastic plugs or
caps.
4. When masking tape is intended to be used
instead of the protection mentioned above,
it shall be subject to FEDO Engineers/ Representatives approval.
However, austenitic stainless steel pipes and
prefabricated pipe spools that may be affected
by chlorine ions, shall be protected in accordance with the individual specification.
SIZE OF PREFABRICATED PIPE SPOOLS
The size of prefabricated pipe spools shall be
determined by consideration of the conditions of
transportation, etc. Consideration shall be given
to the conditions of inland transportation, size of
the carriers hatch, means of transportation, traffic regulations in the country and the economy.
The standard size of a package to transport
prefabricated pipe spools is limited to 2.5 meters
width by 2.5meters height by 13 meters length
with a weight of 5 tons per package.
7.0.0
INSTALLATION OF PIPE SUPPORTS
7.1.0
7.1.1
PIPE SUPPORTS
Pipe supports whose materials & dimensions
conform to fabrication drgs, shall be installed
accurately at the positions shown on the drawings prior to piping installation. When installing
the pipe supports, pay attention to the following:
1. Each support shall be fabricated and assembled so that piping does not become
disengaged from the support by movement
of the piping itself due to operation.
7.2.0
7.2.1
7.3.0
7.3.1
7.3.2
7.4.0
7.4.1
7.5.0
7.5.1
25ES205 / 94 - R1
PAGE 13 OF 28
2. Stanchions requiring foundations shall have

anchor bolts of the correct size, position,
projection, etc.
3. Before installing the supports, the finished
conditions of the cut ends of all members
and welded conditions shall be checked.
4. Pipe supports shall be made level and
plumb to facilitate alignment during piping
installation.
5. In principle, when the main run pipe is lowalloy steel or ss, either a pad plate or support
members of the same material as the main
run pipe shall be used, and carbon steel
supports shall not be welded directly to
these. In this case, when welding the pipe
to the support, the same electrodes as applied to the pipe shall be used, and the
qualified welder specified in Section 3.1.0
shall perform the welding in accordance
with WPS. When the main run pipe requires
heat treatment, the welds for attachment of
pipe supports shall be heat treated if required,as per ANSI B31.3.
6. Welds for anchor supports shall be doublelayer welds to provide a bond of sufficient
strength.
7. When welding dummy pipe to elbows, tees,
etc., the welding shall not melt through to
their interior.
SLIDING SUPPORTS
Sliding supports shall be assembled so that the
expected movement of the supported piping due
to thermal expansion and contraction or other
design requirements is possible.
SPRING HANGERS
The lock-pin or preset-piece of spring hangers
shall not be taken off until pressure testing and
flushing have been completed, except only
when a high temperature fluid such as flushing
steam is streamed.
Adjustment of spring hangers shall be performed by taking off the lock-pin or preset-piece
prior to ini tial operation. It shall be confirmed
that spring hangers operate on the expected
movement according to temperature increase in
the initial operation.
ADDITIONAL SUPPORTS
If additional supports are required to prevent
shaking of piping in the field, they shall be
installed in accordance with the instructions of
the FEDO Engineers / Representatives Engineer in consideration of the effects due to
thermal expansion of the piping.
INSULATION SUPPORTS
The configuration, material, and installation procedure of support rings for hot or cold insulation
of vertical piping shall be in accordance with the
individual specification.
8.0.0
PIPING INSTALLATION
8.1.0
GENERAL ITEMS FOR PIPING INSTALLATION

The general items for attention relating to piping
installation shall be as follows:
ENGINEERING
SPECIFICATION
8.1.1

STEEL PIPING
Pipes shall be stored in accordance with each

category of material, and stacked on sleepers
with wedges or stakes provided to prevent the
stack from collapsing.
8.1.2 Before installation, pipe spools shall be checked
with the piping drawings as to dimensions,
material, class, etc. In principle, the installation
of pipe spools shall start from elevated lines or
larger size lines. The precedence for installation
shall be determined after confirming that all
equipment has been installed and aligned, and
steel structures and pipe racks are ready for
installation of the piping. The part which cannot
be painted after piping installation shall be
painted beforehand.
8.1.3 In principle, underground piping shall be installed before above ground piping.
8.1.4 Before installation, the pipe spool shall be
suspended at one end by a crane, etc., and ham
mered to remove the dust inside.
8.1.5 Supports such as stanchions shall be checked
for the accuracy of position, dimensions, elevation, levelness and plumbness.
8.1.6 When temporary supports are installed unavoidably to the piping, welding shall not be
performed on the main run pipe.
8.1.7 Temporary work for piping installation shall be
planned in advance, and the necessary equipment and materials shall be selected and
prepared in time with the schedule. Moreover,
the scaffolding required for field connections
shall be checked, and whether the required
number of scaffold pipes and boards shall be
sufficient.
8.1.8 Scaffolding shall be provided to permit safe
operation, and the use of small size piping,
pumps, instruments, etc., in lieu of scaffolding
shall be prohibited. All scaffold boards shall be
securely tied to the scaffold pipes or piping with
metal connectors or iron wire.
8.1.9 The primary cards, cables, and grounding wires
of all welding equipment shall be of sufficient
size, and any conductors with damaged insulation shall not be used. They shall be inspected
periodically.
8.1.10 Piping components such as pipe spools and
valves shall be lifted with the designated wire
rope slings, and the use of iron wire shall be
prohibited.
8.1.11 Piping components shall be hauled by mechanical equipments as far as possible. Even for a
short haul, the components shall be securely
tied to prevent them from falling.
8.1.12 Piping requiring cold spring may become
misaligned during field welding, therefore, the
dimensions shall be checked thoroughly in accordance with the piping drawings. After it has
been confirmed that guides and anchors have
been installed at the specified location, the
piping shall be installed. Furthermore, when
there are flanged joints in the same direction
requiring cold spring, a spacer with the same
thickness as the dimension of cold spring shall
be inserted between the flanges, and when the
entire piping system has been assembled, the
spacer shall be removed and the flange fastened.
25ES205 / 94 - R1
PAGE 14 OF 28
8.1.13 Alignment tolerances of flange connections installed in piping shall be as per Figure 9 ( Page
28 of 28 ). However, alignment tolerances of
pipe flanges for the rotational equipment nozzle
shall be as per Section 8.3.0 ( Item 6 ).
8.1.14 In principle, the longitudinal welded joint of
welded pipe shall be located above the horizontal centerline, if the pipe is installed horizontally.
8.2.0 PIPING AROUND COLUMNS, DRUMS AND
HEAT EXCHANGERS
The piping installation around columns, drums,
and heat exchangers shall be as follows:
8.2.1 Piping for columns shall be installed in the order
of the overhead line and the risers, and the
installation of instrument take-off nozzles, supports, spring hangers,etc. The levelness and
plumbness of piping shall be complete and true.
8.2.2 For piping installed at high elevations at the top
of columns, drums, etc., assembly and nondestructive examination and pressure testing
shall be performed on the ground, as far as
possible, to minimize work at high elevations.
When piping installation is unavoidably performed at high elevations, the area below shall
be fenced in with a safety rope and MEN AT
WORK ABOVE signs shall be posted.
8.2.3 When piping components are to be lifted into
place at high elevations by means of large
cranes, in advance, the work data such as the
weight, position of center of gravity, reach of
crane, crane boom length, and other vital data
shall be ob tained, and they shall be studied
sufficiently.
8.2.4 Temporary supports shall not be taken from the
shell (body) of equipment.
8.2.5 After the pipe spool has been installed accurately to the nozzle of the equipment, field welding
shall be performed. In such cases, blinds shall
not be inserted for purposes of pressure testing,
etc.
8.3.0 PIPING AROUND PUMPS AND COMPRESSORS
The piping installation around pumps and compressors shall be as follows.
8.3.1 All piping except for the connections to the
nozzle of rotating machinery shall be assembled
on the ground.
8.3.2 Before installation of piping to rotating
machinery, the required heat treatment, pressure test ing, interior cleaning, etc., shall be
completed. Pressure testing shall not be performed by inserting the blinds directly between
the nozzle of rotating machinery and the flange
of the connected piping.
8.3.3 The protective cover placed on the nozzle of
rotating machinery shall not be removed until
the piping is to be connected.
8.3.4 The preset-piece of spring hangers shall be
taken off and spring hangers shall be adjusted,
so that piping is located accurately.
8.3.5 It shall be confirmed that alignment work of
rotating machinery and measurement preparation for inspecting misalignment has been completed.
ENGINEERING
SPECIFICATION
8.3.6
8.3.7
8.3.8
8.3.9
8.4.0
8.4.1
8.4.2
8.5.0
8.5.1
8.5.2

STEEL PIPING
Pipe flanges shall be aligned with all the nozzles

of rotating machinery. The alignment shall be
performed by the adjustment of pipe supports
and flange connections. Unless otherwise speci
fied, the misalignment between flanges shall be
within the following permissible limits:
a.
Flange face separation

( space for gasket )
: 0.8mm
b.
Flange face parallelism
: 0.2mm
c.
Rotational offset
: 0.8mm
d.
horizontal and vertical bolt

hole offset
: 0.8mm
If the piping alignment specified in Item (6)

above is not within the permissible limits, it shall
be corrected. The correction of piping alignment
or the adjustment work of supports shall be
performed by dismantling piping from rotating
machinery. Care shall be taken so that expansion or distortion due to welding, etc., does not
have a detrimental influence on the rotating
machinery.
When connecting piping to a rotating machine,
if the machine misalignment is more than the
values specified, alignment work of the machine
and piping shall be performed again by dismantling the piping from the machine.
After piping is connected to rotating machinery,
the rearrangement of pipe supports or retightening of flange bolts shall not be performed without
permission.
PIPING AROUND FIRED HEATERS
Piping installation around fired heaters shall be
as follows:
Since piping around the burner tends to become
complicated, piping for one or two burners shall
be installed first, and after confirming operability,
clearance, safety, and other matters, other
piping shall be installed.
Drain piping around the burner shall not be
placed on the ground or in such a way as to
obstruct passage of persons.
PIPING ON PIPE RACK
Piping installation on pipe rack shall be as follows:
Generally, since air cooled heat exchangers are
placed on top of the pipe rack, and pumps are
placed underneath, the precedence for installing piping shall be determined in consideration
of the time of installing such equipment, the
number of stages of the pipe rack itself, etc. In
principle, piping installation will be performed
from the bottom to the top level. When installing
piping, a check shall be performed to ensure that
the pipe rack beams have been painted.
Before connecting piping to other equipment,
piping on pipe racks shall be laid down accurately in the places specified beforehand, and then
slide shoes and stoppers shall be installed accurately in accordance with the drawings, so
that baseline for dimensional adjustments in
field installation may be made. However, elbows, tees, etc., required for take-off connections to outside the pipe rack may be left in place
temporarily since it may be re quired to perform
8.5.3
8.5.4
8.6.0
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.7.0
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
25ES205 / 94 - R1
PAGE 15 OF 28
adjustments.
After the pipe has been laid on the rack, the pipe
shall be tied with wire to prevent it from falling
off until the weld joints are made.
The pipe fittings and welded lines shall be installed so as not to be positioned on the beams.
OFFSITE PIPING
Installation of offsite piping shall be as follows:
Piping installation inside the dike shall be performed after a thorough study of the work
schedule has been made, with consideration
given to other related work such as the confirma
tion of time of tank water filling and of access for
handling materials.
Pipe sleepers and support footings inside the
dike shall be installed after confirming that the
levelness of the ground has not been disturbed
by the water filling test of the tank.
Piping to be connected to the tank nozzle shall
be installed after checking that the valve and
accessories installed on the tank are in accordance with the specification.
Flexible hoses and expansion joints to the tank
nozzle shall be installed accurately in accordance with the drawings.
When laying pipe on sleepers, the sleepers shall
be checked to confirm that they are at the
specified elevation, level in line, and painted.
Piping on pipe sleepers shall be laid on sleepers
that have been marked off. Slide shoes and
stoppers shall be installed accurately in accordance with the drawings. The pipe fittings and
welded lines shall be installed so as not to be
positioned on the sleepers.
For piping penetrating an oil dike, the flanged,
threaded, or welded joints shall not be embedded in the dyke.
INSTALLATION OF VALVES
The installation of valves shall be as follows:
The valve shall be installed accurately so that
its location and the orientation of the handle is
in accordance with the piping drawings. However, when the orientation of the handle is
deemed inappropriate from the viewpoint of
operation or passage, the FEDO engineer shall
be contacted for directions.
The valve shall be checked for its class, body
materials, and trim materials to prevent any
misuse.
Before installing the valve, the flange faces of
the valve and the connected piping shall be
checked to see that they are not damaged or
dirty, and that they are parallel with each other.
Valves shall be installed in the closed position,
except for plug valves and ball valves. After
being installed, valves shall not be opened except for pressure testing. Especially, welding for
installation of the butt weld and socket weld type
valves shall be performed in the closed position,
to prevent the valve seat being damaged.
For lubricant plug valves, the disc shall be left in
the open position and the lubricant shall be
replenished to prevent loss of the sealant.
ENGINEERING
SPECIFICATION

STEEL PIPING
8.7.6
Globe valves, check valves, control valves, and

other similar valves shall be installed in accord
ance with the marked direc tion by checking the
flow direction.
8.7.7 To prevent the stem threads from rusting,
grease shall be applied prior to installation of the
valve.
8.8.0 INSTALLATION OF SAFETY VALVES
The installation of safety valves shall be as
follows:
8.8.1 Until line pressure testing has been completed,
in principle, the safety valves shall not be in
stalled with the piping. If safety valves are
necessary to assemble the piping, a spool of the
same face-to face dimension shall be fabricated
and installed. For threaded safety valves, the
piping shall be capped. However, the safety
valve with test gag may be installed with piping
and subjected to line pressure testing.
8.8.2 All safety valves shall be installed after the
specified set pressure has been tested in the
field.
8.8.3 The seal securing the cap to the safety valve
body shall not be removed without FEDO /
Representatives approval.
8.8.4 The safety valve with a lever shall be installed
with the lever oriented as shown on the drawing.
8.9.0 Installation of expansion joints
The installation of expansion joints shall be as
follows:
8.9.1 Expansion joints shall be installed accurately
and shall be at the location and of the dimensions shown on the piping and detailed drawings, and in a manner so as not to be connected
eccen tric with the pipe.
8.9.2 Expansion joints shall be installed after confirming that the line has been completely assembled
with all anchors, guides, and stoppers installed
in place as shown on the piping drawings.
8.9.3 Expansion joints shall be installed so that no
stress except in the direction intended occurs.
8.9.4 After pressure testing and flushing, all shipping
bolts and fixtures shall be removed and the
joints shall be checked to ensure that nothing
obstructs the expansion movement.
8.9.5 Prior to installation, expansion joints with inner
sleeves shall be checked to ensure that the
sleeve inlet (fixed) is on the upstream side.
8.9.6 Bellows of expansion joints shall be handled
with utmost care, so that no objects will be
dropped upon it.
8.9.7 Each expansion joint shall be blown free of dust
/ foreign matter with compressed air or shall be
cleaned with a piece of cloth.
8.9.8 For handling and installation of expansion joints,
great care shall be taken while aligning. An
expansion joint shall never be slinged with bellows corrugations/external shrouds, tie-rods,
angles etc.
8.9.9 An expansion joint shall preferably be slinged
on the end pipes/flanges or on the middle pipe.
8.9.10 The pipe ends in which the expansion joint is to
be installed shall be perfectlyaligned or shall
8.9.11
8.9.12
8.9.13
8.9.14
8.9.15
8.10.0
8.10.1
25ES205 / 94 - R1
PAGE 16 OF 28
have specified lateral deflection as noted on the

relevent drawings.
The pipe ends / flanges shall be spaced at a
distance specified in the drawings.
The Expansion Joint shall be placed between
the mating pipe ends/flanges and shall be tack
welded/bolted. The mating pipes shall again be
checked for correct alignment.
Butt welding shall be carried out at each end of
the expansion joint. For flanged Expansion
Joint, the mating flange shall be bolted.
After the Expansion Joint is installed the contractor shall ensure that the mating pipes and
Expansion Joint are in correct alignment and
that the pipes well supported and guided.
The Expansion Joint shall not have any lateral
deflection. The contractor shall maintain parallelism of restraining rings or bellows convolutions.
INSTALLATION OF INSTRUMENTS
Kinds of instrument handled
1. The following instruments shall be installed
in the scope of piping installation work:
a. Flow meters to be installed directly on the line
(area type, volume type, magnetic type, etc.).
b. Orifice flanges and orifice plates
c. Displacer type or ball float type level meters
d. Control / self control valves & safety valves
e. Other instruments installed directly on the line
2. In addition, instruments up to the first valve

or flange in the nozzle take-off connections
for the instrument lead piping are included.
8.10.2 General Procedure : General installation procedure for instruments shall be as follows:
a. All instruments shall be checked as to instrument number and shall be installed true
to level, plumbness, or the specified angle
b. The instruments and the associated piping
(excluding instrument piping) shall be supported so that problems will not result due
to distortion or vibration
c. It is preferred to have all the instruments
installed after the interior of piping, columns
and drums have been cleaned. When instruments are to be installed unavoidably
during piping construction, measures shall
be taken to prevent the instruments from
being damaged and to prevent foreign matter from entering the instruments. Orifice
plates shall be installed only after testing
and flushing of pipes.
d. Flow control valves shall be installed after
checking the flow direction mark.
8.10.3 Installation of Flow Meters : The installation of
flow meters shall be as follows:
a. When installing orifice flanges, the straight
lengths of pipe required upstream and
downstream shall be checked to see that
they comply with the piping drawings. In
principle, the upstream straight pipe length
shall be of one piece. When there is an
unavoidable welded line in the length, the
distance between the orifice and the weld
ENGINEERING
SPECIFICATION

STEEL PIPING
line shall be not less than 14 times the pipe

diameter. The straight lengths of pipe shall
not be provided with a vent, drain, or other
similar branch.
b. Jack screws for orifice flanges shall be installed so that they are 180O apart from
each other.
c. When taps are to be taken off from a pipe,
the holes shall be drilled where shown on
the drawings, the burrs removed and the
holes made smooth. Sockets shall not be
embedded in the pipe.
d. The orientation for pressure differential taps
shall be accurate as shown on the drawings
e. Orifice plates shall not be installed until the
pipe interior has been cleaned.
f. When installing orifice plates, the orifice
plate number and the flow direction shall be
checked. In general, the handle is pointed
upwards and the inlet die stamp mark end
is pointed upstream.
g. An orifice plate shall be installed with its
center coinciding with the center of the pipe
and with the gasket not protruding into the
pipe.
g. An orifice plate shall be installed with its
center coinciding with the center of the pipe
and with the gasket not protruding into the
pipe.
h. Installation of flow meters such as area
type, column type, and magnetic type shall
be in accord ance with the instructions of the
FEDO Engineer.
8.10.4 Installation of Control Valves : The installation of
control valves shall be as follows:
a. Control valves shall be installed by checking
the flow direction and, except for special
cases, with the diaphragm at the top in a
vertical position.
b. To prevent internal and external damage
and entry of foreign matter during construction, control valves shall be installed during
the last stage after pressure testing and
flushing of the line. In this case, a spool
having the same face-to-face dimension as
the control valve shall be inserted to keep
the distance during construction. Further
more, after the piping around the control
valve has been installed, the dimensions
shall be checked to confirm that the valve
can be fit in place.
c. When installing control valves unavoidably
during construction, a blind gasket, galvanized iron sheet, or other suitable
material of the same thickness as the main
gasket shall be inserted to prevent entry of
foreign matter. During construction, control
valves shall be covered with vinyl sheet or
other suitable material, and care shall be
taken not to damage the valves. During
pressure testing and flushing of the line, the
valve shall be removed and the end flanges
of the valve shall be covered up.
25ES205 / 94 - R1
PAGE 17 OF 28
9.0.0
INSPECTION AND TEST
9.1.0
DOCUMENTS
The Contractor shall submit the following inspection records for each items of test and
inspection:
Non-destructive inspection
9.1.1
9.1.2
9.1.3
9.2.0
9.2.1
a.
Record of radiographic inspection
b.
Record of magnetic particle inspection
c.
Record of liquid penetrant inspection
d.
Record of ultrasonic inspection
e.
Records of stress relieving
f.
Records of hardness test
g.
Records of hydrostatic & pneumatic pr. tests
Destructive inspection
Record of welding procedure qualification test
Others specifically instructed
Following are to be indicated on the test and
inspection record
1. Name of customer
2. Job number and name of work
3. Name of contractor
4. Line number
5. Date of test and inspection
6. Name(s) of attendant (FEDO, Customer, or
third party)
ITEMS OF INSPECTION AND TEST
Prior to, during and after completion of the
works, the following tests and inspections shall
be performed.
ITEMS FOR INSPECTION AND TEST
PRIOR TO COMMENCING WORK
Checking
materials
Legal qualification certificate
Welding procedure test

Welders technique qualification
test
welders techniqe qualification certificate
Welding rod
check
PRIOR TO WELDING WORK
Edge preparation
Angle, Root opening, Thickness of land, Cleanliness
Shape of pipe
end
Out of roundness, Thickness, Uneven thickness
Bending
Degree of flattening at bent

part, Radius of curvature,
Thickness reduction at bent
part
Tack welding
Bevelled end misalignment,

Root opening
Preheating
Method of preheating,
Temperature of preheating,
width of heating, Temperature measurement, Heating
temperature, Others
ENGINEERING
SPECIFICATION
Welding rod
Drying temperature, Drying

time
DURING WELDING WORK

Welding parameters, Flow
rate of sealing gas, ProtectWelding condition
ing measure for welding,
Condition of ambient
temperature
PAGE 18 OF 28
Under cut
No under cut is allowed for piping of
cold or high temperature service.
Over lap
Height of reinforcement
Inter-layer temperature
: Within 0.8mm or
12.5% of thickness
whichever smaller
: 1.5mm or less
Nominal Wall Thk.
Re-examination of welder
AFTER COMPLETION OF WELDING WORK
Inside surface misalignment,
Outer surface misalignment,
Inside surface weld
Visual approtrusion, Wave irregularity,
pearance inspec- Uneven leg length, Irregular
tion
height of bead, Undercut,
Overlap, Bead centre shift,
Height of reinforcement
welds
Non-destructive
inspection
25ES205 / 94 - R1

STEEL PIPING
Radiography, Dye penetrant,

Magnetic particle
Up to 6.4mm
: 1.6mm or less
Over 6.4mm up to
12.7mm
; 3.2mm or less
over 12.7mm up to
24.5mm
: 4.0mm or less
Over 24.5mm
: 4.8mm or less
Throat thickness of
fillet welds
: 70% of thickness of
the inner plate or
more
Stress relieving temperature and method

Hardness test
DURING OR AFTER COMPLETION OF
WELDING WORK
Product inspection
9.4.0
9.4.1
Dimension, Condition of connection to equipment, Visual

apperance inspection
Non-destructive inspection
Non-destructive inspection shall be performed
according to the grade of inspection stipulated
in the next table. (Pressure classes in accordance with ANSI B16.5)
Grade of Inspection
Treatment of pipe inside

Material
Thread
Seal welding of threaded portion
AFTER COMPLETION OF WORK
Pneumatic pressure test
Carbon
steel
Removal of temporary supports / scafoldings

AT TRIAL OPERATION
Appearance inspection
9.3.0
9.3.1
VISUAL APPEARANCE EXAMINATION

Following shall be met, checking visually or in
using measuring instrument
1
2
Inside surface
: 1.5mm or less
misalignment
Outer surface
misalignment due to
difference of
: 3.0mm or less
diameter of thickness
Inside surface weld protrusion
Nominal Wall Thk.
Up to 6.4mm
: 1.6mm or less
Over 6.4mm to
12.7mm
: 3.2mm or less
Over 12.7 up to
25.4mm
: 4.0mm or less
Over 25.4mm
: 4.8mm or less
Wave irregularity
; 2.5mm or less
Irregular height of
bead
: 2.0mm or less
II
III
P - NO: 1
Completion of work w.r.t piping drawings

Flushing
Pressure classes - ANSI B16.5

(psig.)
Service
temp.
below 3500C
Less
than 300
lb
400 lb 1500 lb
2500 lb
and
above
Service
temp.
3500C or
more
150 lb 900 lb
1500 lb
and
above
150 lb 900lb
1500 lb
and
above
150 lb 900 lb
1500 lb
and
above
150 lb 900 lb
1500 lb
and
above
A312 Gr.
TP304
Less
than 150
lb @
300 lb 600 lb
900 lb
and
above
Other than
above
150 lb 300 lb
400 lb
and
above
Al-killed Steel
P - NO: 3, 4, 5
C- 0.5 Mo Steel
Cr- Mo Steel
P - NO: 9
3.5 Ni steel
P - NO: 8
Austenitic
stainless
steel
Note:
9.4.2
@ When A312 Gr. TP304 is used for cold or

high temperature service, the grade II of inspection shall be applied even if it is not above 150
lb.
Items of non-destructive inspection and number
of samples for the random inspection shall be
as follows:
ENGINEERING
SPECIFICATION

STEEL PIPING
ITEM OF INSPECTION
R - Radiographic Inspection
M - Magnetic particle Inspection
L - Liquid PenetrantInspection
Object of inspection
Material
Peri
phery
Nozzle
(1)
Soc
ket
Non
pressure
part
GRADE - I
Carbon
steel
Less
than 150
lb
A312 Gr. TP304
10 %
(2)
10 %
10 %
10 %
(4)
100 %
9.4.3
10 %
GRADE - II
R
All materials
20 %
Carbon steel
M
(3)
C-0.5 Mo steel
Cr-Mo steel
Al-killed steel
3.5-Ni steel
L
(3)
Austenitic
stainless steel
Non-ferrous metals
GRADE - III
R
All materials
M
(3)
All materials except

for austenitic stainless steel, non-ferrous metals &
non-magnetic metal
L
(3)
Austenitic
Stainless steel
Non-ferrous metal
%
20 % 100 % 100 % 20
(4)
Notes
(1)
In nozzle welding, welded parts of reinforcing
plate and slip-on flange are included.
(2)
This inspection shall be performed for the
welded parts other than those to which
radiographic inspection was applied.
(3)
Either magnetic particle inspection or liquid
penetrant inspection shall be performed.
(4)
This inspection shall be performed for Cr-Mo
steel (A335 Gr. P5 or over grade) and 3.5Ni
steel.
Remarks
1. Radiographic inspection for peripheral joint
shall be performed for pipes of nominal
diameter of 2" or more having the same
condition.
2. Number of random sampling test shall be at
least one, when less than one is obtained in
percentage of sampling
3. Number of photographs to be taken for one
peripheral joint at radiographic inspection
shall be as follows:
PIPE SIZE NB
NO. OF
PHOTOGRAPHS
50 to 80
150 x 2 sheets
100 to 150
300 x 3 sheets
9.4.4
PAGE 19 OF 28
200 to 300
300 x 4 sheets
350 to 400
300 x 5 sheets
450
300 x 6 sheets
500
300 x 7 sheets
600
300 x 8 sheets
650 & above
With film overlap of

