Mounded Bullets LPG Terminal Reference Tender

EM163-MB-PNMV-CP-401
PROJECTS & DEVELOPMENT INDIA LTD
Document No.
SHEET 1 OF 1
1
Rev
PART-II : TECHNICAL
LPG MOUNDED BULLETS
TITLE
TECHNICAL SPECIFICATION FOR LPG MOUNDED

BULLETS.
PROJECT:
INSTALLATION OF LPG MOUNDED BULLETS AT NRL
CLIENT
NRL, ASSAM
05.10.2015
05.10.2015
ISSUED FOR ENQUIRY
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-MB-PNMV-PD-401
Document No.
Rev
SHEET 1 OF 3
PROJECTDESCRIPTION
05.10.2015
05.10.2015
ISSUED FOR ENQUIRY
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
Document No.
SHEET 2 OF 3
1
Rev
1.0 INTRODUCTION
1.1
Numaligarh Refinery Limited, (NRL) presently operates a 3 MMTPA refinery at

Numaligarh, District Golaghat, and Assam. The refinery commenced
commercial production in October, 2000. The project envisages construction of
4 Nos. of mounded bullets of capacity 1760.56 m3 ( 1000MT) each along with 1
No of Drain vessel and upon successful completion / construction of mounded
bullets existing 03 nos. of LPG Spheres and 01 LPG bullet will be dismantled up
to ground level.
1.2
M/s NRL have appointed Projects & Development India Limited (PDIL) for
EPCM services for installation of LPG Mounded Bullets at NRL Assam.
2.0
Site Location
Plant Location
: Numaligarh, Golaghat District
State / Country
: Assam / India
Nearest Railway Station
: Golaghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
Nearest National Highway
4.0
: NH-39
BRIEF SCOPE OF WORK
4.0.1
This document includes design & detailed engineering, preparation of

fabrication drawings, procurement & supply of all raw materials whatsoever
required to meet complete scope of supply, fabrication, post-weld heat
treatment, inspection, testing, coating/painting at site, site fabrication/erection/
installation on compact sand bed, assembly, welding, testing, post-weld heat
treatment of field joints, inspection & NDT, hydro-testing, calibration, cleaning,
coating/painting of field joints / internal surfaces / damaged surfaces etc as
applicable and installation of Cathodic protection system , requisite fire proofing
, supply & installation of related piping and instruments including mound and
other civil works for the LPG/ Mounded bullets, and requisite insert plates in the
RCC wall for pipe supports, supply of spares, guarantee (mechanical and
performance), pre-commissioning and commissioning in strict compliance with
the Specifications, applicable code, relevant drawings and documents enclosed
along with tender documents. This shall be read in conjunction with code,
specification sheet and other tender documents. The scope also covers supply/
fabrication of one number of Drain Vessel. In case of conflict between code and
tender document, the vendor shall contact PDIL/NRL for clarifications. As a
general rule the most stringent requirement shall govern.
4.0.2
Scope also covers obtaining statutory approval on engineering drawings,

design calculations and other related documents.
Allrightsreserved
Document No.
SHEET 3 OF 3
1
Rev
4.0.3
Carrying out route survey up to refinery and inside refinery whatsoever required
for over dimensional consignment (ODC), transportation of all equipment and
material to site including loading and unloading, storage, maintenance,
construction, installation, obtaining all necessary CCOE/PESO/statutory
approvals from concerned Government authorities as applicable. Precommissioning, commissioning including total project management and handing
over of mounded storage bullets and handling facilities on single point
responsibility basis.
4.0.4
Design, drawings, data sheets, specifications & other related documents for
review/approval from PDIL/NRL and issue of As-Built drawings shall be as per
Documentation Schedule.
Allrightsreserved
EM163-MB-PNMV-MI-401
DOCUMENT NO
REV
SHEET 1 OF 8
MASTER INDEX
NUMALIGARH REFINERY LIMITED
PROJECT
INSTALLATION OF MOUNDED BULLETS AT NRL,
ASSAM
TENDER DOCUMENT
FOR
INSTALLATION OF MOUNDED BULLETS
ON LSTK BASIS
AT
NUMALIGARH REFINERY, ASSAM
1
REV
05.10.15
REV DATE
05.10.15
ISSUED FOR ENQUIRY
VB/PK
NB/AKG
GC
EFF. DATE
PURPOSE
PREPD
REVWD
APPD
FORM NO:02-0000-0021F1 REV3

EM163-PNMV-401
All rights reserved
DOCUMENT NO.
1
REV
SHEET 2 OF 8
MASTER INDEX
Section No.
Description
PART-I : COMMERCIAL
PART-II : TECHNICAL
1
Process
Civil
Pressure Vessel
Instrumentation
Electrical
Piping
Construction
Project Execution Plan
General Guidelines For HSE
10
Vendor List
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
All rights reserved
DOCUMENT NO.
1
REV
SHEET 3 OF 8
Detailed Index of various Sections are as follows:

SECTION 1 OF 10 (TECHNICAL)
Process Engg.
Sl. No.
1
Description
Design Basis
Drg. / Doc. No.

EM163-45-DD-DB 101
No. of
Pages
12
Civil
Sl. No.
1.
2.
3.
4.
5.
Description
Scope of work
Drg. / Doc. No.
Design Basis
EM163-PNCV-SOW101
EM 163-PNCV-DB-101
Technical specification
EM 163-PNCV-TS-101
Civil scope drawing for mound
EM163-PNCV-TD-001
Pile Layout for Mound Tentative
EM163-PNCV-PL-001
No. of
Pages
19
9
22
1
1
Pressure Vessel
Sl. No.
Description
Drg. / Doc. No.
No. of
Pages
Cover Page
EM163-TS-401-00
Specification for mounded Bullets
EM163-TS-401
87
Specification for drain vessel
EM163-TS-301
72
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
All rights reserved
DOCUMENT NO.
1
REV
SHEET 4 OF 8
Instrumentation
Sl. No.
Document Description
No. of
pages
Document No. & Rev.
PART - A : General Documents

1.
PART - A, Front Sheet
2.
Technical Scope of Supply & Work for

Instrumentation
3.
Design Philosophy of Instrumentation
EM163-PNIN-7901-Part A
Rev. 1
EM163-PNIN-7901-TS
1
14
Rev. 1
EM163-PNIN-0701-00
23
Rev. 1
PART - B : Specifications for Supply of Field Instruments

4.
5.
6.
7.
8.
9.
PART - B, Front Sheet

Technical Enquiry Specification for
Guided Wave Radar (GWR non-TFMS)
Guided Wave Radar (GWR - TFMS)
Technical Enquiry Specification for Servo
Level Transmitter
Pressure Gauge
Pressure & Diff. Pressure Transmitter
EM163-PNIN-7901-Part B
Rev. 1
EM163-E-7047
18
EM163-E-7147
40
EM163-E-7052
40
EM163-E-7053
15
EM163-E-7044
17
10.
Technical Enquiry Specification for Safety

Relief Valves
EM163-E-7022
19
11.

Temperature Gauges
EM163-E-7058
17
12.

Magnetic Level Gauge
Displacer Type LT
EM163-E-7046
16
EM163-E-7148
15
13.
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
All rights reserved
DOCUMENT NO.
1
REV
SHEET 5 OF 8
PART - C : Specifications for Erection Materials

EM163-PNIN-7901-Part C
1.
PART - C, Front Sheet
2.
ENGINEERING SPECIFICATION FOR

INST. VALVES
ES-7337
3.

COMPRESSION FITTINGS
ES-7334
4.

SS TUBES
ES-7341
5.

PIPE FITTINGS AND ISOLATION
VALVES
ES-7340
6.

CABLE TRAY
ES-7335
7.

JUNCTION BOX & CABLE GLAND
ES-7338
8.

INSTRUMENT CABLE
ES7332
9.
INSTALLATION STANDARDS
(PRIMARY SKETCHES)
EM163-E-0720
Rev. 1
Rev 1
PART - D : BOQ
10.
PART - D, Front Sheet
11.
BILL OF QUANTITY FOR SUPPLY OF

INSTRUMENTATION ITEMS AND
ERECTION MATERIALS
EM163-PNIN-7901-Part D
Rev. 1
EM163-PNIN-BOQ-7001
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
All rights reserved
DOCUMENT NO.
1
REV
SHEET 6 OF 8
Electrical
SR NO.
DESCRIPTION
TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION
SYSTEM OF LPG MOUNDED BULLETS
NO. OF
SHEETS
32
LIST OF ATTACHMENTS
1
Data Sheet for Cathodic Protection system of LPG Mounded Bullet
TS- Basic Survey for Soil Resistant Measurement
TS- Transformer Rectifier Unit for CP System
17
TS- Remote Monitoring Unit of TR Unit for CP System
TS- Anode junction box for CP System
TS- Cathode junction box cum Test Station for CP System
TS-Cu/CuSo4 permanent Reference Electrode for CP System
TS- Reference Electrode ( Zinc) for CP System
TS- -Cables for CP System
10
TS - Monitor Jn. Box. for CP System
11
TS - PDB. for CP System
12
TS -Anodes for CP System
13
TS -Surge Diverter for CP System
14
TS -Solid State Polarisation Cell for CP System
15
TS - Earthing Jn. Box for CP System
16
TS - Monolithic Isolation Joint. for CP System
17
Master Vendor List for CP System
18
Make for Electrical Items. for CP System
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
All rights reserved
DOCUMENT NO.
1
REV
SHEET 7 OF 8
Piping
Sl. No.
1
2
Description
Cover Page
Drg. / Doc. No.

EM163-45-PNMPPS 100
EM163-45-PNMPPS 101 Rev 0
EM163-45-PNMPPS 102
EM00163-51110003 Rev 0
ES 6005
No. of Pages
ES 6006
Piping Material Specification & Valve

Material Specification
Minimum Allowable Nozzle Loadings for
Mounded Bullets
Equipment Layout Plan For Mounded
Bullet
ES-Inspection, Examination of Welding of
Piping
ES- Pressure Testing of Piping
ES- Leak Testing of Process Piping
ES 6007
ES 6010
15
ES 6011
10
ES- Qualification of Welding Procedure

and Welder Performance for Piping
ES- General Specification for Erection of
Piping
ES- Technical Notes for Pipes
ES 6101
11
ES- Technical Notes for Fittings
ES 6102
12
ES- Technical Notes for Flanges
ES 6103
13
ES- Technical Notes for Studs and Nuts
ES 6104
14
ES- Technical Notes for Gaskets
ES 6105
15
ES- Casing Insulators and End Seals
ES 6606
16
ES- Underground Piping
ES 6018
16
17
Tolerances for Fabricated Piping
PDS-P-001
18
Butt Welding End Preparation for Pipe

Joints
Joint Preparation for Pipe Branches and
Tees
Pipe Support -Standard Type and
Applications
Vent, Drain and Steam Trap Assemblies
Steel Ladder with Safety Cage
Hand Railing Details
PDS P 011
PDS P 012
PDS P 01-65
47
PDS P123
PDS ST 101
PDS ST 103
10
3
9
3
4
5
19
20
21
22
23
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
10
3
1
17
All rights reserved
DOCUMENT NO.
1
REV
SHEET 8 OF 8
Construction
Sl. No.
Description
1
Construction/Erection, Pre-commissioning,
Commissioning
Drg. / Doc. No.
No. of Pages
EM163-E-601 Rev 0
51
Drg. / Doc. No.
No. of Pages
EM163-PNPM-003
46
SECTION 8 OF 10 (PROJECT EXECTION PLAN)

General
Sl. No.
1
Description
Project execution plan, Planning,
schedule, monitoring, Control & inspection
SECTION 9 OF 10 (HEALTH, SAFETY & ENVIRONMENT (HSE)

General
Sl. No.
1
Description
General Guidelines For HSE
Drg. / Doc. No.

EM163-MB-ANNEXHSE
No. of Pages
Drg. / Doc. No.

EM-163/Mounded
Bullet/Vendor List
No. of Pages
30
86
SECTION 10 OF 10 (VENDOR LIST)

General
Sl. No.
1
Description
Vendor List
FORM NO: 02-0000-0021F2 REV2

EM163-PNMV-401
All rights reserved
EM163-45-DD-DB 101
Document No.
Sheet 1 of 12
Rev.
DESIGNBASIS
08.06.2015
08.06.2015
First Issue
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
DESIGN BASIS
INSTALLATION OF LPG MOUNDED BULLETS, NRL
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 2 of 12
CONTENTS
SN
Item
1.0
PREFACE
2.0
SITE METEOROLOGICAL DATA
3.0
PLANT DESIGN BASIS
3.1 LPG Composition
3.2 LPG Mounded Storage Facilities
3.3 Bullet Details
3.4 Normal Bullet Operation
3.5 Odorization
3.6 Very Dilute Caustic Draining from Bullet
3.7 LPG Pump Details
3.8 Corrosion Allowances
3.9 Pressure Safety Valve
3.10 Gas Detection system
3.11 Noise Criteria
3.12 Effluent Criteria
UTILITIES
a) Low pressure Steam
b) Service Water
c) Instruments Air
10
d) Inert Gas ( Nitrogen)
10
e) Plant Air
10
NUMBERING AND CODIFICATION
10
5.1 Equipments Identification
10
5.2 Piping Numbering
11
5.3 Instruments Numbering
11
CODES AND STANDARDS
11
6.1 Piping
11
4.0
5.0
6.0
Page No
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 3 of 12
6.2 Pressure Vessel
11
7.0
HAZARDOUS AREA CLASSIFICATION
12
8.0
UNITS OF MEASUREMENTS
12
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 4 of 12
1.0 PREFACE
Numaligarh Refinery Limited, (NRL) presently operates a 3 MMTPA refinery at
Numaligarh, District Golaghat, and Assam. The refinery commenced commercial
production in October, 2000.
This document presents the design basis to be used for the Installation of LPG
Mounded Bullets at Numaligarh Refinery Limited (NRL).
Mounded bullets provide intrinsically passive & safe environment & eradicates the
possibility of Boiling Liquid Expanding Vapor Explosion (BLEVE), through LPG handling
possess many challenges, due to its inherent dangerous properties, modern state of art
safety features has been taken into consideration while designing the facilities using
different OISD codes.
As handling of LPG in above ground vessel has many challenges due to its inherent
dangerous properties, NRL proposed to replace the old aboveground vessels with
mounded bullets of suitable capacity. New statues / guidelines suggest for mounded
bullets which proves to be safer compared to above ground storage vessels. The
project envisages construction of 4 nos. of mounded bullets of capacity 1760.56 m3 (
1000MT) each and upon successful completion / construction of mounded bullets
existing 03 nos. of LPG Spheres and 01 LPG bullet will be dismantled up to ground
level.
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 5 of 12
2.0 SITE METEROLOGICAL DATA
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
1.0
Barometric pressure
2.0
Normal ambient condition
3.0
4.0
: NH-39
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %
Maximum / Design Ambient condition

Air temperature
380C
Relative humidity
85 %
Minimum Ambient Air
50C (Min)
Temperature
5.0
6.0
Rain fall
Heaviest in a day
160 mm
Maximum in one hour
90 mm
Wind
Wind code
As per relevant IS code
Base wind pressure
7.0
Seismic Factor
As per IS: 1893 Seismic Factor - 0.04
8.0
Elevation
90 m above Mean sea level
9.0
Average wind speed
36 km/hr
10.0
Maximum gust speed
140 km/hr
11.0
Site conditions
Prevailing wind direction NE to SW
12.0
Precipitation Annual mean

Maximum/ hr
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 6 of 12
3.0 PLANT DESIGN BASIS

3.1
LPG Composition
Composition
Mole %
Mole %
Mole %( Average for Design)
C3
30
45
37.5
C4
55
70
62.5
H2S
< 10 ppm
< 10 ppm
< 10 ppm
PROPERTIES OF LPG
Designation
LPG
0
Design Sp. Gravity at 40 C
0.558 ( Simulated)
Vapour pressure at 10/-/40 0C , kg/cm2a
3.35/-/7.51( Simulated)
Design Viscosity, at 10/-/40 C Cp
0.152/-/0.113 ( Simulated)
3.2 LPG Mounded Storage Facilities

System Design as per OISD -150
Four ( 4) Mounded bullets of 7,042.24 m3 capacity total
LPG Run Down from Refinery
Line sizing & Piping class
6 & B1A
Receiving rate (T/hr)
13.04
Operating/ Design Temperature (0C)

2
Operating/ Design Pressure (Kg/cm a)

3.3
40/65
20.8/31.6
Bullet Details
Operating LPG storage capacity of each Bullet
1760.56m3
(Operating capacity considered as 85% level of the volumetric capacity of bullet)

Size
Length (TL~TL) 52m X Diameter 7 m
Operating / Design Pressure
8.6 /14.5 kg/cm2g
Design Temperature
(-) 27 to 55 0C
Material
CS (Refer to clause no. 5.1,ii,(a) OISD-150)
Internal bottom surface up to 90 degree shall be provided with a coating suitable for
caustic, water, and H2S dissolve in LPG.
Filling Rate
15.0075 T/hr( 15% Extra)
Pump out Rate ( max)
291 ( 267+27) m3/hr
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 7 of 12
3.4
Normal Bullet Operation

One mounded bullet is receiving mode,
One dispatch mode
Two for recirculation & certification mode
3.5 Odorization (Mercaptan Dosing Skid)

One Mercaptan Vessel (45-VV-105) having capacity of 200 L which is maintained by
positive pressure with N2.
Two nos. Mercaptan dosing pump (45-PA- -112 A/B) (1W+1S)).
The dosing rate is around 20 ppm.
3.6
Water Draining From Bullet

No. of Drain vessel
1 no. ( Vertical cylindrical vessel)
Design Pressure
14.5 kg/cmg
Design Temperature
(-27) 0C to 55 0C
MOC
CS
Capacity
0.5 m3
3.7 LPG Pump Details

Four nos. of LPG forwarding pump to be used.
Two nos. ( 45-PA-CF-101 A/B)(1W+ 1S) for loading gantry & two nos. ( 45-PA-CF-102
A/B) (1W+1S) pump for bottling plant.
3.8
Corrosion Allowance
Internal Corrosion Allowance: 3 mm (minimum).
3.9 Pressure Safety Valve

Each vessel shall have at-least two Safety Relief Valves (SRV).
The full flow capacity of each SRV on mounded vessel(s) shall be minimum 30 % of
the capacity required for an equivalent size of above ground vessel.

The discharge of SRVs shall be connected to existing flare system.
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 8 of 12
3.10 Gas Detection System

Suitable gas detectors Infrared type shall be placed at critical locations in the LPG
storage area such as near the ROVs, and all pumps in inspection tunnel or dome
connection, near water draining/ sampling points.
First level alarm shall be set at 20% of Lower Explosive Limit (LEL) and second level
alarm at 60 % of LEL.
3.11 Noise Criteria
a) Nearby equipment
The maximum allowable noise level nearby equipment shall be 85 dB within one
meter from the equipment, during normal operation and with control valves in line.
b) Near Working Environment
Overall noise level in the working environment shall be below 85dB at 1m.
c) Outside plant limit
The average noise level shall be 60 dB at 100 m from the boundary of plant.
3.12 Effluent Criteria
Gaseous Effluent
Details of existing flare header (Bullet header to be connected with existing header)
Size of existing flare header
24
Operating/Design tem. of flare header
Amb / ( 65 /-27 0C )
Operating/Design Press. of flare header
0.2-1.7/4.5 Kg/cm2g
Normal/Max Back Press
- /1.7Kg/cm2g
Existing load of flare header
162029 Kg/Hr
Installation of mounded bullets for the fire case load comes out 62161 Kg/Hr with
molecular weight 52.8.
All PSV/ TSV discharge shall be routed to the new flare header which will be
connected to existing flare header.
Liquid Effluents
Water coming with LPG shall be drained to drain vessel, and any dissolve LPG in
drain water shall be vented to flare in vapour form and water is drained to a Shallow
Sump (RCC) & finally to the storm sewer.
LPG pump drain is to be connected to drain vessel (45-VV-106), so that LPG in
vapour form is vented to Flare Header.
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 9 of 12
In view of above, no effluent is sent to Existing Effluent Treatment Plant & hence Load
of Existing Effluent Treatment Plant is not increased.
Hence Existing Effluent Treatment Plant is Adequate due to Installation of Mounded
Bullets.
In Drain Vessel vent and drain valve normally are to be kept in closed condition. For
draining water from bullets, deadman type valve to be opened closely watching level
gauge in the drain vessel. When LPG comes along with water. There will be two layer
visible in the level gauge (Interface Float Type ) draining to be done slowly very
carefully and initially from time to time water is to be drained to shallow sump, If any
LPG visible in the level gauge . Then same to be vented in the flare before opening
draining valve of the drain vessel.
4.0 UTILITIES
a)
LP Steam :The Minimum, operating and design conditions for low pressure steam shall be as follows
b)
Design temperature
200 0C
Design pressure
7.5 Kg/cm2g
Operating temperature
165 0C
Operating pressure
4.0 Kg/cm2g
Minimum temperature
155 0C
Minimum Pressure
3.5 Kg/cm2g
Service Water :The Minimum, operating and design conditions for service water stream shall be as follows
Design temperature
650C
Design pressure
8 Kg/cm2g
Amb.
Operating pressure
4.5 Kg/cm2g
Minimum temperature
Amb.
Minimum Pressure
4.0 Kg/cm2g
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 10 of 12
c)
Instruments Air :The Minimum, operating and design conditions for instrument air stream shall be as follows
d)
Design temperature
65 0C
Design pressure
11.5 Kg/cm2g
Amb
Operating pressure
6.5 Kg/cm2g
Minimum temperature
Amb.
Minimum Pressure
4.5 Kg/cm2g
Dew Point
-15 0C at 7.5 kg/cm2a
Inert Gas ( Nitrogen) :The Minimum, operating and design conditions for inert gas (Nitrogen) stream shall be as
follows
e)
Design temperature
65 0C
Design pressure
10 Kg/cm2g
Amb
Operating pressure
3.5 Kg/cm2g
Minimum temperature
Amb
Minimum Pressure
3.0 Kg/cm2g
Plant air :The Minimum, operating and design conditions for plant air stream shall be as follows
5.0
Design temperature
65 0C
Design pressure
11.5 Kg/cm2g
Amb
Operating pressure
6.5 Kg/cm2g
Minimum temperature
Amb
Minimum Pressure
4.5 Kg/cm2g
NUMBERING AND CODIFICATION
5.1 Equipment Identification

The new equipment will be numbered using the 100 series.
Philosophy for Equipment Tag no.:
Unit No. - Equipment Code Seq. No.
Ex.
45-VV-101
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 11 of 12
5.2
Piping Numbering
New piping will be numbered using the 3000 series; pipe class will be as per existing
piping material specification.
Philosophy for Line Tag no. :
Line size - Fluid- Line No. Unit no. - Pipe class - Insulation class
Ex.
5.3
6 P 45-3001 -B1A-N
Instruments Numbering
New instrument will be numbered using the 3000 series.
New instruments indicators / controls / interlock / shall be hooked up by NRL in the
New/ Existing DCS / PLC.
Philosophy for Instruments Tag no.:
Area Code- Item Code - Item No.
Ex.
Level Transmitter 45 - LT -3001
6.0 CODES AND STANDARDS
The system will be designed in accordance with the latest addition of the codes and
standard.
List of codes and standards
6.1
ANSI
American National Standard Institute
OISD
Oil Industry Safety Directorate
API
American Petroleum Institute
ASME
American Society of Mechanical Engineers
IBR
Indian Boiler Regulation
Piping
All process piping shall be in accordance with as per existing PMS.
6.2
Pressure Vessel
All pressure vessels shall be in accordance with ASME section VIII div1/2.
Allrightsreserved
DESIGN BASIS
REFINERY
EM163-45-DD-DB 101
Document No.
Rev.
Sheet 12 of 12
7.0 HAZARDOUS AREA CLASSIFICATION

Hazardous Area classified as Zone 1: Gas Group IIA IIB, Temp. Class-T3
8.0
UNITS OF MEASURMENT
The MKS system of units must be used in all engineering documentation and on
drawings with the exception of the following measurements, which must adopt the
stated preferred units.
The following units of measurements should be applied:
Temperature
[C]
Pressure
[kg/cm2g]/ bar
Volume
[m3], [l]
Length/Diameter
[m], [mm]
Mass or Weight
[kg], [ton]
Volume( gases)
[Nm3], [kmol]
Flow Rate( volume)
[m3/h], [Nm3/h],
Flow Rate(mass)
[kg/h],
Velocity
[m/s]
Energy
[KCal]
Heat Capacity
[kCal/kg C]
Density
[Kg/m3]
Allrightsreserved
EM163-PNCV-TD-101
DOCUMENT NO
SHEET 1 OF 2
0
REV
CIVIL AND STRUCTURAL WORKS

(FOR COMPOSITE TENDER)
FOR
AT
CLIENT: NRL
CONSULTANT: PDIL
0
P
REV
18.09.2015
11.08.2015
REV DATE
18.09.2015
11.08.2015
EFF DATE
FORM NO: 02-0000-0021F1 REV2
ISSUEDFORIMPLEMENTATION
ISSUEDFORREVIEW
PURPOSE
RRB
RRB
PPD
TP/VP
TP
REVWD
BRIJESH
BRIJESH
APPD
All rights reserved
TENDER DOCUMENT
FOR CIVIL & STRUCTURAL WORKS
FOR INSTALLATION OF MOUNDED BULLETS
AT NRL, NUMALIGARH
EM163-PNCV-TD-101
0
DOCUMENT NO
REV
SHEET 2 OF 2
CONTENT
SL. No.
DESCRIPTION
DOCUMENT NO.
1.0
SCOPE OF WORK
EM163-PNCV-SOW-101
2.0
DESIGN BASIS
EM 163-PNCV-DB-101
3.0
TECHNICAL SPECIFICATION
EM 163-PNCV-TS-101
4.0
CIVIL SCOPE DRAWING FOR MOUND
EM163-PNCV-TD-001
5.0
PILE LAYOUT FOR MOUND (TENTATIVE)
EM163-PNCV-PL-001
FORM NO: 02-0000-0021F1 REV2
All rights reserved
SCOPE OF WORK
FOR CIVIL & STRUCTURAL WORK
INSTALLATION OF LPG MOUNDED BULLETS
AT NRL,ASSAM
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 1 of 19
SCOPE OF WORK
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.

AT NRL,ASSAM
Page 2 of 19
CONTENTS
S.No.
DESCRIPTION
SHEET No.
1.0
SCOPE OF WORK
2.0
DETAILED SCOPE OF WORK
3.0
DESIGN ENGINEERING
SPECIFICATIONS
12
4.0
DESIGN CALCULATIONS, DRAWINGS

AND DOCUMENTS
13
5.0
PREAMBLE TO SCHEDULE OF WORKS
16
6.0
SITE CLEANING
19
7.0
COMPLETENESS OF WORK/CONTRACT
20
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
AT NRL,ASSAM
1.
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 3 of 19
SCOPE OF WORK:
The scope of complete Civil, Structural and other Allied Works associated with
Installation of Mounded Bullets at Numaligarh refinery limited, Numaligarh shall
be design, detailed engineering, preparation of working drawings and getting
these checked and vetted by Owner/Consultant, supply, erection and construction
of structures & utilities. The scope also includes providing necessary engineering
supervision through qualified and technical personnel, skilled and unskilled
labour, material, tools & tackles etc. The scope of work also includes disposal of
debris/surplus earth & unserviceable materials at designated area outside refinery
premises as per directions of Engineer-in-charge.
1.1 All civil works shall be carried out both below and above ground level strictly in
accordance with the Scope of work, Design basis for civil & structural work,
Technical Specifications for civil, structural & other allied work, relevant IS Codes
& CPWD specifications. The scope of work shall also be read in conjunction with
other attachments of tender documents including tender drawings.
1.1.1 The Order of priority of documents for specifications of materials and
workmanship shall be as follows:
a)
Approved drawings
b)
Scope of work
c)
Technical specifications for civil, structural works etc; as per the

requirements of specific items.
d)
Bureau of Indian Standard Codes (BIS Codes) with latest amendments &
OISD.
e)
Indian Road Congress (IRC) for road works and Central Public Works
Department (CPWD) for other works with latest amendments
1.1.2
Each of the above mentioned documents shall be supplementary to others and

in
case, description is found inadequate or incomplete or having missing
details in one, reference shall be taken from other documents to make it

complete to complete satisfaction of Owner/ Consultant.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.

AT NRL,ASSAM
1.2.
Page 4 of 19
The complete civil, structural and allied works associated with the Installation
of Mounded Bullets at Numaligarh refinery limited, Numaligarh shall be, but
not limited, to as below:
i)
Mound for 4 Nos LPG storage vessels (LPG bullets) supported on RCC
Pile Cap along with RCC inspection trench, retaining wall, collection pits,
stair case as shown and detailed in enclosed drawings including
installation of bullets in position.
ii).
Foundations and supporting structures for firefighting system.
iii).
Pipe sleepers are to be provided as required.
iv).
RCC peripheral water drain shall be provided all around the mounded
bullet foundation after 1.0 m(min.)x 100mm thk. ( min.) plinth protection.
The size of drain shall be 500 x 600 mm depth having precast cover with
pot holes. The drain shall be suitable designed to connect with the existing
drain of the plant. If required collection pit/manhole shall be considered as
per codes. Storm water drains of min. 600mm width running along the
mound and connected to existing storm water drain.
v).
Barricading for isolation of mound during construction shall be done by

others.
However, all the HSE requirements as per good engineering practice/
OISD Norms have to be strictly followed
vi).
Dressing and cleaning off areas.
vii).
Hooking up jobs as per requirement.
viii).
Removal, Transportation & disposal of surplus material, debris &

unserviceable material at designated area outside or inside refinery
premises as per discretion of Engineer-in-Charge/Owner.
ix).
If required micro grading of mounded bullet storage area to level as

directed by Owner/Engineer-in-charge.
x).
Stripping & rebuild of existing piles required for pile cap shall be in scope of
Contractor including construction of pile cap.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
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AT NRL,ASSAM
Page 5 of 19
xi).
Procurement of all items necessary for completion of scope of work.
xii).
Construction of all units / structures, items of work included in scope of

work.
xiii).
1.3
Statutory Approvals
The following points must be noted and taken into consideration by the
contractor:
a)
All Engineering including preparation of fabrication drawings, BOQ/MTO,

Vendor drawings & bar bending schedule is in contractors scope.
b)
Contractors have to comply with all statutory and regulatory guidelines

like OISD, CCOE, TAC, refinery safety norms and rules and regulations
of local authorities.
c)
All sources of danger from live electric wire, flooding, caving etc. should
be effectively checked.
d)
The construction shall comply to all fire proofing requirements as per IS:
164. Besides, fire protection and safety requirements as per stipulations
of OISD: 150, OISD: 116, OISD: 144, OISD: 118 shall also be complied
to.
e)
Construction water, within plant shall be provided to contractor as per

relevant stipulations mentioned elsewhere in tender documents.
f)
Construction Power shall be arranged by the provided by Client inside

NRL premises at his own cost.
g)
Supply of all materials shall be in Contractors scope.
h)
Local fire barriers shall be used as per instruction of Engineer- In- Charge
in line with Operation/ Production requirement.
i)
All concrete surfaces in superstructure are to be coated with protective

coating Dekguard S of FOSROC or equivalent as per manufacturers
specifications.
j)
All steel structures are to be treated with coats of primer and finish paints
as per painting specifications specified or manufacture specifications.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
AT NRL,ASSAM
k)
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 6 of 19
Cement brands shall be procured from approved vendor list enclosed

along with the tender document.
l)
The design calculations, besides other standards, shall also comply

OISD: 150 stipulations.
m)
Suitable chemical anchors & bolts of HILTI make or equivalent shall be used
for facilitating connections & joinery as per requirement.
2.0
DETAILED SCOPE OF WORK:

MOUND:
Refer attached tender drawing (Drg. No. EM163-PNCV-TD-001 Rev. 0) for
dimensions & type of mound.
2.1
SPECIFICATIONS FOR MOUND MATERIALS:
2.1.1
SAND BED:
The sand for the bullet bed, bullet surround and filling between bullets shall
consist of material complying with the following specifications:
i).
Good quality clean, non-aggressive sand with a maximum organic

material content of 3% by weight.
ii).
A maximum silt content of 10% by weight (particles smaller than 0.063

mm).
iii).
A maximum particle size of 5 mm.
iv).
A grain size distribution having Uniformity Coeff. (D60/D10) between 2 &

8.
2.1.2
SAND SURROUNDING BETWEEN BULLETS:

a.
These shall have same specifications as mentioned in Cl. No.2.1.1.
b.
Sand filling placed between bullets and line extending out at 45o from the
center of the bullet above the bullet center line shall be hand compacted
and fill placed outside this line shall be machine compacted (both to a
minimum of 95% maximum dry density).
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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SCOPE OF WORK
AT NRL,ASSAM
c.
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 7 of 19
Compaction shall be sufficient to avoid significant settlements of the sand

filling / mound surface but shall be such as not to impose undue stresses
on the tanks.
d.
The sand filling shall be placed equally, in maximum 200 mm layers

(uncompacted depth), on each side of the tanks so as to avoid any lateral
displacement / rotation of the tanks during compaction.
e.
Sand filling shall be brought up to the levels and slopes as denoted on the
drawings to below the drainage layer.
2.1.3
PEA GRAVEL:
The pea gravel shall be surrounding perforated PVC drain these shall consist
of clean washed, size varying from 6 to 12 mm (average size 8 mm) round
stone free from all organic matter, dust or any other deleterious material.
2.1.4
NON-WOVEN GEOTEXTILE:
a. Non woven geotextile sheet TERRAM 1000 or equivalent shall be used for
separating two different material layer. A layer is to be provided between
stone finish and UPVC layer as shown in drawing. (Drg. No. EM163-PNCVTD-001 Rev. 0).
b. The textile shall be laid carefully to avoid damage/ tearing etc. Minimum 300
mm overlap is to be maintained at the junctions of two rolls.
2.1.5 UPVC SHEET:

a. 1.2 mm thick UPVC sheet as per BIS-2076 of Finolex brand or equivalent
shall be provided over the sand mound to prevent water percolation into
mound. It shall be laid at the mound slope. Contractor has to take care
about water tight stitching of the joints by providing minimum 300 wide
lap.
b. The contractor has to submit the manufacturers test certificates showing
compliance with relevant BIS specifications.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
AT NRL,ASSAM
2.1.6
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 8 of 19
PERFORATED PVC PIPES:

Perforated PVC pipes as per BIS-4985 (laying as per BIS-7634, Part- III),
rating 6 Kg/cm2 shall be placed to
collect water. It is to be laid above UPVC
sheet. Min. slope to be maintained is 1:100. These pipes shall be surrounded

with pea gravel with size from 10 to 20 mm.
2.1.7 STONE PITCHING:
The sand mound slope is to be protected with stone pitching 300 thk. on
inclined surface and 200mm thick
on other places on 75 thick 1:6 cement
mortar. The voids between boulders shall be filled with 1:6 cement mortar. The
top shall be flush pointed neatly with 1:6 cement mortar to give aesthetic view
of the mound. Proper drainage arrangement shall be made to carry
water
from the outlet of perforated pipe to the drains.

2.1.8 STONE / CEMENT CONCRETE BLOCK FINISH:
The top layer of the mound shall be finished with 200 thick (min.) stone layer 10
to 50 mm size over 200 thick. clean washed pebbles of size 10 to 40 mm laid
over the geotextile sheet or cement concrete block of 450x450x 200mm size of
grade M25 over geotextile sheet as per relevant specification.
2.1.9
RETAINING WALL:
An all round RCC retaining wall shall be provided in around mounds. The height
shall be as per attached drawing. The inside face of wall shall be vertical and
outside face shall be tapered as per design requirement. One all around storm
water channel on top of retaining wall as shown in drawing is to be provided
with sufficient no. of suitable no. of CI pipes ( as per CPWD specifications ) for
disposal of rain water to nearest drainage system. 100 dia GI pipe sleeve weep
holes laid with downward inclination are be provided at a height of 300 mm
above ground at a spacing of 2500 mm (min.)for dissipating rain water during
construction period in all retaining walls. Suitable expansion joints as per
standard engineering practices shall be provided in retaining walls as per
requirements. Insert plates on outer and inner faces of retaining wall as per
requirements shall be provided. The sub surface water shall not be allowed to
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.

AT NRL,ASSAM
Page 9 of 19
enter bullet mound and underground collection pits as shown in drawings shall
be provided to prevent entry for the same.
2.1.10 STEPS & STAIRCASES:
All retaining walls are to be provided with RCC staircase as per standard
engineering practices. RCC steps in M-30 grade are to be provided for
negotiating from top of retaining wall to mound top. These steps shall be cast
along with 100 thick RCC base. The desired tread and risers shall be 250 & 150
mm. The width of staircase & steps shall be 1500 mm. M.S. hand rails as per
details shown are to be provided on both sides.
2.1.11 COLUMNS ON TOP OF MOUND;
If some utility and flare lines are to be laid above mound. Columns supporting
these shall be of RCC, to be suitably anchored to sand bed. Some of these
columns may have to be supported directly on retaining wall and necessary
provision in design/ detailing shall be kept for the same.
2.1.12 RCC TRENCH
RCC trenches of height 2.0m( min.) X 1.7m width (min.) are to be provided for
each bullet as shown in tender drawing. Outlet nozzles (pipes) shall be placed
off centre in this trench. The level of raft of the trench shall not be less than
pavement level. Elastometric bearing (Neoprene padding) as per IRC: 83 shall
be placed at contact surface of top slab and bullet shell to protect bullet shell.
The minimum thickness of neoprene padding shall be 150 mm. The height of
trench shall be sufficient, so that a person can move easily. This can be
reduced near bullet shell by making local adjustment. All trenches shall have
provision of double panel steel doors, openable from outside. These shall be
fixed in retaining walls. The steel doors shall be made with fabricated steel
sections with M.S. sheeting on both faces. While fabricating, the shape of door
shall be designed, keeping in mind, that stability of outlet pipe is not disturbed
due to its operation. Locking arrangement from outside shall also be provided in
doors.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.

AT NRL,ASSAM
Page 10 of 19
a. The floor shall be 250 mm thick heavy duty RCC floor with two layer of
reinforcement placed at centre in both directions with 25 thick IPS toppings.
b. Arrangements for operational HOT Crane shall be kept (if required).
2.2
FIRE FIGHTING :
Generally, new pipelines for firefighting as per details mentioned in other parts of
enquiry documents are to be laid. The main pipelines shall be laid on pipe sleepers.
The height of sleepers above FGL shall be as per functional requirements.
Shielding walls for Deluge valve shall be of RCC-200 mm thick. Cross overs &
platforms for valve operation shall be provided as per requirements. These shall be
of structural steel. Hand rails on both sides of stairs and all round for platforms shall
be provided. The foundation system shall be shallow foundation. For fire water lines
laid on top & sides of mound, RCC pedestals with minimum 500 mm deep
anchorage shall be used.
2.3
PIPE SLEEPERS
Pipe sleepers shall be provided for supporting various utilities. The foundation
system shall be shallow foundation. The length, height and width of these shall be
as per functional requirements. Modification in existing pipe sleepers, construction
of new supports, consequent to relocation of some of utilities or otherwise are also
included in scope.
3.0
DESIGN ENGINEERING SPECIFICATIONS
3.1
GENERAL
3.2
The design considerations given here under indicate the minimum basic
requirements of reinforced cement concrete, brick masonry and structural steel
works. However, all structures shall be designed as per relevant IS code of
practices and according to standard practices for the satisfactory performance of
the functions for which the same are to be constructed.
3.3
Whenever any reference to IS Codes is made, the same shall be taken as the latest
revision with all amendment issued therewith at the time of execution.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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SCOPE OF WORK
AT NRL,ASSAM
3.4
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 11 of 19
Apart from the IS Codes mentioned in particular in the various clauses of this
specification, all other relevant codes related to the specific job under consideration
and / or referred to in the above mentioned codes shall be followed wherever
applicable. Reference to some of the codes in the various clauses of this
specification does not limit or restrict the scope of applicability of other relevant
codes.
3.5
In case of any variation / contradiction between provisions of IS Codes and the

specifications given hereunder, the provisions given in these specifications shall be
followed.
3.6
Following features shall also be considered while designing & detailing
3.6.1 The foundation of mound, pipe / cable rack trestles etc; shall be supported on RCC
bored min. 450mm dia. vertical piles. Miscellaneous foundations such as trenches,
pipe supports, etc., may rest on cohesive non-swelling soil. For Shallow foundation,
footing shall be designed as per Net Bearing Capacity of soil at a suitable depth
below the Original Ground Level as specified in soil report.
3.6.2 Other related parameters such as soil profile, design depth of water table, type of
foundation and anticorrosive treatment for underground concrete works in view of
the pressure of harmful chemicals in soil and subsoil water, recommendation of soil
investigation report shall be followed. If the soil and subsoil water is corrosive,
necessary precautions shall be taken care of for all concrete work / surfaces in
contact with the soil either as per the recommendations of IS : 456 or by providing
necessary treatment depending upon the nature of corrosiveness of soil at the
proposed site.
3.6.3 Care shall be taken to avoid any fouling of foundation with adjacent existing
foundations of buildings / structures and suitable adjustment in depth, location and
sizes may have to be done depending on the actual condition prevailing at site. No
extra claim for such adjustments will be acceptable by the Owner/Consultant.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.

AT NRL,ASSAM
4.0
4.1
Page 12 of 19
DESIGN CALCULATIONS, DRAWINGS AND DOCUMENTS

The contractor shall design all civil and structural
works and prepare all the
required civil and structural Drawings needed for correct and accurate construction.
The design shall comply
with the Design Basis doc. attached elsewhere in the
tender document. The accuracy and correctness of design engineering and

preparation of drawings shall be the sole responsibility of the Contractor and any
loss / damage incurred by the Owner in respect of any mistake / discrepancy /
anomaly in such designs and Drawings shall be entirely borne by the Contractor.
4.2
All design engineering and preparation of Drawings shall be carried out by the
Contractor in their own design office. If such facilities are not available with the
Contractor, it shall be done by an established agency that has done similar type of
jobs and mounded bullet in particular. The name of such agencies, with their
credentials who may be considered for entrusting with the above design and
preparation of drawing works, shall be submitted along with the offer for approval
of Owner/Consultant. If none of the agencies so named is approved, the
Contractor shall submit a fresh list for approval.
4.3
All Drawings shall be of standard sizes and prepared in ink in metric units showing
dimensions in millimeters and elevations / levels in meters. Drawings shall
indicate quantities of concrete grade wise and or nominal mix wise, reinforcement
bars diameter wise and structural steel section wise and or thickness wise as
detailed therein.
4.4
The Contractor shall submit requisite number of prints (as mentioned elsewhere)
of the supporting design calculations along with explanatory notes / sketches,
computer inputs & outputs and Drawings (complete in all respects) to
Owner/Consultant for review and checking purposes. All the above design
calculations and Drawings submitted by the Contractor shall be completed in all
respects and thoroughly checked, approved, stamped as "Approved for
Construction" and signed by the Contractor's
authorized representative
(irrespective of the fact that whether the same are prepared in the Contractor's
own Design Office or by an Approved Agency to ensure accuracy and
correctness) therefore submission to the Owner/Consultant. Incomplete,
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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DOC. NO.
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Page 13 of 19
unchecked and unsigned Drawings and design calculations shall not be accepted
for review / checking and will be returned forthwith.
4.5
The Contractor shall submit a schedule for release of Drawings made in line with
the time schedule given elsewhere.
4.6
The design calculations and drawings prepared for this works shall have to be
checked and approved by the Owner/Consultant as per mutually agreed time
schedule and the Contractor should strictly adhere to these approved drawings
and specifications. Construction work shall be
carried out only with the approved
drawings and specifications. Correctness / soundness of the designs / drawings

and their execution at site shall be the sole responsibility of the Contractor
irrespective
of
the
fact
whether
the
same
has
been
approved
by
Owner/Consultant or not. Any defect, observed during construction or during the

defect liability period of works, shall be rectified and removed by the Contractor.
The Contractor shall carry out whatever modification or reconstruction is needed
for the purposes, to the entire satisfaction of the Owner/Consultant without any
extra cost to the Owner. But this will not in any way absolve Contractor of the final
responsibility for fulfillment of all Guarantee Clauses specified elsewhere.
4.7
The Contractor shall indicate the names of the computer software to be for drafting
and analysis / design work. The Contractor shall get the approval of the
Owner/Consultant for the computer software's prior to their use. The Contractor
shall forward to Owner/Consultant four prints of design calculations and
Drawings preferably for the whole work at a time along with all the concerned civil
scope Drawings and load data sheets.
After reviewing the above design
calculations and drawings, Owner/Consultant will send comments to the

Contractor within four weeks time from the date of receiving the above. The
Contractor will send their designer, if required, to Consultant's office at Noida for
clarifications / modifications / incorporation's and to finalize designs /drawings
across the table. The design calculations and Drawings for each independent
building / structure along with scope / load data shall be submitted by the
Contractor in one lot so as to facilitate systematic
review
checking
and
approval. The contractor shall start submitting such first set of design calculations
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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SCOPE OF WORK
AT NRL,ASSAM
EM163-PNCV-SOW-101
DOC. NO.
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Page 14 of 19
and Drawing within thirty days from the date of issue of Letter of Intent and
complete the submission of the same for all the items / units to Consultant's Office
within the period mutually agreed upon depending on the volume of job. Any delay
in submission of design calculations and / or Drawings with complete data and
getting the same approved from Consultant shall not absolve the contractor of
their responsibility to complete the work within the completion time.
4.8
If at a late stage, the contractor feels the necessity for any addition or alteration,
prior approval of Consultant must be taken for effecting the changes. The
contractor shall also be bound to incorporate any addition and alteration, which
Owner/Consultant may suggest at a later stage.
4.9
At any stage of work Owner/Consultant may review and offer comments /

suggestions on the layout, structural schemes, designs and / or Drawings
prepared by the Contractor and the latter shall adhere to such comments /
suggestions and revise his designs / Drawings accordingly and incorporate the
same in the construction without any extra cost to the Owner. The contractor
shall carry out whatever modification or re-construction is needed for the
purpose, to the entire satisfaction of the Owner/Consultant without any extra
cost to the Owner.
4.10
Contractor shall submit all deliverables like design, construction drawings,

vendor drawings, fabrication drawings, design mix etc to Owner/Consultant.
The Consultant shall review and drawing will be released with following code
status:
Code-1: Reviewed, No Comments
Code-2: Reviewed as Commented, but revised drawings documents required
Code-3: Not meeting the specifications, resubmit
Code-4: Retained for information/records.
General Plans, Elevations, and Sections of all Civil Engineering Works.
4.11
Detailed working Drawings of Civil Structures together with design calculation

sheets, fabrication Drawings and Bar Bending Schedule.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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SCOPE OF WORK
AT NRL,ASSAM
4.12
EM163-PNCV-SOW-101
DOC. NO.
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Page 15 of 19
After the completion of erection and construction work, the Contractor shall
submit to the Consultant six prints each of the "As built " Drawings along with two
sets of reproducible and one compact disk(CD) of approved brand containing
drawing prepared in Autocad Latest Version.
5.0
5.1
PREAMBLE TO SCHEDULE OF WORKS

The plans have been evolved tentatively based on information available with
Owner/Consultant, and the dimensions and details etc. are liable to changes.
The bidders shall not be entitled to claim any higher rate or compensation on this
account. The contractor may come out with a better-proven design which may be
executed with prior approval of Owner/Consultant. However for this contractor
cannot claim higher rate or ask for extra time. The job is to be completed within
the scheduled time to the satisfaction of Owner/Consultant as per specification.
Drawings are intended mainly to give an indication of the probable type of
construction. The successful bidders will however, be required to submit detailed
design engineering and drawings for approval from Owner/Consultant. The job
should not start without prior approved drawings.
5.2
The bidders shall be fully responsible for the correct setting out and execution of
the work in accordance with approved drawings. Deviations from approved
drawing shall not be allowed. Any such deviations to be rectified by the
contractor at his own cost without any liabilities to owner. All tools, tackles,
construction equipments etc. shall be responsibility of the bidder.
5.3
For obtaining the preliminary approval prior to drawings at least three copies of
each drawing shall be sent. One copy of this preliminary approved drawing duly
corrected and signed wherever necessary will be returned to the contractor for
preparing and resubmitting drawings in 3 copies for final approval.
5.4
The Contractor shall furnish detailed design calculations in spread sheet

indicating all assumption, codal references and load calculations etc., For
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
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DOC. NO.
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fabrication drawing they have to submit the design of all joints for full strength. All
calculations to carried out as per relevant IS codes.
5.5
The successful bidders shall be required to supply detail construction

methodology prior to start of construction of bullet mound for approval. Sequence
of construction on the basis of detailed design drawings to be submitted by
contractor for approval.
5.6
The LSTK rates to be quoted are to be fully inclusive of the value of the complete
work described under several items including all costs and expenses which may
be required in and for the construction of the work described together with all
taxes, general risks, liabilities and obligations (e.g. temporary buildings, fencing,
watching, lighting, insurance, labour regulations, indemnity, maintenance and the
like). The prices are to be inclusive of all labour, materials, tools, plants,
equipments, hoists, tackles, scaffoldings, and the sundries etc. as may be
necessary for the full and entire completion of the work in all respects.
5.7
Materials: The procurement of all materials shall be the responsibility of the

contractor. The quality of the materials procured by the contractor shall be
subject to the approval of Owner/Consultant or its authorized representative
before the materials are allowed to be used in the works. All the materials to be
procured by the contractor shall be in conformity with the I.S. codes and in the
absence of which as laid down in the relevant CPWD specifications.
5.8
Materials like sand, gravel, boulders etc. are to be procured from queries
approved from Owner/Consultant. Fulfillment of all necessary statutory rules like
taking permission from mines department and payment of royalty is to be
arranged by contractor.
5.9
Transport of all materials shall be the contractors responsibility and it shall be at

their own risk and cost.
5.10
Tests: According to the nature and importance of works owner shall demand the
conduct of tests on concrete materials and steel etc. in which case the contractor
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
AT NRL,ASSAM
EM163-PNCV-SOW-101
DOC. NO.
REV.
Page 17 of 19
shall get the same done at his own cost in a laboratory to be approved by
Owner/Consultant.
5.11
Providing and operating necessary measurements and testing devices: material

and consumable are included in the scope of work and the LSTK rates quoted
shall be deemed to include the cost of such tests which are required to ensure
achievement of specified quality of work.
5.12 No part of work shall be sublet without written permission of Owner/Consultant.

