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 Fabrication and Erection of steel piping
8122-03-ES-001 Spec for GRP piping
8122-12-DA-001 Spec for Cement Mortar lining
8122-12-DA-002 Spec for Pipeline concrete coating
25ES201 Erection of Static equipments
25ES202 Erection of Machinery items
02ES042/97 Spec for Cold Insulation
02ES023/97 Spec for Painting
8122-01-PS-002DV 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 Overall plot plan
8122-03-UP-00001 Unit plot plan Coastal terminal area
8122-03-UP-00002 Unit plot plan Heat Exchanger area
8122-03-UP-00003 Unit plot plan Sea Water Pump house
8122-03-KP-00001 Piping Key plan
8122-03-KP-00002 Piping Key plan
8122-03-KP-00003 Piping Key plan
8122-03-KP-00004 Piping Key plan
8122-03-KP-00005 Piping Key plan
8122-03-KP-00006 Piping Key plan
8122-01-ZM-00001 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
PIPING
DEPARTEMNT

8122 03 DA 001R0
Page 1 of 6

PRPD. BY : GSP CHKD. BY : KPM APPRD. BY: KAK ISSUED ON: 16-10-2009
FACT ENGINEERING AND DESIGN ORGANISATION


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 J ockey 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
PIPING
DEPARTEMNT
Fabrication and Erection of Piping
8122-03-DA-002R0
Page 2 of 6

FACT ENGINEERING AND DESIGN ORGANISATION


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
Fabrication and Erection of Piping
8122-03-DA-002R0
Page 3 of 6

FACT ENGINEERING AND DESIGN ORGANISATION


The Fabrication and Erection of piping shall be done 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 J ockey
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
Fabrication and Erection of Piping
8122-03-DA-002R0
Page 4 of 6

FACT ENGINEERING AND DESIGN ORGANISATION


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
Fabrication and Erection of Piping
8122-03-DA-002R0
Page 5 of 6

FACT ENGINEERING AND DESIGN ORGANISATION


9 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-DA-
FH100, 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 Scope of work Equipments
1, 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, J ockey 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
Fabrication and Erection of Piping
8122-03-DA-002R0
Page 6 of 6

FACT ENGINEERING AND DESIGN ORGANISATION





2 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.

3 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.

7 Foundation bolts are supplied along with the equipment. Erection contractor shall check whether
correct foundation bolts as per equipment drawings are supplied.

8 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.

9 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.
0 15.10.09 FOR TENDER GSP
PREPARED APPROVED
KAK
REV.NO.
PAGE
8122 - 03 - DA - 001 VL
SUB VENDOR LIST - Piping
OF R 0 2
DATE DESCRIPTION
TECHNICAL
PROCUREMENT
SPECIFICATION
1
0
0
F
T
0
2
4
/
9
4
FACT ENGINEERING AND DESIGN ORGANISATION
KPM
CHECKED


A) GRP PIPES & FITTIGS

1. M/s Shriram SEPL Composites, Chennai
2. M/s Amiantit, Goa
3. M/s Marketing Services Consortium, Coimbatore
4. M/s Sunrise Polymers & Industries, Vadodara
5. M/s Sangir Plastics P.Ltd., Mumbai.
6. M/s Balaji Fibre Reinforce, Vadodara

B) BROZE & CI VALVES

1. M/s Leader valves, Jallunder
2. M/s Brightech Valves, Ahmedabad
3. M/s Steel strong, Mumbai
4. M/s Flowsteer, Ahmedabad
5. M/s Easwar Engg, Chennai

C) METALLIC GASKETS

1. M/s IGP Engineers, Chennai
2. M/s Mechanical Packing Industries, Mumbai
3. M/s Spiraseal Gaskets, Chennai
4. M/s Gaskets India, Mumbai
5. M/s Unique, Mumbai
6. M/s Vicap, Chennai


D) BOLTS & UTS

1. M/s Echjay Industries, Mumbai
2. M/s Fasteners & Allied Products, Hubli
3. M/s Fasteners India Manufacturers, Mumbai
4. M/s Hardwin Fasteners, Mumbai
5. M/s Nagabhushanam Industries, Bangalore
6. M/s Pacific Forgings, Mumbai
7. M/s Vaibhav Industries, Mumbai
8. M/s Fix fit Fasteners, Kolkota

0 15.10.09 FOR TENDER GSP
TECHNICAL
PROCUREMENT
SPECIFICATION
2
0
0
F
T
0
2
4
/
9
4
FACT ENGINEERING AND DESIGN ORGANISATION
KPM
CHECKED REV.NO.
PAGE
8122 - 03 - DA - 001 VL
SUB VENDOR LIST
OF R 0 2
DATE DESCRIPTION PREPARED APPROVED
KAK


E) GI Pipes

1. M/s Ajanta Tubes, New Delhi
2. M/s CSK Tube Enterprise, Chennai
3. M/s Jindal, Mumbai
4. M/s Surya Tubes, New Delhi
5. M/s Sri Laxmi Metal Udyog, Bangalore
6. M/s Ridhi Steel& Tubes, Ahmedabad

F) GI & CS fittings& flanges

1. M/s Madras Engg works, Mumbai
2. M/s Teekay Tubes, Mumbai
3. M/s Metal Forge, Mumbai
4. M/s Super Forge, Mumabi
5. M/s Tube Products, Baroda
6. M/s Evergreen Hardwares, Bangalore

R
7.0
Saha Bhogilal & Jethlal Bros
TECHNICAL
SUB VENDOR LIST - Fire Fighting
8122-01-DA 001 VL
PROCUREMENT
SPECIFICATION PAGE 1
b.
HD Fire Protect Company
c.
New Age Industries
0
1
Fire Hydrant
a.
Zenith Fire Services
OF 1
c.
Zenith Fire Services
a.
HD Fire Protect Company
b.
New Age Industries
2
Medium Velocity Water Spray Nozzles
b.
HD Fire Protect Company
d.
Saha Bhogilal & Jethlal Bros
3
Stand post type water monitors.
a.
Zenith Fire Services
e.
Kidde
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.
FACT ENGINEERING AND DESIGN ORGANISATION
REV NO DATE DESCRIPTION PREPARED CHECKED APPROVED
0 JK 16.11.09 First issue KK CRP
1.0.0 GENERAL
1.1.0 SCOPE
1.1.1 This specification covers the general require-
ments for fabrication and installation of steel
piping (including carbon steels, low-alloy steels,
and stainless steels) within petroleum refineries
and chemical plants.
1.1.2 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.
1.2.0 REFERENCES
1.2.1 The requirements contained in the latest edi-
tions 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,
Sect i on VI I I - Di vi si on 1, UW- 51-
Radiographic Examination of Welded Joint,
Section IX- Welding and Brazing Qualifica-
tions.
1.3.0 DEVIATIONS
1.3.1 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 ac-
cordance with his instructions.
2.0.0 FABRICATION
2.1.0 MATERIAL CONTROL
2.1.1 Packages of piping materials delivered to the
jobsite shall be opened immediately, and the
quantities, specifications, sizes, and identifica-
tion ( color identification and die stamp ) shall be
checked and recorded in the material ledger.
The materials shall be stored promptly and neat-
ly in the designated warehouse or storage yard.
2.1.2 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.
2.1.3 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.
2.1.4 Issued materials shall be indicated on the draw-
ings or material use charts, etc., to prevent
duplication of issues.
2.1.5 Any surplus materials found on the job - site
shall be returned promptly to the warehouse or
storage yard.
2.1.6 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.
2.1.7 Special precautions shall be taken to keep
electrodes and gaskets dry during storage.
2.2.0 PRECAUTIONS FOR PREPARATI ON &
FABRICATION
2.2.1 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.
2.2.2 The minimum clearance between the edges of
two adjacent welds shall exceed 25mm or 4
t i mes the pi pe nomi nal wal l t hi ckness,
whichever is greater.
2.2.3 When both welded pipes and piping com-
ponents 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 dimen-
sion is less than 5 times, both longitudinal
welded joints in the girth butt welds shall be
examined by radiography over 100mm. In ad-
dition, Section 8.1 (14) shall be considered in
the preparation and fabrication.
2.3.0 CUTTING
2.3.1 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.
23.2 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.
2.3.3 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
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: 19 - 8 - 96
iso2.sty
PAGE 1 OF 28
CONTENTS
1.0.0 GENERAL
2.0.0 FABRICATION
3.0.0 WELDING
4.0.0 HEAT TREATMENT
5.0.0 THREADED AND FLANGED JOINTS
6.0.0 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
-
abrasive wheel for stainless steel shall be used.
2.3.4 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 ap-
paratus. 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 ap-
paratus 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.
2.4.0 END PREPARATION
2.4.1 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 require-
ments 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
2.4.2 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 com-
ponent with the wall extending internally
shall be trimmed internally to an angle less
than 30
0
C as shown in Figure2. However,
such trimming shall not result in a finished
wall thickness less than the required mini-
mum design thickness plus corrosion and
erosion allowances.
2.4.3 End Preparation method
In principle, the end preparation shall be per-
formed 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.
2.4.4 Treatment after End Preparation
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.
2.5.0 BENDING
2.5.1 In principle, ready-made elbows shall be used
for bends of piping. However, when bends of a
large radius are required due to fluid charac-
teristics 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.Low-
alloy 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 ex-
terior 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 specifica-
tion.
6 Low-alloy and stainless steel pipe shall be
heat treated in accordance with the in-
dividual 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.
2.6.0 MITRE BENDS
2.6.1 Unless otherwise specified, mitre bends shall be
used for piping 350NB and larger. For piping of
300 NB and smaller, ready-made smooth el-
bows shall be used.
2.6.2 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 45
0
C shall consist of not less than three
segments. The minimum distance (l) be-
tween alternate segments of the mitre bend
shall be 4 times the pipe nominal wall thick-
ness or 25mm, whichever is greater (Fig-
ure3)
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 2 OF 28
FIGURE 1 A
WHEN t - 4mm to 22 mm
33 1/2 2 1/2
1.6 0.8
3.2 0.8
t
FIGURE 1 B
WHEN t > 22 mm
3.2 0.8
t
1.6 0.8
R 3.2mm
37 2.5
10 1
1
9
FIGURE 2
TRIMMING AND PERMITTED MISALIGNMENT
OVER 1.6 mm
30 MAX

THIS PORTION SHALL BE FINISHED
SMOOTHLY SO AS NOT TO HAVE A
SHARP EDGE, WHICH MAY HINDER
RADIOGRAPHIC EXAMINATION

FIGURE 3
SHAPES OF MITRE BENDS
FABRICATION &ERECTION OF
STEEL PIPING
PAGE 3 OF 28
25 ES205 / 94 - R1

ENGINEERING
SPECIFICATION

FACT ENGINEERING AND DESIGN ORGANISATION

15
30
1.5 D
30
FIGURE 4
ANGLE OF MITRE BENDS















1
.
5

D



2 The radius of the mitre bend shall be greater
than the nominal diameter of the pipe.
3 The maximum mitre angle ( of Figure 4) of
each segment shall be as follows:
When design pressure is
8kgf / cm
2
G or less
: 22
0
30
When design pressure is 28
kgf / cm
2
G or less
: 15
0
00
When design pressure ex-
ceeds 28 kgf / cm
2
G
: 11
0
15
4 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 require-
ments (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 seg-
ments 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 per-
formed 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 as-
sembling the fittings that have dimensions and
configurations shown in the piping drawings.Un-
less otherwise specified, branch connections
shall be made in accordance with Figure 5 and
as follows:
2.7.2 Branch connections, which are made by provid-
ing 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 other-
wise 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
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.
2.7.7 The material of reinforcement pads shall be the
same as the main run pipe.
2.7.8 An examination of the welds joining reinforce-
ment pad to the branch shall be made by FEDO
Engineer/ representative before installing the
reinforcement pad.
2.8.0 FABRICATION TOLERANCES
2.8.1 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.
2.8.2 Unless otherwise specified, tolerances for
fabrication shall be in accordance with the re-
quirements shown in Figure 6.
2.9.0 GALVANISED PIPING
2.9.1 Galvanised carbon steel piping shall be com-
pletly cold worked so as not to damage gal-
vanised surfaces
3.0.0 WELDING SPECIFICATION
3.1.0 GENERAL
3.1.1 This specification shall be adopted to all welded
pipe joints of carbon steel, alloy steel and stain-
less steel piping system.
3.1.2 The welded pipe joints are defined as under:
1. All line joints of the longitudinal and circum-
ferential 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.
3.1.3 All welding, and heat treatment, shall be in
accordance with the applicable codes and
specifications.
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 Regula-
tions
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 con-
flicts between different codes or between codes
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 4 OF 28