25mm or more, no of
photographs shall be
equivalent to peripheral
length of the pipe
3%
Over 150
lb to 300 10 %
lb
25ES205 / 94 - R1
Radiographic examination
Unless otherwise specified, radiographic examination shall be as follows:
1. Radiographic inspection shall be performed
in accordance with Article 2, Section V of the
ASME Boiler and pressure vessel code.
2. The welds to be examined shall be selected
based on the number of work products of
each welder and welding operator engaged
in all welding operations. A minimum of one
weld per sample shall be examined.
3. All welded joints in a designated lot of piping
shall be radiographed over the complete
circumference.
4. When a random type examination reveals a
defect, additional examination shall be performed in accordance with the requirements
of appendix IV.
5. The radiation source shall, in principle, be
x-ray or Gama-ray.
6. Film such as Sakura RR, Fuji #100, Kodak
AA, or Equivalent shall be used.
7. Identification mark as shown in Figure 10
( Page 28 of 28 ) shall be marked on every
radiograph, and radiographs of repair weld
shall be marked with repair mark (R).
8. The image quality indicator (IQI) specified
in B UB-51, ASME Section VIII, Division 1,
or equivallent shall be used.
9. Limitations on imperfection shall be in accordance with ANSI B31.3 TABLE 327.4.1
(A) for the degree of radiography involved.
Magnetic Particle/Liquid Penetrant Examination
Liquid penetrant or magnatic particle examination shall be as follows:
1. Liquid penetrant inspection shall be performed in accordance with Article 6, section
V of ASME Boiler and pressure vessel code.
2. Limitations on imperfection shall be in accordance with ANSI B31.3 Table 327.4.1 (A)
3. The weld surface, to which liquid penetrant
or maganetic particle examination is applied, shall be finished smoothly with a
grinder as necessary.
4. If a defect is found in welds, the defect shall
be removed, and liquid penetrant examination or maganitic particle examination shall
be performed again to confirm that no more
defects exist., and then rewelding shall be
performed. After rewelding has been completed, liquid penetrant examination or
maganetic particle examination shall be
ENGINEERING
SPECIFICATION

STEEL PIPING
performed again to confirm that the rewelds

are sound.
a. Magnetic particle inspection shall be performed in accordance with Article 7, Section
V of the ASME Boiler & pressure vessel code
b. Limitations on imperfection shall be in accordance with ANSI B31.3 Table 327.4.1 (A)
9.5.0
9.5.1
9.5.2
9.6.0
9.6.1
9.6.2
9.6.3
HARDNESS TEST
After stress relieving (SR) is performed, hardness shall be tested as follows:
1. If SR is performed by heat coil, the hardness
test shall be carried out for all welds.
2. If SR is performed in furnace, hardness test
shall be performed for 10% of all welds (at
least one-when 10% of all is less than one)
3. Point to be tested shall be finished flat with
file before the test.
4. The hardness points shall be tested to weld
and to heat affected zone. Hardness test of
the heat affected zone shall be made at a
point as near as practicable to the edge of
the weld. When dissimilar materials are
welded, both heat affected zones shall be
tested.
Hardness limit is given in following table ( Hardness In Brinell Max. )
P-No.
MATERIAL
HB
(MAX)
P-3
A335 Gr.P1 (STPA12)
225
P-4
A335 Gr.P12 (STPA22)

A335 Gr. P11 (STPA23)
225
P-5
A335 Gr. P22 (STPA24)

A335 Gr. P5 (STPA25)
241
PRODUCT INSPECTION
Inspection for the finished product shall be performed as follows:
Dimension: Right angle, perpendicularity, parallelness, dimension, etc. shall be measured
visually and by measuring tools and checked
against the drawings. Dimensional tolerances
are as follows:
1. Length + 0 ; -3.2mm or less
2. Inclination of flange surface: less than 0.5o
against the surface perpendicular to the
axis of pipe. (but, not to exceed 2mm at
outside circumference of flange).
3. Perpendicularity of vertical line: 2/1000 or
less.
4. Horizontality: 2/1000 or less
5. Misalignment between flange center and
pipe center: 1.6mm or less
6. Shift of bolt hole center: 1.0mm or less.
Inspection of connection to equipment: For
those pipings which are connected with pump,
compressor, turbine, etc., the above dimensional tolerance shall be submitted by the
tolerances required by each of such machinery.
Appearance inspection:
1. Correction for jig mark.
9.7.0
9.7.1
25ES205 / 94 - R1
PAGE 20 OF 28
2. Removal of spatter and slag

3. Any harmful flaw on the flange face, inner
and outer surface of pipe.
4. As-erected condition
5. Shape and size of branches and other attachment shall comply with drawings.
Inspection for treatment of pipe inside
Inspection shall be performed visually and
touching by hand to confirm that no rust, slag,
spatter, sand, or other foreign matters are left.
Inspector must confirm whether sufficient flushing was performed.
10.0.0 PRESSURE TEST AND OTHERS

10.1.0 GENERAL
10.1.1 Prior to initial operation, the installed piping shall
be pressure tested under witness of FEDO Engineer/ Representative.
10.1.2 Prior to the pressure test, a line check shall be
performed based on P&I diagrams and the
piping draw ings, in accordance with the instructions of the FEDO Engineer/ Representative.
10.1.3 Types of pressure test are as follows, however
the test shall be performed in accordance with
the individual specification:
1. Pressure tests
Hydraulic test (using water or other liquids)
Pneumatic test
2. Leak test
Overall air tightness test
10.1.4 Before filling it with the test fluid, the entire line
to be pressure tested shall be examined in the
manner described in Section 9.0.0, and any
faults shall be repaired. The piping affected by
any repairs or additions made after the pressure
test shall be retested.
10.1.5 In principle, piping shall be pressure tested at a
metal temperature not less than 20C. However,
carbon and alloy-steel piping exceeding 25mm
in thickness shall be pressure tested at a
temperature not less than 160C.
10.1.6 The following equipment and instruments shall
not be connected to the piping before completion of the pressure test:
1. Rotating machinery such as pumps, turbines, and compressors.
2. Pressure relieving devices, such as rupture
discs and pressure relief valves.
3. Equipment that has a castable or lining
material .
4. Instruments.
5. Piping which is normally open to the atmosphere such as drains, vents, and discharge
piping from pressure relieving devices.
6. Any other designated equipment.
10.2.0 TEST FLUID
Test fluid shall be as follows:
10.2.1 In principle, the fluid for hydrostatic testing shall
be fresh water. Unless otherwise specified, the
ENGINEERING
SPECIFICATION
10.2.2
10.2.3
10.3.0
10.3.1
10.3.2
10.3.3
10.3.4
10.3.5
10.4.0
10.4.1
chlorine ion concentration in the fluid used for

austenitic stainless steel piping shall not exceed
30 ppm. After completion of the test, the water
shall be drained immediately, and the interior of
the pipe shall be dried by an air blower, etc.
For piping systems having strong acids and So2
where water may become corrosive, or piping
systems operated at a temperature of 00C or
less, kerosene or similar light oils (with a flash
point not less than 500C) or air is preferred as
the test fluid.
The air to be used for pneumatic testing shall be
compressed air from a portable compressor.
However, for instrument air lines or where
specifically specified, oil-free dry compressed
air or inert gas shall be used. For high pressure
piping (not less than 100 kgf/cm2G), the use of
inert gas is preferable. When pneumatic testing
is performed by the use of an air compressor,
precautions against combustion shall be taken
by blowing clean the oil separator thoroughly so
that no lubricant enters the air.
TEST PREPARATION
The preparation for pressure test shall be as
follows:
All joints (including welds) are to be left uninsulated and exposed for examination during the
test. However, joints previously tested in accordance with this standard may be insulated.
When filling water into piping that is designated
for vapor, gas, etc., not filled with water during
operation, temporary supports or other reinforcements shall be provided beforehand.
Special fittings in piping components, such as
expansion joints, filters, and flame arrestors,
shall be disconnected from the piping.
Equipment which is not to be subjected to the
pressure test shall be either disconnected from
the piping or isolated by blinds or other means
during the test.
If a pressure test is to be maintained for a certain
period and the test liquid in the system is subject
to thermal expansion, precautions shall be
taken to avoid excessive pressure. In particu lar,
for hydrostatic testing, care shall be taken to
ensure that the water will not be subject to
thermal expansion so that the piping is not
damaged during the test.
TEST PRESSURE
Hydraulic Testing of Internally Pressured Piping
1. The test pressure for piping subject to internal pressure shall be as follows:
b. For a design temperature above the test
temperature, the minimum test pressure
shall be calculated by the following formula.
1.5PST
S
ST= allowable stress in kgf/cm2 at test

temperature
S = allowable stress in kgf/cm2 at design
temperature
10.4.2
10.4.3
10.4.4
10.5.0
10.5.1
10.5.2
Where
PT= minimum hydrostatic pressure in
kgf/cm2 G
PAGE 21 OF 28
P = internal design pressure in kgf/cm2 G
a. Not less than 1.5 times design pressure
PT =
25ES205 / 94 - R1

STEEL PIPING
10.5.3
3. If the test pressure as defined in Item (2)

above produces a stress in excess of the
yield strength at the test temperature, the
test pressure may be reduced to the maximum pressure that will not exceed the yield
strength at test temperature.
Hydrostatic testing piping with vessels as a system
1. Where the test pressure of piping attached
to a vessel is the same as or less than the
test pressure for the vessel, the piping may
be tested with the vessel at the test pressure
of the piping. However, the test pressure
shall be controlled carefully so as not to
exceed the test pressure of the vessel.
2. Where the test pressure of piping exceeds
the vessel test pressure, the piping shall be
tested by isolating it from the vessel.
Hydrostatic testing of externally pressured
piping : The test pressure for piping subjected
to external pressure shall be as follows:
a. Lines in external pressure service shall be
subjected to an internal test pressure of 1.5
times the external differential design pressure, but not less than a pressure of1.0
kg/cm2G (15 psig).
b. In jacketed lines, the internal line shall be
pressure tested on the basis of the internal
or external design pressure, which ever is
critical. The jacket shall be pressure tested
on the basis of the jacket design pressure
unless otherwise specified.
Pneumatic testing
1. In principle, pressure tests shall be performed hydraulically, however, when it is
inappropriate to fill piping with water, the test
may be performed with air or inert gas. The
test pressure shall be 1.1 times the design
pressure.
2. Any pneumatic test shall include a preliminary check at not more than 1.75 kgf / cm2G
(25 psig) pressure. The pressure shall be
increased gradually in steps providing sufficient time to check for leaks.
TESTING METHOD
The method of pressure testing shall be in accordance with the instructions of FEDO. However, the general method by using water shall
be as follows:
In principle, pressure tests shall be performed
for each piping system. However, when design
conditions do not permit testing in such a manner, the system may be tested in sections.
Test blinds shall have a handle extending out
from the flange. The handle shall be painted in
red, to ensure removal of blind after testing.
Installation and removal of blinds shall be performed in accordance with the instructions of
ENGINEERING
SPECIFICATION
25ES205 / 94 - R1

STEEL PIPING
FEDO. The number or all the blinds used and

the location of the insertion shall be recorded at
all times.
10.5.4 Test pressure gauges with graduations up to two
times the prescribed test pressure shall be
provided. All the pressure gauges shall be certified by the national authority, and the calibrations shall be checked by periodic inspections.
10.5.5 Two or more pressure gauges shall be installed
so that they are easily observed. When the
piping system to be tested extends from a low
to a high level, pressure gauges shall be installed at both the lowest and the highest points.
10.5.6 For each piping system, an outlet for discharging the pressure in case of emergency shall be
designated and marked to that effect.
10.5.7 During pressure testing of piping, operation of
valves shall be prohibited and the valves shall
be marked to that effect.
10.5.8 Prior to pressure testing, it shall be confirmed
that a strainer is provided at a designated location to remove foreign matter.
10.5.9 Vents on piping subjected to hydrostatic testing
shall be opened to remove the air when filling
the piping with water.
10.5.10 Prior to hydrostatic testing, the piping shall be
checked to confirm that it is free from air pockets
and if necessary, temporary vents shall be
provided to eliminate the air pockets until testing
is completed.
10.5.11 For piping systems with a check valve, the pressure shall be applied from upstream of the valve.
If this is impractical, the check valve shall either
be reversed or shut off with blinds. However,
when reversed, the valve shall be reinstalled
correctly after testing.
10.5.12 When the test pressure is not less than 50 kgf /
cm2G, pressure shall be increased gradually.
10.5.13 The test pressure during a pressure increase
shall be read by the pressure gauge installed at
the lowest point of the piping in consideration of
the water head pressure.
10.5.14 The check for any leaks during the pressure test
shall be performed after the prescribed pressure
is maintained for a time not less than 10 minutes.
All connections and all welded joints shall be
inspected thoroughly.
10.5.15 After the completion of pressure testing, the
water shall be drained immediately from the line
to prevent the piping system from being
damaged by freezing or thermal expansion.
Also to prevent vacuum forming in the piping,
the vents shall be opened when the water is
being drained.
10.5.16 On completion of pressure testing, the line shall
be checked to see that no residual pressure is
present, and the line shall be drained. All blinds
shall be removed.
10.5.17 Short pieces of pipe, which must be removed for
installing blind plates and blind flanges, shall be
tested separately.
10.5.18 All valves, orifice plates, expansion joints, short
pieces of pipe, and other items removed or
installed for the test, shall be reinstalled with the
prescribed gaskets in the correct position.
PAGE 22 OF 28
10.6.0 REPAIR OF DEFECTS

The repair of defects found during test and
inspection of piping systems shall be as follows.
In principle, the repair shall be performed under
witness of FEDO after the approval of the FEDO
Engineer has been given.
10.6.1 Repair of welds
a. Repair welding shall be performed after the
pressure and liquid remaining in the pipe
have been removed.
b. The defects to be repair welded shall
be removed completley with a grinder, etc.
c. The welding, the heat treatment, and the
test and inspection shall be the same as
required for the initial welding, and performed in accordance with the applicable
provisions of this specification.
d. In principle, repair welding of the same portion shall not be performed more than twice.
10.6.2 Repair of Threaded Joints
All defective threaded joints shall be replaced
with complete new ones.
10.6.3 Repair of Flange Joints
All defective flange joints shall be replaced with
complete new ones, except those which can be
repaired in accordance with Section 5.2 (15).
10.7.0 FLUSHING AND CLEANING
10.7.1 Selection of cleaning method
Cleaning method shall be selected in the following methods considering kind of fluid, pipe
material and condition of internal surface of
piping to be cleaned. Cleaning method and extend of cleaning shall be as per specific Project
Requirements.
a.
b.
c.
d.
e.
f.
Water Flushing
Air Blowing
Steam Blowing
Acid Cleaning
Oil Cleaning
Others
10.7.2 Procedure of cleaning in general

1. Cleaning of fabricated pipings
Inside surface and face of weld of fabricated
piping shall be made free from slag, chamfer, scale and other foreign matter, with
grinder, chisel, wire brush, etc., and be airblown. After completion of air blowing and
checking, ends of the piping shall be
covered with vinyl or veneer cap, etc. till the
installation in the field.
2. Temporary Strainers
Temporary strainers shall be used as follows:
a.
After installation of piping, and before

commencement of flushing/cleaning.
b.
The temporary strainers shall be installed

at pump suction piping, upstream of control valve and other locations as specified.
ENGINEERING
SPECIFICATION

STEEL PIPING
c.
Mark plate shall be attached to the temporary strainers to distinguish from other
strainers.
d.
After a constant period of initial operation,

all temporary strainers shall be removed,
cleaned and reinstalled.
10.8.0 WATER FLUSHING

10.8.1 Cleaning method by water
1. As a rule, pure water, service water, steam
condensate, industrial water, etc. shall be
used. If there is any requirement about the
quality of water to be used, it shall be observed.
2. After flushing, drying by compressed air or
natural drying shall be carried out. Drying by
superheated steam shall be carried out with
agreement between Customer and FEDO.
3. Flushing shall be performed till the water
becomes free from foreign matter, scale,
etc. This shall be decided by observing turbidity of water taken out ( into beaker or
cup).
4. Water flushing shall be performed by the
method of running by pressurised water and
hammering, or rapid draining with water
filled. Hammering shall, however, not be
performed for austenitic stainless steel
pipe, copper pipe, aluminum pipe.
5. The primary cleaning shall be performed for
each assembled piping system including
the equipment.
6. Where instruments are included in piping
system to be cleaned, the instruments shall,
as a rule, be disconnected and spool pipe
(distance piece) shall be inserted instead.
7. When cleaning is carried out in the condition
that control valve is connected, the procedure shall be as follows:
a. Disconnect companion flange at upstream
side of the control valve and cover opening of the control valve.
b. Clean the piping of upstream side.
c. Connect the control valve and the piping
of upstream side after cleaning.
d. Close the control valve, open by-pass
valve, and then clean the piping of down
stream side. Where the by-pass valve is
not installed, the temperory strainer
having austenitic stainless steel screen of
No. 50 specified in ASTM E-11 shall be inserted.
10.8.2 Air blowing

1. Air blowing shall be performed by the
method of blowing by pressurized air and
hammering. Hammering shall, however, not
be performed for austenitic stainless steel
pipe, copper pipe and aluminum pipe.
2. Blowing shall be performed till there
remains no scale in the piping. FEDO personnel in charge shall make judgement of
whether the result of the cleaning is statis-
25ES205 / 94 - R1
PAGE 23 OF 28
factory or not
3. The primary cleaning shall be performed for
each assembled piping. The secondary
cleaning shall, as a rule, be performed for
piping from eqpt. to adjacent eqpt. Whether
or not the equipment is included shall be
determined considering shape, internal
construction & packing of the eqpt. and
according to overall cleaning planning.
10.8.3 Steam blowing
1. Execution of steam blowing
Steam blowing shall be executed after completion of pressure test and insulation work.
2. Preparation of steam blowing
a. Temporary piping work, countermeasure
for safety & confirmation of preparation
shall be done according to blowing plan.
b. Support shall be attached to exhaust
piping to prevent accident caused by the
reaction force during blowing.
3. Procedure of steam blowing

a. Warm up the piping with cooperation by
operator
b. Check expansion joints, spring hangers,
etc., for expected thermal expansion.
c. Steam blowing shall be performed at the
temperature near to the operating temperature, considering operating condition of
boiler.
d. To remove the scale effectively by temperature change, it is required to perform flushing and cooling cyclically, having
temperature difference as large as possible between the flushing and cooling.
4. Judgement criteria of steam blowing

a. Judgement on result of steam blowing
shall generally be done by checking color
or quantity of foreign material present in
the drain sampled.
b. If necessary, especially for suction line of
steam turbine etc., result of flushing shall
be judged by observing whether scratch
was produced or not on the test piece inserted in the line.
10.8.4 Acid cleaning

1. Applicable piping of acid cleaning
Unless otherwise specified in specific job
requirements, acid cleaning shall apply to
oil piping system of rotating machinery.
2. Cleaning method by acid
As a rule, acid cleaning procedure shall be
as follows:
ENGINEERING
SPECIFICATION
25ES205 / 94 - R1

STEEL PIPING
a. Ten-percent hydrochloric acid solution or

Ten-percent sulphuric acid solution with
temperature 30 to 400 C shall be used, and
piping shall be pickled in the acid solution
for 1 to 6 hours.
b. After pickling, the piping shall be washed
sufficiently to remove the acid solution by
water.
c. And the piping shall be rinsed for
neutralization of the acid solution by
sodium hydroxide solution, followed by
water flushing.
d. The piping shall be well dried by superhaeted steam or dry air and the inside of
pipes given a coat of the oil of the same
quality as specified to be used in the oil
piping.
Remarks: Oil piping of stainless steel shall not be acid

cleaned.
10.8.5 Oil cleaning
1. Applicable piping of oil cleaning
Oil cleaning shall apply to the oil piping
system after the acid cleaning specified in
par. 10.8.4 has been performed.
2. Cleaning method by oil
The procedure shall be as follows:
PAGE 24 OF 28
10.10.0Disposition
10.10.1All construction equipment used for the piping
work, and all surplus, scrap and debris shall be
disposed of in accordance with the instructions
of the FEDO Engineer.
10.11.0 Test record
10.11.1 All inspection and test results shall be made into
re cords in accordance with the instructions of
FEDO. The records shall be submitted for approval to FEDO.
11.0.0 APPENDICES
11.1.0 The following Appendices shall form a part of
this manual:
TITLE
REFER TO:
Grove face Rust Preventive
APPENDIX I
Selection of welding electrodes
APPENDIX II
Procedure for Flange Bolt up
APPENDIX III
Additional Random Type

Examination for weld defects
APPENDIX IV
a. Oil to be used shall have good quality

suitable for the machinery, and shall be
completly replaced with the specified oil
after cleaning.
b. The cleaning shall be performed by the
method of circulation of the oil and hammering. Hammering shall, not be performed for copper pipe.
c. After completion of cleaning, it shall be
checked that no foreign matter is present
in temporary strainer screen of No.200
specified in ASTM E- 11 for oil pipings of
centrifugal compressor, and screen of
No.100 specified in ASTM E-11 for other oil
pipings.
10.8.6 Other cleaning method

1. Cleaning method by pig or cushion ball
Cleaning by the use of pig or cushion ball
shall confirm to specific job requirements.
2. Cleaning method by sodium hydroxide
Cleaning by sodium hydroxide solution shall
conform to specific job requirements.
3. Special cleaning
Special Cleaning, if specified for special
piping components or systems, shall conform to specific job requirements.
10.9.0 Overall airtightness test
10.9.1 When specified, an overall airtightness test shall
be performed for the piping of process line by
the use of air or inert gas after completion of
flushing.
ENGINEERING
SPECIFICATION

STEEL PIPING
APPENDIX I
GROOVE FACE RUST PREVENTIVE
Features of Product
1.
As rust preventive applied to the groove face, in
general, deoxialuminite is used as it is not
detrimental to the weld. Deoxialuminite is the
brand name of a product of Special Chemical
Co., Ltd.of USA. This was first produced in
Japan by Nippon Oil & Fats Co., Ltd. and is sold
under the brand name of Tasteto Silver.
2.
The composition of the product is 40% resin,
50% solvent, 5% pigment, etc., and the percentage of resin in the compound is high to reduce
the amount of gas produced during welding.
3.
This product is recommended for both marine
and overland transportation. The thickness of
the applied product shall not be more than 30
microns.
4.
The adherent durability is not more than three
months.
Directions for Use
5.
Before applying the rust preventive, it shall be
confirmed that the groove face is clean.
6.
After the rust preventive has been applied, welding shall not be performed within two weeks.
7.
In principle, the application shall be sprayed by
maintaining a distance not less than 30 cm from
the spray nozzle to the object. Unless otherwise
specified, the product shall not be applied with
a brush.
25ES205 / 94 - R1
PAGE 25 OF 28
Procedure for Bolt Up

Procedure for flange bolt up shall be as follows
5.
Hand tighten bolts with a short wrench by the
procedure shown in Figure 11.
6.
Tighten bolts a second time with a spanner
wrench and light hammer (about 1 kg), again by
the procedure shown in Figure 11.
7.
Continue tightening gradually by the procedure
shown in Figure 11, using a heavy hammer
(about 2 kg) until bolts are completely drawn
tight. This may take two or three additional
rounds by the same procedure.
8.
For bolts larger than 25mm in diameter, a final
round or two with a heavier hammer (about 3.5
kg) is recommended to reach the correct bolt
tension.
Precautions
Special precautions shall be taken for the following items for bolt up:
9.
Never draw up tight on one or two bolts only.
This will cause local gasket crushing or pinching, which will result in leaks.
10.
After each round of tightening, the alignment
may be checked by measuring the distance
between flange faces.
11.
The bolts should be gradually and evenly
tightened with a wrench and hammer until the
hammer begins to bounce with a distinct ring.
APPENDIX IV
APPENDIX II
SELECTION OF WELDING ELECTRODES & RODS
Table - I : Selection of welding electrodes & rods
for joining similar materials except Aluminium
Table - II : Selection of welding electrodes & rods
for joining disimilar materials except Aluminium
( Tables overleaf )
APPENDIX III
PROCEDURE FOR FLANGE BOLT UP
Confirmation Prior to Bolt Up
The following items shall be confirmed prior to
bolt up:
1.
The gasket has been inserted and centered.
2.
Bolts and nuts have been lubricated.
3.
Bolts have been inserted and are finger tight.
4.
There are at least two threads extending beyond
the nut on either side.
ADDITIONAL RANDOM TYPE EXAMINATION FOR

WELD DEFECTS
(Taken from ANSI / ASME B31.3b-1982, 336.5)
When the required examination of a spot or
random type reveals a defect requiring repair,
two additional examinations of the same type
shall be made on the same kind of item (if of a
weld, others by the same welder or welding
operator). If the second group of items examined is acceptable, all items represented by
these additional examinations shall be accepted.
For each of the second group of items which
reveals defects requiring repair, two additional
items shall be examined. If all of the third groups
of items examined are acceptable, the items
requiring repair shall be repaired or replaced to
meet the requirements of the code, and all items
represented by the examined items shall be
accepted.
If any of the third group of items examined reveal
defects requiring repair, all comparable items
may be replaced or they shall fully examined
and repaired as necessary to meet applicable
quality requirements.
ENGINEERING
SPECIFICATION
25ES205 / 94 - R1