All sub contractors shall have to be approved by Owner/Consultant.
5.13 Notwithstanding the subdivision of enquiry documents into separate sections and
volumes along with attached drawings, every part of each shall be deemed to be
supplementary to and complimentary of every other part. All these are to be
read in totality. If there is any variance or discrepancy found, more stringent as
interpreted by Owner/Consultant shall be considered for execution of work.
5.14
No work shall be undertaken at site until detailed approved drawings have been
approved by Owner/Consultant in writing. Subsequent revisions in the drawings
which become necessary shall be incorporated and to be submitted by the
contractor to Engineer-In-Charge for approval. Revision work at shall not
commence unless the revised drawing is approved by Owner /Consultant.
Nothing extra shall be paid on this account and no claim whatsoever will be
entertained on this account and also no extension in the completion time should
be allowed for these changes. Owner/Consultant reserves to themselves the
right to modify/revise/alter etc. the scope supplied to contractor.
5.15
Any fabrication / construction done before final approval of the drawings shall be
the contractor's responsibility.
5.16
No compensation for any damage done by rain or traffic during the execution of
the work shall be made by Owner/Consultant.
5.17 The portion which is under "HOLD" shown in the approved drawing, the
construction of that the portion would be kept under "HOLD". For clearing the
HOLD the contractor has to submit the drawing with revision for approval of
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
EM163-PNCV-SOW-101
DOC. NO.
REV.

AT NRL,ASSAM
Page 18 of 19
Engineer-In-Charge. The contractor can execute only after the said "HOLD" is
withdrawn and Engineer-In-Charge has approved it. The contractor on this
account shall not be entitled to claim for any compensation.
5.18 The work shall have to be so arranged, planned and programmed as to complete
all work within the schedule time. Bidder shall have to strictly adhere to time
schedule.
5.19
The contractor shall prepare and get approved from Owner/Consultant, the bar
bending schedule for all reinforced cement concrete work as per detailed
drawings furnished by them.
5.20
All tools & tackles, inspection instruments, machineries, equipments and

transports etc. required in connection with this work shall be the Contractor's
responsibility.
5.21
Regular testing of cements at site:
In order to ensure the proper quality of cement to be used, contractor shall carry out
following tests at site at the rate of half percent for each lot of cement received before
consuming the cement in the work:
a) Initial setting time
b) Final setting time.
c) Compressive test of cement paste for 3 days duration.
Test results shall be properly recorded and maintained at site.
5.22
Quality assurance planning is to be submitted by LSTK Contractor and get it

approved by Owner/Consultant before starting of work.
6.0
SITE CLEANING
During construction and on completion of construction (inclusive of all internal and
external finish), clearing all the debris and waste materials scattered around the site
and disposal of the same as per direction of the Engineer- In- Charge shall be in the
scope of the Contractor.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
SCOPE OF WORK
AT NRL,ASSAM
7.0
7.1
EM163-PNCV-SOW-101
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Page 19 of 19
COMPLETENESS OF WORK/CONTRACT
The scope of work mentioned in the contract/NIT is not the comprehensive one, but
gives total idea/outline of the scope of work; however contract shall be responsible for
completeness of the job for the purpose indicated elsewhere to make the system fully
functional and operational.
7.2
The work furnished shall be complete in every respect with all mounding, fittings,
fixtures and standard accessories etc. normally provided for such item/ equipment
and or needed/required for erection, completion and safe operation of the
item/equipment/system as required by applicable codes/OISD-NORMS though they
may not have been specially detailed in the respective specifications, unless
included in the list of exclusions.
7.3
Any additional items and materials which are not specifically mentioned but are
required to complete the system offered in every respect in accordance with the
technical specifications and required for safe operation
and quaranteed
performance shall be deemed as included in the scope of work of this tender.

Contractor shall not be eligible for any extra payment in respect of such moundings,
fittings,fixtures,accessories etc. which are needed/required for safe operation of the
item/ equipment/ system, as required by applicable codes of the country though
they may not have been explicitly spelt out in the NIT/Contract.
_____________________________________________________________________________________________________________
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
DESIGN BASIS FOR CIVIL & STRUCTURAL WORK

INSTALLATION OF LPG MOUNDED BULLETS,
NRL REFINERY
EM 163-PNCV-DB-101
Document No.
Rev.
Sheet 1 of 9
DESIGN BASIS
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NRL REFINERY
EM 163-PNCV-DB-101
Document No.
Rev.
Sheet 2 of 9
CONTENTS
S.No
Item
Page No
1.0
INTRODUCTION
2.0
DESIGN LOADS
3.0
DESIGN CRITERIA FOR FOUNDATIONS
4.0
DESIGN CRITERIA FOR RCC STRUCTURES
5.0
DESIGN CRITERIA FOR STEEL STRUCTURES
6.0
OTHER SPECIFICATIONS
7.0
FABRICATION DRAWING
8.0
DESIGN CRITERIA GENERAL
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Sheet 3 of 9
1.0 INTRODUCTION
1.1
Scope
This engineering design basis defines the minimum design criteria that shall form the basis for
carrying out detailed design engineering of mound for LPG Bullets and associated facilities.
All structures shall be designed for the satisfactory performance of the functions for which they
are being constructed.
1.2
Units of Measurement
Units of measurement shall be in metric system.
1.3
Codes and Standards

The design shall be in accordance with established codes, sound engineering practices and
shall conform to the statutory regulations applicable to the country.
The main codes and standards and statutory regulations considered as minimum requirements
are as follows (Latest revision of these shall be followed):
IS:456
Code of practice for plain & reinforced concrete
IS:800
Code of practice for general construction in steel
IS:816
Code of practice for use of metal arc welding for general construction
IS:875
Code of practice for design loads
IS:1893
Criteria for earth quake resistant design of structures
IS:2911
Code of practice for design and construction of pile foundations
IS:13920
Code of practice for ductile detailing of reinforced concrete structures subjected

to seismic forces.
National Building Code
Factory Rules
All work shall comply OISD Norms and CPWD Specifications.
2.0 Design Loads

The following design loadings shall be considered:
1. Dead loads including self weight
2. Live load
3. Wind load
4. Seismic load
5. Equipment load
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6. Load from lifting appliances

7. Erection loads / maintenance loads
8. Thermal load
9. Earth pressure / Hydrostatic Loads
10. Any other load not mentioned above, but applicable
These loadings shall be applicable to all structures irrespective of the material employed for
construction.
2.1
Dead Loads
Dead load shall comprise of the weight of all permanent construction including retaining walls,
filling material, floors, stairways and fixed services
Bullets shall be considered as full of water for test case.
2.2
Equipment Loads
The empty / operating / test weight of equipment including all fixtures, platforms, ladders and
attached piping, shall be considered. If piping weight is not indicated separately or not included
in the weight of the equipment, the same shall be taken as 10% of the weight of the equipment.
2.3
Live Loads
Live loads shall, in general, be as per IS:875. However, the following minimum live loads shall
be considered in the design of structures to account for maintenance and erection phases; if
equipment layout / vendor drawings indicate loads of greater magnitude, the same shall be
adopted.
2.4
1. Top of mound -
5.0 kN/m
2. Staircase
5.0 kN/m2
Wind Loads
Wind loads for structural design shall be as per IS-875 (Part-3). The design life span of all
structures, except temporary structures shall be taken as 50 years.
2.5
Seismic Loads
Seismic loads shall be as per IS:1893 (Latest Revision).
2.6
Miscellaneous Loads
Apart from the specified live loads, possible overloading during construction / hydro-test
maintenance / erection shall also be considered in the design Job specifications and shall also
be referred to, for any specific loading.
Hydrostatic pressure shall be adequately accounted for, in the design of structures, below
ground water table.
All the handrails, parapets, parapet walls, balustrades shall be designed for horizontal load
mentioned in Table 3 of IS-875 (Part-2).
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2.7
Load Combinations
Structure & its member shall be designed for worst combination of the above loads.
3.0 DESIGN CRITERIA FOR FOUNDATIONS

3.1
General
Foundation sizing shall be based on working loads without any factor.
3.2
Pile Cap
Pile cap shall be designed to cater the entire load of the mound (including the bullets).This shall
be resting on pile heads, layout of which is attached in the tender.
3.3
Foundation Bolts
3.3.1 Minimum cover to Foundation Bolts

Minimum distance from the center line of foundation anchor bolt to edge of pedestal shall 6d
(d = dia of bolt).
4.0 DESIGN CRITERIA FOR REINFORCED CONCRETE STRUCTURES

4.1
General
All retaining walls, access tunnels, trenches, pits etc. shall be of RCC and designed based on
the applicable IS codes (latest revision with all amendments, issued there to) .
Only limit state method as per IS:456 shall be followed for the design unless otherwise specified
elsewhere for special structures.
Where the specified design depth of groundwater table so warrants, all underground pits,
tunnels, basements, etc. shall be leak-proof R.C.C. construction using water proofing
compounds.
4.2
Concrete Grade
43 GRADE OPC should be used.
Minimum M30 Grade Reinforced Cement Concrete shall be used in RCC pile cap, Retaining
wall for the mound, and water retaining structures, if any.
Minimum M25 grade of reinforced cement concrete shall be used for all other structures and
foundations except for grade slabs / paving for which M20 may be used. From durability
consideration the minimum cement content and maximum water-cement ratio shall be as
follows :
Type of Cement
Plain concrete
Reinforced concrete
Remarks
Exposure
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Sheet 6 of 9
Condition
43 Grade-OPC
Minimum
cement
content (kg/m)
Maximum
watercement
ratio
Minimum
cement
content
(kg/m)
Maximum
watercement
ratio
240
0.55
330
0.45
Moderate
100 mm thick lean concrete of grade M10 (nominal mix) shall be provided under all RCC
foundations. The lean concrete shall extend 100 mm beyond the foundation.
4.3
Reinforcement Bars
All reinforcement bars for RCC works should be high yield strength deformed TMT steel bars
of grade Fe500D conforming to IS:1786 of make SAIL,RINL,TISCON,IISCO.
4.4
Minimum Cover to Reinforcement

Minimum clear cover shall be provided to all steel reinforcement as per IS:456 & IS:3370.
4.5
Expansion Joints
Expansion joints in concrete structures shall be provided at 30-35 m. Sliding joints shall be
avoided as far as possible.
4.6
Miscellaneous Applications
4.6.1 Admixtures
Generally admixtures should not be used. If required, admixtures shall conform to IS:9103
and to be mixed with concrete strictly as per manufacturers recommendations.
4.6.2
Plinth protection
The peripheral area around bullet foundation & building shall be provided with minimum 1.0
m wide concrete M20, 100 thick laid on 75 mm thick M10 concrete with 8 Tor @ 250 c/c both
ways Reinforcement bars all round as plinth protection. A surface drain to be provided alongwith plinth protection which shall be connected to the drainage system of the plant.
4.6.3
Cold Bitumen Paint

All underground structures including top surface of foundations shall be painted with two
coats of cold bitumen as per manufacturer specification.
5.0 Design Criteria For Steel Structures

5.1
General / Design Methods
5.1.1
Design, fabrication and erection of structural work shall be carried out in accordance with the
following IS Codes as applicable to the specific structures, viz, IS:800, 816, 875, 1893, etc.
Basic consideration of structural frame work shall primarily be stability, ease of
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fabrication/erection and overall economy, satisfying relevant Indian Standard Codes of

Practice. Steel structures adequately braced in vertical and horizontal planes, consistent with
functional requirements, shall be preferred over structure having moment connections.
Moment connections, if adopted, shall be fully rigid as per IS:800. Where fully rigid joints are
adopted they shall generally be confined to the major axis of the column member.
5.1.2
Steel staircases shall have channels provided as stringers with minimum clear width of 1000
mm. Minimum size of Stringer channel shall be MC200. The vertical height between
successive landings shall not exceed 4.0 meters. Treads shall be minimum 250 m wide
made of grating (with curved chequered plate nosing) spaced equally so as to restrict the
rise to maximum 150 mm. If relevant local by-laws or applicable Factory Act Rules stipulates
more stringent requirements in this regard, the same shall be adhered to.
5.1.3
Electro-forged galvanized MS gratings shall be minimum 30 mm deep. The maximum size of

voids in the grating shall be limited to 34 mm x 65 mm. The minimum thickness of
galvanizing shall be 86 microns. Gratings shall be suitable for the operation and
maintenance loads for the floors.
5.1.4
Bolted connections shall be adopted as far as practicable, except for cases where welded
connections are required. Structural connections shall have minimum two bolts of 20 mm dia,
unless otherwise limited by the size of members.
5.1.5
Lock nuts shall be provided for anchor bolts of structures, process columns, vibrating
equipment, etc.
5.1.6
Minimum two nuts shall used for all anchor bolts except for ladder, stair and hand rail.
5.2
Steel Grade
Structural steel shall be of yield stress of 250 Mpa conforming to grade B of IS:2062. Make of
steel shall be SAIL, RINL, TISCON, IISCO.
6.0 Other Specification

6.1
Platforms
Platforms shall be provided according to the requirements for regular operating procedure and
normal recurring maintenance.
6.2
Hand Rail
Flexible hand rail system consisting of 1050 mm high vertical posts @ max 1.5 mtr C/C made
up of 32 NB medium duty pipe, top and middle hand rail of size 32 NB and 25 NB MS pipe
respectively and MS Flat 100 mm x 6 mm Toe guard, all jointed, bended and welded with
suitable angle cleat or plates and base plate of size 100 mm x 50 mm x 8 mm thick properly
welded with vertical posts and sand blasting followed by one coat of epoxy primer and two
coats of finished paint as per specifications shall be provided.
7.0 DESIGN CRITERIA GENERAL

7.1
Site Grading
The grading of the area shall be done by cutting and filling with the following:
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Document No.
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Sheet 8 of 9
1. Cutting Area :
2. Filling Area :
Thoroughly rolled and compacted.

Compacted in layers not exceeding 20cm to achieve minimum
95% of maximum dry density.
The finished floor level ( FFL) shall be as per the adjoining road level of existing plant.
7.2
Storm Water Drainage

The storm water drains shall be designed for maximum rain water intensity in the area or as
specified in metrological data elsewhere.
Storm water drains shall be sized for the higher discharge arising out of either rain water or fire
fighting water. All drains should be of RCC.
Minimum width of drains: 500 mm X (depth > 600mm) shall be connected to storm water drains.
8.0
Specific Requirement:
8.1
Fire Proofing: The contractor shall design, supply and apply vermiculite type of fire proofing to
structural steel members, wherever required, as per OISD Standard, TAC rules and other
requirements as applicable. The Fire proofing of 2 Hours rating shall be provided to all
exposed portion on major or minor structures.
8.2
LSTK Contractor shall get the design mix done from reputed and approved laboratory in
consultation with owner/ consultant before start of civil works.
8.3
The more stringent of OISD requirement/specification and IS shall prevail.
8.4
All reinforcement bars shall be TMT (Thermo Mechanical Treated) only. All
and reinforcements shall be procured from SAIL / TISCO or RINL.
8.5
All gratings shall be hot dipped galvanized.
8.6
No material shall be supplied by NRL for Civil & structural works.
8.7
Minimum grade of concrete mix for RCC work shall be M: 30.
8.8
Minimum grade of concrete mix for RCC work in Pile cap shall be M:30.
8.9
Anti-corrosive lining shall be provided on all concrete surfaces.
structural steel
8.10 Cement in foundations shall be Sulphate Resisting Portland Cement conforming to IS:12330 ,if
sulphate content is present in soil.
8.11 Minimum size / section structural members shall be:a.
b.
c.
d.
e.
Column and framing beams shall be ISMB150-ISMC-150.

Thickness of stiffeners plates shall be 8m.
Size of bracing angle shall be 50X50X6.
Base plate for major structural columns-16mm.
base plate for minor structural columns-12mm.
8.12 Clear Height and width of Man access Tunnel shall be minimum of 2000mm X 1700mm to
provide with closed at rear end. The bottom of man access tunnel shall be minimum 100mm
above FFL .Man access Tunnel shall be designed of RCC with minimum thickness of wall and
slab 250mm with opening for cables and pipes as required. The fixing arrangement shall be
provided on R.C.C surface where ever required.
8.13 The RCC foundation /pile cap shall be designed with minimum thickness of 1500mm .The top
of R.C.C retain wall shall have 300mm with a provision of R.C.C. drain with clear width of
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350mm X depth of 450mm with proper slope having outlet through rain water down take C.I.
pipe of minimum dia. 150mm all fittings and bends to provide for smooth flow of storm water.
8.14 The top of mound shall have Cement concrete. block of minimum size
mmX450mmX200mm Thickness with rounded edge and corners.
300
8.15 The minimum filling above the vessel including top layer shall not be less than 1000mm.
8.16 Soft copies of input files, for analysis & design calculations for all the RCC & Steel structures
shall also be submitted along with hard copies. Other calculations can be submitted in hard
copy.
8.17
All drawings are required to be prepared in Auto-CAD only.
8.18
Review of drawing & documents / supervision & inspection done by Owner/Consultant or its
representative will not off-load the LSTK-contractor from any of its responsibility.
8.19
To fulfill all statutory requirement of project and to maintain good quality in work shall be the
responsibility of the LSTK Contractor.
The above shall be read in conjunction with the Scope of work, Technical requirements &
Specifications given elsewhere in this document.
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FORM NO. : 02-0000-0021F2 REV. 1
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EM 163-PNCV-TS-101

NRL REFINERY
Document No.
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Page 2 of 22
CONTENTS
SL.NO DESCRIPTION
PAGE NO.
1.
GENERAL
2.
REFERENCE STANDARDS
3.
EARTH WORK
4.
PLAIN AND REINFORCED CONCRETE WORK
5.
STEEL REINFORCEMENT
11
6.
FORM WORK
12
7.
STRUCTURAL STEEL WORK
14
8.
PAINTING ON STRUCTURAL STEEL
15
9.
FLOORING AND PAVING
18
10.
PLASTERING
19
11.
WHITE
&
COLOUR
WASHING,
CEMENT 20
PAINTING
FORM NO. : 02-0000-0021F2 REV. 1
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1.0 GENERAL
1.1
These technical Specifications shall be supplementary to the specifications contained

in the IS codes and CPWD specifications, wherever at variance; these Particular
Specifications shall take precedence over the provisions in the IS Codes and CPWD
Specifications.
2.0 REFERENCE STANDARDS

2.1
Wherever reference of BIS Specifications/ or BIS Codes of Practice are made in the
Specifications/ Schedule of Rates or Preambles, reference shall be to the latest
edition of BIS (Bureau of Indian Standards).
IS - 383
Coarse & Fine aggregates from natural sources for concrete.
IS - 432
Mild Steel & Medium tensile steel bars
IS - 455
Code of Practice for Portland Slag Cement
IS - 456
Code of Practice for Plain and Reinforced Concrete
IS - 800
Code of Practice for General Construction in Steel
IS - 816
Metal Arc Welding for General Construction of Mild Steel.
IS - 1079 Hot rolled carbon steel sheets & strips

IS - 1161 Steel tubes for structural purposes.
IS - 1363 Hexagon head bolts, screws & nuts of product grade C: Part - I Hexagon
head bolts (size range M5 to M64)
IS - 1367 Technical supply conditions for threaded steel fasteners
IS - 1786 High strength deformed steel bars & wires for concrete reinforcement.
IS - 2062 Steel for general structural purposes.
IS - 2116 Sand for masonry mortars.
IS - 4923 Hollow Steel sections for structural use.
IS - 4925 Concrete batching and mixing plant.
IS - 5410 Cement Paint
IS - 10262 Recommended guidelines for concrete mix design.
FORM NO. : 02-0000-0021F2 REV. 1
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NRL REFINERY
3.0
EARTHWORK
3.1
Excavation
Document No.
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3.1.1 Excavation shall be carried out in soil of any nature and consistency, in the
presence of water or in the dry, met on the site to the lines, levels and contours
shown on the detailed drawings and contractor shall remove all excavated materials
to soil heaps on site or transport for use in filling on the site or stack them for reuse
as directed by the Owner / Consultant.
3.1.2 Surface dressing shall be carried out on the entire area occupied by the buildings
including plinth protection as directed without any extra cost. The depth of
excavation shown on the drawings is the depth after surface dressing.
3.1.3 The site around all buildings and structures to a width of 3 metres beyond the edge
of plinth protection, ramps, steps, etc. shall be dressed and sloped away from the
buildings.
3.1.4 Black cotton soil, and other expansive or unsuitable soils excavated shall not be
used for filling in foundations, and plinths of buildings or in other structures including
man holes, septic tanks etc. and shall be disposed off within the contract area
marked on the drawings, as directed, leveled and neatly dressed.
3.1.5 In case of trenches exceeding 2 metres depth or where soil is soft or slushy, the
sides of trenches shall be protected by timbering and shoring. The Contractor shall
be responsible to take all necessary steps to prevent the sides of trenches from
caving in or collapsing. The extent and type of timbering and shoring shall be as
directed by the Owner / Consultant.
3.1.6 Where the excavation is to be carried out below
the foundation level of adjacent
structure, the precautions to be taken such as under pinning, shoring and strutting
etc. shall be determined by Owner / Consultant. No excavation shall be done
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unless such precautionary measures are carried out as per directions of Owner /
Consultant.
3.1.7 Specification for Earthwork shall also apply to excavation in rock in general. The
excavation in rock shall be done such that extra excavation beyond the required
width and depth as shown in drawings is not made. If the excavation done in depth
greater than required / ordered. The contractor shall fill the extra excavation with
concrete of mix 1:5:10 as the foundation concrete at his own cost.
3.1.8 Contractor shall make all necessary arrangements for dewatering / defiling as
required to carry out proper excavation work by bailing or pumping out water, which
may accumulate in the excavation pit from any cause/ source whatsoever
3.1.9 Contractor shall provide suitable draining arrangements at his own cost to prevent
surface water entering the foundation pits from any source.
3.1.10 The contractor is forbidden to commence the
construction of structures or to carry
out concreting before Owner / Consultant has inspected, accepted and permitted
the excavation bottom.
3.1.11 Excavation in disintegrated rock means rock or Boulders including brickbats which
may be quarried or split with crow bars. This will also include laterite and hard
conglomerate.
3.1.12 Excavations in hard rock - meant excavation made in hard rock to be done
manually, or by blasting using only explosives and / or pneumatic hammers. In case
of blasting, control blasting should be adopted depending on site conditions. For
using explosives contractor shall follow all provisions of Indian Explosives Act /
Rules 1983, corrected / revised upto date.
3.1.13 In case of hard rock excavation to be carried out using explosives the, contractor
shall obtain the written approval in advance.
3.1.14 The measurements for excavations shall be restricted and limited to minimum
excavation line as per drawing for payment purposes.
FORM NO. : 02-0000-0021F2 REV. 1
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3.2
FILLING
3.3
Back filling of excavations in trenches, foundations and elsewhere shall consist of one
of the following materials approved by Owner / Con
i) Soil
ii) Sand
iii) Moorum
iv) Hardcore
v) Stone/gravel
All back filling material shall be approved by the Owner / Consultant
3.2.1 Soil / moorum filling - Soil material shall be free from rubbish, roots, hard lumps and
any other foreign organic material. Filling shall be done in regular horizontal layers
each not exceeding 20 Cm. depth.
3.2.2 Back filling around completed foundations, structures, trenches and in plinth shall be
done to the lines and levels shown on the drawings.
3.2.3 Back filling around pipes in the trench shall be done after hydro testing is done.
3.2.4 Back filling around liquid retaining structures shall be done only after leakage testing
is completed and approval of Owner / Consultant is obtained.
3.2.5 Sand used for filling under foundation
concrete, around foundation and in plinth
etc. shall be fine/ coarse, strong, clean, free from dust, organic and deleterious
matter. The sand filling under foundation shall be rammed with Mechanical
compactor. Sand material shall be approved by Owner / Consultant.
3.2.6 Moorum for filling shall be supplied by NRL as per terms and conditions as
stipulated in other parts of tender documents. Size of moorum shall vary from dust
to 10 mm.
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3.2.7 Hard-core shall be of broken stone of 90 mm to 10 mm size suitable for providing a

dense and compact sub grade. Stones shall be sound, free from flakes, dust and
other impurities. Hard core filling shall be spread and leveled in layers, 15 cm thick,
watered and well compacted with ramming or with mechanical / hand compacts
including hand packing wherever required.
4.0
PLAIN AND REINFORCED CONCRETE WORK

This specification deal with cement concrete, plain or reinforced, for general use,
and covers the requirements for concrete materials, their storage, grading, mix design,
strength & quality requirements, pouring at all levels, reinforcements, protection,
curing, formwork, finishing, painting, admixtures, inserts and other miscellaneous
works.
4.1
Materials
4.1.1 Water: Water used for mixing and curing concrete and mortar shall conform to the
requirements as laid down in clause 5.4 of IS: 456: 2000. Seawater shall not be used
for concrete work.
4.1.2 Aggregates: Coarse and fine aggregates for cement concrete plain and reinforced
shall conform to the requirements of IS 383 and / or IS 515. Before using, the
aggregates shall be tested as per IS: 2386.
4.1.3 Coarse aggregate: Coarse aggregate for all cement concrete work shall be broken or
crushed hard stone, black trap stone obtained from approved Quarries or gravel.
4.1.4 Sand: Fine aggregate for concrete work shall be coarse sand from approved sources.
Grading of coarse sand shall be within grading zones I, II or III be laid down in IS:
383, table 4. If required the aggregates (both fine and coarse) shall have to be
thoroughly washed and graded as per direction of Owner / Consultant.
4.2
Mixing: All cement concrete plain or reinforced shall be Ready mixed Concrete unless
mentioned otherwise. Mixing by hand may be employed where quantity of concrete
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involved is small, with the specific prior permission of the Owner / Consultant. 10%
extra cement shall be added in case of hand mixing
4.3
Water Cement Ratio: Once a mix, including its water-cement ratio, has been
determined and specified for use by the Owner / Consultant, that water cement ratio
shall be maintained.
4.4
Laying: Concreting shall be commenced only after the Owner / Consultant
has
inspected and passed the sub-base / base or the centering, shuttering and
reinforcement. Concrete in slab beams, columns, footings etc. shall be laid gently in
layers not exceeding 15 cm and shall be properly consolidated by means of
approved mechanical vibrators.
4.5
Curing
a) After the concrete has begun to harden, it shall be protected with moist Gunny
bags, sand or any other material approved by the Owner / Consultant against
quick drying. After 24 hours of laying concrete, the surface shall be cured by
flooding with water or by covering with wet absorbent materials for 7 days as per
the direction of Owner / Consultant.
b) Approved curing compounds may be used in lieu of moist curing with the
permission of the Owner / Consultant. Such compounds shall be applied to all
exposed surfaces of the concrete as soon as possible after the concrete has set.
No extra payment shall be made for the same.
4.6
Grades of Concrete
4.6.1 Grades of cement concrete shall be as given below:

Grade Specified
Characteristic compressive strength

at 28 days (N/mm2)
i)
M 7.5
7.5
ii)
M 10
10
iii)
M 15
15
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iv)
M 20
20
v)
M 25
25
vi)
M 30
30
4.6.1 A sieve analysis test of aggregates shall be carried out as and when the source of
supply is changed without extra charge not withstanding the mandatory test
required to be carried out as per relevant IS codes.
4.6.2 All tests in support of mix design shall be maintained as a part of records of the
contract. Test cubes for mix design shall be prepared by the contractor under his
own arrangements and at his costs, but under the supervision of the Owner /
Consultant.
4.7
4.7.1
Design mix concrete

At the time of tendering, the contractor, after taking into account the type of
aggregates, plant and method of laying he intends to use, shall allow in his tender
for the design mix i.e., aggregate/cement and water/cement ratios which he
considers will achieve the strength requirements specified, and workability for
concrete to be properly finished. Unless specified otherwise, only Ready Mix
Concrete shall be used.
4.7.2
Soon after the contractor gets L.O.I. to commence the work, he shall carry out
preliminary tests for design mix on trial mixes proposed by him in design of mix to
satisfy the Owner / Consultant that the characteristic strength specified in clause
3.6.1 is obtained. Prior to this may ask the contractor has to get design mix done
as per IS: 10262 through govt. approved/reputed institute and contractor shall
arrange the same at his own cost. The concrete mix to be actually used shall be
approved by the Owner / Consultant.
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4.7.3 The workability of concrete produced shall be adequate, so that the concrete can
be properly placed and compacted. The slump shall be as follows, when vibrators
are used.
i) Mass concrete in RCC
10 to 25 mm
Foundations & retaining walls :

ii) Beams, slabs & columns
25 to 40 mm
simply reinforced :
iii) Thin RCC sections or
40 to 50 mm
sections with congested

reinforcement:
4.8
Testing of concrete
4.8.1 Testing of concrete, sampling and acceptance criteria shall be in accordance with
Clauses 15, 16 & 17 of IS-456: 2000.
4.9
Pre cast concrete:
4.9.1 The specifications for pre cast concrete will be similar as for the cast in situ concrete.
All pre cast work shall be carried out in a yard made for the purpose. This yard shall
be dry, properly levelled and having a hard and even surface. If the ground is to be
used as a soft former of the units, shall be paved with concrete or masonry and
provided with a layer of plaster (1:2 proportion) with smooth neat cement finish or a
layer of MS sheeting. The casting shall be over suitable vibrating tables or by using
form vibrators as per directions of Owner / Consultant.
4.9.2 The yard, lifting equipment, curing tank, finished material storage space etc. shall be
designed such that the units are not lifted from the mould before 7 (seven) days of
curing and can be removed for erection after 28 (Twenty Eight) days of curing. The
moulds shall preferably be of steel or of timber lined with G.I.sheet metal. The yard
shall preferably be fenced.
4.9.1
Lifting hooks, wherever necessary or as directed by Owner / Consultant shall be

embedded in correct position of the units to facilitate erection, even though they
may not be so on the drgs. and shall be burnt off and finished after erection.
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Pre cast concrete units, when ready shall be transported to site by suitable means
approved by Owner / Consultant. Care shall be taken to ensure that no damage
occurs during transportation. All adjustments, leveling and plumbing shall be done
as per the instructions of the Owner / Consultant. The contractor shall render all
help with instruments, materials and staff to the Owner / Consultant for checking
the proper erection of the pre cast units.
4.9.3
After erection and alignment the joints shall be filled with grout or concrete as
directed by Owner / Consultant. If shuttering has to be used for supporting the pre
cast unit they shall not be removed until the joints has attained sufficient strength
and in no case before 14 (fourteen) days. The joint between pre cast roof planks
shall be pointed with 1:2 (1 cement : 2 sand) mortar where called for in the drgs
4.10
Protection of Concrete: All concrete shall be protected from damage by rain or

by workmen, equipment, overload or any other causes. All edges, corners and
projections of concrete members likely to be damaged, shall be protected by
means of wooden cover fillets.
4.11
Construction Joints: Construction joints shall be made only where shown on the
drawings or as approved by the Owner / Consultant. The procedure given in
clause 13.4 of IS: 456 shall be followed for general guidance.
4.12
Separation Joint: Separation Joint shall be obtained by using an approved

alkathene sheet struck on the surface against which concrete shall be placed.
Adequate care should be taken to cause no damage to the sheet.
4.13
Sampling of Concrete: Sampling & strength Test of concrete, Acceptance criteria

and Inspection & Testing of Structure: This shall be as per the requirements laid
down in clause Nos: 15.16 & 17 of IS- 456:2000.
5.0
STEEL REINFORCEMENT
5.1
All joints in reinforcement shall be lapped adequately to develop the full strength of
the reinforcement, unless reinforcement are as per provision of IS : 456 or as per
instruction of Owner / Consultant.
Following procedure shall be followed for welding of TMTsteel reinforcement bars.
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1) Welding of TMT steel reinforcement bars shall be taken up only after

specific approval by Owner / Consultant.
2) Lap welding with longitudinal beads shall only be adopted.
3) The thickness of weld bead should be 0.2 x diameter of bar and the length
of the longitudinal bead required shall be 10 x diameter of bar, however, the
maximum length of continuous bead shall be limited to 5 x diameter of bar
with intermediate gap. When welding is done on both sides bead length
shall be 5 x diameter of bar on each side.
4) Stripper at closer spacing shall be provided in the lap welded joints as
directed by Owner / Consultant.
6.0
FORM WORK
6.1
The shuttering or formwork shall conform to the shape, lines and dimensions as
shown on the drawings and be so constructed as to remain sufficiently rigid during
placing and compacting of the concrete and shall be sufficiently tight to prevent
loss of liquid from the concrete. The surface that becomes exposed on the
removal of forms shall be examined by Owner / Consultant or his authorised
representative before any defects are made good. Work that has sagged or
bulged out, or contains honey combing, shall be rejected. All shuttering shall be
plywood or steel shuttering.
6.2
The Contractor shall be responsible for sufficiency and adequacy of all formwork.
Centering and formwork shall be approved by the Owner / Consultant, before
placing of reinforcement and concreting.
6.3
Stripping Time : Forms shall not be struck until the concrete has reached
strength at
least
twice the stress to which the concrete may be subjected at
the time of removal of formwork. The strength referred to shall be that of concrete
using the same cement and aggregates, with the same proportions and cured
under conditions of temperature and moisture similar to those existing on the
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work. Where possible, the formwork shall be left longer as it would assist the
curing.
Note 1 - In normal circumstances and where ordinary Portland Cement is used,

forms may generally be removed after the expiry of the following periods:
For other types of cements, the stripling time recommended for ordinary
\Portland Cement may be suitably modified.
Note 2 - The number of props left under, their sizes and disposition shall be such
as to be able to safely carry the full dead load of the slab, beam or arch as the
case may be together with any live load likely to occur during curing or further
construction.
a) Walls, columns and vertical aces

of all structural members
24 to 48 hours as may be
decided by the Owner /
Consultant
b) Slabs ( props left under)
3 days
c) Beam soffits ( Props left under )
7 days
d) Removal of props under slabs

1) Spanning upto 4.5 m
7 days
2) Spanning over 4.5 m
14 days
e) Removal of props under beams

and arches :
1) Spanning up to 6 m
14 days
2) Spanning over 6m
21 days
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STRUCTURAL STEEL WORK

This specification covers the technical requirements for the preparation of shop
drawings, supply, fabrication, protective coating, painting and erection of all structural
steel rolled sections, built up sections, plates and miscellaneous steel required for the
completion of the work.
7.1
Fabrication: Fabrication of steel structure shall be carried out in conformity with the
best modern practices and with due regard to speed with economy in fabrication and
erection and shall conform to IS-800. All members shall be so fabricated as to
assemble the members accurately on site and erect them in correct positions. Before
dispatch to site the components shall be assembled at shop and any defect found
rectified. All members shall be free from kink, twist, buckle, bend, open joints etc. and
shall be rectified before erecting in position. Failure in this respect will subject the
defective members to rejection.
7.2
Fabrication Drawings:
Fabrication and erection drawings shall be prepared by
the contractor on the basis of approved design. These drawings shall be prepared
by the contractor or by an agency approved by the Owner / Consultant.
7.3
MS Black/High Strength Bolts and Nuts: M.S. Black or high strength bolts, nuts
and washers etc. shall be as per IS-800, IS-1363 and IS-1367. Manufacturer's test
certificate shall be made available to the Owner / Consultant or his representative,
when called for. For bolted joints, shanks and threaded bolts are to be used to
ensure that threaded length do not encroach within the thickness of connected
members of dimension beyond the following limit:
i.
1.5 mm for connected members of thickness below 12 mm and
ii.
2.5 mm for connected member of thickness 12 mm and above and that

adequate shearing and bearing values required as per design are
achieved.
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Every portion work shall have its erection mark or numbers stenciled on the
member for guidance in erection and bear all necessary marks of erections as
directed by the Owner / Consultant.
7.4
No part of the work is to be oiled, painted (except contact surfaces) packed,

bundled, crated or dispatched until it has been finally inspected and approved by
the Owner / Consultant. The whole steel work before being dispatched from the
contractor's shop shall be dry and after being thoroughly cleaned from dust, mills
scale, rust etc., and shall be given two coats of primer and one coat of final paint as
per painting specification attached in this enquiry. Unless otherwise specified, all
surfaces inaccessible after welding shall be given two coats of primer and two
coats of paints as per painting specification.
7.5
The Owner / Consultant shall have free access at all reasonable time to all places
where the work is being carried out, and shall be provided by the contractor at his
own expenses all necessary facilities for inspection during fabrication and erection.
The Owner / Consultant shall be at liberty to reject the work in whole or in part if
the workmanship or materials do not conform to the terms of the specifications
mentioned herein. The contractor shall remove, replace or, alter any part of the
work as ordered by the Owner / Consultant.
8.0
8.1
PAINTING ON STRUCTURAL STEEL

Scope
This specification shall be used in non coastal area.
Surface Preparation
The surfaces to be painted shall be sand blasted to Sa - 2.5 as per Swedish
Standard SIS 05-59-00. Air used for Shot blasting/ grit blasting must be dry and oil
free. Sand used for Shot blasting shall be good quality river sand suitable for
achieving the required surface finish. For optimum results pressure of Shot
blasting/ grit blasting gun should be maintained at around 7 kg/cm2 and maximum
height of profile should be kept around 50 microns. Sand blasted surfaces must be
coated with primer within 4 hrs iin dry climate. Moreover it is not advisable to carry
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out Shot blasting/ grit blasting when humidity exceeds 85% (RH).
8.1.1
Painting system to be used are indicated below:

a) Epoxy Painting :
Primer P 1-2 coats + finish paint FP1 (2 coats) where P1 is epoxy polyamide cured
zinc chromate primer having DFT of 35 micron per coat and FP1 is epoxy ployamide
cured finish paint having DFT (Dry Film Thickness) of 35 micron per coat.
b) For chlorinated rubber paint.

Primer P2 - 2 coats - finish paint FP2 - 2 coats. Where P2 is high chlorinated zinc
phosphatphosphate primer having DFT of 50 microns per coat and FP2 is chlorinated rubber
based
based paint having DFT of 50 microns per coat.
8.1.2 Equivalent product chart for approved paint manufactures for primer P1 and P2 finish
paint FP1 and FP2 indicated above is enclosed.
8.1.3
All the surfaces must be sand blasted and 2 coats of primer plus 1 coat of finish paint
applied in the shop before the same are shifted to site for erection. All the members
r must be suitably match marked for facilitating proper assembly.
After erection is over all surfaces shall be washed up as follows:
i.Washing with clean water (pressure 7 kg/cm2) using suitable nozzles.
ii.During washing broom corn brushes shall be used to remove foreign matters.
iii. Solvent washing if required to remove traces of oil grease etc.
After washing the surface as indicated above, the surfaces shall be suitably touched up
to the extent required so that all the damages to the premiered surfaces caused during
erection are done up.
The surfaces affected by welding and / or gas cutting during erection shall also be
suitably touched up. Before touch up is taken up surfaces shall be prepared by
mechanical means such as grinding, power brushing etc. to achieve surface finish to
ST-3.
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After touch up work is over as indicated above, all the surface shall be given one coat
of finish paint to the required specification.
8.1.4 The following points must be observed for painting work:
a)
Primer and paint shall be compatible to each other and should be from the
same manufacturer.
b) The recommendation of the paint manufacturer regarding mixing, matching

and application must be followed meticulously.
c) Technical representative of paint manufacturer should be available at site as
and when required by Owner / Consultant for their expert advice as well as to
ensure that the painting work is executed as per the instruction of paint ma
manufactures.
Paints and primers shall be supplied at site in original container with factory seal
otherwise such paints and primers shall not be allowed to be used
8.2
EQUIVALENT CHART FOR VARIOUS PAINT MANUFACTURERS
ASIAN
P1
P2
APCODUR -
G&N
SHALIMAR
AMERCOAT-71 EPIGARD-4 ZINC
J&N
BERGER
BOMBAY
EPILAC ZINC
EPILUX-4 ZINC
PENTADUR
Epoxy Zinc
CHROMATE
CHROMATE
CHROMATE
PRIMER 1532
Chrome Primer
PRIMER
PRIMER
PRIMER
CHLOROKOTE
JENSOLAC CR
LINOSOL HB
PRIMER
ASIOCHLOR HB
NEROLAC
ZINC
PHOSPHATE
ZINC
ZINC
ZINC
PHOSPHATE
PRIMER
PHOSPHATE
PHOSPHATE
PHOSPHATE OR
PRIMER
PRIMER
PRIMER
KANGAROO HB
HEMPATEX
PRIMER 1632
FP1
APCODUR CF
NEROLAC TWO
EPIGARD XL
EPILAC 974
EPILUX-4
PENTADUR
692
COMP EPOXY
FINISH
ENAMEL
ENAMEL
ENAMEL 5534
GRAY
FP2
ASIOCHLOR CF
NEROLAC CR
CHLOROKOTE
JENSOLAC
625
PAINT
FINISH
CHLORINATD.
RUBR. PAINT
FORM NO. : 02-0000-0021F2 REV. 1
LINSOL
PENTACHLOR
CHLORINATED GP ENAMEL 5638

RUBR.PAINT
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9.0
FLOORING AND PAVING
9.1
Sub Base of floor
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9.1.1 The area to be paved shall be divided into suitable panels. Formwork shall be
provided. The boarding / battens shall be fixed in position with their toe at proper
level, giving slope where required. Alternatively base concrete may be deposited in
the whole area at a stretch.
9.1.2
Before placing the base concrete the sub-base shall be properly wetted and rammed.
The concrete of the specified mix shall then be deposited between the forms where
provided, thoroughly tamped and the surface finished level with the top edge of the
forms. The surface of base concrete shall be spreader uniformly. The surface shall be
finished rough to provide adequate bond for the topping. Two or three hours after
concrete has been laid the surface shall be brushed with wire brush to remove any
scum or Laitance and swept clean so that coarse aggregate is exposed.
9.2
Cement Concrete Floor Finish
9.2.1 The surface of base concrete shall be thoroughly cleaned by scrubbing with coir or
steel wire brush. Before laying the toping, the surface shall be soaked with water at
least for 12 hours and surplus water mopped up immediately before the toping is laid.
9.2.2 The forms shall be fixed over the base concrete dividing into suitable panels. Where
glass dividing strips are provided, thickness of glass dividing strips shall be 4 or as
indicated. Before placing the concrete toping, neat cement slurry at the rate of 2
kg/sq.m shall be then thoroughly brushed into the base concrete just ahead of the
finish. The topping shall then be laid, thoroughly compacted by using screed
board/plate vibrator. The surface floated with a wooden float to a fair and even
surface shall be left for some time till moisture disappears from it. Junctions with
skirting / dado or wall surfaces shall be rounded off using cement mortar 1:2 curing
shall be carried out for a minimum of 7 days.
10.0
10.1
PLASTERING
Sand for plastering: shall be 50% fine sand and 50% coarse sand from approved
sources.
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10.2
Preparation of surface shall be done as per specifications.
10.3
Cement mortar shall be of the mix as indicated in the items and shall be mixed as
specified in the specifications.
10.4
Joints in walls etc. shall be raked to a depth of 12 mm, brushed clean with wire
brushes dusted and thoroughly washed before starting the plaster work. The surface
shall be thoroughly washed with water cleaned and kept wet to saturation point before
plastering is commenced.
10.5
Cement mortar as indicated, shall be firmly applied to the masonry walls in a uniform
layer to the thickness specified and will be pressed into the joints. On concrete
surfaces rendering shall be dashed to the roughened surface to ensure adequate
bond. The surface shall be finished even and smooth. Hectoring wherever required
shall be done as per directions of Owner / Consultant. Nothing extra shall be paid on
this account.
10.6
All plaster work shall be cured for at least 7 days.
10.7
Integral water proofing compound shall be mixed with cement in the proportion
recommended by the manufacturer. Care shall be taken to ensure that the water
proofing material gets well and integrally mixed with cement. All other operations are
the same as for general plaster work.
10.8 For sand face plaster undercoat of cement plaster 1:4 (1 cement: 4 sand) of thickness
not less than 12 mm shall be applied similar to one coat plaster work. Before the
under coat hardens the surface shall be scared to provide for the top coat. The top
coat also of cement mortar 1:4 shall be applied to a thickness not less than 8 mm and
brought to an even surface with a wooden float. The surface shall then be tapped
gently with a wooden float lined with cork to retain a coarse surface texture, care
being taken that the tapping is even and uniform.
11
11.1
WHITE & COLOUR WASHING AND CEMENT PAINTING

White Washing
Where white wash is indicated, 3 coats of white wash shall be applied. The surface
shall present a smooth and uniform finish.
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White wash shall be prepared from lime slaked at site and mixed and stirred with
5 litres of water for one kg. of unsalted lime to make a thin cream. The cream shall
be screened through a clean, coarse cloth and suitable adhesive such as DDL or
equivalent as per manufacturer specification. About 1.3 kg of sodium chloride in hot
water shall also be added for every 10 kg. of lime for making the coat hard and rule
resistant. Indigo shall also be mixed @ 3 gm/Kg of lime. Each, coat shall be allowed
to dry before next coat is applied. When dry, the wash should show no sign of
cracking. One coat consists of application with brushes in horizontal stroke followed
by vertical stroke.
11.2
Colour Washing
11.2.1 Where colour wash is indicated, one coat of white wash and two coats of colour of
tints approved by the Owner/Consultant shall be applied. Dados and skirting shall not
be white washed, colour washed or distempered or painted.
11.2.2 Only Colour Steiner of approved brand not affected by lime, shall be added to
colour wash. Indigo (Neel) shall, however, not be added in colour wash.
11.2.3 The colour wash shall be applied as described for white wash. After the surface has
been prepared the first primary coat shall be of white wash. Minimum two coats of
colour wash shall then be applied. The entire surface shall present a smooth and
uniform finish of even tint or shade.
11.3
11.3.1
Distempering
Where distempering is indicated, two coats of distemper oil emulsion or dry
distemper over a priming coat as specified in the item shall be applied. Each coat of
distemper shall be approved by the Owner / Consultant before next coat is applied.
11.3.2 Distemper oil emulsion shall be as per IS: 248 of approved brand and manufacture.
The distemper shall be diluted with water or a prescribed thinner in the proportion of
4 parts of paste by weight to one part of cold water or in the proportion specified by
the manufacturer, which shall be invariably followed.
11.3.3 The surface to be distempered shall be cleaned of dust, dirt, chalking and other
foreign matter. All cracks, holes and surface defects shall be repaired with gypsum to
give a smooth surface, and papered and wiped clean. The surface shall then be
rubbed down again with sand paper and made smooth. The surface thus prepared
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shall be given a coat of alkali resistant, priming paint conforming to IS: 109, or any
other primer as specified by the manufacturer and allowed to dry at least for 48 hours.
11.3.4 Dry distemper shall be of approved make and
shade conforming to IS 427 and
shall be prepared as per manufacturer's specification. The surface to be

distempered shall be cleaned of dust, dirt, chalking and other foreign matter. All
cracks, holes and surface defects shall be repaired with gypsum to give a smooth
surface, and papered and wiped clean. The surface shall then be rubbed down
again with sand paper and made smooth. The surface thus prepared shall be given
a coat of alkali resistant, priming paint conforming to IS: 109, or any other primer as
specified by the manufacturer and allowed to dry at least for 48 hours.
11.3.5 After the primer coat has dried for at least 48 hours, the surface shall be lightly sand
papered to make it smooth for receiving the distemper, taking care not to rub cut the
priming coat and then dusted off. Prepared distemper shall then be applied with
brushes in horizontal strokes followed immediately by vertical ones, which together
constitute one coat.
11.3.6
Subsequent coats shall be applied in the same way, with time intervals of at least
24 hours between consecutive coats.
11.3.7
A uniform finished surface without patches, brush marks, or distemper drops shall
be obtained.
11.4
11.4.1
Cement Painting
Cement paint shall comply with IS: 5410 specification for cement paint, of colour as
required.
11.4.2
Where shown on drawings for external surfaces of sand faced plaster, or any
other surface, two coats of cement paint shall be applied of tint and shade as
approved by the Owner / Consultant.
11.4.3 The surfaces shall be prepared as specified for white washing. Before applying
cement paint the surface shall be thoroughly wetted to control surface suction. The
surface shall be moist but not dripping wet, when the paint is applied. Not less
than 24 hours shall be allowed between the two coats. In hot weather the first coat
shall be slightly moistened before applying the second coat.
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
EM 163-PNCV-TS-101

NRL REFINERY
11.4.4
Document No.
0
Rev.
Page 22 of 22
On external plastered surfaces, sand faced or
plain
plastered and concrete
surfaces, cement paint shall be vigorously scrubbed on to work the paint into the
voids and provide a continuous paint film free from pin holes and other openings.
Curing shall be done between the coats and for at least 2 days following the final
coat.
FORM NO. : 02-0000-0021F2 REV. 1
All rights reserved
EM163-TS-401-00
Document No.
Rev.
SHEET 1 of 2
TECHNICAL DESCRIPTION
EQUIPMENT: MOUNDED LPG BULLETS
AND DRAIN VESSEL
29.09.2015
29.09.2015
ISSUED FOR ENQUIRY
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-TS-401-00
Document No.
Rev.
SHEET 2 of 2
LIST OF SPECIFICATIONS
Sl.
No.
Description
Doc. No.
Rev
No of
Pages
Specification for Mounded Bullets
EM163-TS-401
87
Specification for Drain Vessel
EM163-TS-301
72
29.09.2015
29.09.2015
ISSUED FOR ENQUIRY
VB/PK
NB/AKG
GC
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
EM163-TS-401
REV
DOCUMENT NO
SHEET 1 of 36
TITLE
: TECHNICAL SPECIFICATION FOR LPG MOUNDED BULLETS
PROJECT : INSTALLATION OF LPG MOUNDED BULLETS AT NUMALIGARH

REFINERY LIMITED
CLIENT
1
REV
29.09.15
REV DATE
: NRL, ASSAM
29.09.15
EFF DATE
ISSUED FOR ENQUIRY

PURPOSE
VB/PK
PREPD
NB/AKG
REVWD
GC
APPD
EM163-TS-401
REV
DOCUMENT NO
SHEET 2 of 36
CONTENTS
Sl. No.
Description
INTENT
APPLICABLE CODES, STANDARDS & SPECIFICATIONS
DESIGN
SCOPE OF SUPPLY
SCOPE OF WORK / SERVICES / ACTIVITY
MATERIAL
BARRICADING FOR FABRICATION YARD
FABRICATION
FABRICATION & ERECTION METHODOLOGY OF BULLETS
10
MINIMUM QUALITY CONTROL REQUIREMENTS
11
INSPECTION AND TESTING
12
HYDROTESTING & SETTLEMENT
13
CALIBRATION
14
PRE-COMMISSIONING / COMMISSIONING
15
GUARANTEE
16
DOCUMENTATION
EM163-TS-401
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DOCUMENT NO
SHEET 3 of 36
LIST OF ATTACHMENTS
Sl.
No
1
2
3
4
5
6
7
1.0
Rev
No. of
Pages
15
EM163-TS-401-ANNEX I
EM163-TS-401 FORM E
EM163-TS-401-ANNEX II
11
EM163-TS-401-ANNEX III
EM163-45-PNMP-PS 102
Description
Drg. / Doc. No.
PROCESS DATA SHEET FOR

MOUNDED BULLETS
GA DRG. OF LPG MOUNDED
BULLETS
SUPPLEMENTARY REQUIREMENTS
FOR MOUNDED BULLETS
CHECK LIST (TECHNICAL)
EM163-DD45-VV101/102/103/104
EM163-PNMV-DD45-VV101/102/103/104
EM163-TS-401-SR
SCHEDULE OF EXCEPTIONS AND

DEVIATIONS (TECHNICAL)
COATING / PAINTING
SPECIFICATION
MINIMUM QUALITY ASSURANCE
PLAN FOR MOUNDED BULLET
MINIMUM ALLOWABLE NOZZLE
LOADINGS FOR MOUNDED
BULLETS
INTENT
This Attachment / Annexure covers design & detailed engineering, preparation of
fabrication drawings, procurement & supply of all raw materials whatsoever required
to meet complete scope of supply, fabrication, post-weld heat treatment, inspection,
testing,
coating/painting
at
site,
site
fabrication/erection/
installation on compact sand bed, assembly, welding, testing, post-weld heat
treatment of field joints, inspection & NDT, hydro-testing, cleaning, coating/painting
of field joints / internal surfaces / damaged surfaces and installation of Cathodic
protection system ,supply & installation of related piping and instruments including
mound and other civil work for the LPG/ Mounded bullets, and requisite insert plates
in the RCC wall for pipe supports, supply of spares, guarantee, pre-commissioning
and commissioning in strict compliance with the Specifications, applicable code,
relevant drawings and documents enclosed along with tender documents which
forms an integral part of this specification.
Scope also covers obtaining statutory approval on engineering drawings, design
calculations and other related documents.
The requirements for completeness of LPG mounded storage installation with
respect to piping up to companion flange all the valve required for installation of the
in instrument & with piping flanges in the tunnel with its analysis safety security as
per various OISD, GRE Cones for Dome along-with requisite insulation & SS Traps,
Lifting requirements, bolts, fasteners, internal stair, civil, instrumentation, electrical,
cathodic protection system etc. are covered separately (in various Attachments /
Annexure) in the main package.
EM163-TS-401
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This specification shall be read in conjunction with code, specification sheet and
other tender documents. In case of conflict between code and tender document, the
vendor shall contact PDIL/NRL for clarifications. As a general rule the most
stringent requirement shall govern.
S. No.
1
Item No.
45-VV101/102/103/104
Description
Reqd. Qty.
MOUNDED BULLET
PDIL Specification sheet Doc. No.