FACT ENGINEERING AND DESIGN ORGANISATION

and tender specifications the more stringent
shall be applicable.
3.2.0 INSPECTION & TESTING
3.2.1 General
1. The owners inspector shall have free ac-
cess to all concerned places, where the
actual work is being performed. The con-
tractor shall also provide the owners in-
spector 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 pre-
fabrication and erection of pipe lines are
being done with ( but not limited to ) the
following functions :
a. To check the quantity, consumables and
welding equipments used on the job
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 con-
formity with the relevant specification and
codes of practice followed in pipe line con-
struction.
e. To carry out Non Destructive Examination
of welds.
3. Contractor shall intimate sufficiently in ad-
vance the commencement of qualification
tests and welding work to enable the
owners inspector to be present to supervise
them.
3.2.2 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 ap-
prove 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 equip-
ments, 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 QW-
483 format given in ASME Sec. IX. for approval.
3.2.3 Welders Qualification
1. Welders qualification shall be in accord-
ance with the relevent codes specified in
scope of work. Owners inspector shall wit-
ness 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.
For piping covered by Indian Boiler Regula-
tions, welders with valid IBR certificate,
qualified by Boiler Inspectors and accept-
able to the local Boiler Authority shall only
be employed.
2. The welders shall always have in their pos-
session the identification card as per Format
and shall produce it whenever demanded
by owners Inspector. It shall be the respon-
sibility 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. Name of Contractor
b. Name of welder
c. Stamp No.
d. Address
e. Recent passport size photograph
f. Details of qualifications
i Welding process and P numbers
ii Range of pipe diameters
iii Range of thickness
iv Welding positions
g. Date of qualification test
h. Period of validity
i. Signature of manufacturer
j. 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 per-
formed shall be cut and redone at the ex-
pense of the Contractor.
6. Engineer-in-charge reserves the right to ask
the contractors to perform requalification
test at their cost for wel ders whose
workmanship technique etc. are found un-
satisfactory during the execution of the job.
3.3.0 SELECTION OF WELDING MATERIALS
3.3.1 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
3.4.0 STORAGE AND ISSUE OF ELECTRODES
Electrodes shall be stored and issued as fol-
lows:
3.4.1 Electrodes shall be stored indoors free from
moisture as far as possible.
3.4.2 Electrodes shall be dried in a heating cabinet in
accordance with the manufacturers recommen-
dation before welding.
3.4.3 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 - 100
0
C
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 7 OF 28
b. Others : 100 - 150
0
C
3.4.4 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.
3.4.5 Electrodes exposed to the atmosphere for more
than 4 hours shall be redried. However, only two
redryings are permitted.
3.4.6 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.
3.4.7 Issue of electrodes shall be controlled by the
assigned person.
3.5.0 SURROUNDING CONDITIONS FOR WELD-
ING
3.5.1 Welding shall not be performed under the fol-
lowing 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.
3.5.2 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.
3.6.0 GENERAL FOR WELDING
3.6.1 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 proce-
dure qualification test based on the specification
for welding procedure qualification, according to
this specification and ASME Section IX.
3.6.2 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 weld-
ing progression to keep distortion to a min-
imum.
6. In multi-layer welding, before welding the
following layer, the surface of each layer
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 ).
3.7.0 BUTT WELDS
3.7.1 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 specifica- tion by
the use of tack weld pieces (fit-up pieces), line-
up clamps, etc., and shall then be welded.
3.7.2 Backing rings shall not be used unless other-
wise specified.
3.7.3 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.
3.7.4 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.
3.7.5 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 proce-
dure as the product welding. Tack welds that
are cracked or not fused properly shall be
removed.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 8 OF 28
3.7.6 Pieces for tack welds shall be removed with a
grinder. If a concave surface due to overgrind-
ing, etc., is produced on the pipe, the repair
welding shall be performed in accordance with
WPS, which has been approved by FEDO En-
gineer / 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.
3.7.7. Internal weld protrusions of butt welds for orifice
flanges shall be finished smoothly to the pipe
inside diameters with a grinder.
3.7.8. The root pass of all buttwelds on pipe of size
less than 50NB shall be made in GTAW grove
only.
3.8.0 FILLET WELDS
3.8.1 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.
3.9.0 SEAL WELDS
3.9.1 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 ex-
posed 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.
3.10.0 FLANGE ATTACHMENT WELDS
Flange attachment welding shall be performed
as fol lows:
3.10.1 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 orien-
tation.
3.10.2 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.
3.10.3 Joining welding neck flanges to the pipe shall be
performed in accordance with the requirements
of Section 3.7.
3.10.4 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
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 gas-
ket 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 PREHEATING
4.1.1 Unless otherwise specified, the preheating ap-
plies to gas cutting and welding (all welds includ-
ing butt welds, fillet welds, socket welds, repair
welds, tack welds, and seal welds of thread ed
joints ). Preheating shall be performed as fol-
lows:
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 80
0
C and main-
tained at that temperature for surface weld-
ing.
3. When welding dissimilar metals, unless
other wi se speci fi ed, the preheati ng
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.
4.1.6 Temperature measurements of preheating, in-
terpass 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.
4.2.0 INTERPASS TEMPERATURE
4.2.1 The following items shall be confirmed for inter-
pass 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 com-
pleted.
2. Interpass temperature of austenitic stain-
less steel pipe shall not exceed 150
0
C.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 9 OF 28






FACT ENGINEERING AND DESIGN ORGANISATION

4.3.0 POSTHEATING
4.3.1 When postheating is required it shall be carried
out for more than 30 minutes within the tempera-
ture range of 300 to 400
0
C, and the material
shall be cooled gradually by the use of insula-
tion, etc. However, when post weld heat treat-
ment is performed immediately after welding,
post - heating is not necessary.
4.4.0 POST WELD HEAT TREATMENT
4.4.1 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 dis-
similar ferritic metals shall be within the
temperature ranges for the higher grade
steel.
2. Al l the machi ned surf aces shal l 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 con-
trolled rate of cooling shall be applied to
ensure that no effects detrimental to the
piping shall result. The pre-heat tempera-
ture in the welding must be applied before
welding is resummed.
6. When heat treatment is performed, the hold-
ing temperature, holding time, rate of heat-
ing 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 measur-
ing the metal temperature by the use of a
thermocouple,or by other suitable methods.
However, when t he heat t r eat ment
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 ac-
cordance 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
the exposed surface of pipe. For this pur-
pose temperature at the exposed surface of
pipe should not be allowed to exceed
400
0
C.
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 fol-
lows.( HAZ - Heat Affected Zone )
DIA OF
PIPE
NOS.
OrientatIO
N (
0
)
LOCATION
15NB &
below
2 0 , 180
One on weld & one
in HAZ
200 to
500 NB
3
0 , 120 ,
240
one on weld & rest in
HAZ on either side
of weld
600 Nb &
above
4
0 , 90 ,
180 , 270
two on weld & rest in
HAZ on either side
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 mov-
able 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 in-
jury 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
315
0
C shall be determined by the follow-
ing formula, but in no case shall the rate
exceed 220
0
C