STEEL PIPING
PAGE 26 OF 28
TABLE - I : SELECTION OF WELDING ELECTRODES & RODS FOR SIMILAR MATERIALS EXCEPT ALUMINIUM
MATL.
BASE
MATERIAL
NO.
1
2
AWS SPEC.
CLASSIFICATION
E6010/E6013 (1)
(2) (3) (4)
UTS 60,000psi & above
A 5.1
E6010/ E7018 (1)
(2) (3) (4)
A333 Gr - 1
A 5.1
E7018 -1(5)
(5)
--
A 5.5
E70XX-A1
(2) (3) (4)
2a
3
carbon-molybdenum
1
AWS SPEC PREFERRED ELECTRODE
WELDING RODS
A 5.1
UTS UNDER 60,000psi

carbon
steel
COVERED ELECTRODES
2 /4 nickel
A 5.5
E80XXC1
(2)
31/2 nickel
A 5.5
E80XX-C2
(2)
9 nickel
A 5.11
ENi Cr Fe - 3
A5.14
ER Ni Cr -3
/2Cr1/2Mo
A 5.5
E8015-B2L
(2)
0.05C max.
1Cr /2Mo
A 5.5
E8015-B2L
(2)
0.05C max.
11/4Cr1/2Mo
A 5.5
E8015-B2L
(2)
0.05C max.
2 /4Cr1Mo
A 5.5
E9015-B3L (0.05C max.)
(2)
0.05C max.
5Cr /2Mo
A 5.4
E502-I5 (0.05C max.)
A5.9
ER502(0.05C max)
7Cr1/2Mo
A 5.4
E7Cr-I5 (0.05C max.)
(2)
(0.05C max.)
10
11
low
chromium
ferrtic
steels
12
13
9Cr1Mo
A 5.4
E505-I5 (0.05C max.)
A5.9
ER505(0.05C max)
14
AISI Type405
A 5.4
E410-I5 (0.05C max.)
A5.9
ER410(0.05C max)
AISI Type 410S
A 5.4
E410-I5 (0.05C max.)
A5.9
ER410(0.05Cmax)
15
16
ferrtic
stainless
steels
AISI Type410
A 5.4
E410-I5 (0.05C max.)
A5.9
ER410(0.05C max)
17
AISI Type430
A 5.4
E430-I5
A5.9
ER430
18
AISI Types 304&304H
A 5.4
E308-I5 or 16
A5.9
ER308
19
AISI Type 304L
A 5.4
E308L-I5 or 16
A5.9
ER308L
20
AISI Types321&321H
A 5.4
E347-I5 or 16
A5.9
ER347
AISI Types 347 & 347H
A 5.4
E347-I5 or 16
A5.9
ER347
AISI Types 316 & 316H
A 5.4
E316-I5 or E 16 -8 -2
A5.9
ER316
AISI Type 316L
A 5.4
E316L-I5 or 16
A5.9
ER316L
AISI Type309
A 5.4
E309-I5 or 16
A5.9
ER309
21
22
23
austenitic
stainless
steels
24
25
AISI Type310
A 5.4
E310-I5 or 16
A5.9
ER310
26
Incoloy(32Ni46Fe20Cr)
A 5.11
ENi Cr Fe-2
A5.14
ERNiCr -3
27
AluminiumBronze
A 5.6
ECu Al-A1
A5.7
RCu Al-A2
28
Phosphor Bronze
A 5.6
ECuSn-C
A5.7
RCuSn-A
29
Copper
A 5.6
ECu
A5.7
RCu
30
31
32
non
ferrous
metals &
alloys
67Ni-30Cu Monel
A 5.11
ENiCu-4
A5.14
ERNiCu-7
Hastalloy(60Ni-28Mo-5Fe)
A 5.11
ENiMo - 1
A5.14
ERNiMo-4
Inconel(75Ni 15Cr8Fe)
A 5.11
ENiCrFe -1
A5.14
ERNiCrFe-5
33
70Cu-30Ni
A 5.6
ECuNi
A5.7
RCuNi
34
Nickel
A 5.11
ENi-1
A5.14
ERNi-3
35
20Cr-29Ni-21/2Mo-3Cu
Alloy 20 Cb - 3
Alloy 20Cb3
Notes:
(1) For materials Nos.1 and 2 (Carbon steel) where SMAW is followed, the root run shall be with E 6010 electrodes.
(2) Where no AWS specification exists for base wire, it is acceptable to use wire or rods of the same nominal composition as
the base material with substantially neutral flux or inert gas, provided they have been qualified in the procedure test.
(3) MIG wire shall conform to AWS A5.18 and A5.20
(4) SAW wire and flux shall conform to AWS A5.17
(5) The root run of butt welds for material No. 2a shall be made in GTAW process using ER70S - 2 wires.
ENGINEERING
SPECIFICATION
25ES205 / 94 - R1

STEEL PIPING
PAGE 27 OF 28
TABLE II SELECTION OF WELDING ELECTRODES & RODS FOR WELDING DISSIMILAR MATERIALS EXCEPT ALUMINIUM
Lower
base
matl
No.
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 35
2
3
4
5
6
7
8
9
Higher base material number
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
DESCRIPTION OF CODE LETTERS IN ABOVE TABLE

A
As specified in table I for material corresponding to either the higher or lower base material number
ASME SFA-5.5, E8015-82L electrode
ASME SFA-5.4, E309 electrode. Acceptable alternatives shall be as specified in table I for the higher base
material number
As specify in table I for the material with the higher base material number
ASME SFA-5.11, ENiCrFe-2 electrode and ASME SFA-5.4. ERNiCr-3 rods shall be used where design
temperature exceeds 10000F (5380C). ASME SFA-5.4, E310 electrodes are to be used where service
temperatures are below 10000F (5380C) and expected to be relatively constant after start up. All rods, excluding alternatives shall require written approval from designated authority.
ASME SFA-5.4, E308 electrode or as specified in table I for the material with the higher base material number
Welding of these material combinations are not permitted without written approval from designated authority.
8122-03-ES-001
Page 1 of 4
Specification for Glass Reinforced Plastic (GRP) piping
1
Scope
This specification defines the requirements for glass-fiber-reinforced thermosetting resin pipe
(RTRP) as defined in AWWA C950) couplings, fittings, flanges and spools using polyester, vinyl
ester or epoxy resin with restrained adhesive-bonded joints, restrained gasketed joints, butt joints
with laminated overlay, bell & spigot joints with laminated overlay.
The minimum pressure/temperature rating of the pipe and fittings shall be 10 bar (150 psig) at 65
deg C
Materials and Fabrication

The products shall be defined by a cell classification system and shall meet the performance
requirements of Section 4 of this specification.
Pipe and couplings shall be filament-wound using polyester, vinylester or epoxy resin and
fiberglass reinforcement or centrifugally cast.
Resin System
Resin shall be suitable for the services specified, and shall be noted by the vendor in his
proposal. The resin system used for the interior liner, the structural wall, fittings, and adhesives
shall be polyester, vinylester or epoxy, with suitable curing agents so that it meets the
performance requirements and temperature limits in this Specification.
Glass Reinforcements
The structural wall reinforcement shall be of commercial-grade glass fiber ( E type) treated with
a compatible binder and coupling agent
Additives
Resin additives such as pigments, dyes or coloring agents may be used, provided they do not
detrimentally affect the performance of the pipe. The pipe exterior must contain a UV inhibitor.
Reinforcing Fiberglass Ribs
Pipe sizes 2600 mm and higher can be manufactured with reinforcing fiberglass external ribs to
achieve the required stiffness.
Adhesives and solvent cleaners
Adhesive and solvent cleaner for bonded joints shall be of a material suitable for the services and
design conditions specified. It shall be mutually compatible with the resin used to manufacture
the pipe. Adhesives and solvent cleaners shall be provided in a self-contained kit with all
necessary materials and instructions. Shelf life of adhesive and solvent cleaner kits, at 35 deg C,
shall not be less than 9 months from the date of shipment. Adhesive and solvent cleaner kits
shall indicate the required storage conditions and date of expiration of shelf life.
Flexible Elastomeric Seals and Joint Tightness
The chemical composition of the flexible elastomeric seals shall be compatible with the type of
service and environment to which it will be subjected.
Fittings
Flanges, bends, reducers, tees, wyes and other fittings may be compression-molded,
manufactured from mitered section of pipe, or manufactured by the filament wound process,
using thermosetting polyester, vinylester or epoxy resin and fiberglass reinforcement such that
the resistance to chemical attack, the pressure rating, and the temperature rating, are equal to or
better than that of the pipe.
Except for compression-molded fittings, all pipe, fitting, and flange surfaces that are exposed to
the fluid shall have a smooth, uniform, resin-rich liner. The interior liner shall be reinforced with
either non-woven polyester fibers or epoxy. Liner reinforcement is not required on 100 mm and
smaller fittings at the mitered joints, provided all gaps at the joints are completely filled with resin
to act as an effective corrosion barrier and to prevent the presence of any exposed glass fibers.
8122-03-ES-001
Page 2 of 4
All machined or cut surfaces shall be post-coated with catalyzed resin, except for bonding
surfaces for field points and mechanical RTR (fiberglass) threads. Post-coating shall be
performed within four hours of machining or other surface preparation.
Adhesive-bonded joints shall be bell-and-spigot type and shall not require a field-applied
overwrap to develop the required strength.
Flanges shall be flat-faced, or flat-faced with a confined O-ring gasket groove.
All pipe, fittings and flanges for a particular installation shall be manufactured or supplied by the
same Vendor to avoid incompatibility problems
Fasteners and Gaskets
Machine bolts shall be as per A307 Gr B, galvanised and nuts shall be as per A563 Gr B
galvanised. The gaskets shall be full face, non metallic as per B16.21. suitable for the fluid.
3
Dimensions and Tolerances

Dimensions and surface finishes shall be measured in accordance with ASTM D3567 and
ASME/ANSI B46.1. The average wall thickness of the pipe shall not be less than the nominal
wall thickness published in the manufacturer literature. The minimum wall thickness at any point
shall not be less than 87.5% of the nominal wall thickness, when measured in accordance with
ASTM D3567.
Flange bolt hole sizes and the number of bolt holes and bolt hole circles for up to 600 mm
nominal pipe size shall comply with ASME/ANSI B16.5. For larger than 600 mm nominal pipe
size, flange bolt holes sizes and the number of bolt holes and bolt hole circles shall comply with
AWWA C207, or MSS SP-44.
Unless otherwise defined in the Purchase Order, specified face-to-face, centerline-to-face, and
centerline-to-centerline dimensions of special fabrications (spools) shall have a tolerance of + 6
mm. The lateral offset of flanges from the pipe centerline and rotation of flanges shall be limited
to 3 mm. The flange face alignment shall be within 1.5 mm of the required position when
measured across the flange face. These tolerances shall be doubled for piping 450 mm nominal
size and larger.
Performance Requirements
General
The Manufacturer shall perform following Design Type tests and Test reports shall be furnished
to Buyer.Testing and test reports shall pertain to items representative of those supplied under the
Purchase Order. Design type testing shall be repeated after any change in materials,
manufacturing methods, or product design.
Design Type Tests
Hydrostatic Design Stress and Pressure Ratings
The long-term hydrostatic strength of pipe shall be determined in accordance with Procedure A
or B of ASTM D2992. The Manufacturer shall select the procedure and one representative size
for these tests. Adhesive joints shall be included, using both the factory and field adhesives and
their respective joining and curing procedures, if different.
Pressure rating calculations shall be performed in accordance with AWWA-C950.
The calculated pressure ratings shall equal or exceed the pressure rating of the piping specified
in section 1 of this specification and in the Purchase Order.
Long-Term Ring Bending Strength
Long-term ring bending strength shall be determined in accordance with AWWA C950, with
stress relaxation or creep failure tests instrumented to detect an abrupt, significant reduction in
mechanical properties.
Flange Pressure Rating
Flanges shall be pressure-rated and marked in accordance with ASTM D4024.
The
manufacturer shall test, on a one-time basis, three samples of minimum, median and maximum
flange sizes of the manufacturing range at the plant for each pressure rating.
8122-03-ES-001
Page 3 of 4
Joint Integrity Test
Joints shall be of the adhesive-bonded, reinforced overlays or mechanical type joints, as defined
in AWWA C950.
The joints shall meet or exceed the hoop tensile and axial tensile strength requirements of the
pipe as tested in accordance with AWWA C950. One test for each jointing method shall be
performed to establish design stress values.
5
Test Requirements
Pipe Stiffness
The pipe stiffness shall be determined in accordance with AWWA C950.
The pipe shall exhibit, without structural damage, the minimum stiffness at 5 percent deflection of
124 kPa (18 psi)
Axial Tensile Strength
The pipe shall be sampled and tested for axial tensile strength in accordance with AWWA C950.
The test results shall meet or exceed the minimum axial tensile strength requirements listed in
Table 11 of AWWA C950
Hoop Tensile Strength
The pipe shall be sampled and tested for hoop tensile strength in accordance with AWWA C950.
The test results shall meet or exceed the minimum hoop tensile strength requirements listed in
Table 10 of AWWA C950
Visual Inspection
Components shall be visually inspected for compliance with the defect limits in Table below
Name
1. Air Bubble
(Void)
2. Foreign
Inclusion
3. Pit
(Pinhole)
5. Scratch
6. Wrinkle
Interior Surface
Not to penetrate any
surface - limits apply to
all surfaces, maximum
dimension
6
mm
diameter,
0.75
mm
thickness, 4 per 0.09 sq.
m area
Not to penetrate any
surface - limits apply to
all surfaces, maximum
dimension 1.5 mm, 1 per
0.09 sq. m area
Max. depth 0.25 mm,
maximum width 1.5 mm,
35 per sq. cm
Max. depth 0.40 mm not
to exceed liner thickness
Max. depth 2 mm
Exterior Surface
Same requirements
as
for
Interior
Surface
O-Ring
Sealing Surface
Same requirements
as
for
Interior
Surface
Same requirements
as
for
Interior
Surface
Same requirements
as
for
Interior
Surface
Not to penetrate
reinforced wall
Maximum
dimension 0.25 mm
Not to penetrate
reinforced wall
Not applicable
Maximum
depth
0.25 mm
None allowed
Hydrostatic Leak Test

All pipe, fittings and spools shall be hydrostatically leak tested at the factory in accordance with
AWWA C950, to a test pressure equal to twice the pressure rating.
If air is used as the pressurizing medium, the component shall be completely submerged in clear
water during the pressurization and inspection period.
All pipe, fittings, spools and joints shall be visually examined for leakage. Any item showing
evidence of weeping or leakage shall be rejected.
8122-03-ES-001
Page 4 of 4
The standard adhesive-bonded flanges, standard adapters, saddles, nonstandard fittings with
plain ends configurations, and prefabricated spools with plain ends that cannot be hydrotested at
the manufacturing facility due to size limitations and configurations shall be handled as follows:
a)
The Vendor shall mark these items to be field hydrotested.
b)
The assembled items and the testing shall be at Vendor's risk.
c)
Buyer's Representative shall witness the test. The rejected parts shall be removed from the
system or repaired by the. The replaced or repaired part shall be retested.
Rejection
If the results of any QC test do not conform to the requirements of this specification, that test
shall be repeated on two additional samples from the same lot of pipe. Each of the two samples
shall conform to the requirements specified. If either of the two additional samples fail, the lot
shall be rejected.
Documentation
Drawings
Product drawings that show product dimensions and tolerances, including couplings, fittings and
joints, shall be submitted
Test Reports
The Manufacturer's test reports, both Design Type tests and acceptance tests, shall be furnished
to the Buyer.
Identification Tagging
All components shall be permanently marked for proper identification. All required marking shall
remain legible under normal handling and installation practices. The marking shall include the
following:
-
Manufacturer's name or trade name, and identification code

Pressure/temperature rating
Nominal diameter
Packing
Unless otherwise specified in the Purchase Order, pipe, fittings, O-rings, gaskets, locking rings,
and adhesives shall be packed suitably, to withstand rough handling.
End Protectors
End protectors shall be provided and securely attached to both bell and spigot ends of all pipe.
End protectors shall be designed to protect the pipe ends from impact damage, contamination,
and weathering of machined bonding surfaces due to ultraviolet exposure. They shall have an
open center permitting inspection of the pipe bore.
Flange faces on fabricated piping shall have 12 mm minimum protective plywood covers not
smaller than the flange outside diameter
DATA
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8122- 12 DA - 002
PAGE 1 OF 13
MANGALORE LPG BLENDING FACILITIES
SPECIFICATION FOR PIPELINE CONCRETE

COATING
PREPARED FOR
HPCL
PROJECT NO. 8122
OCTOBER 2009
19.10.2009
LTA
SA
SA
REV.
DATE
PRPD. BY
CHKD. BY
APPRD. BY
FACT
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TABLE OF CONTENTS
PAGE O.
FACT
12FT026A/94
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
COATING REQUIREMENTS
5.0
APPLICATION METHOD
6.0
EQUIPMENT
7.0
COATING OF FIELD WELDS
8.0
CURING
9.0
MEASUREMENTS & LOGGING
10.0
IDENTIFICATION
10
11.0
INSPECTION AND TESTING
10
12.0
TESTING METHODS
11
13.0
PERMISSIBLE REPAIRS TO THE COATING
12
14.0
HANDLING
13
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SPECIFICATION FOR PIPELINE CONCRETE COATING
1.0
SCOPE
1.1
This specification covers the minimum requirements for the materials, application, inspection,
handling and other activities for external concrete coating for pipelines.
1.2
This specification shall be read in conjunction with the conditions of all specifications and
documents included in the contract between company and contractor.
1.3
CONTRACTOR shall execute the work in compliance with all laws, by-laws, ordinances,
regulations, etc. and provide all services and labour, inclusive of supervision thereof, all materials,
equipment, appliances or other things of whatsoever nature required for the execution of the work,
whether of a temporary or permanent nature.
1.4
This document is not intended to be all-inclusive, and the use of the guidelines set forth does not
relieve the contractor of his responsibility to supply a product capable of performing its intended
service.
2.0
RFEFERENCE DOCUMENTS
a)
IS 8112
Indian standard specification for 43 grade ordinary Portland cement.
b)
IS 383
Indian standard specification for coarse and fine aggregates

from natural sources for concrete.
c)
IS 2386
Indian standards methods of test for aggregates for concrete
Part 1 To VIII
d)
IS 4826
Specification for hot dipped galvanized coatings on round steel wires
e)
IS 1566
Specifications for hard drawn steel wire fabric for concrete reinforcement
f)
IS 432
Specification for mild steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement.
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g) IS 1199
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Method of sampling and analysis of concrete.
h) ASTM C309
Liquid membrane forming components for curing concrete
i) IS 456
Code of practice for plain & reinforced concrete
j) IS 516
Methods of tests for strength of concrete
k) IS 4031
Methods of Physical tests for hydraulic cement
l) IS 4032
Methods of chemical analysis of hydraulic cement
m) IS 1916
3.0
OF
Steel Cylinder Pipes with Lining and Coating- Specification
MATERIALS
The contractor shall supply all the materials necessary for the performance of the work. Materials
for concrete coating shall comply with the following requirements.
3.1
Cement
43-grade ordinary Portland Cement conforming to IS 8112 shall be used. Cement which has
hardened or partially set or which has become lumpy shall not be used. Test certificates from the
cement manufacturer shall be supplied to the company for all cement delivered to site.
3.2
Aggregates
3.2.1
Aggregate shall comply with the requirements of IS-383 and shall be tested in accordance with
IS-2386.
3.2.2
Fine aggregates:
Fine aggregate shall mean any of the following as defined in IS 383.
i)
Natural sand
ii)
Crushed stone sand
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Crushed gravel sand
iii)
Sand shall be well graded from fine to coarse in accordance with Table 4 of IS 383.
3.2.3
Aggregates shall be clean and free from injurious amounts of salt, alkali, deleterious substances
or organic impurities that may affect the strength of concrete.
3.3
Water
The water shall be fresh and clean and shall be free from injurious amount of oils, acids, alkalies,
salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It
shall not contain chlorides, sulphates and magnesium salts. Water from doubtful sources shall be
tested by the CONTRACTOR at his expense and approved by the Engineer-in-charge before use.
3.4
Reinforcement
3.4.1
Reinforcement shall consist of 50 mm x 50 mm x 3 mm diameter galvanized welded wire fabric in

rolls or in sheet to satisfy the application requirement.
3.4.2
Reinforcing mesh shall conform to IS 432 for steel wire, IS 1566 for welded wire mesh and IS
4826 for galvanized steel. Minimum steel in both longitudinal and transverse direction shall be
0.5% of the concrete cross sectional area, or 3 mm dia wire @ 50 mm c/c whichever is more.
For coating thickness of 50mm and above, two layers of mesh shall be provided clear cover being
5 mm from either side.
3.4.3
Alternative reinforcement, having steel cross sectional area per metre of concrete coat, equal to
or more than area of the mesh mentioned above, may be submitted for approval.
Reinforcing steel shall be spooled on with a lap of not less than 25 mm (1 inch) or one mesh
whichever is greater.
thickness.
It shall be embedded approximately midway in the concrete coating
The reinforcing wire shall not contact the pipe corrosion coating. If the concrete
thickness is equal to or greater than 50 mm, at least two layers of mesh shall be installed.
3.4.4
The reinforcing materials shall not be in physical or electrical contact with the pipes.
Reinforcement shall rest on synthetic resin spacers forming a crown, whose number shall be such
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as to avoid any contact with the pipes protective coating.
R0
Spacing between the two crown
centers shall be 500 to 1000 mm.
All materials supplied by the contractor, which in the opinion of company, do not comply with the
appropriate specifications shall be rejected and immediately removed from site by contractor at
his expenses.
4.0
COATING REQUIREMENTS
4.1
Pipes shall be concrete coated to a thickness as specified in the drawings and documents. The
concrete unit weight shall be minimum 2300 kg/m3 and the compressive strength shall not be less
than 250 kg/cm2 in 28 days.
4.2
Contractor shall design the mix by suitably proportioning the materials to achieve the specified
requirements of concrete strength, density and weight with a minimum cement content of
600kg/m3.
5.0
APPLICATION METHOD
5.1
Concrete coating shall be applied either using casting or impingement method. Any alteration or
modifications to the methods described in this specification shall be submitted to the Owner/
Engineer-in-charge for approval.
The application method shall however ensure the basic
characteristics of concrete coating in compliance with the minimum requirements of this

specification.
5.2
Contractor shall submit to the Engineer-in-charge, prior commencement of work, the

procedure/method of application for approval. Wherever practical the total thickness shall be
applied in a single pass. If more than one application is required to produce a coating of the
specified thickness, then the time allowed between successive applications shall not exceed 30
minutes. If the time between coats exceeds 30 minutes, all previous coating shall be removed
and shall be recoated.
The cost of removing coating and recoating shall be at contractors
expense.
5.3
All pipes shall be kept clean and free from cement, concrete & grout either inside or outside of the
uncoated section.
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Cutback on concrete coating.
Both ends of each joint for a distance of 305 mm 25 mm shall be completely free of concrete to
facilitate field joints. The concrete shall be tapered backside at these points at a minimum two to
one slope, until the required thickness of coating is reached. Also it shall terminate approx. 50
mm short of the end of the corrosion coating applied to the pipe surface.
6.0
EQUIPMENT
6.1
The equipment used for performing the concrete coating shall be capable of doing so with a
reasonable degree of uniformity with respect to thickness, density and strength.
The
proportioning equipment and procedure shall be of the type to assure consistently proportioned
materials by weight. Concrete shall be mixed in mechanical mixers, which shall ensure thorough
mixing of all materials. Any equipment that tends to separate the ingredients shall not be used.
In all cases concrete shall be placed within 30 minutes after water is first added to the mix.
Before placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and
wetted to obtain a good bond between the fresh material and previously placed materials.
7.0
COATING OF FIELD WELDS
7.1
The contractor shall coat the uncoated pipe surface at field welds in accordance with methods
approved by the company.
Contractor shall submit a detailed procedure for joint coating for
companys approval.
The reinforcement for the field welds shall be the same as that for line pipe coating with the same
7.2
number of layers and the same space between layers as for the existing coating. The edges of
this netting must be carefully secured with galvanized wire to the reinforcement extending from
the existing coating.
7.3
The reinforcement shall not make direct or electrical contact with the pipe.
7.4
Synthetic resin spacer blocks may be used to keep the reinforcement free from the pipe coating.
7.5
The moulds used for applying the concrete coating shall be supplied by the contractor.
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7.6
The composition of the concrete shall be same as that of the concrete coating of the pipe.
7.7
When using moulds, the contractor shall prevent air being trapped by applying mechanical
vibrators or by striking the outside of the mould by sticks.
7.8
If the moulds remain around the pipe, eg: in the case of submerged pipes floated into position,
the contractor shall take appropriate measures to prevent too much water entering the mould.
This can be achieved by clamping strips of burlap between the ends of the mould and the existing
concrete coating. After the mould has been filled with concrete the opening for filling must also be
closed off.
8.0
CURING
8.1
Immediately after concreting, the exposed surfaces of the concrete shall be protected during
hardening from the effects of sunshine, drying winds, rain etc and then after the initial set has
taken place, the concrete coating shall be properly cured. The coated pipe shall be handled
gently by suitable means to prevent undue distortion.
8.2
During curing the concrete coated pipe shall be racked on sand ridges or on flat earth surface
free of obstruction.
If the joints are placed on sand ridges they should be so placed as to
eliminate any injurious deflection in the pipe. The concrete shall be cured by application of curing
membrane approved by the Engineer-in- charge.
8.3
Curing shall be performed by application of an approved curing membrane using sealing

compounds and shall meet the requirements as mentioned in the manufacturers specifications.
The material shall be stored, prepared and applied in strict conformity with the instructions of the
manufacturer. The ingredients of any such compound shall be non-toxic and non-inflammable
and shall not react with any ingredient of concrete, the reinforcement, the protective coating or
pipe. The application of this curing compound shall take place immediately after the coating is
completed and preferably before the pipe is removed from the concrete coating apparatus.
8.4
The surface of the concrete shall be lightly sprayed with water before applying the curing
compound or as specified in the manufacturers specifications. The pipe surface shall be kept wet
during day light hours for (7) seven days after application of the concrete coating. The concrete
shall not be allowed to dehydrate.
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All concrete coated pipes shall be cured continuously for a period of seven days. Pipe shall not
be handled or loaded out from the yard until so cured. No deviation from this requirement shall be
permitted.
Transportation/handling of concrete coated pipe shall be done after 28 days of
concreting.
9.0
MEASUREMENTS & LOGGING
9.1
All measurements as mentioned below shall be taken during the work stages and clearly logged
in a proper log-book. A separate log-book shall be used for recording tests and trial results.
9.2
Pipes having same nominal diameter, steel wall thickness and protection coating shall be
recorded in a single register.
9.3
The following shall be entered in the log book for each pipe length.
a)
Line pipe
i.
Field identification number (F)
ii.
Mill serial number (M)
iii.
Length (L)
iv.
Weight (BW)
v.
Average outside diameter (OD)
(Shall be obtained by measuring the girth at least at five places, two of which 400 mm from the
ends of pipe and the other equispaced between them)
b)
Concrete coating
i.
Batch identification number (B)
ii.
Date of concrete coating (TD)
iii.
Average concrete coating thickness (CT)
iv.
Dry weight of concrete coated pipe and date of weighing, after 28 days
(DW) of
application of concrete.
9.4
No concrete coating shall be allowed unless all the details pertaining to the pipe before coating
are entered in the log-book. In addition each batch/shift shall be identified and registered against
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cube samples/core samples taken for crushing strength tests, and the same shall be logged.
10.0
IDENTIFICATION
10.1
A certified permanent records shall be supplied to Engineer-in-charge showing the serial number,
average outside diameter, length and weights.
Pipe identification shall be maintained by the
contractor for each joint of pipe and restencilling pipe mill coding shall be done on the internal
surface of the pipe.
10.2
For each concrete coated pipe length, at one of the two ends, the field identification number and
the date of concrete placing shall be marked.
11.0
INSPECTION AND TESTING
11.1
Contractor shall provide the method and means of obtaining the weight, length, and average
outside dia of each joint of pipe immediately after being coated. A permanent record certifying
such data shall be compiled daily and copies of such records shall be promptly be made available
to Engineer-in-charge.
11.2
Contractor shall furnish all materials to be tested and required testing apparatus. Contractor shall
obtain test samples in accordance with the applicable standard specification for the concrete
being applied and shall provide company with the results of tests made on these samples.
Samples shall be taken and tests performed at least once per shift during continuous operation or
once for every twenty five joints for non continuous operations.
11.3
The Engineer-in-charge or his representative shall have full and free access to the office and/or
plant, every part of the coating yard, and the ON/OFF loading facilities of the contractor.
Contractor shall assist the Engineer-in-charge or his representative for inspecting the works at
every stage. Pipe coating not meeting requirements, as outlined herein, shall be rejected.
11.4
Causes for rejection of the concrete coating shall include, but not be limited to, the following:
a)
Coatings that weighs less than or more than five (5) percent of the weight specified.
b)
Improper placement of reinforcing steel
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Coating damaged in handling or storage that is considered by Engineer-in-charge to be