EM163-DD45-VV-101/102/103/104 Rev.
2
Additional Mechanical Details for LPG
Mounded Bullets Drg. No. EM163-PNMVDD45-VV-101/102/103/104 Rev. 0.
1.1.0
General
1.1.1
Thicknesses shown in drawing/equipment specifications shall be considered

minimum constructed and indicative only. Contractor shall check the adequacy of
the same. Any increase in thickness, if required, to comply with the requirements of
specifications, code/ tender documents shall be incorporated by the contractor
without any price and/or delivery implications.
1.1.2
Contractor shall adhere to the technical specifications and shall not waive / alter any
part of the specifications or relevant drawings without the written permission of
Owner / PDIL.
1.1.3
Fabrication/Erection methodology mentioned in this specification shall be

considered as a guideline. However, contractor shall submit along-with the bid, a
technically suitable / feasible and satisfactory methodology for fabrication / erection,
postweld heat treatment and hydro-test of 4 nos. LPG Bullets in one mound
alongwith complete details, for technical evaluation of the bid.
1.1.4
The supply shall be in strict compliance with this specification, PDIL drawings, and
other referred codes/standards. Components, for which there are no relevant
codes/standards, shall be designed as per good engineering practice, after getting
approval from PDIL.
Any comments made by PDIL shall be incorporated without any commercial
implication. The Contractor is advised to essentially visit NRL Numaligarh Refinery
site before quoting, to have a clear picture of the interrelated existing facilities
available & specific requirements for the execution of this job. No extra claim shall
be entertained after the award of contract on account of ignorance of site
conditions.
The mounded bullets shall be partially prefabricated including rolling of plates, shot
blasting, edge preparations and application of primer painting etc in bidders shop.
EM163-TS-401
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However the assembly of the bullets shall be carried out in-situ position in mound.
Accordingly contractor has to ascertain the safe transportation of the pre fabricated
parts/sections. Route survey in connections with above shall be carried out by
contractor. Any material consigned by contractor to site which is damaged or lost
shall be to the contractors risk and he shall replace such material at his own cost.
1.1.5
The contractor shall certify that the offer is in complete compliance with all the
technical requirements as specified in the enquiry documents without any deviation.
Contractor shall submit duly filled in, signed & stamped CHECK LIST (TECHNICAL)
document no EM163-TS-401-ANNEX I REV 0 along with offer.
1.1.6
Exceptions & Deviations, if any, from the clauses stipulated here in or code and any
other technical specifications, shall be clearly spelt out in the enclosed Schedule of
Exceptions and Deviations (Technical) Confirm form E (EM163-TS-401 FORM E
REV 0), with proper reference to specific document number, subject, clause number
etc. Absence of any such indication shall mean that the offer complies with all
requirements and such assumptions shall strictly be binding on the contractor,
without any price and/or delivery implications. Any deviation written elsewhere in
the offer but not on the format shall not be recognized and the same shall be
treated as null and void.
1.1.7
Certain items & stipulations, by virtue of their importance may be repeated in one or
the other documents to attract sure attention under any circumstances.
1.1.8
Sub-Contractor, if any, shall have prior approval of NRL / PDIL. Contractor shall
specify the nature of sub-contract. In absence of any such information, it shall be
presumed that complete job shall be executed by the Contractor alone and such
assumption shall be binding on the Contractor.
1.1.9
Contractor shall submit a consolidated sub-vendor list for all the materials and
supplies for PDIL/NRL approval.
1.1.10
The Contractor shall be responsible for compliance with all statutory laws, rules and
regulations (local/state/central) and arranging all necessary permits, approval,
license, certificates etc. that may be obligatory for him to obtain and process for the
execution of his work from appropriate authority.
1.1.11
Contractor shall be responsible for preparing a detailed specification of operations

to be performed on site in particular the sequence in which civil work is to be
performed.
1.2
Language and Measurement System
1.2.1
Official Language :
1.2.2
Measuring System : Metric (e.g. Pressure in Kg/cm2g.)
English
EM163-TS-401
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1.3
Priority of Order
In case of conflict among the documents, priority of validity shall be in following
order:
a) Statutory requirements ( local / state / central )
b) Equipment Drawings
c) This Specifications
d) Codes
e) Contractors bid
2.0
APPLICABLE CODES, STANDARDS & RULES
2.1.1
Codes & Standards

The design, construction and testing of the Bullet shall be in accordance with the
requirements out lined in the drawing and following relevant Codes / Standards.
For all the Codes/Standards the latest edition valid as on date of order shall be
applied:ASME Sec. VIII Div.2
ASME Sec. VIII Div.1
ASME Sec. IX
ASME Sec. II & ASTM
IS:875
IS:1893
Rules for Construction of Pressure Vessel Alternate

Rules
Rules for Construction of Pressure Vessel
Welding and Brazing Qualifications.
Material Specifications
Code of practice for design loads other than
earthquake
Criteria for earthquake resistant design of structures
Other PDIL standards (PDS & ES) and other national/international standards
mentioned on drawing & documents such as relevant ASME for Gasket, Flange
Bolting etc.
2.1.2
Rules & Regulations

All the relevant requirements outlined in the following rules, regulations and
recommendations shall also be complied with
i) SMPV Rules (1981 & subsequent notifications)
ii) OISD 116, 118 and 150
iii) EEMUA
2.2
Materials
Materials other than stipulated code of design shall meet all the requirements of
design code. Various testing methods on alternative material shall also comply with
code of design.
Materials for pressure parts shall be designated in accordance with ASME.
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2.3
Coatings / Painting
Surface preparations, primer & internal and external painting/coating shall be grit
blast cleaned & coated as per Doc. No. EM163-TS-401-ANNEX II REV 0 and GA
Drawing Number EM163-PNMV-DD45-VV-101/102/103/104.
2.4
Cathodic Protection System

The requirement of cathodic protection system of mounded bullets shall be as per
relevant specification Document No.:- EM163 -TS-0801 Rev 1 enclosed in Tender.
2.5
Piping
All piping shall strictly meet the requirements of specifications/ documents, Piping
Material Specification (Piping Class) etc. Piping shall be in accordance with ASME
B 31.3
The bullets will be subjected to settlement. Also, the ends of the bullets will move in
a longitudinal direction due to change in temperature and internal pressure. These
effects shall be taken into account in the piping design.
Stresses caused by external forces in flanges connected to bullet dome are not
acceptable.
The piping design & works shall be in accordance with relevant specifications
enclosed elsewhere in the Tender. Piping material specification & valve material
specifications are attached with the Tender. The Insert Pates in the RCC wall for
the Pipe support for which location shall be provided during the detailed engineering
phase after the award of the Contract. The Approximate weight of plate insert may
be 4000 kg of weight.
The support details will be provided at the time of execution of the piping on the
mound along with ISOMETRIC DRAWINGS.
The analysis of piping hanger in the tunnel for outlet Nozzle before ROV is in the
scope of contractor.
2.6
Instrumentation
The instrumentation design & works shall be in accordance with relevant
specifications enclosed elsewhere in Tender (Doc No: - EM163-PNIN-7901-00 Rev
0). However valves required for installation of the instruments are under the scope
of contractor. In case of safety valve the scope is till the inlet of the safety valve &
the tapping from outlet of safety valve to flare shall be carried by others.
2.7
Electrical
All cathodic protection electrical supplies erection, testing & commissioning shall be
carried out by the contractor in accordance with relevant specifications enclosed
elsewhere in Tender (Document No.:- EM163 -TS-0801 Rev 1).
2.8
Structures and Civil Design & Work

Structures and Civil Design & works shall be in accordance with relevant
specifications enclosed elsewhere in Tender.
EM163-TS-401
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2.9
Earthquake Factor
According to Design basis and IS: 1893.
2.10
Design Wind Speed

According to Design basis and IS: 875.
2.11
BATTERY LIMIT / TERMINAL POINTS

The terminal points shall be in conformity with drawings/specifications and layout
drawing enclosed in Tender.
3.0
DESIGN
3.1
Equipment shall be designed as per the conditions and Codes / Stds. / Specs.
indicated in respective equipment specification sheets / drawings.
3.2
External loadings like mound load (in axial and radial directions), live load, Seismic
loads, thermal loads, bending & frictional force, mound interaction load, load due to
uneven support by foundation etc. shall be considered in the design of unstiffened
Shell, Domes, Manholes & stiffeners.
3.3
Bullet shall be supported, while hydro testing, on the sand bed, which is to be laid
and compacted.
The bullet design shall be based on a theoretical settlement of 1:2500 (Minimum
50mm). The bullet shall be considered as supported on elastic foundations with a
varying modulus. This modulus shall be taken to vary as under;
a) Maximum Modulus = 1.5 x Minimum modulus.
b) No less than One-third of the length of the bullet shall deem to be supported on
a bed with minimum modulus in any analysis.
However bullet foundation shall be designed for following settlement values:
3.4
i)
Immediate settlement value: - 5mm (max.)
ii)
Max. Settlement value between centre & end of the bullet (at empty,
operation, test case): 10mm (max.)
3.5
Shell thickness shall be set so that under operation / hydrotest conditions, the
combined stresses in any shell component do not exceed the following;
a). Tensile Stress : 90% Ambient Yield.
b). Compressive Stress : Code Allowable Stress
3.6
Design external pressure (P0) shall be determined by the external load caused by
the mound in combination with negative internal pressure based on worst of
assumed design support distribution pattern & FE Analysis.
Supporting pressure (P0)) by the foundation (sand bed angle 120O) resulting from
dead weight(Q1), weight of liquid/water fill(Q2), mound weight(Q5), live load(Qlive)
EM163-TS-401
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between maximum stiffener spacing (Ls), and shall be added with negative internal
design pressure (F.V.) and the same shall be considered for design.
P0 = [1.33*(Q1 + Q2 + Q5 +Qlive) / (1.2*R*Ls)]
P0 = Maximum shear load (by FEA) * Ls / (1.2*R*Ls)
Where, R is mean radius of shell & Ls is stiffener spacing
3.7
Double corrosion allowance shall be considered in design of stiffeners.
3.8
For parts/components, design of which are not covered in ASME Sec. VIII Div.2,
recommendations of PD5500 or any other international code regarding stability and
buckling / lateral buckling (flange buckling) shall be followed and analytical check
shall be submitted for review & approval of PDIL.
3.9
Stiffener weld (shell to web, flange to web) shall be checked for radial loads in shell.
3.10
The maximum longitudinal compressive stress at mid span of the vessel must be
calculated and compared with code.
3.11
The bullet shall also be analyzed with Finite Element Analysis using latest version
of ANSYS or Equivalent software.
3.12
All equipment shall also be designed for field hydro (without mound cover) and
periodic hydro at latter stage (with mound cover) in new and corroded condition
respectively. Allowable stress during hydraulic testing shall be less than or equal to
90% of yield stress.
3.13
Lifting lug shall be designed with a shock factor of 2.0.
3.14
Live load on mound/Bullet shall be considered as 150 Kg/m2.
3.15
Tentative Forces and Moments coming on the nozzles are indicated in the tender,
However the final Forces and Moments shall be furnished after order placements by
PDIL which shall be considered in the design by contractor without any commercial
implications. Alternatively contractor shall indicate maximum forces and moment
caused by bullet contractions and mound settlements for review and confirmations
by PDIL.
3.16
The thickness of stiffener web and flange should not exceed the thickness of shell.
The stiffener webs and flanges shall be of the same material grade and thickness
as of the shell.
3.17
Domes, nozzles and manholes shall be designed to withstand both internal and
external (soil pressure and piping) loads in accordance with ASME section VIII
DIV.2. Due to horizontal movements of vessel, passive soil pressure may generate
large lateral soil pressure/forces and high bending moments on the dome and
manholes. This can be prevented by creating free space around dome and
EM163-TS-401
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manholes using split sleeves. The installation of sleeve structure made of glass
reinforced epoxy or unplasticised polyvinyl chloride (PVC) may be considered.
3.18
At least two manholes, one at each end of the vessel, shall be installed. Each
manhole shall be provided with internal permanent ladder
3.19
Each vessel shall be electrically isolated from all other vessels, pipelines, plant, and
buried metal structures and electrical and instrument earthlings systems.
4.0
SCOPE OF SUPPLY
The extent of supply shall also include but not be limited to the following:
4.1
Unless otherwise specified, the complete main equipment and their various
components as specified in GA drawings and various specifications/documents
spelt out in the tender shall be included in contractors scope of supply.
4.2
To carry out Mechanical Design, FE Analysis and preparation of detailed fabrication

drawings as per specified requirements and submission of same to PDIL/Owner for
review/approval.
4.3
Obtaining all statutory approvals from PESO/CCOE for bullets, and from CPWD /
Weight & Measure for Calibration.
4.4
Procurement and supply in sequence and at appropriate schedule, all metallic and
nonmetallic consumables required for complete construction, fabrication,
installation, inspection, testing and Post Weld Heat Treatment shall be contractors
responsibility.
4.4.1
All plates, Forged Flanges, SR Nozzle necks & Dome and Fittings
4.4.2
All materials for internal piping, domes, nozzle necks and ladder at each manhole
complete with supports and fasteners.
4.4.3
Companion / mating flanges, Cover flanges for manholes and all instrument
connections.
4.4.4
Fasteners & Gaskets for Companion/mating flanges, Cover flanges for manholes
and all instrument connections.
4.4.5
Blind flanges, bolting and gasket for Hydro-testing / Commissioning for all nozzles
connection without cover/blind flanges with companion flanges.
4.4.6
Minimum two number Manholes each with Davit and permanent fixed internal
ladder up to the bottom of bullet
4.4.7
S.S. Name Plate with bracket.
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4.4.8
Settling Markers (bench mark).
4.4.9
Lugs for CP system of bullets.
4.4.10
Suitable pipe supports for bottom outlet nozzle of bullets.
4.4.11
All materials required for surface preparation, painting & coating.
4.4.12
Selection, engineering & supply of fireproof coating materials required for fire
proofing (material certified by Underwriters Laboratory as per their test method
UL1709 for Hydrocarbon fire test 2 hours fire rating).
4.4.13
All materials for external piping and instruments including all mounted permanent
instruments as specified in relevant specification enclosed with ITB.
4.4.14
All materials and equipment required for mounding like earth, sand, clay, gravel,
PVC sheet, terram-1000 sheet, PVC pipe, stone, inspection tunnel/trench, resilient
material at tunnel opening, fire barricading in the fabrication yard, fences etc as
specified in relevant specification enclosed with Tender.
4.4.15
Supply of all materials for Fire Barricading Screen with water spray system and
hydrocarbon detector with local hooter for detection of any fire leakage as
applicable.
4.4.16
Supply of Template of the size and shape of LPG Bullet for mound shaping.
4.4.17
All materials for viz. cables, electric wire, tubing, junction boxes, etc. required for
Instruments, as specified in relevant specification enclosed with ITB.
4.4.18
All instruments, controls, valves etc. as per relevant specification enclosed with ITB.
4.4.19
All materials, electrical cables, instruments, all accessories required for Cathodic
Protection system including Monolithic Insulating joints for all liquid and vapor lines
including utility pipe lines and insulating flange joint kit for all Instrument
connections (Manhole excluded) as specified in relevant specification enclosed with
Tender.
4.4.20
The Contractor shall arrange at his own expenses all consumables materials such
as, but not limited to, Welding consumables, welding gases, filler wires, fluxes,
electrodes, grinding wheels, cotton waste, bolts and nuts and all other temporary
fastenings, clips, cleats, packing materials, gaskets, etc. that might be required by
him to execute the entire erection & commissioning (as applicable) job in a
satisfactory manner.
EM163-TS-401
4.4.21
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Providing all tools, tackles, jigs, fixtures, lifting / handling cranes, wire rope slings,
DShackles, hoist, chain pulley blocks, hydra, other machines, safety equipment, A
Frame, welding/cutting / grinding machines, air compressors, blower, pump for
filling/dewatering/hydro-testing, valves, pressure gauges, spray guns for painting,
PWHT equipment / recorder etc., and any other items required to carry out the
entire job properly and in schedule time.
4.4.22
All measuring tools, gauges, inspection, ND Examination & testing

instruments/machines, portable hardness tester, radiography films and other
consumables for radiography, MPI, DP and all other destructive/non-destructive
examination and testing.
4.4.23
All inspection and ND Examination / testing consumables like radiography films,

Dye / Developers, Magnetic particles etc.
5.2
SCOPE OF WORK / SERVICES / ACTIVITY
5.1.0
Fabrication, PWHT, testing, coating / painting at shop/fabrication yard.
5.1.1
Inspection and testing at shop/fabrication yard and site.
5.1.2
Safe Transportation of items/equipment package, prefabricated bullet sections from

contractors shop/fabrication yard to site, receipt of materials at site, site unloading /
handling, arrangement of storage at site, movement/handling of materials at site /
on mound.
5.1.3
Assembly, Fabrication, inspection, testing, local PWHT, hydrotesting, localized

coating/painting of field weld joints and internal surface coating on mound.
5.1.4
Calibration of bullets including preparation and submission of calibration charts and

obtaining approval from competent Statutory Authorities as per IS:2009 & IS:2166.
5.1.5
Application of Coating/painting as specified in Specification EM163-TS-401ANNEX-II REV 0.
5.1.6
Application / installation of fireproof coating materials required for fire proofing

(material certified by Underwriters Laboratory as per their test method UL1709 for
Hydrocarbon fire test 2 hours fire rating) of the exposed portion of bullet up to
battery limit and all ROVs.
5.1.7
Installation of Monolithic Insulating joints for all liquid and vapor lines including utility
pipe lines and insulating flange joint kit for all Instrument connections (Manhole
excluded).
5.1.8
Erection / installation of Complete Bullet Earthing System.
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5.1.9
Cathodic protection system.
5.1.10
Support cleat for fire detection system.
5.1.11
Cleaning of inside of bullet with vacuum cleaner and blowing of equipment as per
instruction of site in-charge after Hydro test.
5.1.12
Civil foundation i.e. preparation of mound as per civil scope of work and
specifications.
5.1.13
Installation of all instrumentation (for Mounded Bullets, other equipment & piping
mounted Instruments) and valves as marked in drawings & as specified in relevant
specification enclosed with Tender.
5.1.14
Min. 6 thick resilient material (Neoprene rubber or equiv.) for seating/resting of

bullet shell on cutout (to be provided for outlet nozzle) on tunnel cover with
weathering / fire protection arrangement.
5.1.15
4 thick HDPE bolted sleeve (in two halves) with flexible cover fixed with SS Strap
around dome-1, dome-2 and nozzles mark M1 & M2 for absorbing bending
moment due to earth pressure / vessel expansion.
5.1.16
Dismantling of Fabrication Barricading Screen.
5.1.17
Pre-commissioning, commissioning (as applicable), etc. required to complete the

work in totality to make the system functional is in contractors scope,
5.1.18
cleaning of site and final handing over of the complete package to the purchaser.
5.1.19
Documentation according to Table 1 & Table 2 of this specification.
5.1.20
All items/materials/consumables and activities / services which are not specifically

listed above, but are required for satisfactory completion of mounded bullet and
their support bed, mound and cathodic protection system in all respect within
battery limit to make storage vessel ready for commissioning and for
accomplishment of all the items of work required as per instruction of site in charge,
shall be within contractors scope of supply.
5.2
Following Spares are to be included in scope of supply:

a)
Mandatory spares:
Contractor shall indicate item-wise prices for following:All spares recommended for requisite piping, cathodic protection system, as
specified in respective specifications.
Mounded Bullet & other Spares
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Gaskets: 200% for each nozzle with companion flanges, blind flanges including
manholes & instrument nozzles.
Fasteners: 10 % (min in each size) of installed fasteners
Contractor / Vendor shall supply Mandatory spares as per the list furnished in
Tender. Contractor shall provide all mandatory spares and same shall be handed
over to Maintenance after commissioning of the unit. Quoted price by contractor
shall include the cost towards the mandatory spares and the same shall be
considered for bid evaluation. Cost of Mandatory Spares shall be included by
contractor in the lump sum cost of basic equipment as well as unit rate also.
b)
Commissioning spares:
Bidder shall provide spares required for commissioning. Any spares required during
commissioning shall be supplied by Bidder without any time and price implication.
Price of commissioning spares shall be included in the lump sum price of the
package.
Replacement of commissioning spares, if any, required during commissioning stage
shall be done by contractor/ Vendor on free of cost. Generally this will not be
quantified and also not be considered for bid evaluation.
c)
Spares for Two years Normal Operation
Contractor shall indicate Spares for two years normal operation along with the bid
and item wise prices shall also be submitted for such recommended spares.
Price lists of these Two years normal operation spares are intended for information
purpose only and shall not be included in quoted Lump-sum price. These prices
shall remain valid for 12 (twelve) months from the date of mechanical Completion.
Gaskets for Two years Normal Operation
200% for each nozzle with companion flanges, blind flanges including manholes &
instrument nozzles.
Fasteners for Two years Normal Operation
2 sets of studs & nuts for each nozzle with companion flanges, blind flanges
including manhole & instrument nozzles
6.0
MATERIAL
6.1
All materials shall be as indicated in respective equipment drawing / specification

sheets. All raw materials shall be covered with proper identifiable material mill test
certificate endorsed by third party: Lloyds / BV / TUV for imported materials & PDIL
for indigenous materials.
The bullet plate material test certificate must cover details like Heat, cast and Plate
number, Chemical properties (Laddle & Product Analysis) including Carbon
Equivalent, Physical/Mechanical properties (Tensile, Yield, Elongation, Charpy-V
Impact), Ultrasonic test results, Cycle of simulation PWHT & Mechanical Test
Coupons Results of Simulation PWHT in 3(Three) conditions (single SR & double
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SR for shell/stiffener plates & Normalizing + SR for plates of Dished Head) in

addition to the test results in as rolled condition of plate.
A sample shall be tested in the presence of TPIA and the same shall be reviewed/
certified if required.
6.2
Unless otherwise specified material used for pressure parts / stress bearing
components shall be fully killed
6.3
Unless more restrictive prescription given in material specifications, the maximum

carbon content of carbon steel used for fabrication as shown by the laddle analysis
shall be less than
0.23% for plates, pipes & tubes
0.25% for forgings
In addition the carbon equivalent shall comply with the following formula
C + Mn/6+(Cr+MO+V)/5+(Ni+CU)/150.45 for SA 516 Gr.60+A20,S5
6.4
UTS of material for Bullet shell, head & stiffener shall be limited to 80,000 psi.
Maximum.
6.5
C.S. material shall be procured in normalised / annealed condition only.
6.6
Production test coupon for plate shall undergo heat treatment twice at temperature
610 + 100C for SR (SR of each section at shop and Local SR of field weld joints) &
910 + 100C for normalizing of dished head during forming and SR of bullet section.
Details of the mechanical test as simulated shall also be indicated in mill test
certificate.
6.7
Plate shall be procured with zero negative tolerance on thickness.
6.8
Material including Weld and Heat Affected Zone shall be impact tested (Charpy-V)
at the lowest of minimum ambient temperature, design temperature and minimum
design metal temperature (MDMT) as per design code & relevant ASME
Specification.
6.9
C.S. and low alloy steel plates exceeding thickness of 50 mm shall be vacuum
degassed except for plate ring flanges.
6.10
In case of quenched and tempered steel material, plates shall be procured UT

tested after heat treatment (in mill)
6.11
All materials of pressure bearing components exceeding 16.0 mm thickness shall

be U.T. tested on surfaces and edges as per ASTM A 578 Level 1.
6.12
All forgings shall be ultrasonically tested as per ASTM A 388 for thickness greater
than 100 mm with criteria shown in ASME Sec.VIII Div.2 Para AM-203-2. In case
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any defect is found, no repair by welding shall be allowed. ANSI flanges for
equipment designed as per ASME Sec.VIII Div.1 need not be ultrasonically tested.
6.13
All forgings (including nozzle flanges) shall be examined for surface defects by
MP/DP after machining.
6.14
All pipe fittings including those elbows shall be forged / wrought. All fittings shall
conform to ASME B 16.9 and ASME B 16.11.
6.15
For bullets, Flanges of sizes 24NPS shall be welding neck, according to ASME B
16.5, Size of Flanges >24 NPS shall be as per ASME B 16.47, series A.
Bolt holes of Flanges & Counter flanges of all instrument nozzles, bearing insulating
joint gasket kit, shall be suitable to accommodate stud bolts insulating sleeve and of
length suitable to accommodate washers.
6.16
Flange raised face for gasket seating face shall have smooth finish 125 AARH (63
to 125 in AARH) finish except nozzle mark N2. Flange for nozzle mark N2 shall
have RTJ face with smooth finish 63 AARH (32 to 63 in AARH) finish
6.17
Brinnel hardness for RTJ groove shall be at least 20BHN more than that of
corresponding gasket as specified.
6.18
Nonmetallic gaskets shall conform to ANSI B16.21 up to 24, and B16.47 series A
beyond 24, unless otherwise specified.
6.19
Spiral wound gaskets and ring joint gaskets shall conform to ANSI B16.20 with
inner & outs ring of SS.
6.20
All gaskets shall be SS304 spiral wound with graphite filler with SS ring. Gaskets
shall be lapped with insulating gasket kit, excluding gasket for RTJ.
6.21
All bare electrodes and fluxes shall be selected as per ASME IIC. All weld metal
shall have equal or better mechanical properties than the parent metal. Only dry flux
shall be used.
7.0
BARRICADING OF FABRICATION YARD
7.1
Before starting any welding at site fire barricading (temporary) screen with water
spray system shall be erected as per the guidelines of clients safety department
and requirements of concerned statutory authority.
The barricading structure should be open able type to allow movement for
construction, men, material and machinery for pump house.
Hydrocarbon detector with local hooters shall be provided by contractor. Fresh
water shall be used for sprinkler. Water for barricading shall be once through with
closed circuit system (recycling) which shall be arranged by contractor.
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8.0
FABRICATION
8.1
The manufacturer of the equipment shall comply, in all respects, with the provisions
of the applicable code/standards and specifications including such jobs as welding,
fabrication, forming of heads etc. radiography, heat treatment, inspection, testing
and quality control etc. unless otherwise specified.
8.2
During execution of job within NRLs site premises, NRLs safety rules/ regulations
shall be strictly followed.
8.3
Fabrication work, planning and scheduling shall be done in such way that minimum
fabrication works will be done at site i.e. (a) Rolling of plates (b) Edge preparation
(c) Blasting & primer application etc. will be done at fabricator shop only.
8.3.1
Forming of shell sections and heads shall be done by machines, either hot or cold,
in such a way so as to preserve the specified material properties and to produce a
regular finish.
8.3.2
Transverse rolling while forming of shell sections is not allowed. Plate shall be bent
/ rolled along the direction of the mill rolling of plate during shell forming. The
hemispherical head shall be fabricated in 2 pieces (4 petals each) & 1 crown
separately. Caps of dome shall be formed in single piece. Latest applicable code
requirement shall be satisfied.
8.3.3
Oxy-acetylene flame cutting done in any circumstances, shall be followed by

machining or grinding to eliminate any dis-colouration (of material) effects.
8.4
All welding jobs shall be carried out by qualified welders using qualified welding
procedure to requirement of Design Code and specification etc. and approved by
the inspecting authority. All new welding procedures must be got approved from
authorized inspecting authority before starting any fabrication job
8.5
Contractor is suggested to visit NRL site to have clear picture of the inter related
existing facilities and specific requirements for the executions of the job. No extra
claim shall be done after award of contract on account of ignorance of site
conditions. Contractor shall note that the Mounded Bullets shall be fabricated in 6
sections or as applicability for erection of equipments, ND Tested & inspected
before installation on foundation/mound including external anti corrosive coating.
Inter-section circumferential (field) weld seams shall be welded in-situ position in
mound. All exposed uncoated surfaces & internal bottom 900 shall be coated after
hydro and MPI examined.
8.6
Sections/ Finished rolled plates of bullet will be transported to NRL site, from
contractors fabrication shop/yard. Route survey up to refinery and inside refinery
shall be carried out by the contractor to assess the transportation constraints.
Accordingly nos. of shell sections / joints shall be firmed up on the basis as well as
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the area demarcated within refinery premises for carrying out the mounded bullet
fabrication.
It shall be the responsibility of contractor to arrange and provide all loading /
unloading facilities, transportation of bullet sections from refinery gate to site inside
the Refinery premises (where bullets are to be erected / installed), including all roll
on, roll off facilities, crane(s), labor etc. contractor shall conduct complete survey
and shall strengthen all weak areas. Contractor shall remove all route hindrances
to facilitate transportation of bullet sections. Quoted price shall include all charges
towards all activities not specifically mentioned but required to transport the bullet
sections from refinery gate to erection site inside the refinery. Contractor shall
submit transportation scheme along with the offer.
8.7
Damage / loss of material consigned by contractor to site in transit shall be to the

contractors risk and damaged / lost material shall be replaced/ resupplied by the
contractor free of cost.
8.8
All materials whatsoever required for welders qualification, welding procedure tests
and production control coupons shall be arranged by the contractor. All instruments
required during performance testing to establish guaranteed figures shall also be
arranged by the contractor.
8.9
Selection of electrodes and filler wires shall be as per Standards/Codes and

specification. Welding consumables (Electrodes / Filler wires / Fluxes) shall be of
repudiated make like D&H / ADVANI / ESAB. Tests required, if any, to satisfy the
technical suitability of these electrodes/filler wires shall be arranged and done by
contractor without any price/time implication.
8.10
Welding parameters of any approved weld procedure shall not be changed without
prior approval of the Owner / PDIL.
8.11
All electrodes & fluxes shall be properly baked/dried as per manufacturers

recommendation before use.
8.12
Suitable trench (with proper arrangement to safe guard the compactness of mound)
shall be made to carry out the in-situ welding of closing circ. seams. Width of trench
shall be suitable for carrying out heat treatment and there after coating of the
closing seams.
8.13
Plates of different thickness shall be made flush at the inner surfaces of equipment
unless otherwise stated.
8.14
Bullets dished head shall be hemispherical, Dome dished head shall be

torispherical type
8.15
C.S. dished head, if cold formed or hot formed below normalising temperature, shall
be subsequently normalised. Formed ends of vessels with diameter less than
1600mm shall preferably be made in one piece. Larger heads which can not be
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formed in one piece shall be fabricated in minimum number of pieces, with prior
approval with following guide lines;
a) If in two pieces, the welding seam shall be included in the middle third and
preferably on the center line.
b) If in petal construction it shall be with meridional seams and a central cap of
diameter not larger than 0.75 times the vessel OD.
c) For Bullets, the number of pieces / petals shall be indicated in offer.
8.16
Production test coupons shall be applicable for all the mounded bullets irrespective
of thickness.
The production test plate shall be from material of the same heat and thickness as
of shell/head. During and after welding, the test plates shall be subjected to same
heat treatment as and together with the course they represent. Test plate coupons
shall be subjected to all tests like Micro, Macro, Hardness, Charpy-V Impact test
etc. in addition to mechanical tests (Tensile, Transverse tensile, Bend (root and
face) test as required.
Minimum numbers of production test plate coupons shall be as under,
a). Two production test plate coupons representative of one longitudinal and
another circumferential seam shall be provided for each welder ,procedure,
position, thickness & heat in each bullet shell.
b). One production test plate coupons representative of weld seams shall be
provided for each welder, procedure, position, thickness and heat for welded
dished heads/cones.
c). Extra coupons shall be preserved to take care of eventuality of retests.
8.17
Equipment having diameter greater than 2 meters shall have only two longitudinal
welds. Orientation of longitudinal weld seams between adjacent courses shall be
staggered. Location of weld seams shall be kept so as to avoid coverage with initial
mound i.e. 1200 to bullet center line to permit visual inspection. Orientation of
longitudinal seams and position of circumferential seams shall be clearly marked in
the fabrication drawing.
8.18
All sharp corners shall be rounded off with smooth radius. Inside edge of manhole
and hand holes at the internal surface shall be rounded to min. radius 5 mm.
8.19
All welding neck flanges shall be bored to suit nozzle I.D.
8.20
Internal Stiffener Rings (T-type) shall be fabricated and fitted to the shell belts and
welded in position immediately after shell forming to avoid distortion.
8.21
All parts involving welding construction including stiffeners shall have continuous
welds unless otherwise stated.
8.22
All manways, pads, nozzles, lugs for lifting, CP lugs etc., shall be fabricated and
welded on bullet section in contractors shop/fabrication yard before transporting to
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site. Contractor shall ensure the overall dimension of the bullet pieces / sections
with nozzle welded can be transported as an ODC by the transporter
8.23
Suitable mouse hole/Notch shall be provided in stiffener to clear long seam weld.
8.24
Stiffeners shall be provided with drain holes of radius between 50 and 100mm in the
bottom part to allow the vessel to be completely drained and to allow sufficient flow
towards either the bottom discharge. Drain opening shall be suitably reinforced.
Stiffeners, protruding nozzles shall be provided with mouse holes of 25mm radius in
the top of the vessel to release the air during hydrotest.
8.25
Due provisions must be kept for venting out entrapped gases during welding of
pads, flanges etc.
8.26
Inner edges of all mouse holes, notches in stiffeners shall be seal welded.
8.27
All nozzles shall be self-reinforced nozzle type including those on dome unless
otherwise specified.
8.28
All nozles shall be set-in type welded. If manhole & dome with pad construction is
specified, all nozzle reinforcing pads shall be tested pneumatically at 0.5 Kg/cm2g
pressure with soap solution on attachment welds. Tell-tale holes shall be plugged or
filled with non-hardening mastic to prevent ingress of water.
8.29
All internals fabricated in pieces shall be shop / fabrication yard assembled and
properly match marked for easy assembly at site.
8.30
Matching sections of bullets to be assembled at site, shall be trial assembled &

match marked in shop / fabrication yard, for proper assembly at site. Each section
to be assembled at site shall be provided with lifting lugs to facilitate handling during
transportation and erection at site. Lifting lugs shall be preferably welded at the
location of internal stiffener to avoid over stressing of shell.
8.31
Equipment / sections shall be provided with suitable bracing / stiffeners to avoid any
damage during transportation and erection at site. Welded temporary attachments
shall be kept to a minimum, and may only be used for alignment or of lifting of
vessel segments during construction. The same shall be removed after erection.
8.32
All flange bolts shall straddle centerline unless otherwise stated.
8.33
All butt-welds shall be double-V full penetration welds with back chipping and
rewelding from the second side. Single V welding with backing strips shall not be
permitted.
For those joints which are inaccessible for back chipping, the root run shall be
carried out with TIG process.
Cable with CP lugs shall be thermit welded.
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All welding shall be done preferably by submerged arc welding SAW. SMAW / SAW
shall be adopted for field weld closing circumferential seams of bullet section and
areas where SAW is not possible
8.34
For general fabrication tolerances requirements, code of design shall apply.

However, because of relatively high external pressure on mounded bullet, some of
the tolerances shall be limited as follows:
a). For circumferential joints, the misalignment of the center lines of plates shall
not exceed 10% of the thickness of the thinner plate or 3mm, whichever is the
smaller.
b). The out of roundness of the cylinder sections, i.e. the difference between the
maximum and minimum internal diameters measured at any one cross section,
shall not exceed 0.5 times the thickness of the vessel shell.
8.35
Bolts & Nuts

External bolting for gasketed flanges shall always be stud bolts and nuts. For all the
flanges according to ASME B 16.5, ASME B 16.47 and API 605, the threads shall
be in accordance with ASME B 1.1, having class 2A allowance for Bolts & Studs,
and class 2B tolerance for nuts. Nuts for Stud Bolts shall be Hexagonal heavy
series.
UNC for dia < 1
8UN for dia > 1
For flanges not in standard, the threads shall follow the rules of ISO (diameter in
mm) Threads of bolts and nuts shall be coated with lubricant before installation to
prevent galling of threads.
8.36
Preheat treatment requirement shall be specified for each type of weld including
those for all attachments (including temporary attachments) and tack welds, taking
into account climatological effects.
8.37
Stress relieving is mandatory for bullet. Welding of all parts (including temporary
attachments) must be completed before heat treatment of individual section. Inter
section circ. seams shall be local stress relieved electrically.
After PWHT of vessel/sections, no welding / cutting of temporary attachment shall
be permitted.
8.38
Only steel scaffolding shall be permitted.
8.39
4 mm thick HDPE bolted sleeve (in two halves) with flexible cover fixed with SS
Strap shall be provided around dome-1, dome-2 and nozzles mark M1 & M2 to
avoid any damage caused by bullet expansion / contraction due to pressure /
temperature and movement due to seismic effect. Suitable sealing arrangement
shall also be provided to disallow any ingress of rainwater to mound. One 3 thk.
Aluminium canopy shall also be provided over the dome and nozzles to further
safeguard against rain water ingress.
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8.40
Bullet shall rest on a minimum 150mm resilient pad (Neoprene rubber) placed
below the bullet shell at tunnel cut out, made for outlet nozzle. Suitable metallic
enclosures shall be provided to safeguard the pad from fire and weathering effect.
8.41
All internal pipes / stilling well shall be perfectly vertical and the same shall be
checked & recorded.
8.42
Inside diameter / surfaces of stilling well pipes shall be free from welding / drilling
burrs
8.43
Permanent reference points shall be located longitudinally on the top of the vessel
to monitor the bullet settlements. The maximum spacing of these reference points
shall be approximately twice the vessel diameter. A minimum three reference points
shall be installed to identify possible vessel bending (i.e. two near the tan line and
one on middle)
8.44
Name plate: NRL contractor shall provide name plate on each equipment. In
addition to providing name plate, the following details are to be punched on the
manhole flange ring: design code, design temperature, test pressure, date of first
test, inspected by, certificate number, drawing number.
9.0
FABRICATION AND ERECTION METHODOLOGY OF LPG BULLETS
9.1
The Methodology proposed here is for the guidance of the Contractor.
9.2
The construction methodology for mound shall be as stated in civil scope of work.
9.3
The Contractor shall provide a detailed methodology and this must be submitted
formally to the Owner / PDIL for their review / acceptance.
9.4
The following Methodology should be read in conjunction with the overall

Construction Methodology.
9.5
LPG Bullets shall be fabricated in 6 sections or as the length shell piece shall be
decided to suit transportation & erection and each duly tested, inspected, trial
assembled only for connecting ends, match marked and stress relieved at
shop/fabricated yard & transported to site.
9.6
It is presumed that the Contractor shall use steel plates having minimum 2.5 meters
width. The plates should be ordered in such lengths so as to ensure that there are
Maximum 2(two) longitudinal weld joints in one shell belt of the bullets of equal shell
length.
9.7
To reduce stress concentration at shell to dome weld joint & to make dome bottom
piece forging economical, insert plate has been proposed.
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9.8
The Contractor shall roll and weld together the 2.5 meter wide plates into 2.5 meter
wide shell belts and re-roll after welding to the exact internal diameter as per
approved drawing.
9.9
A number of the shell belts will be welded together to form a shell section. The
number of shell belts forming a shell section depends upon the transportation of
each section from the shop / fabrication yard to its final location on the mound sand.
9.10
To reduce the number of inter section circ. seams, size of shell section shall be
suitable for moving by minimum two (2) Nos. mobile cranes of suitable capacity.
9.11
Length of Bullet shell piece shall be decided to suit transportation by ODC

transporter.
9.12
It is proposed that hemispherical ends will be used for these bullets. However the
Contractor may wish to import pre-fabricated hemispherical ends or Petal sections
thereof.
9.13
External Coating of bullet sections will be done prior to installing the same on the
sand bed. Contractor shall follow recommendations of the applicator on handling
and transportation of coated sections / bullets with a view to eliminate / minimise
damage of coating in transit. Suitable resilient / nonmetallic sheet shall be wrapped
on shell during transportation
9.14
An A frame shall be installed on the mound. If segments are proposed to be

erected by crane, the crane is to be positioned close to final segment erection
position to handle the said activity. Further lifting frames shall be used for lifting/
handling the shell covers over the foundation during different stages of fabrication,
inspection & testing.
9.15
The sections for each bullet shall then be lifted and transported to the sand bed in
accordance with the overall approved Construction Methodology.
9.16
The first bullet section to be laid on the prepared, templated and leveled sand bed
will be the section adjacent to the R.C.C. Wall.
9.17
The other section will be installed in sequence and each section aligned with
adjacent section within tolerance limits and tack-welded in place.
9.18
The Contractor shall ensure that prior to commencement of final circ. welding, bullet
sections that are tack-welded together are dimensionally inspected to ensure the
alignment and other dimensional requirements have been met.
9.19
After completeness of welding & prior to commencing hydrotesting, the Contractor

shall ensure that both the outermost bullet to be tested and the adjacent bullet are
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supported upto 600 from the center line on either side of the bullet (total 1200). This
is the minimum sand bed level for Hydrotesting.
At the time of hydrotest, the adjacent bullets on either side of the bullet under test
pressure shall be kept water filled, i.e., minimum three adjacent bullets including the
one under test in the middle shall remain completely filled with water anytime during
hydrotest.
9.20
After completion of the final circ. welds and acceptance / approval of radiography,
the whole LPG bullet will be finally hydrotested. The whole bullet shall be air dried
to remove all moisture after hydrotesting. In case of bullet having in-tank pump
system, Removal of water from bullet shall be done by employing a water draining
pump and manually removing the balance water till the bullet is completely emptied.
Contractor shall arrange suitable draining pump and air compressor.
9.21
After successful completion of the hydrotest, weld areas resting on the mound
which could not be visually inspected during hydrotest, shall be checked by
ultrasonic testing & MPT from inside the bullet for leakage. Wet fluorescent MP
Examination of all welds shall be done after hydrotest (100% on inside & excepting
lower 1200 of C seam welds from outside).
9.22
After ND Examination, testing & inspection, the surface around the final circ. Welds
shall be coated in accordance with coating specifications enclosed.
9.23
Trench provided for field weld shall be properly filled and compacted. It is extremely
important during the filling of the mound that the fill is raised uniformly on each side
of bullets so as to avoid any pressure imbalance whatsoever on any of the bullets.
9.24
During the whole fabrication process the Contractor shall have to work strictly in
compliance with the QA/QC procedures and requirements as set out in ASME SEC
VIII Div 2 (latest) and this specification.
9.25
After award of job, within 3 weeks, the contractor shall submit the following for
PDILs approval
a) Erection schemes indicating type of cranes used, their capacity & sketches
showing the location of crane for unloading, shifting & erection etc. The
erection schemes must be safe & workable. Decision of PDIL/Owner in this
regard shall be final & binding.
b) Manpower deployment at site.
10.0
MINIMUM QUALITY CONTROL REQUIREMENT.
10.1
Quality Assurance (QA) shall mean the organizational set up, procedures as well as
test methods and facilities developed by contractor in order to ensure that all
equipment leaving Contractors shop are of the highest possible standard quality i.e.
equal to or exceeding the requirements specified.
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Quality Control (QC) shall mean all the test, measurements, checks and calibrations
to be carried out in Contractors shop in order to compare the actual characteristics
of the equipment with the specified ones, as well as the documentation
(certificates/records) containing the data or results of these activities.
10.3
Contractor shall submit a description (manual) of his QA/QC with a view to this
specification along with offer.
10.4
QA/QC systems may be based on systems already developed and implemented by

Contractor for other similar jobs/scheme. It is the contractual obligation of
Contractor to develop and implement adequate QA/QC system. Owner/PDIL shall
have the prerogative to check all aspects of agreed QA/QC systems and to
introduce modification, if deemed necessary, during the execution stage of this job.
10.5
QA/QC systems shall cover all products and services of the contract including
subcontracted jobs, if any, e.g. documentation and site works etc..
10.6
Minimum quality control requirements as specified in Doc. No. EM163-401ANNEXIII shall be considered as indicative only and they shall need expanding to
incorporate items such as (a) Characteristic to be verified (b) Procedure Reference.
(c) Acceptance Criteria, (d) Verifying Document etc.
10.7
The operation sequences denoted in Doc. No. EM163-TS-401-ANNEX-III REV 1

are indicative only and shall be revised as required, by the contractor to conform to
his detailed fabrication methodology and sequencing.
10.8
Contractor shall be required to produce a detailed and exhaustive quality plan

based on these minimum quality control requirements and to suit his fabrication and
hydrotesting.
11.0
11.1
All raw materials shall be covered with proper identifiable material mill test
certificate endorsed by third party: Lloyds / BV / TUV for imported materials & PDIL
for indigenous materials. All charges towards such inspection shall be included in
price.
11.2
All equipment shall be inspected during various stages of manufacture starting from
identification of raw materials to completion by PDIL/Owner or its authorized
inspecting authority. The equipment shall be considered acceptable and for
dispatch only after final certification for acceptance & dispatch clearance are issued
by the inspector
11.3
Bought out items or items sub-contracted to other approved sub-contractors shall

also be inspected at the sub-contractors works. However, standard items like bolts,
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nuts, ordinary gaskets etc. may be exempted from the stage inspection with specific
approval from PDIL.
11.4
Inspection categorization plan specifying critical, pressure parts and non-pressure

parts shall be prepared by the LSTK contractor for PDIL /NRL approval.
11.5
Inspection by third party, if specified, shall be arranged by the contractor. It shall be

the responsibility of the contractor to make available to the inspector all the
new/revised latest drawings, calculations and other enquiry / relevant
documents/information to facilitate successful inspection.
11.6
Inspection order on third party shall also include specific instructions for making
copies of all correspondence from inspecting authorities to PDIL and reporting
monthly progress and status with indication of status (delayed/on time) of delivery of
the order to owner / PDIL. Complete responsibility of getting approval of drawings,
calculations and documents from inspecting authority shall be that of the contractor.
11.7
All charges / fees for statutory approvals shall be borne by contractor.
11.8
The following NDT requirements are mandatory in addition to the requirements of

code/specifications.
A)
Radiography
i) Technique for radiography and acceptance criteria shall be as per code of
design and construction.
ii) Radiography when called for shall be applicable to all pressure welds i.e.
longitudinal and circumferential butt-welds including butt-welds in stiffener.
iii) When formed heads are made of welded plates/petal construction all weld
seams prior to forming and after forming shall be fully radiographed.
iv) All the T-joints shall be radiographed.
B)
Ultrasonic Examinations
i. Butt weld plate thickness > 50 mm as supplement to radiography.
ii. All butt-weld (after Heat Treatment)
iii. Full penetration welds of nozzle attachments on equipment shell/head as
substitute for radiography.
iv. 4 inch around the nozzle opening (before cutting / opening hole)
v. Any repair welds (before and after hydrotest)
vi. All circumferential welds located in the lower 1200 of sand bed (after hydrotest).
vii. 100% T-joints (after hydrotest).
C).
Magnetic Particle Inspection

i. Back Gouge of all butt-weld and final layer (from outside)
ii. All welding edges of welds to come in shell over a width of 50mm on either side
of plate for detection of crack, lamination, segregations control.
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iii.
iv.
v.
vi.
Edges of nozzle opening.