per hour.
25 x 220
wall thickness (mm)
(
o
C

h)
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/ Repre-
sentative.
5.0.0 THREADED AND FLANGED JOINTS
5.1.0 THREADED JOINTS
Threading of joints shall be as follows.
5.1.1 Taper pipe threads shall be as per ANSI B2.1,
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 11 OF 28
ANSI Standard Taper Pipe Thread (NPT).
5.1.2 Unless otherwise specified, when threading on
pipes of NPS 1
1
/2 or smaller, the pipe thickness
shall be Schedule 80.
5.1.3 In principle, all threads shall be cut with a thread-
ing 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 150
0
C 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 ac-
cordance 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 ser-
vice 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 En-
gineer / 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 The thread and bearing surfaces of bolts and
nuts to be used on piping at temperatures of
250
0
C or higher shall be coated thinly and
uniformly with a lubricant to prevent them be-
coming burnt and stuck.
5.2.7 Lubricant shall not be applied to machine bolts
unless other wise specified.
5.2.8 Bolts shall be of material and length as
specified. In principle, all the bolts shall extend
2 or 3 threads through their nuts.
5.2.9 Flanges shall be tightened with a wrench or
spanner of the specified length and with a ham-
mer if required, or with a torque wrench. Care
shall be taken so that the bolt is not tightened
excessively or unevenly.
5.2.10 As the tightening force varies according to the
flanges, gaskets, and bolts used, the tightness
shall be controlled with care. In particular, flan-
ges 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.
5.2.11 Bolts of flanged joints shall be successively and
evenly tightened in a symmetrical pattern ( Ap-
pendix IV ).
5.2.12 Cast iron flanges of equipment such as pumps,
turbines, compressors, or other similar equip-
ment shall be tightened carefully so that the
flange does not break.
5.2.13 The flange clearance with connections of
pumps, compressors, or other similar equip-
ment, and ring-joint flanges shall be measured
by the use of a clearance gauge and the paral-
lelism shall be checked, and then the bolts shall
be tightened evenly.
5.2.14 Ring-joint gaskets shall be ground with the
groove of the flange for a tight fit prior to instal-
lation. The grinding shall be performed by using
a compound (coarse, intermediate, or fine), and
red paste shall be applied to confirm the rough-
ness of the contact face between the ring and
the groove of the flange. The paste shall be
removed completely before the ring is installed.
5.2.15 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
6.1.1 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 clean-
ing, 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.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 12 OF 28
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.
6.1.2 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 ( Appen-
dix 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/ Rep-
resentatives approval.
6.1.3 However, austenitic stainless steel pipes and
prefabricated pipe spools that may be affected
by chlorine ions, shall be protected in accord-
ance with the individual specification.
6.2.0 SIZE OF PREFABRICATED PIPE SPOOLS
6.2.1 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, traf-
fic regulations in the country and the economy.
6.2.2 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 PIPE SUPPORTS
7.1.1 Pipe supports whose materials & dimensions
conform to fabrication drgs, shall be installed
accurately at the positions shown on the draw-
ings prior to piping installation. When installing
the pipe supports, pay attention to the following:
1. Each support shall be fabricated and as-
sembled so that piping does not become
disengaged from the support by movement
of the piping itself due to operation.
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 low-
alloy 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 ap-
plied 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 re-
quired,as per ANSI B31.3.
6. Welds for anchor supports shall be double-
layer 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.
7.2.0 SLIDING SUPPORTS
7.2.1 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.
7.3.0 SPRING HANGERS
7.3.1 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.
7.3.2 Adjustment of spring hangers shall be per-
formed 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.
7.4.0 ADDITIONAL SUPPORTS
7.4.1 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 En-
gineer in consideration of the effects due to
thermal expansion of the piping.
7.5.0 INSULATION SUPPORTS
7.5.1 The configuration, material, and installation pro-
cedure 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 INSTALLA-
TION
The general items for attention relating to piping
installation shall be as follows:
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 13 OF 28
8.1.1 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 in-
stalled 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, eleva-
tion, levelness and plumbness.
8.1.6 When temporary supports are installed un-
avoidably 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 equip-
ment 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 insula-
tion 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 mechani-
cal 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 ac-
cordance 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 fas-
tened.
8.1.13 Alignment tolerances of flange connections in-
stalled 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 horizon-
tal 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, sup-
ports, 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 non-
destructive 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 per-
formed 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 accurate-
ly 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 COMPRES-
SORS
The piping installation around pumps and com-
pressors 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 instal l ation of pi pi ng to rotati ng
machinery, the required heat treatment, pres-
sure test ing, interior cleaning, etc., shall be
completed. Pressure testing shall not be per-
formed 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 prepara-
tion for inspecting misalignment has been com-
pleted.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 14 OF 28
8.3.6 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
8.3.7 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 expan-
sion or distortion due to welding, etc., does not
have a detrimental influence on the rotating
machinery.
8.3.8 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 disman-
tling the piping from the machine.
8.3.9 After piping is connected to rotating machinery,
the rearrangement of pipe supports or retighten-
ing of flange bolts shall not be performed without
permission.
8.4.0 PIPING AROUND FIRED HEATERS
Piping installation around fired heaters shall be
as follows:
8.4.1 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.
8.4.2 Drain piping around the burner shall not be
placed on the ground or in such a way as to
obstruct passage of persons.
8.5.0 PIPING ON PIPE RACK
Piping installation on pipe rack shall be as fol-
lows:
8.5.1 Generally, since air cooled heat exchangers are
placed on top of the pipe rack, and pumps are
placed underneath, the precedence for install-
ing 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.
8.5.2 Before connecting piping to other equipment,
piping on pipe racks shall be laid down accurate-
ly in the places specified beforehand, and then
slide shoes and stoppers shall be installed ac-
curately in accordance with the drawings, so
that baseline for dimensional adjustments in
field installation may be made. However, el-
bows, tees, etc., required for take-off connec-
tions to outside the pipe rack may be left in place
temporarily since it may be re quired to perform
adjustments.
8.5.3 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.
8.5.4 The pipe fittings and welded lines shall be in-
stalled so as not to be positioned on the beams.
8.6.0 OFFSITE PIPING
Installation of offsite piping shall be as follows:
8.6.1 Piping installation inside the dike shall be per-
formed 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.
8.6.2 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.
8.6.3 Piping to be connected to the tank nozzle shall
be installed after checking that the valve and
accessories installed on the tank are in accord-
ance with the specification.
8.6.4 Flexible hoses and expansion joints to the tank
nozzle shall be installed accurately in accord-
ance with the drawings.
8.6.5 When laying pipe on sleepers, the sleepers shall
be checked to confirm that they are at the
specified elevation, level in line, and painted.
8.6.6 Piping on pipe sleepers shall be laid on sleepers
that have been marked off. Slide shoes and
stoppers shall be installed accurately in accord-
ance with the drawings. The pipe fittings and
welded lines shall be installed so as not to be
positioned on the sleepers.
8.6.7 For piping penetrating an oil dike, the flanged,
threaded, or welded joints shall not be em-
bedded in the dyke.
8.7.0 INSTALLATION OF VALVES
The installation of valves shall be as follows:
8.7.1 The valve shall be installed accurately so that
its location and the orientation of the handle is
in accordance with the piping drawings. How-
ever, when the orientation of the handle is
deemed inappropriate from the viewpoint of
operation or passage, the FEDO engineer shall
be contacted for directions.
8.7.2 The valve shall be checked for its class, body
materials, and trim materials to prevent any
misuse.
8.7.3 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.
8.7.4 Valves shall be installed in the closed position,
except for plug valves and ball valves. After
being installed, valves shall not be opened ex-
cept 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.
8.7.5 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.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 15 OF 28
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 dimen-
sions shown on the piping and detailed draw-
ings, and in a manner so as not to be connected
eccen tric with the pipe.
8.9.2 Expansion joints shall be installed after confirm-
ing 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 bel-
lows 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
have specified lateral deflection as noted on the
relevent drawings.
8.9.11 The pipe ends / flanges shall be spaced at a
distance specified in the drawings.
8.9.12 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.
8.9.13 Butt welding shall be carried out at each end of
the expansion joint. For flanged Expansion
Joint, the mating flange shall be bolted.
8.9.14 After the Expansion Joint is installed the con-
tractor shall ensure that the mating pipes and
Expansion Joint are in correct alignment and
that the pipes well supported and guided.
8.9.15 The Expansion Joint shall not have any lateral
deflection. The contractor shall maintain paral-
lelism of restraining rings or bellows convolu-
tions.
8.10.0 INSTALLATION OF INSTRUMENTS
8.10.1 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 proce-
dure for instruments shall be as follows:
a. All instruments shall be checked as to in-
strument 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 sup-
ported 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 in-
struments are to be installed unavoidably
during piping construction, measures shall
be taken to prevent the instruments from
being damaged and to prevent foreign mat-
ter 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
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 16 OF 28
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 in-
stalled so that they are 180
O
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 construc-
tion, 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, gal-
vanized 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.
9.0.0 INSPECTION AND TEST
9.1.0 DOCUMENTS
The Contractor shall submit the following in-
spection records for each items of test and
inspection:
9.1.1 Non-destructive inspection
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
9.1.2 Destructive inspection
Record of welding procedure qualification test
9.1.3 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)
9.2.0 ITEMS OF INSPECTION AND TEST
9.2.1 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 proce-
dure test
welders techniqe qualifica-
tion certificate
Welders techni-
que qualification
test
Welding rod
check
PRIOR TO WELDING WORK
Edge preparation
Angle, Root opening, Thick-
ness of land, Cleanliness
Shape of pipe
end
Out of roundness, Thick-
ness, 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, Tempera-
ture measurement, Heating
temperature, Others
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 17 OF 28
Welding rod
Drying temperature, Drying
time
DURING WELDING WORK
Welding condition
Welding parameters, Flow
rate of sealing gas, Protect-
ing measure for welding,
Condition of ambient
temperature
Inter-layer temperature
Re-examination of welder
AFTER COMPLETION OF WELDING WORK
Visual ap-
pearance inspec-
tion
Inside surface misalignment,
Outer surface misalignment,
Inside surface weld
protrusion, Wave irregularity,
Uneven leg length, Irregular
height of bead, Undercut,
Overlap, Bead centre shift,
Height of reinforcement
welds
Non-destructive
inspection
Radiography, Dye penetrant,
Magnetic particle
Stress relieving temperature and method
Hardness test
DURING OR AFTER COMPLETION OF
WELDING WORK
Product inspec-
tion
Dimension, Condition of con-
nection to equipment, Visual
apperance inspection
Treatment of pipe inside
Thread
Seal welding of threaded portion
AFTER COMPLETION OF WORK
Completion of work w.r.t piping drawings
Pneumatic pressure test
Flushing
Removal of temporary supports / scafoldings
AT TRIAL OPERATION
Appearance inspection
9.3.0 VISUAL APPEARANCE EXAMINATION
9.3.1 Following shall be met, checking visually or in
using measuring instrument
1 Inside surface
misalignment
: 1.5mm or less
2 Outer surface
misalignment due to
difference of
diameter of thick-
ness
: 3.0mm or less
3 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
4 Wave irregularity
; 2.5mm or less
5 Irregular height of
bead
: 2.0mm or less
6 Under cut
No under cut is al-
lowed for piping of
cold or high tempera-
ture service.
: Within 0.8mm or
12.5% of thickness
whichever smaller
7 Over lap
: 1.5mm or less
8 Height of reinforcement
Nominal Wall Thk.
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
9.4.0 Non-destructive inspection
9.4.1 Non-destructive inspection shall be performed
according to the grade of inspection stipulated
in the next table. (Pressure classes in accord-
ance with ANSI B16.5)
Material
Grade of Inspection
I II III
Pressure classes - ANSI B16.5
(psig.)
P - NO: 1
Carbon
steel
Service
temp.
below 350
0
C
Less
than 300
lb
400 lb -
1500 lb
2500 lb
and
above
Service
temp.
350
0
C or
more
-
150 lb -
900 lb
1500 lb
and
above
Al-killed Steel -
150 lb -
900lb
1500 lb
and
above
P - NO: 3, 4, 5
C- 0.5 Mo Steel
Cr- Mo Steel
-
150 lb -
900 lb
1500 lb
and
above
P - NO: 9
3.5 Ni steel -
150 lb -
900 lb
1500 lb
and
above
P - NO: 8
Aus-
tenitic
stainless
steel
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
Note: @ When A312 Gr. TP304 is used for cold or
high temperature service, the grade II of inspec-
tion shall be applied even if it is not above 150
lb.
9.4.2 Items of non-destructive inspection and number
of samples for the random inspection shall be
as follows:
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 18 OF 28
ITEM OF INSPECTION
R - Radiographic Inspection
M - Magnetic particle Inspection
L - Liquid PenetrantInspection
Material
Object of inspection
Peri
phery
Noz-
zle
(1)
Soc
ket
Non
pres-
sure
part
GRADE - I
R
Carbon
steel
Less
than 150
lb
3 %
- - - Over 150
lb to 300
lb
10 %
A312 Gr. TP304 10 %
GRADE - II
R All materials 20 % - - -
M
(3)
Carbon steel -
10 % 10 %
10 %
(4)
C-0.5 Mo steel
Cr-Mo steel
Al-killed steel
3.5-Ni steel 10 %
(2)
L
(3)
Austenitic
stainless steel
Non-ferrous metals
GRADE - III
R All materials 100 % - - -
M
(3)
All materials except
for austenitic stain-
less steel, non-fer-
rous metals &
non-magnetic metal 20 % 100 % 100 %
20 %
(4)
L
(3)
Austenitic
Stainless steel
Non-ferrous metal
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
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
9.4.3 Radiographic examination
Unless otherwise specified, radiographic ex-
amination 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 per-
formed 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 ac-
cordance with ANSI B31.3 TABLE 327.4.1
(A) for the degree of radiography involved.
9.4.4 Magnetic Particle/Liquid Penetrant Examination
Liquid penetrant or magnatic particle examina-
tion shall be as follows:
1. Liquid penetrant inspection shall be per-
formed in accordance with Article 6, section
V of ASME Boiler and pressure vessel code.
2. Limitations on imperfection shall be in ac-
cordance with ANSI B31.3 Table 327.4.1 (A)
3. The weld surface, to which liquid penetrant
or maganetic particle examination is ap-
plied, 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 examina-
tion 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 com-
pleted, liquid penetrant examination or
maganetic particle examination shall be
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 19 OF 28
performed again to confirm that the rewelds
are sound.
a. Magnetic particle inspection shall be per-
formed in accordance with Article 7, Section
V of the ASME Boiler & pressure vessel code
b. Limitations on imperfection shall be in ac-
cordance with ANSI B31.3 Table 327.4.1 (A)
9.5.0 HARDNESS TEST
9.5.1 After stress relieving (SR) is performed, hard-
ness 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.
9.5.2 Hardness limit is given in following table ( Hard-
ness 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
9.6.0 PRODUCT INSPECTION
Inspection for the finished product shall be per-
formed as follows:
9.6.1 Dimension: Right angle, perpendicularity, paral-
lelness, 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 0.5
o
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.
9.6.2 Inspection of connection to equipment: For
those pipings which are connected with pump,
compressor, turbine, etc., the above dimen-
sional tolerance shall be submitted by the
tolerances required by each of such machinery.
9.6.3 Appearance inspection:
1. Correction for jig mark.
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 at-
tachment shall comply with drawings.
9.7.0 Inspection for treatment of pipe inside
9.7.1 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 flush-
ing 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 En-
gineer/ 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 instruc-
tions 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 2
0
C. However,
carbon and alloy-steel piping exceeding 25mm
in thickness shall be pressure tested at a
temperature not less than 16
0
C.
10.1.6 The following equipment and instruments shall
not be connected to the piping before comple-
tion of the pressure test:
1. Rotating machinery such as pumps, tur-
bines, 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 atmos-
phere 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
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 20 OF 28
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.
10.2.2 For piping systems having strong acids and So2
where water may become corrosive, or piping
systems operated at a temperature of 0
0
C or
less, kerosene or similar light oils (with a flash
point not less than 50
0
C) or air is preferred as
the test fluid.
10.2.3 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/cm
2
G), 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.
10.3.0 TEST PREPARATION
The preparation for pressure test shall be as
follows:
10.3.1 All joints (including welds) are to be left uninsu-
lated and exposed for examination during the
test. However, joints previously tested in ac-
cordance with this standard may be insulated.
10.3.2 When filling water into piping that is designated
for vapor, gas, etc., not filled with water during
operation, temporary supports or other reinfor-
cements shall be provided beforehand.
10.3.3 Special fittings in piping components, such as
expansion joints, filters, and flame arrestors,
shall be disconnected from the piping.
10.3.4 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.
10.3.5 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.
10.4.0 TEST PRESSURE
10.4.1 Hydraulic Testing of Internally Pressured Piping
1. The test pressure for piping subject to inter-
nal pressure shall be as follows:
a. Not less than 1.5 times design pressure
b. For a design temperature above the test
temperature, the minimum test pressure
shall be calculated by the following for-
mula.
P
T
=
1.5PST
S
Where
PT= minimum hydrostatic pressure in
kgf/cm2