excessive and beyond repair.
d)
Coating that are allowed to remain unfinished for a period of time exceeding 30 minutes,
as in the case of breakdown, or otherwise.
e)
Any failure to meet the requirements of this specification.
In general substandard concrete coating causing lesser weight, improper placement of steel,
coating damage and unfinished concrete etc. shall lead to rejection of the concrete coating and
decision of the Engineer-in-charge in this respect shall be final.
12.0
TESTING METHODS
12.1
Samples of the concrete mix, as applied during the coating operation, shall be taken to determine
the compressive strength and density of the concrete coating.
12.2
All testing shall be at the contractors expense and as directed by the Engineer-in-charge or his
representative. The testing methods to be used are outlined below.
a)
Compressive strength test
i.
Concrete shall be so proportioned so as to produce a compressive strength of not

less than 250 kg/cm2 at 28 days and not less than 167 kg/cm2 in 7 days. Test
shall be carried out as per the relevant Indian standards.
ii.
Minimum of six (6) cubes, three (3) each for 7 days strength and 28 days strength
shall be taken. Copies of all test reports shall be made for 7 days and 28 days
strength as decided by the Engineer-in-charge and the contractor.
b)
Coated pipe tolerance and weight tests
i.
Contractor shall maintain a surface tolerance of +/- 6 mm maximum for 30 mm thick

and +8mm/-6mm for thickness above 30 mm over outside diameter of the coated
pipe, between high and low elevations of pipe.
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The acceptable weight tolerance for any pipe shall be limited to +5/-2 % of the
calculated theoretical weight. The theoretical weight shall be calculated using total
weight of the pipe with concrete and corrosion coating.
13.0
PERMISSIBLE REPAIRS TO THE COATING
13.1
The following are repairs that will be permitted to coating due to unavoidable damage in handling
and storage. This is applied only to concrete that has hardened.
13.2
Spalling is defined as damage, which cause a loss in concrete of more than 25% of the total
thickness of the coating at the point of damage. Damage due to spalling of an area of less than
0.1m2 (1 ft2) where remaining concrete is sound will be accepted without repairs. Damage due to
spalling of an area more than 0.1 m2 and less than 0.3 m2 shall have the concrete removed as
necessary to expose the reinforcing steel throughout the damaged area. Edges of the spalled
area shall be undercut so as to provide a key lock for the repair material. A stiff mixture of cement
and aggregate of 1:3 ratio shall be trowelled into and through the reinforcement and built up until
the surface is level with the coating around the repair. The pipe shall then be carefully laid with
the repaired area at the top and shall be moist cured for a minimum of thirty six ((36) hours
before further handling. If the damaged area is more than 0.3 m2, the coating shall be removed
around the entire damaged area.
The repairs shall be made by satisfactorily restoring the
reinforcement, forming the area with a metal form and pouring a complete replacement of
materials similar to that from which the coating was made. The mixture shall be one (1) part of
cement, three (3) parts of aggregate and necessary water to produce a slump not to exceed 100
mm. The resulting coating shall be equal in weight, density, uniformity, thickness, strength and
other characteristics to the originally applied coating. The pipe shall then be carefully laid in a
position where it shall be allowed to remain for a minimum of thirty six (36) hours before further
handling.
14.0
HANDLING
14.1
Pipes shall be handled in a manner to prevent damage to coating, pipe walls and beveled ends.
Adequate strapping and padding shall be provided when loading for transfer to any location.
14.2
Pipes shall be raised or lowered to or from the stockpile, ground barge, truck by using brass lined
end hooks inserted in the ends of the pipe, and carried by a canvas sling with a spreader bar
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between the lines. All pipe handling shall be with equipment approved by Engineer-in-charge or
his representative. Contractor shall submit written handling, stacking and storage procedure for
approval of the Engineer-in-charge.
14.3 If the Engineer-in-charge or his representative observed coating or pipe damage due to handling,
the contractor shall take immediate corrective action. Finally, pipe shall not be loaded or stacked
until such handling will not damage the concrete coating.
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MANGALORE LPG BLENDING FACILITIES
SPECIFICATION FOR CEMENT MORTAR LINING

INSIDE PIPELINES
PREPARED FOR
HPCL
PROJECT NO. 8122
OCTOBER 2009
19.10.2009
LTA
SA
SA
REV.
DATE
PRPD. BY
CHKD. BY
APPRD. BY
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TABLE OF CONTENTS
1.0
Scope Of Work
2.0
Reference Documents
3.0
Materials
4.0
Application
5.0
Curing
6.0
Procedure Qualification
7.0.
Inspection
8.0
Repair Of Lining
9.0
Pipe Jointing
10.0
Fittings And Flanges
10
11.0
Branch Connection
10
12.0
Cutting Methods For Cement Lined Pipes
10
13.0
Damage Protection
11
14.0
Installation
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SPECIFICATION FOR PIPELINE CEMENT MORTAR LINING
1.0
SCOPE
1.1
This specification covers the minimum requirements for the materials, mixing,
application of cement lining, curing, inspection, repair, handling, transportation
and other activities for internal cement mortar lining for pipelines.
1.2
This specification shall be read in conjunction with the conditions of all

specifications and documents included in the contract between company and
contractor.
1.3
CONTRACTOR shall execute the work in compliance with all laws, by-laws,
ordinances, regulations, etc. and provide all services and labour, inclusive of
supervision thereof, all materials, equipment, appliances or other things of
whatsoever nature required for the execution of the work, whether of a temporary
or permanent nature.
1.4
This document is not intended to be all-inclusive, and the use of the guidelines
set forth does not relieve the contractor of his responsibility to supply a product
capable of performing its intended service.
2.0
RFEFERENCE DOCUMENTS
a) ANSI/ AWWA
C 205 00
Cement mortar Protective Lining and Coating for Steel water

pipe- shop Applied
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pipe- shop Applied

b)
IS 8112
Indian standard specification for

43 grade ordinary Portland cement.
c)
IS 383
Indian standard specification for

coarse and fine aggregates from natural sources for
concrete.
d)
IS 2386
Indian standards methods of test
Part1 To VIII for aggregates for concrete

e)
IS 1199
Method of sampling and analysis of concrete
f)
IS 456
Code of practice for plain & reinforced concrete
g)
IS 4031
Part 6 Determination of compressive strength of hydraulic

cement.
h)
IS 1916
Steel Cylinder Pipes with Concrete Lining and Coating Specification
i)
3.0
IS 4032
Methods of chemical analysis of hydraulic cement
MATERIALS
The contractor shall supply all the materials necessary for the performance of the
work. Materials for cement mortar lining shall comply with the following
requirements.
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Cement
43 grade ordinary Portland Cement conforming to IS 8112 shall be used.

Cement which has hardened or partially set or which has become lumpy shall not
be used. Test certificates from the cement manufacturer shall be supplied to the
company for all cement delivered to site.
3.2
Fine aggregates:
Fine aggregate shall mean any of the following as defined in IS 383.

i)
Natural sand
ii)
Crushed stone sand
iii)
Crushed gravel sand
Sand shall consist of inert granular material and the grains shall be strong,
durable and uncoated. Sand shall be clean and free from injurious amounts of
dust, clay, flaky particles, oil, alkali, mica and other deleterious substances. Sand
shall conform to IS:383 Grading Zone III.
3.3
Water
The water used for cement mortar mixing and curing shall be fresh and clean and
shall be free from injurious amount of oils, acids, alkalies, salts, sugar, organic
materials or other substances that may be deleterious to concrete or steel. It
shall not contain chlorides, sulphates and magnesium salts. Water from doubtful
sources shall be tested by the Contractor at his expense and shall be approved
by the Engineer-in-charge before use.
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4.0
APPLICATION
4.1
Cement Mortar mixing
Cement lining shall be done in the field shop, which may be outside the project
site boundary. Suitable mechanical equipment capable of mixing mortar and
doing the lining work to a reasonable degree of uniformity with respect to
thickness, density and strength shall be employed. Mortar shall be mixed in
batches.
Mortar shall compose of cement, sand and water and mixed well in proper
consistency to obtain a dense, homogeneous lining that shall adhere firmly to the
pipe surface. Cement mortar for lining shall consist of one part cement to not
more than three parts sand by weight and shall have a minimum cement content
of 600kg/m3. Water to cement ratio shall be between 0.3 to 0.4 by volume.
Trial mixes shall be made to arrive at mix to achieve the requirements specified in
procedure qualification clause 6.0 below:
4.2
Surface Preparation & Primer Application
Pipes shall be welded in suitable length and immediately prior to lining, the
surface shall to be thoroughly cleaned removing all grease, scale, dust, etc. by
power tool to St. 3 as per IS 9954. Surface cleaning shall be followed by spray
application of welding grade of inorganic Zinc silicate prefabrication primer from
approved paint manufacturers with a dry film thickness of 25 microns at both the
pipe ends upto 100 mm pipe length. The cement lining shall be done at least
after 10 hours of drying of the prefabrication primer to avoid damage of the
primer. Suitable products are such as Inter plate 11 from M/s AKZO NOBEL
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Coatings (India) Ltd., Bangalore, Carboweld 11 from M/s Carboline products

Chennai.
4.3
Application Method
The lining shall be applied in one course for the pipe section. No unfinished
surface shall remain exposed for more than 20 minutes. Mortar shall be handled
so as to avoid any kind of segregation and excessive moisture loss. During
mortar application pipe should be at ambient temperature. If pipe is hot due to
such reasons as lying in the hot sun, then the pipe must be cooled with the help
of wet gunny bags prior to application of mortar. Lining shall be free of any sharp
corners and edges and must be suitably contoured/rounded prior to curing.
Straight sections of pipe shall be lined by using spinning method or a method

known to provide equivalent results such as by a machine traveling through the
pipe and distributing the freshly mixed mortar uniformly along the full section and
long radius bends of the pipe. The lining machine shall be provided with
attachments for mechanically trowelling the mortar.
Both the application and
trowelling of the mortar shall take place at the rear of the machine so that the
freshly placed and trowelled mortar will not be damaged. The trowel attachment,
the rate of travel of machine and the rate of discharge of mortar shall be such that
the pressure applied to the lining will be uniform and produce a lining of uniform
thickness with a smooth, finished surface.
Hand patching at the end of the pipe, for length not more than 100 mm length,
shall be permitted to rectify the thinning of linings.
Fittings and specials shall be centrifugally spray lined to the same standard as
straight pipes or, if this is precluded by their shape, be hand patched so as to
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achieve comparable results.
The thickness of lining shall be as per Drg No. 8122-12-DG-00001, however to

accommodate the disc movement of Butterfly valves the cement lining of the
mating flanged spools shall be suitably tapered keeping minimum 3 mm lining
thickness.
5.0
CURING
After lining, the pipes shall be marked with the date of lining and shall be covered
with plastic caps and shall be moved carefully to a curing yard. The curing area
shall be sheltered so that lined pipes and fittings are protected from harmful
climatic conditions.
Moist curing shall start after 24 hours of completion of cement lining and shall be
done by continuous wetting or ponding. Under no circumstances the lining shall
be allowed to dry during curing period. Curing shall be carried out for a minimum
period of 7 days.
6.0
PROCEDURE QUALIFICATION
Prior to the application of the shop cement lining the manufacturer shall perform
procedure tests and qualify a working procedure to demonstrate that he is able to
produce a lining system in accordance with design requirement.
The
constituents, mortar & finished pipes shall be tested. To establish the correct
combination of sand & water, minimum of five samples shall be prepared. For
each mix following shall be accurately checked and recorded.
For individual constituents

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Cement
Sand
Water
Proportions & weights of respective materials
For Cement Mortar Test Specimen
Density
Compressive Strength
Water absorption
Test blocks of this material when subjected to testing as per IS 4031 shall exhibit
compressive strength of not less than 250 Kg/Sq.cm. after 28 days of curing and
the density of cured lining shall not be less than 2300 kg/cu.m. Water absorption
as per ASTM C642 shall not exceed 10% for the test specimen.
Based on the test results a procedure shall be standardised for mixing of the
materials.
Inspection personnel shall witness the mixing of materials and sample

preparations for procedure qualification.
Test results shall be correlated with
sample no. and a standard procedure shall be evolved.
7.0
INSPECTION DURING PRODUCTION
The entire procedure of applying cement-mortar lining shall be subjected to

continuous inspection by Owner or their authorised representative.
However,
such inspection shall not relieve the contractor of the responsibility of meeting the
specifications. The job shall be subjected to inspection at the following stages:
i)
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ii)
After application and curing
Any lining not applied in accordance with this standard or not as per required
thickness shall be subjected to rejection and replaced/repaired at the expense of
the contractor.
The inspector shall have free access to all areas and facilities concerned, and the
contractor shall furnish all reasonable assistance.
The inspection of lining in pipe upto 600NB shall be made from both ends of the
lined pipe segment by using strong lights and/or mirrors. The inspection shall be
done before the lining has attained its initial set. For pipes 650NB & above, a
manual, visual inspection of the lined pipe interior shall be made.
Defects in cement mortar lining include, but are not limited to sand pockets, voids,
over sanded areas, honey comb, excessively cracked, drummy areas, areas of
lining thinner than specified and areas of unsatisfactory surface finish.
The surface of lining shall be smooth and free from irregularities, cracks upto 0.8
mm wide and not over 300 mm in length are acceptable. Trough to crest height
shall not exceed 1.0 mm.
8.0
REPAIR OF LINING
8.1
For pipes up to 600NB, the defective lining shall be removed in total from the
pipe segment before the initial setting. The pipe segment shall then be relined in
full compliance with specifications.
8.2
For pipes above 600NB, small defective areas shall be repaired by manual
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removal of the defective lining and by hand reapplication of mortar lining.

Defective areas encompassing the full diameter of the pipe shall be replaced by
machine wherever practical.
8.3
A pipe that has been exposed by spilling or cracking of the lining shall be cleaned
thoroughly free from debris.
8.4
When an epoxy pipe-joining compound is to be used for the repair, the surface
shall be dry and dust free and a coating of the compound shall be applied with a
small trowel or spatula. When the cement mortar mix is to be used, the surface
shall be dust free and moistened with clean fresh water.
Immediately after
moistening the cement mortar mix shall be applied using a small trowel.
If
necessary a brush can be used for feathering in the surface edges of the repair.
8.5
Where cement mortar is used for the repair, the adjacent lining shall be coated
far enough back to cover any visible cracks and shall be maintained in a moist
condition for three days using a wet hessian sack or similar means. Alternatively,
if the line can be filled, it shall be put into use after the initial set has taken place.
9.0
PIPE JOINTING
Pipe joints both for above ground and underground upto 600NB shall be done by
collars in general and by flanged fittings in specific cases wherever requirement
arises for ease of fabrication, inspection and maintenance. Typical joint details
shall be as shown in Drg. No.8122-12-DG-00001.
9.1
Jointing Methods
9.1.1 Pipes which have been cement-mortar lined cannot be butt welded together in
the normal way as the mortar adjacent to the weld will be damaged by heat.
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9.1.2 For pipe size upto 600NB, Pipe OD and sleeve ID & both end faces of the cement
lining shall be provided with epoxy coating. The sleeve welds should be located at
90 deg. clear of any longitudinal pipe weld.
9.1.3 The terminal ends shall be cut at right angles to the pipe axis and after completion
of all welding out of roundness shall be within the limits specified by API Spec.
5L.
10.0
FITTINGS & FLANGES
All fittings upto 600NB size shall be generally collar joined with pipe. However
flanged joints can be provided at critical locations for ease of fabrication,
inspection and maintenance. Flanges may be welded in field/shop prior to lining.
Flange faces shall be free of cement lining. For detail refer Drg. No.8122-12-DG00001.
11.0
BRANCH CONNECTION
11.1 Branches in cement lined pipes shall be of minimum of 150 NB size. Stub in
branch connections of size 150 NB onward shall be collar joined as per Drg.
No.8122-12-DG-00003.
However to meet specific requirement at critical
locations for ease of fabrication, inspection and maintenance flanged joints may
also be used as per Drg. No.8122-12-DG-00003.
11.2
Instruments branches for Pressure instruments shall be as per Drg. No.812212-DG-00002.
The
150NB
blind
flange
shall
be
drilled
to
suit
instrument/vent/drain size.
11.3
Vents and drains on cement-lined piping shall be by 150NB flanged stub with
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blind flange, which is internally epoxy (FRE) lined. The blind flange shall be
provided tapped hole and vent/drain with valve & blind.
12.0
CUTTING METHODS OF CEMENT LINED PIPES
12.1
For cutting lined pipe, a slitter saw supported as necessary and containing a
nylon bonded carborundum disc shall be used. Alternatively, a rigid pipe cutting
machine using tungsten carbine tipped tools ground to the cutting angles shall be
used.
12.2 On fusion welded steel pipes, the external weld shall be removed flush with, but
not below, the face of the pipe for the width of the cutters, and if necessary for the
complete width of the cutting machine.
12.3 The section to be removed and the adjacent pipe ends shall be suitably supported
to avoid imposing any weight on the concrete lining when breaking through.
13.0
DAMAGE PROTECTION
13.1 Handling
Handling of lined pipe lengths shall be by means of nylon belts such that the
pipes are supported 1/5 of their length from each end. Pipe shall not be lifted
using hooks inserted in the pipe ends.
13.2
Transportation
13.2.1 Lined pipes being transported shall be adequately supported in a level

horizontal position in order to minimize flexing and prevent induced bending and
damage to the lining.
FACT
12FT026A/94
ORGANISATION
DATA
SHEET
8122- 12 - DA - 001
PAGE 14 OF 14
13.2.2 Pipes shall be protected from direct and indirect impact by means of suitable
cushioning material.
13.2.3 Pipes shall not be transported using tractor units with trailing bogies or other
method offering no central support.
13.2.4 During transportation and storage pipe lengths shall have end caps or other
suitable means of protection, with sufficient holes to permit air circulation,
provided this does not cause drying out and cracking of the lining. Means shall
be taken to ensure that the end protection remains securely fastened, especially
during transportation.
13.2.5
Branch connections shall be suitably plugged or capped as described above.
14.0
INSTALLATION
14.1
Care shall be taken when handling jointed lengths of pipes to ensure that the
induced bending and the possibility of damage to the lining is minimized.
14.2
During pipeline installation, when handling, lifting and laying pipe, the spacing
of lifting points and supports shall be adequate to avoid induced bending.
FACT
12FT026A/94
ORGANISATION
DATA SHEET
FIRE HYDRANT SYSTEM
8122-01-DA- FH101
PAGE
Applicable to :
Site :
Unit :
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
Purchase
X Proposal
MANGALORE
LPG BLENDING FACILITY
Make
Model
Type
No. off
Codes / Standards
Monitor size
Connection size
Nozzle diameter
Base flange details
Type of joint
Design pressure
Back pressure at base flange
Water barrel pipe thickness
Perfomance
Flow rate
Pressure
Jet length
- Horizontal
- Vertical
Rotation Angle
- Horizontal plane
- Vertical plane
Material of construction
Base flange
Swivel joints
Water barrel
Nozzle
Locks for swivel joints
Lubrication
Accessories
Monitor weight
Certification
Test pressure
As built
OF
TPS No. :
Job No :
Item No. :
WATER MONITOR
1
8122
Stand post type with swivel joints, Type 1 of IS 8442

2
IS 8442
75 with 100 NB base flange
mm
mm
mm
Kg/cm2G
Kg/cm2G
mm
lpm
Kg/cm2G
M
32
100 NB, ANSI B16.5, Class 150, SORF
Swivel joints
7 operating / 15 design
IS 1239, Heavy
1750
7
53
20
Deg.
360
+80, (-)45
CS
Gun mettal
IS 1239 Seamless
Aluminium alloy
Gun mettal
Grease lubrication for joints
Kg
Kg/cm2G
ISI marking
23
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
PAGE
1 OF
CONTENTS:
1.0.0. SCOPE
2.0.0. MATERIALS
3.0.0. SURFACE PREPARATION
4.0.0. STORAGE OF PAINTING MATERIALS
5.0.0. MIXING AND THINNING
6.0.0. PAINTING
7.0.0. SAFETY
8.0.0. INSPECTION
9.0.0. GUARANTEE
10.0.0. CODIFICATION OF PAINTING MATERIALS
11.0.0. SCHEME OF PAINTING
12.0.0. COLOUR CODING & MATERIAL FOR PIPING TABLES
PRPD.BY:- RS
CHKD.BY:- GPN
APPRD. BY:- KV
ISSUED ON:- 23.07.97
13
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
1.0.0. SCOPE
a)
1.1.0. This
specification
covers
the
requirements for surface preparation,
painting and painting materials for
equipment, structures and piping
(including those painted/primed at shop
and those painted at Field/Site.
b)
c)
d)
e)
f)
g)
h)
i)
1.2.0. Requirement of painting for any item

shall be as specified in any of the
following documents.
a)
b)
c)
d)
Equipment Data Sheet

Piping line schedule
Design Basis for
items
Painting schedule
package
1.3.0. The purpose of painting described in

this specification is generally for
protection against corrosion.
1.4.0. Painting for other reasons shall be as
indicated in the respective equipment
data sheets or painting schedule.
1.5.0. The following surfaces exposed to
atmosphere are covered by this
specification, which are not provided
by any other form of covering/coating.
a)
b)
c)
d)
PAGE 2 OF
Pressure vessels, Tanks, Heat

Exchangers and other process
equipment with Carbon steel
and low alloy steel as material
of construction.
Machinery
items
including
motors.
Steel structures
Carbon and low alloy steel
piping
1.6.0. The following items shall not be

painted unless otherwise specifically
required by respective equipment Data
Sheets/Painting schedule
j)
13
Non ferrous surfaces, stainless

steel and High Alloy steel
surfaces.
Glass, tile or ceramic surfaces
Name plates and identification
tags
Valve stems
Machined contact surfaces
Galvanised surfaces
Insulation covers
Plastics
Underground / buried piping
and equipments which are
provided with special type of
protective coatings.
Surfaces / Items which are
excluded from painting due to
specific reasons.
1.7.0. This specification also covers painting

of Markings and color-coding of
carbon steel, low/high alloy steel,
stainless steel, galvanized iron and
insulated pipes.
2.0.0. MATERIALS
2.1.0. All painting materials shall be of good
quality as covered by respective IS or
other international specifications
2.2.0. Special paints and painting materials
shall have proven quality and shall
meet the requirements laid down in the
respective data sheets for equipment
and piping.
2.3.0. All painting materials shall not have
passed the date of expiry or shelf life as
recommended by manufacturer.
3.0.0
SURFACE PREPARATION
3.1.0
All surfaces to be painted shall be free

from rust, oil, grease, dust, stain,
moisture or any other foreign
material/contamination, as per IS 1477
Part I.
02ES023/97
PAINTING
ENGINEERING
SPECIFICATION
Surfaces to be
completely dry.
be
deg.C or when the relative humidity of

air exceeds 90%.
3.3.0
Oil, grease, stains and other similar

contaminants shall be completely
removed by using proper solvents and
removers, After cleaning, the surfaces
shall be free from even traces of
contaminants and solvents/removers.
3.9.3. Blasting operations shall not be carried

out during rain, snow, or strong winds.
3.5.0
shall
13
3.2.0
3.4.0
painted
PAGE 3 OF
Dust shall be removed by air blowing

or vacuum cleaning.
Hard and caked dust, mud, mill scale
and rust shall be removed by
mechanical means like wire brushing,
sand blasting , shot blasting or grit
blasting.
3.6.0
Wet surfaces shall be dried by blowing

warm air.
3.7.0
All surfaces cleaned by different

methods shall be painted immediately
with out allowing the clean surfaces to
gather dust, rust and other external
substances.
3.8.0
During the course of painting if it is

found
that
the
surfaces
are
contaminated due to any reason, the
same shall be cleaned by any of the
methods described earlier, before
further proceeding with painting.
3.9.4. Blasting medium viz. Slag, grit, or shot

shall be completely dry and shall be
free from any sort of contaminants like
dust, oil, grease etc.
3.9.5. Blasting air shall be completely dry
and shall have minimum pressure of
3.5 kg/cm2 .
3.10.0 Surfaces which are not suitable for
blast-cleaning or could not be blastcleaned due to practical reasons shall
be thoroughly wire brushed to exhibit a
pronounced metallic sheen, equivalent
to St 3 as per IS 9954.
3.10.1 Absence
of
compressed
air,
slag/shot/grit and/or blasting equipment
and accessories shall not be a reason
for not carrying out blast cleaning.
4.0.0. STORAGE
MATERAILS
OF
PAINTING
4.1.0. Paints, varnishes, thinner, additives and

other volatile substances shall be stored
in a flame proof enclosure, away from
heat.
3.9.0
All surfaces to be painted after sand,

grit or shot blasting shall exhibit almost
clean white metal and shall have
surface finish of SA 2 as per IS
9954.
4.2.0. Fire extinguishers or sand and water

for emergency fire fighting operations
shall be provided near storage area at
easily accessible place for use, in case
of fire.
3.9.1
Blast cleaned surfaces shall be primed

within 2 hrs, after blasting, before rerusting starts and before contamination.
4.3.0. Warning Boards and signs shall be

exhibited around the storage area.
3.9.2. Blast cleaning shall not be carried out

when temperatures are less than 20
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
5.0.0. MIXING AND THINNING