Nozzle attachment welds (both sides)
Root run and final layer of nozzle to shell weld.
Knuckle surface (inside and outside surfaces) of dished ends / toriconical and
pipe bends, after forming for crack detection.
vii. Fillet weld of internal shell stiffener and R.F. Pads of nozzle and lifting lugs.
viii. All pressure bearing welds (both Butt and Fillet welds), Shell to stiffener ring
welds, flange to web weld of stiffening ring & Nozzle welds etc. (after PWHT).
ix. 1/3rd. length of fillet weld of stiffeners (both side) at 00, 900, 1800 and 2700
(after hydrotest)
x. 100% MPI on all welds on inner surface and also on outer surfaces of all
accessible welds e.g. field joint (after hydrotest).
(Note: wherever DPT is mentioned in Specification and/or design code, MPI
shall be employed. All MPI shall be wet fluorescent type)
D).
Hardness & Impact test

i. Hardness test shall be carried out of HAZ/Weld of production Test coupons and
on actual weld of vessel. The value of hardness shall not be more than 225
BHN.
ii. Hardness survey at every 2500mm distance after final PWHT shall include all
pressure bearing welds (both Butt and Fillet welds), Shell to stiffener ring
welds, flange to web weld of stiffening ring & Nozzle welds etc. The value of
hardness shall not be more than 200 BHN.
iii. Impact test value / energy of production test coupon shall meet the requirement
of ASTM specification SA 20 for minimum design metal temperature.
iv. The RTJ face of flange shall not have hardness greater than 140BHN.
v. Hardness of Soft Iron Octagonal ring type gasket shall not exceed 90BHN
maximum.
E).
Test on Production Weld Coupons

The following test shall be carried out as per methods of testing in the governing
codes:
i. Two transverse tension tests.
ii. One all weld tensile test.
iii. Four bends (2 Roots & 2 Face test).
iv. Two sides bend test with weld located in the center of bend.
v. Hardness test on PTC weld & HAZ (the hardness value shall not exceed 200
BHN).
vi. Micro & Macro examination of welds.
vii. Charpy-V notch impact test on welds and HAZ.
For low temperature service impact test shall be carried out at lowest of
minimum ambient temperature, design temperature and minimum design metal
temperature (MDMT).
viii. The acceptance criteria for energy absorption shall be as per Table A 2.15 of
SA 20 / 20M in case of Design Code ASME Sec.VIII Div.2 & or the Design
Code whichever is more stringent.
EM163-TS-401
REV
DOCUMENT NO
SHEET 28 of 36
ix. For equipment meant for caustic service, H2S service, Amine service etc., one
hardness test reading shall be taken on inside of each shell section, head,
longitudinal weld, circumferential weld and nozzle longitudinal weld after
PWHT.
F) Four points on each shell course at position 0, 90, 180, & 270 degree shall be
marked by preparation of proper dimensional sketch for future checking record of
initial NDT list of these reference points shall be maintained for periodic/
subsequent inspection per OISD- 150. Base UT reading of shell, dome & nozzles is
required for future comparison purpose & trending/ corrosion rate analysis.
12.0
HYDROTESTING & SETTLEMENT
a).
Hydrotesting
All completed equipment shall be tested hydrostatically as per the requirements of
specifications/codes & approved hydrotest procedure in presence of the inspecting
authority. Prior to hydrotest, all weld splatter, weld studs, scale, dirt, etc. shall be
removed from the vessel. The vessel is to be supported while hydrotesting on sand
bed which is to be laid & completed upto a level of 120 degree taken from the
center of vessel to the edge of vessel. Entrapped air near dome shall be completely
removed by suitable means during hydrotest. Contractor shall submit a detail
procedure for Hydrostatic testing for approval by Owner/PDIL prior to
commencement of testing time. Pressure-Time graph shall also be submitted.
All necessary precautions shall be taken to safe guard against the risk of brittle
fracture during hydrostatic test at site. It is suggested that the temperature of the
testing medium shall not be less than 15C. PH of water used for hydrotest shall be
between 6.0 7.0. After hydro testing water shall be drained in NRL drains.
At the time of hydro test the adjacent bullets on either side of the bullet under test
pressure shall be kept water filled, i.e., minimum three adjacent bullets shall remain
completely filled with water anytime during hydro test.
A method of measuring the water height in the bullet is also to be established.
Water shall be filled / emptied in stages 25%, 50%, 75% and full with 2 hours
holding period at stages. Loading rate shall be monitored such that the loading rate
does not exceed 2.0M/day subject to a pumping rate of not more than 20cm/hour.
Minimum 2 nos. Dial gauges, dial graduated over the range of not less than 1.5
times and not more than about 2 times the test pressure and an accuracy of +/- 0.6
percent or finer, shall be used.
All pressure gauges / pressure recorders (the same accuracy or finer) used in
testing shall have a calibration record showing values of standard indicated
pressure and validity period. Inspector shall verify that calibration tag is displayed
on the pressure gauge/recorder.
Pressure pumps, pipe / hose pipe, fittings and other accessories shall be capable of
developing and withstanding the test pressure.
Hydro Test pressurization shall be developed in stages i.e. 0 Working Pressure,
Design Pressure, Hydro test Pressure with holding period of two hours minimum at
EM163-TS-401
REV
DOCUMENT NO
SHEET 29 of 36
stages. Depressurization shall also be done in stages i.e. Hydro test Pressure,
Design Pressure, Working Pressure with holding period of two hours minimum at
stages. All visible weld joints / connections shall be visually inspected for any
leakage/sweating at various stages.
After successful hydrotesting, test water shall be transferred to the other Bullet
ready for hydro testing.
Unless otherwise stated, gaskets used during testing shall be same as specified for
operating conditions.
Sweet potable water shall be used for hydrotesting. Minimum duration to hold
hydraulic pressure shall be 4 hours
b) Settlement
Their initial levels of equidistant points (bench marks) placed on top of the bullet
shall be taken with respect to minimum 3 numbers permanent bench marks for
settlements readings which shall be provided as near to bullet as possible but not
more than twice the vessel diameter from the periphery of the mound. Further
bench marks shall be painted as per vessel specifications. Standard reference level
for comparison of future readings with current measurements shall be provided.
Mound settlement shall be recorded / checked after allowing 24 hours time at
different filling/emptying stages of hydrotesting of each bullet and after 48 hours
with the bullet completely filled. Also after completion of hydro-testing, settlement
recording shall be continued by the contractor during construction of mound, and till
successful commissioning of bullet once in a week. Settlement recording shall be
done preferably when atmospheric temperature is not more than 30 Celsius..
IMPORTANT
The settlement rate during this testing period needs to diminish with time as
otherwise there would be a danger of instability. If the rate does not diminish
adequately, the client/inspecting authority shall be informed immediately. The bullet
shall be (partly) emptied, and a geotechnical / specialist should be consulted.
13.0
CALIBRATION
13.1
Contractor shall prepare & submit a LPG Mounded Bullet calibration procedure
including Calibration Chart in accordance with IS:2009 & IS:2166. Contractor shall
obtain necessary approval for calibration from statutory authority CPWD / Weight &
Measurement Deptt. or competent authority.
14.0
PRE-COMMISSIONING/ COMMISSIONING
14.1
Pre-commissioning shall include cleaning, testing & calibration of instruments to

make the bullet ready for commissioning.
EM163-TS-401
15.0
REV
DOCUMENT NO
SHEET 30 of 36
GUARANTEE
15.1
The contractor shall guarantee all the bullets and their components against faulty
design with regard to mechanical adequacy, improper material of construction and
poor workmanship after successful testing at site for a period as specified in
commercial terms and conditions.
15.2
Approval by PDIL of design calculation and detailed shop drawings will not in any
way absolve the contractor from his responsibilities to supply equipment in
accordance with order specifications
15.3
Should any repair or replacement be necessary owing to any type of failure on

account of design, material or workmanship of the equipment, the contractor shall
by dint of his guarantee be bound to replace the same either in part or in entirety
without additional cost at site. Repaired or replaced parts shall be covered by same
guarantee as in case of main supply.
16.0
DOCUMENTATION
16.1
Before starting any fabrication, drawings / design calculation must be get approved
from PDIL and inspection authorities. Detailed design, fabrication drawings & FE
Analysis shall be prepared by contractor based on contract documents and shall
bear reference document number & revision of the corresponding PDIL reference
drawings including item name & code, clients name, project name, fabricators
name, P.O. No. clearly indicating all design data, nozzle data, details of all parts
with tolerances, all welding joint details and detailed bill of materials etc. Location of
weld seams, construction notes, welding processes, detailed specification of
electrodes including NDT tests etc. as applicable shall be clearly indicated in the
drawing.
16.2
Contractor shall furnish to PDIL within 2(Two) weeks of award of contract, a

complete list of drawings/ documents which will be prepared and used. This
schedule of drawing shall show the title, drawing no., revision no. together with the
proposed date of issue/submission. A revised schedule shall also be furnished
periodically at least on monthly basis, until the fabrication work is completed.
16.3
Drawing submitted for approval must be complete in all respects and thoroughly
checked and approved by contractors competent authority before submitting to
PDIL. Drawings without complete information are likely to be rejected and any delay
on this account shall be attributable to the contractor.
16.4
All drawing shall be drawn in AUTOCAD 2000 R-14 to the scale. Subsequent
revisions, incorporation of comments shall also be made in AUTOCAD R-14.
Manually drawn new and/or revised drawings shall not be accepted.
EM163-TS-401
16.5
REV
DOCUMENT NO
SHEET 31 of 36
All documents/drawings shall be in English Language and in Metric system

(Pressure in Kg/cm2g.).
16.6
Documents and letters shall be furnished in electronic format. The software used
shall be as follows.
a). MS OFFICE 2003 or above.
b). ADOBE ACROBAT 6.0 & above
16.7
Before starting any fabrication, drawings / design calculation must be get approved
from PDIL and inspection authorities. Any comments marked on fabrication
drawings shall have to be incorporated and decision of PDIL in this regard shall be
considered as final. In case of third party inspection COPY OF
CORRESPONDENCES WITH THIRD PARTY shall also be endorsed to PDIL.
16.8
Approval / comments on various documents shall be given progressively by PDIL

within 2(two)-3(three) weeks of the receipt of the same mailing time excluded.
Turnaround time for resubmission of revised drawing incorporating PDIL comment
shall be 2(two) weeks maximum from the date of dispatch of earlier commented
drawing / doc. By PDIL. Any delay in approval due to delayed submission shall be
wholly attributed to the contractor.
16.9
After approval, one set of drawings/documents shall be given to the inspector by the
contractor.
16.10
Contractor shall submit 1(one) soft copy (CD-ROM) along with 8(eight) prints of
documents to PDIL and 4(Four) prints of documents to NRL followed by visit of their
personnel on an agreed schedule for getting spot approval. Contractor shall depute
their concerned engineer along with draughtsman for deciding and incorporating the
various agreed comments during their stay. Same procedure shall also be followed
for the approval of subsequent revisions, if any. All soft copy documents/drawings
shall be in an editable format compatible with Auto CAD 2000.
16.11
Revision for AS-BUILT shall also be entered in CAD files. The nos. of copies for
ASBUILT Drawings, Documents, Design calculations, Data Folders comprising
Material Test Certificates, Inspection /measurements records, NDT reports, WPS,
PQR, WPQ, QAP, PWHT records, Hydro & Pneumatic test reports, rub-off Name
Plate, catalogues, Literatures etc. shall be 8 (eight) sets of hard copies, properly
bound in folders and indexed. Two sets of CDs of all drawings & two sets of
Reproducibles shall also be submitted. Documents shall be with certification for
ASBUILT by the inspecting authority (Uncertified drawing / documents shall not be
accepted as AS-BUILT).
16.12
For the documents submitted for approval or comments, the delivery is fulfilled only
when documents are received in a state suitable for the action required.
EM163-TS-401
16.13
REV
DOCUMENT NO
SHEET 32 of 36
Payment against submission of approval of drawing, if applicable, shall be made

after approval of drawing under code 2.
16.14
Approval of design calculation and detail fabrication drawing by PDIL will not in any
way absolve the contractor his responsibilities to supply the equipment in
accordance with the order.
16.15
DRAWING APPROVAL CODE:

i) Approval code-1 shall mean finally approved.
ii) Approval code-2 shall mean approved for fabrication with comments and
revised drawing to be submitted after incorporating comments.
iii) Approval code-3 shall mean Drawing not approved and new drawing to be
submitted incorporating the comments.
16.16
Equipment shall fall under the purview of PESO/CCOE and shall require statutory
approval from inspector of Explosives. It will be the responsibility of the contractor to
get the fabrication drawings / design calculation of the equipment approved at his
cost.
Contractor shall obtain approval from CCOE for drawings and design calculations
before start of bullet fabrication
Bullet shall be requiring statutory approval from CPWD/Weight and Measure deptt.,
it will be the responsibility of the contractor to get the calibration procedure /
calibration chart of the bullet approved at his cost.
16.17
16.18
Documents marked with (*) are to be approved by the PDIL Design Office.
Documents marked with (**) shall be approved endorsed by the inspecting authority
during detail engineering stage.
16.19
All approved PESO/CCOE documents must be supplied.
16.20
All final documents indicated against Sl.No. 16 to 47 must be properly arranged,

INDEXED and bound in one folder for each project.
16.21
All documents, their number of copies and schedule for approval and submission
shall be as specified below.
16.22
The delivery time in weeks from the data of Telex of Intent/Order for each document
is given below and defines the documents for approval. Documents are to be
received in a state suitable for action required.
EM163-TS-401
REV
DOCUMENT NO
SHEET 33 of 36
TABLE - 1 (Contractors Drawings & Documents Submission)

Sl.
No.
Description
Out line sketch showing thickness of

main parts, weight & mound details
List of items likely to be subcontracted
with probable vendors
Fabrication / Erection Methodology
Details of coating & CP system
Details of Instrumentation system
Based on delivery stipulations a time
bar chart indicating time required for
material procurement, fabrication,
testing, transportation, site assembly,
erection, Hydro- test
Man power deployment schedule
List of Machinery & deployment
schedule
List
of
machinery
for
excavation/mounding
List of crane for erection of section on
mound indicating details like boom
length, radius, lifting capacity, load to
be lifted
Latest Test certificate of fire proofing
coating material of Underwriters
Laboratory
Reference list of similar equipment
already supplied indicating various
parameters
and
material
of
constructions.
Give description of present shop load
and spare load available for this job
and annual turn over
Final civil load data ( * )
List of drawings, calculations, various
procedures etc. with schedule of
submission ( * )
Design calculations of bullet, enframe
/ FE analysis (2-D & 3-D), safety
valve sizing, C.P. system calculation,
mound / retaining wall calculation,
civil design calculation etc. ( * )
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Copies Reqd
with Bid
Copies Reqd after L.O.I.

Qty.
Days
from
L.O.I.
8
8
8
8
8
8
8
8
8
8
21
21
EM163-TS-401
REV
DOCUMENT NO
SHEET 34 of 36
17
18
19
20
21
22
23
24
25
26
Detail Shop Drgs./fabrication Drgs. of

a). Bullet Mechanical design( * )
b). Bullet FE Analysis( * )
c) Bullets & Bullet components ( * )
d) Barricading & sprinkler for
fabrication yard ( * )
e) CP system ( * )
f) TRU ( * ) (**15 days from LOI)
g) Earthing layout ( * )
h) G.A. of mound ( * )
i) Excavation ( * )
j) Mound detail including pipe support
columns (*)
k) Retaining wall layout & detail (*)
l) Platform detail ( * )
m) Drainage network drg. for mound
system. ( * )
n) Specs. of Instruments & valves ( * )
o) Details of instruments & valves ( * )
p) Any other detail/drgs. reqd. (*)
q) Mound const. Methodology (*)
All other document required by,
a). Piping scope of work
b). Civil scope of work
c) Instrument scope of work
d). Electrical scope of work
Un-priced copy of purchase order of
bought out items ( * )
Quality Assurance Plan ( * )
Procedure
for
shot
blasting,
coating/painting including painting of
closing seam ( * )
Procedure for hydraulic test, heat
treatment including PWHT of closing
seams, settlement check. ( * )
Procedure for bullet calibration (*)
Procedure for alignment of bullet
sections. ( ** )
Detailed
manufacturing
schedule
CPM / PERT to be submitted every
month ( * )
Detailed
transportation
Drawing
indicating overall dimensions. C.G.,
weights & permissible forces during
transportation & handling instructions.
10
21
10
21
21
8
8
30
30
30
8
8
30
30
30
30
EM163-TS-401
REV
DOCUMENT NO
SHEET 35 of 36
27
28
29
30
30
30
30
After handling
over
equipment
After handling
over
equipment
After handling
over
equipment
-do-
-do-
-do-
8
8
8
-do-do-do-
8
8
-do-do-
8
8
8
8+2R+
2E
8
-do-do-do-do-
8+2R+
2E
-do-
31
Records of ovality, alignment, visual

check, dimensional check etc. ( ** )
32
Records
of
NDT
tests
e.g.
Radiography, UT, DP, MPI, hardness,
impact etc. ( ** )
(Radiographed films shall also be
supplied)
Records
of
shot
blasting,
coating/painting. (** )
Materials
test
certificates
duly
stamped by inspecting authority ( ** )
PWHT Charts ( ** )
Test on production test coupons ( ** )
Hydraulic & pneumatic test report of
bullet and R.F. Pad respectively (**)
Bullet Settlement check record. ( ** )
Inspector
final
certificate
of
compliance
Inspector Release Note
Suppliers Guarantee Certificate
Rub-off Name Plate (**)
All final as built drgs. including
detailed fabrication/shop drgs ( ** )
Mechanical design calculation and
FEAnalysis
Operating manual wherever required
including C.P. System
All Drgs./Doc. of bought out items
PESO/CCOE approved drawings and
calculations
Statutory Agency approved calibration
charts
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
(*)
Welding procedure & performance
record approved by inspecting
authority (as per ASME SEC. VIII
DIV. 2) ( ** )
NDE personnel qualification/record
(**)
Sketch showing weld seams no. &
welder identification number. ( ** )
Specification of welding consumables
(meeting ASME SEC. IX (**)
-do-
-do-do-
-do-
EM163-TS-401
REV
DOCUMENT NO
SHEET 36 of 36
R Reproducible / Polyester film

E Electronic file / CD ROM
TABLE 2 (No of copies)
Description
Technical offers
GA
Drawings,
Fabrication
Shop
drawings & documents
for approval
Mechanical
design
calculation, FE analysis
for review / approval
QAP
for
review /
approval
Find / As built drawings,
design and calculation,
FEA, QAP, WPS, PQR,
WPQ, Material Test
Certificate
ND
test
reports documents Data
folder(Bound & duly
Indexed.
Hard
copy
6
8
No. of Copies
PDIL
Soft files
Reproducible Hard
CD ROM
polyester film copy
--4
1
-4
NRL
Soft files Reproducible
CD ROM polyester film
--1
--
--
--
--
--
--
--
--
--
--
1
(Editable
Soft files)
PROJECTS & DEVELOPMENT

INDIA LTD
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 1 of 6
PROCESS DATA SHEET

FOR
MOUNDED BULLETS
2
1
0
REV
02.09.2015
18.06.2015
29.05.2015
REV DATE
02.09.2015
18.06.2015
29.05.2015
EFF DATE
Client Comments Incorporated

Comments Incorporated
First Issue
PURPOSE
SKK/ VKS
SKK/ VKS
SKK/ VKS
PREPD
SCA
SCA
SCA
REVWD
SCA
SCA
SCA
APPD

INDIA LTD
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 2 of 6
Project:InstallationofLPGMoundedBulletsat
NRLRefineryLimited
Equipment:LPGMoundedBullets
TagNo.: 45VV101/102/103/104
No.ofunits:Four(4)
Service:LPGSTORAGE
Size:mm(ID)7000x52000(TLTL)
Position:HorizontalCylindricalwithdishedends
DESIGNDATA
MATERIALOFCONSTRUCTION
Fluid:LPG
Shell:CS(Refer.Clauseno5.1,ii(a))ofOISD150
(NOTE2&NOTE14.)
CapacityTypem3:2071.3(waterCapacity)
Liningifany:NOTE2
Capacity(Max.LPGStored)m3:1760.56(85%
Capacity)
Head:
Flow(INLET)T/hr:13.04
NozzleNeck
PumpOutm3/hr:291(Max.)
NozzleFlanges
Workingpressurekg/cm2g:2.3378.6
StudsandBolts
DesignPr.Kg/cm2g(Internal):14.5+Statichead
DesignPr.kg/cm2g(External):FullVacuum+Wtof Nuts
Mound
WorkingtempOC10/40/55
Gaskets
DesigntempOC:()27TO55
Distributors
SpecificGravity:0.500.57
Grates
Outlet(Vapour)/(Liquid)Kg/m3:
AdditionalAttachmentsInternals:
CorrosionAllowance(mm):3
InternalAttachments:
All Right Reserved

INDIA LTD
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 3 of 6
NOZZLES
MARK
SIZE
RATING REMARK
LiquidLPGInlet
N1
300#
WithDippipe
LiquidLPGOutlet
N2
12
300#
Note16B
LPGVapourReturn/Balance
N3
300#
RadarTypeLevelIndicator
N4
8
Hold
300#
ServoTypeLevelIndicatorNote18
RadarTypeLevelIndicator Note18
N5
6
Hold
300#
N6
8
Hold
300#
300#
8
Hold
300#
300#
Temp.IndicatorNote18 N7A/B
Sizeshallbe
confirmedby
instrumentvendor
SafetyValve(NOTE3)
N8A/B
PressureTransmitter
N9 A/B
RecirculationLine
N10
300#
WithDippipe
SpareNozzle
N11
300#
ManualVent
N12
300#
Manhole1
M1
32
300#
Manhole2
M2
24
300#
All Right Reserved

INDIA LTD
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 4 of 6
Despatch
CompleteSegments
SpecialInstruction
NOTES.
1.
AllprocessdataareindicatedinBold&italic.
2.
AsperOISD150InternalBottomportionoftheVessel(90oCAngle)shallbecoatedwith
anticorrosivecoatingsuitableforCAUSTIC.
3.
Twonos.ofPSVwillbeprovidedonN8A/BforeachBullet.Onewillbeinlineandothershallbe
spare.
4.
Vesselwillbeslopedtowardsthebottomoutlet@1:200.
5.
Thetopandsidesoilcovertobeofneutralmaterialwhichiswellcompactedtopreventwaterand
airerosion.
Themoundshouldhavegooddrainagetopreventanywateraccumulationonthemound.Material
shouldbefreefromabrasivematerialorparticleslikelytodamagetheequipment.
6.
Theentirenozzletobeoutsidetheearthlevel/mound,suitablecoatingforexternalsurfacetobe
provided.
7.
Vesseltobedesignedfortheexternalloading.
8.
Thefireproofingtotheexposedvessel,bottomoutletlineinsidetunnel,nozzles&pipeshallbe
doneuptothefirstROV.
9.
Alldrawings,documents,designcalculation,stageinspection&certificationshallbegotapproved
bychiefcontrollerofexplosives.
10. Inspectiontunnelshallbeprovidedforbottomoutletnozzle(N2)asperOISD150.
11
HydrocarbonLeakdetectorintheLiquidOutletLineTunnel&nearROVstobeprovided.
12. VortexbreakershallbeprovidedinthebulletOutlet.
13. Firefightingfacilitiesshallbeconsideredasperrelevantcode.
14. Mercaptandosing:20ppmApprox
15. AllnozzlesexceptN2shallbelocatedonthedome.
16A. ManholeswithstaircaseshallbeprovidedontheBullettop.Accessplatformshallbeprovidedat
theTopforaccessingofInstrument/maintenancealongwithhandrail.
All Right Reserved

INDIA LTD
EM163-DD 45-VV-101/102/103/104
Document No.
Rev
SHEET 5 of 6
16B. MatchingflangewithROVs(BottomOutletnozzleN2)onbulletandpipingsideshallbeRTJtype.
17. Remoteoperatedvalves(ROV)shallbeprovidedoninletandoutletLPGnozzlefromBullet,Recycle
liquidLPG&vapourreturnline.Thesevalvesshallbefiresafedesign.
18. Radar&ServoGauge,Temperaturemeasurementshallbewithstillingwell.Perforations/slotsshall
beasperInstrumentationrequirement.
19. Safetyvalvesetpressureshallbe14.5kg/cm2g;itshallbedesignedfor21%overpressure(fire
sizing).Thefullflowcapacityofeachsafetyvalveshallbeminimum30%ofthecapacityrequired
foranequivalentsizeofabovegroundvessel.
20. DuringLPGfillinginbullet,thebulletshellshallexpandduetopressure.TheRCCwalldesignshall
beabletotakecareofthethrust.
21. Bullet&moundingshallbedesignedasper latest OISD 150.
22. Suitablecathodicprotectionshallbeprovidedforeachbullettoguardagainstcorrosion.Monolithic
insulationjointshallbeprovidedoninlet/outletpipelines&PSVdischargepipeline.
23. AreaClassification:ZoneI,IIA/IIB,T3.
24
Bottomdrawofflineshallhaveslopeangle1.50 minimumdistanceof3mfromvesseltangentline
toROVatnozzleN2shallbemaintainedasperOISD150
All Right Reserved
EM163-TS-401-SR
DOC
CUMENT NO
O
REV
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
S
SHEET
1 OF
F 15
SUPPLEME
ENTARY REQUIR
REMENTS
S FOR
MOUNDE
M
ED BULL
LET
0
P
RE
EV
15.09
9.15
24.07
7.15
REV DATE
D
15.09.15
24.07.15
EFF DATE
D
ISSUED F
FOR ENQUIR
RY
ISS
SUED FOR CLIENTS COM
MMENTS
PU
URPOSE
VB/PK
VB/PK
PREPD
NB/AKG
NB/AKG
REVWD
GC
GC
APPD
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
CON
NTENTS
CLAUS
SE NO.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10
0.0
DESCRIPTION
D
G
GENERAL
R
RESPONSIB
BILITY OF SUPPLIER
S
M
MECHANICA
AL DESIGN
N
M
MATERIALS
S
S
SCOPE
OF SUPPLY
F
FABRICATIO
ON
I
INSPECTIO
N AND TES
STING
C
CLEANING,
PAINTING AND DESPATCH
G
GUARANTE
EE
D
DOCUMENT
TATION
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SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
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1.0
GENERAL
1.1
The speciffication defines the responsibiliity of the supplier and covers

supplementary requirem
ments relating to desig
gn, materialss, fabrication
n, inspection,
testing, painting, packiing and disspatch etc. The speciffication shalll be read in
conjunction with code, specification
s
n sheet and other enquiry documen
nts. In case of
o
conflict betw
ween code and enquiryy documentss, the vendo
or shall con
ntact PDIL fo
or
clarificationss. As a gene
eral rule the most stringe
ent requirem
ment shall govern.
The offer sh
hall include a sketch indicating thicknesses of m
major parts, empty
e
weigh
ht,
operating weight
w
and test
t
weight.. After deta
ailed design and during
g approval of
o
drawing/doccuments, if thicknessess are required to be increased to meet th
he
requirementts of code, PDIL
P
standa
ards and specification, ssame shall be taken intto
account with
hout any co
ommercial/de
elivery impliccation. How
wever decrea
ase in offere
ed
thickness sh
hall not be allowed.
Sub-fabricattors shall ha
ave to be app
proved by PDIL
PDIL shall have
h
the righ
ht to split the
e order and part
p orders sshall be acce
eptable to th
he
supplier.
The offer must
m
be tech
hnically and
d commercia
ally complette. Incomple
ete offers arre
liable to be rejected.
r
Any deviatio
on from the clauses stip
pulated hereiin, specified codes and other enquiry
documents shall be clearly mention
ned in the offer
o
with pro
oper references to clausse
numbers. In
n absence of
o any such
h indication it shall be assumed that
t
the offe
er
complies with all require
ements and such assum
mption shall be strictly binding
b
on th
he
supplier.
Some of the
e sizes and dimension marked und
der HOLD on
o enquiry drawings
d
an
nd
data sheetss shall be rem
moved laterr on and the required sizze/dimensions shall havve
to be adopte
ed by supplie
er without an
ny commerc
cial implicatio
on.
1.2
1.3
1.4
1.5
1.6
1.7
2.0
RESPONSIBILITY OF THE
T
SUPPL
LIER
2.1
s
include
e but not be
e limited to the following
g.
The responsibility of the supplier shall
w
is nott listed here but is requiired for com
mpletion of th
he
Any other ittem/activity which
supply as pe
er the enquiry documentt shall also be
b the respo
onsibility of th
he supplier.
a) Comple
ete design of
o the equipm
ment includin
ng civil/strucctural, piping
g, electrical &
instrumentation dessign as per code indica
ated in relevvant drawing
gs, equipment
specific
cation sheets, standardss and any other enquiry documen
nts; supply of
o
civil load data for fo
oundation de
esign.
b) To obtain approva
al of PDIL on design
n calculation
ns, drawing
gs and othe
er
docume
ents as spec
cified in Para
a 10.0.
c) To obttain statutorry approval of design calculation
ns, drawing
gs and othe
er
docume
ents whereve
er applicable
e.
d) Procure
ement of alll the materiials whatsoe
ever require
ed to meet the scope of
o
supply.
e) Shop Fabrication,
F
inspection, testing, painting, matcch marking, packing an
nd
dispatch
h of the shop fabricated//assembled items/equip
pment.
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
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f)
g)
h)
i)
j
j)
Site fab
brication, inspection, te
esting, paintting, refracto
ory lining, site
s
handling
g,
erection
n, assemblyy, welding, te
esting etc. in-situ
i
condition of the prefabricate
ed
and site
e assembled
d items/equip
pment, if app
plicable.
Site hyd
dro-testing, ifi applicable.
Pre-com
mmissioning & assistancce during commissioning
g, if applicab
ble.
Submis
ssion of the periodic
p
prog
gress report showing the
e status of th
he job.
Supply of the final documents
d
a
as specified in para 10.0
0.
3.0
CAL DESIGN
N
MECHANIC
3.1
Complete mechanical
m
d
design
of eq
quipment as per latest ccode of cons
struction sha
all
be the respo
onsibility of the
t supplier.. Strict comp
pliance with the requirem
ments of cod
de
/ equipmentt specificatio
on and any o
other referred
d document shall be fullyy ensured.
Detailed des
sign calculations for ade
equacy of sttrength of alll individual parts
p
shall be
b
made and submitted
s
to PDIL for co
omments an
nd approval. After receip
pt of approval
from PDIL the desig
gn of equ
uipment sha
all be con
nsidered ass final. An
ny
change/com
mment, mad
de on desig
gn calculatio
ons to satissfy the req
quirements of
o
code/enquirry documents shall havve to be incorporated without anyy commercial
implicationss. For high alloy
a
steel pa
arts/components designe
ed as per ASME Sec.VIII
DIV.1/2 low
wer allowable
e stresses sshall be ado
opted, for fla
anges of ga
asketed joints
unless othe
erwise speciified. After tthe approva
al of variouss documentss subsequent
deviations shall
s
be disco
ouraged (no
ot considered
d).
Any modification in desiign parameters as may be required by PDIL at any
a time sha
all
have to be suitably in
ncorporated. Commercia
al implicatio
ons, if any, due to succh
changes shall be mutua
ally discusse
ed and settle
ed. Any subssequent cha
anges desire
ed
by supplier owing to changes in m
material of construction
c
n/fabrication details, sha
all
have prior approval
a
of PDIL
P
design office.
All equipme
ents shall also be desig
gned for hyd
drostatic tesst in operatin
ng position in
corroded co
ondition considering 25%
% of design
n wind load.. Allowable stress durin
ng
hydraulic tes
sting shall be 90% of yie
eld stress.
Unless othe
er wise speccified elsewh
here in enquiry/order doccument, Win
nd loads sha
all
be calculate
ed in accorda
ance with IS
S: 875 (Part 3)
3 with follow
wing conside
eration:
Equipment shall
s
be con
nsidered as IImportant Bu
uilding Classs of Structurre accordingly
risk coefficie
ent (K1 Facttor) shall be taken from Table
T
1 IS: 8
875.
Terrain cate
egory (K2 Fa
actor) shall b
be taken con
nservatively as 2; Terrain Class sha
all
depend upo
on the size of equipmentt.
Topography
y (K3 Factor)) shall be takken to be eq
qual to 1.0.
Force coeffiicient (Cf) fo
or the equipm
ment (non-ssmooth) shall be taken from
f
table 23
2
accordingly wind force calculated.
c
Wind forcess shall be in
ncreased byy 20% to ca
ater for the effect of piping system
m,
platforms an
nd ladders etc.
e
Vertical ves
ssels with height/diame
h
eter ratio eq
qual to or greater than 6 shall be
b
analyzed fo
or vibration due
d
to vorte
ex shedding
g when criticcal wind spe
eed does no
ot
exceed 30 m/s.
m
Unless othe
erwise site spectra furnisshed by clie
ent, Seismic loads shall be calculate
ed
in accordan
nce with IS: 1893(Latesst Edition). For the dessign values of horizontal
3.2
3.3
3.4
3.5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
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3.6
3.7
3.11
3.12
3.13
3.14
seismic co-e
efficient h Response S
Spectrum Me
ethod shall be compute
ed as given in
section 2 sta
ack line structures IS:18
893, ( Part 4)):2005.
Design of supports
s
and
d anchor/fou
undation bo
olts shall be the respon
nsibility of th
he
supplier. Th
he type, num
mbers, locatiion and any
y other inform
mation if furrnished in th
he
specification
n sheets shall be strictlly adhered to.
t Howeverr, adequacyy of the sam
me
must be che
ecked by the
e supplier. In no case diameter
d
of a
anchor bolts shall be lesss
than M24 fo
or skirt suppo
ort and M16 for others.
All items wh
hether intern
nal or extern
nal which arre welded directly to a shell or hea
ad
shall be of the
t same ma
aterial categ
gory as that of the shell or head. Th
his shall app
ply
to all nozzle
es, brackets, pads and upper portion
n of the skirt for vertical vessels.
v
Forces & moments com
ming on the nozzles sha
all be furnish
hed after ord
der placement
by PDIL wh
hich shall be
b considere
ed in the design
d
by th
he supplier,, without an
ny
commercial implication.. Alternative
ely supplier shall indicate maximum
m permissible
forces & mo
oments for re
eview and co
onfirmation by
b PDIL.
Lifting lug sh
hall be desig
gned with a sshock factorr of 2.
Unless othe
erwise speciffied minimum
m corrosion allowance fo
or C.S and low alloy steel
material sha
all be 1.5 mm
m.
In case of vessels minimum
m
thicckness of shell
s
and h
head includiing corrosio
on
allowance shall
s
be as under unless otherwise specified
s
Shell Dia
D in mm
ID 500
500 < ID 1200
1200 < ID 2000
1200 < ID 2000
ID > 2600
C.S. / Low Alloy

y Steel
5 mm
5 mm
6 mm
8 mm
10 mm
High Allloy Steel

3 mm
m
4 mm
m
5 mm
m
6 mm
m
8 mm
m
3.15
Minimum no
ozzle diametter shall be 1 nomina
al.
4.0
MATERIALS
4.1
All materialss, whatsoevver, required

d to complette the suppllies shall be
e procured b
by
the supplierr and all succh materialss shall be co
overed with due identifiiable material
test certifica
ates.
Materials in
ndicated in specificatio
on sheets are
a
recomm
mended for the require
ed
service conditions. Sup
pplier howevver, may usse better or equivalent material witth
prior approvval of PDIL. Details of such materia
als must be iindicated in the offer witth
proper referrence.
Materials prrocured to other
o
approvved specification than sstipulated in design cod
de
shall be ac
cceptable prrovided it meets
m
all the
e requirements of appliicable desig
gn
code.
Unless othe
erwise specified all C.S
S and low alloy steel m
materials including forgin
ng
used for pre
essure parts shall be fullyy killed and in normalize
ed condition
Unless othe
erwise spec
cified coppe
er or copperr alloys sha
all not be used.
u
Coppe
er
content up to
t 0.40% are
e acceptable
e in carbon steel
s
and 0.6
6% in stainle
ess steel.
4.2
4.3
4.4
4.5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
4.6
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4.20
Material used in low temperature

t
e service sh
hall be impact tested (Charpy-V) if
required as per design code and sp
pecification. Impact testt temperaturre and energ
gy
value shall be
b in accordance with co
ode requirem
ment, unlesss specified otherwise.
o
For coarse grained and
d high tensille materials in carbon ssteel (UTS > 52 Kg/mm
m2)
and low allo
oy steel, gua
aranteed impact strengtth shall be e
ensured at a temperaturre
15C below
w envisaged hydraulic ttest tempera
ature as a precaution
p
a
against
brittle
fracture durring hydraulic test. Simillar precautio
on shall be ttaken for thiicker plates >
50 mm for equipment
e
de
esigned for p
pressure > 15
1 Kg/cm2g.
C.S. and low
w alloy stee
el exceeding thickness of
o 50 mm sh
hall be vacuu
um degasse
ed
except for plate ring flan
nges.
All plate materials ove
er 50 mm th
hickness sh
hall be ultrasonically tested both on
o
surfaces and edges as per ASTM A 435.
Unless morre restrictive
e prescription given by material sp
pecification the
t
maximum
carbon conttent of carb
bon steel ussed for fabriication as sshown by laddle analyssis
shall be
0.23% for pllates, pipes & tubes
0.25% for fo
orgings.
All forgings shall be ultrasonically tested as per
p Sec. AS
STM A 388 for thicknesss
greater than
n 100 mm with
w the criterria shown in
n ASME Secc.VIII Div.2 Para
P
AM-203
32. In case any
a defect iss found, no rrepair by we
elding shall b
be allowed. ASME flang
ge
for equipme
ent designed as per ASM
ME Sec.VIII Div.1
D
need n
not be UT te
ested.
All forgings including no
ozzles flange
es shall be examined
e
fo
or surface de
efects MP/D
DP
after machin
ning.
F IS 2062
For
2 materials without
w
mill test certifica
ates, check test, if calle
ed for by th
he
inspector, shall be perfo
ormed witho
out any commercial implication. Matterial shall be
b
fully killed.
All nozzles 10 NPS shall
s
be seam
mless.
Spiral- wound gasket shall
s
be provvided with S.S
S guide rin
ngs. Outside
e diameter of
o
gaskets sha
all extend up
p to bolting.
All pipe fittin
ngs including
g elbows for sizes 10 NPS
N
shall be
e forged / wrrought.
Gasket for all
a medium except
e
cooliing water se
ervice with flange rating 600 # sha
all
be spiral wo
ound graphite filled gassket with extternal & inte
ernal guide rings 3.2 mm
thk. for prevvention of crrushing of g
gasket. For CW
C service gaskets forr flange ratin
ng
150 # .com
mpressed fib
ber gaskets type in acc
cordance witth ANSI B 16.21 shall be
b
used.
Gaskets witth flange ratiing 900 # shall be octagonal ring--joint gasket. Hardness of
o
the gasket shall
s
be 50 BHN
B
lesser than
t
that of the
t mating fllange gaske
et groove.
Liquid outletts to pumps shall be fitte
ed with vorte
ex breakers
5.0
SCOPE OF SUPPLY
5.1
Unless oth
herwise spe
ecified the complete main equipment and its variou
us
components
s as specifie
ed in speciffication shee
ets and enq
quiry documents shall be
b
included in suppliers scope
s
of supply. Scope
e of supply shall includ
de but not be
b
limited to the
e following:
4.7
4.8
4.9
4.10
4.13
4.14
4.15
4.16
4.17
4.18
4.19
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
5.1.1
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5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
5.1.11
5.1.12
5.2
Cover flanges for manholes,

m
h
hand
holess, inspectio
on openingss instrument
connections
s etc. with bo
olting and ga
askets.
Jack screws
s and dowel pins.
All external welded attachments like
e platforms and
a ladder ccleats, insula
ation supporrts
and pipe support cleats, earthing cle
eats etc.
Lifting lugs / erection lug
gs.
Manhole davit
Cleats for ea
arthing conn
nections
Name plate with bracke
et
Foundation / Anchor / Holding
H
down
n bolts with two
t
nuts and
d washers.
Vortex Brea
akers
Cleats with pad for Platfforms, hand rails, ladderrs and pipe ssupports.
Documents according to
o clause 10.0.
Spare parts according to
o clause 5.2
2.
The following 2-Years
s Operation
nal Spares shall be supplied
s
alo
ong with th
he
equipment.
i) 200% gaskets
g
for all
a nozzle con
nnections with blind flan
nge.
ii) 200% riing joint gasskets.
iii) 10% bo
olts/nuts for each
e
nozzles with blind/companion flanges
f
(min
n 5 pieces).
iv) 10% intternal bolts, nuts & clam
mps (min 5 pieces of each size)
6.0
FABRICATIION
6.1
The manufa
acturer of the
e equipment shall comp
ply in all resspects with the
t provision
ns
of the app
plicable cod
de/standardss and spec
cifications with
w
respectt to welding
g,
fabrication, forming of heads,
h
radio
ography, heat treatment, inspection
n, testing an
nd
quality contrrol etc.
All welding shall be carried out byy qualified welders
w
using
g approved procedure in
compliance with the req
quirements o
of code & sp
pecificationss and duly ce
ertified by th
he
inspecting authority.
a
Alll welding prrocedure mu
ust be got a
approved fro
om authorize
ed
inspecting authority
a
beffore starting any fabricattion job. We
elding of all parts
p
must be
b
completed before
b
heat treatment.
t
Plates of different
d
thiccknesses sh
hall be mad
de flush witth the innerr surfaces of
o
equipment unless
u
otherrwise stated..
Minimum skkirt height off dished hea
ad shall be 50
5 mm unlesss otherwise stated.
CS / Alloy steel dished
d end/toricon
nical head including
i
co
one if cold formed
f
or ho
ot
formed belo
ow normalisin
ng temperatture shall be
e subsequently normalise
ed. In case of
o
austenitic SS
S materials
s solution a
annealing shall
s
be carried out if hot worked
d.
Formed end
ds of vesse
els with diam
meters less than 1600 mm shall preferably
p
b
be
made in one piece. Larger heads which can not
n be formed in one piece
p
shall be
b
fabricated as follows witth prior apprroval from PDIL:
a) In two pieces,
p
with the welding seam includ
ded in the middle
m
third and
a preferab
bly
on the centre
c
line.
b) In petall constructio
on, with meridianal seam
ms and a ce
entral cap off diameter no
ot
larger th
han 0.75 tim
mes the vessel outside diameter.
5.1.2
5.1.3
6.2
6.3
6.4
6.5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
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6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
Formed hea
ads when fab
bricated in p
pieces shall be normalized and weld
d seams radio
graphed afte
er forming.
Impact test when requ
uired as perr code & sp
pecifications shall be ca
arried out on
o
parent meta
al, weld and HAZ.
Production control coup
pons, when required ass per code & specificattions shall be
b
subjected to
o impact te
est, corrosio
on test etc. in addition to mechan
nical tests as
a
required. In case of hea
at tested equ
uipment testt coupons shall be given
n similar hea
at
treatment ass for the equ
uipment.
Each shell section havving diameter equal fo
or less than 2 meters to
t the extent
possible, sh
hall be rolled out of a single plate witth one longittudinal seam
m.
Orientation of longitudinal seams and position of circumferential sea
ams shall be
b
clearly mark
ked in the fa
abrication drawings. Noz
zzles, suppo
ort and otherr attachments
shall be loca
ated clear off weld joints..
The centerss of the weld
ded longitudinal joints of adjacent co
ourses shall be staggere
ed
or separated
d by a distan
nce of five times the thic
ckness of the
e thicker pla
ate or 100 mm
whichever iss greater.
All parts invvolving weld
ding constru
uction includ
ding internalss and stiffen
ner ring sha
all
have continu
uous welds unless otherrwise stated.
All welds sh
hall be full penetration w
welds with back chipping
g and rewelding from th
he
second side
e. For those joints which
h are inacce
essible for ba
ack chipping
g the root ru
un
shall be carrried out with
h TIG proce
ess. Single side
s
welding
g with backin
ng strip is no
ot
permitted.
Due provisions must be
b kept for venting
v
out entrapped gases durin
ng welding of
o
pads, flange
es and liner plates etc.
All nozzle reinforcing pads
p
shall be
e tested pne
eumatically at 0.5 Kg/cm2g pressurre
with soap solution
s
on attachment welds. Ven
nt holes shall be plugg
ged with no
on
hardening mastic
m
to pre
event ingresss of water.
Pads for sup
pports and external
e
clea
ats etc. shall be of same material as that of shelll.
All sharp co
orners shall be rounded off with sm
mooth radius. Inside edg
ge of nozzles,
manhole and handhole at the intern
nal surface shall
s
be roun
nded to min. radius 5 mm
m.
Unless othe
erwise state
ed all nozzle
e flanges shall be weld
d neck type
e. For nozzle
flange size 24 dimen
nsions shall cconform to ASME
A
ANSI B16.5 and nozzle flang
ge
size > 24 NPS
N
dimensions shall co
onform to AS
SME ANSI B
B16.47 (Serie
es-B).
All welding neck flangess shall be bo
ored to suit nozzle I.D. F
Flange facin
ngs shall havve
suitable serrrations for gasket seatin
ng in case off plain, male//female and raised.
Unless othe
erwise stated
d all girth flange joins sh
hall be confin
ned type. Minimum deptth
of gasket fa
acing for girth
h flanges sh
hall be 5 mm
m for compre
essed fiber gaskets
g
and 6
mm for spira
al wound / metal
m
jackete
ed gaskets
In case of equipment
e
to
o be assemb
bled at site trrial assembly in shop sh
hall be carrie
ed
out and mattch marked for
f proper asssembly at site.
s
Equipment shall
s
be pro
ovided with suitable
s
braccings/stiffene
ers to avoid any damag
ge
during transsportation an
nd erection a
at site.
In case of equipment involving site assembly/fa
abrication, th
he entire site
e job includin
ng
fabrication, radiographyy, heat treatment, inspe
ection, testing and tran
nsportation to
t
site shall be
e in supplierss scope of w
works at his cost.
c
All flange bo
olts & skirt-b
bolts shall strraddle centre
e line unlesss otherwise stated.
s
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
6.22
6.23
6.24
6.25
6.26
EM-1
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Page9of1
15
Flange gasket contact surface sha