G
P = internal design pressure in kgf/cm
2
G
ST= allowable stress in kgf/cm
2
at test
temperature
S = allowable stress in kgf/cm
2
at design
temperature
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 maxi-
mum pressure that will not exceed the yield
strength at test temperature.
10.4.2 Hydrostatic testing piping with vessels as a sys-
tem
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.
10.4.3 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 pres-
sure, but not less than a pressure of1.0
kg/cm
2
G (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.
10.4.4 Pneumatic testing
1. In principle, pressure tests shall be per-
formed 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 prelimi-
nary check at not more than 1.75 kgf / cm
2
G
(25 psig) pressure. The pressure shall be
increased gradually in steps providing suffi-
cient time to check for leaks.
10.5.0 TESTING METHOD
The method of pressure testing shall be in ac-
cordance with the instructions of FEDO. How-
ever, the general method by using water shall
be as follows:
10.5.1 In principle, pressure tests shall be performed
for each piping system. However, when design
conditions do not permit testing in such a man-
ner, the system may be tested in sections.
10.5.2 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.
10.5.3 Installation and removal of blinds shall be per-
formed in accordance with the instructions of
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 21 OF 28
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 cer-
tified by the national authority, and the calibra-
tions 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 in-
stalled at both the lowest and the highest points.
10.5.6 For each piping system, an outlet for discharg-
ing 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 loca-
tion 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.
10.5.10Prior 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 pres-
sure 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.
10.5.12When the test pressure is not less than 50 kgf /
cm
2
G, pressure shall be increased gradually.
10.5.13The 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.
10.5.14The 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.
10.5.15After 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.
10.5.16On 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.
10.5.17Short pieces of pipe, which must be removed for
installing blind plates and blind flanges, shall be
tested separately.
10.5.18All 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.
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 per-
formed in accordance with the applicable
provisions of this specification.
d. In principle, repair welding of the same por-
tion 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 follow-
ing methods considering kind of fluid, pipe
material and condition of internal surface of
piping to be cleaned. Cleaning method and ex-
tend of cleaning shall be as per specific Project
Requirements.
a. Water Flushing
b. Air Blowing
c. Steam Blowing
d. Acid Cleaning
e. Oil Cleaning
f. 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, cham-
fer, scale and other foreign matter, with
grinder, chisel, wire brush, etc., and be air-
blown. 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 fol-
lows:
a. After installation of piping, and before
commencement of flushing/cleaning.
b. The temporary strainers shall be installed
at pump suction piping, upstream of con-
trol valve and other locations as specified.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 22 OF 28
c. Mark plate shall be attached to the tem-
porary 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 ob-
served.
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 tur-
bidity 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 proce-
dure shall be as follows:
a. Disconnect companion flange at upstream
side of the control valve and cover open-
ing 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 in-
serted.
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 per-
sonnel in charge shall make judgement of
whether the result of the cleaning is statis-
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 com-
pletion 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 tempera-
ture, considering operating condition of
boiler.
d. To remove the scale effectively by tempera-
ture change, it is required to perform flush-
ing and cooling cyclically, having
temperature difference as large as pos-
sible 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 in-
serted 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:
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 23 OF 28
a. Ten-percent hydrochloric acid solution or
Ten-percent sulphuric acid solution with
temperature 30 to 40
0
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 super-
haeted 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:
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 ham-
mering. Hammering shall, not be per-
formed 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 con-
form 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.
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.
10.11.0Test record
10.11.1All inspection and test results shall be made into
re cords in accordance with the instructions of
FEDO. The records shall be submitted for ap-
proval 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
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 24 OF 28
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 percent-
age 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, weld-
ing 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.
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.
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 follow-
ing items for bolt up:
9. Never draw up tight on one or two bolts only.
This will cause local gasket crushing or pinch-
ing, 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
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 ex-
amined is acceptable, all items represented by
these additional examinations shall be ac-
cepted.
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.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 25 OF 28
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 26 OF 28
TABLE - I : SELECTION OF WELDING ELECTRODES & RODS FOR SIMILAR MATERIALS EXCEPT ALUMINIUM
MATL.
NO.
BASE
MATERIAL
COVERED ELECTRODES WELDING RODS
AWS SPEC PREFERRED ELECTRODE AWS SPEC. CLASSIFICATION
1
carbon
steel
UTS UNDER 60,000psi A 5.1 E6010/E6013 (1) (2) (3) (4)
2 UTS 60,000psi & above A 5.1 E6010/ E7018 (1) (2) (3) (4)
2a A333 Gr - 1 A 5.1 E7018 -1(5) (5) --
3 carbon-molybdenum A 5.5 E70XX-A1 (2) (3) (4)
4 2
1
/4 nickel A 5.5 E80XXC1 (2)
5 3
1
/2 nickel A 5.5 E80XX-C2 (2)
6 9 nickel A 5.11 ENi Cr Fe - 3 A5.14 ER Ni Cr -3
7
low
chromium
ferrtic
steels
1
/2Cr
1
/2Mo A 5.5 E8015-B2L (2) 0.05C max.
8 1Cr
1
/2Mo A 5.5 E8015-B2L (2) 0.05C max.
9 1
1
/4Cr
1
/2Mo A 5.5 E8015-B2L (2) 0.05C max.
10 2
1
/4Cr1Mo A 5.5 E9015-B3L (0.05C max.) (2) 0.05C max.
11 5Cr
1
/2Mo A 5.4 E502-I5 (0.05C max.) A5.9 ER502(0.05C max)
12 7Cr
1
/2Mo A 5.4 E7Cr-I5 (0.05C max.) (2) (0.05C max.)
13 9Cr1Mo A 5.4 E505-I5 (0.05C max.) A5.9 ER505(0.05C max)
14
ferrtic
stainless
steels
AISI Type405 A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05C max)
15 AISI Type 410S A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05Cmax)
16 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
austenitic
stainless
steels
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
21 AISI Types 347 & 347H A 5.4 E347-I5 or 16 A5.9 ER347
22 AISI Types 316 & 316H A 5.4 E316-I5 or E 16 -8 -2 A5.9 ER316
23 AISI Type 316L A 5.4 E316L-I5 or 16 A5.9 ER316L
24 AISI Type309 A 5.4 E309-I5 or 16 A5.9 ER309
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
non
ferrous
metals &
alloys
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 67Ni-30Cu Monel A 5.11 ENiCu-4 A5.14 ERNiCu-7
31 Hastalloy(60Ni-28Mo-5Fe) A 5.11 ENiMo - 1 A5.14 ERNiMo-4
32 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-2
1
/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.
25ES205 / 94 - R1
ENGINEERING
SPECIFICATION
FABRICATION & ERECTION OF
STEEL PIPING
FACT ENGINEERING AND DESIGN ORGANISATION
PAGE 27 OF 28
TABLE II SELECTION OF WELDING ELECTRODES & RODS FOR WELDING DISSIMILAR MATERIALS EX-
CEPT ALUMINIUM
Lower
base
matl
No.
Higher base material number
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 35
1 A A A A A B B B B B B B B B B B C C C C C C D D E C
2 A A A A B B B B B B B B B B B C C C C C C D D E C
3 @ @ @ B B B B B B B B B B B C C C C C C D D E C
4 A A @ @ @ @ @ @ @ @ @ @ @ C C C C C C D D E @
5 A @ @ @ @ @ @ @ @ @ @ @ C C C C C C D @ E @
6 @ @ @ @ @ @ @ @ @ @ @ E E E E E E E @ E @
7 A A A A A A A A A A C C C C C C D E C @
8 A A A A A A A A A C C C C C C D E C @
9 A A A A A A A A C C C C C C D E C @
10 A A A A A A A C C C C C C D E C @
11 A A A A A A C C C C C C D E C @
12 A A A A A C C C C C C D E @ @
13 A A A A C C C C C C D E @ @
14 A A A C C C C C C D E @ @
15 A A C C C C C C D E @ @
16 A C C C C C C D E @ @
17 C C C C C C D E @ @
18 A A A A A A A A C
19 F F F A F F F C
20 A A A A A A C
21 A A A A A C
22 A A A A C
23 A A A C
24 C E C
25 E C
26 C
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
B ASME SFA-5.5, E8015-82L electrode
C ASME SFA-5.4, E309 electrode. Acceptable alternatives shall be as specified in table I for the higher base
material number
D As specify in table I for the material with the higher base material number
E ASME SFA-5.11, ENiCrFe-2 electrode and ASME SFA-5.4. ERNiCr-3 rods shall be used where design
temperature exceeds 1000
0
F (538
0
C). ASME SFA-5.4, E310 electrodes are to be used where service
temperatures are below 1000
0
F (538
0
C) and expected to be relatively constant after start up. All rods, exclud-
ing alternatives shall require written approval from designated authority.
F 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
2 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.
4 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 Interior Surface Exterior Surface O-Ring
Sealing Surface
1. Air Bubble
(Void)
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
Same requirements
as for Interior
Surface
Same requirements
as for Interior
Surface
2. Foreign
Inclusion
Not to penetrate any
surface - limits apply to
all surfaces, maximum
dimension 1.5 mm, 1 per
0.09 sq. m area
Same requirements
as for Interior
Surface
Same requirements
as for Interior
Surface
3. Pit
(Pinhole)
Max. depth 0.25 mm,
maximum width 1.5 mm,
35 per sq. cm
Not to penetrate
reinforced wall
Maximum
dimension 0.25 mm
5. Scratch

Max. depth 0.40 mm not
to exceed liner thickness
Not to penetrate
reinforced wall
Maximum depth
0.25 mm
6. Wrinkle Max. depth 2 mm Not applicable 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.
6 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.
7 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
8 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

8122- 12 DA - 002 DATA
SHEET
SPECIFIC REQUIREMETS OF WORK
PAGE 1 OF 13 R0


0 19.10.2009 LTA SA SA
REV. DATE PRPD. BY CHKD. BY APPRD. BY
FACT EGIEERIG AD DESIG ORGAISATIO

12FT026/94


MANGALORE LPG BLENDING FACILITIES



SPECIFICATION FOR PIPELINE CONCRETE
COATING


PREPARED FOR
HPCL


PROJECT NO. 8122




OCTOBER 2009

8122- 12 - DA - 002 DATA
SHEET
SPECIFIC REQUIREMETS OF WORK
PAGE 2 OF 13 R0
FACT EGIEERIG AD DESIG ORGAISATIO

12FT026A/94



TABLE OF CONTENTS


PAGE O.


1.0 SCOPE 3

2.0 REFERENCE DOCUMENTS 3

3.0 MATERIALS 4

4.0 COATING REQUIREMENTS 6

5.0 APPLICATION METHOD 6

6.0 EQUIPMENT 7

7.0 COATING OF FIELD WELDS 7

8.0 CURING 8

9.0 MEASUREMENTS & LOGGING 9

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








8122- 12 - DA - 002 DATA
SHEET
SPECIFIC REQUIREMETS OF WORK
PAGE 3 OF 13 R0
FACT EGIEERIG AD DESIG ORGAISATIO

12FT026A/94



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 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 Steel Cylinder Pipes with Lining and Coating- Specification

3.0 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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iii) Crushed gravel sand

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. It shall be embedded approximately midway in the concrete coating
thickness. 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. 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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5.4 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.

7.2 The reinforcement for the field welds shall be the same as that for line pipe coating with the same
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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8.5 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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c) 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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ii. 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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0 19.10.2009 LTA SA SA
REV. DATE PRPD. BY CHKD. BY APPRD. BY
FACT ENGINEERING AND DESIGN ORGANISATION

12FT026/94
MANGALORE LPG BLENDING FACILITIES

SPECIFICATION FOR CEMENT MORTAR LINING
INSIDE PIPELINES

PREPARED FOR
HPCL
PROJECT NO. 8122

OCTOBER 2009
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TABLE OF CONTENTS



1.0 Scope Of Work 3
2.0 Reference Documents 3
3.0 Materials 4
4.0 Application 5
5.0 Curing 7
6.0 Procedure Qualification 7
7.0. Inspection 8
8.0 Repair Of Lining 9
9.0 Pipe Jointing 9
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 11













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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) IS 4032 Methods of chemical analysis of hydraulic cement


3.0 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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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 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) After surface preparation and prior to application of lining
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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
8122- 12 - DA - 001 DATA
SHEET
SPECIFIC REQUIREMENTS OF WORK
PAGE 11 OF 14
FACT ENGINEERING AND DESIGN ORGANISATION

12FT026A/94
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.

8122- 12 - DA - 001 DATA
SHEET
SPECIFIC REQUIREMENTS OF WORK
PAGE 12 OF 14
FACT ENGINEERING AND DESIGN ORGANISATION

12FT026A/94

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-DG-
00001.

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.8122-
12-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
8122- 12 - DA - 001 DATA
SHEET
SPECIFIC REQUIREMENTS OF WORK
PAGE 13 OF 14
FACT ENGINEERING AND DESIGN ORGANISATION

12FT026A/94
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.
8122- 12 - DA - 001 DATA
SHEET
SPECIFIC REQUIREMENTS OF WORK
PAGE 14 OF 14
FACT ENGINEERING AND DESIGN ORGANISATION

12FT026A/94
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.









X
4
5
8
9
10
11
12
13
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
50
51
52
53
54
55
FACT ENGINEERING AND DESIGN ORGANISATION
49
19.0 Certification ISI marking
20.0 Test pressure
Kg/cm
2
G
23
17.0 Accessories
18.0 Monitor weight Kg
Locks for swivel joints Gun mettal
16.0 Lubrication Grease lubrication for joints
Water barrel IS 1239 Seamless
Nozzle Aluminium alloy
Base flange CS
Swivel joints Gun mettal
+80, (-)45
15.0 Material of construction
- Vertical plane
- Horizontal plane 360
Rotation Angle Deg.
53
- Vertical 20
- Horizontal
Pressure
Kg/cm
2
G
Jet length M
Perfomance
7
1750 Flow rate lpm
14.0
16
13.0 Water barrel pipe thickness mm
12.0 Back pressure at base flange
Kg/cm
2
G
IS 1239, Heavy
14
11.0 Design pressure
Kg/cm
2
G
7 operating / 15 design 15
10.0 Type of joint Swivel joints
8.0 Nozzle diameter mm 32
9.0 Base flange details 100 NB, ANSI B16.5, Class 150, SORF
6.0 Monitor size mm 75 with 100 NB base flange
7.0 Connection size mm
4.0 No. off 2
5.0 Codes / Standards IS 8442
6
3.0 Type Stand post type with swivel joints, Type 1 of IS 8442 7
2.0 Model
Item No. :
1.0 Make
3
WATER MONITOR
1
Site : MANGALORE Job No : 8122
Unit : LPG BLENDING FACILITY
1
Applicable to : Proposal Purchase As built TPS No. :

FIRE HYDRANT SYSTEM
8122-01-DA- FH101
DATA SHEET
PAGE 1 OF
02ES023/97
ENGINEERING
SPECIFICATION

PAINTING

PAGE 1 OF 13

PRPD.BY:- RS CHKD.BY:- GPN APPRD. BY:- KV ISSUED ON:- 23.07.97
FACT ENGINEERING AND DESIGN ORGANISATION







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




















02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION


1.0.0. SCOPE

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.