5.1.0
Mixing and thinning of paints shall be

carried out as per manufacturers
recommendations.
5.2.0
Mixing and thinning operations shall

be carried out in well ventilated rooms.
5.3.0
Only that quantity of paint which is

sufficient to cover the required area
within the specified painting time, shall
be mixed at a time.
5.4.0
Mixed paints shall be used with in the

time span as recommended by
manufacturer. Mixed paints, for which
standing time specified has elapsed,
shall not be used.
5.5.0
5.6.0
Ready-mixed paints containers shall

be opened only at the time of painting.
Containers shall be closed air tight
after drawing paint from it.
Ready-mixed paints shall be stirred
well before drawing from the storage
container as well as during painting
operations.
5.7.0
Ready-mixed paints shall be thinned

only if absolutely necessary by using
thinners commended by manufacturer.
5.8.0
Balance of ready-mixed paints shall not

be poured back into the main container
after use, but shall be kept in a separate
air tight container.
6.0.0
PAINTING
6.1.0
General Requirements.
6.1.1
Painting of equipment, piping and

structurals shall be carried out at shop
or site as prescribed in the respective
eqpt. data sheets, piping line schedule
or structural detail drawing.
.
6.1.2
PAGE 4 OF
13
Painting shall not be carried out on

surfaces not prepared and not meeting
the requirements of clause 3.0.0.
6.1.3
Painting shall be carried out only under

favourable conditions. Painting shall
not be carried out in dusty and draught
conditions in damp areas and during
rainy seasons or cold atmosphere.
6.1.4
During painting, adjacent equipments

or surfaces shall be protected from
paint sprays, splashes or drips.
6.1.5
Painting shall be carried out only by

using brushes, rollers, air/airless spray.
6.1.6
Caution boards indicating wet paint

shall be posted after painting is over
and kept till the curing time is
completed.
6.1.7
For painting of multiple coating, each

coat shall be applied only after
sufficient curing time has elapsed after
the previous coat, as recommended by
manufacturer.
6.1.8
All painted surfaces shall have a

uniform and smooth regular finish.
The surfaces shall be free from foreign
particles, brush marks, bristles, ridges,
waves, laps wrinkles etc. If such
surface defects occur, the same shall be
removed by using abrasive paper/cloth
and re-painted.
6.1.9
Surfaces inaccessible after assembly

shall be painted to requirement before
assembly.
6.1.10 Any imperfect or damaged layer/coat

shall be repaired before subsequent
coating.
6.1.11 At places where welding is to be
carried out at field after assembly, a
space of 100 to 200 mm width shall be
left unpainted on both sides of the
welding joint.
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
6.1.12 Field welded areas shall be thoroughly

cleaned as required in clause 3.0.0 and
painted in the same manner as the
remaining area.
6.2.0
Shop Painting/Priming.
6.2.1
Shop painting/priming shall be carried

out as specified in the respective data
sheets/line schedule etc. and shall meet
all
the
requirements
of
this
specification.
6.3.0
Painting at Field /Site.
6.3.1
Field/site painting shall be carried out

as specified in the data sheets/painting
schedule and shall meet all the
requirements of this specification for
painting.
6.3.2
Where
equipments/piping/structures
have
already
received
shop
painting/priming, the painted/primed
surfaces shall be thoroughly cleaned
and inspected for any damage or
defects. Such damages or defects shall
be repaired before starting the filed/site
painting.
7.2.0. Open flames and exposed elements or

sources of ignition of any kind shall be
prohibited in the area where painting
materials are stored and painting
operations are carried out.
7.3.0. Warning
or
Caution
boards
indicating chances of fire shall be
displaced around the paint storage and
painting areas.
13
7.4.0
Electrical fittings and appliances shall

be spark proof and shall not cause a
fire in the painting storage and painting
areas.
7.5.0
Cleaning agents with flash point less

than 400 C shall be used.
7.6.0
Adequate ventilation shall be ensured

during painting and storage of paints.
7.7.0
Painting workmen shall wear face

masks, gloves and protective clothing
during painting and mixing operations.
In addition, workmen engaged in
blasting operations shall be earmuffs
also.
7.8.0
Area where painting is carried out, as

well as materials are stored shall be
clean, After work, the areas shall be
cleared of all scaffoldings, balance
materials etc. in order to prevent fire
hazards and hinder fire fighting
operations.
7.9.0
Painting materials shall be stored and

painting and blasting operations shall
be carried out only in areas where fire
fighting
equipments/vehicles
and
personnel evacuation vehicles can have
easy access. In areas where such easy
access is not available suitable
precautions are to be ensured.
8.0.0
INSPECTION
7.0.0. SAFETY
7.1.0. Sufficient safety precautions shall be
taken to ensure protection of Personnel,
equipments, piping structures and
buildings in the vicinity, where
painting
materials are stored and
painting and blasting operations are
carried out.
PAGE 5 OF
8.1.0. All painting materials and related items

shall be inspected to check the
suitability of the same for the specified
purposes.
8.2.0. Painting surfaces are to be inspected
after cleaning operation, to ensure that
the surfaces are fit for painting.
8.3.0. Finished surfaces shall be checked for
uniformity in colour, finish and
appearance as well as for defects.
02ES023/97
PAINTING
ENGINEERING
SPECIFICATION
8.4.0. Thickness of each coat of paint shall be

checked after curing time. The total
thickness of multiple coats shall be as
specified in the data sheets/piping line
schedules/painting schedules.
8.5.0. Paint thickness gauge shall be either
mechanical or electronic. The gauges
shall be calibrated regularly. Defective
gauges shall not be used.
8.6.0. Absence of paint thickness gauge shall
not be made for each eqpt/line/structure
separately.
8.7.0. A detailed quality / inspection report
shall be made for each eqpt / line /
structure separately
9.0.0. GUARANTEE
Guarantee shall cover materials and
workmanship.
10.0.0. CODIFICATION
MATERIALS
OF
PAINTING
10.1.0. Primers
A.01
A.02
A.03
A.04
A.05
A.06
Synthetic
Zinc
Phosphate
Primer
Epoxy based Zinc Phosphate
Primer
Epoxy based Zinc Rich Primer
Alkyd
High
Build
Zinc
Phosphate Primer
Inorganic Zinc Silicate Primer
Chlorinated Rubber based High
Build Zinc Phosphate Primer
10.2.0. Finish Paints

B.01
B.02
B.03
B.04
B.05
Epoxy Resin based Enamel

Epoxy Resin based Micaceous
Iron Oxide Paint
Epoxy Resin based High Build
Paint
Coal Tar Epoxy Resin based
Paint
Chlorinated Rubber Paint
PAGE 6 OF
13
C.01
Nontoxic Inert Coating for

drinking water tanks
C.02 Acid Alkali and Heat Resisting
Coating
10.4.0. Heat Resistant Paints
D.01
D.02
Dual Pack Aluminium Paint

(upto 250o C)
Single Pack High Temperature
Silicon Aluminium Paint (upto
600o C)
10.5.0. Polyurethane Coating. (For low temp.

application)
E.01
E.02
Two-Pack Polyurethane Holding

Primer
High Build Polyurethane Coating
10.6.0. General Purpose Paints

F.01
F.02
F.03
Synthetic Resin based Enamel

Chemical Resistant Enamel
Alkyd,
Antiskid
Abrasion
Resistant Synthetic Floor Paint
10.7.0. Special Applications

G.01
G.02
G.03
Bituminous Mastic Coating

Asphalt doping as per IS 10987
App-B
Thermocolour Paint
10.8.0 As an alternative, in place of one coat

of E.01 Two pack Polyurethane
Holding Primer, one coat of Epoxy
Zinc Phosphate Primer A02 (20
microns) followed by one coat of High
Build Epoxy containing Micaceous
Iron oxide-Bo2 (20 microns) shall be
applied before applying finish paint E02-High build Polyurethane coating.
11.0.0 SCHEME OF PAINTING
11.1.0. Scheme of painting of equipment,
piping, structures and other items shall
conform to class 1, class II or class III
as specified in the equipment data
sheet/ piping line schedule/ painting
schedule/ structural drawings.
11.2.0 Representation of painting
10.3.0. Bituminous Coating

02ES023/97
PAINTING
ENGINEERING
SPECIFICATION
Requirement of painting of an item

shall be indicated in respective
drawings/ data sheets/ line schedule/
painting schedule as follows. Indicate
primer or finish or both as
requiredfollowed by subclass indicated
in Table 1, Table 2 or table 3 as the
case may be.
Eg
Primer
Finish
Primer & Finish
Primer
Primer & finish
Primer
Finish
Primer & Finish
Class I
(1)L
Class I
(1)L
Class I
(2)M
Class II
(2)O
Class II
(3)O/P
Class III
(1)
Class III
(1)
Class III
(3)
PAGE 7 OF
13
12.0.0 COLOUR CODING AND MARKING

FOR PIPING
12.1.0 In addition to the requirements of
painting as per 11.0 the finish painting
of the piping shall have the specified
colors as per Table 4 Color coding
for pipes, for purposes of identification
of service.
12.2.0 All pipes and pipe lines covered under
1.7 shall be provided with Markings
such as color bands, hazard markings,
line
identification
markings,
flow
arrow markings etc. at specified
locations/intervals and dimensions as
indicated in Table 5 Marking of
pipes.
*******************
02ES023/97
PAINTING
ENGINEERING
SPECIFICATION
PAGE 8 OF
13
TABLE 1 CLASS I Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping
Sl.
No.
SERVICE
CONDITIONS
OPERAT
ING
TEMP.
PAINT
SUBCLASS
Type
UN
INSULATED
NON
CORROSSIVE
ATMOSPHERE
UN
INSULATED
CORROSSIVE
ATMOSPHERE
INSULATED
CORROSSIVE
ATMOSPHERE
=/< 15
=/< 65
=/< 125
=/< 400
(1) L
(1) N
(1) M
(1) H
=/< 15
=/< 65
=/< 125
=/< 400
=/< 15
=/< 65
=/< 125
=/< 400
INSULATED
=/< 15
CORROSSIVE
=/< 65
ATMOSPHERE =/< 125
=/< 400
SUPPORTS
=/< 15
FOR
ALL =/< 65
EQPTS.(INSUL =/< 125
ATED/UN
=/< 400
INSULATED)
EQPT.
AND =/< 15
STRUCTRURE
=/< 65
S SUBJECTED =/< 125
TO
SALINE =/< 400
ATMOSPHERE
UN
INSULATED
PRIMER
*DFT
Type
E.01
A.01
D.01
D.02
No.of
coats
1
2
2
2
*DFT
E.02
F.01
D.01
D.02
No.of
coats
2
2
2
2
30
20
20
20
(2) L
(2) N
(2) M
(2) H
(3) L
(3) N
(3) M
(3) H
(4) L
(4) N
(4) M
(4) H
(5) L
(5) N
(5) M
(5) H
E.1
A.06
A.02
D.02
E.01
A.04
D.01
D.02
E.01
A.06
D.01
D.02
E.01
A.01
D.01
D.02
1
2
2
2
1
2
2
2
1
1
1
1
1
2
2
2
30
20
20
20
30
25
20
20
30
30
30
30
30
20
20
20
E.02
B.05
B.02
D.02
E.02
F.01
D.01
D.02
2
2
2
2
2
2
2
2
20
20
20
20
30
20
20
20
(6) L
(6) N
(6) M
(6) H
E.01
A.06
A.02
D.02
1
2
2
2
30
20
20
20
E.02
B.05
B.01
D.02
2
2
2
2
30
30
30
20
* DFT Dry film Thickness per coat microns

Notation:
L
N
M
H
FINISH
Low Temperature
Normal Temperature
Moderate Temperature
High Temperature
30
20
20
20
02ES023/97
PAINTING
ENGINEERING
SPECIFICATION
PAGE 9 OF
13
TABLE 2 CLASS II OTHER EQUIPMENTS

PRIMER
PAINT
SUB
CLASS
Sl.
No. TYPE OF ITEM
2
3
4
5
8
9
10
11
Chimneys,Stacks,
Furnaces,heaters
(fired
and
unfired)operating
Temp upto450o C
D.M.Water
Storage Tanks
Fresh Water/fire
Water
Storage
Tanks
Drinking
Water
Storage Tanks
Acid/alkali
Storage Tanks
Storage
Tanks/Vessels for
Petroleum
Products
Floating
Roof
Tanks:Inside
of
shell,
top
of
bottom
plate,topside and
underside
of
deck, inside of
pontoon
Underside
of
Bottom Plate of
Tanks
Underground
Tanks (buried)
Below Ground
(submersible)
Tanks
Secondary
Reformer&Simila
r
Eqpt.(Thermo
colour paint)
*DFT :
**
:
Notation:
FINISH
Type
No.of
coats
*DFT
Type
No.of
coats
*DFT
Outside
(1)
A.05
25
D.02
20
Outside
Inside
Outside
(2)O
(2)P
(3)O
A.01
A.03
A.01
2
2
2
20
35
20
F.01
B.03
F.01
2
2
2
25
35
25
Inside
Outside
Outside
(3)P
(4)O
(4)P
A.03
A.01
A.01
2
2
2
35
20
20
B.04
F.01
C.01
2
2
3
75
25
20
Outside
(5)
A.04
30
C.02
25
Outside
(6)O
A.04
50
D.01
25
Inside
(6)P
A.02
30
B.03
75
Outside
(7)O
A.04
50
D.01
25
(7)P
A.02
30
B.03
75
(7)Q
A.01
25
(8)
A.01
20
G.01
80
Outside
(9)
A.01
20
G.02
Outside
(10)
A.06
35
B.05
35
(11)
G.03
**
G.03
**
Dry Film Thickness per coat microns

As per Manufacturers recommendations
O- Outside
P-Product Side
Q-Specified Side
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
PAGE 10 OF
13
TABLE 3 CLASS III MISCELLANEOUS
Sl. TYPE OF ITEM

No.
Steel structures, Platform

Supports
PAINTING
SUB
Type
CLASS
PRIMER
No.
of
*DFT
coats
FINISH
Type
No.of
coats
*DFT
(1)
A.04
20
B.01
25
Chequered
Plate,Floorplanks&Gang
ways
(2)
A.04
20
F.03
25
Handrails
Posts,Railings,Ladders
and Stairways
(3)
A.04
20
B.01
25
* DFT Dry Film Thickness per coat microns
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
PAGE 11 OF
13
TABLE 4 COLOUR CODING FOR PIPES

Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Identification
Ground / Finish Colour
Instrument Air0
Sky Blue
Service Air
Sky Blue
Plant Air
Sky Blue
Cooling Water
Sea Green
Service Water
Sea Green
Demineralised Water
Sea Green
Boiler Feed Water
Sea Green
Steam Condensate
Sea Green
Boiler Blow Down
Sea Green
Turbine condensate
Sea Green
Process Condensate
Sea Green
Low Pressure Steam
Silver Grey
Medium Pressure Steam
Silver Grey
High Pressure Steam
Silver Grey
Very
High
Pressure Silver Grey
Steam
Naphta Liquid
Light Brown
Naphta Vapour
Light Brown
Fuel Oil
Light Brown
Antifoam Solution
Black
Phosphate
Black
Hydrazinc
Black
Waste Water
Black
Oily Water
Black
Ammonia Liquid
Dark Violet
Ammonia Water
Dark Violet
Ammonia gas
Dark Violet
MDEA Solution
Dark Violet
Process Vent
Canary Yellow
Carbondioxide
Canary Yellow
Hydrogen
Canary Yellow
Nitrogen
Canary Yellow
LPG
Canary Yellow
Fuel gas
Canary Yellow
Process Gas
Canary Yellow
Synthesis Gas
Canary Yellow
Effluent
Black
Drinking Water
Sea Green
Service
Colour Band - 1
Colour Band - 2
White
Light Brown
French Blue
French Blue
French Blue
Light Orange
Light Brown
White
White
Black
Light Orange
Light Brown
Signal Red
Signal Red
Signal Red
French Blue
Signal red
French Blue
French Blue
French Blue
White
Sea Green
Signal Red
Signal Red
Sea Green
White
French Blue
French Blue
French Blue
Black
Light Grey
Light Grey
Signal Red
Black
French Blue
Light Brown
Sea green
White
Sea Green
Light Orange
White
Sea Green
Signal Red
Sea Green
Canary Yellow
White
Signal Red
Signal Red
-
02ES023/97
PAINTING
ENGINEERING
SPECIFICATION
PAGE 12 OF
13
TABLE 5 MARKING FOR PIPES

1.0.
GROUND COLOUR
UNIT OF MEASUREMENT
Insulated Line all
(excludes buried line)
1.1.
Un-insulated LinesStainless : Ground colour for a length Per Marking as per para 6.0
Steel,GI ,Alloy steels &
of 2 meters
below including pipe supports
Other non-ferrous pipelines
(excludes buried line)
___________________________________________________________________________
1.2.
Un-insulated carbon steel
: Ground colour applied
Run length in Meters along
Lines (excluded buried
throughout entire length
centreline including Markings
Lines)
as per Para 6.0 below &
pipe supports
___________________________________________________________________________
2.0.
COLOUR BANDS MARKINGS
Colour band(s)and its width,Band 2 downstream of Band 1(ie.after band 1
along the direction of flow)
Pipe size NB
(D-pipe size in inches)
80 NB and below
Above 80 NB(3) up to 100 NB(4)
Above 100 NB(4) up to 300 NB(12)
Above 300 NB(12)
Band 1
mm
75
D x 25
D X 20
D x 15
B and 2
mm
of Band 1
(Rounded to
nearest mm)
the
HAZARD
Diagonal strips of Black and golden Yellow as per IS2379 superimposed on
MARKINGS the ground color. If color bands exists,the hazard marking shall be painted
Downstream of the bands (ie. after bands in the direction of flow)
3.0.
LINE IDENTIFICATION
MARKINGS
Color shall be Black or White to contrast with the color on

which they are painted. It shall consist of Line No., Line size,
Fluid code & Pipeline Spec. No. The lettering dimensions
Shall be as per IS2379.
4.0.
FLOW ARROW
MARKINGS
Color shall be Black or White to contrast with the color on

which they are painted. The dimension of the arrow shall
be as follows and is based on the size of the pipeline.
a
c
a
b
c
d
150NB &
below
65
30
95
20
200NB &
above
90
50
125
30
02ES023/97
ENGINEERING
SPECIFICATION
5.0.
PAINTING
PAGE 13 OF
13
LOCATION OF MARKINGS
Marking includes 2M long ground
color,
color
band(s),
hazardous
marking, Line No. & flow direction
arrow which shall be located at the
following points with proper visibility
as per IS2379.
a.
b.
c.
d.
e.
Battery Limit Points

Either side of walls & dyke
walls
For long yard piping at 30M
interval
Inter-section on pipe bridge
Any other location indicated by
the Engineer-in-charge at site
6.0.
PIPE SUPPORTS
6.1.
This includes base springs, hanger

springs, shoes and trunnions etc. and
excludes
pipe
bridge
structures,
platform, equipment support structures
and such structures which do not
actually support the pipeline.
6.2.
The painting of pipe supports forms

part of the pipelines and a
separate rate will not operate.
6.3.
The
painting specification for pipe

supports shall be same as that
for
pipe
ground
colour.
****************
ENGINEERING
SPECIFICATION
02ES042/97
COLD INSULATION
PAGE 1 OF 26
CONTENTS
PRPD.BY:- CK
1.0.0
SCOPE
2.0.0
INSULATION MATERIALS
3.0.0
ANCILLARY MATERIALS
4.0.0
INSULATION THICKNESS
5.0.0
APPLICATIOIN
6.0.0
PIPING INSULATION
7.0.0
MACHINERY ITEMS
8.0.0
INSTRUMENTS & MISC. ITEMS
9.0.0
INSULATION CAST - IN - SITU
10.0.0
SAFETY
11.0.0
GUARANTEE
12.0.0
APPLICATION DETAILS
CHKD.BY:- GPN
APPRD. BY:- KV
ISSUED ON:- 24-7-97
ENGINEERING
SPECIFICATION
02ES042/97
COLD INSULATION
1.1.0 SCOPE
This
specification
covers
the
requirements for the supply and
application of external, self extinguishing
type thermal insulation of equipment and
piping for cold service conditions.
1.1.0 REQUIREMENT OF COLD
INSULATION
1.1.1 Requirement of cold insulation of any
equipment or piping shall be as specified
in any of the following documents.
a. Equipment data sheets / drawings
b. Piping line schedule
c. Design basis for package items
d Insulation schedule
1.1.2
Cold insulation is required to be provided

on Pressure vessels, Heat Exchangers,
Columns, Tanks other process equipment
and Piping to meet the following
requirements.
a.. To maintain process / operating
temperature.
b. To prevent ingress of heat from
external source/atmosphere.
c. To avoid surface condensation.
1.1.3 Insulation requirement to maintain
process/operating temperature shall be as
indicated in documents referred to in
1.1.1.
1.1.4 Insulation for preventing ingress of heat
from external source/atmosphere and to
avoid surface condensation shall be
provided on all equipment and piping
operating below 20o C.
1.2.0 Limits of Application.
1.2.1 The following items shall not be
insulated unless otherwise specified.
a.
Bonnets of valves above packing glands
b.
Nameplates and data plates of equipment.
1.2.2
PAGE 2 OF 26
All attachments and projections such as

supports, structures attached to
equipment pipe hanger supports,
Instrument lead lines, branch lines like
vents and drains and instrument
connections connected directly to cold
insulated equipment and piping shall be
cold insulated up to a distance of 5
times the adjoining insulation thickness.
2.0.0 INSULATION MATERIALS

2.1.0 The material of insulation shall be as
specified in the documents indicated in
1.1.1 and shall be one of the following.
a.
Polyurethane foam
b.
Expanded Polystyrene
2.2.0 Material of insulation shall be nonabsorbent with a closed cell structure
to
ensure
non-permeability
of
moisture / water vapour.
2.3.0 Material of insulation shall be fungus
and vermin proof.
2.4.0 Insulation material shall not contain
chemicals, which may be harmful to
the equipment or piping or to the
protective coating at ambient or
service temperatures in wet or dry
condition.
2.5.0 Insulation material used for austenitic
steel equipment and piping shall be
free from water-soluble chlorides and
other harmful chemicals.
2.6.0 POLYURETHANE FOAM (PUF)
2.6.1 Polyurethane foam (PUF) may be
used for insulation of equipment and
piping either as preformed sections or
cast-in-situ.
2.6.2 Polyurethane foam shall be of rigid
preformed cellular urethane foam and
self-extinguishable type in accordance
with ASTM-C 591, Type II, Gr.2.
ENGINEERING
SPECIFICATION
2.6.3 The foam shall be formulated in such a

way that it shall be of selfextinguishing quality which shall not
cause fire to spread under any
circumstances.
2.7.5
2.6.4 The finished foam, in the form of

sections, slabs or cast-in-situ, shall be
of uniform closed cell structure, free
from unreacted material, shrinkage and
distortion.
2.6.5 Density of finished foam shall be
approximately 45 Kg/m3.
2.6.6 Thermal conductivity of the finished
polyurethane foam shall not exceed 15
Kcl/hr deg C at 10 deg C mean
temperature after ageing.
2.6.7 Closed cell content of finished PUF
shall be at least 95% by volume.
2.6.8 Maximum permeance of finished PUF
shall be 4.0 gms/m. 24h.mm Hg.
2.6.9 Resistance of 10% compression of
finished PUF at ambient temperature
shall be 1.5 Kg/cm
2.7.0 EXPANDED PLYSTYRENE (EPS)
2.7.1 Expanded polystyrene (EPS) may be
used for insulation of equipment and
piping in the form of preformed sections
or slabs.
2.7.2 Expanded polystyrene shall be of selfextinguishing type with closed cell
structure in accordance with IS-4671
type 2.
2.7.3 Finished EPS shall be free from
shrinkage distortion and unreacted
materials.
2.7.4 Density of finished EPS shall be given
below:
Preformed sections
Slabs
02ES042/97
COLD INSULATION
20 to 22 Kg/m3
18 o 20 Kg/m3
PAGE 3 OF 26
Thermal conductivity of finished EPS

shall be as given below:
---------------------------------------------Density
Thermal conductivity
Kcal/m.hr. oC
0oC
10oC
---------------------------------------------18
0.028
0.031
20
0.027
0.030
22
0.026
0.029
2.7.6 Maximum permeance of finished EPS

shall not be more than 4.0 gms/m. 24
hr.mm.Hg.
2.7.7 Finished EPS shall be free from
leachable chlorides.
3.0.0 ANCILLARY MATERIALS
3.1.0 Wire netting; Lacing & Stitching
Wire netting of preformed sections and
slabs shall be of 24 swg x 20 mm GI.
Lacing and stitching wires shall be of
20 swg and 22 swg GI respectively.
3.2.0 BANDS
Aluminium bands of size 20mm width x
24 swg shall be used for securing
insulation sections and slabs in place.
3.3.0 METAL CLADDING
Commercial quality aluminium jacketing
conforming to IS 737 shall be used for
all equipment and piping. Thickness of
cladding sheets shall be as indicated in
table. 1.
3.4.0 SELF TAPING SCREWS
Self tapping screws to be used for
securing the metal cladding shall be
6mm dia cadmium plated or
galvanised, and best quality.
3.5.0
SEALING COMPOUND
ENGINEERING
SPECIFICATION
3.5.1
02ES042/97
COLD INSULATION
To ensure perfect water proofing,

cladding joints shall be packed with
sealing materials, which may either be
in the form of bituminous mastic
sealing compound or fibre based
bituminous felt strips.
3.5.2 Sealing compound shall be suitable to

withstand the temperature of insulation
to seal the joints.
3.6.0 MASTIC BEDDING
Insulating sections and slabs shall be
bedded in non-setting mastic to
eliminate air pockets. The same mastic
shall be used for ensuring vapour tight
joints between adjacent sections/slabs.
3.7.0 HARD SETTING PLASTER
Hard setting plaster (mixture of sand &
cement or asbestos & cement shall be
applied over wire netting on piping
subjected to foot traffic.
3.8.0 BITUMINISED
SELF-FINISHING
ROOFING FELT.
Bituminised self-finishing roofing felt
shall conform to IS 1322 Type 3 Gr. 1.
[
3.9.0 VAPOR BARRIER

3.9.1 Sealing mastic for the vapour barrier
shall be fire retardant mastic,
bituminous
emulsion
mastic
or
elastomeric polymer mastic.
3.9.2 Instead of sealing mastic, aluminium
foil of about 0.025mm (25 microns)
thick glued to craft paper using
polyethylene glue or aluminium foil
(.025mm thick) coated with polyester
may also be applied as vapour barrier.
4.0.0 INSULATION THICKNESS
4.1.0 Insulation thickness shall be as
specified in the equipment data
sheet/piping line schedule/insulation
schedule.
4.2.0 For package items, the insulation
thickness as per table 2 may be used as
PAGE 4 OF 26
a guidance for selecting the minimum

thickness of insulation required. The
vendor shall check the same for process
adequacy.
5.0.0 APPLICATION
5.1.0 GENERAL
5.1.1 The surfaces to be insulated shall be
thoroughly cleaned by wire brushing to
remove dirt and loose scale. Equipment
and piping which have received primer
/ painting shall be cleaned well, without
disturbing the surface treatment already
received.
5.1.2 Unprimed carbon and low alloy steel
surfaces shall be thoroughly cleaned by
wire brush and one coat (30 microns) of
epoxy based zinc phosphate primer
shall be applied before starting cold
insulation. Sufficient curing time shall
be allowed for surface treatment.
5.1.3 Stainless steel and other non-ferrous
surfaces shall not be primed.
5.1.4 The equipment drawings indicate the
extend of insulation and location of
insulation supports.
However, the
insulation contractor shall recommend,
furnish and install any additional
supports and anchorage that may be
required to adequately support the
insulation. Field welding of clips and
supports shall be carried out only with
the prior approval of the Engineer-incharge.
5.1.5 All insulating and ancillary materials
shall be new and unused and shall be
free from contaminating materials, dust
and dirt.
5.1.6 All insulation materials shall be stored
in covered areas protected from
moisture and dust. Insulation materials
shall not be stacked directly on ground.
Insulation materials showing any
evidence of absorption of moisture shall
not be used.
ENGINEERING
SPECIFICATION
COLD INSULATION
5.1.7 Insulation work shall be carried out

only after hydrostatic testing of
equipment / piping have been
completed.
5.1.8 Insulation of flange joints shall be come
only after they have been proved to be
leak tight.
5.2.0 MULTILAYER INSULATION
5.2.1 When thickness of insulation exceeds
60mm, the insulation may be applied
with multi layers, with all joints
staggered. Each layer of insulation
shall be secured by metallic banding.
5.2.2 All cracks and voids in the insulation
shall be completely sealed by using the
mastic bedding indicated in 3.6.0.
5.2.3 No. of layers to be employed shall
determined as given below:
Insulation thickness
Up to 60 mm
Up to 120 mm
Above 120mm
No. of layers
1
2
3
5.3.0 VAPOR BARRIER