all not exce
eed 125 in roughness. In case of
o
metallic gas
sket the side
e wall surfacce of the gassket groove shall not exxceed 63 in
roughness.
All nozzles less than or
o equal to DN
D 65 shalll be stiffene
ed with three
e equispace
ed
plate ribs off the same material
m
as th
hat of shell.
External bo
olting for ga
asketed flanges shall always
a
be stud bolts an
nd nuts. Bo
olt
threads sha
all be in acco
ordance with
h ANSI B1.1 (UNC for dia. 1, 8 UN
N for dia.> 1)
Threads of bolts and nuts shall be coated before insta
allation with
h lubricant to
t
prevent galling of the threads.
A grip rail of
o 20 mm dia, 300 mm long bar sh
hall be weld
ded to the in
nside of she
ell
approx. 300
0 mm above the apex of manhole op
pening for ea
asy entry and
d exit.
In case of nozzle with
h butt-end cconstruction, extra leng
gth shall be
e provided to
t
facilitate hydraulic testing and sub
bsequently cutting
c
and edge prepa
aration as pe
er
ANSI B 16.2
25 to suit pip
ping welding at site.
7.0
INSPECTIO
ON AND TESTING
7.1
All raw mate

erials shall be
b inspected
d at source by
b authorize
ed inspection
n agency an
nd
test certifica
ates with du
ue identifica
ation shall be
b submitted
d. In case of equipment
under PDIL inspection, imported raw materials will be prrocured under third parrty
inspection, unless
u
otherrwise specified.
All equipme
ent shall be inspected du
uring variouss stages of m
manufacture
e starting from
identification
n of raw ma
aterials to ccompletion. The equipm
ment shall be
b considere
ed
acceptable for dispatch only after ffinal certifica
ation for accceptance is issued
i
by th
he
inspector.
Bought out items or ittems sub-co
ontracted to
o other sub
b-suppliers shall
s
also be
b
inspected at
a the sub-s
suppliers wo
orks. Howev
ver, standarrd items like
e bolts, nuts,
ordinary gas
skets etc. may
m be exem
mpted from the inspectio
on with specific approval
from PDIL.
Inspection by
b third partty, if specifie
ed, shall be arranged byy the supplier. It shall be
b
the respons
sibility of the supplierr to make available to the inspector all th
he
and other enquiry docum
new/revised
d drawings, calculations
c
ments.
Inspection order
o
on third party sha
all also inclu
ude specificc instructions
s for markin
ng
copies of all
a correspon
ndence from
m inspecting
g authoritiess to PDIL and
a
reportin
ng
monthly pro
ogress of the
e order to P
PDIL. Complete responssibility of gettting approval
of drawings
s/calculationss and docum
ments from inspecting authority sh
hall be that of
o
the supplier.
In case of site fabricatted/assembled equipme
ent same insspection age
ency shall be
b
responsible for inspectio
on, testing a
at site.
Unless othe
erwise stated
d gaskets ussed during te
esting shall be same as
s specified fo
or
operating co
onditions. Affter testing, gaskets use
ed during tessting shall be
e replaced b
by
new gasketss.
Vessel conttaining lethal, toxic and highly inflam
mmable subsstance shall be fully radio
graphed and
d stress relie
eved.
The followin
ng NDT requ
uirements are
a mandatory in additio
on to the req
quirements of
o
code/specifiications:
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
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a)
7.13
7.14
Ultraso
onic Examina
ations
i) Butt weld in thick
kness > 50 m
mm as supplement to ra
adiography.
ii) Full penetration welds of n
nozzle attachments on equipment shell/head of
o
thickkness > 50 mm
m as substtitute for radiiography.
iii) All fo
orgings
b) Magnettic particle / Liquid penettrant examin
nation
i) All edges
e
of plattes and openings in she
ell of C.S. ha
aving thickness > 40 mm
and low alloy stteel / S.S. h
having thickn
ness > 25 m
mm and allo
oy steel of all
a
thickkness.
ii) Roott-run and final layer of all butt welds.
iii) All welds
w
having
g thk. > 50 m
mm, all weldss of low allo
oy steels and
d all materia
als
with UTS > 52 Kg/mm2.
K
iv) Knu
uckle surface of dished
d ends / to
oriconical se
ections, pipe
e bends an
nd
expa
ansion bellow
w.
v) All welds
w
of SS and
a non ferrrous materia
als and weld
ds for vessells with desig
gn
temp
p. (-) 45C and below aftter hydro tessting.
vi) All weld
w
surface
es after PWH
HT.
vii) All forgings
f
after machining.
c) Radiogrraphy
i. Radiiography wh
hen called fo
or shell be applicable tto all pressu
ure welds i.e
e.
longitud
dinal & circumferential.
ii. In ca
ase heads are
a formed of
o welded pla
ates / petal construction
n, all the weld
seams prior to form
ming and afte
er forming.
iii. Circu
umferential joint of shell to dished he
ead.
iv. All T-weld
T
joints..
d) Hardness
Hardness va
alue shall no
ot exceed 215
2 HB for steel
s
having Cr < 2% an
nd 240 HB fo
or
steel having
g Cr > 2%.
All complete
ed equipme
ent shall be tested hydrraulically as per the req
quirements of
o
specification
n/codes in presence of
o the inspe
ecting autho
ority. Pneum
matic test of
o
completed equipment
e
s
shall
be carrried out on
nly when sp
pecially men
ntioned in th
he
specification
n sheets. Ch
hloride conte
ent in water used for tessting shall not
n exceed 30
3
ppm for SS equipment and 40 ppm
m for CS and
d low alloy steel
s
equipm
ment. Duratio
on
of test shall be 1 hour minimum
m
When requiired as per specification / code, strain gauge measurements shall be
b
carried out on
o outside circumferenc
c
ce during hydrostatic tessting. The re
esults shall be
b
plotted both
h during pre
essurizing an
nd depressu
urizing and procedure to such strain
measureme
ents shall hav
ve prior app
proval of PDIL.
8.0
CLEANING, PAINTING
G AND DESP
PATCH
8.1
After hydrau
ulic testing, the
t equipme
ent shall be dried,
d
thorou
ughly cleane
ed from insid
de
and outside and shall be
e free from a
all shop dirt, loose scale
e, grease etcc.
All external surfaces of CS includin
ng internal surface
s
of skkirt to be painted shall be
b
degreased and
a all rust and
a mill scalle removed.
i) Austeniitic stainlesss steels and non-ferrous materials sh
hall not be painted.
p
8.2
8.3
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
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SR
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Page11of15
ii)
8.4
8.5
8.6
8.7
The equ
uipment sha
all be shot/grit blasted (m
min SA 2.5
5 ISO 8501--1) before th
he
primer coat is app
plied on extternal surfaces. Primerr shall be compatible
c
t
to
succeed
ding painting
g.
iii) In gene
eral, uninsula
ated equipm
ment working
g below 94C
C, alkyd high
h build prime
er
of thickn
ness 50 miccrons DFT sh
hall be applie
ed.
iv) For Un
ninsulated equipment
e
above 94C
C to 204C
C working temperature
e,
aluminu
um paint of 30
3 microns D
DFT shall be
e applied.
v) For uninsulated eq
quipment upto 420C wo
orking temp.. inorganic zinc
z
silicate of
o
50 micrrons zinc silic
cate shall be
e applied.
vi) For insu
ulated equip
pment up to 94C, prime
er painting sh
hall be of alkkyd high build
epoxy primer
p
of 50 microns DFT shall be applied.
vii) For ins
sulated equ
uipment tem
mperature exceeding 94C, prim
mer shall be
b
aluminu
um paint of 30
3 microns D
DFT.
viii) Thermo
o-indicative paint (three
e colour pha
ases) shall be applied on refractory
lined equipment
e
to give w
warning of insulation/rrefractory failure.
f
Paint
manufa
acturers reco
ommendatio
on shall be fo
ollowed.
ix) All flang
ge faces, bo
olting and otther machine
ed surfaces shall be pa
ainted with an
a
easily re
emovable ru
ust-preventivve coating.
All machine
ed surfaces, boltings an
nd flange facces shall be
e properly protected from
rust and me
echanical inju
ury during transit and sto
orage.
Nozzles sha
all be sealed
d suitably. Th
hreaded con
nnections an
nd beveled openings
o
sha
all
be suitably protected.
p
Name and code numb
ber of equip
pment shall be painted on each eq
quipment at a
conspicuouss place in lettters 150 mm
m high.
After hydrau
ulic testing, all
a SS parts of equipmen
nt shall be p
pickled and passivated
p
a
as
per the following proced
dure:
a)
Cleanin
ng
Clean surface
s
and remove all extraneous matter with a hard fiberr brush or S
SS
wire bru
ush. M.S. wire
w
brush shall not be used. All organic mate
erials shall be
b
remove
ed with any paint remo
over like lig
ght solvent naphtha orr benzene o
or
equivale
ent. Motor petrol
p
shall not be used.
b)
Pickling
g
Aqueou
us pickling so
olution shall be as follow
ws :
Nitric accid (Tech. grade)
g
10 to 25% plus Hydrofluoric
H
acid 1 to 8%
% (to be use
ed
only forr stabilized SS
S grades). Temperaturre 50 to 60C
C for 10% Nitric
N
acid an
nd
20C fo
or 25% Nittric acid. W
When size and
a
shape of product permit, tottal
immersion in the piickling solutiion is preferrred. Where immersion is
i impractica
al,
pickling
g may be accomplishe
a
ed by wettin
ng the surfface by 1) swabbing or
o
spraying
g 2) by pa
artial filling tthe item with pickling solution and rotating or
o
rocking so that all th
he surface receive the re
equired chemical treatm
ment.
The ma
aximum perio
od for which
h the pickling
g solution sh
hall be allow
wed to remain
on the surface
s
is 30
0 minute. Du
uring pickling
g removal off oxides may
y be hastene
ed
by brushing with a hard
h
fiber orr SS wire bru
ush. Over pickling shall be avoided.
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
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Page12of15
The picckling agent shall be wa

ashed off wiith plenty off water so as to leave no
n
trace be
ehind.
Passivation
After piickling and water rinsin
ng, an aque
eous causticc permanga
anate solutio
on
containing NaOH
N
10 we
eight % and KMnO4 4 we
eight % shall be used fo
or neutralizin
ng
pickling solu
ution. This shall
s
be follo
owed by tho
orough wate
er rinsing. Water
W
used fo
or
pickling and
d washing sh
hall not have
e chloride contents excee
eding 30 ppm.
c)
8.8
8.9
8.10
8.11
Equipment intended for transportation by ship

p shall be kept
k
in hatch
h of the ship.
Suitable sea
aworthy paccking/paintin
ng shall be applied
a
to a
avoid any da
amage durin
ng
transshipme
ents.
The responssibility of tra
ansport, packking and forrwarding of tthe equipme
ent shall be of
o
the supplierr. In case of inland tran
nsportation equipment shall
s
be pro
operly lashed
d,
fixed on the
e wagon/trailler to avoid any damage
e due to sho
ocks in transsport. In casse
of ODC mo
ovement, ODC
O
sanctio
ons for movvement eith
her by rail/ro
oad shall be
b
arranged byy the supplier from ap
ppropriate authorities
a
in advance to meet th
he
scheduled delivery.
d
Sup
pplier shall h
have to arran
nge the chassers.
All spares shall be properly paccked, marke
ed and sen
nt separately
y along witth
equipment.
When speciified equipm
ment shall be
e dispatched
d with N2 filling. In case of equipment
assembled and welded
d at site, it shall be fille
ed with N2 after testing
g at site. Dry
Nitrogen shall be filled at a pressure of 0.5 Kg
g/cm2g and equipment shall
s
be fitte
ed
with a press
sure gauge and
a valve.
9.0
GUARANTE
EE
9.1
The supplier shall guara

antee equipm
ment and their compone
ents againstt faulty desig
gn
with regard to mechanical adequa
acy, imprope
er material o
of constructtion and poo
or
workmanshiip for the spe
ecified perio
od
Approval of design calc
culations and
d detailed sh
hop drawings by PDIL, will
w not in an
ny
way absolv
in
ve the supp
plier from h
his responsibilities to ssupply the equipment
e
.
accordance with order specification
s
be necesssary owing to
Should anyy repair or replacement
r
t any type of failure on
o
account of design,
d
mate
erial or workkmanship off the equipm
ment, the sup
pplier shall b
by
dint of this guarantee, be bound to
o replace th
he same eith
her in part or
o in entirety,
without additional cost, at site. Repa
aired or replaced parts sshall be cove
ered by sam
me
guarantee as
a in case orr main supplyy.
In case pro
ocess design
n is also in ssuppliers sco
ope, guaran
ntee shall inc
clude processs
guarantee also
a
in addittion to abovve. All special instrumen
nts required
d to verify th
he
guarantee; fixtures as outlined in the equipm
ment specifiication shall have to be
b
brought sup
pplier on draw
w-back basis.
9.2
9.3
9.4
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
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Page13of15
10.0
DOCUMENTATION
10.1
Detailed fab
brication dra
awings shall be preparred by supp
plier clearly indicating all
a
design data, nozzle data
a, details of all parts with
h tolerancess, all welding
g joints details
and detailed bill of ma
aterials etc.. Location of
o weld sea
ams, constrruction notes,
welding processes, detailed specifiication of ele
ectrodes inccluding NDT
T tests etc. a
as
applicable shall
s
be clea
arly indicated
d in the draw
wing. Drawin
ng submitted
d for approval
must be co
omplete in all respectts and thorroughly che
ecked and approved b
by
suppliers competent
c
authority befo
ore submittiing to PDIL
L. Drawings without succh
information are likely to be rejeccted and an
ny delay on
n this acco
ount shall be
b
attributable to the supplier.
Before startting any fab
brication, drrawings mus
st be got ap
pproved from PDIL. An
ny
comments marked on fabrication drawings shall
s
have to be incorporated an
nd
decision of PDIL
P
in this regard shalll be considered as final.
In case of vessels und
der the purrview of IBR
R, complete responsibillity of gettin
ng
approval of drawings an
nd design ca
alculations etc.
e from con
ncerned IBR authorities of
o
state of man
nufacture an
nd state of in
nstallation sh
hall be with the supplier at
a his cost.
For equipment requiring
g statutory a
approval fro
om Inspector of Explosivves, it will be
b
the respons
sibility of th
he supplier to get the fabrication drawings of
o equipment
approved att his cost, wh
herever requ
uired.
All drawings
s shall be drrawn in CAD
D to scale. Subsequent
S
revisions/inccorporation of
o
comments shall
s
also be
e made in CA
AD. Manual drawing sha
all not be acccepted.
It will be preferable; the
e soft copy along with 6 prints is b
brought to PDILs
P
desig
gn
office for getting
g
apprroval. Supp
plier shall depute
d
the concerned engineers &
draftsmen with
w prior inttimation and
d agreed datte for decidiing and inco
orporating th
he
various agre
eed commen
nts during th
heir visit/stay
y. Same pro
ocedure sha
all be followe
ed
for the apprroval of subssequent revisions, if any
y. Revisionss shall also be entered in
CAD file. Ma
anual revisio
on in drawing
g shall not be
b accepted..
After approv
val one set of drawingss / documents shall be g
given to the
e inspector b
by
the supplier.
Approval / comments
c
on various do
ocuments sh
hall be given
n by PDIL within
w
3 weekks
of the receip
pt of the sam
me, mailing time exclude
ed
Turn around
d time for su
ubmission off revised dra
awings / doccuments bassed on PDIL
Ls
comments shall be tw
wo weeks. Any
A
delay in approval on account of delay in
submission of revised drawings / do
ocuments sh
hall be attribu
utable to the
e supplier.
Payment ag
gainst submission/appro
oval of draw
wing if appliccable shall be
b made afte
er
approval of drawing und
der Code 1 or
o as per com
mmercial terrms & condittions of ITB.
All documen
nts / drawing
gs shall be in
n English lan
nguage and in Metric sysstem.
All final doccuments ind
dicated agaiinst Sl.No.08
8 to 30 sha
all be prope
erly arranged
d,
indexed and
d bound in one folder.
The docume
ent as marke
ed (**) are to
o be approve
ed by authorrized inspecting agency.
The number of copies of
o documentts and required deliveryy time in wee
eks from datte
of letter of intent / orrder for eacch documen
nt is given below unle
ess otherwisse
indicated in the technica
al specification
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.11
10.12
10.13
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
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REV
Page14of15
Sl.No.
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Descriptio
on
2
Outline sketch
s
show
wing thickne
ess
of main parts,
p
weight & anchora
age
details (R
Refer Clause
e 10)
List of items likely to be
subcontra
acted
witth
probable
vendors
Based on
o delivery stipulationss a
time bar chart in
ndicating time
required for materiall procureme
ent,
fabrication, testing, transportation
a
as
s required.
and site assembly
Billing Sc
chedule
Reference list of simiilar equipme
ent,
indicatin
ng
vario
ous
supplied
of
ers
&
material
paramete
construction
Descriptio
on of prese
ent shop lo
oad
and spare
e load availa
able for this jjob
and annu
ual turnover.
List of dra
awings
Final civvil load data
d
including
details of foundation/anchor boltss
Design ca
alculation & FE analysiss
Detail fab
brication draw
wing
Spare parts list
Procedurre for hydra
aulic test a
and
heat treattment ( ** )
Procedurre for sitte jobs like
assembly
y, heat trea
atment, testing
etc
Detailed manufacturing schedule
RT & progre
ess report to be
CPM/PER
submitted
d every month ( ** )
Welding
proced
dure
a
and
performance recordss approved by
inspecting
g authority ( ** )
Transporttation draw
wing showing
overall dimension,
d
ght
C.G., weig
and han
ndling insttructions duly
approved
d by appropriate authoritty
Operating
g/maintenan
nce
manual
whereverr required
Records of NDT
T tests e
e.g.
phy, UT, MP
P/PT, hardne
ess
radiograp
etc. ( ** )
Materials test cerrtificates duly
stamped by inspectin
ng authority ( **
)
Reqd
d.
with bid
b
Copie
es
3
Required after purchase orde

er
Copies
4
Days
D
from L//I
5
SUPPLEM
S
MENTARY
Y REQUIR
REMENTS
S
FOR MOUNDED BULLETS
20
21
22
23
24
25
26
27
28
PWHT Ch
harts ( ** )
Test on production test coupo
ons
( ** )
Corrosion
n test reportts including C,
Cr, Ni, Mo and fe
errite contents
als, weldmen
nts,
report of raw materia
HAZ etc. ( ** )
Hydraulicc / pneumattic test repo
orts
( ** )
Strain gauge measurrement ( ** )
Inspectorrs final certifficate ( ** )
Suppliers
s guarantee certificate
Procedurre
for
removal
&
reassemb
bly of weld seal
s
gasket
All final as
a built sho
op drawingss &
calculatio
ons duly certified by
inspecting
g authority( ** )
EM-1
163-TS-401-S
SR
DOC
CUMENT NO
O
REV
Page15of15
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 1 of 4
REV
Enquiry No.
N
: EM163-TS-401
Items: LPG Mounde
ed storage fa
acilities
Bidder ____
__________
___________
__________
Bid No.____
__________
__________
__________
The conttractor/Vendor must confirm and clarify the follow

wing, failing which bid is
s liable to be
e
rejected.
Sl.No.
A
1
5
6
Description
Confirm that
t
following details / informa
ation are
furnished / attached alo
ong with offe
er
Past expe
erience reccord of co
ontractor along with
references / other ne
ecessary documents forr meeting
the qualifyiing requirem
ments as per Tender doccument
Furnish de
etailed reference list o
of Mounded
d storage
Bullets sup
pplied earlierr and in servvice for atlea
ast 1 year.
Details sha
all include i.e. size, dessign conditio
ons, shell
thickness, weight, ma
aterial of con
nstruction, inspection
agency, client, year of supply, orde
er value.
Contractor shall submiit along with the bid, a te
echnically
asible and satisfacto
ory methodology of
suitable/fea
fabrication//erection, post-weld
p
h
heat treatm
ment and
hydro-test for LPG Mounded
M
Bullets with complete
details, forr technical evaluation
e
o
of the bid. This
T
shall
specificallyy keep in view transporta
ation limitatio
ons of the
bullet partss/items as well as site co
onstraints
Route survvey upto refinery and in
nside refineryy shall be
carried out
o
by the
e contracto
or to asssess the
transportattion constraints (Route ssurvey reporrt shall be
submitted to
t PDIL/Own
ner for review
w)
Contractor shall get him
mself familia
ar with site conditions,
c
d storage a
area constraints etc.
approach to mounded
oting
before quo
Site facilities to the extent
e
as sp
pecified in document
d
SITE FAC
CILITY Do
oc. No. EM
M163-E-601 shall be
provided
Contractor to indica
ate the extent of su
ubcontract
proposed, if any.
at any workk or part of it can be
Contractor to note tha
oved by
subcontraccted, only to agencies appro
PDIL/Clien
nt. Approval from PDIL//Client shall be taken
prior to sub
bcontracting any work
Time Bar chart.
c
Duly Fille
ed in, stam
mped & ssigned Sch
hedule of
Exceptions
s & Deviations (FORM E) is enclosed.
d
taken by the
e contracto
or to the
1) Any deviation
stipulattions of th
he Tender document shall be
brough
ht out as pe
er this forma
at only and enclosed
Vendors co
onfirmation
(Tick mark which
w
ever iss
applicable)
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 2 of 4
REV
along with
w the offer.
10
B
1
2) Any de
eviation writtten elsewhere in the offfer but not
on the
e format, sh
hall not be recognized
d and the
same shall
s
be trea
ated as null and
a void
Itemwise price
p
of Sparres for 2 Years normal operation
and recom
mmended sp
pares submittted (Unpriced List of
spares encclosed)
Bid compliies with all items / works as per Technical
tender spe
ecifications, Codes / sta
andards & drawings
d
/
documentss
Confirm th
hat the sco
ope of work is exactly
y as per
requiremen
nts of bid do
ocuments.
Yess / No
Yess / No
Confirm tha
at:
a) Thickness shown in drawings enclosed with ITB

dered minimum & indicative.
i
shall be consid
Thickness of shell and disshed end shall be
nto account thinning an
nd scaling
achieved taking in
ontractor shall check th
he adequacyy of same
etc. Co
before quoting. Any chang
ge in thickness, if
require
ed, to comp
ply with enq
quiry specific
cations &
code requiremen
nts shall be
b
incorporated by
contrac
ctor withou
ut any prrice and/orr deliver
implica
ations.
b) Nos. & Details of stiffeners
s
sh
hall be as ind
dicated in
Engine
eering draw
wings enclosed with Tender.
Howevver, Contracctor shall check the ade
equacy of
same before quo
oting. Any change in
n size, if
ed, to comp
ply with enq
quiry specific
cations &
require
code requiremen
nts shall be
b
incorporated by
ctor withou
ut any priice and/or delivery
contrac
implica
ations.
Confirm tha
at
a) Where hot forming
g and subse
equent heat treatment
is involved, adopte
ed procedurre shall not impair
i
the
mecha
anical properties of the material be
eyond the
limits specified
s
in respective
r
m
material spec
cification.
b) Numbe
er of produ
uction coup
pons and the tests
thereon
n shall be as per Technicall Tender
Specifiications EM1
163-TS-401 & code requ
uirement
c) Confirm
med that all
a non desstructive tessting like
magnetic
radiogrraphy,
ulltrasonic
testing,
particle
e/dye penettrant examination etc. shall be
conduccted as per requirem
ments of Technical
Tenderr Specificatiions EM163
3-TS-401 & Minimum
QAP Doc.
D
No.EM1
163-TS-401--ANNEX-III.
Confirm tha
at:
I. A deta
ailed proce
edure for sshop/fabricattion yard
fabrica
ation, assem
mbly, post w
weld heat treatment,
t
testing etc. inclu
uding welding procedu
ures and
qualificcations shall be submitted to the inspecting
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 3 of 4
REV
authoriity by the co
ontractor
All site
e work includ
ding compacction of grou
und, bullet
section
ns assembly
y, welding, ra
adiography, post weld
heat trreatment, tes
sting etc. sh
hall be in co
ontractors
scope and shall be execu
uted by co
ontractors
person
nnel. Cranes
s, tools, ta
ackles, cons
sumables,
devices for inspecttion and testing etc. sha
all also be
in conttractors scope.
Confirm the
t
inclusio
on and fa
abrication (wherever
(
necessary)) of followin
ng, as per the scope of supply
defined in bid
b documen
nt:
i) Manho
ole davit, Liftting lugs & ssettling markker
ii) Lugs/ccleats for CP
P.
iii) Piping works
M
& Strructural workks
iv) Civil, Mound
v) Electrical works
mentation wo
orks
vi) Instrum
vii) Cathod
dic protection system
viii) Manda
atory spares
s.
ix) Coatin
ng & Painting
g
x)
Any other accesssories as sspecified in technical
Enquiry Specificattions
II.
Yess / No
Yess / No
Contractor shall note and

a confirm tthe following
g:
6
9
10
a) The qu
uoted price includes
i
for the Holds details of
which are
a indicated
d on the drawing
b) The weights
w
of each
e
mound
ded bullets shall be
indicated by contra
actor.
Confirm gu
uarantee off LPG Moun
nded Bulletss, and all
other allie
ed work ind
dicated in the Tender for the
following:
n
a) Design
b) Materia
als and supp
plies
c) Workm
manship fo
or construcction/ fabriication /
installa
ation
system
d) Satisfa
actory
p
performance
and
comple
eteness
a) Contra
actor to note
e that CCO
OE/PESO ap
pproval is
require
ed for all LPG Bullets and the sa
ame is in
contrac
ctor scope.
b) Confirm
m that quoted price includes obtaining
statuto
ory approval of dra
awings, do
ocuments,
inspecttion and fina
al certificatio
on of equipm
ment from
CCOE//PESO
Confirm tha
at quoted prrice includess calibration of bullets
including preparation
n, submisssion and obtaining
o calibration
n chart from
m competentt statutory
approval of
authorities like CPWD / weights an
nd measures
s.
Equipmentt shall be offfered for sta
age wise insp
pection to
TPIA / Clie
ents authorissed agency.
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
Yess / No
EM163-TS
S-401-ANNEX
X1
CHEC
CK LIST (TE
ECHNICAL
L)
DOCU
UMENT NO
S
SHEET 4 of 4
REV
11
12
13
All site job

bs including welding, testing etc. in
ncluded in
contractors scope
Submission
n of Drawin
ngs & Documents as per
p clause
16.0 of Docc. No. EM16
63-TS-401 shall be comp
plied with
Contractor shall furn
nish require
ement of space
s
for
ed bullet in situ at site and
assembly of mounde
constructio
ons power.
Vendor shall
s
tick (
) whichever agreed
Yess / No
Yess / No
Yess / No
SCHEDULE OF EXC
CEPTIONS
S AND
ATIONS (T
TECHNICAL
L)
DEVIA
EM163-TS
S-401 FORM
ME
DOCU
UMENT NO
REV
SH
HEET 1 OF 1
(FORM E)
SCHEDULE OF EXC
CEPTIONS
S AND DEV
VIATIONS (TECHNICA
(
AL)
In line with Tende
er Documen
nt, Vendor may stipulate exceptions / devia
ations to th
he
t
tender
cond
ditions if co
onsidered unavoidable.
Sl.
No.
Tender
T
Doc
cument No.,
Page
P
No.
Clause No. of
er Documen
nt
Tende
Subject
Deviation
NOTE:
1).
A deviation
Any
n taken by th
he vendor to
o the stipulattions of the tender
t
document shall be
b
brrought out as
a per this format only an
nd enclosed along with tthe offer.
2).
A deviation
Any
n not brough
ht out in this form and written
w
elsewhere in the offer
o
shall no
ot
be
e recognized
d and the sa
ame is treate
ed as null an
nd void.
3).
THIS FORM IS EXCLUS
SIVELY FOR
R TECHNICA
AL DEVIATIO
ON. FOR CO
OMMERCIA
AL
D
DEVIATIONS
S REFER CO
OMMERCIAL PART OF THE ENQU
UIRY.
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 1 of 11
0
REV
TITLE
E:
MO
OUNDED BUL
LLET
SP
PECIFIC
CATION
COATING
C
G
PAINTING
G
NSTALLA
ATION O
OF MOUNDED BULLETS
B
S AT
PROJECT: IN
NR
RL
NT:
CLIEN
NR
RL, ASS
SAM
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
CON
NTENTS
Sl. No.
1
2
3
4
5
6
7
8
9
10
11
Descriptio
on
SCOPE
REFEREN
NCE DOCUMENTS
GENERAL
L REQUIRE
EMENTS
SAFE PRA
ACTICES
MATERIAL SPECIFIC
CATION
SURFACE
E PREPARA
ATION
PRIMING
COATING
G
INSPECTIION
QUALITY ASSURANC
CE
RECOMMENDED PA
AINT MANUFACTURER
R
DOCUMENT NO
SH
HEET 2 of 11
0
REV
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 3 of 11
0
REV
1.0
1.1
1.2
1.3
1.4
1.5
2.0
SCOPE
This specifiication gove
erns the minimum requ
uirements fo
or materials
s, equipmen
nt,
application, inspection, repair, han
ndling and other
o
aspeccts of extern
nal Corrosio
on
Protection Coating
C
of Mounded
M
LPG (Liquefied
d Petroleum
m Gas) using
g 100% solid
ds
(Solventless
s) two com
mponent, Hig
gh liquid, fast
f
cure Elastomeric
E
Polyurethan
ne
Coating.
It is envisag
ged that the Polyurethan
ne Coating on external surface of bullets
b
should
provide a ve
ery hard, tou
ugh surface with
w outstan
nding adhesion and impa
act resistancce
to protect against da
amage during the pro
ocess of burying
b
for undergroun
nd
(mounded) service con
ndition and tthereafter. Variation
V
of temperature
e between (
(
)50C (Low)) and + 55C (ambient)) may be en
ncountered a
and are to be
b considere
ed
for design conditions.
The work to
o include fu
urnishing all labour (skilled and un
nskilled), ma
aterials, tools,
equipment and
a the perfformance off all operatio
ons and incid
dentals nece
essary for th
he
coating, han
ndling, storin
ng and transporting of co
oated LPG Bullets
B
- or part thereof.
The steel su
urface prepa
aration, priorr to actual co
ommenceme
ent of coatin
ng, to conform
to SSPC SP 10-63T
T (STEEL S
STRUCTUR
RE PAINTING COUNCIIL SURFAC
CE
PREPARAT
TION SPECIFICATIONS
S) near - white
w
blast ccleaning, inccluded in th
he
scope of wo
ork.
Also include
ed in the sco
ope of work iis removal of
o all equipm
ment and exccess materia
als
from site, following completion of co
oating appliccation.
Applicator to
t obtain prior written approval from
f
the Ow
wner/Consu
ultant for an
ny
deviations from
f
the req
quirements o
of this specification and/or the stan
ndard referre
ed
herein.
REFERENC
CE DOCUME
ENTS
The following docume
ents (latest revision or as specifie
ed) are refferred in this
specification
n. In case of
o conflict be
etween referrence standa
ards or speccifications th
he
most stringe
ent shall ap
pply. In case
e of conflictt between th
his specifica
ation and th
he
reference do
ocument, thiis specificatiion shall app
ply.
a. NACE 6H
6 284
: Urethan
ne Top coatss for (1984) Atmospheric
c application
ns
(Technica
al Committee Report)
b. AWWA C-203
: Coal Ta
ar Protective Coatings fo
or pipelines - Enamel an
nd
Linings fo
or Steel wate
er pipelines.
: Structurral Steel Pain
nting Counccil: Solvent Cleaning
C
c. SSPC - SP1
d. SSPC - SP10
: Structu
ural Steel Painting
P
Co
ouncil: Nearr white Blast
Cleaning.
: Recomm
e. API RP 5L1
mended practice for "Ra
ail Road tran
nsportation of
o
Line Pipe
e"
: Recommended pra
actice for "M
Marine Tran
nsportation of
o
f. API RP 5L5
Line Pipe
e".
5900
: Pictorial surface preparation sttandard for painting steel
g. SIS 055
structuress.
h. NACE TM-01
T
-7
: "Visual Standard for
f surfaces and new steel
s
Air-blast
cleaned w
with sand ab
brasives".
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 4 of 11
0
REV
i.
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
NACE TM-01-75
T
: "Visual S
Standard forr surfaces and new stee
el centrifugally
last clean
ned with stee
el Grit and Shot.
S
GENERAL REQUIREM
MENTS
The Applica
ator shall perrform all worrk in accorda
ance with th
his specificattion and othe
er
requirementts noted. Applicator shalll submit a detailed writte
en descriptio
on in the form
of an annua
al covering coating equip
pment proce
edure, materials, inspecttion, tests an
nd
repair etc. fo
or Owner /Consultant's a
approval.
The Applica
ator shall prrovide the skilled
s
perso
onnel requirred for execcution of this
work. The equipment required sh
hall be in good operatiing conditio
on improvise
ed
equipment shall
s
not be acceptable.
a
The Applica
ator shall supply all coatting materia
als required by this spec
cification, an
nd
shall carry out
o tests on one sample
e per batch of
o supply, ass described subsequenttly
in this specification in se
ection.
The tests sh
hall be carried out by th
he Applicator at his yard
d and the re
esults shall be
b
reported to the
t Owner/C
Consultant fo
or approval and
a accepta
ance.
If the Appliccator does not have ad
dequate facilities at the
e yard to ca
arry out thesse
tests, the same shall be
b got done
e at a Owne
er/Consultan
nt approved independent
laboratory.
The Applica
ator shall un
nload the bu
ullets, or parrts thereof a
at the coatin
ng plant, tally,
store and provide
p
security for the
e bullets an
nd parts the
ereof during coating an
nd
storage. The Applicatorr shall be re
esponsible fo
or placemen
nt of the barre and coate
ed
bullets, or part thereof in
n storage in accordance
e with the refference speccifications.
All coating operations shall
s
be perrformed under the superrvision of, and performe
ed
by, personn
nel skilled in
n the appliccation of the
e coating syystem. Insp
pection of th
he
coating sha
all be perfo
ormed by qualified in
nspectors. T
The qualificcation of th
he
inspectors shall be verified and appro
oved by the Owne
er/Consultants
Representative.
The Applic
cator shall provide access,
a
durring all phases of work,
w
to th
he
Owner/Conssultant and their
t
represe
entatives/insspectors. Any expense caused
c
by th
he
Owner/Conssultants insp
pector stopp
ping the worrk because iit is not bein
ng carried out
as per this specification
s
shall be borrne by Applicator.
All tools and
d equipmentt furnished b
by Applicatorr shall be off good quality, maintaine
ed
in good operating cond
dition and suitable
s
for use to app
ply materials
s as per this
specification
n. All equipm
ment shall be
b subject to
o approval by
b the Owne
er/Consultants
representatiive.
All cleaning, priming and coating machines sha
all be prefera
ably equippe
ed with rubbe
er
or wheels ovverlaid with hard fiber to
o prevent ma
arking or den
nting the steel surface.
The Owner shall be re
esponsible fo
or the strucctural integrity of the steel and sha
all
advise the Applicator
A
re
egarding ava
ailable Sche
edules and shall
s
provide
e Engineerin
ng
information to the con
ntractor as required., including
i
drrawings when available
e,
showing all dimensions
s, obstructio
ons and acccess for the area to be
e coated, an
nd
giving sufficcient informa
ation for calculation of arrea to be sprrayed.
Before bid submission, the Appliccator to accclimatize hiimself with Site workin
ng
conditions and
a owner will
w permit applicator to viisit site.
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 5 of 11
0
REV
3.11 Th
he applicator shall im
mmediately bring to Owner/Con
nsultants attention
a
an
ny
unacceptable metal deffects detecte
ed at the time of surface preparation
n and hold th
he
steel piece till
t such time
e as cleared for further action
a
3.12
4.0.
4.1
4.2
4.3
5.0
5.1
The coating
g to be app
plied using plural
p
compo
onent Airlesss Spray syystem, as pe
er
recommend
dation of Prim
mer, Polyure
ethane manu
ufacturer.
SAFE PRAC
CT ICES
Urethane coatings
c
beiing inflamm
mable and potentially
p
T
Toxic,
requiire all safety
regulations (local, state, central) to be observed
d during the
e coating ope
erations. Alsso
safe storag
ge practices
s should be
e followed for
f
storage of Primer and Coatin
ng
materials att site. Prope
er safety pre
ecautions must be obse
erved againsst recognize
ed
safety hazarrdous.
Ingredients in Urethane coatings wh
hich may pose a hazard include ISO
OCYANATES
S,
HYDROCAR
RBON SOLVENTS, PIGMENTS & ADDITIVES etcc. Applicable
regulation (sstatutory, sta
ate local etc.) shall applyy governing safe handlin
ng practices.
Isocyanates
s in Urethane Coatings have been associated with skin an
nd respiratory
irritations and sensitiza
ation of individuals (do
oing coating operations, as well as,
those prese
ent in close
e vicinity and inhale vapour
v
mistt or over spray
s
beyon
nd
threshold lim
mit value (TL
LV) during spray applica
ation) overexxposed to this. Therefore
e,
proper prev
ventive mea
asures shall be adopted
d to preven
nt such ove
erexposure. A
careful evaluation of the controls, p
protective equipment an
nd work pra
actices should
be made to reduce unw
wanted (haza
ardous expossure).
If an individ
dual is sensiitized to ISO
OCYNATES, completelyy removing the
t
Individual
from area's potential exposure is ma
andatory.
MATERIAL SPECIFICA
ATION
ELASTOME
ERIC URETH
HANE COA
ATING (Bulle
et External s
surfaces):
Spray applied, Imperm
meable Elasstomeric Arromatic Ure
ethane Coa
ating, As pe
er
ASTM-D16, Type V (100% solids, tw
wo compone
ent, chemica
al cure) having:
TENSILE
E STRENGT
TH
ADHESIO
ON (ELECTOMETER PULL OFF)
[TO STEEL BLAST CLEANED
C
TO
T SSPCSP10, SU
UITABLY PR
RIMED] (AST
TM D 897)
RECOVE
ERABLE ELONGATION
N ASTM D
638)
SURFAC
CE HARDNE
ESS (CURED
D FILM)
(SHORE D)
WATER VAPOUR. PERMEABIL
P
LITY (ASTM
E-96)
OPERAT
TING TEMPE
ERATURES
S
SALT SP
PRAY (ASTM
M B117-73) (6000
HOURS))
NOMINA
AL THICKNE
ESS (FILM BUILD)
B
IMPACT RESISTANCE (ASTM G-14
G
ON
STEEL PIPE)
P
TEAR ST
TRENGTH (ASTM D624
4)
ABRASIO
ON RESISTA
ANCE (TAB
BER
ABRASE
ER H-10 WH
HEEL 1000 GMS
G
15 N/mm
m2 (Min.)
8 N/mm2
2 (Min.)
50% Min
n. AT 25 C
50 Min.
0.5gms/2
24hour/m2M
Max
(-)50C TO
T +60C
NO EFFECT
1000 MICRONS (un
nless otherwise notified)
1.1 X 10
0gm cm (100
00 inch-lbs)
200 PLI
WEIGHT
T LOSS 0.05
5 gms (Max.)
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
1000CYC
CLES) (AST
TM D 4060)
RESISTA
ANCE TO CATHODIC
DISBONDMENT (30
0 DAYS, 70O
O-75O F)
(ASTM G8)
G
FLEXIBIL
LITY (ASTM
M D 1737)
ACCELE
ERATED WE
EATHERING
G (ASTM
G23)
DOCUMENT NO
SH
HEET 6 of 11
REV
NO LOS
SS OF ADHE
ESION NO EFFECT
E
ON
N
COATIN
NG
TO PASS 180 BEN
ND OVER 1 inch
i
el
MANDre
EXCELL
LENT, SOME
E CHALKING
G
5.2
PRIMER
The type of primer used
d shall be ass per coating specificatio
on viz.
For areas
s not to be
Purethane
P
(P
Polyvinyl, Bu
utryl wash) tyype.
Cathodicc protected
For areas
s to be Cath
hodic
Primer
P
P-111 (Aluminium
m filled Moissture cured) Urethane.
protected
d
or
o
R-Primer
R
(tw
wo component chemical cure) Uretha
ane.
Single packkage moisturre-cured Ure
ethane prime
ers containin
ng non-leafin
ng Aluminium
pigmented, are fast cu
uring, chem
mical & corrrosion resisttant, and eliminates
e
th
he
mixing and pot
p life~ limitations of tw
wo-package materials.
m
The followin
ng characteristics for the
e Primer:
FLASH POINT
P
COVERA
AGE
SHELF LIFE
L
DRYING TIME
CLEAN UP
U
5.3
28C TCC
@ 1 Mil DF
FT Square fe
eet per gallo
on
810 Theo
oretical
648 Pracctical (Based
d on possible
e 20% loss fa
actor due to
o over
spray, wind
d etc.)
Six(6) mon
nths
At 25C
To touch 30 minutes.
To handle 45 minutes
To recant 4 Hrs.
Toluene (im
mmediately a
after use.)
In all case, Urethane