1.2.0. Requirement of painting for any item
shall be as specified in any of the
following documents.

a) Equipment Data Sheet
b) Piping line schedule
c) Design Basis for package
items
d) Painting schedule

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) Pressure vessels, Tanks, Heat
Exchangers and other process
equipment with Carbon steel
and low alloy steel as material
of construction.
b) Machinery items including
motors.
c) Steel structures
d) 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

a) Non ferrous surfaces, stainless
steel and High Alloy steel
surfaces.
b) Glass, tile or ceramic surfaces
c) Name plates and identification
tags
d) Valve stems
e) Machined contact surfaces
f) Galvanised surfaces
g) Insulation covers
h) Plastics
i) Underground / buried piping
and equipments which are
provided with special type of
protective coatings.
j) 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.
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PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION


3.2.0 Surfaces to be painted shall be
completely dry.

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.

3.4.0 Dust shall be removed by air blowing
or vacuum cleaning.

3.5.0 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.

3.9.0 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.

3.9.1 Blast cleaned surfaces shall be primed
within 2 hrs, after blasting, before re-
rusting starts and before contamination.

3.9.2. Blast cleaning shall not be carried out
when temperatures are less than 20


deg.C or when the relative humidity of
air exceeds 90%.

3.9.3. Blasting operations shall not be carried
out during rain, snow, or strong winds.

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/cm
2
.

3.10.0 Surfaces which are not suitable for
blast-cleaning or could not be blast-
cleaned 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 OF PAINTING
MATERAILS

4.1.0. Paints, varnishes, thinner, additives and
other volatile substances shall be stored
in a flame proof enclosure, away from
heat.

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.

4.3.0. Warning Boards and signs shall be
exhibited around the storage area.





02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION


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 Ready-mixed paints containers shall
be opened only at the time of painting.
Containers shall be closed air tight
after drawing paint from it.

5.6.0 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 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
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FACT ENGINEERING AND DESIGN ORGANISATION


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.

7.0.0. 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.

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.


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 40
0
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

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
ENGINEERING
SPECIFICATION
PAINTING
PAGE 6 OF 13




FACT ENGINEERING AND DESIGN ORGANISATION


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 OF PAINTING
MATERIALS

10.1.0. Primers

A.01 Synthetic Zinc Phosphate
Primer
A.02 Epoxy based Zinc Phosphate
Primer
A.03 Epoxy based Zinc Rich Primer
A.04 Alkyd High Build Zinc
Phosphate Primer
A.05 Inorganic Zinc Silicate Primer
A.06 Chlorinated Rubber based High
Build Zinc Phosphate Primer

10.2.0. Finish Paints

B.01 Epoxy Resin based Enamel
B.02 Epoxy Resin based Micaceous
Iron Oxide Paint
B.03 Epoxy Resin based High Build
Paint
B.04 Coal Tar Epoxy Resin based
Paint
B.05 Chlorinated Rubber Paint

10.3.0. Bituminous Coating

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 Dual Pack Aluminium Paint
(upto 250
o
C)
D.02 Single Pack High Temperature
Silicon Aluminium Paint (upto
600
o
C)

10.5.0. Polyurethane Coating. (For low temp.
application)

E.01 Two-Pack Polyurethane Holding
Primer
E.02 High Build Polyurethane Coating

10.6.0. General Purpose Paints

F.01 Synthetic Resin based Enamel
F.02 Chemical Resistant Enamel
F.03 Alkyd, Antiskid Abrasion
Resistant Synthetic Floor Paint

10.7.0. Special Applications

G.01 Bituminous Mastic Coating
G.02 Asphalt doping as per IS 10987
App-B
G.03 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 E-
02-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

02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
PAGE 7 OF 13




FACT ENGINEERING AND DESIGN ORGANISATION


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 Class I ( 1) L
Fi ni s h

Class I ( 1) L
Primer & Finish

Class I ( 2) M
Primer Class II ( 2) O
Primer & finish

Class II ( 3) O/ P
Primer

Class III ( 1)
Finish

Class III ( 1)
Primer & Finish Class III ( 3)




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
ENGINEERING
SPECIFICATION
PAINTING
PAGE 8 OF 13




FACT ENGINEERING AND DESIGN ORGANISATION


TABLE 1 CLASS I Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping
PRIMER FINISH Sl.
No.
SERVICE
CONDITIONS
OPERAT
ING
TEMP.
PAINT
SUB-
CLASS
Type No.of
coats
*DFT Type No.of
coats
*DFT

=/< 15 (1) L E.01 1 30 E.02 2 30
=/< 65 (1) N A.01 2 20 F.01 2 20
=/< 125 (1) M D.01 2 20 D.01 2 20
1 UN
INSULATED
NON
CORROSSIVE
ATMOSPHERE
=/< 400 (1) H D.02 2 20 D.02 2 20
=/< 15 (2) L E.1 1 30 E.02 2 20
=/< 65 (2) N A.06 2 20 B.05 2 20
=/< 125 (2) M A.02 2 20 B.02 2 20
2 UN
INSULATED
CORROSSIVE
ATMOSPHERE
=/< 400 (2) H D.02 2 20 D.02 2 20
=/< 15 (3) L E.01 1 30 - - -
=/< 65 (3) N A.04 2 25 - - -
=/< 125 (3) M D.01 2 20 - - -
3 INSULATED
CORROSSIVE
ATMOSPHERE
=/< 400 (3) H D.02 2 20 - - -
=/< 15 (4) L E.01 1 30 - - -
=/< 65 (4) N A.06 1 30 - - -
=/< 125 (4) M D.01 1 30 - - -
4 INSULATED
CORROSSIVE
ATMOSPHERE
=/< 400 (4) H D.02 1 30 - - -
=/< 15 (5) L E.01 1 30 E.02 2 30
=/< 65 (5) N A.01 2 20 F.01 2 20
=/< 125 (5) M D.01 2 20 D.01 2 20
5 SUPPORTS
FOR ALL
EQPTS.(INSUL
ATED/UN
INSULATED)
=/< 400 (5) H D.02 2 20 D.02 2 20
=/< 15 (6) L E.01 1 30 E.02 2 30
=/< 65 (6) N A.06 2 20 B.05 2 30
=/< 125 (6) M A.02 2 20 B.01 2 30
6 EQPT. AND
STRUCTRURE
S SUBJECTED
TO SALINE
ATMOSPHERE
UN
INSULATED
=/< 400 (6) H D.02 2 20 D.02 2 20

* DFT Dry film Thickness per coat microns

Notation:

L Low Temperature
N Normal Temperature
M Moderate Temperature
H High Temperature


:

02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION


TABLE 2 CLASS II OTHER EQUIPMENTS
PRIMER FINISH
Sl.
No.
TYPE OF ITEM

PAINT
SUB
CLASS
Type
No.of
coats
*DFT Type
No.of
coats
*DFT
1
Chimneys,Stacks,
Furnaces,heaters
(fired and
unfired)operating
Temp upto450
o
C
Outside (1) A.05 2 25 D.02 2 20
Outside (2)O A.01 2 20 F.01 2 25
2
D.M.Water
Storage Tanks Inside (2)P A.03 2 35 B.03 2 35
Outside (3)O A.01 2 20 F.01 2 25
3
Fresh Water/fire
Water Storage
Tanks
Inside (3)P A.03 2 35 B.04 2 75
Outside (4)O A.01 2 20 F.01 2 25
4
Drinking Water
Storage Tanks Outside (4)P A.01 2 20 C.01 3 20
5
Acid/alkali
Storage Tanks
Outside (5) A.04 2 30 C.02 3 25
Outside (6)O A.04 2 50 D.01 2 25
6
Storage
Tanks/Vessels for
Petroleum
Products
Inside (6)P A.02 2 30 B.03 2 75
Outside (7)O A.04 2 50 D.01 2 25

(7)P A.02 2 30 B.03 2 75
7
Floating Roof
Tanks:Inside of
shell, top of
bottom
plate,topside and
underside of
deck, inside of
pontoon
(7)Q A.01 2 25
8
Underside of
Bottom Plate of
Tanks

(8) A.01 1 20 G.01 1 80
9
Underground
Tanks (buried)
Outside (9) A.01 1 20 G.02
10
Below Ground
(submersible)
Tanks
Outside (10) A.06 2 35 B.05 3 35
11
Secondary
Reformer&Simila
r Eqpt.(Thermo
colour paint)
(11) G.03 2 ** G.03 1 **

*DFT : Dry Film Thickness per coat microns
** : As per Manufacturers recommendations
Notation: O- Outside P-Product Side Q-Specified Side
02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
PAGE 10 OF 13




FACT ENGINEERING AND DESIGN ORGANISATION





TABLE 3 CLASS III MISCELLANEOUS

PRIMER FINISH
Sl.
No.
TYPE OF ITEM
PAINTING
SUB
CLASS
Type
No.
of
coats
*DFT Type
No.of
coats
*DFT
1
Steel structures, Platform
Supports

(1) A.04 2 20 B.01 2 25
2
Chequered
Plate,Floorplanks&Gang
ways
(2) A.04 2 20 F.03 2 25
3
Handrails
Posts,Railings,Ladders
and Stairways
(3) A.04 2 20 B.01 2 25




* DFT Dry Film Thickness per coat microns






























02ES023/97
ENGINEERING
SPECIFICATION
PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION



TABLE 4 COLOUR CODING FOR PIPES

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




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ENGINEERING
SPECIFICATION
PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION


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)
Band 1
mm
B and 2
mm
80 NB and below 75
Above 80 NB(3) up to 100 NB(4) D x 25
Above 100 NB(4) up to 300 NB(12) D X 20
Above 300 NB(12) D x 15
of Band 1
(Rounded to the
nearest mm)

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 Color shall be Black or White to contrast with the color on
MARKINGS 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 Color shall be Black or White to contrast with the color on
MARKINGS which they are painted. The dimension of the arrow shall
be as follows and is based on the size of the pipeline.



150NB &
below
200NB &
above
a 65 90
b 30 50
c 95 125


d a

c b
d 20 30


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SPECIFICATION
PAINTING
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FACT ENGINEERING AND DESIGN ORGANISATION


5.0. 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. Battery Limit Points
b. Either side of walls & dyke
walls
c. For long yard piping at 30M
interval
d. Inter-section on pipe bridge
e. 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.




****************






02ES042/97
ENGINEERING
SPECIFICATION

COLD INSULATION
PAGE 1 OF 26

PRPD.BY:- CK CHKD.BY:- GPN APPRD. BY:- KV ISSUED ON:- 24-7-97
FACT ENGINEERING AND DESIGN ORGANISATION















CONTENTS

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








02ES042/97
ENGINEERING
SPECIFICATION
COLD INSULATION
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FACT ENGINEERING AND DESIGN ORGANISATION


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 20
o
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 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 non-
absorbent 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.
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COLD INSULATION
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FACT ENGINEERING AND DESIGN ORGANISATION


2.6.3 The foam shall be formulated in such a
way that it shall be of self-
extinguishing quality which shall not
cause fire to spread under any
circumstances.
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/m
3
.
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 self-
extinguishing 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 20 to 22 Kg/m
3
Slabs 18 o 20 Kg/m
3



2.7.5 Thermal conductivity of finished EPS
shall be as given below:
----------------------------------------------
Density Thermal conductivity
Kcal/m.hr.
o
C
0
o
C 10
o
C
----------------------------------------------
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
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COLD INSULATION
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FACT ENGINEERING AND DESIGN ORGANISATION


3.5.1 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
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-in-
charge.
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.
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SPECIFICATION
COLD INSULATION
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FACT ENGINEERING AND DESIGN ORGANISATION


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 No. of layers
Up to 60 mm 1
Up to 120 mm 2
Above 120mm 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
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
02ES042/97
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SPECIFICATION
COLD INSULATION
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FACT ENGINEERING AND DESIGN ORGANISATION


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
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
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SPECIFICATION
COLD INSULATION
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FACT ENGINEERING AND DESIGN ORGANISATION


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.
5.9.4 Each layer of insulation shall be banded
separately and bands of successive layers
shall be staggered.
5.9.5 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.
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.
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FACT ENGINEERING AND DESIGN ORGANISATION


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.
7. Apply a 20mm thk hard setting non-
conductive plaster made from asbestos
fluff and Portland cement troweled to a
smooth and even finish.
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.