5.3.1 Vapour barrier shall be applied on
insulation of all equipments at the
outermost layer before metal cladding
is applied.
5.3.2 Polyurethane foam and expanded
polystyrene
insulation
shall
be
completely covered with a continuous
vapour tight layer to prevent
permeation of vapour into the insulating
material.
5.3.3 A layer of sealing mastic shall be
applied over the entire surface of the
insulation, to obtain a thickness of 2 to
2.5 mm when completely dry. Over
this coat while it is still wet a layer of
open weave glass fibre cloth of 10 mesh
size and 0.125 mm thick stretched with
out any wrinkles or air pockets shall be
laced with glass fibre threads. A final
coat of sealing mastic shall be applied
02ES042/97
PAGE 5 OF 26
over the glass fibre mesh to obtain a

thickness of 2.5 mm when dry.
5.3.4 Alternative type of vapour barrier as
described in 3.9.2 may be applied
instead of that given in 5.3.3, in which
case all joints shall be completely
sealed and shall leave an overlap of at
least 100 mm. Sealing of joints shall be
done by using airtight and waterproof
adhesive tape.
5.4.0 WIRE NETTING & BANDING
5.4.1 Aluminium bands as specified in 3.2.0
shall be fixed over insulation blocks at
an interval of 300 mm.
5.4.2 Before application of vapour barrier,
the insulation sections and slabs shall
be completely covered by wire netting,
laced and stitched by using wire nets,
lacing and stitching wire specified in
3.1.0. The bands shall be sufficiently
tightened to keep the insulation
sections/slabs firmly in place without
deforming the insulation.
5.4.3 Protruding ends of the bands shall be
cut off or turned down so as not to
damage vapour barrier.
5.5.0 FILLING OF VOIDS
5.5.1 Polyurethane dust mixed with specified
adhesive shall be packed tightly so as to
fill voids and contractions on PUF
insulation.
5.5.2 Blown bitumen mixed with polystyrene
beads shall be used to fill voids and
contractions in EPS insulation.
5.6.0 ALUMINIUM CLADDING
5.6.1 Vapour barrier of PUF or EPS
insulation shall be protected by
aluminium cladding specified in 3.3.0.
5.6.2 Aluminium cladding shall be bent to
shape grooved & properly riveted by
using pop rivets.
5.6.3 All joints of the cladding shall overlap
aluminium of 50 mm and shall be
arranged in such a way as to shed
ENGINEERING
SPECIFICATION
COLD INSULATION
water. Joints shall be offset between

pieces.
5.6.4 Cladding shall be secured to aluminium
bands of size 20 x 3 mm. Which are
provided at a gap or 450 mm along the
circumference.
5.6.5 All joints in the cladding shall sealed
water tight by using seating compound
or tapes as described in 3.5.0.
5.6.6 Jacketing for dished heads shall be
fabricated radial segments with an
overlap of 50mm. The sheeting shall
be secured in position by radial
tensioned metallic bands stretched over
the heads. One end of each band is
anchored to the circumferential band
with shell, while the other is fastened to
a floating ring fabricated in the form of
a ring. The sheet metal bands may be
held in place by using pop rivets.
5.7.0 FLASHING
5.7.1 Openings in metal jackets for nozzles,
manholes, brackets shall be cut as close
as possible for a smug fit.
5.7.2 All openings through insulation finish
shall be flashed weather tight by an
approved sealant particularly where
connections are not insulated.
5.7.3 Skirt supported vessels shall have the
skirt insulated inside and outside for at
least 600 mm below the tan gent line.
5.7.4 Unless
otherwise
specified
no
insulation shall be applied to the inside
of the skirt, which are externally, fire
proofed.
5.7.5 For leg-supported vessels, insulation
shall be provided to a length of at least
5 times the insulation thickness
minimum.
5.8.0 VERTICAL VESSELS
5.8.1 Cylindrical Shell
1. Slabs/sections in handy sizes shall be
applied resting on to the supports with
joints tightly butted, staggered and
02ES042/97
PAGE 6 OF 26
adhering to each other with specified

adhesives.
2. The slabs/sections are to be secured in
position by circumferential metallic
bands at an interval of 300mm. When
multi layer insulation is applied each
layer shall be banded separately.
5.8.2 Top Heads
1. Insulating material shall be properly
shaped and tightly pressed on the top
head.
2. The insulation shall be held in position
by using metallic bands one end of
which shall be fastened to the floating
ring and the other end shall be anchored
to the circumferential band laced on
shell near the head.
3. Radial bands shall be spaced at 300 mm
gap measured along the circumference
of the vessel.
4. The final layer of insulation shall be
held in position by metallic wire net
laced at the top vortex nozzle by about
two to three loop of 10 swg galvanised
iron wire and the wire net over the
insulation of he shell close to the head.
5. When there are no top vertex nozzles,
the insulation shall be held in position
by wire netting and metallic bands
stretched over the head and anchored
on the cylindrical section close to the
head by circumferential metallic band
on the shell near the head.
5.8.3 Bottom Heads
1. Preformed and shaped insulation
sections shall be used for insulating the
bottom head.
2. Preformed and shaped insulation
sections shall be held in place in the
same manner as for top heads.
3. While one end of the metallic bands
shall be fastened to floating ring if a
bottom vortex nozzle is present, the
other end shall be anchored to the
ENGINEERING
SPECIFICATION
insulation support ring provided inside

the skirt support.
4. Radial bands shall be spaced at 300mm
pitch
measured
along
the
circumference.
5. In case of absence of a bottom vortex
nozzle, the metallic bands shall be
stretched across the bottom head and
anchored at the ring inside the skirt.
5.9.0 HORIZONTAL VESSELS
5.9.1 Insulation of horizontal vessels shall be
carried out by using preformed and
shaped insulation blocks/sections.
5.9.2
Insulation material shall be held in place

by using metallic bands a spacing of 300
mm.
5.9.3
Final layer of insulation shall be provided

with netting, laced and stitched.
Each layer of insulation shall be banded
separately and bands of successive layers
shall be staggered.
5.9.4
5.9.5
02ES042/97
COLD INSULATION
Insulation blocks/sections shall be held in

position by metallic bands at radial pitch
of 300mm on the heads and anchored to
the circumferential metallic bands on
shell near the head.
5.10.0 HEAT EXCHANGERS

5.10.1 Insulation of vertical heat exchangers
shall be carried out in the same manner as
in 6.0.0.
5.10.2 Insulation of horizontal heat exchangers
shall be carried in the same manner as in
7.0.0.
5.10.3 Exchanger channels and channel covers
including bolting flanges shall be
insulated with removable aluminium
covers
lined
with
insulation
sections/blocks of specified thickness.
5.11.0 SPHERICAL VESSEL
5.11.1 Shaped insulation block shall be used for
spherical vessels.
5.11.2 All joints shall be sealed well by
approved joint sealant.
PAGE 7 OF 26
5.11.3 Inner layers of insulation shall be held

separately in place by metallic bands at
300 mm pitch at equator.
5.11.4 The bands shall be tied up with floating
rings of 20mm O/D made of 15 SS rod at
the poles of the sphere.
5.11.5 The bands on the successive layers shall
be staggered and the clip ends are to be
bent and recessed in to the insulation.
5.11.6 Outer layer of insulation shall be secured
in place by wire netting, laced and
stitched together.
5.12.0 STORAGE TANKS
5.12.1 Insulation of storage tank shell shall be
carried out in the same manner as
described in 6.0
5.12.2 Where tank fabricator has provided
support rings and vertical flats on the
tank shell, the insulation contractor shall
provide additional rings at a pitch of 900
mm. These additional rings shall be tack
welded only to the support rings and
vertical flats. No welding shall be
permitted on the tank surface.
5.12.3 Metal cladding of tank shell shall be with
22 swg corrugated aluminium sheet. All
points shall be staggered by 300mm and
shall be sealed water proof with approved
sealing material.
5.12.4 Tank Roof
1.Tank roof shall be thoroughly cleaned of
all dirt and rust and other contaminants.
2.Preformed insulation sections/slabs shall
be laid over one coat of adhesive mastic
and pressed well. All joints shall be
sealed with adhesive mastic to make it
airtight.
3. When multi layer insulation is applied
of successive layers shall be staggered
and sealed with adhesive mastic.
4. Each lay of insulation shall be secured
with bands and wire netting laced and
stitched as detailed in 5.8.2.
ENGINEERING
SPECIFICATION
6.1.7
At un-insulated flanges, insulation shall

be terminated at suitable distance from
the flange so that the flange bolts can be
withdrawn without disturbing the
insulation.
7. Apply a 20mm thk hard setting nonconductive plaster made from asbestos
fluff and Portland cement troweled to a
smooth and even finish.
6.1.8
In case of vertical piping, insulation

supports shall be installed by the
insulation contractor. These shall consist
of spacer rings at 4 metres intervals
clamped to the pipes.
6.1.9
Insulation of piping shall be complete

with mastic bedding, sealing compound,
vapour barrier, filling of voids and metal
cladding as described earlier in the
specification.
6.0.0
6.1.0
6.1.1
PIPING INSULATION
GENERAL
External surfaces of pipes shall be
cleaned well with wire brush (CS brush
for CS pipes and SS brush for SS pipes)
to remove all dirt rust and contaminating
material and wiped well.
6.1.2
If painting is provided for specific

reasons the insulation contractor shall not
carry out any harsh cleaning and shall
ensure that painting is undisturbed.
6.1.4
6.1.5
6.1.6
PAGE 8 OF 26
5. Vapour barrier shall be applied as

specified in 5.3.0.
6. Fix a shed water shroud constructed from
20 swg GI plain sheets at the periphery of
the tank.
8. When hard setting plaster is completely

dry apply a standard 4 course bitumen
felt as per IS 1346. Aluminium cladding
shall be applied over this.
6.1.3
02ES042/97
COLD INSULATION
All pipes and supports shall be

permanently set before commencement
of insulation.
Disturbed pipes and
supports shall be restored to their original
location and alignment when insulation is
complete.
All insulation shall be applied when
piping is at ambient temperature.
Spacer rings for supporting metal
cladding shall be installed by the
contractor.
Insulation in the form of preformed pipe
sections shall be applied over the pipe
without spacer rings. On top of each
layer wire netting shall be applied and
tightly butted against each other so that
the wires interlock both longitudinally
and circumferentially. The wire net
joints shall be stitched with 20 swg soft
galvanised iron wire.
6.1.10 Insulation of flanges and valves shall be

provided only when specifically
mentioned in the line schedule/work
order. When specified, removable covers
shall be provided over all flanges and
valves.
The insulation shall be
preformed, filled in aluminium sheet
boxes, and fitted with quick release clips.
6.2.0
INSULATION OF PIPING FOR FOOT

TRAFFIC
6.2.1
After application of insulation including

vapour barrier the insulation sections are
to be held together with GI wire netting
and joints laced with GI wire.
Wire netting shall be held together with
20mm wired hoop iron bands at 300mm
spacing.
6.2.2
6.2.3
Apply hard setting plaster as per 3.7.0 of

20mm thick-troweled smooth.
6.2.4
After the hard setting plaster has dried

wrap bituminised self-finishing roofing
felt over the plaster with an overlap of
50mm
both
longitudinally
and
circumferentially.
6.2.5
The roofing felt shall be secured with 24

swg x 20mm GI wire netting and all
joints are to be laced with 20 swg GI
wire.
ENGINEERING
SPECIFICATION
6.2.6
Apply 3mm thick bituminous emulsion

mastic compound for water and weather
proofing.
6.2.7
When bitumen emulsion has completely

dried the surfaces shall be painted with
bitumen based aluminium paint.
6.3.0
6.3.1
6.3.2
6.3.3
6.3.4
02ES042/97
COLD INSULATION
PIPING INSPECTION WINDOWS

Plug type inspection windows shall be
provided on all insulated pipelines having
size 50 mm and above.
item to be insulated for the approval of

Engineer-in-charge.
8.0.0
INSTRUMENTATION &
MISCELLANEOUS ITEMS
8.1.0
Drain and vent piping up to the first

valve on insulated equipment shall be
insulated with similar type of insulation
and finish as the equipment to which it is
attached.
8.2.0
Headers,
branch
lines
sample
connections and pipelines to instruments
shall be insulated with similar type of
insulation and finish as the connected
piping.
8.3.0
The thickness and type of insulation for

all lines mentioned before shall be
determined from piping like schedule for
corresponding temperature and pipe
sizes. Thickness of insulation for the
parts not mentioned shall be as specified
by Engineer-in-charge.
9.0.0
9.1.0
INSULATION CAST-IN-SITU
Large vessels and equipment may be
insulated using polyurethane foam,
foamed in situ.
The size of the inspection windows shall

be as indicated below:
Pipe dia (mm)
Window dia (mm)
50
35
80
45
100
75
150 and above
100
Inspection windows shall be provided at
the bottom of the pipelines.
There must be at least one inspection
window within a span of 10m.
PAGE 9 OF 26
6.3.5
At least 50% of the bends shall be

provided with inspection windows.
6.3.6
In case of critical pipelines, more number

of inspection windows may be provided
at the discretion of the Engineer-incharge.
9.2.0
Sheet metal covering of inspection

windows shall be of the same gauge as
that of insulation cladding. These covers
are to be fixed on with 6 mm self-tapping
screws.
Before commencement of foaming-insitu, the contractor shall demonstrate the

foaming procedure to the approval of
Engineer-in-charge to check for the
presence of voids after formation.
9.3.0
3 samples of PUF per shift shall be

foamed in transparent polyethylene bags
in
presence
Engineer-in-charge.
Insulation work shall commence only
after the approval of samples by the
Engineer-in-charge.
9.4.0
Both the surface of equipment to be

insulated and the cladding shall be free of
rust, dirt and other contaminating matters.
9.5.0
The sheet metal cladding shall be

adequately strapped and braced to
withstand pressures developed during
foaming, without distortion or failure.
All joints of cladding shall be made leak
6.3.7
6.3.8
7.0.0
The plug shall be of perfect fit into the

inspection window and shall ensure leak
tightness.
MACHINERY ITEMS
in general PUF/EPS filled removable
prefabricated sheet metal boxes shall be
adopted for insulation of machinery
items. The contractor shall submit
insulation details of individual items of
equipment depending on the nature of
ENGINEERING
SPECIFICATION
9.6.0
9.7.0
02ES042/97
COLD INSULATION
PAGE 10 OF 26
proof by using impermeable mastic

sealing compound.
Air escape holes provided in the cladding
shall be sealed well after foaming.
Table 1 Thickness of Aluminium

cladding sheets
Table 2 Thickness for Cold Insulation
The annular space between the

equipment and the cladding shall not be
less than the thickness of insulation
specified and shall be maintained
uniform throughout by use of performed
Polyurethane spacers, which will remain
embedded in foam.
Fig.1
Insulation of Vertical Vessels
Fig.2
Insulation of Exchanger Shell &

Head
Expansion joint for Rigid
Insulation
10.0.0 SAFETY
The insulation contractor shall provide
adequate protective appliances, like
gloves, masks, glasses and clothing to
workmen carrying out the insulation
work for protection against any
hazardous / toxic chemicals and gases.
Sufficient for protection methods /
gadgets shall also be deployed at the
place of insulation.
11.0.0 GUARANTEE
11.1.0 The insulation contractor shall furnish
authentic test certificates to confirm
that all materials offered conform to
the requirements of this specification
and standards mentioned therein.
11.2.0 All insulation works shall be guaranteed
against defective materials and bad
workmanship for the period specified in
enquiry / order.
Fig.3
Fig.4
Support for Vertical Insulated

Piping
Fig.5
Fig 6
Fig.7
Welded Elbow Insulation

Tee Insulation
Bottom Head Insulation for
Vertical Vessels
Fig.8
Fig.9
Fig.10
Flange Insulation
Valve Insulation
Flashing at Nozzles & Other
Projections.
Fig.11
Fig.12
Fig.13
Uninsulated Flange
Tank shell insulation-Details
Support detail for metal covering
of insulation.
Fig.14
Fig.15
Man hole Insulation

Details of Corrugated sheet
overlapping
Fig.16
Details of Tank Roof Insulation

supports.
Details of Tank Top setting
Plaster Finish
Fig.17
12.0.0 APPLICATION DETAILS
Refer the following details attached to
this specification for application of
insulation of various parts.
Fig.18
Fig.19
*******************
Single layer Insulation for Piping

Multiple layer Insulation for
Piping.
02ES042/97
COLD INSULATION
ENGINEERING
SPECIFICATION
PAGE 11 OF 26
TABLE 1 THICKNESS OF ALUMINIUM CLADDING SHEETS

Size (mm)
Or Dia
Item
< / = 350 NB
Equipment
Piping
Type of aluminium sheeting

Vertical
Other portions
24 SWG plain
24 SWG plain
>350 NB
22 SWG Corrugated
24SWG plain
Tanks
22 SWG Corrugated
22 SWG plain for

roof and 24SWG
plain for other parts
< / = 350 NB
24 SWG plain
22 SWG plain
> 350 NB
Valves, flanges
etc.
24 SWG plain
24 SWG plain
24 SWG plain
22 SWG plain
TABLE 2 THICKNESS OF COLD INSULATION

Nom:
Dia < / =
20
65
80
150
400
500
900
Above
900
-40
60
Insulation Thickness (mm) for Temperature Deg.C

-30
-20
-10
0
10
60
60
50
50
40
70
80
90
100
110
120
130
70
80
90
100
110
120
130
70
80
90
100
110
120
130
60
70
80
80
80
80
80
60
70
80
80
80
80
80
20
40
50
50
50
50
50
50
50
50
50
50
50
50
50
50
iso2.sty
ENGINEERING
SPECIFICATION
ERECTION OF STATIC EQUIPMENT
PAGE 1 OF 5
h. Strength calculation sheet including stress
diagram of gin pole/ boom derrick, guy
ropes and anchor points.
i. Orientation and position and strength of
lifting lugs or lifting beam.
j. List of temporary equipment and tools to be
prepared.
k. L ist of prin ciple comp onen ts of g in
pole/boom derrick.
l. Transportation plans of gin pole/ boom derrick construction equipment and special
vehicles.
m. Installation plan and progress schedule of
gin pole/boom derrick.
n. Electric power to be consumed during installation.
CONTENTS
1.0.0
2.0.0
3.0.0
4.0.0
5.0.0
6.0.0
7.0.0
8.0.0
9.0.0
10.0.0
SCOPE
REFERENCES
GENERAL
PLANNING
CONSTRUCTION EQUIPMENT
INSTALLATION
ALIGNMENT
GROUTING
LOOSENING SLIDE END ANCHOR BOLT
INSPECTION RECORD
1.0.0
SCOPE
This specification covers the requirement for the
installa tion, alignment and grouting work of
static equipments like towers, vessels and heat
exchangers.
2.0.0
REFERENCES
The requirements contained in the latest editions of the following standards shall form an
integral part of the requirements of this
specification in the manner and to the extent
specified herein.
ANSI B 30.5 Safety Code for Crawler,
Locomotive & Track Cranes
ANSI B 30.6 Safety Code for Derricks.
ANSI B 30.9 Safety Standard for Slings.
ANSI S 310
3.0.0
Specification for Design ,

Fabrication & Erection of
Structural Steel for Buildings
GENERAL
The installation work shall further comply with
the requirements of the applicable codes or
regulations in force at the locality of the job site.
4.0.0
PLANNING
After investigating the job site but prior to commencing of the work, installation plans shall be
made by considering the following items:
a. Shape, dimension, weight, and material of
equipment.
b. Installation sequance of equipment.
c. Transportation route of equipment.
d. Strength and condition of unloading jetty.
e. Installation procedure, including utilisation
plan of gin pole, boom derrick, crane, construction equipment, and special vehicles.
f. Work space around the installation area.
g. Schedule of installation of each equipment.
PRPD. BY:
25ES201 / 94
CHKD. BY:
5.0.0
CONSTRUCTION EQUIPMENT
5.1.0
5.1.1
HOISTING EQUIPMENT
Gin pole / Boom derrick
Select the gin pole/boom derrick according to
the shape, weight, and dimension of the equipment to be installed, and the surrounding condition. The gin pole/Boom derrick shall have
ample height to lift the tallest equipment to be
installed.
The mast base of the gin pole/boom derrick shall
be anchored securely. The erection plan of the
gin pole/boom derrick shall be made by considering the following:
1. Site of Gin Pole/Boom derrick.
Prior to starting the gin pole/boom derrick erection, the soil condition shall be investigated and
a temporary concrete foundation shall be
provided, if necessary.
2. Strength
The gin pole/boom derrick shall be of a design
to withstand all loads of equipment weight,
d y na m ic fo rce s su ch as wind lo ad , o r
earthquake load, etc.
The design of the gin pole/boom derrick shall be
in accordance with the AISC specifications. The
loads shall not exceed the manufacturers rating
with the recommended reeving.
3. Guy Rope
All guy ropes of the gin pole shall conform to the
following requirements:
a. The gin pole of the double mast type shall
have atleast eight guy ropes. For the single
pole type, six guy ropes shall be provided.
If the gin pole of the double mast type is to
be used at an inclined position, at least two
wire ropes shall be provided to limit the gin
pole inclination. Preferably, the guy ropes
shall be equally spaced around the mast.
b. All guy ropes shall be stretched to have a
uniform and ample slack. Guy ropes shall
be installed so as not to interfere with other
work or traffic.
c. All guy ropes shall be fitted with a minimum
APPRD. BY:
ISSUED ON: MAR 94
ENGINEERING
SPECIFICATION
of three cable clamps or equivalent at each

connection to prevent slippage. The
diameter of the usable guy ropes shall not
be less than that specified in the installation
plan. The safety factor of guy ropes shall
comply with ANSI B 30.6.
4. Anchor
Anchoring of winch, guy ropes etc. shall be
accomplished by installing deadmen unless
otherwise specified. Deadmen shall be
placed so as not to interfere with eqpt foundations, underground facilities & structures.
5.1.2 Winch
1. The winch shall be located so that it does
not obstruct passage of equipment nor
prevent the operator from observing the
signalman.
2. Anchors to the winch shall be provided to
withstand the maximum force working on
the winch. Brakes and clutches shall be
protected from the weather so that a sudden
rain fall, during lifting, shall not cause the
load to slip or drop.
5.1.3 Mobile crane
1. All mobile crane operators shall be qualified
by governmental or other equivalent
authorities.
A set of the manufacturers lift tables shall
be placed conspicuously in the mobile
crane operators cab at the jobsite. The
capacities given shall be adhered to strictly.
Additional boom sections installed on the
equipment shall be compensated by additional counterweights in accordance with
the instruction manual. Timber mats and/or
steel mats shall be provided for treads or
tires considering the soil bear ing. Basically,
outriggers and jacks shall be provided on
the mobile crane to guard it against sudden
tire failures and overturning while lifting
heavy equipment.
2. All cranes shall be inspected in accordance
with ANSI B 30.5 . When a risky condition is
found, appropriate measures shall be taken
immediately.
Major items of inspection shall be as follows:
a. All control mechanisms as to maladjustment.
b. All control mechanisms as to excessive
wear of components and contamination by
lubricants or other foreign matter.
c. All control mechanisms as to malfunction.
d. Deterioration or leakage in air or hydraulic
systems.
e. Electrical apparatus as to malfunctions and
signals.
f. Crane hooks with deformations or cracks.
g. Deformed, cracked, or corroded members
in the crane structure and boom..
h. Rope reeving as to noncompliance.
i. Ropes.
25ES201 / 94
PAGE 2 OF 5
5.2.0
WIRE ROPE, SLINGS, CHAINS AND FITTINGS

1. Wire Rope
Wire ropes shall be of suitable size, grade and
construction to withstand the maximum load
imposed.
Wire ropes in the main hoisting system shall be
of ample length for the entire range of movement
specified with at least two full wraps of the rope
on the hoist drum at all times.
Wire ropes shall be inspected in accordance
with ANSI B 30.6.
When any of the risky conditions listed below is
found, the wire rope shall be removed from the
sling service and appropriate measures shall be
taken to improve the condition.
a. In running ropes, six randomly distributed
broken wires in one rope lay, or three broken
wires in one strand in one rope lay.
b. Wear of one-third of the original diameter of
the outside individual wires.
c. Linking, crushing, bird caging or any other
damage resulting in distortion of the rope
structure.
d. Evidence of any heat damage from any
cause.
e. Reductions from nominal diameter of rope
exceeding:
3/64 inch for diameters upto 3/4 inch inclusive.
1/16 inch for diameters 7/8 inch to 1-1/8
inches inclusive.
3/32 inch for diameters 1-1/4 inches to 1-1/2
inches inclusive.
f. In standing ropes, more than two broken
wires in one lay in sections beyond the end
connection or more than one broke wire at
an end connection.
2. Wire Rope and Sling
Wire rope slings shall comply with ANSI B
30.9.
The safety factor for wire rope slings of all
grades shall be not less than five.
3. Chain
All chains shall be forged or electric welded
steel link type of the proper size for the loads
to be lifted.
Overloaded chains shall be discarded immediately.
4. Drum, Pulley and Sheave
The diameter of the drum or pulley shall be
not less than 20 times the rope diameter.
The diameter of sheaves shall be not less
than 10 times the rope diameter.
5. Fitting
All hooks, swivel hooks, anchor shackles,
swivel sockets, safety hooks, cable clamps,
turnbuckles, and other attach ments shall
be made of drop forged steel.
6. Safety Factor
ENGINEERING
SPECIFICATION
PAGE 3 OF 5
TABLE - 1
ITEM
MIN.
SAFETY
FACTOR
6.2.0
6.2.1
6.2.2
Hoist Rope
Hoist Rope for Raising and
Falling Boom
Wire Rope for Turning
Wire Rope or Guy Rope

for Tension
Wire Rope for Sling
6.0.0
INSTALLATION
6.1.0
6.1.1
ERECTION OF GIN POLE/BOOM DERRICK