U
Co
oating manu
ufacturer reco
ommendatio
ons should be
b followed.
Nominal DF
FT of Primer : 50 micronss
In case no primer
p
is use
ed, DFT shall be 1050 microns.
m
COATING / PAINTING (Bullet Inte
ernal Surfac
ces)
The bottom 90o internal portion of th
he bullet (sh
hell, stiffenerr, Dip pipes, etc.) shall be
b
near white blast
b
cleaned
d before app
plication of coating.
c
The bottom 90o internal portion of th
he bullet (sh
hell, stiffenerr, Dip pipes, etc.) shall be
b
coated with
h anticorrosiive solvent--less air dried epoxy ccoating suita
able for LPG
immersion service
s
after hydro test.
Primer :One
e coat of Tw
wo component high build
d solvent-lesss phenolic epoxy Prime
er
cured with polyamine
p
ha
ardener @ 50-75
5
micron
ns D.F.T./coat +
Intermediate
e
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 7 of 11
0
REV
One coat of
o Two com
mponent high
h build solv
vent-less ph
henolic interrmediate coa
at
cured with polyamine
p
ha
ardener @ 7
75-100 micro
ons D.F.T./coat +
Finish Paintt
One coat off Two compo
onent high build
b
solvent-less pheno
olic finish co
oat cured witth
polyamine hardener
h
@ 75-100 micrrons D.F.T./c
coat
(Total dry film
f
thicknesss inclusive primer = 200
2
micronss minimum, 275 micron
ns
maximum)
6.0
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
TION (Extern
nal surfaces)
SURFACE PREPARAT
c
material has exceptionall corrosion and Erosion resistant
Urethane coating
properties but
b must be
e considered
d part of an
n engineered
d system which
w
include
es
adequate surface preparation. It iss axiomatic in protectivve coating work
w
that th
he
performance
e of most appropriately chosen coa
ating work w
will be no be
etter than th
he
surface prep
paration.
The externa
al surface off bullets, or part thereoff, shall be blast cleaned to SSPC-S
SP
10- 63T No.10 specifica
ation. Near white Blast cleaning witth 2-3 Mil Anchor
A
profile
e.
Or else confform to (SIS
S) Gra. SA 2--1/2 specification.
nish is defin
Near white blast cleane
ed surface fin
ned as one ffrom which all
a oil, grease
e,
dirt, Mill sca
ale, rust, corrrosion products, oxidess, paints or o
other foreign
n matter havve
been completely removed.
The overall blast cleaning effect exxpanded (no
ozzle time) shall
s
be not less than tw
wo
thirds (2/3) of
o that which
h would be required
r
to produce
p
aw
white metal surfaces
s
finissh
as per SSPG
G - SP5 on the same su
urface: nor should
s
more
e than ninetyy five per cent
(95%) of suc
ch effort be required. Ho
owever, this limitation sh
hall not be co
onstrued as a
waiver of an
ny of the abo
ove requirem
ments.
REPARATIO
PROCEDUR
RES FOR SURFACE PR
ON
Near White Blast Cleaning shall con
nsist of the following
f
seq
quence of op
perations:
(Dry sand blasting
b
/ We
et sand blastting shall no
ot be employyed)
Heavy depo
osits of oil orr grease sha
all be removved by the methods
m
outlined to spec.
SSPC-SPl-6
63,"Solvent Cleaning". S
Small quantities of oil orr grease mayy be remove
ed
by the blast cleaning op
peration. If o
oil and greasse are removved by blast cleaning, th
he
abrasive sha
all not be reused if such
h reuse is de
etrimental to the surface..
Excessive rust
r
scale may be remo
oved by impa
act tools, ass outlined in Spec.SSPC
CSP2- Hand
d Tool Clean
ning" or SS
SPC-SP-3, P
Power Tool Cleaning" or by special
blast cleanin
ng equipmen
nt.
The surface
e shall be blast cleaned to a Ne
ear-White Finish
F
by an
nyone of th
he
following me
ethods.
Dry sandbla
asting using compressed air blast nozzles
n
and dry sand of
o a maximum
particle size
e no larger than that p
passing thro
ough a 16 m
mesh screen
n, U.S. sievve
series.
Wet or water vapor sa
andblasting using comp
pressed air b
blast nozzle
es, water an
nd
sand of a maximum
m
pa
article size no larger th
han that passses through a 16 messh
screen, U.S. sieve serie
es.
Grit blasting
g using comp
pressed air b
blast nozzles and crushed grit made
e of cast iron,
malleable iron, steel, orr synthetic g
grits other than sand, of a maximum
m particle sizze
no larger th
han that pa
assing through a 16 mesh screen,, U.S. sieve
e series. Th
he
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 8 of 11
0
REV
6.4.7
6.4.8
6.4.9
6.4.10
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
largest commercial grad

de of metal grit permitte
ed by this sp
pecification iss SAE No. GG
25 abrasive material.
Shot blastin
ng using com
mpressed air nozzles an
nd cast iron, malleable iron, steel, or
o
synthetic sh
hot of a maxximum particcle size no la
arger than th
hat passing through a 16
1
mesh scree
en, U.S. siev
ve series. T
The largest commercial grade perm
mitted by this
specification
n is SAE No. S330
Closed re-circulating no
ozzle blasting using com
mpressed airr, vacuum and any of th
he
preceding abrasive.
Grit blasting
g using centrifugal whee
els and crushed grit mad
de of cast iron, malleable
iron, steel, or
o synthetic grits other tthan sand, of
o a maximu
um particle size
s
no large
er
than that passing
p
thro
ough a 16 mesh screen, U.S. sieve series. The largest
commercial grade of me
etal grit perm
mitted by this
s specificatio
on is SAE No
o. G-25.
Shot blastin
ng using ce
entrifugal wheels
w
and cast iron, malleable
m
irron, steel, or
o
synthetic sh
hot of a: maxximum particle size no larger than that J passing through a
16 mesh sccreen, U.S. sieve
s
series.. The largest commercia
al grade perrmitted by this
specification
n is SAE No. S330.
The surface
e if dry blaste
ed, shall be brushed witth clean brusshes made of
o hair, bristle
or fibre, or blown
b
off with compressed air (from which detrim
mental oil an
nd water havve
been removved), or clea
aned by vaccuum, for the
e purpose o
of removing any traces or
o
blast produc
cts from the surface, an
nd also for th
he removal of abrasive from pockets
and cornerss.
The surface
e, if wet san
ndblasted, sshall be cleaned by rin
nsing with frresh water to
t
which suffic
cient corrosio
on inhibitor has been ad
dded to prevvent rusting or with fressh
water follow
wed immediately by an inhibitive treatment. This clean
ning shall be
b
supplemented by brushing, if necesssary, to rem
move any ressidue.
The compre
essed air use
ed for nozzle
e blasting sh
hall be free o
of detrimenta
al amounts of
o
condensed water
w
or oil. Adequate separation
s
an
nd traps sha
all be provide
ed.
Blast cleaning operation
ns shall be done in succh a mannerr that no dam
mage is don
ne
to partially or
o entirely co
ompleted porrtions of the work.
Dry blast cleaning operrations shall not be con
nducted on surfaces tha
at will be we
et
after blast cleaning
c
and
d before painting, or wh
hen ambient conditions are such tha
at
any visible rusting occu
urs before. Painting or coating. If any rust forrm after blast
cleaning, the
e surface sh
hall be re-bla
ast cleaned before
b
coatin
ng.
The blast cleaned
c
surrface shall be
b examine
ed for any ttraces of oil, grease, or
o
smudges. Iff present, th
hey shall be
e removed as
a outlined in Spec.SS
SPC-SP1- 63
3,
"Solvent Cle
eaning".
The height of
o profile of the anchor pattern prod
duced on the
e surface sh
hall be limite
ed
to a maximum height that
t
will not be detrimental to the life of the paint film. Th
he
maximum particle
p
sizes
s specified in
n paragraph
hs 3.1.3.1 to
o 3.1.3.7 may produce an
a
anchor patte
ern that is to
oo high or to
oo rough for the paint syystem to be used. In succh
cases the abrasive size
es should be
e reduced. If the applicattion of the se
econd coat of
o
paint is defe
erred, an ade
equate reduction in anch
hor pattern height
h
shall be
b made.
The height of the anchor pattern ccan be deterrmined by grinding a fla
at spot on th
he
blasted surfface until the bottoms o
of the pits are
a almost reached.
r
The height ma
ay
then be me
easured with
h a microme
eter depth gauge
g
gradu
uated to rea
ad 0.001" an
nd
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 9 of 11
0
REV
6.13
6.14
6.15
6.16
6.17
7.0
7.1
7.2
7.3
with a base
e having a bearing
b
leng
gth of two in
nches and a measuring
g rod of 3/32
2"
diameter.
The blast clleaned surfa
ace should be further trreated or prrimed, as sp
pecified in th
he
agreement covering the
e work, prefe
erably within
n 24 hours after
a
blast cleaning whe
en
practicable, but in any event
e
before any visible or detrimenttal rusting occcurs
Where chemical conta
amination off the surfac
ce may occcur, the steel should be
b
painted as soon
s
as posssible after bllast cleaning
g.
All above op
perations to be witnesse
ed by & certiffied by Owner/Consultants inspecto
or.
As stated in the SSP
PC Steel Sttructures Pa
ainting Man
nual (P114. Vol.1), it is
axiomatic in
n protective coating wo
ork that the
e performancce of the most
m
carefully
selected coating will be
e no better than the su
urface prepa
aration. A co
oating system
well suited to
t a particula
ar exposure system will perform poo
orly if surfacce preparatio
on
is not carrie
ed out in a manner
m
com
mpatible with
h the expose
ed PURETH
HANE coatin
ng
material has exceptional corrosion
n and erosio
on resistantt properties but must be
b
considered part of an
a enginee
ered system
m which in
ncludes pro
oper surfacce
preparation,, priming an
nd applicatio
on for these propertiess to be fullyy effective in
protecting th
he coated su
urface.
The abrasivve shall not be reused a
as this could
d be detrime
ental to the surface.
s
Mark
150 mm width around the bullet ssection conn
necting seam
ms where circumferential
welding (in-s
situ on sand
d bed) is to be
b done.
PRIMING
Prior to prim
ming the blasted surface, all dustt, abrasive residue
r
and
d loose metal
particles shall be remo
oved from th
he steel surfface. If amb
bient conditio
ons are succh
that condensate or dustts form on th
he surface of
o the steel, p
priming shalll not be don
ne
until these conditions
c
arre satisfactorily modified
d.
Before beg
ginning prim
ming and ccoating me
easure the humidity using a slin
ng
psychrometer and calcu
ulate the dew
w point. Dela
ay spraying if the air dew
w point is lesss
than 3C be
elow the ambient tempe
erature. Under controlled
d conditionss it is possible
to heat the steel
s
surface
e to eliminate
e condensattion problem
ms.
The type of primer used
d shall be ass described in the coatin
ng specificattion. Normally
for areas not subject to
t cathodic Protection Voltages
V
Pu
urethane P--24 (Polyvinyl
Butryl Wash
h) Primer sh
hall be used
d and for ca
athodically p
protected ste
eel. primer PP
111 (Alumin
nium Moisture cured Urrethane) or R-primer (Tw
wo component Chemical
Cure Uretha
ane) shall be used. The
e clean blassted steel sh
hall be grimed preferab
bly
within 2 ho
ours after blast cleanin
ng but not more
m
than 24 hours and
a
under no
n
circumstanc
ces shall th
he Primer b
be applied to a surfacce where corrosion
c
ha
as
occurred. Primer shall be
b sprayed onto the cle
eaned surfacce in a fog coat as thinly
as possible (approx 1 Mil)
M so as to tint but not mask
m
the colour of the substrate.
s
Th
he
primer on application sh
hall be free from runs or
o drips. The
e primed surrface shall be
b
protected so
o that it will not come in
n contact with rain, for mist spray, dust or othe
er
foreign subs
stances unttil completelly hardened
d and the U
URETHANE top coat ha
as
been applied. The URE
ETHANE top coat shall be
b applied. b
before the prrime coat ha
as
completely cured, not le
ess than two hours norr more than 18 hours affter the prim
me
coat has been applied but
b in any ca
ase prime co
oat shall be h
hard and nott tacky.
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
8.0
8.1.1
8.2
8.3
8.4
8.5
8.6
9.0
9.1
9.2
9.3
9.4
9.5
9.6
DOCUMENT NO
SH
HEET 10 of 11
1
0
REV
COATING
Equipment for spray ap
pplication sh
hall be Plura
al Compone
ent Airless Spray
S
System
ego Pressu
ure produce
ed at tip 2
2200-3000 PSI, Tip S
Size 0.66 to
t 0.76 mm
m,
Temperature (Resin 50--60C, activa
ator 10- 30C). Follow sstandard insttructions from
supplier from
m spray, ma
aterial handling and stora
age as per g
general speccification.
Always kee
ep a blanket of dry nitrog
gen over materials.
Nominal thickness of Polyurethan
ne 386/9000
0 shall be 40 Mils (1000 Micron
ns
minimum) or
o as otherw
wise specified
d for the ap
pplication. In case no prrimer is used
d,
DFT shall be
e 1050 Micro
ons minimum
m.
Before application on th
he substrate
e apply a tesst patch and
d inspect for runs or drip
ps
and gel time
e as well as tack free tim
me. Test for adhesion
a
if in doubt.
Calculate th
he 'unit repe
eat area', ma
aterial volum
me in counters numbers (counters arre
attached on the Unit tha
at measure tthe volume of
o materials dispensed),, approximatte
speed and number of passes.
p
Spra
ay applies required
r
thicckness in mu
ultiple passe
es
in a single application
a
k
keeping
gun
n perpendicu
ular to the su
ubstrate. If the
t surface is
large enoug
gh to require
e more than one day for the coating, the edges of the coate
ed
area shall be
b feathered
d and roughened with a grinding to
ool for over spraying an
nd
primed. Are
eas /equipm
ment not to be coated should be
e masked by
b disposable
cardboard/p
plastic sheets
s.
Any holidayys or skips should
s
be re
epaired with Urethane 3
385/9000 ha
and mix kit or
o
equivalent after
a
roughen
ning the edg
ges. .
INSPECTIO
ON
All work under
u
this specificatio
on shall be
b subject to inspecction by th
he
owner/consu
ultant or his
s representa
ative. All parts of the wo
ork shall be accessible to
t
the inspecto
or. The Appliicator shall ccorrect such work as is found
f
defecttive under th
he
specification
ns. If the Applicator
A
do
oes not agre
ee with insp
pector, the arbitration or
o
settlement procedure
p
es
stablished th
he contract, if any, shall be followed.
During Coa
ating application the wet film thickne
ess shall be measured using Nordso
on
or equivalen
nt Wet Film Gauge
G
as per ASTM D 4414. The dry
d film thick
kness shall be
b
checked with a Magne
etic Mil Gau
uge (posites
st by DeFelsko or equ
uivalent). Th
he
coating shall be checked for holidayys using Tinker Rasor or equivalent High Voltag
ge
Holiday Dettector. Due care shoulld be taken
n not to use
e voltage exceeding
e
th
he
dielectric strrength of the
e coating (40
00 Volts/Mil) to avoid damage.
Pull Off adh
hesion to ste
eel measured
d using elcometer Adhesion Tester as per ASTM
D- 4541 using an Alumiinium dolly a
attached to the
t coating and
a a perpendicular forcce
applied to th
he dolly. Ave
erage readin
ng from three
e randomly sselected spo
ots shall be at
a
least 1200 Psi.
P Test are
ea to be flat without
w
curvature.
All above tests to be wittnessed and
d certified by Owner/Con
nsultants inspector.
All the batch
hes of coating material, primer to be
b tested at Applicator's laboratory o
or
at any otherr recognized
d laboratory and
a test results duly cerrtified by the
e laboratory to
t
be handed over
o
to Owner/Contracto
or by Applica
ator as QC records.
r
All painting materials including
i
prrimers, thinn
ners & final for applica
ation shall be
b
procured directly
d
from
m manufaccturers as per speciffications an
nd shall be
b
accompanie
ed by manuffacturers test certificate
es for all the
e parameterrs specified in
their printe
ed datasheet for the
e supplied batch of paint mate
erials beforre
EM163-TS--401-ANNEX
X II
CO
OATING / PAINTING
P
SPECIFICATION
DOCUMENT NO
SH
HEET 11 of 11
1
0
REV
10.0
11.0
commencem
ment of paiinting job. Paint formu
ulations with
hout certific
cates are no
ot
acceptable. All paint ma
aterials shall be fresh/ne
ew.
Stage-wise inspection for
f the total painting job
b shall be ca
arried out byy the qualifie
ed
engineer of the contracttor as underr and Record
d shall be ma
aintained
Checkin
ng of surface
e preparation, cleanlinesss & surface
e profile
Checkin
ng of airless spray equip
pment.
Wet film
m thickness of
o first coat and
a intermed
diate coats
Dry film
m thickness of
o total paint system afte
er curing of fiinal coat.
Low volltage holidayy/pin hole de
etection test
Adhesio
on test by crross cut method
Visual inspection fo
or surface fin
nish & covera
age.
Cathodic disbondm
ment test datta at ambien
nt condition as per BS 4164
4
shall be
b
submitted
QUALITY ASSURANC
A
E
The contractor shall guarantee
g
tthat the ch
hemical and
d physical properties of
o
coating/pain
nt materials used are in
n accordanc
ce with the specificatio
ons containe
ed
herein/to be
e provided du
uring executtion of work.
RECOMMENDED PAIN
NT MANUFA
ACTURERS
A). Interna
al surfaces Coating
C
i). Asian Paints
P
ii). J&N
iii). Berger Paint
B). Polyure
ethane Coating
i. M/s. Am
mchem Products Pvt. Ltd
d., Noida
ii. M/s. Go
oldschmidt TIB
T GmbH, G
Germany
iii. M/s. Me
etrotech Ltd.., England
iv. M/s. Fu
utura Coating
gs Inc., St. Louis,
L
USA
v. M/s. Ca
arboline Com
mpany, St. Louis, USA
vi. M/s. Mo
odison Chem
mical Industrries Inc., Can
nada
(1) Apart fro
om these ve
endors LST
TK contracto
or shall prop
pose their approved sub
bvendors for PDIL / NRL approval
MINIMUM QUALITY ASSURANCE PLAN FOR MOUNDED BULLET
DOCUMENT NO
SHEET 1 of 10
REV
MINIMUM QUALITY ASSURANCE PLAN

Sl.
No.
Characteristics
checked
Type of
check
Approval of
fabrication
drawing & design
calculation, FE
Analysis
Approval of
Engg
Drgs./docs
Review/
verification/
check
QAP
Approval of
QAP
4
5
Item Description
NDT Procedure
(PT, RT, MT, UT),
Weld Repair
Procedure
Hydro-test &
Pneumatic Test
Procedure
FABRICATION
Raw Materials,
Bought out items
identification
(Plate, Pipe,
Flanges, SR
Nozzles/Dome),
Pipe fittings, etc.,
correlation of mill
TC & witness of
stamp & stamp
transfer
Non pressure
Parts
Extent
Reference
Document
Acceptance
Document
Inspection By
Contractor
PDIL
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Review
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Approval of
Procedure
Review
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Approval of
Procedure
Review
100%
PO/
Applicable
Code / Stds.
PO/ Applicable
Code / Stds.
Perform
Review/
Approval
Material Spec.,
Chem./Physical,
Dimension,
Punch Mark, etc
Visual &
verification,
correlation
100%
PO /
Applicable
Code / Stds.
Mill TC, Lab

Test Record,
Inspection
Certifi by TPIA
Hold
Witness/ Review
Material Spec.,
Chem./Physical,
Dimension,
Punch Mark,
etc.
Visual &
verification
100%
PO /
Applicable
Code / Stds.
Mill TC, Lab

Test Record,
Inspection
Certifi by TPIA
Hold
Review
Remarks
* Fabrication
shall start
after recpt.
Of Appd.
Drawing
REV
DOCUMENT NO
SHEET 2 of 10
Welding
Consumable
Spec., Brand
Approval of
WPS/PQR & WPQ
Compatibility,
Appd. Brand,
T.C.
Welding
parameters,
Approved
procedure
Review
100%
PO /
Applicable
Code / Stds.
Manufacturers
Batch TC
Review
100%
WPS
Applicable
Code / Stds.
Witness/
Review
Witness/
Review/Approval
Review
Certificate
Level
100%
LEVEL II
Certificates
Review
Hold / Review
Hold
Hold
Approved
Drawing
Perform
Review
Approved
Drawing, Code
Hold
Witness
Approved
Drawing, WPS
Hold
Witness
Approved
Drawing
Hold
Witness
10.1
NDE Personnel
Level, minimum
Qualification
10.2
Welders
Identification
Number
Welders stamp
location sketch
11
Shell plate,
marking, cutting,
edge preparation,
pre-pinching &
rolling
Dimension,
surface,
rectangularity,
rolling direction
Visual /
dimension /
profile
100%
12
Dished end,
Crown, Petal
plates marking,
cutting, edge
preparation &
Pressing
Dimension,
surface check,
profile check
with template
Visual /
dimension /
profile, edge
DPT
100%
13
Shell course LSeam joint preweld Fit-up
Cleanliness of
Plate/ Edge,
Root gap, Bevel
Angle,
Alignment,
Ovality
Visual /
dimension /
profile, edge
DPT
100%
14
Root weld back

gouging of LS
joints
Weld defects,
soundness
Visual, MPI
100%
PO /
Applicable
Code /
Stds./
Approved
Drawing
PO /
Applicable
Code /
Stds./
Approved
Drawing
PO /
Applicable
Code / Stds.
PO /
Applicable
Code / Stds.
WPS
Witness/
Review/Approval
DOCUMENT NO
SHEET 3 of 10
REV
15
Post weld visual

inspection of LS
joint
16
Radiography of
LS joint before SR
Weld
soundness
RT
Stiffener
Fabrication & Fitup to shell
Cleanliness of
Plate/
Edge, Root gap,
Bevel Angle,
dimension,
Alignment,
Ovality
Visual,
Dimension
Meas. &
template
checking
17
Visual, MPI
Post weld of
stiffener ring weld
Weld
soundness
Visual, RT &
MPI
19
Shell circum seam

pre weld fit-up
Cleanliness of
Plate/
Edge, Root gap,
Bevel Angle,
Alignment,
Ovality
Visual, Meas.
dimension &
profile, DP on
edges
20
Root weld back

gouging of CS
joints
21
Post weld visual

inspection of CS
joint
18
Weld Finish /
Weld
Reinforcements
Visible defects
Weld finish /
weld
Reinforcement
Visual / MPI
Visual / MPI
PO /
Applicable
Code / Stds.
Approved
Drawing
Hold
Witness/ Review
* 100% for
outside final
pass/ 25%
inside final
pass
100%
PO /
Applicable
Code /
Stds.
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
100%
PO/
Applicable
Code /
Stds.
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
Butt-weld of
Stiffener
joint RT,
Fillet weld
MPI
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness /
Review
REV
DOCUMENT NO
SHEET 4 of 10
22
Radiography of
CS joints before
SR
Weld
soundness
RT
23
All Nozzles
(Comp. Plate,
Pads etc. Fit-up)
MPI of shell
edges
to be welded &
alignment
Visual, Meas.
dimension &
MPI
24
Nozzle to flange &

nozzle to shell
root
weld & final layer
25
Post weld
inspection of
above completed
weld
26
26.1
26.2
26.3
26.4
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
Weld defects
Visual / MPI
Weld
Soundness
Visual, RT,
UT,
Pneumatic
test
RF Pads
Dimension &
profile
Visual, Meas.
dimension &
MPI on
knuckle
100%
Applicable
Code / Stds.
Profile &
workmanship
Visual & MPI
100%
Applicable
Code / Stds.
Normalising of
petals
Normalising of
petals
Review of
normalising
chart
100%
Applicable
Code / Stds.
Fitup of dished
head joints
Cleanliness of
Plate/
Edge, Root gap,
Bevel Angle,
Alignment,
Ovality
Dished head
Profile,
dimensions &
thickness after
pressing
Crown / petals
after pressing /
gauging & edge
preparation
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Perform
Review
Hold
Witness
Perform
Witness &
Review
Hold
Witness &
Review
Hold
Witness
Hold
Hold
Hold
Review
Visual &
Meas.
dimension
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
REV
DOCUMENT NO
SHEET 5 of 10
26.5
Root weld back

gouging / grinding
of above joints
Weld defects
26.6
Post weld
inspection of
above joints
Weld finish,
weld
reinforcement
26.7
Radiography of
above joints
Weld
soundness
27
Fitup of lifting
lugs & welding
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
RT
100%
Applicable
Code / Stds.
Location,
Orient., Weld
soundness
Visual,
Meas., MPI
100%
Applicable
Code / Stds.
28
Temporary
attachment weld
areas after
grinding
Surface
soundness
Visual & MPI
100%
Applicable
Code / Stds.
29
Individual section
before PWHT
Completeness
Visual
100%
Applicable
Code / Stds.
30
PWHT of
individual section
(SR)
Visual
100%
Applicable
Code / Stds.
31
Production test
coupons
Visual &
Mechanical
property
100%
Applicable
Code / Stds.
32
Hardness test
(spot), weld &
HAZ
100%
Applicable
Code / Stds.
Verification of
thermocouple
location,
PWHT Cycles
Impact,
Mechanical
property incl.
Hardness
Hardness
Visual & MPI
Visual, MPI
Brinell
Hardness
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
Hold
Witness /
Review
Perform
Review
Hold
Witness /
Review
Hold
Witness /
Review
Hold
Hold
Hold
Hold
Hold
Hold
Hold
Witness
Portable
hardness
tester
REV
DOCUMENT NO
SHEET 6 of 10
33
NDT of butt weld

joints after SR
Weld
soundness
34
NDT of butt &

Fillet weld jointsshell, stiffeners,
nozzles (after SR)
Weld
soundness
35
Painting / Coating
material
identification
Matl.
Identification,
Appd. Coating /
Paint
Spec, Quality,
Brand,
36
Painting / Coating
Procedure
Approved
procedure
37
Grit Blasting &

coating of
individual
sections (external
surfaces) before
transportation to
site
38
Final Assembly of
bullet section field
joint fit up,
welding
Grit matl. / spec.

size,
masking by tape
of
field weld joints
/
edges before
coating,
coating thick
(DFT)
spark test etc.,
Cleanliness of
plate
edges,
alignment
RT/TOFD
MPI
100%
Applicable
Code / Stds.
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
Hold
Witness
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Review
Review &
Approval
Review
Applicable
Code / Stds.
/
Specification
-do-
Perform
Review &
Approval
Visual, blast
surface
profile,
primer
thick.(DFT),
finish thick
(DFT)
measurement
100%
Applicable
Code / Stds.
/
Specification
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness /
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Hold
Visual,
Manuf. TC
Visual,
dimension
& Weld
reinforcement
100%
REV
DOCUMENT NO
SHEET 7 of 10
RT of CS field
joints before
Local SR
Weld defects
40
PWHT of field
weld joints (local
SR)
Verification of
thermocouple
its
location,
Recorder
calibration,
PWHT
cycles
41
NDE UT of field
weld joints after
PWHT
Weld
soundness
42
Final visual /
dimensional
check /
completeness
check before
Hydro test
Final
Dimension,
Orientation,
Slope,
Level etc.
Visual, Meas.
Hydrotest
Procedure
Approval of
Hydrotest
procedure,
Pump,
Pressure
gauges
Visual /
Meas.,
Verification of
Pressure
Gauge
Calibration
certificate
39
43
44
Hydrotest of bullets
and settlement
measurement &
Recordw.r.t
permanent
reference bench
mark.
Leakage /
seepage,
settlement
Visual / RT
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
Visual,
Meas.,
Calibration
Certificate
TOFD
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Review
100%
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
Hold
Witness
Applicable
Code / Stds.
Applicable
Code / Stds. &
Approved
Drawing
100%
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Perform
Review &
Approval
100%
Applicable
Code / Stds.
Applicable
Code/Stds.
& Approved
Drawing
Hold
Hold
Visual, Meas
100%
Hold
Hold
DOCUMENT NO
SHEET 8 of 10
REV
45
46
47
48
49
Draining out of
water & drying
MP of Stiffener
web to shell fillet
weld seam & Web
to flange fillet
weld (both sides)
after Hydro
UT (TOFD) of
Shell circ. buttwelds seams
(bottom 1200 ) &
MPI of all Internal
& accessible Ext.
butt-weld circ &
long. seams after
PWHT.
Wire brush,
cleaning, painting
of field joint area /
components,
Repair of Paint
Damage s, DFT
survey (Stages &
Final)
Wire brush
cleaning, painting
of 90O bottom
internal bullet
area including
stiffening ring,
DFT survey
(Stages & Final)
Complete
draining &
Cleanliness
Weld
soundness
due to mound
settlement
Weld
soundness
due to mound
settlement
Surface
cleanliness,
Paint surfaces,
Paint
thickness,
Spark test
Surface
cleanliness,
Paint surfaces,
Paint
thickness,
Spark test
Visual
MPI
TOFD/MPI
Visual, Meas.
Visual, Meas.
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Hold
Review
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Hold
Witness
100%
Applicable
Code / Stds.
Applicable
Code /
Stds. &
Approved
Drawing
Hold
Witness
100%
PO,
Approved
Coating
Procedure,
& Approved
Drg.
PO, Approved
Coating
Procedure,
& Approved
Drg.
Hold
Witness/ Review
100%
PO,
Approved
Coating
Procedure,
& Approved
Drg.
PO, Approved
Coating
Procedure,
& Approved
Drg.
Hold
Witness/ Review
100%
100%
DOCUMENT NO
SHEET 9 of 10
REV
50
Calibration of
bullets under
State Government
Statutory
Authority
Calibration
procedure,
chart
Visual, Batch
/
Matl.
Correlation
100%
Applicable
Code/ Stds.
IS:2009 &
IS:2166
Hold
Review
Statutory
Authority
100%
PO,
Approved
Fire
proofing
Procedure
& Apprd
Drg.
PO, Approved
Fire
proofing
Procedure
& Apprd Drg.
Review
Review
Perform /
Hold
Witness/ Review
Hold
Witness/ Review
51
Fire Proofing
Material
Matl.
Identification,
TC
52
Fire Proofing
Application /
Procedure
Surface
cleanliness,
Fire proofing
thickness
Visual, Meas.
100%
Applicable
Code /Stds.
53
Final acceptance
As-Built,
Documents,
Dossier
Verify
100%
Applicable
Code /Stds.
54
Cp System
55
DOCUMENTATION
Design/Drawing/
Procedure
(As-Built Fabrication Drgs., Docs.,

Design Calculation, FE Analysis, All
material test certificates, NDE test
record, PWHT chart, Hydrotest
record, Settlement check record,
Calibration
Chart,
Thickness
Measurement for periodic test
comparison, Inspector Release Note
Verify
PO,
Applicable
Code / Stds.
Verify
100%
Final
Certification
by
inspecting
authority /
site incharge
100%
Applicable
Code /
Stds. &
Approved
Drawing
Applicable
Code /
Stds. &
Approved
Drawing
Applicable
Codes/stand
ards /Spec.
As per tender
Document
Perform
Witness/ Review
AsPerP.O.
AsPerP.O.
Hold
Review/
Approval
DOCUMENT NO
SHEET 10 of 10
1
REV
All other documents required by

Civil, Piping, Electrical & Instrument
Scope of Work)
NOTES:
The test / inspection indicated in the above table is minimum requirement. Any other test / inspection / stages, if called for by the inspector, to get satisfied himself with the quality of fabrication, shall be included
by the contractor without any implications.
Contractor shall perform all the Inspection / Testing activity with their men / materials / machines without any implications.
LEGENDS :
APPLICABLE CODE ASME SEC.VIII Div.2 ; ; Stds. As attached with tender
A APPROVAL (Design & fabrication Drawing from PDIL Design office, inspection/testing related doc. By inspecting authority)
H - HOLD POINT (Do not proceed till inspector clears the item / activity in writing)
R - REVIEW - Job can be performed; inspector may review later with records.
W - WITNESS - this activity can proceed further, if PDIL / client is not available to witness the activity and gives permission in writing to proceed, before the date notified in writing.
UT Ultrasonic Testing, MPI Wet florescent Magnetic Particle Test (wherever DPT specified in code and/or specs. MPI shall be employed), Meas. - Measurement
Document No.
Sheet 1 of 3
Rev.
MINIMUMALLOWABLENOZZLELOADINGS
FORMOUNDEDBULLET
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ALLOWABLENOZZLELOADINGS
OF LPG MOUNDED BULLETS, NRL REFINERY
Document No.
Rev.
Sheet 2 of 3
Allrightsreserved
Document No.
Rev.
Sheet 3 of 3
Allrightsreserved
EM163-TS-301
DOCUMENT NO
REV
SHEET 1 OF 14
FOR
DRAIN VESSEL (45-VV-106)
(DOC: EM163-TS-301)
INSTALLATION OF LPG MOUNDED BULLETS AT NRL,

NUMALIGARH
ISSUED BY
PROJECTS & DEVELOPMENT INDIA LIMITED

(A GOVT. OF INDIA UNDERTAKING)
PDIL BHAWAN, A-14, SECTOR -1
NOIDA 201301
DISTT. GAUTAM BUDH NAGAR
UTTAR PRADESH, INDIA
0
P
REV
21.09.15
17.07.15
21.09.15
17.07.15
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV4
ISSUED FOR ENQUIRY

ISSUED FOR CLIENTS COMMENTS
PURPOSE
VB
VKV
PREPD
PK/NB
NB/PK
REVWD
GC
GC
APPD
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 2 OF 14
CONTENTS
SL. NO.
DESCRIPTION
1.
Scope
2.
Mechanical Design
3.
Special Requirements
4.
Scope of Supply
5.
Material of Construction
6.
Fabrication
7.
Cleaning, Painting & Dispatch
8.
Inspection & Testing
9.
Quality Assurance & Control
10.
Performance & Guarantees
11.
Documentation
12.
Spares (Erection & Commissioning, 2 Years Operation)
13.
Completion period
14.
Information Required in Bid
15.
List of Deviation
16.
Waiver / Deviation Format
17.
Reference List
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 3 OF 14
LIST OF ATTACHMENTS
SL.
NO.
DESCRIPTION
1.
PDIL Specification Sheet for Drain Vessel (45VV106)
EM163DD45VV106,Rev1
2.
Additional Mechanical Detail of Drain Vessel (45VV106)
EM163-PNMV-DD-45-VV-106
3.
List of Spares
EM163-PNMV-TS301-SP01
4.
Spare Parts card format for Erection & Commissioning and 2

Year Operation for Drain Vessel (45VV106)
EM163-PNMV-TS301-F1
5.
Documentation Schedule
EM163-PNMV-TS301-DOC
6.
Check List Technical
EM163-PNMV-TS301-CL01
7.
List Of Deviation
EM163-PNMV-TS301-D1
8.
Waiver/Deviation/Concession
EM163-PNMV-TS301-W1
9.
Vessel Tolerances
PDS : PV 001
10. Projection For Nozzles
PDS : PV 002
11. Name Plate For Vertical Vessel
PDS : PV 003
12. Leg Support For Vertical Vessel
PDS: SR 300
13. Lifting Lug
PDS: PV 302
14. Inlet Deflector Baffle / Plate
PDS: PV 225
15. Earthing Boss/Cleat
PDS : SR 104
16. Standard for Anchor Bolts
EM163-0000-0202 Rev 0
17. Allowable Nozzle Loadings
EM163-9511-0905 Rev P
18. Painting Specification
ES 2001
FORM NO: 02-0000-0021F2 REV3
DOCUMENT NO.
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 4 OF 14
1.0 Scope
Detailed mechanical design of equipment along with supporting arrangements, preparation of fabrication
drawings, complete procurement of all materials and other bought-out items whatsoever deemed
necessary, fabrication at shop, transportation up to the respective projects sites, inspection & testing,
complete painting and supply of following equipments including all internals(if applicable) with their
supporting arrangement, mechanical guarantees, supply of spare parts both for main equipment and
internals(if applicable) in accordance with the applicable equipment specification and other documents
enclosed with enquiry.
S. No.
Item Code
Description
Quantity
DRAIN VESSEL
1.
45-VV-106
PDIL Specification Sheet Document No. EM163-DD45-VV-106, Rev 1

Additional Technical Specification for Drain Vessel;
Document No EM163-PNMV-DD-45-VV-106, REV 1
1 No.
2.0
Mechanical Design
2.1
Design & fabrication Code for all vessels shall be ASME Section VIII Div 1 Latest or as
mentioned in attached specification sheet of relevant vessel.
2.2
Complete mechanical design of Equipment as per latest codes / standards of construction shall
be the responsibility of the bidder. Strict compliance with the requirement of codes/equipment
Specification & any other referred document shall be ensured.
2.3
Detailed design calculations for adequacy of strength of all individual parts shall be made by
bidder and submitted to Owner/PDIL for comments & approval. After receipt of approval from
Owner/PDIL the design of equipment shall be considered as final. Any change/comment made
on design calculations and drawing to satisfy the requirement of code/enquiry documents to
make the equipment perfectly fit for smooth operation shall have to be incorporated by Bidders
without any commercial implications.
2.4
Design conditions for the equipment shall be as per equipment specification sheet & Technical
Specification enclosed with the enquiry. Minimum required thicknesses of various components
shall be calculated based on design parameters considering different types of loadings
conditions including effect of static head of liquid column, wind pressure, force of moment owing
to connected piping & other attachments as platform etc. Equipment shall also be designed for
hydrostatic condition. Final thickness shall be decided giving due consideration for corrosion
allowance & thinning allowance.
2.5
Design pressure indicated in datasheets shall be considered at the top of the Vessel. The design
Pressure at any lower point shall be determined by adding the maximum operating liquid head
and any pressure gradient within the column.
2.6
Wind analysis shall be performed as per IS-875 (Latest Edition). Wind forces shall be increased
by 30% (over & above design code requirement) to cater the effect of piping system, platforms
and ladders etc. Wind Speed shall be 55 m/s and Wind Zone VI is to be considered.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
2.7
2.8
EM163-TS-301
DOCUMENT NO
REV
SHEET 5 OF 14
Seismic analysis shall be performed by Response spectrum method (RSM) as per IS 1893-2005
part 4 considering seismic Zone-III.
Local stresses in column wall resulting from nozzle load shall be determined by WRC 107/537,
WRC 297 code requirements. Forces and moments acting on nozzles shall be considered in the
design of vessel and resultant stresses shall not exceed allowable stresses as per applicable
codes /standards/specifications. The Forces and moments on nozzles shall be furnished during
detailed engineering after award of contract. Bidder shall take care of the same during
mechanical design of equipment without any delivery/commercial implications to owner.
2.9
All carbon steel (CS) pressure parts shall have minimum of 3.0 mm corrosion allowance unless
specified otherwise. All internal CS parts including low temperature materials shall have at least
1mm corrosion allowance on either side unless otherwise specified.
2.10
Unless otherwise specified, all internal parts / components shall be removal type unless
2.11
Each lifting lug shall be designed with shock factor 2.
2.12
Bolts of size M52 and above shall be designed and spaced so as to permit tightening with a
hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of
approximately 1 bolt diameter and shall be provided with threaded protection caps. Hex nuts
shall have suitable holes for manual tightening. Equipment having bolt size above M52 shall be
supplied with hydraulic bolt tensioning device along with recommended spares and operating
manual indicating tightening torque. For bolts size above M52 the following information are
required to be furnished along with offer:
i)
ii)
iii)
iv)
v)
Size of bolt indicating pitch of thread.

P.C.D. of bolt holes
Required tightening torque.
Dimension of the nut (across flat & across corner)
Catalogue indicating range of operation etc.
2.13
Bolt/studs of manhole should be so designed to accommodate normal Heavy duty

spanners (i.e. bolt/stud centre to centre distance between outer edge of nuts and
piping/nozzle flange OD should be able to accommodate normal width H.D. spanners).
2.14
All items whether internal or external which are welded directly to a shell or head shall be of the
same material category as that of the shell or head. This shall apply to all nozzles, brackets,
pads and upper portion of the skirt for vertical vessels.
2.15
Design & Supply of Anchor Bolts shall in scope of Bidder. The permissible tensile stress for
Anchor Bolts shall be 120 N/mm2 and Shear Stress shall be 80 N/mm2.
2.16
When design pressure is more than 400# class and/or shell thickness is 50 mm and above, self
reinforced forged nozzle shall be provided. Nozzle size 3 NPS Shell to SR nozzle welding shall
be set-in type welding.
2.17
As it is a drain vessel, under deposit corrosion of bottom dished end will be more than other
components, hence suitable lining on bottom dished end may be considered
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 6 OF 14
3.0
Special requirements
3.1
Thicknesses of various parts wherever indicated in the PDIL equipment specification

sheet is minimum & indicative only. Bidders shall check the adequacy of same before
quoting. However during detailed engineering, if thicknesses need to be increased to meet
code/standard requirements for the adopted code/standard under corroded condition for all load
combination including nozzle loads the same shall be considered by Bidder without any delivery/
commercial implication.
3.2
For equipment to be designed as per IBR all requirements specified therein shall be taken care.
3.3
The design of equipment supports and anchor bolts shall be the responsibility of the Bidder. The
type, number and location etc. indicated in the equipment specification sheets are minimum and
indicative, adequacy of the same must be checked by the Bidder & design calculation shall be
submitted for Owner/PDIL approval.
3.4
Design of the support shall be based on seismic / wind / thermal considerations and fireproofing /
insulation requirements. Saddles to equipment support shall also be analysed for all loading
conditions.
3.5
ASME Section VIII, Div. 1, Appendix S shall be shall be considered mandatory for bolted flange
connections. However flange shall be designed as per Appendix2 for different loading
conditions.
3.6
Local stress calculations for external structural attachments, such as platform clips, pipe support
clips and lifting lugs shall be performed & submitted to PDIL/owner for approval.
3.7
International System of Units (SI) System and English language shall be used for all drawing and
documents.
3.8
Deviations from ITB, if any, shall be clearly spelt out in the offer with proper reference to clause
numbers. In absence of any such indication it shall be assumed that the offer complies with all
the requirements and such assumptions shall be strictly binding on bidder.
4.0
Scope of Supply
4.1
Bidder shall include the following items in scope of supply besides supply of equipment including
spares etc. referred under 1.0 Scope.
i)
Lifting lugs / Erection lugs as required
ii)
All external cleats/pads required for ladders, platforms, pipe support pads including
cleats for earthing connections etc. Details of pads & cleats for ladders, platforms &
pipe supports shall be defined during approval of design & drawing stage. Such details
shall have to be incorporated by Bidder without any commercial/delivery implication.
However Bidder shall include cost of such attachments in the Bid based on his
experience.
iii)
Name plate with bracket
iv)
Foundation / Anchor bolts with nuts and washers
v)
Templates for skirt support of equipment
vi)
Nitrogen filling of equipment alongwith pressure gauge & a valve
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 7 OF 14
vii)
Cleats for earthing connections (2 nos. diagonally opposite to each other)
viii)
Cleats for Insulation. However supply and application of insulation is excluded from
bidders scope.
ix)
All specials instrument & fixtures required to verify the guarantee.
5.0
Material of Construction
5.1
Material of construction for equipments shall be as per Datasheets & Technical specification.
5.2
The following additional material requirements as indicated below shall be considered by Bidder.
5.2.1
All raw materials including bought-out items, whatsoever required, to complete the supplies shall
be procured and supplied with due identifiable mill material test certificates & inspection reports
duly certified by third party inspection agency.
5.2.2
For coarse grained and high tensile materials in carbon steel (UTS > 52 Kg/mm2) guaranteed
impact strength shall be ensured at a temperature 150C below envisaged hydraulic test
temperature as a precaution against brittle fracture during hydraulic test.
5.2.3
a)
b)
c)
d)
e)
f)
Carbon steel plates shall be procured in fully killed condition. CS plates shall be
normalized / annealed.
Dish ends of the equipment shall be stress relieved.
All plates above 50mm thickness shall be vacuum-degassed and examined by Ultrasonic
Testing (UT) at surfaces & edges as per SA-578 Level B and other equivalent applicable
material specification code/standard.
Pressure parts having thickness between 16 mm to 50 mm shall be ultrasonically tested
as per SA - 435.
Bend test as per supplementary requirement S-14 of SA -20.
Material used for pressure parts and attachment to pressure parts shall be necessarily
impact tested (Charpy-V) as per design code & specifications. Impact test temperature
shall be minimum of MDMT, impact test temp. Specified in applicable material code or
given in job
specification which ever is lower. Impact energy values shall be as per
Para UG-84 of ASME code or specified in material specification, which ever is higher.
Orientation of test bar shall be transverse to rolling directions.
5.2.4
All forgings except for flanges as per ANSI shall be UT tested as per applicable material
specification & shall be examined according to ASTM A388 with criteria shown in ASME Section
VIII. Div. 2 (AM 203.2).
5.2.5
All forgings including self reinforced nozzles & flanges shall be examined for surface defects by
MP/PT testing after machining as per applicable material specification code & standard.
5.2.6
All external / internal attachments, pads/cleats directly welded to the equipment shall be of same
materials as that of equipment, unless specified otherwise.
5.2.7
For sizes above DN 12 Nozzle connection shall be rolled from plates with full radiography.
5.2.8
Unless otherwise specified copper or copper alloys shall not be used. Copper content up to
0.40% are acceptable in carbon steel and 0.6% in stainless steel.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
5.2.9
EM163-TS-301
DOCUMENT NO
REV
SHEET 8 OF 14
Unless more restrictive prescription given by material specification the maximum carbon content
of carbon steel used for fabrication as shown by ladle analysis shall be 0.23% for plates, pipes &
tubes, 0.25% for forgings.
5.2.10 C.S. exceeding thickness of 50 mm shall be vacuum degassed except for plate ring flanges.
6.0
Fabrication
6.1
The Bidder shall comply in all respects with the provision of the applicable codes, standards and
specification during fabrication with respect to tolerances, welding, fabrication, forming of heads,
radiography, heat treatment, inspection, testing and quality control etc. unless & otherwise
specified.
6.2
Plates of different thicknesses shall be made flush with the inner surfaces of equipment unless
otherwise stated.
6.3
All dish heads shall preferably of single piece construction. Larger heads which can not be
formed in one piece shall be fabricated as follows with prior approval from Owner.
a)
In two pieces, with the welding seam included in the middle third and preferably on the
centre line.
b)
In petal construction, with meridian seams and a central cap of diameter not larger than
0.75 times the column outside diameter.
6.4
Due provisions must be kept for venting out entrapped gases during welding of pads, flanges
and liner plates etc.
6.5
All welds shall be full penetration welds with back chipping and re-welding from the second side.
For those joints which are inaccessible for back chipping the root run shall be carried out with
TIG process. Single side welding with backing strips shall are not permitted.
6.6
All sharp corners shall be rounded off with smooth radius. Inside edge of manhole and hand hole
at the internal surface shall be rounded to minimum radius 5 mm.
6.7
All flange bolts shall straddle center line unless otherwise stated.
6.8
In case of nozzle with butt-end construction, extra length shall be provided to facilitate hydraulic
testing and subsequently cutting and edge preparation to suit piping welding at site.
6.9
All nozzles less than or equal to NB 65 mm shall be stiffened with three equi-spaced plate ribs of
the same material as that of shell.
6.10
Orientation of longitudinal seams and position of circumferential seams shall be clearly marked in
the fabrication drawing. Nozzles, support and other attachments shall be located clear of welded
joints.
6.11
The centres of the welded longitudinal joints of adjacent courses shall be staggered or separated
by a distance of five times the thickness of the thicker plate or 100mm whichever is greater.
6.12
All parts involving welding construction including internals and stiffener ring shall have
continuous weld unless otherwise stated.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 9 OF 14
6.13
All welds shall be full penetration welds with back chipping and rewelding from the second side.
For those joints which are inaccessible for back chipping the root run shall be carried out with
TIG process. Single side welding with backing strip is not permitted.
7.0
Cleaning, Painting & Dispatch
7.1
After hydraulic testing, the equipment shall be dried, thoroughly cleaned from inside and outside
and shall be free from all shop dirt, loose scale, grease etc.
7.2
All CS equipment shall be shot/grit blasted (min SA 2.5 ISO 8501-1) before the primer coat is
applied on external surfaces. Primer shall be compatible to succeeding painting as per ES-2001.
7.3
All machined surfaces, bolting and flange faces shall be properly protected from rust and
mechanical injury during transit and storage.
7.4
Name and code number of equipment shall be painted on each equipment at a conspicuous
place in letters 150 mm high.
7.5
After hydraulic testing, all SS parts of equipment shall be Pickled & Passivated as per following
procedures; if applicable:
a) Cleaning:
Clean surface and remove all extraneous matter with a hard fibre brush or SS wire brush. M.S.
wire brush shall not be used. All organic materials shall be removed with any paint remover like
light solvent naphtha or benzene or equivalent. Motor petrol shall not be used.
b) Pickling:
Aqueous pickling solution shall be as follows:
Nitric acid (Tech. grade) 10 to 25% plus Hydrofluoric acid 1 to 8% (to be used only for stabilized
SS grades). Temperature 50 to 60 C for 10% Nitric acid and 20 C for 25% Nitric acid. When
size and shape of product permit, total immersion in the pickling solution is preferred. Where
immersion is impractical, pickling may be accomplished by wetting the surface by
i)
ii)
Swabbing or spraying
Partial filling the item with pickling solution and rotating or rocking so that the entire surface
receives the required chemical treatment.
The maximum period for which the pickling solution shall be allowed to remain on the surface is
30 minute. During pickling removal of oxides may be hastened by brushing with a hard fibre or
SS wire brush. Over pickling shall be avoided.
The pickling agent shall be washed off with plenty of water so as to leave no trace behind.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 10 OF 14
c) Passivation
After pickling and water rinsing, an aqueous caustic permanganate solution containing NaOH 10
weight % and KMnO4 4 weight % shall be used for neutralizing pickling solution. This shall be
followed by thorough water rinsing.
Water used for pickling and washing shall not have chloride contents exceeding 30 ppm.
7.6
Equipment intended for transportation by ship shall be kept in hatch of the ship. Suitable
seaworthy packing/painting shall be applied to avoid any damage during transhipments.
7.7
The responsibility of transport, packing and forwarding of the equipment shall be of the supplier.
In case of inland transportation equipment shall be properly lashed, fixed on the wagon/trailer to
avoid any damage due to shocks in transport.
7.8
All spares shall be properly packed, marked and sent separately along with equipment.
7.9
When specified equipment shall be dispatched with N2 filling. In case of equipment assembled
and welded at site, it shall be filled with N2 after testing at site. Dry Nitrogen shall be filled at a
pressure of 0.5 Kg/cm2g and equipment shall be fitted with a pressure gauge and valve.
8.0
Inspection & Testing
8.1
The equipment shall be inspected and tested (including NDT) in accordance with applicable
codes, standards and specifications referred in the enquiry. The equipment shall be inspected
during various stages of manufacturing starting from identification of raw materials to final
completion as per agreed Quality Assurance Plan (QAP) which shall be furnished by bidder
along with their bid and successful bidder after award of contract shall submit QAP to
owner/Third Party Inspection agency for their approval. However all the bought-out items must
be supplied with test certificates and inspection reports.
8.2
In case of Indian bidders, the third party inspection is in scope of Owner/PDIL and in case of
foreign bidders, the third party inspection is by any of the approved third party inspection
agencies to be finalized by Owner/PDIL.Foreign bidders shall quote the charges for third party
inspection agency separately along with the bid.
It shall be the responsibility of the Bidder to make available to the inspector all the drawings,
calculations and other documents. However the owner /inspection agency shall have free access
for inspection at vendors/sub-vendors shop at all stages of manufacturing.
Further the following tests / procedure are mandatory to be witnessed / reviewed by concerned
third party inspection agency.
i)
ii)
iii)
iv)
v)
Vi)
Vii)
Viii)
Review of drawings & design calculations

Welding procedure specifications approval
Heat treatment procedure approval (if applicable).
Hydraulic test
Review of NDT tests reports e.g. RT, UT, MP / PT & hardness etc. including Leak test,
Ferrite check, Iron contaminated test, Inter-granular corrosion test etc.
Review of material test certificates & Positive material identifications
Review of PWHT charts (if applicable).
Review of production test coupons
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
ix)
EM163-TS-301
DOCUMENT NO
REV
SHEET 11 OF 14
Witness of hydraulic testing.
8.3
All imported raw materials shall only be inspected by TPIA. The cost of the same shall be
considered by bidder in their scope.
8.4
The equipment shall be considered acceptable for dispatch only after final certification for
acceptance is issued by concerned inspector.
8.5
Production control coupons, when required as per codes & standards shall be subjected to
mechanical tests as required. In case of heat treated equipment test coupons shall be given
similar heat treatment as for the equipment. Test plates for production testing shall be sufficient
for performing all tests.
8.6
Formed heads cold formed or hot formed below normalizing temperature shall be subsequently
normalized and weld seams if any shall be fully radio graphed after forming.
8.7
All nozzle reinforcing pads wherever applicable shall be tested pneumatically at 1.25 Kg/cm2g
pressure with soap solution on attachment welds. Vent holes shall be plugged with nonhardening mastic to prevent ingress of water.
8.8
All completed equipment shall be tested hydraulically as per the requirements of codes,
standards & specifications in presence of the inspecting authority. Pneumatic test of completed
equipment shall be carried out only when specially mentioned in the specification sheets.
Chloride content in water used for testing shall not exceed 30 ppm.Duration of test shall be as
per applicable codes& standards. Test medium/water shall be tested for the chlorine contents
before filling the equipment.
8.9
The temperature of test water shall comply with requirement of Fabrication code.
8.10
Unless otherwise stated gaskets used during testing shall be same as specified for operating
conditions. After testing, gaskets used during testing shall be replaced by new gaskets.
8.11)
a set of detailed test should be carried out on the vessel and their test certificates should be
made available to NRL/PDIL along with other certificates like
a) Detailed drawings of the fabricated vessels and associated instruments
b) CCOE approval stating that the vessels, various instruments and panels are suitable for
use in LPG service
c) Guarantee Certificate of vessels and instruments
d) Manufacturers Certificate
e) Quality Assurance Certificate for various parts of vessel
f) WPS, PQR & WPQ Certificate
g) Raw material Heat Chart
h) Vessel Dimension Inspection Report
i) Radiography Inspection Report
j) Heat Treatment Chart
k) Hydro-test Report
l) Impact Test Report
m) Stability Test Report
n) TPIA certificates
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
8.12
8.12.1
EM163-TS-301
DOCUMENT NO
REV
SHEET 12 OF 14
NDT Requirements
The following NDT requirements are mandatory in addition to codes, standards &
specification requirements.
A) UT examination:
i)
ii)
iii)
iv)
All butt - as supplement to radiography (where radiography is not possible).

FPW of nozzle attachments as supplement to radiography
All forgings
All butt welds after hydrotest
B) MP / PT examination:
i)
ii)
iii)
iv)
v)
vi)
v)
viii)
ix)
All edges of plates and opening in shell of CS.