6.0.0 PIPING INSULATION
6.1.0 GENERAL
6.1.1 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.
6.1.3 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.
6.1.4 All insulation shall be applied when
piping is at ambient temperature.
6.1.5 Spacer rings for supporting metal
cladding shall be installed by the
contractor.
6.1.6 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.
6.1.7 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.
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.
6.1.10 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.
6.2.2 Wire netting shall be held together with
20mm wired hoop iron bands at 300mm
spacing.
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.
02ES042/97
ENGINEERING
SPECIFICATION
COLD INSULATION
PAGE 9 OF 26



FACT ENGINEERING AND DESIGN ORGANISATION


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 PIPING INSPECTION WINDOWS
6.3.1 Plug type inspection windows shall be
provided on all insulated pipelines having
size 50 mm and above.
6.3.2 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
6.3.3 Inspection windows shall be provided at
the bottom of the pipelines.
6.3.4 There must be at least one inspection
window within a span of 10m.
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-in-
charge.
6.3.7 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.
6.3.8 The plug shall be of perfect fit into the
inspection window and shall ensure leak
tightness.

7.0.0 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
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 INSULATION CAST-IN-SITU
9.1.0 Large vessels and equipment may be
insulated using polyurethane foam,
foamed in situ.
9.2.0 Before commencement of foaming-in-
situ, 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
02ES042/97
ENGINEERING
SPECIFICATION
COLD INSULATION
PAGE 10 OF 26



FACT ENGINEERING AND DESIGN ORGANISATION


proof by using impermeable mastic
sealing compound.
9.6.0 Air escape holes provided in the cladding
shall be sealed well after foaming.
9.7.0 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.

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.

12.0.0 APPLICATION DETAILS
Refer the following details attached to
this specification for application of
insulation of various parts.
Table 1 Thickness of Aluminium
cladding sheets
Table 2 Thickness for Cold Insulation

Fig.1 Insulation of Vertical Vessels
Fig.2 Insulation of Exchanger Shell &
Head
Fig.3 Expansion joint for Rigid
Insulation
Fig.4 Support for Vertical Insulated
Piping
Fig.5 Welded Elbow Insulation
Fig 6 Tee Insulation
Fig.7 Bottom Head Insulation for
Vertical Vessels
Fig.8 Flange Insulation
Fig.9 Valve Insulation
Fig.10 Flashing at Nozzles & Other
Projections.
Fig.11 Uninsulated Flange
Fig.12 Tank shell insulation-Details
Fig.13 Support detail for metal covering
of insulation.
Fig.14 Man hole Insulation
Fig.15 Details of Corrugated sheet
overlapping
Fig.16 Details of Tank Roof Insulation
supports.
Fig.17 Details of Tank Top setting
Plaster Finish
Fig.18 Single layer Insulation for Piping
Fig.19 Multiple layer Insulation for
Piping.



*******************





02ES042/97
ENGINEERING
SPECIFICATION
COLD INSULATION
PAGE 11 OF 26



FACT ENGINEERING AND DESIGN ORGANISATION




TABLE 1 THICKNESS OF ALUMINIUM CLADDING SHEETS






TABLE 2 THICKNESS OF COLD INSULATION







Type of aluminium sheeting
Item
Size (mm)
Or Dia Vertical Other portions
< / = 350 NB
24 SWG plain

24 SWG plain

>350 NB 22 SWG Corrugated
24SWG plain

Equipment

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 24 SWG plain 24 SWG plain
Piping
Valves, flanges
etc.
24 SWG plain 22 SWG plain
Insulation Thickness (mm) for Temperature Deg.C Nom:
Dia < / =
-40 -30 -20 -10 0 10 20
20 60 60 60 50 50 40 40
65 70 70 70 60 60 50 50
80 80 80 80 70 70 50 50
150 90 90 90 80 80
50 50
400 100 100 100 80 80
50 50
500 110 110 110 80 80
50 50
900 120 120 120 80 80
50 50
Above
900
130 130 130 80 80 50 50
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 edi-
tions 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 Specification for Design ,
Fabrication & Erection of
Structural Steel for Build-
ings
3.0.0 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 com-
mencing 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, con-
struction equipment, and special vehicles.
f. Work space around the installation area.
g. Schedule of installation of each equipment.
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. Li st of pri nci pl e components of gi n
pole/boom derrick.
l. Transportation plans of gin pole/ boom der-
rick construction equipment and special
vehicles.
m. Installation plan and progress schedule of
gin pole/boom derrick.
n. Electric power to be consumed during in-
stallation.
5.0.0 CONSTRUCTION EQUIPMENT
5.1.0 HOISTING EQUIPMENT
5.1.1 Gin pole / Boom derrick
Select the gin pole/boom derrick according to
the shape, weight, and dimension of the equip-
ment to be installed, and the surrounding con-
dition. 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 con-
sidering the following:
1. Site of Gin Pole/Boom derrick.
Prior to starting the gin pole/boom derrick erec-
tion, 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,
dynami c forces such as wi nd l oad, or
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
25ES201 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION OF STATIC EQUIPMENT
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: MAR 94
PAGE 1 OF 5
iso2.sty
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCES
3.0.0 GENERAL
4.0.0 PLANNING
5.0.0 CONSTRUCTION EQUIPMENT
6.0.0 INSTALLATION
7.0.0 ALIGNMENT
8.0.0 GROUTING
9.0.0 LOOSENING SLIDE END ANCHOR BOLT
10.0.0 INSPECTION RECORD

of three cable clamps or equivalent at each

connecti on to prevent sl ippage. 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 foun-
dations, underground facilities & struc-
tures.
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 job- site. The
capacities given shall be adhered to strictly.
Additional boom sections installed on the
equipment shall be compensated by addi-
tional 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 maladjust-
ment.
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.
5.2.0 WIRE ROPE, SLINGS, CHAINS AND FIT-
TINGS
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 in-
clusive.
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 im-
mediately.
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
25ES201 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION OF STATIC EQUIPMENT
PAGE 2 OF 5
TABLE - 1
ITEM
MIN.
SAFETY
FACTOR
Hoist Rope
3.5
Hoist Rope for Raising and
Falling Boom
Wire Rope for Supporting
Boom
3 Wire Rope for Turning
Wire Rope or Guy Rope
for Tension
Wire Rope for Sling 5
6.0.0 INSTALLATION
6.1.0 ERECTION OF GIN POLE/BOOM DERRICK
6.1.1 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.
6.1.2 Grounding
The gin pole/boom derrick shall be equipped
with grounding. Resistance of grounding shall
be under 10 ohms.
6.1.3 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.
6.1.4 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 con-
nections thereof.
2. Anchor of winch.
3. Guy ropes as to number, tension and con-
dition.
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.
6.1.5 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.
6.2.0 PREPARATION OF SHIMS AND WEDGE
6.2.1 Shims & wedges shall be made of carbon steel.
6.2.2 In general shims & wedges shall be prepared by
machining or grinding as indicated in Table 2.
TABLE - 2
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.)
4
o
-5
o
6.3.0 INSTALLATION OF EQUIPMENT
6.3.1 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.
6.3.2 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 stor-
my winds, heavy rain or heavy snow.
6.3.3 Special crew
1. During heavy equipment installation, espe-
cially installation by the gin pole/boom der-
rick a special crew shall be organized.
2. The crew shall comprises a general super-
visor, signal/flag man, hoist operator, crane
operator, rigger, safety supervisor, etc.
3. The function of each individual of the crew
shall be clearly defined.
6.3.4 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.
25ES201 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION OF STATIC EQUIPMENT
PAGE 3 OF 5
3. The protective cover on equipment for noz-
zles and flanges shall not be removed
without the approval of the Engineer-in-
charge.
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 founda-
tion 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 GENERAL
7.1.1 All installed equipment shall be aligned plumb-
ness or level.
7.1.2 Towers/vertical vessels shall be aligned plumb-
ness and satisfy the requirements of Par. 7.2.0
7.1.3 Horizontal vessels & heat exchangers shall be
aligned level and satisfy the requirements of
Par.7.3.0
7.2.0 PLUMBNESS
1. Plumbness shall be checked by viewing
from two directions 90
o
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.
7.3.0 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 equip-
ment. ( Refer to Fig. on Page 5 of 5 )
2. The maximum tolerance shall be as shown
in Table 3, unless otherwise specified.
TABLE - 3
POINT TOLERANCE
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 main-
tenance, the channel end of the heat ex-
changer 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 GROUTING
Grouting shall be accomplished in accordance
with the fol lowing requirements, unless other-
wise specified.
8.1.0 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.
8.2.0 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.
8.3.0 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.
9.0.0 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 ex-
changers, and when requested by the En-
gineer- in - charge
10.0.0 INSPECTION RECORD
The results of the following inspections shall be
recorded and submitted.
1. Alignment
a. Plumbness
b. Leveling
25ES201 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION OF STATIC EQUIPMENT
PAGE 4 OF 5
25ES201 / 94
ENGINEERING
SPECIFICATION
ERECTION OF STATIC EQUIPMENT
PAGE 5 OF 5

FACT ENGINEERING AND DESIGN ORGANISATION

00FT001






LEVELLING POINTS FOR HORIZONTAL EQUIPMENT


X
A B








C D
X

PLAN





SCALE



A C

B D









VIEW X X LEVEL
INSTRUMENT









1.0.0 SCOPE
1.1.0 This specification covers the general require-
ments for the erection, alignment and grouting
of machinery.
1.2.0 For specific machineries, the requirements of
the manufacturers installation manuals shall
apply in addition to all non-conflicting require-
ments 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. Spe-
cial care must be taken to see that the loosely
packed items such as foundation bolts, cou-
plings 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 sup-
plied with the unit.
2.2.0 The Engineer in charge shall also determine
whether any damage has occured to the equip-
ment during transit.
2.3.0 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.
2.4.0 The tags on equipment shall indicate the follow-
ing details:
a. Equipment No. & Description.
b. Plant and Location of Erection.
c. P.O. Ref.
d. Date of receipt & inspection at site.
2.5.0 The equipments are to be stored separately
plant wise to facilitate easy location and iden-
tification during erection.
2.6.0 Should the equipment be not installed immedi-
ately after delivery, the closest adherence to the
following in structions is strongly recommended.
2.6.1 The base plate to rest fully on a flat surface and
not just partially.
2.6.2 The components not to be stacked one upon the
other.
2.6.3 All components and the equipment to be stored
in a dry clean place.
2.6.4 All machined parts, likely to corrode, either in-
side or outside, to be protected by suitable
inhibitors (grease or rust preventive compound).
2.6.5 All lids and covers to be closed to prevent dust
or foreign matters from entering the equipment.
2.6.6 Bearings and motors shall be kept in indoor
installations.
2.7.1 In rotating machinery, rotate the shaft weekly to
coat the bearings and shaft surfaces with
lubricant and to retard oxidation and corrosion.
2.7.2 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 sup-
port the weight of the unit. Lifting hooks, Eye-
bolts, etc. if provided, should be used for lifting.
Strings/wire ropes are to put through the por-
tions of the equipment marked/recommended
by the manufacturer of the equipment.
3.2.0 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.
4.0.0 ERECTION
4.1.0 Well before preparing for erection of the equip-
ment ensure that the details of the equipment
nozzle dimensions and locations, couplings,
base plate, anchor bolts dimension and loca-
tions, direction of rotation of drive and driven
units, details of key and key way as per the
relevant drawings.
4.2.0 Prepare an outline sketch of the equipment,
which shall be used as ready reference sheet,
marking the design requirements such as co-or-
dinates of the equipment centre lines, P.O.S.
elevations, critical nozzle elevation, distance
between shaft ends, minimum projection re-
quired for the anchor bolts from P.O.S. eleva-
tion, location and dimensions of anchor bolts,
grouting clearance, etc.
4.3.0 With the above details check the equipment and
the respective foundation to take remedial ac-
tions for any discrepancy noted if it is beyond
acceptable limits.
4.4.0 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.
4.5.0 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.
4.6.0 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.
4.7.0 The top of the foundation shall be placed 25 to
25ES202 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION-ALIGNMENT AND GROUTING OF
MACHINERY ITEMS
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: MAR 94
PAGE 1 OF 3
iso2.sty
CONTENTS
1.0.0 SCOPE
2.0.0 INSPECTION AND STORAGE
3.0.0 HANDLING
4.0.0 ERECTION
5.0.0 GROUTING
6.0.0 ALIGNMENT
-
50 mm below the final level of the equipment.
4.8.0 Mark the centre-line of the equipment both on
the foundation and on the equipment.
4.9.0 Lift the equipment and place it on the foundation
with the foundation bolts in position.
4.10.0 Proper equipment and tools for lifting, leveling
and alignment should be made ready before
putting the machine over the foundation.
4.11.0 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.
4.12.0 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 instal-
lation 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 equip-
ments are directly erected on the foundation in
the assembled form.
4.13.0 The foundation surface will support the equip-
ment 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.
4.14.0 Always use thick shims wherever possible to
avoid spongy shim base.
4.15.0 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).
4.16.0 For leveling the equipment use machined true
surface viz. pump flange, coupling face, shaft
surface, etc.
4.17.0 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 foun-
dation 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.
5.2.0 Saturate with water the top surface of the foun-
dation 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.
5.3.0 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
be operated easily on the narrow space under
the base frame. The grout prepared must flow
easily.
5.4.0 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.
5.5.0 To avoid shrinkage of grout during setting any
non shrinking compound can be added to grout
mixture as additive.
5.6.0 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.
5.7.0 The grout should be poured quickly and con-
tinuously to prevent unequal setting of grout.
5.8.0 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.
5.9.0 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.
6.2.0 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 founda-
tion.
6.3.0 The driven unit viz. pump, blower, compressor
etc. is assembled and levelled on the base
frame already grouted.
6.4.0 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.
6.5.0 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 cou-
plings of the driving and driven units by at least
one coupling pin. Alternatively where free move-
ment 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 90
o
and readings taken only when
the mark are in line.
6.6.0 Alignment is to be done using minimum dial-
gauges or with any suitable instruments avail-
able. Radial and axil alignment shall be checked
simultaneously using two dial gauges.
25ES202 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION-ALIGNMENT AND GROUTING OF
MACHINERY ITEMS PAGE 2 OF 3
6.7.0 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.
6.8.0 ALIGNMENT OF BELT DRIVE
6.8.1 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.
6.8.2 The motor belts sheave is assembled on the
motor shaft by using tapered bushing and cap
screws. Do not lubricate the cap screws.
6.8.3 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 The foundation bolts of the slide rails are
grouted.
6.8.5 The slides are also grouted after checking the
levelling.
6.8.6 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.
6.8.7 Install the belts in sheave grooves without forc-
ing 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 ser-
vice life.
6.8.8 With the belts in the grooves, reposition the
motor to take up the slack until the belts are fairly
tight.
6.9.0 BELT TENSION
6.9.1 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 operat-
ing underload.
6.9.2 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.
6.9.3 The drive is now properly tensioned and should
operate satisfactorily with only an occasional
readjustment to compensate for normal belt and
sheave groove wear.
25ES202 / 94
FACT ENGINEERING AND DESIGN ORGANISATION
ENGINEERING
SPECIFICATION
ERECTION-ALIGNMENT AND GROUTING OF
MACHINERY ITEMS PAGE 3 OF 3
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48
FACT ENGINEERING AND DESIGN ORGANISATION
Rev DATE PRPD. CHKD. APPRD.
0 16.11.09 KK CRP JK
VENDOR
HPCL
1 P.O No.
2
PROJECT
3
4
CLIENT
LPG BLENDING FACILITY
PLANT AT MANGALORE
End connection of landing valve shall be 80 NB flange drilled to suit ANSI B 16.5
Note:
Blind cap with chain required (brass)
14.0 Certification ISI marking
13.0 Accessories
Coupling Instantaneous female
Landing valve body
Landing valve disc Gun mettal
Material of construction
Gun mettal
CS Stand pipe
11.0
16
10.0 Pressure
Kg/cm
2
G
7 operating / 15 design
9.0 Flow rate lpm 900
14
8.0 Landing valve size mm 63 female instantaneous 15
Dimensions ANSI B16.5 150#
Flanged
Size 80 NB
Type
6.0 Hydrant size mm 63
7.0 Connection
4.0 No. off 1
5.0 Codes / Standards IS 5290 : 1993 Type A
7
1.0 Make
2.0 Model 6
3
FIRE HYDRANT ASSEMBLY
1
Site : MANGALORE Job No : 8122 2
LPG BLENDING FACILITY Item No. :
1
Applicable to : Proposal Purchase As built TPS No. :