Inspection of gin pole components
Prior to erecting the gin pole/boom derrick all
winches, hooks, shackles, thimbles, wires,
chains, etc., shall be inspected thoroughly as to
material, capacity, wear and tear.
Grounding
The gin pole/boom derrick shall be equipped
with grounding. Resistance of grounding shall
be under 10 ohms.
Assembly and disassembly
The following precautions shall be taken in the
assembly and disassembly of the gin pole.
1. During the assembly and disassembly
operation of the gin pole/boom derrick only
persons to be engaged directly in the work
shall be admitted into the work area.
2. Only qualified operators for hoisting and
slinging shall be assigned and a list of such
operators shall be prepared and filled.
Inspection after assembling
Immediately after assembly and prior to starting
the lifting of any equipment, the following parts
of the gin pole/boom derrick shall be inspected
carefully:
1. Gin pole/boom derrick members and connections thereof.
2. Anchor of winch.
3. Guy ropes as to number, tension and condition.
4. Wire ropes as to condition of wear and
damage.
5. Hook, shackle, thimble and other hanging
implements as to conditions of wear and
damage.
6. All control mechanisms and other safety
devices.
7. Electrical apparatus and controls of winch.
Preventing accidents by guy rope
For preventing accidents, all guy ropes shall be
attached with red flags so that they will be
recognizable from a distance.
6.1.3
6.1.4
6.1.5
PREPARATION OF SHIMS AND WEDGE

Shims & wedges shall be made of carbon steel.
In general shims & wedges shall be prepared by
machining or grinding as indicated in Table 2.
TABLE - 2
3.5
Wire Rope for Supporting

Boom
6.1.2
25ES201 / 94
ITEM
LENGTH
mm
WIDTH
mm
THICK
mm
SLOPE
Shim
100-450
50-200
3.2,4.5,9,12,
19,25
Wedge
100-450
50-200
6,9,12,16,19,
25 (max.)
4o-5o
6.3.0
6.3.1
6.3.2
6.3.3
6.3.4
INSTALLATION OF EQUIPMENT
Inspection before installation
1. Prior to commencing the installation work,
any damage during the transportation, the
orientation of the equipment, the center of
gravity, base level from the datum line of the
foundation, the condition of the slings and
lifting lugs, and the condition of the anchor
bolts etc., shall be inspected thoroughly.
2. The function of brakes, clutches, other
safety devices and controls of the winch
shall be inspected.
3. To prevent overloading, any test water or
other temporary materials remaining or left
in the equipment shall be drained or
removed.
4. The bottom face of the equipment base
plate shall be cleaned.
5. The concrete surface of the foundation shall
be thoroughly chipped and then be cleaned
completely with compressed air, etc.
6. The required number of shims and wedges
with the necessary tools shall be prepared
to ready use.
Precautions against storm
1. When the wind velocity exceeds 15m/sec.
all installa tion work shall be stopped.
2. No equipment shall be installed under stormy winds, heavy rain or heavy snow.
Special crew
1. During heavy equipment installation, especially installation by the gin pole/boom derrick a special crew shall be organized.
2. The crew shall comprises a general supervisor, signal/flag man, hoist operator, crane
operator, rigger, safety supervisor, etc.
3. The function of each individual of the crew
shall be clearly defined.
Installation
1. Heavy equipment shall tentatively be lifted,
slightly, to examine all parts of the gin
pole/boom derrick, crane, wire ropes, tools,
etc. If any defect is found, the equipment to
be installed, shall be lowered on the ground.
After the defect is corrected, the equipment
shall be lifted slowly.
2. Crane work shall not be suspended at
dangerous and incomplete positions during
the lifting operation.
ENGINEERING
SPECIFICATION
PAGE 4 OF 5
3. The protective cover on equipment for nozzles and flanges shall not be removed
without the approval of the Engineer-incharge.
4. During installation work, special care shall
be taken so as not to damage the anchor
bolts or their threads.
5. While seating and leveling, use shims and
pairs of wedges.
6. As a rule, shims and wedges shall be placed
on liner plates fixed on the concrete foundation at both sides of the anchor bolts, and
leveling shall be done temporarily. Where
the distance between anchor bolts is larger
than 800mm, extra shims and wedges shall
be located between the anchor bolts to
prevent the base plate from bending.
Wedges or shims shall not be substituted
with wooden strips, bricks concrete blocks,
etc.
7. After leveling is finished and all anchor bolts
are firmly tightened, all shims and wedges
to remain in place shall be tack-welded to
prevent them from becoming loose.
8. As a rule, welded lifting lugs used in the
installation shall be left in place.
7.0.0
ALIGNMENT
7.1.0
7.1.1
GENERAL
All installed equipment shall be aligned plumbness or level.
Towers/vertical vessels shall be aligned plumbness and satisfy the requirements of Par. 7.2.0
Horizontal vessels & heat exchangers shall be
aligned level and satisfy the requirements of
Par.7.3.0
PLUMBNESS
1. Plumbness shall be checked by viewing
from two directions 90o apart with a transit.
Check of plumbness of very tall equipment
shall be done early in the morning.
2. Out-of-plumb of the equipment installed
shall not exceed 1.0mm per lm of height or
a total of 25mm for the entire height,
whichever is smaller, unless otherwise
specified in the job Specification.
3. After alignment is finished and the lock nuts
of the anchor bolts are tightened firmly, the
shims and wedges shall be tack-welded to
each other and any excess in the shims and
wedges shall be cut off with gas cutter.
LEVELING
1. The alignment level shall be made using a
spirit level instrument or a transit at four
points based on the center line marked on
the equipment in the shop. The level shall
be aligned in the direction of AB or CD and
AC or BD at the center line on the equipment. ( Refer to Fig. on Page 5 of 5 )
2. The maximum tolerance shall be as shown
in Table 3, unless otherwise specified.
7.1.2
7.1.3
7.2.0
7.3.0
TABLE - 3
POINT
25ES201 / 94

A and B or C and D
l mm per Meter of Length
A and C or B and D
2 mm Max.
3. Considering the drain-out during maintenance, the channel end of the heat exchanger shall be lowered 1 to 2mm/m than
the shell cover end.
4. After leveling is finished and the lock nuts of
the anchor bolts are tightened firmly, the
shims and wedges shall be tack-welded to
each other and any excess in the shims and
wedges shall be cut off with a gas cutter.
8.0.0
8.1.0
8.2.0
8.3.0
9.0.0
GROUTING
Grouting shall be accomplished in accordance
with the fol lowing requirements, unless otherwise specified.
PREPARATION FOR GROUTING
1. The foundation surface shall be cleaned
thoroughly and be removed of any dirt or oily
spots.
2. The top surface of the foundation shall be
wetted thoroughly with fresh water prior to
grouting.
MATERIAL
1. Portland cement mortar may be used in
grouting under the base plates, unless
otherwise specified.
2. The mixing ratio of portland cement and
clean fine sand shall be approx. 1:2 in
volume, and the ratio of water to cement
shall be less than 40 percent in volume
unless other wise specified.
GROUTING PROCEDURE
1. The base plate shall be grouted as follows:
a. The space under the base plate shall be
packed full with grout.
b. The grout shall cover all shims and wedges.
2. After the grouting mortar has been poured
fully, the excess grout shall be trimmed
away. The surface of the mortar outside of
the base plate shall be finished smoothly.
3. The shims and wedges shall not be
removed, unless otherwise specified.
LOOSENING SLIDE END ANCHOR BOLT

1. After grouting has set and hardened, the
nuts of the sliding end anchor bolts shall be
loosened to allow for thermal expansion.
2. The above requirement shall be applied to
horizontal vessels, shell and tube heat exchangers, and when requested by the Engineer- in - charge
10.0.0 INSPECTION RECORD

The results of the following inspections shall be
recorded and submitted.
1. Alignment
a. Plumbness
b. Leveling
TOLERANCE
ENGINEERING
SPECIFICATION
25ES201 / 94
PAGE 5 OF 5
LEVELLING POINTS FOR HORIZONTAL EQUIPMENT
X
A
PLAN
SCALE
VIEW X X
LEVEL
INSTRUMENT

00FT001
iso2.sty
ENGINEERING
SPECIFICATION
ERECTION-ALIGNMENT AND GROUTING OF

MACHINERY ITEMS
CONTENTS
1.0.0
2.0.0
3.0.0
4.0.0
5.0.0
6.0.0
SCOPE
INSPECTION AND STORAGE
HANDLING
ERECTION
GROUTING
ALIGNMENT
2.6.5
2.6.6
2.7.1
2.7.2
1.0.0 SCOPE
1.1.0
1.2.0
This specification covers the general requirements for the erection, alignment and grouting
of machinery.
For specific machineries, the requirements of
the manufacturers installation manuals shall
apply in addition to all non-conflicting requirements of this specification.
2.0.0
INSPECTION AND STORAGE
2.1.0
On receipt of machinery at site, it should be

checked for completeness against the packing
list and the purchase order specifications. Special care must be taken to see that the loosely
packed items such as foundation bolts, couplings with bolts and nuts, belts, auxillary piping,
all spares items including spares required
during erection, special tools, coupling guard,
hold down bolts, eye bolts, etc. have been supplied with the unit.
The Engineer in charge shall also determine
whether any damage has occured to the equipment during transit.
The equipment with all the loosely packed items
and spare parts shall be tagged and stored
under covered storage place, to protect the
equipment from weather and other forms of
abuse.
The tags on equipment shall indicate the following details:
a. Equipment No. & Description.
b. Plant and Location of Erection.
c. P.O. Ref.
d. Date of receipt & inspection at site.
The equipments are to be stored separately
plant wise to facilitate easy location and identification during erection.
Should the equipment be not installed immediately after delivery, the closest adherence to the
following in structions is strongly recommended.
The base plate to rest fully on a flat surface and
not just partially.
The components not to be stacked one upon the
other.
All components and the equipment to be stored
in a dry clean place.
All machined parts, likely to corrode, either inside or outside, to be protected by suitable
inhibitors (grease or rust preventive compound).
2.2.0
2.3.0
2.4.0
2.5.0
2.6.0
2.6.1
2.6.2
2.6.3
2.6.4
PRPD. BY:
CHKD. BY:
25ES202 / 94
PAGE 1 OF 3
All lids and covers to be closed to prevent dust

or foreign matters from entering the equipment.
Bearings and motors shall be kept in indoor
installations.
In rotating machinery, rotate the shaft weekly to
coat the bearings and shaft surfaces with
lubricant and to retard oxidation and corrosion.
Some vendors may provide lock nuts to prevent
the rotating parts from revolving during transit
and handling. In such cases ensure appropriate
coating method is done as per 2.6.4 above.
3.0.0
HANDLING
3.1.0
When handling the equipment, care must be

taken to avoid supporting or lifting in a manner
that would place excessive stress on parts or
shaft extensions that are not designed to support the weight of the unit. Lifting hooks, Eyebolts, etc. if provided, should be used for lifting.
Strings/wire ropes are to put through the portions of the equipment marked/recommended
by the manufacturer of the equipment.
All equipments are normally balanced at shop
and sent to site. If the rotator shaft and rotator
is damaged in anyway during handling it may
cause an out of balance condition, which would
require rebalancing or replacement of shaft.
3.2.0
4.0.0
ERECTION
4.1.0
Well before preparing for erection of the equipment ensure that the details of the equipment
nozzle dimensions and locations, couplings,
base plate, anchor bolts dimension and locations, direction of rotation of drive and driven
units, details of key and key way as per the
relevant drawings.
Prepare an outline sketch of the equipment,
which shall be used as ready reference sheet,
marking the design requirements such as co-ordinates of the equipment centre lines, P.O.S.
elevations, critical nozzle elevation, distance
between shaft ends, minimum projection required for the anchor bolts from P.O.S. elevation, location and dimensions of anchor bolts,
grouting clearance, etc.
With the above details check the equipment and
the respective foundation to take remedial actions for any discrepancy noted if it is beyond
acceptable limits.
The foundation block shall be made ready in
advance, with regard to the date of erection of
the equipment so as to permit the same suitably
set.
Before shifting the equipment to position the
location of foundations, bolt holes, etc. shall be
inspected the cross checked with the equipment
to be erected. Any mistake noticed is to be
rectified before erection.
Before placing the equipment on the foundation
roughen and clean the top of the foundation to
remove oil, grease, dirt and any loose particles.
Clean out care fully by compressed air hose the
foundation bolt-holes.
The top of the foundation shall be placed 25 to
4.2.0
4.3.0
4.4.0
4.5.0
4.6.0
4.7.0
APPRD. BY:
ISSUED ON: MAR 94
ENGINEERING
SPECIFICATION
4.8.0
4.9.0
4.10.0
4.11.0
4.12.0
4.13.0
4.14.0
4.15.0
4.16.0
4.17.0

MACHINERY ITEMS
50 mm below the final level of the equipment.

Mark the centre-line of the equipment both on
the foundation and on the equipment.
Lift the equipment and place it on the foundation
with the foundation bolts in position.
Proper equipment and tools for lifting, leveling
and alignment should be made ready before
putting the machine over the foundation.
The equipment shall rest on steel packing
plates.Packing plates shall be placed very close
to the foundation bolts and on either sides of all
the foundation bolts. If the distance between
anchor bolts are more than 800mm, additional
packing plates shall be provided in between.
Level and align the equipment base frame with
utmost care using spirit levels or master level,
depending on the precision required. High
speed and high torque machinery shall be
aligned with special care. The tolerances on
alignment shall be maintained as per the installation manual furnished by the equipment suppli
er.
Note: Small equipments like centrifugal pumps
etc. are aligned and assembled on the base
frame at the shop. In these cases the equipments are directly erected on the foundation in
the assembled form.
The foundation surface will support the equipment with the packing plates under the base
frame. The foundation should be smooth and
level at these points to distribute the load evenly
on the foundation through packing plates. A thin
metal plate leveled in a puddle of grout is the
easiest way to achieve this level and smooth
surface.
Always use thick shims wherever possible to
avoid spongy shim base.
Adjust shims under base plate until the base
frame/equipment is level. The space between
the base frame and foundation shall be 25 mm
to 50 mm (or as per the instructions given in the
manufacturers manual).
For leveling the equipment use machined true
surface viz. pump flange, coupling face, shaft
surface, etc.
After checking the level, the equipment is to be
imme diately grouted - grouting shall be done as
per 5.0.0
5.0.0
GROUTING
5.1.0
Grout compensates for unevenness in the foundation and base frame and distributes the
weight of the unit uniformly over the foundation.
It is preferable that the unit be expertly grouted
with a non shrinking grout.
Saturate with water the top surface of the foundation and the foundation bolt holes. Wetting
with water should be done at least six hours prior
to grouting.
Remove excess water with air hose or rage
before pouring grout.
The grout mixture must be sufficiently fluid at the
same time shrinkage must be minimum. Use a
grout with lower water content and which can
5.2.0
5.3.0
5.4.0
5.5.0
5.6.0
5.7.0
5.8.0
5.9.0
25ES202 / 94
PAGE 2 OF 3
be operated easily on the narrow space under

the base frame. The grout prepared must flow
easily.
Normal grouting mixture comprises of one part
of port land cement and one part of clean fine
sharp sand mixed in adequate quantity of water.
To avoid shrinkage of grout during setting any
non shrinking compound can be added to grout
mixture as additive.
During grouting of large base frames there is a
possi bility of air trapping, which can be avoided
by temporarily introducing thick walled rubber
tubes to provide venting. Remove the tubes
after the grout has filled all the cavities before
pouring the remainder.
The grout should be poured quickly and continuously to prevent unequal setting of grout.
It is preferable to shut down other machines
near the equipment which is being erected, as
the vibration of running machineries will have
damaging effect on the grouting and alignment
of the new machine.
The frame work for grout should be built to such
a height that on setting the top of the grout is
approximately 15mm above the bottom of the
base plate.
6.0.0
ALIGNMENT
6.1.0
When the grouting is set, the holding down bolt

should be gently but firmly tightened. Great
care must be taken not to spring the bed plate
by excessive tightening. Check the level again.
Eventhough it is normal that small equipments
will be aligned in the factory itself, it is mandatory
that the unit be field aligned since any base plate
can be warped in and when installed on foundation.
The driven unit viz. pump, blower, compressor
etc. is assembled and levelled on the base
frame already grouted.
Then the drive unit is bolted on the base frame,
the clearance between couplings shall be set as
per the manufacturers directive using feeler
gauge and the unit be aligned.
Preliminary coupling alignment may be done
using straight edge and feeler gauge. The
parallelism (angular alignment) and intersection
of axes (shafts in line at the coupling ends) can
be checked accurately using dial gauge. For
using dial gauges it is essential that both driving
and driven shafts rotate together. This can
generally be accomplished by linking the couplings of the driving and driven units by at least
one coupling pin. Alternatively where free movement between two half couplings are difficult the
above alignment can be checked by rotating the
half-drive coupling keeping the magnetic base
of the dial gauge on the drive coupling, but the
rim of the machine coupling should be marked
at intervals of 90o and readings taken only when
the mark are in line.
Alignment is to be done using minimum dialgauges or with any suitable instruments available. Radial and axil alignment shall be checked
simultaneously using two dial gauges.
6.2.0
6.3.0
6.4.0
6.5.0
6.6.0
ENGINEERING
SPECIFICATION
6.7.0
6.8.0
6.8.1
6.8.2
6.8.3

MACHINERY ITEMS
TOLERANCES
It is difficult to lay down limits of accuracy within
which adjustments should be made because of
the differences in the size and speed of units,
but as a rough guidance, the following variations
in the dial gauge readings can be tolerated.
For angular alignment
Couplings upto 12" dia : 0.002"
Couplings over 12" dia : 0.003"
For radial alignment readings more than 0.004"
(i.e. 0.002" eccentricity) call for adjustment.
The above figure are suggested for speeds upto
1500 rpm. For speeds of 3000 rpm or over a
greater degree of accuracy should be observed.
ALIGNMENT OF BELT DRIVE
For belt driven equipment, the drive motors are
generally mounted on independent slide rails.
After final levelling and grouting of the driven
equipment the slide rails are placed on steel
shims over the motor foundation.
The motor belts sheave is assembled on the
motor shaft by using tapered bushing and cap
screws. Do not lubricate the cap screws.
The motor is placed on the slide rails nearer to
the equipment side. The alignment of the driven
unit sheave with the motor shaft sheave is
checked by placing a straight edge or string
across both sheave faces. Adjustments if any,
may be done by moving the motor rails.
6.8.4
6.8.5
6.8.6
6.8.7
6.8.8
6.9.0
6.9.1
6.9.2
6.9.3
25ES202 / 94
PAGE 3 OF 3
The foundation bolts of the slide rails are

grouted.
The slides are also grouted after checking the
levelling.
After setting of foundation bolts grouting as well
as side rails grouting, move the motor towards
the driven unit as far as the slide base will permit.
Install the belts in sheave grooves without forcing them. Do not pry the belts over the sheave
rims with a screw driver or similar tool as this will
damage the belts and greatly reduce belt service life.
With the belts in the grooves, reposition the
motor to take up the slack until the belts are fairly
tight.
BELT TENSION
Start the drive motor, and continue to adjust the
belt tension until the belts have only a slight
bow in the slack side of the drive while operating underload.
After a few days of operation, the belts will seat
themselves in the sheave grooves and it may
become necessary to readjust them so that the
drive once again shows a slight bow in the
slack side.
The drive is now properly tensioned and should
operate satisfactorily with only an occasional
readjustment to compensate for normal belt and
sheave groove wear.
DATA SHEET
8122-01-DA FH100
FIRE HYDRANT SYSTEM
PAGE
Applicable to :
Site :
Unit :
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
13.0
14.0
Purchase
X Proposal
MANGALORE
Make
Model
Type
No. off
Codes / Standards
Hydrant size
Connection
Type
Size
Dimensions
Landing valve size
Flow rate
Pressure
Stand pipe
Landing valve body
Landing valve disc
Accessories
Coupling
Blind cap with chain
Certification
As built
TPS No. :
8122
mm
Single Hydrant
1
IS 5290 : 1993 Type A
63
mm
lpm
Kg/cm2G
Flanged
80 NB
ANSI B16.5 150#
63 female instantaneous
900
7 operating / 15 design
CS
Gun mettal
Gun mettal
Instantaneous female
required (brass)
ISI marking
PROJECT
CLIENT
P.O No.
16.11.09
DATE
KK
PRPD.
CRP
CHKD.
JK
APPRD.
1
1
Job No :
Item No. :
FIRE HYDRANT ASSEMBLY
Note:
End connection of landing valve shall be 80 NB flange drilled to suit ANSI B 16.5
4
3
2
1
0
Rev
OF

PLANT AT MANGALORE
HPCL
VENDOR
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
DATA SHEET
8122-01-DA FH103
FIRE HYDRANT SYSTEM
PAGE
Applicable to :
Site :
Unit :
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Purchase
X Proposal
MANGALORE
Make
Model
Type
No. off
Codes / Standards
Dimensions
Capacity
8.0 Material of construction

Thickness
9.0 Accessories
Hose reels
Couplings
Keys
Stand with foundation bolts
10.0 Hose station
No. off
Capacity
As built
OF
TPS No. :
Job No :
Item No. :
HOSE BOX
1
8122
Stand mounted type, glass fronted

1
mm
mm
30" x 10" x 24" (Height 24")

To hold 1 no 15 M long hoses with branch pipes,
nozzles & couplings
MS galvanised and painted
20 guage
required
required
N/A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
DATA SHEET
8122-01-DA FH102
FIRE HYDRANT SYSTEM
PAGE
Applicable to :
Site :
Unit :
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
Purchase
X Proposal
MANGALORE
Make
Model
Type
No. off
Codes / Standards
Spray nozzle
Half coupling
Flow rate
K factor
Orifice size
Connection size
Cone angle
Acessories
Spanner
Half coupling
As built
OF
1
1
TPS No. :
Job No :
Item No. :
SPRAY NOZZLE
8122
Medium velocity spray nozzles - pendant type

11
FM / UL / NFPA
Marine Bronze
A 105 galvanized
lpm
mm
Threaded Suitable for 15 mm, IS 554
deg.
required
required
Dimensional check and performance test shall be

done on 10 % of nozzles selected at random
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
DATA SHEET
8122-01-DA-FH 104
FIRE HYDRANT SYSTEM
PAGE
Applicable to :
Site :
Unit :
X Proposal
Purchase

HPCL, MANGALORE
Make
Model
Type
No. off
Codes / Standards
Valve size
Connection
Type
Size
Dimensions
10.0 Pressure
11.0 Material of construction
Valve body
Valve internals
Valve disc
13.0 Accessories
Isolation valves
Bypass valve
Pressure gauges
Actuation piping
Mating flages & pipe fittings
Solinoid valve
Pressure switch
01FT074C/94
1.0
2.0
3.0
4.0
5.0
6.0
7.0
4
3
2
1
0
Rev
20.11.09
DATE
kk
PRPD.
crp
CHKD.
As built
TPS No. :
1
1
Job No :
Item No. :
DELUGE VALVE SYSTEM
8122
2
mm
50
Kg/cm2G
Flanged
50NB
As per B16.5, Class 150. FF
12
ALUMINIUM BRONZE
Bronze
Bronze
ALUMINIUM BRONZE
ALUMINIUM BRONZE
A105, galvanised, threaded
jk
APPRD.
OF
PROJECT
CLIENT
P.O No.
HPCL
VENDOR
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Page 1 of 6
ENGINEERING
SPECIFICATION
8122-01-PS-002 DV
Page 1 of 7
R0
STANDARD SPECIFICATION FOR
00FT021A/94
DELUGE VALVE
23.11.09
REV. NO.
DATE
First issue
DESCRIPTION
KK
CRP
JK
PREPARED
CHECKED
APPROVED
TECHNICAL
PROCUREMENT
SPECIFICATION
8112-01-PS-002 DV
SPECIAL REQUIREMENT OF THE PROJECT

2 of 7 R0
CONTENTS
1. SCOPE
2. CODES AND STANDARD
3. DESIGN REQUIREMENTS
4. MATERIAL OF CONSTRUCTION
5. CONSTRUCTION AND PERFORMANCE
6. INSPECTION AND MARKING
7. INFORMATION REQUIRED FROM VENDOR
ANNEXURE - 1
00FT021B/94
P&ID OF DELUGE VALVE (HYDRAULIC DETECTION SYSTEM)
TECHNICAL
PROCUREMENT
SPECIFICATION
1.
8112-01-PS-002 DV

3 of 7 R0
SCOPE
This specified describes design requirements, material of construction and performance of
automatic deluge valve for fire water distribution.
2.0
CODES AND STANDARDS

1.
2.
3.
NEPA Codes
Rules for Water Spray System (BY TAC)
Indian Standard Specifications
3.0
DESIGN REQUIREMENTS
3.1
An automatic deluge valve shall consist of following:

1.
2.
3.
4.
5.
6.
7.
8.
3.2
Deluge valve unit

Diaphragm unit
Integral test and drain valve manifold
Alarm system
Priming equipment
Installation stop valve with pressure gauge and outlet valve
By pass ball valve
Detector pipe work manifold
Size and capacity of deluge valve shall be as under:

Size (Inch(mm)
00FT021B/94
2(50)
3(80)
4(100)
6(150)
8(200)
Rated Flow(lpm)
Working Pressure(kg/cm2g)
1150
5000
13500
18500
7.0
7.0
7.0
7.0
7.0
to
to
to
to
to
10.5
10.5
10.5
10.5
10.5
3.3
The deluge valve shall be provided with solenoid operated water release valve for remote
operation in addition to automatic operation of deluge valve.
3.0
MATERIAL OF CONSTRUCTION
4.1
For non saline water service

Body
Seat
Clack
Diaphragm spindle
and hinged pin
Test and drain valve,
Cast iron to IS 210 Gr. FG 200

Bronze
Graphite iron
SS 304
)
TECHNICAL
PROCUREMENT
SPECIFICATION
8112-01-PS-002 DV
Installation stop valve , )

Outlet valve and
)
Check valve
)
4 of 7 R0
Cast steel (A53A spec)
4.2
For saline water service aluminum bronze in place of cast iron and cast steel shall be used.
5.0
CONSTRUCTION AND PERFORMANCE
5.1
The deluge valve unit shall be provided with a clack to keep the valve close through a
diaphragm unit.
5.2
The deluge valve shall also be fitted with an integral test and drain manifold. It shall
consist of 50mm test and drain valve, body drain valve and a drip plug.
5.3
The test valve shall allow water to flow through the deluge valve to drain during testing of
deluge valve and to drain water from distribution pipe after fire. At open position the valve
clack shall be held against its seating by an internal compression spring of sufficient
strength to keep it in closed position till the pressure acting on underside of it does not
exceed approx. 0.3 kg/cm2. The clack will open at pressure exceeding 0.3 kg/cm2.
5.4
The drain valve shall drain all the water from the deluge valve body and the outlet
connection during maintenance of the deluge valve. The drain pipe work is to be designed
to periodically check the rate of flow available in the system to satisfy the requirements
appropriate to the hazard class for which the deluge valve is provided. Flow measurement
shall be checked with differential pressure.
Water operated alarm motor gang shall be connected to the test and drain valve so that it
gives an alarm as the deluge valve opens.
5.5
On detector pipe work manifold, test valve shall be provided at one end while on supply
pipe pressure control regulator with by pass, isolation valve, check valve, strainer and
restricted orifice shall be provided. Both detector pipe work and supply line shall be
terminated with flanged ends. Piping shall be GI conforming to specification BIS. In case
of hydraulic detector network, tapping from existing fire water network on U/S of deluge
shall be taken by the vendor.
5.6
In addition to above an electric pressure switch shall be provided to give alarm at Low
pressure. Low pressure alarm shall be set at 1.7kg/cm2.
Provision of changing the set pressure of both the alarms shall also be provided.
00FT021B/94
The alarm switch(s) shall thus activate at low pressure of 1.7 kg/cm2 and with alarm to
initiate warning of fire. Vendor shall confirm the set pressure based on inlet water supply
pressure.
For remote operation of the deluge valve, solenoid operated valve shall be provided.
TECHNICAL
PROCUREMENT
SPECIFICATION
8112-01-PS-002 DV