Root and final layer of all butt welds.
Fillet welds of CS.
All weld surfaces after PWHT.
All forgings after machining
All fillet & butt weld after hydro testing
Each layer of weld deposit in case of weld overlay, cladding & lining.
Knuckle surface of dished ends / toriconical sections, pipe bends, etc.
All attachment welds
C) Radiography:
i)
ii)
iii)
iv)
All weld seams of formed head, if made in more than one segment shall be full
radiography after forming and heat treatment if any.
When spot radiography is specified, all T - Joints & minimum 10% of total weld
length excluding T joints shall be radiographed
All nozzles fabricated from plates shall be 100% radiographed
All but welds irrespective of thickness (100% radiographed) before PWHT and
hydrotest.
D) Hardness test:
Weld and Heat affected zone (HAZ) of all pressure bearing welds in Cr-Mo steel shall be
tested after final heat treatment using a portable hardness tester. Hardness value shall
not exceed 200 BHN for steel having Cr< 2 % and 240 HB for steel having Cr 2%.
9.0
Quality Assurance & control
9.1
Quality Assurance (QA) shall mean the organizational set up, procedures as well as test
methods and facilities developed by Bidder in order to assure that The equipment leaving
Bidders shop are of the highest possible quality i.e. either equal to or better than the
requirement specified.
9.2
Quality Control (QC), shall mean all the tests, measurement, checks and calibration which
are to be carried out in Bidders shop in order to compare the actual characteristics of the
equipment/unit/system with the specified ones, along with furnishing of the relevant
documentation (certificates/records) containing the data or result of these activities. The
bidders are required to furnish a detailed & comprehensive list of the inspection facilities
available at their shop along with the bids.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
EM163-TS-301
DOCUMENT NO
REV
SHEET 13 OF 14
9.3
Bidder shall submit a comprehensive description (manual) of QA/QC measures contemplated

by him for implementation with regard to this specification. It is contractual obligation of the
Bidder to develop and implement adequate QA/QC systems.
9.4
QA/QC system shall cover all products and services required for the equipment as per scope
defined in enquiry specification including job sub contracted by the Bidder.
9.5
On award of contract the vendor shall submit all the testing procedure including PWHT, NDT
etc. to PDIL/TPI/Owner for approval .Records of all the QAP & test records shall be duly
maintained and produced to the inspector visiting the vendors shop for the purpose of
inspection. The comprehensive records & all the relevant reports shall be finally sent to the
NRL respective unit along with the supply of equipment.
10.0
Performance & Guarantees
10.1
Mechanical Guarantees
Bidder shall guarantee the equipment against faulty design, improper material of
construction and poor workmanship, as per commercial specifications. Approval by
Owner/Third Party Inspection Agency/PDIL for design calculations, drawings & other
documents will not in any way absolve the Bidder from his responsibility. Should any repair
or replacement be necessary owing to any type of failure on account of design material and
workmanship of the item, Bidder shall in view of this guarantee be bound to replace the same
either in part or whole without any commercial implications to Owner. Repaired or replaced
part shall also be covered by same guarantee as in case of main supply.
11.0
Documentation
11.1
Refer Attached Doc. No. EM163-PNMV-TS301-DOC.
11.2
Detailed fabrication drawings shall be prepared by Bidder clearly indicating all design data,
nozzle data, details of all parts with tolerances, all welding joints details and detailed bill of
materials etc. Location of weld seams, construction notes, welding processes, detailed
specification of electrodes including NDT tests etc. as applicable shall be clearly indicated in
the drawing. Fabrication drawing shall also indicated Civil load datas i.e. Empty Weight,
operating weight & hydrotest weight of the equipment including base shear force and base
moment for civil foundation design. Drawing submitted for approval must be complete in all
respects and thoroughly checked and approved by Bidders competent authority before
submitting to Owner/PDIL/Third Party Inspection Agency.
i)
All drawings shall be drawn in AUTOCAD to scale. Manual drawing shall not be
accepted.
ii)
All documents / drawings shall be in English language and in Metric system.

Further the following documentation shall be submitted by Bidder for review &
approval as per Owners requirement besides other documentation listed elsewhere.
a)
8 sets of hard copies of Rev. 0 of GA drawing, design calculation etc with soft
copies to PDIL for review.
b)
Vendor shall also submit 02 hard copies of GA drawing, design calculation etc with
soft copies to PDIL for review.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
c)
12.0
EM163-TS-301
DOCUMENT NO
REV
SHEET 14 OF 14
6 sets of all final documents such as design calculations, fabrication drawings, test
certificates, material test reports, repair procedure along with the reproducible & soft
copies, hard copies etc shall be properly arranged, indexed and bound in one
folder and submitted to owner. All fabricated drawings to be furnished in
*.DWG/DXE format on rewritable CD of reputed make.
Spares (Erection & commissioning, 2 years operation & Special Spares etc.)
Refer Doc. Nos. EM163-PNMV-TS301-F1.

All spares shall be packed separately in wooden packet to avoid damage in Transport. All
commissioning & 2 yrs. operations spares shall be packed & marked separately to avoid any
mix up at site.
Bidder shall submit cost of Erection & Commissioning & 2 years operational spares in PDIL
format separately with price bid. A copy of unpriced format confirming that all the spares
indicated in the format are quoted by the bidders shall be indicated in the unpriced bid.
13.0
Completion Period
Completion period shall be as per commercial part.

14.0
Information Required in the Bid
Bidder shall include all the relevant information for complete technical and commercial
evaluation of the bid as per documentation schedule doc. No. EM163-PNMV-TS301-DOC.
Further bidder shall indicate his response on checklist (Technical) Doc. No. EM163-PNMVTS301-CL01.
15.0
List of Deviations (in prescribed format)

Refer attached format
16.0
Waiver/Deviation/Concession (in prescribed ISO format) to be used by the Bidder after

award of contract)
Refer attached format
17.0
References List
Bidder shall provide detailed references list for executing similar jobs of similar capacity in the
last three years indicating Process Parameters, Design codes & standards, clients name,
name of Inspection agency etc. along with offer.
FORM NO: 02-0000-0021F2 REV3
All rights reserved

INDIA LTD, NOIDA
EM163DD45VV106
DOCUMENT NO.
REV
SHEET 1 OF 3
PROCESSDATASHEET
FOR
DRAINVESSEL
1
0
REV
17.09.2015
10.06.2015
REV DATE
17.09.2015
10.06.2015
EFF DATE
As per Clients Comments

First Issue
PURPOSE
VKS/ SKK
VKS/ SKK
PREPD
SCA
SCA
REVWD
SCA
SCA
APPD
All rights reserved

INDIA LTD, NOIDA
EM163-DD-45-VV-106
Doc. No
REV
VESSEL SPECIFICATION SHEET

Project :
Installation Of LPG Mounded Bullets at NRL ,
Numaligarh
Location : Outdoor
Equipment : Drain Vessel
No. of units : One (1)
Size :
600mm ID
1600 mm HT (TL-TL)
DESIGN DATA
Fluid :
Drain Bullet Caustic Water / LPG
Capacity (Normal/Rated) m3:
0.5
Flow: INLET : m3 /hr
Varies
OUTLET : m3 /hr
Working pressure (Kg/cm2 g)
2.337- 8.6
Design pressure (Kg/cm2 g)
14.5
Working temp. oC
10/40/55
Design temp.(Max/Min) oC
(-)27/55
Specific Gravity ( Inlet)
0.5-.57
Corrosion Allowance (mm)
3 ( Due to Caustic water)
MECHANICAL AND CONSTRUCTION DETAILS

Joints
Weld Efficiency
Post Weld H.T
Radiography
Plant/Section:
2 of 3
45
Tag No:
Service:
Position
45-VV-106
Water Drain Out from Bullet
Hor: ( )
Ver: ( )
MATERIAL OF CONSTRUCTION (1)
Shell:
Carbon Steel
Lining If Any:
Yes 8)
Head:
Nozzle Neck
Nozzle Flange
Studs and Bolts
Nuts:
Gaskets:
Distributers:
Grates:
Additional Attachments Internals :
Internal Attachments:
NOZZLES
L:iquid Inlet
Liquid Drain
Vapour Outlet
Level Connection
Level Transmitter
Displacer Type
Thermo well
Safety Valve
Pressure Gauge
Utility Connection
Design Code
Manhole
Boiling Stds.
Gasket Stds.
Supports
Anchor Bolts
Location
Insulation
Type Of Insulation :
Sheet
MARK
RATING
N4A-B
SIZE
2
1.5
2
2
3
300 #
300 #
300 #
300 #
300 #
N5
N6
N7
N8
1.5
1
1
2
300 #
300 #
300 #
300 #
N1
N2
N3
L1-2
4), 6)
* Hold
* Hold
7)
No
General Notes: 1. All Process data are indicated in bold

2. Vessel shall be used for draining water from LPG bullets
3. Safety valve shall be Fire Sized
4. Interface Float Type
5. * Size shall be confirmed by instrument vendor
6. Connection of DP type LT, LG along with stand pipe.
7. Nozzle has to be provided with blind flange.
8. Bottom dished end and upto 200 mm vertical height from bottom TL shall be coated with Epoxy lining.
Inspection:
Despatch:
SPL. Instruction:
Complete/Segments
Process Dept.
Designed by:
Checked by:
Approved by:
VKS/ SKK
SCA
SCA
Date
10.06.2015
10.06.2015
10.06.2015
No.
1
1
1
REVISION
Signature
Date
VKS/ SKK 17.09.2015

SCA
17.09.2015
SCA
17.09.2015
No.
REVISION
Signature
Date
LIST OF SPARES
DRAIN VESSEL
NRL, NUMALIGARH
1.0
Drain Vessel
1.1
For Erection & Commissioning:
EM163-PNMV-TS301-SP01
DOCUMENT NO
REV
SHEET 1 of 1
a) For Main Equipment:

i) 200% gaskets for each nozzle connection with blind flanges
ii) 5% studs / bolts & nuts for each connection (minimum 5 pieces of each size)
iii) 10% internal bolts, nuts & clamps (minimum 10 pieces of each size)
1.2
For 2 years operation:

a) For Main Equipment:
i) 200% gaskets for each nozzle connection having blind flanges
ii) 5% studs / bolts & nuts for each connection (minimum 5 pieces of each size)
b) For Internals:
i) Clamps 2% excess, min. 5 pieces
ii) Bolts & Nuts 15% excess, min. 10 pieces
iii) Washer 15% excess, min. 10 pieces
Note:
Supply of any additional spares if required for erection and commissioning & 2 years
operational spares whatsoever required shall be under Bidders scope. Bidder shall
furnish the list of such proposed additional spares.
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
FORM NO: 02-0000-0021F3 REV2
ISSUED FOR ENQUIRY

PURPOSE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
All rights reserved
PROJECT : EM163
CLIENT: NRL, NUMALIGARH
ENQUIRY NO. : EM163-TS-301
ITEM : DRAIN VESSEL (45-VV-106)

QTY : 1 No.
BIDDERS NAME:
S.NO.
PRICE IN RUEPES:
DESCRIPTION OF PARTS
(1)
(2)
MATERIAL OF
CONSTRUCTION
MAJOR
DIMENSIONS
(3)
(4)
ERECTION &
COMM.
NO. OF PARTS REQUIRED

2 YEARS OPERN.
UNIT PRICE
(EX - WORKS)*
(5)
(6)
(7)
A)
Main Equipment:
A1
Gaskets
1.
For Nozzles N2, N5 (1.5)
2.
For Nozzles L1-2, N8 ( 2 )
3.
For Nozzle N4(3)
4.
For Nozzle N6, N7 (1)
A2
Studs, Nuts/Bolts
1.
For Nozzles N1, N3, L1-2,

N8 (2)
2.
3.
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
For Nozzles N2, N5 ( 1.5 )
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
For Nozzle N4 (3)
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
SPARE PARTS CARD FOR ERECTION &

COMMISSIONING AND 2 YEARS
OPERATION
FORM NO: 02-0000-0021 F4 REV 0
EM163-PNMV-TS301-F1
DOCUMENT NO
REV
15.09.15 15.09.15
REV DT
EFF DT
TOTAL PRICE FOR

ERECTION &
COMMISSIONING
TOTAL PRICE FOR

2 YEARS. OPERN.
(5) X (7) =
(8)
(6) X( 7) =
(9)
VB
PK/NB
GC
1 OF 2
PREP
D
REVWD
APPD
SHEET NO
All rights reserved
4.
5%(minimum 5
pieces of each
size)
5%(minimum 5
pieces of each
size)
Clamps
10% of total for

each type / size
(minimum 10
nos. of each size)
2% of total for
each type / size
(minimum 5 nos.
of each size)
Internal Bolt ,Nuts &

Washers
10% of total for

each type / size
(minimum 10
nos. of each size)
15% of total for

each type / size
(minimum 10
nos. of each size)
For Nozzle N6, N7 (1)
For Internals:
B)
Note:
*To be filled by Bidder
SPARE PARTS CARD FOR ERECTION &

COMMISSIONING AND 2 YEARS
OPERATION
FORM NO: 02-0000-0021 F4 REV 0
EM163-PNMV-TS301-F1
DOCUMENT NO
REV
15.09.15 15.09.15
REV DT
EFF DT
VB
PK/NB
GC
1 OF 2
PREP
D
REVWD
APPD
SHEET NO
All rights reserved
DOCUMENTATION SCHEDULE
DRAIN VESSEL
NRL, NUMALIGARH
DOCUMENT NO
REV
SHEET 1 of 3
INSTALLATION OF LPG MOUNDED BULLETS AT NRL,

NUMALIGARH
FORM NO: 02-0000-0021F2 REV1
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
DOCUMENT NO
REV
SHEET 2 of 3
Sl.
No.
1.0
2.0
3.0
4.0
Name of Document
Outline sketches showing thickness of main pressure

parts, details of internal weight (erection & operating)
and anchorage details as applicable
Details of internals along with their makes, model no. &
catalogues
Final
civil
load
data
including
details
of
foundation/anchor bolts
Drawing list
With
Bid
Delivery Time in Weeks from placement of

Letter of Intent (LOI)
Y/N
For
approval
For
information
Final /
approved/ Asbuilt
5.0
Mechanical Design calculations & fabrication drgs.

Complying with the specifications and codes.
6.0
Detailed manufacturing drawings alongwith design

calculations for mechanical strength and stability of
internals and corresponding supporting arrangement
showing identification marks, list of materials , type of
fixing and erection instructions.
Welding procedure specification, QAP and performance
records approved by inspecting authority
( ** )
Transportation drawing showing overall dimension, C.G.
weight and handling instructions duly approved by
appropriate authority. Bidder to submit design
calculation for C.G. & adequacy of transportation
saddles etc.
Procedure for hydraulic test and heat treatment ( ** )
After
Hydrotesting
-DO-
-DO-
-DO-
After
Hydrotesting
-DO-
13.0
Recommended spares for commissioning & for 2 years

operation.
Records of NDT tests e.g. Radiography, Ultrasonic
Testing(UT), Magnetic Particle / Penetrant Testing
(MP/PT), hardness etc. including leak test, ferrite check
,Iron contamination test Inter granular corrosion test
etc.( ** )
Materials test certificates duly stamped by inspecting
authority ( ** )
PWHT Charts (**)
-DO-
14.0
Test on production test coupons ( ** )
-DO-
15.0
Hydraulic/Pneumatic test reports ( ** )
16.0
All final As- built shop drgs. & design calculations duly
certified by CIB & inspecting authority ( ** )
Records/drawings, charts duly approved, signed and
stamped by statutory Authorities (**)
All Radiography films ( ** )
& strain gauge
measurement wherever applicable (**)
Mechanical and hydrodynamic Guarantee Certificate
( ** )
Inspectors final certificate ( ** )
-DO-DO-
-DO-
-DO-
-DO-
-DO-
7.0
8.0
9.0
10.0
11.0
12.0
17.0
18.0
19.0
20.0
GENERAL
1.0
2.0
Master Time Schedule/Network (PERT Network/ Bar

chart) showing all the activities required for work
(design , material procurement, fabrication, PWHT,
hydrotesting and transportation etc.
Reference list for supply of similar equipments with
details.
LEGEND: Y Yes, N - No
FORM NO: 02-0000-0021F2 REV1
All rights reserved
DRAIN VESSEL
NRL, NUMALIGARH
DOCUMENT NO
REV
SHEET 3 of 3
Notes:
1.
Final documentations including approved documentation from statutory design verifying

authority shall be supplied in hard copies as well as soft copes in CD formats. Applicable
softwares are MS Office, Word, Access and Excel.
2.
Document marked as (**) are to be approved by authorised Inspection Agency and

Statutory Authorities as applicable.
3.
Bidder shall submit document in required number of sets as stated elsewhere in commercial
part.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

DRAIN VESSEL
EM163-PNMV-TS301-CL01
DOCUMENT NO
REV
SHEET 1 of 1
CHECK LIST: TECHNICAL (VESSEL)

Bidder shall furnish/confirm the following informations/points along with technical offer:
Bidder Name:
Sl.
Description
No.
1.
Equipment data sheet
2.
Outline sketches showing thickness of main parts
3.
Details of internals along with their makes, model no. & catalogues
4.
Erection , Operating ,hydro test weight including internals
5.
Anchorage details
6.
Master Time Schedule/Network (PERT Network/ Bar chart) showing all the
activities required for work (design, material procurement, fabrication,
PWHT, hydro testing and transportation etc.)
7.
Filled in Spares for 2 years operation & commissioning (As per attached
PDIL Format)
8.
References list for executing similar jobs of similar capacity in the last three
years
9.
List of sub-vendors
10. Preliminary Quality Assurance Plan
11. Shipping dimensions & weight
12 Delivery Period
13 Scope of supply including internals etc. as per Tech. Specification
14 Compliance to technical specifications, otherwise clause wise deviations, if
any
15 Compliance of connecting piping load in nozzle design without any
commercial implication
16 Inspection & testing as per ITB. Third party inspection quoted separately (if
applicable)
17 Equipment foundation bolts shall be supplied to project site within 2 months
after approval of drawing & design calculation
18 All necessary pads, cleats, rings etc. required for insulation, pipe supports,
ladder /platform cleats & rings etc. whatsoever required shall be under
bidders scope
19 Sub-contracting shall be restricted to the bought-out items which do not fall
in bidders manufacturing range and NDT assistance shall be offloaded to
the extent of non available facilities. List of such vendors shall be enclosed
along with Bid
20 Raw material from outside sources shall be identified by third Party for
correlation of the source of the material.
Legend:
Bidders reply
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
F / NF
Y/N
Y/N
Y/N
Y/N
Y/N
Y/N
Y/N
Y/N
F Furnished / NF Not furnished / N No / Y - Yes
(BIDDERS NAME & SIGNATURE)
LIST OF DEVIATIONS
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-D1
DOCUMENT NO
REV
SHEET 1 of 2
FORMAT FOR LIST OF DEVIATIONS
The requirements and guidelines set forth in the Technical Specification are binding and
the Bidder shall take due cognizance of all the causes before submitting the Bid. If however
any deviation from Technical Specification requirements, sought by the Bidder the same
shall be indicated clearly against the relevant Technical Specification clauses in the
enclosed format. Any deviation not listed in the enclosed format shall not be considered. It
will be presumed that the Bidder has accepted all the other conditions stipulated in
Technical Specification for all intent and purposes - wherever the deviations are not clearly
earmarked.
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
FORM NO: 02-0000-0021F3 REV2
ISSUED FOR ENQUIRY

PURPOSE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
All rights reserved
LIST OF DEVIATIONS
DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-D1
DOCUMENT NO
REV
SHEET 2 of 2
LIST OF DEVIATIONS
SL.
NO.
RFQ CLAUSE
REF. NO.
DESCRIPTION OF CLAUSES
PROPOSED DEVIATION
0
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15.09.15
17.07.15
REV DATE
EFF DATE
FORM NO: 02-0000-0021F3 REV2
ISSUED FOR ENQUIRY

PURPOSE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
All rights reserved

DRAIN VESSEL
NRL, NUMALIGARH
DEVIATION NUMBER
APPROVERS NO
EM163-PNMV-TS301-W1
DOCUMENT NO
REV
SHEET 1 of 2
OWNERS JOB NO
APPLICANT NO
DATE
PROJECT: _____________________
JOB NO. :_____________________
D W
ORDER/CONTRACT NO.____________________
APPLICANT IDENTIFICATION: _____________________________________________
DETAILS
SPECIFIED REQUIREMENTS
REQUESTED MODIFICATION
JUSTIFICATION:
Commercial impact :
Yes
No
Impact on delivery :
Yes
No
If yes, indicate time: _________ weeks.
Forward request to disposing authority
Signature: ____________________
Name
: ____________________
Deviation request receipt date: ____________

Acknowledgement sent on
: ____________ Signature: ___________________
Name
: ___________________
(Disposing Authority)
To, Originator of the specified requirement
Disposal Decision:
Ref. No.:
Date
:
DECISION
JUSTIFICATION
Negotiation required: Yes / No

1. Notification to Applicant
2. Copy to specialist department
3. Copy to RCM/Inspector (as applicable)
0
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REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
FORM NO: 02-0000-0021F3 REV2
Signature: _________________________
Name
: _________________________
ISSUED FOR ENQUIRY

PURPOSE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
All rights reserved

DRAIN VESSEL
NRL, NUMALIGARH
EM163-PNMV-TS301-W1
DOCUMENT NO
REV
SHEET 2 of 2
(Disposing Authority)
(This sheet to be retained at PDIL and not to be send to sub contractor)

Inspectors/RCM Comments/Recommendations
(Incase of deviation from subcontractors)
Signature: ____________________
Name
: ____________________
(RCM/Inspecting Officer, Owner)
COMMENTS/RECOMMENDATIONS:
Signature: _________________________
Name
: _________________________
(Originator of specified requirements)
Co-ordination with interfacing departments:
The above opinion has been arrived at in consultation and with agreement with the
following departments by this deviation:
1) ______________ 2) ______________ 3) _______________4) ________________
These affected groups/departments are carrying out necessary changes in their

outputs.
To, Disposing Authority
0
P
REV
15.09.15
17.07.15
15.09.15
17.07.15
REV DATE
EFF DATE
FORM NO: 02-0000-0021F3 REV2
ISSUED FOR ENQUIRY

PURPOSE
VB
VKV
PREPD
PK/NB
PK/NB
REVWD
GC
GC
APPD
All rights reserved
PDS : PV 002
PDIL
PROJECTION OF NOZZLES
ISSUE : SEP. 1999
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or shown to third parties without the written permission of PDIL.
FORM NUMBER 02-0000-0021 F3 REV 0
SHEET
1 OF 1
VALUES OF J
Nozzle Diameter
NPS
< 3//
Rating
Rating
150#
300#
200
//
200
Rating
1500#
200
Rating
2500#
350
250
250
350
250
250
350
250
300
350
550
250
250
300
200
//
200
//
//
10
//
12
//
14
250
250
//
16
18//
20//
24//
//
Rating
600#
26 < NPS < 38
//
Rating
900#
350
550
300
350
350
550
300
350
450
--
Remarks
300
300
300
350
350
350
350
350
350
450
450
500
----
Refer Note-4
Refer Note-4
300
350
350
500
--
Refer Note-4
300
350
--
--
Refer Note-6
350
--
NOTES :1. All dimensions are in millimeter unless otherwise shown.

2. The above projections are valid for all types of flanges.
3. However in case of forged nozzle, the projection shall be suitably increased to meet reinforcement requirement.
4. In case of manhole,projection shall be increased by the sum of 50 mm and difference of insulation thickness
exceeding 50 mm.
5. Projection from vessel axis to nozzle facing shall be rounded off to 10 mm.
6. Flanges > NPS 26// will be as per ASME B 16.47 series B.
30/09/99
ISSUED FOR IMPLIMENTATION
DATE
PURPOSE
PREPARED
DKM\DAYTODAY\STANDARD\MECH\PDS-PV002-F3.LWP
REVIEWED
APPROVED
EM15095110905
EM163
DOCUMENTNo
PROJECTSANDDEVELOPMENTINDIALTD
P
Rev
Page1of2
VESSELSANDS/THEATEXCHANGERS
P
Rev
19.05.15
Date
Issued
Purpose
AS
PrpdBy
AS
ChkdBy
AMAR
AppdBy
VESSELSANDS/THEATEXCHANGERS
EM15095110905
EM163
DOCUMENTNo
P
Rev
Page2of2
NOTE:
Theabovelistgivesthetentativeallowablenozzleloads.Actualloadsshallbeforwardedafterstress
analysisofconnectingpiping.
ES-2001
DOCUMENT NO
REV
Page1of26
FOR
PAINT & PROTECTIVE COATINGS
ON STEEL SURFACES
0
REV
01.01.2011
REV DATE
FORM NO: 02-0000-0021F3 REV3
01.01.2011
EFF DATE
FOR IMPLEMENTATION
PURPOSE
RV
PREPD
MKS
REVWD
MKS
APPD
All rights reserved
TECHNICAL SPECIFICATIONS
FOR PAINT & PROTECTIVE COATINGS
ES - 2001
DOCUMENT NO
REV
Page2of26
CONTENTS
Section
Number
Description
Sheet Number
1.0
GENERAL
1.1
Scope
1.2
Definitions
1.3
Safety Regulations
1.4
Material Safety Data Sheet
1.5
Materials
2.0
CODES AND STANDARDS
2.1
Indian Standards
2.2
International Standards
2.3
Other Standards
3.0
SURFACE PREPARATION
3.1
Metal Surface Preparation
3.1.1
Safety
3.1.2
Pre-cleaning
3.1.3
Surface Decontamination
3.1.4
Abrasive Blasting
3.1.5
Alternate Methods of Surface Preparation
4.0
APPLICATION
4.1
General
4.1.1
General Requirements for Shop Application
4.1.2
General Requirements for Site Application
4.1.3
Qualifications and Materials
4.1.4
Handling and Transport
Application of Coatings
10
4.2.1
General
10
4.2.2
Atmospheric Conditions
10
4.2.3
Conventional or Airless Spray
11
4.2.4
Brush Application
11
4.2.5
Roller Application
11
4.2.6
Thickness of Coatings
11
4.2.7
Multiple Coat Applications (Except Wet-on-Wet)
11
4.2
FormNo020000021F3Rev3AllRightsReserved
Section
Number
4.2.8
ES - 2001
DOCUMENT NO
REV
Page3of26
Description
Sheet Number
Protective Coating for Fasteners
12
4.3
Hot Dip Galvanising
12
4.4
Damaged or Inaccessible Surfaces
13
4.4.1
Damaged Paint Surface
13
4.4.2
Damaged Galvanised Surfaces
13
4.4.3
Inaccessible Surfaces
13
4.5
Surfaces Not to be Coated
14
4.6
Wash-up
14
4.7
Touch- up Painting
14
4.8
Paint Storage
14
5.0
COATING SYSTEM SELECTION
15
6.0
MACHINERY, ELECTRICAL AND INSTUMENT EQUIPMENT
21
6.1
Machinery
21
6.2
Electrical And Instrument Equipment
21
7.0
COLOURS
21
8.0
PARTICULAR DESCRIPTION
23
9.0
24
10.0
INSPECTION & TESTING

ADHESION TEST RESULTS
11.0
SUBMISSION OF DATA
25
12.0
LETTER AND NUMBER INSCRIPTION
25
13.0
COLOUR BAND FOR PIPING
26
14.0
LIST OF MANUFACTURER
26
25
ATTACHMENTS
ANNEXURE- I
Brand Names of approved Paints
ANNEXURE- II Technical data Sheet of approved Paint Manufacturer
ES - 2001
DOCUMENT NO
REV
1.0
GENERAL
1.1
Scope
Page4of26
This specification covers the technical requirements for shop and site application of paint and
protective coatings and includes; the surface preparation, priming, application, testing and quality
assurance for protective coatings of mechanical equipment, structural steelwork, plate work,
tankage, guards, pipe work, handrails and associated metal surfaces, which will be exposed to
atmospheric for industrial plants.
1.2
1.3
Definitions
C.S
Carbon steel and low chrome (1-1/4 Cr through 9 Cr) alloys
S.S
Stainless steel, such as 304,316, 321, 347,
Non-ferrous
Copper, aluminium, and their alloys.
High Alloy
Monel, Inconel, Incoloy, Alloy 20, Hastelloy, etc.
DFT
Dry Film thickness, the thickness of the dried or curved paint or

coating film.
Safety Regulations
Protective coatings and their application shall comply with all national, state, and local codes and
regulations on surface preparation, coating application, storage, handling, safety, and
environmental recommendations.
Sand or other materials producing silica dust shall NOT be used for any open-air blasting
operations.
1.4
Material Safety Data Sheets

The latest issue of the coating manufacturers product datasheet, application instructions, and
Material safety data Sheets shall be available prior to starting the work and shall be complied
with during all preparation and painting / coating operations.
1.5
Materials
All paints and paint materials shall be obtained from the companys approved manufacturers list.
All materials shall be supplied in the manufacturers containers, durably and legibly marked as
follows.
Specification number
Colour reference number
Method of application
Batch number
Date of Manufacture
Shelf life expiry date
Manufacturers name or recognised trade mark.
2.0
ES - 2001
DOCUMENT NO
REV
Page5of26
CODE AND STANDARDS:

Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, the following codes & standards shall be followed. Wherever reference to any code is
made, it shall correspond to the latest edition of the code.
2.1
Indian Standards:
IS-5: 1994
Colors for ready mixed paints and enamels.
IS-2379: 1990
Color codes for identification of pipe lines.
IS-2629: 1985
Recommended practice for hot-dip galvanizing on iron and steel.
IS-2633: 1986
Methods for testing uniformity of coating of zinc-coated articles.
IS-8629: 1977
Code of practice for protection of iron and steel structures from

atmospheric corrosion.
IS:110
Specification for Ready Mixed Paint, Brushing, Grey Filler, for

Enamels, for Over Primers
IS:101
Methods of test for ready mixed paints & enamels.
2.2
Other Standards:
2.2.1
Swedish Standard: SIS-05 5900-1967 / ISO-8501-1-1988

(Surface preparations standards for Painting Steel Surface).
This standard contains photographs of the various standards on four different degrees of rusted
steel and as such is preferable for inspection purpose by the Engineer-in-charge.
2.2.1
DIN: 53151 Standards for Adhesion test.
2.3
The paint manufacturers, instructions shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
a)
Instructions for storage to avoid exposure as well as extremes of temperature.
b)
Surface preparation prior to painting.
c)
Mixing and thinning.
d)
Application of paints and the recommended limit on time intervals between coats.
3.0
SURFACE PREPARATION
3.1
Metal Surface Preparation
3.1.1
Safety
ES - 2001
DOCUMENT NO
REV
Page6of26
All work in adjacent areas, which may negatively affect the quality of blast cleaning, and/or
impose safety hazards, must be completed or stopped before the blasting operation starts.
3.1.2
Pre-cleaning
Prior to surface preparation all weld spatter shall be removed from the surface, all sharp edges
ground down and all surfaces cleaned free of contaminants including chalked paint, dust, grease,
oil, chemicals and salt. All shop primed surfaces shall be water washed by means of suitable
solvent, by steam cleaning, with an alkaline cleaning agent if necessary or by high-pressure
water, to remove contaminants prior to top-coating
3.1.3
Surface Decontamination
Surface decontamination shall be performed prior to paint application when uncoated surface is
exposed to a corrosive environment or existing paint work is to be repaired.
Existing coatings shall be removed by abrasive blast cleaning, and then high pressure potable
water shall be used to clean steel surfaces.
Prior to application of coatings, the surface shall be chemically checked for the presence of
contaminants. A surface contamination analysis test kit shall be used to measure the levels of
chlorides, iron salts and pH in accordance with the kit manufacturers recommendations.
Swabs taken from the steel surface, using cotton wool test swabs soaked in distilled water shall
not be less than one swab for every 25m2 of surface area to be painted.
Maximum allowable contaminant levels and pH range is as follows:
Sodium chloride, less than 50 microgram / cm2;
Soluble iron salts, less than 7 microgram / cm2; and
pH between 6 8
If the results of the contamination test fall outside the acceptable limits, then the wash water
process shall be repeated over the entire surface to be painted, until the contaminant test is
within the specified levels.
3.1.4
Abrasive Blasting
All C.S. materials shall be abrasive blast cleaned in accordance with Codes (Ref. Clause 2.0). To
reduce the possibility of contaminating S.S., blasting is not usually specified. However, for
coatings which require a blast-cleaned surface for proper adhesion, S.S. may be blast cleaned
using clean aluminium oxide or garnet abrasives (Free from any chloride or Iron / Steel
contamination).When hand or power tool cleaning is required on S.S., only S.S. wire-brushes
(including 410 S.S.) which have not been previously used on C.S. surfaces may be used.
The surface profile of steel surfaces after blasting shall be of preparation grade Sa 2-1/2 of
Swedish Standards SIS-05-5900 (Latest Revision) or better according to ISO 8501-1 and shall be
measured using the replica tape method or the comparator method.
The roughness (profile) of blast-cleaned surfaces shall be Medium (G) according to ISO 8503-2:
1988 (appendix 1 ) unless otherwise specified. Medium defines a surface profile with a maximum
peak-to-valley height of 60-100 microns, and G indicates that the surface profile is obtained by
grit blasting. For the evaluation of surface roughness Comparator G shall be used.
ES - 2001
DOCUMENT NO
REV
Page7of26
Abrasive blast cleaning shall NOT be performed when the ambient or the substrate temperatures
are less than 3o C above the dew point temperature. The relative humidity should preferably be
below 50% during cold weather and shall never be higher than 60% in any case.
Abrasive blast cleaning shall be performed with a clean, sharp grade of abrasive. Grain size shall
be suitable for producing the specified roughness. Abrasives shall be free from oil, grease,
moisture and salts, and shall contain no more than 50ppm chloride. The use of silica sand,
copper slag and other potentially silica containing materials shall not be allowed
The blasting compressor shall be capable of maintaining a minimum air pressure of 7 kPa at the
nozzle to obtain the acceptable surface cleanliness and profile.
The blast cleaning air compressor shall be equipped with adequately sized and properly
maintained oil and water separators. The air supply shall be checked to ensure no oil and water
contamination at the beginning of each work shift.
Blast cleaning abrasive shall be stored in a clean, dry environment at all times. Recycling of used
abrasive is prohibited.
After blast cleaning, the surfaces shall be cleaned by washing with clean water (Pressure
7kg/Cm2 using suitable nozzles. During washing broom corn brushes shall be used to remove
foreign matter.
Assessment of the blast cleaned surfaces shall be carried out in accordance with reference code.
Blast cleaned surfaces which show evidence of rust bloom or that have been left uncoated
overnight shall be re-cleaned to the specified degree of cleanliness prior to coating.
All grit and dust shall be removed after blasting and before coating application. Removal shall be
by a combination of blowing clean with compressed air, followed by a thorough vacuum cleaning
with an industrial grade, heavy duty vacuum cleaner.
All cleaned surfaces shall have protection from atmospheric corrosion as per IS8629:1977
3.1.5
Alternate Methods of Surface Preparation

When open air blasting is not permitted on site, or when space limitations or surface
configurations preclude blasting, the alternate cleaning methods listed below may be used with
prior approval. Alternate cleaning methods shall consider the degree of surface cleanliness and
roughness profile required by the specified coating system.
-
Vacuum or suction head abrasive blast-cleaning,
Wet jet abrasive blast-cleaning,
Compressed-air wet abrasive blast cleaning,
Pressurized liquid blast-cleaning,
Power tool cleaning,
Hand or power tool cleaning,
ES - 2001
DOCUMENT NO
REV
Page8of26
Hand and/or power tool cleaning shall only be used for spot repair where abrasive blasting is not
permitted or is impractical, and on items which could be damaged by abrasive blasting. Power
tool cleaning shall not be carried out with tools which polish the surface, e.g. power wire brushes.
The surfaces of equipments and prefabricated piping
etc. which are received at site
Primerised or with finish paints, depending upon their conditions, shall be touched up and
painted at site. For these surfaces sand blasting is not envisaged and these surfaces shall
be prepared using power brushes, buffing or scraping, so as to achieve a surface finish to
St-3 as per SIS-05-5900 . After wash-up the area to be touched up shall be jointly marked,
measured and recorded for payment purposes. The type of system & nos. of coat (primer and/or
finish paint) to be applied after touch up, which shall be decided by OWNER/CONSULTANT in
writing before taking up the job.
When paint is to be applied on damaged painted surfaces of equipments all loose and flaking
paint work should be removed to a firm feathered edge. Rusted spots should be cleaned by one
of the methods specified in the clauses 4.4.1 & 4.4.2 above. In case the previous paint work is
not compatible to the specified one the entire coating must be removed.
It shall be ensured that sand blasted surface/machine cleaned surface is not contaminated with
oil and grease. Water shall also not be allowed to come in contact with sand blasted surface.
4.0
APPLICATION
4.1
General
The final specification of paint systems to be used to suit the exposure conditions of equipment
and steelwork, shall be as specified on the scope of work, equipment data sheets or the
drawings.
All coatings shall be in accordance with Indian / International Standards, the coating
manufacturers product data sheets and application instructions and the requirements contained
in this specification.
4.1.1
General Requirements for Shop Application

All structural steelwork shall be surface prepared for painting and have the paint system applied
before installation.
In all cases, where surfaces will be inaccessible after shop assembly, they shall be prepared and
have the paint system applied before assembly is carried out. Drying times between successive
coats shall be at least those recommended by the manufacturer.
All known field weld areas shall be given the specified abrasive blast surface preparation but left
uncoated for a distance of 50mm from the weld line. Such areas shall be given the appropriate
touch-up treatment after installation.
The manufacturer's directions for preparation and application of coatings shall be followed to
ensure that the durability of the coating system is not impaired.
The Contractor shall submit the full details of the proposed surface preparation and paint
systems prior to the commencement of any surface preparation.
ES - 2001
DOCUMENT NO
REV
4.1.2
Page9of26
General Requirements for Site Application

Paint shall be stored only in accordance with the manufacturer's instructions.
All materials used for the specific system being applied shall be products supplied by one
manufacturer and details of such product shall be submitted for approval before commencement
of work.
The contents of cans shall be thoroughly stirred before being poured into paint pots and shall be
thinned only in the specified proportions in accordance with the manufacturer's instructions.
Finish coats may be applied by spraying except where any over spray is likely to affect finished
surfaces or where spraying constitutes a health hazard to workmen in the other areas. Brush
and roller application will require multiple coats to achieve the specified dry film thickness.
Brush application may be used only with the approval of the company.
Roller application shall only be used on relatively large surface areas ( i.e. > 50m2) and only if
spraying is not an option.
The Contractor shall complete the application of any one type of paint or each coat thereof,
before beginning the next coat on that section.
In cases nominated as critical, the application of each coat shall be approved before application
of the next coat can proceed, in accordance with hold points nominated in the Inspection and
Test Plans (ITPs)
All fittings within any given area are to be painted with the same system as the area unless
Where 2 coat of finish paint are indicated they shall be applied in two different shades to ensure
that two coat are applied.
Paint shall not be applied in rain, snow, fog or mist or when the relative humidity is such as to
cause condensation on metal surface.
The CONTRACTOR must ensure the availability of a specialist from the paint manufacturer, at
SITE during pendency of CONTRACT within his quoted rates to ensure the quality of
painting & procedure. Addition of drying agents, pigments or other substances is not allowed
unless specifically prescribed or approved by paint manufacturer's specialist.
Name plates/tags attached to the equipments/machineries shall not be painted or removed
during painting job. Failing to comply with above, the CONTRACTOR may be required to replace
name plates/tags at his cost.
4.1.3
Qualifications and Materials

All surface preparation, coatings application and inspection, shall be carried out by personnel
experienced in that particular field. Contractors shall submit the names of subcontractors to be
employed for the specific work together with the brand names of coating materials for approval
prior to commencement of application.
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4.1.4
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Handling and Transport

All pipe work, steelwork and equipment that have been finish coated shall be handled with care
to preserve the coating in the best practical condition.
Painted materials shall not be handled until the coating has completely cured and dried hard
Supports in contact with coated steel during transport and storage shall be covered with a soft
material to prevent damage to the coating. Appropriate materials shall be used during
transportation between coated steelwork and holding down chains to prevent damage to the
coating.
4.2
Application of Coatings
4.2.1
General
The application method and type of equipment to be used shall be suitable for the paint specified
and the surface being painted.
Paints and thinners shall be brought to the point of usage in unopened original containers
bearing the manufacturer's brand name and colour designation and ready-mixed unless
otherwise specified. Two-pack systems shall be mixed at the site of application to the paint
manufacturer's recommendations. The mixed amount prepared shall be no more than the
amount that can be applied during the stated pot life.
Paint shall be applied so that an even film of uniform thickness, tint and consistency covers the
entire surface and is free of pin holes, runs, sags or excessive brush marks. Film finish shall be
equal to that of first class brushwork.
Unless it is practical to do so colour shades for primer, intermediate coat and finish coat must be
different to identify each coat without any ambiguity
Paint ingredients shall be kept properly mixed during paint application.
Equipment shall be kept clean to ensure dirt, dried paint and other foreign materials are not
deposited in the paint film. Any cleaning solvents left in the equipment shall be completely
removed before painting.
To ensure the required film thickness is achieved on angles, welds, sharp external edges, nuts
and bolts, a coat shall be applied to such items/locations immediately prior to the application of
each coating to the whole area.
Care shall be taken to ensure paint application into all joints and crevices.
The contact surfaces between steelwork to be fastened by means of friction grip bolting shall be
abrasive blast cleaned and prime coated only, prior to erection.
4.2.2
Atmospheric conditions
Surface preparation and coating shall not be carried out in inclement weather and shall be
carried out such that the surface being coated is free of moisture, wind-borne or blast cleaning
dust.
Coatings shall not be applied if:
-
The relative humidity exceeds 85%.
The ambient temperature is less than 50C (depending on local condition)
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The metal temperature is less than 30C above the dew point.
There is likely hood of an unfavourable change in weather conditions within two hours
after painting.
As a general rule, sufficient ventilation, dehumidification and heating capacity to cope with local
climatic conditions must be secured before any coating related work is started.
In any case, humidity, ambient and surface temperature conditions at the time of paint
application, and curing and drying time before application of the next coat, shall be in accordance
with the paint manufacturer's recommendations. These conditions shall be recorded in the
Inspection Test Record (ITR) by the Contractor and be available for review.
4.2.3
Conventional or Airless Spray

Spray equipment shall be equipped with accurate pressure regulators and gauges. Spray gun
nozzles and needles shall be those recommended by the paint manufacturer.
Air from the spray gun shall be clean and dry with no traces of oil or moisture.
Coatings shall be wet on contacting the painted surface. Areas of dry spray shall be removed
and the correct system re-applied.
4.2.4
Brush Application
The method of "laying-off" shall be suited to the paint specified and shall ensure minimum brush
marking.
4.2.5
Roller Application
A uniform method of application shall be adopted when painting large areas. The rolling direction
shall minimise paint joint build up. Edges and areas subject to possible roller damage shall be
brush-painted prior to rolling.
4.2.6
Thickness of Coatings
The maximum thickness DFT in any one application shall not exceed that specified in Technical
specifications/ recommended by the paint manufacturer.
Wet film thickness gauges shall be used to make frequent checks on the applied wet film.
The Contractor shall maintain at the site of painting operations, a dry film thickness tester of an
approved type with a valid current calibration.
Coating thickness checks in accordance with reference code shall be performed, and the
Contractor shall undertake remedial action if the measured thickness is less than specified.
Build up of each material to required thickness shall be made prior to the application of the
subsequent coat; final film build shall be the minimum specified.
4.2.7
Multiple Coat Applications (Except Wet-On-Wet)

Before successive paint coats are applied, intermediate coats shall be inspected for surface
contamination. The presence of any grease or oil, shall be removed by a suitable solvent, and
any salt and dirt adhering to the surface shall be removed by scrubbing with a solution of non-
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toxic detergent (except those prescribed by the manufacturer as wet-on-wet"). Removal of

contaminants shall only be performed after an intermediate coat has had sufficient time to cure.
The surface shall then be pressure hosed or dusted down by brush to disturb and remove
deposits not apparent on visual inspection.
Coatings shall be applied only under the following conditions:
-
The surface has been cleaned and is dry;
The manufacturer's stated minimum time for re-coat has elapsed;
The manufacturer's stated maximum time for re-coat has not elapsed. If the maximum
time has elapsed then pre-treatment shall be in accordance with the paint manufacturer's
recommendations; and
Damaged areas in preceding coat have been made good in accordance with this
Specification.
When multiple coat of finish paint are indicated, they shall be applied in different shades to
ensure that multiple coats have been applied.
4.2.8
Protective Coatings for Fasteners

Black and galvanised erection bolts and galvanised holding down bolts shall be prepared and
painted in accordance with Section 4.4 of this Specification.
Black high tensile bolts shall be painted after erection to the same paint system specification as
the surrounding structural steel.
4.3
Hot Dip Galvanising

All galvanising shall be carried out by the hot dipping process and conform to the requirements of
IS-2629:1985 and uniformity of coating shall confirm to IS 2633:1986.
All welding slag shall be removed by chipping, wire brushing, flame cleaning or abrasive blast
cleaning where necessary.
For temporary identification, either water-soluble marking paints or detachable metal labels shall
be used. For permanent identification, figures shall be heavily punched or embossed by the
fabricator.
For galvanised items after pickling, the work shall be inspected and any defects that render the
work unsuitable for galvanising shall be repaired. After such repairs, the work shall again be
cleaned by pickling.
The coating mass of zinc shall be as specified on equipment data sheets and the Drawings.
Galvanised coatings shall be tested by the methods described in referred code.
After galvanising all material shall be cooled to air temperature in such a manner that no
embrittlement occurs.
Galvanised coatings shall be smooth, uniform, adherent and free from stains, surface
imperfections and inclusions.
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All gratings and fixtures including nuts, bolts and washers that are required to be galvanised,
shall be hot dipped galvanised and all nut threads shall be re-tapped after galvanising and a
lubricant applied on Cold working of galvanised steelwork shall be avoided.
4.4
Damaged or Inaccessible Surfaces
4.4.1
Damaged Paint Surface

Repair of damaged painted surfaces, as well as painting of galvanised and black bolts, and
galvanised holding down bolts after erection shall comply with this Clause. The treatment shall
be:
-
Pre-clean the damaged or unpainted areas in accordance with Section 4.2.1 of this
Specification;
Disc or hand sand to clean bright metal;
Inorganic zinc primers subject to mechanical damage or weld etc shall be power tool
cleaned
Feather backs by sandpapering or whip blasting the original coatings surrounding the
damaged area over a 50mm distance. A rough surface shall be obtained on epoxy
coatings;
Clean surface to remove all dust;
Conduct surface contaminant test in accordance with Section 4.2.2 of this document; and
Build up a new paint system over the affected area with paints equal to those originally
used and having the same dry film thickness for each coat. As an exception, damaged
inorganic zinc primers shall be repaired with epoxy organic zinc rich paint and shall be
applied within four hours of blast cleaning.
4.4.2
The new coatings shall overlap the original coating over the 50mm prepared distance and shall
be colour matched to the specified colour of the original coating.
Damaged Galvanised Surfaces
Damaged areas caused by oxy-cutting, welding or physical impact shall be treated as follows:
-
Prepare the surface by removing any weld slag followed by vigorous power wire brushing
of the coating surrounding the damaged area over a 50mm distance;
Clean surface to remove all dust; and
Apply two coats of organic zinc-rich primer to a minimum DFT of 100 microns.
The area to be reinstated shall be colour matched to the surrounding finish colour with 40
microns of aluminium paint to the manufacturer's written instructions.
4.4.3
Inaccessible Surfaces
Surfaces that will be inaccessible after erection of other elements of the structure, shall be fully
painted prior to the installation of the obstructing item.
4.5
Surfaces Not To Be Coated

The following surfaces shall not be blasted or coated unless specifically directed:
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Machined surfaces, bearings, seals, grease fittings, adjusting screws and name plates, and
identification tags.
-
Valve stems;
Raised faces on pipe and equipment flanges;
Electrical cabling;
Instrumentation, gauges and sight glasses;
Titanium, stainless steel and non-metallic surfaces; and

Field weld margins, 50mm either side of weld, on tankage and piping, prior
welding.
The rear face of piping flanges shall be shop prime coated only. Flange holes for fasteners shall
be fully coated.
4.6
Wash-Up
All surface of equipments/prefabricated piping etc. Primerised / painted at Vendor shop and
received at site if required shall be washed up as follow:
4.7
a)
Washing with clean water (Pressure 7 Kg/cm2) using suitable nozzles. During washing,
broomcorn brushes shall be used to remove foreign matter.
b)
Solvent washing, if required , to remove traces of wash up as per above procedure of all
surfaces of equipment, piping, structure etc. completely painted at contractor's shop
shall be included in the quoted rates of oil, grease etc. Wash up as per above procedure
of all surfaces of equipment, piping, structure etc. completely painted at contractor's shop
shall be included in the quoted rates.
Touch-Up Painting
Prior to the application of any coat, all damage to the previous coat(s) shall be touched-up.
Damage to finished work shall be thoroughly cleaned and re-coated.
Surface preparation shall be done as per clause no. 3.0..........................
Items supplied with the manufacturers standard coating system shall be touched-up with the
same generic coating system or recoated.
4.8
Paint Storage
The following must be ensured:
a)
All paints and painting material shall be stored only in such rooms assigned for the
purpose. All necessary precaution shall be taken to prevent fire. The Storage building
shall preferably be separate from adjacent buildings. A sign-board bearing the Words
"PAINT STORAGE- NO NAKED LIGHT" shall be clearly displayed outside. The building
shall be properly ventilated and shall be adequately protected with fire fighting equipment.
b)
Storage shall be far away from heated surface open flames, sparks & well protected from
sun rays.
c)
Ambient temperature at which paints are stored shall be intimated to paint manufacturer &
their advice sought regarding precautions to be taken if any,
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regarding flammability, explosiveness & toxicity.
5.0
d)
Maximum allowed storage time for various paint materials shall be clearly indicated on
individual containers. Materials which have passed expiry date shall not be used.
e)
Paints in non-original containers and/or in containers without seals, shall not be used.
COATING SYSTEM SELECTION

Coating Systems for Structures Piping and Equipment
The following Table 1 shall be used as a general guide for the selection of a paint system suitable for a
particular plant area application. Paint systems specified on equipment data sheets and the Drawings
shall take precedence over the general paint system area applications listed in Table 1
TABLE - 1
Ref
No.
01
02
Application
Surface Preparation
Structural Steel work with

operating temp. Up to 90O
C (Steel structures, Piping
support, uninsulated CS
piping, flanges, valves,
stairways, walkways etc.
except grating).
Blast cleaning to near

white metal grade 2
, of Swedish
Standards SIS-055900 (Latest).
Wash-up As per
clause no.4.60.
Touch-up As per
clause no.4.70
Uninsulated CS piping,
flanges, valves with
operating temp. From 90O
C to 200O C.

white metal grade
Sa-2, of Swedish
Standards SIS-055900 (Latest) washup As per clause
no. 4.60. Touch-up
As per clause no.
4.70
Generic Coating
System
Primer: Two coats
of two pack zinc
rich epoxy
polyamide cured
Primer.
Finish coat: Three
coats of two
packs. Polyamide
Cured Epoxy.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Minimum
DFT
Primer :35
microns
For each coat
(Total70microns).
Finish: 40
microns for
each coat
(Total 120
microns.
Primer: 75
microns
Finish:
25 microns for
each coat Total
- 50 microns.
Remarks
Total dry film
thickness of
paint system:
190 microns.
Total dry film

thickness of
paint system:
125 microns.
NOTE : Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting,
ready mixed Aluminium Paint will be applied on surface without inorganic zinc primer and surface
preparation to grade Sa-2 of Swedish Standard SIS-05-5900 (Latest).
03
Uninsulated CS piping,
operating temp. Over 200O
C.

white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no.4.70.
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of Heat
Resisting Silicon
Aluminium Paint.
Primer: 75
microns
Finish:
20 microns for
each coat Total
- 40 microns.
Total dry film

thickness of
paint system:
115 microns.
Ref
No.
Application
Surface Preparation
Generic Coating
System
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Minimum
DFT
Remarks
NOTE: Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting
Silicon Aluminium Paint will be applied on surface without inorganic zinc primer and surface
04
05
06
Insulated CS piping
operating temp up to 90O
C
Insulated CS piping,
operating temp. From 90O
C to 200O C.