FIRE HYDRANT SYSTEM
8122-01-DA FH100
DATA SHEET
PAGE 1 OF
Unit :
3.0 Type Single Hydrant
X
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5
8
9
10
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FACT ENGINEERING AND DESIGN ORGANISATION
49
Capacity
No. off
required
10.0 Hose station N/A
Stand with foundation bolts
Keys required
Couplings
Hose reels 16
14
9.0 Accessories 15
8.0 Material of construction MS galvanised and painted
Thickness mm 20 guage
Capacity To hold 1 no 15 M long hoses with branch pipes,
nozzles & couplings
5.0 Codes / Standards
6.0 Dimensions mm 30" x 10" x 24" (Height 24")
7
4.0 No. off 1
3.0 Type Stand mounted type, glass fronted
6
3
HOSE BOX
1
Site : MANGALORE Job No : 8122 2
LPG BLENDING FACILITY
Purchase As built TPS No. :

Item No. :
8122-01-DA FH103
DATA SHEET
PAGE 1 OF 1
Applicable to : Proposal
7.0
FIRE HYDRANT SYSTEM
Unit :
1.0 Make
2.0 Model
X
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8
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55
FACT ENGINEERING AND DESIGN ORGANISATION
49
Dimensional check and performance test shall be
done on 10 % of nozzles selected at random
Spanner required
Half coupling required
10.0 Cone angle deg.
11.0 Acessories
14
8.0 Orifice size mm 15
9.0 Connection size Threaded Suitable for 15 mm, IS 554 16
7.0 Flow rate lpm
K factor
Spray nozzle Marine Bronze
Half coupling A 105 galvanized
5.0 Codes / Standards FM / UL / NFPA
6.0 Material of construction
6
3.0 Type Medium velocity spray nozzles - pendant type 7
4.0 No. off 11
1.0 Make
2.0 Model
FIRE HYDRANT SYSTEM
8122-01-DA FH102
MANGALORE Job No : 8122
Unit : LPG BLENDING FACILITY Item No. :
DATA SHEET
PAGE 1 OF
3
SPRAY NOZZLE
1
Site : 2
1
Applicable to : Proposal Purchase As built TPS No. :

X
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48
Size
Dimensions
Accessories
Valve body
Valve internals
Valve disc
Codes / Standards
Valve size
Connection
Type
Make
Model
Type
Flanged
mm
No. off
As per B16.5, Class 150. FF
50
12
50NB
A105, galvanised, threaded
0
1
F
T
0
7
4
C
/
9
4
LPG BLENDING FACILITY PROJECT
HPCL
kk
APPRD.
VENDOR
P.O No.
crp jk 20.11.09 0
1
FACT ENGINEERING AND DESIGN ORGANISATION
CHKD. PRPD. DATE Rev
CLIENT
3
2
4
TPS No. : Applicable to : As built Proposal Purchase
DATA SHEET
FIRE HYDRANT SYSTEM
8122-01-DA-FH 104
1 OF 1 PAGE
2
1
8122
3
LPG BLENDING FACILITY
HPCL, MANGALORE
7
6
14
Site :
Unit :
Job No :
Item No. :
DELUGE VALVE SYSTEM
2
ALUMINIUM BRONZE
Bronze
Bronze
ALUMINIUM BRONZE
ALUMINIUM BRONZE
10.0 Pressure
Material of construction 11.0
Kg/cm
2
G
1.0
2.0
3.0
4.0
5.0
6.0
7.0
13.0
Pressure gauges
Actuation piping
Isolation valves
Bypass valve
Mating flages & pipe fittings
Solinoid valve
Pressure switch
Page 1 of 6






0 23.11.09 First issue KK CRP JK
REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

Page 1 of 7 R0
8122-01-PS-002 DV
ENGINEERING
SPECIFICATION



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STANDARD SPECIFICATION FOR

DELUGE VALVE



















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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

P&ID OF DELUGE VALVE (HYDRAULIC DETECTION SYSTEM)























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1. 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. NEPA Codes
2. Rules for Water Spray System (BY TAC)
3. Indian Standard Specifications

3.0 DESIGN REQUIREMENTS

3.1 An automatic deluge valve shall consist of following:

1. Deluge valve unit
2. Diaphragm unit
3. Integral test and drain valve manifold
4. Alarm system
5. Priming equipment
6. Installation stop valve with pressure gauge and outlet valve
7. By pass ball valve
8. Detector pipe work manifold

3.2 Size and capacity of deluge valve shall be as under:

Size (Inch(mm) Rated Flow(lpm) Working Pressure(kg/cm2g)

2(50) 7.0 to 10.5
3(80) 1150 7.0 to 10.5
4(100) 5000 7.0 to 10.5
6(150) 13500 7.0 to 10.5
8(200) 18500 7.0 to 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 Cast iron to IS 210 Gr. FG 200
Seat Bronze
Clack Graphite iron
Diaphragm spindle
and hinged pin SS 304
Test and drain valve, )


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Installation stop valve , )
Outlet valve and ) Cast steel (A53A spec)
Check valve )



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.

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.



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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.

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


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- 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
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
FOR TENDER PURPOSE ONLY
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INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
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FOR TENDER PURPOSE ONLY
REF DRAWINGS
FLOW SHEET REF.
INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
REF DRAWINGS
FLOW SHEET REF.
INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
REF DRAWINGS
FLOW SHEET REF.
INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
REF DRAWINGS
FLOW SHEET REF.
INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
REF DRAWINGS
FLOW SHEET REF.
INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
REF DRAWINGS
FLOW SHEET REF.
INSULATION
FACT ENGINEERING & DESIGN ORGANISATION
NOTES
FOR TENDER PURPOSE ONLY
R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
0
3
F
T
0
6
7
B
/

9
6
Project - LPG Blending
facilities
FACT ENGINEERING AND DESIGN ORGANISATION
PrepAred - GSP Checked - KAK Approved - KAK 15.10.09
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
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 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.
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.
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
A FABRICATION AND INSTALLATION OF PIPING
Description of item Amount Rs.
(2) Words (6)
Rate Rs. (5)
PIPING
SCHEDULE OF ITEMS OF WORK
8122 - 03 - SW - 001
DEPARTMENT PAGE 1 OF 10
R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
A.1
1 20NB SCH160 M 2
2 25 NB SCH 80 6
3 40NB SCH 80 2
4 50 NB SCH 40 6
5 100 NB SCH 40 6
6 250 NB SCH 40 6
7 300 NB SCH 40 235
A.2
1 20NB SCH160 M 2
2 40NB SCH 80 2
3 150NB SCH 40 12
4 200 NB SCH 40 200
5 250 NB SCH 40 200
6 300 NB SCH 40 24
A.3
1 25 NB PN 10 M 1
2 40 NB PN 10 1
3 50 NB PN 10 2
4 100 NB PN 10 1
5 150 NB PN 10 18
6 200 NB PN 10 3
7 250NB PN 10 3
PIPING
SCHEDULE OF ITEMS OF WORK
8122-03-SW-001
DEPARTMENT PAGE 2 OF 10
(6)
Rate Rs. (5) Description of item Amount Rs.
(2) Words
CARBON STEEL, ASTM A 106 GR B
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6
GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION

R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
A.3
C/O
8 300 NB PN 10 M 3
9 400NB PN 10 194
10 450 NB PN 10 1
11 500 NB PN 10 1
A.4
1 100 NB M 5
2 300NB 5
3 450NB 35
B
1 20NB 60 MM THICK M 4
2 25NB 60 MM THICK 9
3 40NB 60 MM THICK 4
4 50NB 60 MM THICK 6
5 100NB 60 MM THICK 6
GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION
(6)
Rate Rs. (5) Description of item Amount Rs.
(2) Words
PIPING
SCHEDULE OF ITEMS OF WORK
8122-03-SW-001
DEPARTMENT PAGE 3 OF 10
CEMENT LINED PIPING
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.
SUPPLY AND APPLICATION OF COLD INSULATION
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
The rate shall also include making Tie in connections, galvanised fasteners,
non metallic gaskets, sleeves, sand, cement, reinforcement etc

R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
B
C/O
6 150NB 60 MM THICK M 12
7 150NB 90 MM THICK 6
8 200NB 90 MM THICK 195
9 250NB 60 MM THICK 195
10 300NB 60 MM THICK 250
C
LS 1
D
RADIOGRAPHY / DYE PENETRANT TESTS.
1 CMS 27000
2 CMS 700 DP Inspection
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
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
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
SUPPLY AND APPLICATION OF COLD INSULATION
Description of item Amount Rs.
(2) Words (6)
Rate Rs. (5)
PIPING
SCHEDULE OF ITEMS OF WORK
8122-03-SW-001
DEPARTMENT PAGE 4 OF 10
R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
E C/O
1 100NB M 5
2 300NB 5
3 450NB 35
4
150NB 6
5
250NB 6
6
300NB 6
F
1 Fabrication, erection and Painting of structural supports
MT 2.5
2 Cu M 5
3 Chipping of RCC for fixing insert plates, clamps, making cut outs etc Cu M 2
4
Nos 2
FACT ENGINEERING AND DESIGN ORGANISATION
Total / Sub-total
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
Carbon Steel piping
MISCELLANEOUS JOBS
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
PCC/ RCC pedestals for pipe supports including cost of materials
PIPING
SCHEDULE OF ITEMS OF WORK
8122-03-SW-001
DEPARTMENT PAGE 5 OF 10
Amount Rs.
(2) Words (6)
Rate Rs. (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).
Erection of Basket Filters
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 .
Description of item
R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
G
G.1
C/O
1 25NB M 1
2 40NB 1
3 50NB 2
4 100NB 1
5 150NB 18
6 200NB 3
7 250NB 3
8 300NB 3
9 400NB 194
10 450NB 1
11 500NB 1
G.2
1 25NB NOS 16
2 40NB 2
3 50NB 1
4 100NB 4
5 150NB 8
6 200NB 2
7 250NB 3
SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION
SCHEDULE OF ITEMS OF WORK
GRP PIPES, PN 10
8122-03-SW-001
DEPARTMENT PAGE 6 OF 10
(6)
Rate Rs. (5) Description of item Amount Rs.
(2) Words
PIPING
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
GRP FLANGES, 150#, FF, DRILLING AS PER B16.5