5 of 7 R0
When deluge valve is located in an hazardous area, SOV and alarm switches shall be
explosion proof/intrinsically safe and suitably for hazardous area.
5.7
Installation stop valve and outlet valve above deluge valve shall be as per piping
specifications described above. In addition following provisions shall be made.
Valve must be strapped (not chained) end padlocked in open position a all normal times.
5.8
The deluge valve shall be tested for operation/opening at set pressure and operation of the
alarms at set pressure.
5.9
For testing and setting of deluge valve a priming valve and a vent valve shall be provided
with deluge valve assembly. At all normal times, and when testing the deluge valve
according to various tests required, the body of the deluge valve shall remain full of water.
5.10
Pressure gauge shall be fitted immediately above the deluge valve on water supply line.
Another pressure gauge shall be provided on detector pipe work manifold.
00FT021B/94
Pressure gauges shall be bourden type and shall be weather proof to NEMA-4. Vendor
shall specify the range of pressure gauge and also submit detailed specification / data
sheet of the instrument.
5.11
The complete valve assembly shall be of good workmanship and finish and free from burrs
and sharp edges. All waterways shall have smooth finish.
5.12
The deluge valve shall be tested for a test pressure of 18kg/cm2g.
6.0
INSPECTION AND MARKING
6.1
HPCL or its authorised representatives shall have access at all reasonable times to the
manufacturers work where the deluge valve assembly are being manufactured or being
tested.
6.2
Deluge valve assembly shall be clearly and permanently marked with the purchasers name,
design and test pressure.
7.0
INFORMATION REQUIRED FROM VENDOR
7.1
The vendor shall furnish the following information along with the offer and for approval
prior to fabrication.
-
P&ID of deluge valve

General arrangement of deluge valve assembly and elevation
Constructional features of deluge valve assembly
Initial setting procedure of deluge valve
Automatic and manual operational procedures
TECHNICAL
PROCUREMENT
SPECIFICATION
00FT021B/94
8112-01-PS-002 DV

6 of 7 R0
Periodic testing and safety procedures
7.2
Following information shall be furnished by the vendor along with the supply of the deluge
valve.
7.2.1
Instruction book(s) for the guidance of the user including both the operating and normal
maintenance procedures. The book(s) shall include an itemized and illustrated part list /
spare parts list giving reference no. of all the wearing parts.
7.2.2
Duly approved final drawings listed in Clause 7.1.
FOR TENDER PURPOSE ONLY
INSULATION

FLOW SHEET REF.
REF DRAWINGS
NOTES
FACT ENGINEERING & DESIGN ORGANISATION
INSULATION

FLOW SHEET REF.
REF DRAWINGS
NOTES
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REF DRAWINGS
NOTES
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REF DRAWINGS
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FLOW SHEET REF.
REF DRAWINGS
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FLOW SHEET REF.
REF DRAWINGS
NOTES
INSULATION

FLOW SHEET REF.
REF DRAWINGS
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FLOW SHEET REF.
REF DRAWINGS
NOTES
INSULATION

FLOW SHEET REF.
REF DRAWINGS
NOTES
INSULATION

FLOW SHEET REF.
REF DRAWINGS
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INSULATION

FLOW SHEET REF.
REF DRAWINGS
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FLOW SHEET REF.
REF DRAWINGS
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FLOW SHEET REF.
REF DRAWINGS
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INSULATION

FLOW SHEET REF.
REF DRAWINGS
NOTES
INSULATION

FLOW SHEET REF.
REF DRAWINGS
NOTES
INSULATION

FLOW SHEET REF.
REF DRAWINGS
NOTES
PIPING
DEPARTMENT
Sl. No.
(1)
A
SCHEDULE OF ITEMS OF WORK

Description of item
(2)
Unit
(3)
Quantity
(4)
8122 - 03 - SW - 001
PAGE 1 OF 10 R 0
Rate Rs. (5)
Amount Rs.
Fig.
Words
(6)
FABRICATION AND INSTALLATION OF PIPING
The scope of work under this item includes transportation of all piping items from storage point,
handling, cleaning, welding, fabrication, erection, painting, testing and commissioning of above
ground piping as per the drawings and specifications.
All activities associated with making weld joints such as cleaning, marking out, cutting , profiling,
bevelling, grinding, aligning, fitting up, tack welding, chipping, preheating, placing of wind
shields/weather protection and final welding together with any special wlelding requirement are
included in the scope.
Installation of all types of valves, control valves, safety valves, Y strainers, static mixure, orifice
plates and assembling of flanged joints are also included in the rate. The contractor shall ensure
the initial satisfactory operation of the valves. Cleaning of flange faces, insertion of gaskets, bolts
etc, aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also
included
All the works required for the proper installation, at all elevations, of piping with attached fittings
and valves, handling, rigging, scaffolding, placing and alignment of pipes and fittings to their
respective positions and on to their respective supports, fabrication and erection of trunnion
supports, pad at supports are also included in this item. Hydraulic testing of the piping
systems, flushing, draining and drying up also included in this.
03FT067B/ 96
All the CS pipes, fittings etc shall be painted with 1 coat of 'Two pack poly urethane holding primer
as per 02ES023/97 after surface cleaning by mechanical means
The pay quantity shall be the actual centreline length in metres of straight or fabricated pipe
including valves, etc. actually installed as required. Payment for the work done will be made only
when the piping is properly located and permanently supported in its final position in the field after
hydrotesting.
This rate does not cover radiography/UT/MP/DP tests,which shall be paid as per item D
PrepAred - GSP
Project - LPG Blending
facilities
Checked - KAK
Approved - KAK
15.10.09
PIPING
DEPARTMENT
Sl. No.
(1)
A.1

Description of item
(2)
Unit
(3)
Quantity
(4)
CARBON STEEL, ASTM A 106 GR B
20NB
SCH160
25 NB
SCH 80
40NB
SCH 80
50 NB
SCH 40
100 NB
SCH 40
250 NB
SCH 40
300 NB
SCH 40
235
A.2
LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6
20NB
SCH160
40NB
SCH 80
150NB
SCH 40
12
200 NB
SCH 40
200
250 NB
SCH 40
200
300 NB
SCH 40
24
A.3
Fig.
8122-03-SW-001
PAGE 2 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION
25 NB
PN 10
40 NB
PN 10
50 NB
PN 10
100 NB
PN 10
150 NB
PN 10
18
200 NB
PN 10
250NB
PN 10
3
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)
A.3

Description of item
(2)
Unit
(3)
Quantity
(4)
C/O
300 NB
PN 10
400NB
PN 10
194
10
450 NB
PN 10
11
500 NB
PN 10
A.4
Fig.
8122-03-SW-001
PAGE 3 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
CEMENT LINED PIPING

The rate shall also include making Tie in connections, galvanised fasteners,
non metallic gaskets, sleeves, sand, cement, reinforcement etc
100 NB
300NB
450NB
35
SUPPLY AND APPLICATION OF COLD INSULATION

Supply and application of Pre formed PUF cold Insulation, over pipes, valves,
flanges, specials as per specifications/standards/drawings and instruction
from the site in charge. 12 mm concrete coating shall be provided over the
insulation. All the materials, tools/tackles, scaffolding, transportation/handling,
manpower etc. shall be arranged by the contractor.
Measurements for the release of payment shall be as per IS 14164.
20NB
60 MM THICK
25NB
60 MM THICK
40NB
60 MM THICK
50NB
60 MM THICK
100NB
60 MM THICK
6
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)
B

Description of item
(2)
Unit
(3)
Quantity
(4)
C/O
150NB
60 MM THICK
150NB
90 MM THICK
200NB
90 MM THICK
195
250NB
60 MM THICK
195
10
300NB
60 MM THICK
250
12
TIE IN CONNECTIONS
All activities required for taking two tappings from the existing header at Terminal and
shall include all safety precautions such as draining/ flushing/ blinding etc, cutting the
header, providing flanged MOV in the line , welding two equal tees in the pipeline
oneither side of the MOV etc
Fig.
8122-03-SW-001
PAGE 4 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
LS
RADIOGRAPHY / DYE PENETRANT TESTS.

Radiographic, UT/ DP / MP inspection of the weld joints shall be conducted as per the
code, specs., drgs. and instructions of the Engineer-in-charge. The rate quoted shall be
inclusive of all operations necessary to fulfill the work of radiography ( X ray / Gamma
ray ), DP / MP tests including all tools / tackles, films, chemicals etc. complete. After
testing, if any joint is found defective, the same shall be rectified and re-tested free of
cost. The pay quantity shall be linear centimeters of weld successfully passed. Penalty
shots shall not be counted for payment.
Radiographic/ UltrasonicInspection
CMS
27000
DP Inspection
CMS
700
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)

Unit
(3)
Description of item
(2)
DISMANTLING OF PIPING
Cutting and dismantling of pipelines including attached fittings, flanges, valves,

instruments, insulation etc, transporting to owner's store or other designated areas
without damage to nearby equipments, pipelines, structures etc in a safe and sound
manner.
Cement lined piping
100NB
Quantity
(4)
C/O
300NB
450NB
35
150NB
250NB
300NB
Carbon Steel piping
Fig.
8122-03-SW-001
PAGE 5 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
MISCELLANEOUS JOBS
Fabrication, erection and Painting of structural supports

Supply, transportation, handling, rigging, cutting, edge preparation, drilling, threading,
welding and fixing of structural supports at all elevations and chipping and grouting and
clamping/ bolting/ fixing of pipelines (including cost of sand & cement for grouting).
MS Plates & structurals shall be included in the rate
MT
2.5
The structural supports shall be painted with 1 coat of Two pack poly urethane holding
primer ( 30 microns DFT) and final painting shall be 2 coats of High build poly
urethane coating ( 60 microns total DFT).
2
PCC/ RCC pedestals for pipe supports including cost of materials
Cu M
Chipping of RCC for fixing insert plates, clamps, making cut outs etc
Cu M
Erection of Basket Filters

Nos
Erection of flanged basket filter, 400NB, 150#, on the foundation, levelling, grouting ,
anchoring, fixing of accessories such as vent/drain valves, davit assembly, pressure
guages etc, initial servicing .
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)
Description of item
(2)
Unit
(3)
Quantity
(4)
GRP PIPES, PN 10
C/O
25NB
40NB
50NB
100NB
150NB
18
200NB
250NB
300NB
400NB
194
10
450NB
11
500NB
G.2
Fig.
8122-03-SW-001
PAGE 6 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION
G
G.1
GRP FLANGES, 150#, FF, DRILLING AS PER B16.5
25NB
NOS
16
40NB
50NB
100NB
150NB
200NB
250NB
3
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)
G.3

Description of item
(2)
Unit
(3)
Quantity
(4)
Fig.
8122-03-SW-001
PAGE 7 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
C/O
300NB
NOS
18
400NB
22
450NB
500NB
5
G.4
GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5
40 NB
400 NB
G.5
NOS
2
1
90 DEG ELBOW, GRP, PN 10
50NB
100NB
150NB
14
200NB
250NB
400NB
15
G.6
NOS
400NB
NOS
150NB
NOS
400NB
G.7
EQUAL TEE, GRP, PN 10
2
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)
Fig.
8122-03-SW-001
PAGE 8 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
C/O
G.8
CONCENTRIC REDUCER , GRP, PN 10

500NB X 400NB
NOS
450NB X 400NB
NOS
300NB X 250NB
1
G.9
G.10
G.11
ECCENTRIC REDUCER , GRP, PN 10
GATE VALVES - LEADED TIN BRONZE BODY AS PER IS 318

LTB2 AND TRIM AS PER IS 320 ALLOY HT2. ENDS SHALL BE
FLANGED AS PER CLASS 150, B 16.5, FF. DESIGN PR - 10
BAR, TEMP - 50 DEG C.
25NB
RUBBER EXPANSION BELLOWS SUITABLE FOR SEA WATER PUMP

DISCHARGE LINE . OPERATING PRESSURE - 10 BAR. FLANGED AS
PER B16.5, FF, CLASS 150.
SIZE - 300NB. OVERALL
LENGTH 400MM.
NOS
11
NOS
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Quantity
(4)
GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS
C/O
25NB
40NB
43
50NB
50
80NB
100NB
30
H.2
H.3
Fig.
SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS
H
H.1
Unit
(3)
8122-03-SW-001
PAGE 9 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
GI FLANGES, A105, 150#, FF, DRILLING AS PER B16.5,

THREADED - 100NB
GI FITTINGS, A105, CLASS 3000, THREADED
40
NOS
NOS
90 ELBOW
25 NB
90 ELBOW
40 NB
90 ELBOW
50 NB
EQUAL TEE
25 NB
EQUAL TEE
40 NB
EQUAL TEE
50 NB
UNEQUAL TEE
40 NB x 25 NB
UNEQUAL TEE
40 NB x 15 NB
UNEQUAL TEE
25 NB x 15 NB
14
10
CON. REDUCER
40 NB x 25 NB
11
CON. REDUCER
50 NB x 40 NB
12
COUPLING
25 NB
13
COUPLING
40 NB
10
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)
I
I.1
I.2
I.3

Description of item
(2)
Unit
(3)
Quantity
(4)
Fig.
8122-03-SW-001
PAGE 10 OF 10
R0
Rate Rs. (5)
Amount Rs.
Words
(6)
SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS INCLUDING GASKETS AND FASTENERS
SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST
TYPE 1, SIZE 63MM
WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM
SPRAY NOZZLES AS PER IS 319 TYPE II & DATA SHEET, SIZE K40
NOS
NOS
NOS
11
I.4
QUARTZOID BULB, 15 MM, MALE THREADED
NOS
11
I.5
CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS.

FLANGED AS PER B16.5 , 150# , FF, 100NB
NOS
I.6
DELUGE VALVE ASSEMBLY CONSISTING OF DELUGE VALVE, 2 NOS

ISOLATION VALVES, BYPASS VALVE, CONNECTED PIPING,
GASKETS, FASTENERS AND MATING FLANGES AS PER DATA
SHEET& ENGG SPEC. SIZE 50NB
NOS
I.7
HOSE BOX AS PER DATA SHEET
NOS
C/O
INSTALLATION OF EQUIPMENTS
J
J.1
P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR
J.2
P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR
J.3
JOCKEY PUMP- VERTICAL- 1TE APPR
J.4
E301- LPG HEATER- HORIZONTAL
NOS
TE
10.5
DISMANTLING OF PUMPS
K
K.1
JOCKEY PUMP- VERTICAL- 1 TE APPR
NOS
K.2
WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR
NOS
1
Total / Sub-total
PIPING
DEPARTMENT
Sl. No.
(1)
A

Unit
(3)
Description of item
(2)
Quantity
(4)
FABRICATION AND INSTALLATION OF PIPING
The scope of work under this item includes transportation of all piping items from storage point,
handling, cleaning, welding, fabrication, erection, painting, testing and commissioning of above
ground piping as per the drawings and specifications.
All activities associated with making weld joints such as cleaning, marking out, cutting , profiling,
bevelling, grinding, aligning, fitting up, tack welding, chipping, preheating, placing of wind
shields/weather protection and final welding together with any special wlelding requirement are
included in the scope.
Installation of all types of valves, control valves, safety valves, Y strainers, static mixure, orifice
plates and assembling of flanged joints are also included in the rate. The contractor shall ensure the
initial satisfactory operation of the valves. Cleaning of flange faces, insertion of gaskets, bolts etc,
aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also
included
All the works required for the proper installation, at all elevations, of piping with attached fittings and
valves, handling, rigging, scaffolding, placing and alignment of pipes and fittings to their respective
positions and on to their respective supports, fabrication and erection of trunnion supports, pad at
supports are also included in this item. Hydraulic testing of the piping systems, flushing,
draining and drying up also included in this.
All the CS pipes, fittings etc shall be painted with 1 coat of 'Two pack poly urethane holding primer
as per 02ES023/97 after surface cleaning by mechanical means
03FT067B/ 96
The pay quantity shall be the actual centreline length in metres of straight or fabricated pipe
including valves, etc. actually installed as required. Payment for the work done will be made only
when the piping is properly located and permanently supported in its final position in the field after
hydrotesting.
This rate does not cover radiography/UT/MP/DP tests,which shall be paid as per item D
PrepAred - GSP
Project - LPG Blending
facilities
Checked - KAK
Approved - KAK
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)
CARBON STEEL, ASTM A 106 GR B

2
20NB
SCH160
25 NB
SCH 80
40NB
SCH 80
50 NB
SCH 40
100 NB
SCH 40
250 NB
SCH 40
300 NB
SCH 40
235
LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6

9
20NB
SCH160
10
40NB
SCH 80
11
150NB
SCH 40
12
12
200 NB
SCH 40
200
13
250 NB
SCH 40
200
14
300 NB
SCH 40
24

15
25 NB
PN 10
16
40 NB
PN 10
17
50 NB
PN 10
18
100 NB
PN 10
19
150 NB
PN 10
18
20
200 NB
PN 10
21
250NB
PN 10
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)

22
300 NB
PN 10
23
400NB
PN 10
194
24
450 NB
PN 10
25
500 NB
PN 10
CEMENT LINED PIPING

The rate shall also include making Tie in connections, galvanised fasteners,
non metallic gaskets, sleeves, sand, cement, reinforcement etc
26
100 NB
27
300NB
28
450NB
35

Supply and application of Pre formed PUF cold Insulation, over pipes, valves,
flanges, specials as per specifications/standards/drawings and instruction from
the site in charge. 12 mm concrete coating shall be provided over the
insulation. All the materials, tools/tackles, scaffolding, transportation/handling,
manpower etc. shall be arranged by the contractor.
Measurements for the release of payment shall be as per IS 14164.
29
20NB
60 MM THICK
30
25NB
60 MM THICK
31
40NB
60 MM THICK
32
50NB
60 MM THICK
33
100NB
60 MM THICK
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)
12

34
150NB
60 MM THICK
35
150NB
90 MM THICK
36
200NB
90 MM THICK
195
37
250NB
60 MM THICK
195
38
300NB
60 MM THICK
250
39
TIE IN CONNECTIONS
All activities required for taking two tappings from the existing header at Terminal and
shall include all safety precautions such as draining/ flushing/ blinding etc, cutting the
header, providing flanged MOV in the line , welding two equal tees in the pipeline
oneither side of the MOV etc
LS
RADIOGRAPHY / DYE PENETRANT TESTS.

Radiographic, UT/ DP / MP inspection of the weld joints shall be conducted as per the
code, specs., drgs. and instructions of the Engineer-in-charge. The rate quoted shall be
inclusive of all operations necessary to fulfill the work of radiography ( X ray / Gamma
ray ), DP / MP tests including all tools / tackles, films, chemicals etc. complete. After
testing, if any joint is found defective, the same shall be rectified and re-tested free of
cost. The pay quantity shall be linear centimeters of weld successfully passed. Penalty
shots shall not be counted for payment.
40
Radiographic/ UltrasonicInspection
CM
27000
41
DP Inspection
CM
700
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)
DISMANTLING OF PIPING
42
Cutting and dismantling of pipelines including attached fittings, flanges, valves,

instruments, insulation etc, transporting to owner's store or other designated areas
without damage to nearby equipments, pipelines, structures etc in a safe and sound
manner.
Cement lined piping
100NB
43
300NB
44
450NB
35
150NB
46
250NB
47
300NB
45
Carbon Steel piping
MISCELLANEOUS JOBS
48
Fabrication, erection and Painting of structural supports

Supply, transportation, handling, rigging, cutting, edge preparation, drilling, threading,
welding and fixing of structural supports at all elevations and chipping and grouting and
clamping/ bolting/ fixing of pipelines (including cost of sand & cement for grouting). MS
Plates & structurals shall be included in the rate
TM
2.5
The structural supports shall be painted with 1 coat of Two pack poly urethane holding
primer ( 30 microns DFT) and final painting shall be 2 coats of High build poly urethane
coating ( 60 microns total DFT).
49
PCC/ RCC pedestals for pipe supports including cost of materials
Cu M
50
Chipping of RCC for fixing insert plates, clamps, making cut outs etc
Cu M
51
Erection of Basket Filters

Nos
Erection of flanged basket filter, 400NB, 150#, on the foundation, levelling, grouting ,
anchoring, fixing of accessories such as vent/drain valves, davit assembly, pressure
guages etc, initial servicing .
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
R0
Unit
(3)
Quantity
(4)
SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION

GRP PIPES, PN 10
52
25NB
53
40NB
54
50NB
55
100NB
56
150NB
18
57
200NB
58
250NB
59
300NB
60
400NB
194
61
450NB
62
500NB

63
25NB
NOS
64
40NB
65
50NB
66
100NB
67
150NB
68
200NB
69
250NB
16
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)
NOS
18

70
300NB
71
400NB
22
72
450NB
73
500NB
GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5

74
40 NB
75
400 NB
NOS
2
1

76
50NB
NOS
77
100NB
78
150NB
14
79
200NB
80
250NB
81
400NB
15

82
400NB
NOS
83
150NB
NOS
84
400NB
EQUAL TEE, GRP, PN 10
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
Quantity
(4)
500NB X 400NB
NOS
86
450NB X 400NB
NOS
87
300NB X 250NB
CONCENTRIC REDUCER , GRP, PN 10

85
ECCENTRIC REDUCER , GRP, PN 10
GATE VALVES - LEADED TIN BRONZE BODY AS PER IS 318

LTB2 AND TRIM AS PER IS 320 ALLOY HT2. ENDS SHALL BE
FLANGED AS PER CLASS 150, B 16.5, FF. DESIGN PR - 10
BAR, TEMP - 50 DEG C.
25NB
88
89
RUBBER EXPANSION BELLOWS 300NB
NOS
11
NOS
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
Unit
(3)
R0
Quantity
(4)
SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS

GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS
90
25NB
40
91
40NB
43
92
50NB
50
93
80NB
94
100NB
30
GI FLANGES, 150#, FF, DRILLING AS PER B16.5, THREADED

95
100NB
NOS
NOS
GI FITTINGS, A105, CLASS 3000, THREADED

96
90 ELBOW
25 NB
97
90 ELBOW
40 NB
98
90 ELBOW
50 NB
99
EQUAL TEE
25 NB
100
EQUAL TEE
40 NB
101
EQUAL TEE
50 NB
102
UNEQUAL TEE
40 NB x 25 NB
103
UNEQUAL TEE
40 NB x 15 NB
104
UNEQUAL TEE
25 NB x 15 NB
14
105
CON. REDUCER
40 NB x 25 NB
106
CON. REDUCER
50 NB x 40 NB
107
COUPLING
25 NB
108
COUPLING
40 NB
10
PIPING
DEPARTMENT
Sl. No.
(1)

Description of item
(2)
R0
Unit
(3)
Quantity
(4)
SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS

109
110
111
SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST

TYPE 1, SIZE 63MM
WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM
SPRAY NOZZLES AS IS 319 TYPE II & DATA SHEET, SIZE K40
NOS
NOS
NOS
11
112
QUARTZOID BULB, 15 MM, MALE THREADED
NOS
11
113
CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS.

FLANGED AS PER B16.5 , 150# , FF 100NB
NOS
114
DELUGE VALVE ASSEMBLY
NOS
115
HOSE BOX AS PER DATA SHEET
NOS
NOS
INSTALLATION OF EQUIPMENTS
116
P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR
117
P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR
118
JOCKEY PUMP- VERTICAL- 1TE APPR
119
E301- LPG HEATER- HORIZONTAL
TM
10.5
DISMANTLING OF PUMPS
120
JOCKEY PUMP- VERTICAL- 1 TE APPR
NOS
121
WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR
NOS

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LPG Blending facilities List of documents for Tender

2, Sub vendor list

8122-03-DA-001 VL, 8122-01-DA-001 VL

Fabrication and Erection of steel piping

4, Data Sheets of Fire equipments

Overall plot plan

Supply, Fabrication, Erection, Testing and Commissioning of Piping and Equipments

APPRD. BY: KAK

ISSUED ON: 16-10-2009

FACT ENGINEERING AND DESIGN ORGANISATION

Fabrication and Erection of Piping

8, Tie in connections with the existing systems

Fabrication and Erection of CS and LTCS piping

Supply, fabrication and erection of GI & GRP piping

FACT ENGINEERING AND DESIGN ORGANISATION

Fabrication and Erection of Piping

The Fabrication and Erection of piping shall be done

strictly as per drawings, codes,

Fabrication and Erection of Cement lined piping

Testing and Commissioning

out by the Contractor.

Supply and Application of Painting

FACT ENGINEERING AND DESIGN ORGANISATION

Fabrication and Erection of Piping

Supply and Installation of Cold Insulation as per 02ES042/97

Dismantling of existing piping

Tie in connections with the existing system

FACT ENGINEERING AND DESIGN ORGANISATION

Fabrication and Erection of Piping

Structural supports etc

Free issue of Materials

bore lines below 50NB.

Scope of work Equipments

FACT ENGINEERING AND DESIGN ORGANISATION

Fabrication and Erection of Piping

Leveling of equipment shall be done by precision tools.

FACT ENGINEERING AND DESIGN ORGANISATION

GRP PIPES & FITTI GS

M/s Shriram SEPL Composites, Chennai

M/s Leader valves, Jallunder

M/s IGP Engineers, Chennai

BOLTS & UTS

M/s Echjay Industries, Mumbai

FACT ENGINEERING AND DESIGN ORGANISATION

M/s Ajanta Tubes, New Delhi

M/s Madras Engg works, Mumbai

FACT ENGINEERING AND DESIGN ORGANISATION

SUB VENDOR LIST - Fire Fighting

Medium Velocity Water Spray Nozzles

Stand post type water monitors.

FACT ENGINEERING AND DESIGN ORGANISATION

FABRICATION & ERECTION OF

tion ( color identification and die stamp ) shall be

FACT ENGINEERING AND DESIGN ORGANISATION

FABRICATION & ERECTION OF

abrasive wheel for stainless steel shall be used.

Over 4mm (but over 3mm

Shape of Internal Trimming and Misalignment