R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
G.3
C/O
1 300NB NOS 18
2 400NB 22
3 450NB 1
4 500NB 1
5
G.4
1 40 NB NOS 2
2 400 NB 1
G.5
1 50NB NOS 1
2 100NB 3
3 150NB 14
4 200NB 3
5 250NB 3
6 400NB 15
G.6
1 400NB NOS 3
G.7
1 150NB NOS 1
2 400NB 2
45 DEG ELBOW, GRP, PN 10
90 DEG ELBOW, GRP, PN 10
EQUAL TEE, GRP, PN 10
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
(2) Words
GRP FLANGES, 150#, FF, DRILLING AS PER B16.5
GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5
8122-03-SW-001
DEPARTMENT PAGE 7 OF 10
(6)
Rate Rs. (5) Description of item Amount Rs.
PIPING
SCHEDULE OF ITEMS OF WORK

R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
C/O
G.8
1
NOS 1
G.9
1
NOS 1
2
3
G.10
1 NOS 11
G.11 NOS 3
300NB X 250NB
25NB
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.
CONCENTRIC REDUCER , GRP, PN 10
ECCENTRIC REDUCER , GRP, PN 10
500NB X 400NB
450NB X 400NB
(6)
Rate Rs. (5) Description of item Amount Rs.
(2) Words
PIPING
SCHEDULE OF ITEMS OF WORK
8122-03-SW-001
DEPARTMENT PAGE 8 OF 10
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.
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
H
H.1
C/O
1 25NB M 40
2 40NB 43
3 50NB 50
4 80NB 1
5 100NB 30
H.2 NOS 1
H.3
1 25 NB NOS 4
2 40 NB 7
3 50 NB 4
4 EQUAL TEE 25 NB 3
5 EQUAL TEE 40 NB 1
6 EQUAL TEE 50 NB 1
7 UNEQUAL TEE 1
8 UNEQUAL TEE 8
9 UNEQUAL TEE 14
10 3
11 2
12 25 NB 7
13 40 NB 10
CON. REDUCER
COUPLING
COUPLING
40 NB x 25 NB
40 NB x 25 NB
50 NB x 40 NB
40 NB x 15 NB
25 NB x 15 NB
90 ELBOW
90 ELBOW
90 ELBOW
CON. REDUCER
GI FLANGES, A105, 150#, FF, DRILLING AS PER B16.5,
THREADED - 100NB
GI FITTINGS, A105, CLASS 3000, THREADED
PIPING
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
Description of item Amount Rs.
(2) Words
8122-03-SW-001
DEPARTMENT PAGE 9 OF 10
SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS
SCHEDULE OF ITEMS OF WORK
GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS
(6)
Rate Rs. (5)

R 0
Sl. No. Unit Quantity
(1) (3) (4) Fig.
I
I.1 NOS 1 C/O
I.2 NOS 1
I.3 NOS 11
I.4 NOS 11
I.5 NOS 1
I.6 NOS 2
I.7 NOS 1
J
J.1 NOS 2
J.2 3
J.3 2
J.4 TE 10.5
K
K.1 NOS 2
K.2 NOS 1
8122-03-SW-001
DEPARTMENT PAGE 10 OF 10
SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST
TYPE 1, SIZE 63MM
SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS INCLUDING GASKETS AND FASTENERS
SCHEDULE OF ITEMS OF WORK
(6)
Rate Rs. (5) Amount Rs.
Words
JOCKEY PUMP- VERTICAL- 1 TE APPR
Total / Sub-total
FACT ENGINEERING AND DESIGN ORGANISATION
QUARTZOID BULB, 15 MM, MALE THREADED
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
WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR
PIPING
SPRAY NOZZLES AS PER IS 319 TYPE II & DATA SHEET, SIZE K40
WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM
Description of item
(2)
INSTALLATION OF EQUIPMENTS
P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR
CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS.
FLANGED AS PER B16.5 , 150# , FF, 100NB
HOSE BOX AS PER DATA SHEET
DISMANTLING OF PUMPS
P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR
JOCKEY PUMP- VERTICAL- 1TE APPR
E301- LPG HEATER- HORIZONTAL

Sl. No. Unit Quantity
(1) (3) (4)
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
PIPING
SCHEDULE OF ITEMS OF WORK
DEPARTMENT
A FABRICATION AND INSTALLATION OF PIPING
Description of item
(2)
0
3
F
T
0
6
7
B
/

9
6
Project - LPG Blending
facilities
FACT ENGINEERING AND DESIGN ORGANISATION
PrepAred - GSP Checked - KAK Approved - KAK
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
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
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.
aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also
included
Sl. No. Unit Quantity
(1) (3) (4)
2 20NB SCH160 M 2
3 25 NB SCH 80 6
4 40NB SCH 80 2
5 50 NB SCH 40 6
6 100 NB SCH 40 6
7 250 NB SCH 40 6
8 300 NB SCH 40 235
9 20NB SCH160 M 2
Description of item
(2)
PIPING
SCHEDULE OF ITEMS OF WORK
DEPARTMENT
CARBON STEEL, ASTM A 106 GR B
LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6
9 20NB SCH160 M 2
10 40NB SCH 80 2
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 M 1
16 40 NB PN 10 1
17 50 NB PN 10 2
18 100 NB PN 10 1
19 150 NB PN 10 18
20 200 NB PN 10 3
21 250NB PN 10 3
FACT ENGINEERING AND DESIGN ORGANISATION
GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION
Sl. No. Unit Quantity
(1) (3) (4)
22 300 NB PN 10 M 3
23 400NB PN 10 194
24 450 NB PN 10 1
25 500 NB PN 10 1
26 100 NB M 5
27 300NB 5
PIPING
SCHEDULE OF ITEMS OF WORK
DEPARTMENT
The rate shall also include making Tie in connections, galvanised fasteners,
non metallic gaskets, sleeves, sand, cement, reinforcement etc
CEMENT LINED PIPING
GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION
Description of item
(2)
27 300NB 5
28 450NB 35
29 20NB 60 MM THICK M 4
30 25NB 60 MM THICK 9
31 40NB 60 MM THICK 4
32 50NB 60 MM THICK 6
33 100NB 60 MM THICK 6
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.
SUPPLY AND APPLICATION OF COLD INSULATION
FACT ENGINEERING AND DESIGN ORGANISATION
Sl. No. Unit Quantity
(1) (3) (4)
34 150NB 60 MM THICK M 12
35 150NB 90 MM THICK 6
36 200NB 90 MM THICK 195
37 250NB 60 MM THICK 195
38 300NB 60 MM THICK 250
39
LS 1
PIPING
SCHEDULE OF ITEMS OF WORK
DEPARTMENT
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
SUPPLY AND APPLICATION OF COLD INSULATION
Description of item
(2)
RADIOGRAPHY / DYE PENETRANT TESTS.
40
CM 27000
41
CM 700
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
DP Inspection
FACT ENGINEERING AND DESIGN ORGANISATION
oneither side of the MOV etc
Sl. No. Unit Quantity
(1) (3) (4)
42 100NB M 5
43 300NB 5
44 450NB 35
45
150NB 6
46
250NB 6
47
300NB 6
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
Carbon Steel piping
MISCELLANEOUS JOBS
PIPING
SCHEDULE OF ITEMS OF WORK
DEPARTMENT
Description of item
(2)
48 Fabrication, erection and Painting of structural supports
TM 2.5
49 Cu M 5
50 Chipping of RCC for fixing insert plates, clamps, making cut outs etc Cu M 2
51
Nos 2
FACT ENGINEERING AND DESIGN ORGANISATION
MISCELLANEOUS JOBS
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
PCC/ RCC pedestals for pipe supports including cost of materials
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).
Erection of Basket Filters
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 .
R 0
Sl. No. Unit Quantity
(1) (3) (4)
52 25NB M 1
53 40NB 1
54 50NB 2
55 100NB 1
56 150NB 18
57 200NB 3
58 250NB 3
DEPARTMENT
Description of item
PIPING
SCHEDULE OF ITEMS OF WORK
(2)
SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION
GRP PIPES, PN 10
58 250NB 3
59 300NB 3
60 400NB 194
61 450NB 1
62 500NB 1
63 25NB NOS 16
64 40NB 2
65 50NB 1
66 100NB 4
67 150NB 8
68 200NB 2
69 250NB 3
FACT ENGINEERING AND DESIGN ORGANISATION
GRP FLANGES, 150#, FF, DRILLING AS PER B16.5
Sl. No. Unit Quantity
(1) (3) (4)
70 300NB NOS 18
71 400NB 22
72 450NB 1
73 500NB 1
74 40 NB NOS 2
75 400 NB 1
GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5
DEPARTMENT
Description of item
PIPING
SCHEDULE OF ITEMS OF WORK
(2)
GRP FLANGES, 150#, FF, DRILLING AS PER B16.5
75 400 NB 1
76 50NB NOS 1
77 100NB 3
78 150NB 14
79 200NB 3
80 250NB 3
81 400NB 15
82 400NB NOS 3
83 150NB NOS 1
84 400NB 2
FACT ENGINEERING AND DESIGN ORGANISATION
45 DEG ELBOW, GRP, PN 10
90 DEG ELBOW, GRP, PN 10
EQUAL TEE, GRP, PN 10
FACT ENGINEERING AND DESIGN ORGANISATION
Sl. No. Unit Quantity
(1) (3) (4)
85
NOS 1
86
NOS 1
87
3
PIPING
SCHEDULE OF ITEMS OF WORK
300NB X 250NB
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.
DEPARTMENT
Description of item
(2)
ECCENTRIC REDUCER , GRP, PN 10
500NB X 400NB
450NB X 400NB
CONCENTRIC REDUCER , GRP, PN 10
88 NOS 11
89 NOS 3
25NB
BAR, TEMP - 50 DEG C.
FACT ENGINEERING AND DESIGN ORGANISATION
RUBBER EXPANSION BELLOWS 300NB
R 0
Sl. No. Unit Quantity
(1) (3) (4)
90 25NB M 40
91 40NB 43
92 50NB 50
93 80NB 1
94 100NB 30
95 100NB NOS 1
Description of item
GI FLANGES, 150#, FF, DRILLING AS PER B16.5, THREADED
GI FITTINGS, A105, CLASS 3000, THREADED
(2)
GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS
DEPARTMENT
SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS
SCHEDULE OF ITEMS OF WORK
PIPING
96 25 NB NOS 4
97 40 NB 7
98 50 NB 4
99 EQUAL TEE 25 NB 3
100 EQUAL TEE 40 NB 1
101 EQUAL TEE 50 NB 1
102 UNEQUAL TEE 1
103 UNEQUAL TEE 8
104 UNEQUAL TEE 14
105 3
106 2
107 25 NB 7
108 40 NB 10
90 ELBOW
25 NB x 15 NB
FACT ENGINEERING AND DESIGN ORGANISATION
COUPLING
40 NB x 25 NB
40 NB x 25 NB
50 NB x 40 NB
40 NB x 15 NB
COUPLING
CON. REDUCER
CON. REDUCER
90 ELBOW
90 ELBOW
R 0
Sl. No. Unit Quantity
(1) (3) (4)
109
NOS 1
110
NOS 1
111
NOS 11
112 NOS 11
113 NOS 1
Description of item
DEPARTMENT
SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST
TYPE 1, SIZE 63MM
SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS
SCHEDULE OF ITEMS OF WORK
QUARTZOID BULB, 15 MM, MALE THREADED
PIPING
SPRAY NOZZLES AS IS 319 TYPE II & DATA SHEET, SIZE K40
WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM
(2)
CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS.
113 NOS 1
114 NOS 2
115 NOS 1
116 NOS 2
117 3
118 2
119 TM 10.5
120 NOS 2
121 NOS 1
E301- LPG HEATER- HORIZONTAL
DISMANTLING OF PUMPS
JOCKEY PUMP- VERTICAL- 1 TE APPR
WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR
HOSE BOX AS PER DATA SHEET
FACT ENGINEERING AND DESIGN ORGANISATION
DELUGE VALVE ASSEMBLY
P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR
JOCKEY PUMP- VERTICAL- 1TE APPR
INSTALLATION OF EQUIPMENTS
P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR
CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS.
FLANGED AS PER B16.5 , 150# , FF 100NB