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no.4.70
Primer: One coat

of high
temperature
phenolic epoxy
Finish Coat : One
coat of high
temperature
phenolic epoxy

white metal grade
Sa-2, of Swedish
no. 4.60. Touch-up
As per clause no.
4.70
Primer: One coat

of high
temperature
phenolic epoxy
Finish coat : One
coat of high
temperature
phenolic epoxy
Primer :100
microns
Finish : 100
micron
Total dry film

thickness of
paint system:
200 microns.
Primer: 100
microns
Total dry film

thickness of
paint
system:200
microns
Finish: 100
micron
NOTE : Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting,
ready mixed Aluminium Paint will be applied on surface without inorganic zinc primer and surface
Blast cleaning to near Primer: One coat
Insulated CS piping,
Primer: 75
Total dry film
white metal grade 2
of Ethyl Silicate
microns
thickness of
operating temp. Over 200O , of Swedish
zinc rich with
paint system:
C.
Standards SIS-05solvent.
Finish: 25
100 microns.
5900 (Latest).
Finish coat: One
micron
Wash-up As per
coat of Heat
clause no. 4.60.
resisting Silicon
Touch-up As per
Aluminium paint.
clause no.4.70.
NOTE: Only for valves where it will be impossible to blast cleaning, four to five coats of Heat Resisting
Silicon Aluminium Paint will be applied on surface without inorganic zinc primer and surface
07
08
Uninsulated CS
equipment with operating
O
temp. Up to 90 C, to be
treated at Manufacturers
shop.
Uninsulated CS
temp. From 91O C to
200oC, to be treated at

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no.4.70.
Primer: Two coats

of two pack zinc
rich epoxy
polyamide cured
Primer.
Primer: 35
micron for each
coat. Total 70
microns.
Finish: N.A
Finish coat :
Three coats of
two pack
Polyamide Cured
Epoxy
Finish:
40 microns for
each coat Total
- 120 microns.

white metal grade 2
, of Swedish
Standards SIS-05-
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Primer: 75
microns
Finish:
Total dry film

thickness of
paint system:
190 microns.
Total dry film

thickness of
paint system:
125 microns.
Ref
No.
09
Application
Surface Preparation
Manufacturers shop.
5900 (Latest).
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
Uninsulated CS
temp. Over 200oC , to be
shop.
10
11
12
13
14
Insulated CS equipment
with operating temp. Up to
90O C, to be treated at
Manufacturers shop.
with operating temp. From
91O C to 200oC, to be
shop.
with operating temp. Over
200oC, to be treated at
Manufacturers shop.
Stainless steel pipe

flanges, valves,
equipments with operating
temp. Up to 200oC
Surface of structural steel

for furnaces, external
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Generic Coating
System
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Minimum
DFT
25 microns for
each coat Total
- 50 microns.
Remarks

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of Heat
Resisting Silicon
Aluminium Paint.
Primer: 75
microns
Total dry film

thickness of
paint system:
115 microns.

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no.4.70.
white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
Lightly Blast cleaned
as per grade Sa-1.0,
of Swedish
no. 4.60. Touch-up
As per clause no.
4.70
white metal grade 2
Primer: One coat

of high
temperature
phenolic epoxy
Primer: 100
micron Finish:
100 microns
Total dry film

thickness of
paint system:
200 microns.
Primer: 100
microns
Total dry film

thickness of
paint system:
200 microns.
Finish coat: One

coat of high
temperature
phenolic epoxy
Primer: One coat
of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Finish:
20 microns for
each coat Total
- 40 microns.
Finish: 100
micron
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: One
coat of Heat
resisting Silicon
Aluminium paint.
Primer: 75
microns
Primer: One coat

of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Primer: 100
microns
Primer: One coat

of Ethyl Silicate
Primer: 75
microns
Finish: 25
microns
Finish:
100 microns
Total dry film

thickness of
paint system:
100 microns.
Total dry film

thickness of
paint system:
200 microns.
Total dry film

thickness of
Ref
No.
15
Application
Surface Preparation
surface of furnaces,
external surface of flue
duct, metal stacks and
similar with operating
temp. Up to 200oC. (With
exclusion of stair ways,
walk ways etc.).
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no.4.70.
For external surfaces of

flue ducts, metal stacks,
and similar with operating
temp. Above 200oC.

white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
Generic Coating
System
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of Heat
Resisting Silicon
Aluminium Paint.
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Minimum
DFT
Finish:
25 microns for
each coat Total
- 50 microns.
Primer: 75
microns
Finish:
20 microns for
each coat Total
- 40 microns.
Remarks
paint system:
125 microns.
Total dry film

thickness of
paint system:
115 microns.
NOTE: Only for zones where it will be impossible to blast cleaning, four to five coats of Heat Resisting
Silicone Aluminium Paint will be applied on surface without inorganic zinc primer and surface
16
NOTE:
17
For surfaces of air cooler

heads not galvanized with
operating temperature up
to 910 C TO 200OC,
treated at manufacturers
shop.
NOTE:
18
a)
Blast cleaning to near Primer: Two coats Primer: 35

Total dry film
white metal grade 2
of two pack zinc
micron for each thickness of
, of Swedish
rich epoxy
coat.
paint system:
Standards SIS-05polyamide cured
190 microns.
5900 (Latest).
Primer.
Finish:
Wash-up As per
Finish coat: Three 40 microns for
clause no.4.60.
coats of two pack. each coat Total
Touch-up As per
Polyamide Cured
- 120 microns.
clause no. 4.70.
Epoxy.
All surfaces shall be galvanized at manufacturers shop with exception of the end header of air
cooled heat exchangers that shall be treated as described above at Manufacturers shop. In case
the same surfaces shall not be treated at shop, they shall be treated at site according to
environmental and operating conditions.
For surfaces of air cooler

heads not galvanized with
operating temperature up
to 900 C, treated at
manufacturers shop.

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Primer: 75
microns
Finish:
25 microns for
each coat Total
- 50 microns.
Total dry film

thickness of
paint system:
125 microns.
All surfaces shall be galvanized at manufacturers shop with exception of the end header of air
cooled heat exchangers that shall be treated as described above at Manufacturers shop. In case
the same surfaces shall not be treated at shop, they shall be treated at site according to
environmental and operating conditions.
STORAGE TANKS
Acid / Alkali CS Storage
Tank (External Surface

white metal grade 2
Primer: Two coats

of two pack zinc
Primer: 35
micron for each
Total dry film

thickness of
Ref
No.
b)
Application
Surface Preparation
including all stair ways)
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
CS Storage Tanks,
Excluding indicated in Sl.
No. (a)

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
Generic Coating
System
rich epoxy
polyamide cured
Primer.
Finish coat: Three
coats of two
packs. Polyamide
Cured Epoxy.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of epoxy
amine cured tank
liner.
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Minimum
DFT
coat. Total 70
microns.
Finish:
40 microns for
each coat Total
- 120 microns.
Primer: 75
microns
Finish:
30 microns for
each coat Total
- 60 microns.
Remarks
paint system:
190 microns.
Total dry film

thickness of
paint system:
135 microns.
Cold Insulated Carbon

Steel and low alloy Steel
(1-1/4 Cr through 9 Cr)
Piping and Equipment.

white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: One
coat of Epoxy
Coal Tar paint
with solvent.
Primer: 75
microns
Finish:
40 microns
Total dry film

thickness of
paint system:
115 microns.
20
Cold Insulated high alloy

Steel piping and
Equipment

as per Sa 1.0
Swedish Standards
SIS-05-5900 (Latest).
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
Primer: One coat

of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Primer: 100
microns
Finish:
100 microns
Total dry film

thickness of
paint system:
200 microns
21
Cold insulated Stainless

Steel piping and
equipments

as per Sa 1.0
Swedish Standards
SIS-05-5900 (Latest)
wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
Primer: One coat

of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Primer: 100
microns
Total dry film

thickness of
paint system:
200 microns

white metal grade 2
, of Swedish
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat : Two
Primer: 75
microns
19
22
Surface (CS) with

Equipment with temp.
Indicating paint from
220oC to 240oC treated at
Manufacturers shop
Finish:
100 microns for
each coat
Finish:
25 microns for
Total dry film

thickness of
paint system:
125 microns.
Ref
No.
Application
Surface Preparation
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
23
a)
PACKAGE:
Surface(CS) with
operating temperature
upto 90oC treated at
Manufacturers shop

white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no.4.70.
ES - 2001
DOCUMENT NO
REV
Page20of26
Generic Coating
System
coats of Silicon
Acrylic Paint
Minimum
DFT
each coat Total
- 50 microns.
Remarks
Primer: Two coats

of two pack zinc
rich epoxy
polyamide cured
Primer.
Primer: 35
micron for each
coat. Total 70
microns.
Finish:
40 microns for
each coat Total
- 120 microns.
Total dry film

thickness of
paint system:
190 microns.
Primer: 75
microns
Total dry film

thickness of
paint system:
125 microns.
Finish coat: Three

coats of two
packs. Polyamide
Cured Epoxy.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Primer: One coat
of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of Heat
Resisting Silicone
Aluminium Paint.
Surfaces (CS) with

operating temperature
upto 910 C TO 200OC,
treated at manufacturers
shop.

white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
Surface (CS) with

operating temp. Over
200oC, treated at
manufacturers shop.

white metal grade 2
, of Swedish
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
Package in Carbon Steel

and low Alloy Steel (1-1/4
Cr through 9 Cr) with cold
insulated surface treated
at manufacturers shop

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: One
coat of Epoxy
Coal Tar paint
with solvent.
Primer: 75
microns
e)
Package in Cold Insulated

high alloy Steel.

as per Sa 1.0
Swedish Standards
SIS-05-5900 (Latest).
Wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70.
Primer: One coat

of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Primer: 100
microns
Finish:
100 microns
Total dry film

thickness of
paint system:
200 microns
f)
Package in Cold insulated
Primer: One coat
Primer: 100
Total dry film
b)
c)
d)
Finish:
25 microns for
each coat Total
- 50 microns.
Primer: 75
microns
Finish:
20 microns for
each coat Total
- 40 microns.
Finish:
40 microns
Total dry film

thickness of
paint system:
115 microns.
Total dry film

thickness of
paint system:
115 microns.
Ref
No.
Application
Surface Preparation
Stainless Steel.
as per Sa 1.0
Swedish Standards
SIS-05-5900 (Latest)
wash-up As per
clause no. 4.60.
Touch-up As per
clause no. 4.70
For external surface of

shell, roof of CS tanks,
with operating temp. Upto
110oC

white metal grade 2
, of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
25
For down external

surfaces(CS) below only
of the fixed tanks, bottom
& shell shall be treated as
follows:

white metal grade 2
, of Swedish
26
CS Equipment and
associated piping subject
to cyclic, intermittent or
regeneration operating
condition (e.g. Molecular
Sieve Driers) subjected to
very severe corrosion with
wide operating
temperature range.

white metal grade 3,
of Swedish
Wash-up As per
clause no.4.60.
Touch-up As per
clause no. 4.70.
24
ES - 2001
DOCUMENT NO
REV
Page21of26
Generic Coating
System
of high
temperature
phenolic epoxy
Finish coat: One
coat of high
temperature
phenolic epoxy
Minimum
DFT
microns
Finish:
100 microns
Primer: One coat

of Ethyl Silicate
zinc rich with
solvent.
Finish coat: Two
coats of single
pack special
Synthetic Rubber
based heat
resistant ready
mixed Aluminium
Paint.
Primer : None
Finish Coat: Two
coats of Epoxy
Coal Tar Solvent
base.
Primer: 75
microns
200 microns for

each coat Total:
400 microns
Total dry film

thickness of
paint system :
400 microns
Primer: One coat

of Thermal spray
Aluminium paint
and sealed with a
Silicon Aluminium
seal
Primer: 125
microns
Total dry film

thickness of
paint system
250 microns.
Finish:
25 microns for
each coat Total
- 50 microns.
Finish:
125 microns
Remarks
thickness of
paint system:
200 microns
Total dry film

thickness of
paint system:
125 microns.
Finish Coat: One

coat of Thermal
spray Aluminium
paint and sealed
with a Silicon
Aluminium seal.
6.0
MACHINERY, ELECTRICAL AND INSTRUMENT EQUIPMENT:
6.1
Machinery
Steel surfaces shall be treated with complete paint system at Manufacturers shop. The paint
system shall be according to Manufacturers Std. However, suitable for operating condition and
the environmental condition where the machinery will operate. Where necessary machinery shall
be restored at site by Contractor with suitable finish.
6.2
ES - 2001
DOCUMENT NO
REV
Page22of26
Electrical and Instrument Equipment

Steel surfaces shall be treated with complete paint system at Manufacturers shop. The paint
system shall be according to Manufacturers Std., however suitable for operating condition and
the environmental condition where the electrical and instrument equipment will operate. Where
necessary Electrical and Instrument Equipment shall be restored at site by Contractor with
suitable finish.
7.0
COLOURS:
These shall be as required by specification and in particular for :
Description
Colour
Ra1
Piping with temperature less

than 90oC
GREY
7035
Piping, hot surface, flue gas

ducts and stacks with
temperature above 90oC
SMOOTH
ALUMINIUM
Cooling Water Piping
Fire fighting Piping
SEA
GREEN
Correspond. Asian
Paint colors to be
defined See Note-2
Red
3002
Structures upto 2 MT
BLACK
9005
Structures above 2 MT
GREY
7010
Stair cases ladders
BLACK
9005
Walkwais
GREY
7010
Handrails assemblies
YELLOW
1004
Equipment
GREY
7035
Hot equipment
SMOOTH
ALUMINIUM
Fire fighting equipment
RED
3002
Valves in general
GREY
7035
Hot valves
SMOOTH
ALUMINIUM
Safety and Fire fighting valves
RED
3002
Valves handwheels
BLACK
9005
Electric Rotary Machines
SKY
BLUE
5012
Electric Static Machines
GREY
7035
Machinery (compressors &

pumps) with operating
temperature less than 90oC
GREY
7035
Machinery (compressors &

pumps) with operating
temperature above 90oC
SMOOTH
ALUMINIUM
SMOOTH
ALUMINIUM
FURNACES
-
Cassing and connected steel
Description
ES - 2001
DOCUMENT NO
REV
Page23of26
Colour
Ra1
Correspond. Asian
Paint colors to be
defined See Note-2
SMOOTH
ALUMINIUM
SMOOTH
ALUMINIUM
works
-
Steel work not connected to

casing
AIR COOLER
-
High Temperature Surfaces

(Temp. > 90oC)
Low Temperature surface

(Temp. < 90oC)
GREY
7035
Flare < 90oC
GREY
7035
SMOOTH
ALUMINIUM
Flare > 90 C)
TANKS
-
Shell of fixed roof
WHITE
9010
Roof of fixed roof tank
WHITE
9010
T-301
SMOOTH
ALUMINIUM
T-303
WHITE
9010
NOTE-1:
The colours shall be according to IS2379:1990/International STD. RAL or BS,

proposed by Contractor or Manufacturer
8.0
PARTICULAR DESCRIPTION
The abrasive to be used shall be chloride-free siliceous sand (marine sand excluded) or metal
grit.
Primerized surface shall be faultless and shall not have mud-cracking, dripping over thickness
and dry sprays.
Blast cleaning and painting shall not be carried out on wet surfaces.
Blast cleaning shall not be done when surfaces temperatures are less than 3oC above dew point
of below 5oC.
No acid washes or other cleaning solutions or solvents shall be used on metal surfaces after they
have been blasted.
The surface preparation of all steel surfaces to be coated shall be free of all mill scale, rust
corrosion product, oxides, paint, oil or other foreign matter
Only dry sand blasting procedures will be allowed. The compressed air supply used for blasting
shall be free of detrimental amounts of water and oil. Adequate separator and traps shall be
provided and these shall be kept emptied of water and oil.
All welded areas and appurtenances shall be given special attention for removal of welding flux in
crevices. Welding splatter, slivers, laminations and underlying mill scale exposed during sand
blasting shall be removed or repaired.
The blast-cleaned or power brushing surfaces shall be coated with primer within four hours of
surface preparation.
ES - 2001
DOCUMENT NO
REV
Page24of26
No primer or intermediate or finishing coating shall be applied without prior notification to the
Company.
The application of the products shall be carried out in strict compliance with the paint
manufacturers recommendation.
The Contractor shall provide suitable protection for all adjacent plants or equipment from airbone
during spraying and sand blasting.
9.0

The inspection and testing requirements outlined in this section shall be performed for shop and
site applied coating systems.
Preference shall be given to manufacturers and applicators that are quality certified to ISO 9001:
2000.
Documentation of coating material manufacturers and applicators shall include daily inspection
reports, equipment reports, and shall clearly identify and trace materials supply and testing
performed on coated items and areas.
Inspection and Test Plans (ITPs), and quality control procedures used for application of coating
systems shall form part of the Method Statement and shall be submitted for approval by the
Principal prior to commencement of work.
The applicator shall appoint a certified inspector of coatings for inspection and testing of coating
systems.
Tests of coated areas and items shall form part of the ITPs.
Surface Preparation in accordance to Swedish Standard SIS-05-5900 (Latest).
Blast Cleaning profile shall be checked using a suitable profile meter Acceptable profile
shall be 25-30 microns.
Check of time of top coating and drying in accordance with the direction of the paint
manufacturer.
Check of dry film thickness by suitable non-destructive Instrument such as

MIKROTEST, DIAMETER or equivalent.
Before any coating work is preformed on the site, the contractor shall ensure that any
works applied by others is acceptable.
Any defect that are discovered, are to be notified in writing to the owner before
proceeding with the contract work. To ensure the good execution of painting work
following test shall be performed:
-
Surface Preparation
Surface contaminant tests
Surface profile tests
Coating thickness tests
Tests for cure of coatings
Adhesion tests
ES - 2001
DOCUMENT NO
REV
-
Page25of26
Continuity testing
Iron contamination
Chloride contamination
Dust Contamination
All Inspection and Test Records (ITRs) shall be submitted with the Manufacturers Data
Report (MDR) at the conclusion of the job.
Defective coated areas shall be suitably marked for rectification work to be performed in
compliance with this specification.
Access shall be granted for inspection of all paint work, and witnessing of test work. This
shall not however relieve the Contractor of their own QA/QC responsibilities.
10.0
ADHESION TEST RESULTS

For all type of primer the Contractor shall guarantee the Classification of Adhesion Test Results
as per DIN 53151. The acceptable Rate Adhesion Test Results shall be for sandblasted and
primerized surfaces upto GT2.
For primer plus finishing coat(s) the Contractor shall guarantee the Classification of Adhesion
Test Results as per DIN 53151. The acceptable Rate Adhesion Test Results shall be for
sandblasted and painted surfaces upto GT2.
After test, the surface must be repaired according to the system applied.
11.0
SUBMISSION OF DATA
Contractor shall submit in phase of bid the original technical data sheet and system for all
material supplied by him to apply for the permanent works and test report for the paint in
compliance to IS101.This material shall be subject to Owners approval.
12.0
LETTER AND NUMBER INSCRIPTION

Inscriptions letters, as herebelow indicated, shall be made on equipments, piping, storage tanks,
machinery etc.
12.1
Geometric forms and dimensions

Letters and numbers dimensions shall be orientativally fixed according to following:
(A Dimension of side of unitary elements of grid)
a) Storage Tanks A 60 mm
b) Equipments and piping with O.D. above 600 mm A 40 mm and
c) Equipments and pipings with O.D. from 300 to 600 mm and for machinery of great
dimensions A 20 mm
d) Equipments and pipings with O.D. less than 300 mm and for machinery with small
dimensions A 10 mm
12.2
Inscriptions Colours
ES - 2001
DOCUMENT NO
REV
Page26of26
Inscriptions shall be Black ENI 901 (RAL 9005) on light base

Inscriptions shall be White ENI 101 (RAL 9010) on dark base
12.3
Spaces and Interspaces
Spaces between words and assemblage of numbers shall have dimensions equal to 2A
Interspaces between letters or numbers shall have dimensions equal to A.
13.0
Colour Band for piping ;-
As a rule minimum width of colour band shall confirm to the following Table:-
14.0
Nominal pipe Size
Width L (mm)
3 & below
25
4 NB-6 NB
50
8 NB-12NB
75
14 OD & above
100
LIST OF MANUFACTURERS :
1. M/s Berger Paints
2. M/s Asian Paints
3. M/s GRAUER & WEIL (I) LTD, (Unit-Bombay Paints)
EM163-PNIN-7901-00
DOCUMENT NO
SHEET 1 of 3
1
REV
FOR SUPPLY AND
ERECTION / COMMISSIONING OF
INSTRUMENTATION ITEMS
Job NO
: EM163
Project
: INSTALLATION OF MOUNDED BULLETS
Plant
: NUMALIGARH, ASSAM
Client
: NRL
24.09.2015
--
CLIENTS COMMENTS INCORPORATED
HK
RA
SKT
14.09.2015
--
HK
RA
SKT
21.07.2015
--
ISSUED FOR CLIENTS REVIEW
HK
RA
SKT
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
FORM NO: 02-0000-0021F1 REV3
All rights reserved

AT NRL, ASSAM
INSTRUMENT DESIGN PHILOSOPHY
EM163-PNIN-7901-00
DOCUMENT NO
SHEET 2 of 3
1
REV
CONTENTS
Sl.
No.
Document Description
Document No. & Rev.
No. of
pages
PART - A : General Documents

1.
PART - A, Front Sheet
2.
Technical Scope of Supply & Work for

Instrumentation
3.
Design Philosophy of Instrumentation
EM163-PNIN-7901-Part A
Rev. 1
EM163-PNIN-7901-TS
Rev. 1
EM163-PNIN-0701-00
Rev. 1
14
23
PART - B : Specifications for Supply of Field Instruments

EM163-PNIN-7901-Part B
4.
PART - B, Front Sheet
5.

Guided Wave Radar (GWR non-TFMS)
EM163-E-7047
18
6.

Guided Wave Radar (GWR - TFMS)
EM163-E-7147
40
7.
Technical Enquiry Specification for Servo

Level Transmitter
EM163-E-7052
40
8.

Pressure Gauge
EM163-E-7053
15
9.

Pressure & Diff. Pressure Transmitter
EM163-E-7044
17
10.
Technical Enquiry Specification for Safety

Relief Valves
EM163-E-7022
19
11.

Temperature Gauges
EM163-E-7058
17
12.

EM163-E-7046
16
Rev. 1

AT NRL, ASSAM
EM163-PNIN-7901-00
DOCUMENT NO
SHEET 3 of 3
1
REV
13.

Displacer Type LT
EM163-E-7148
15
PART - C : Specifications for Erection Materials

EM163-PNIN-7901-Part C
14.
PART - C, Front Sheet
15.
ENGINEERING SPECIFICATION FOR INST.

VALVES
ES-7337
16.

ES-7334
17.
ENGINEERING SPECIFICATION FOR SS

TUBES
ES-7341
18.
ENGINEERING SPECIFICATION FOR PIPE

FITTINGS AND ISOLATION VALVES
ES-7340
19.

CABLE TRAY
ES-7335
20.

ES-7338
21.

INSTRUMENT CABLE
ES7332
22.
INSTALLATION STANDARDS (PRIMARY

SKETCHES)
EM163-E-0720
Rev. 1
Rev 1
PART - D : BOQ
23.
PART - D, Front Sheet
24.
BILL OF QUANTITY FOR SUPPLY OF

INSTRUMENTATION ITEMS AND
ERECTION MATERIALS
EM163-PNIN-7901-Part D
Rev. 1
EM163-PNIN-BOQ-7001
EM163-P
PNIN-7901-PA
ART A
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTA
GENERAL DOCUM
MENTS OF
O
L SPECIF
FICATIO
ONS
TECHNICAL
FOR SUPPLY
S
Y AND
ERECT
TION / C
COMMIS
SSIONING OF
INST
TRUMEN
NTS
Job
b NO
: EM
M163
Pro
oject
: IN
NSTALLA
ATION OF MOUNDED BULL
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
Clie
ent
: NR
RL
24.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
14.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
FORM NO: 02-0000-0021

0
F1 REV3
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 1 of 14
TECHNICAL SCOPE
OF
SUPPLY&WORK
FOR
INSTRUMENTATION
1
0
P
REV
Job NO
: EM163
Project
Plant
: NUMALIGARH, ASSAM
Client
: NRL
24.09.2015
14.09.2015
21.07.2015
REV DATE
---EFF DATE
FORM NO: 02-0000-0021F1 REV3

PURPOSE
HK
HK
HK
PREPD
RA
RA
RA
REVWD
All rights reserved
SKT
SKT
SKT
APPD
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 2 of 14
CONTENTS
1.
GENERAL
2.
SCOPEOF TENDER
3.
SCOPE OF EXECUTION
4.
PROGRESS OF WORK
5.
GENERAL GUIDELINES FOR EXECUTION
6.
CALIBRATION OF INSTRUMENTS
7.
STORAGE
8.
POWER SUPPLY DISTRIBUTION
9.
INSTRUMENT GROUNDING/ EARTHING SYSTEM
10.
FIELD INSTRUMENTS
11.
SUPPORTS
12.
ELECTRICAL CONNECTIONS TO THE FIELD INSTRUMENTS
13.
CONSUMABLE
14.
INSPECTION, TESTS AND ACCEPTANCE OF INSTALLATION
15.
HYDRO TEST FOR PRIMARY CONNECTION IMPULSE TUBING
16.
FUNCTIONAL CHECK FOR SWITCHS FOR ALARM & TRIP CIRCUIT
17.
FUNCTIONAL CHECKING OF LOOPS / CIRCUITS :-
18.
TOOLS TACKLES CALIBRATION & TESTING EQUIPMENT : -
19.
PRE - INSTALLTION CHEC
20.
CHECKING AND TESTING FOR MECHANICAL COMPLETION
21.
Pre commissioning for start up
2_EM163_7901_INST REQUIREMENTS_rev0
Page 2 of 14
All rights reserved
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 3 of 14
1.00
GENERAL
1.01
M/s. NRL, Numaligarh are setting up installation of 4 nos. of new Mounded Bullet of
capacity 1760.56 m3 each along with associated Utilities & Offsite facilities inside the
Numaligarh Refinery Limited Assam as per the details given elsewhere in this Tender.
1.02
As a part of this job all instruments coming in field on the Mounded Bullets are to be
installed.
2.00
Scope of Tender:
2.01
The Scope of Instrumentation in this Package mainly consists of Instrumentation required

for control and monitoring of the Mounded Bullet storage as per P&I diagram,
Specifications & other documents attached.
2.02
The scope includes Supply of Inst. / Materials; Installation of Contractors supplied as well
as free issue materials; Hook-up, testing/Calibration, Commissioning & handing over to
Client of Complete Instrumentation System mentioned in the Tender.
2.03
In case of discrepancy between different documents / clauses of Tender Specifications the

most appropriate one that meet the Plant requirement as decided by NRL Engineer-incharge shall be considered as applicable. Where ever the words Contractor Package
vendor Vendor Supplier etc. mentioned in the document, these will mean the successful
bidder for this contract.
2.04
The Supply portion mainly involves procurement and supply of New field instruments,
erection materials as detailed in the attached documents.
2.05
All Inst. & Erection materials shall be of Makes & models approved by NRL/PDIL.
Contractor/Vendor to follow Approved Sub-Vendor list attached to enquiry. Specific
approval of Owner/PDIL are to be obtained for makes outside approved list.
2.06
The Erection / Installation include Items to be supplied as per the Documents enclosed
and the free issue items.
2.07
The scope also includes residual Engineering, i.e. the Engineering involved not covered in
this Tender Documents, but essential to complete the Instrumentation job as per
requirements of basic Documents like P&IDs etc., site visits by contractor and discussions/
communications take place from time to time.
2.08
Vendors shall supply, install & commission including local cabling, cable trays etc. upto
their battery limit. All local cabling shall be terminated in Field junction boxes/local panels.
From JB/Local panel shall be taken to Main Central Control Room through Multi-core
cables. The supply of Multi-core cables shall not be in the scope of vendor.
3.00
SCOPE OF EXECUTION
Scope of execution work shall cover but not be limited to the following:
3.01
Unpacking, assorting, physical checking, cleaning & drawl of Instruments, its accessories
and erection material at contractors own stores and / or from places of storage, return of
the left over materials if necessary to owners stores with suitable return notes.
3.02
Transportation & handling of Instruments, instrument accessories & erection materials from
stores / or from places of storage to work site and / or contractors stores
3.03
Dust free & air conditioned storage of Instruments if necessary for some of the items.
Page 3 of 14
All rights reserved
EM163-PNIN-7901-TS
DOCUMENT NO
REV
SHEET 4 of 14
3.04
To make arrangements for services such as transport medical, lighting canteen etc. for
working round the clock for own staff.
3.05
To arrange supply of drinking water to the contractors own staff so as to avoid personnel
inconvenience.
3.06
To make arrangement & supply of consumables like welding electrodes, industrial glasses,
cleaning fluids (such as CTC. Kerosene etc.) primer for structural. Teflon tape, insulation
tapes, sealing compound, all clamping materials for cables, tubes, trays, racks, impulse
tube like aluminum strips, screws, washers, clamps GI nuts & bolts of different sizes, cable
lugs, all identification ferrules for cables/wires structural of MS/CS .
3.07
Cutting of gaskets of various material to suitable sizes including making additional cut outs
on plane & /or to cover the existing cut outs on panels (if required) at no extra cost.
3.08
Any minor modification job either in insulation of instruments /accessories or making

support etc. for the same.
3.09
Fabrication of frames, supports, mounting stands, clamps, brackets, etc. for the racks &
trays IF APPLICABLE.
3.10
Laying & supporting of tubing on racks / trays inclusive of connection of tubes with
connectors. Tube laying shall include connection by connectors & 5% of joints by brazing if
necessary & required at few places.
3.11
Laying & supporting of multi core & single core electrical cables, multi core single core
compensating cables & any other special cables on racks/trays.
3.12
Any civil job involved in the installation of supports, mounting stands, etc. This may involve
cutting holes in walls/floors, chipping the foundations/floors & grouting and / or furnishing
after the job is over.
3.13
Testing of compensating cable & any other special cables for proper connection, continuity
& insulation.
3.14
Cleaning & painting of frames, supports, clamps, mounting stands & racks etc. ,and
retouching of painting surface of panels wherever is required at no extra cost of owner.
3.15
Base steel structures shall be painted with one coat of the red oxide zinc chromates primer
to IS:2074 (25 Microns) & two coats of synthetics enamel paint to IS:2932 (50 Microns).
Before painting the surface should be thoroughly scraped & cleaned to remove rust, grease,
plaster & any other foreign material. The quality of the paint must confirm to relevant Indian
standards & shall be approved by the consultant.
To touch up with paint all instruments mounted in the field & in the control panel with its
accessories which are scratched or damaged during handling, erection or repair without any
extra cost. The paint used shall match exactly the painted surface of the instruments or its
accessories on which touch up is done.
3.16
Testing, calibration, functional checking of the instruments, accessories, control &

sequence logic loops to the satisfaction of the owner.
3.17
Modification of certain erected instruments/tray cables, tubes cutting of structural members

as per site requirement by dismantling & reinstallation.
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Removal & re-erection of some of the instruments in panel or in field during testing and/or
calibration & functional testing if required /necessary.
Additional Work: Where requested by Owner / Engineer-in-Charge or his Authorized

representatives, all or any of the works not detailed shall also be executed as per NRL,
approved rates if available. If not available, rates shall be arrived from similar jobs & mutually
agreed upon.
NEW ITEMS
There could be new Items / erection materials or jobs not envisaged & listed in BOQ .These
generally result from Package Sub-vendor supplies or changes in supplies.
Contractor shall execute such jobs as per instructions of NRL / PDIL Site Engineer.
In such cases Unit rates shall be derived based on rates of similar items or similar type of jobs.
Either interpolated or extrapolated after mutual discussions between Contractor, NRL & PDIL site
engineer.
NRLs decision/ rate fixed after such discussions shall be binding on the Contractor.
In these cases the overall contract value limitations shall not arise.
Bidder to co-ordinate with NRMT TFMS vendor (Emerson/Honeywell) for installation,

commissioning & hookup of Radar Instrument in NRMT TFMS in all respects including licence,
software etc if required without any extra cost.
Bidder to co-ordinate with sub-vendor supplying Radar and Servo gauges for installation,
commissioning & hookup to PLC without any extra cost.
4.00
(i)
(ii)
(iii)
(iv)
PROGRESS OF WORK
If any time in the opinion of Engineerin-charge, the contractor has fallen behind the
construction schedule, the Engineer-in-charge may, without any extra cost to OWNER
require the contractor to take such steps as may be necessary to improve his progress
(such as but not limited to )
comply overtime operations
increase the number of shifts
work on Sunday and holiday
increase his resource of deployment .
The contractor in such case, shall demonstrate the manner as to how he proposes to
maintain the construction schedule and make up the loss time period to be specified by
OWNER.
Failure of the contractor to comply with the above shall be considered a failure to executive
the contract with due diligence and then owner shall without prejudice to any other right or
remedy which shall have accrued or shall accrue thereafter, may sublet the balance job in
part or in full outside the contractors scope and get it done at contractors risk and cost.
5.00
GENERAL GUIDELINES FOR EXECUTION
5.01
The following describes the general guidelines for the execution and testing of works
related for the installation of instruments, control panels, accessories and to their initial
maintenance during and after installation until final checking testing and handling over to
the client are completed.
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5.02
The works shall be performed with perfect workmanship according to the national and
international codes and standards mentioned else where in the Tender.
5.03
The contractor will bear all expenses for repositioning and reinstalling of the instruments
accessories including those like control panels ,etc. (inside or outside control room ), in
case of any poor workmanship or wrong execution /assembly. However, the contractor shall
obtain the consultants authorization before proceeding with the same.
5.04
The contractor will bear all expenses incurred for disassembling and reassembling of
instruments / accessories for inspection and testing operation.
5.05
The supply of all types of materials required and necessary for the construction /fabrication
and installation of supports for instruments, cable conduits, control panels etc. shall be
included in the scope of supply of the contractor.
All cable tray supports shall be grinded to remove rough edges and deformities after
fabrication, sand blasted and painted as per the painting specification attached before
securely fastened in their position.
5.06
5.07
Cable trays shall be supported at a minimum interval of every 1500 mm (for 300 wide), at
every 1000 mm (for 200 wide), at every 500 mm (for 50 mm wide) trays.
5.08
All cable trays shall be fastened at a minimum of two places on each support through the
length of the trays by means of galvanized /plated corrosion resistant bolts and nuts. The
bolt head shall be round type so that they do not damage the cable sheath while pulling the
cables in the trays.
5.09
All cables shall be of single run /length only and no intermediate joints shall be permitted.
5.10
All cables shall be identified by cable markers at both ends and at every 20 Mtrs. through
the length of the cable .Individual cores /wires shall be identified using grafoplast method or
suitable color codes ferrules Wire connection shall be made using cable lugs of proper size
employing crimping Tool.
5.11
All instruments shall be protected from atmospheric agents like salt dust etc. and from any
damages caused by other contractors working in the area by suitable cardboard boxes and/
polythene bags of sufficient thickness and size properly fastened by the instrument
contractor after installation of the instruments.
5.12
The erection material mentioned in the NIT is to meet the minimum requirement for
erection/ Installation of the instrument items, however if contractor feels to include any
important item to meet site requirement same are to be included in the scope of supply. In
case any item required during erection/commissioning for completion of the work, shall be
arrange by the contractor without any extra cost to the owner.
6.00
CALIBRATION OF INSTRUMENTS
6.01
All instruments shall be calibrated before installation.
6.02
The general rules to be followed for calibration of some of the instruments are as detailed
below.
6.03
For calibration of pressure gauges, temperature gauges (dial thermometers) and other
similar local gauges the calibration shall be checked at least at five different points of the
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range span Viz., 0%,25%,50%,75% and 100%.The standard gauge employed for
comparison shall be at least 5 to 10 times better in accuracy to the gauges being calibrated.
6.04
For calibration of transmitters the check/examination must be made at least at different

points in ascending and descending order namely 0%, 25%, 50%, 75%, and 100% of the
range.
6.05
Mercury or water manometers shall be employed for calibration check of low pressure
instruments.
7.00
STORAGE
From receipt at site until the installation of the instruments is completed, all materials
including those of erection hardware shall be kept in a store house re-wrapped in their
original weather proof packing (after site inspection)wherever possible, to keep them dry
and dust free.
The instruments /equipment and accessories taken out from the store shall be installed at
the earliest after necessary calibration, and they shall not be kept in the open without
protection for any reason.
During erection, installation all the instruments, equipment, control panels etc. shall have
weather and dust protection covering ensuring sufficient protection.
8.00
POWER SUPPLY DISTRIBUTION
8.01
Power supply distribution to various users shall be made by the instrument Contractor
utilizing 4 Sq. mm or 2.5 Sq mm multi standard, armoured 3 core copper conductor cables.
8.02
The number of feeders available from the UPS for instrumentation systems along with their
rating will be given later on. The instrument contractor / bidder shall arrange switch fuse
units / MCBS /thermal cutouts of proper rating for each of the feeder in the instrument
cabinet connecting it to the respective loads.
9.00
INSTRUMENT GROUNDING / EARTHING SYSTEM
9.01
The instrument contractor shall provide a high integrity grounding /earthling system for
connecting the electronic equipment .The system shall consist of two parts, one a clean
earth and the other dirty clean .Both shall be having a resistance of almost zero ohm.
9.02
All electronic systems shields and circuit grounds shall be connected to the clean earth
where as the cabinets panels etc. Shall be connected to the dirty earth.
9.03
The number of electrodes to be provided and their location will be dependent on the earth
resistance achieved. In any case the number shall be such that the resistance obtained is
almost zero.
10.00
FIELD INSRUMENTS
10.01
The selection of location for field mounted instruments such as gauges, indicators,
transmitters transducers etc. shall be based on :
-- avoidance of excessive heat and vibration
-- avoidance of mounting directly beneath drain points and above vent points.
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-- accessibility for maintenance and calibration.

-- ease in reading the indicators.
10.02
10.03
10.04
10.05
10.06
10.07
10.08
The gauges both pressure as well as temperature shall be mounted on brackets on the
walk way ( for valve manifolds ).In case where more than one gauge / indicator have to be
mounted in one location small stainless steel gauge boards shall be used for mounting the
gauges supported by fabricated standpipe / paddle securely fastened to the base
structures. SS impulse tubing with compression joints of stainless steel shall be used for all
impulse tubing including that of pressure gauges and transmitters.
Junction boxes shall be installed in an easily accessible location on the walk ways of valve
platform so as to facilitate maintenance ease.
All junction boxes shall have markings of the tag number / identification number of the JB
.On the front cover along with the multi core cable number being terminated in that
particular JB.
While terminating cables inside junction boxes it shall be ensured that sufficient length of
free excess cable is coiled inside after glancing for subsequent modification and or recrimping.
All cores as well as shields shall be terminated on the junction box at proper terminal points
without leaving any cores / shields loose.
All cables shall have tags tied to them with them origin identification (single pair) destination
identification (multi core cable).
The covers of junction boxes shall be perfectly closed after installation termination, testing
and final check are over and the screws ,gasket etc. shall have a coat / layer of grease on
them before fixing to avoid, rusting, infiltration of moisture, dust etc.
11.00
SUPPORTS
11.01
The brackets, pedestals, standpipes, frames and other structural steel items used for
supporting instruments, junction boxes, cable trays, conduits and various other instrument
installation shall be prefabricated at the site works / workshop of the instrument contractor.
Before moving them to the location for installation they all must be cleaned thoroughly from
rust slag and other dirty materials painted with epoxy primer two coats (rust proof) and then
with two coats of epoxy based paint (gray).
11.02
Type and exact dimensions of supports shall be decided during erection as per the
requirement and general sketches can be obtained from the consultants during
engineering. Sketches made by the bidder shall have consultants approval, or in case of
site fabrication without sketches approval shall be obtained from the site engineer of owner.
11.03
Primary connections shall be made as per the installation drawings attatched. Only
stainless steel tubing and compression joints of SS 316 shall be used for impulse tubing.
All threaded fittings (other than the compression joints) shall be provided with Teflon band
sealant on the threads.
11.04
11.05
11.06
Process tubing / connections to the remotely located instruments shall be adequately

supported on existing permanent members with brackets, clamps etc., so that the piping /
tubing weights and stresses do not burden the instruments / transmitters etc.
Single pair cables from individual instrument location to the junction box shall run through
50 mm anodized, perforated aluminium trays.
All tray sections shall be properly aligned and leveled. Tray section shall be assembled on
their supports and joined together using tray manufacturers standard connector units like
fish plates etc. Properly aligned and secured. Only prefabricated bends, risers elbows etc.
of tray manufacturer shall be used for main cable trays of 200 mm wide and above.
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11.07
Power cables and Instrument Signal cables (including those of descrete signals) shall be
laid on different trays as per IEC norms.
11.08.
The following shall be compiled with while installing pneumatic tubing and impulse tubing:
-- Joints shall be through unions / straight connectors only.
-- When a tube is cut any flash, extra material inside which could reduce the cross section
has to be eliminated before making the connection by union or any other compression joint.
-- The threads of fittings shall have a Teflon sealant (taped) on the non compression joint
end.
-- In case if a joint fails due to non positioning and /non seating of ferrule properly the tube
shall be cut & a fresh joint shall be make with fresh ferrules and other components .Once
used ferrules / components shall not be used again.
11.09
Grounding of field equipment/ instrument, local panels & large size electrical equipment
shall be connected to general grounding network by 16 mm2 copper wire with PVC
insulation.
All instrument casting /body with IS circuits shall be connected to the general grounding
network by 6 mm2 copper wire PVC insulated.
The insulation cover of the grounding wire shall be green.
12.00
ELECTRICAL CONNECTIONS TO THE FIELD INSTRUMENTS :Each electrical wire connected to the instrument terminal strip shall be provided with
suitable lug, terminal number / wire number, indicating the destination details etc. with
ferrules. Shields of all cables shall be insulated & left floating at the field end.
All wiring has to be adequately supported near the terminal point to prevent the terminal
connection from supporting the cable. Wiring shall be tested after installation to confirm that
the wire are not grounded shorted or open. these tests shall be conducted before the
instruments proper are connected.
All cable shall be laid in one piece only, with interruption from control room to JB or from
individual instrument location to JB or from control room to individual instrument location
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CONSUMABLE
13.00
The instrumentation contractor shall include in the scope of supply the following
consumable in required quantities for proper execution of instrumentation work. The list
shall not be treated as a complete list. It is the responsibility of the instrumentation
contractor to include all materials required for proper installation of all systems without any
extra charges to the Consultant / Owner.
Sl.
1.
Description
Size
2.
3.
Interlocking type identification ferrules made from Suitable for core size 0.5, 1.5. 2.5, 4.0
high grade PVC of yellow colour with black and 6.0 Sq.mm
engraving, marked with alphabets from A to Z,
numericals from 0 to 9, +ve, -ve etc.
PTFE sealing tapes
10- 25 mm width
Rag bolts, washers and nuts (M.S.Galvanised)
M10 X 100, M10 x 150, M12 x 100
4.
Cable lugs (Sleeves - tinned copper)
Suitable for core size 0.5, 1.5, 2.5, 4.0

and 6.0 Sq. mm
6 mm2 & 16 mm2 for earthing cable
5.
O, J bolts, washer & nuts (M.S. Galvanised)
6.
O , J bolts, washer & nuts (M.S. Galvanised)
7.
Metallic conduit
M8 SuitM8 suitable for // NB,

//
M10 SuM10 suitable for 1 NB
M12 Su M12 suitable for 2// NB Pipe
and others as reqd.
For Blazing // OD tube,
M8 X 75 thread length 40 mm suitable
for // NB pipe
For laying ignitor cable
8.
Nuts, bolts & washers (Cold forged Galvanised)
9.
Machine screws (M.S.Galvanised) with mushroom

heads complete with washer & nuts according to
British Association Standard Thread or British
Whitworth Standard thread.
10.
Aluminium strips in coiled form made of HE9 M alloy

& temper conforming to IS-733 - 1967.
11.
Insulation Taps
12.
Cleaner Solution
13.
Soap solution for pneumatic loop checking.
M6 X 20, M6 x 40,
M6 x 6 M6 X 65 & above
M15 x M15 X 30 Nuts suitable for M12
OBA X //, 2BA x 1//,
4BA x 4 BA X // , 4BA x 1//,// BS
// BSW x// BS
// BSW x 1// x //
20 (0.3 mm ) X 1.6 ( 0.2 mm ) as
required.
14.00
INSPECTION, TESTS AND ACCEPTANCE OF INSTALLATION
14.01
The work being executed by the contractor will be subject to phase wise & periodical
inspection & testing by the consultant, owner or their representative. The contractor shall
bear all expenses for such tests & inspection.
14.02
Tests/inspection shall include all those procedures and operations necessary to ensure that
the instruments have been perfectly installed & interconnections made correctly. These
tests/inspection shall be taken up as and when a work or portion of work is completed by
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the contractor & offered for inspection in writing by the contactor. More guidelines on
checking, testing and calibration are described in the subsequent pages.
14.03
If the work do not correspond to the technical requirements as spelt out in the specification,
drawings, documents instruction manuals or not executed with perfect workmanship (in the
view or in the opinion of the consultant, owner or their representative) the inspecting officer
/consultant will give oral/written instruction for elimination of the defects. The contractor will
rectify/redo the work at no extra cost to the consultant /owner.
15.00
HYDRO TEST FOR PRIMARY CONNECTION IMPULSE TUBING

All primary instrument connection shall be checked hydraulically with water with the help of
a manual pump at the pressure of about 1.5 times the design pressure of the main process
piping or instrument maximum range (URV) whichever is more.(In case the test pressure
exceeds the instrument safe pressure range / over range the instrument shall be excluded /
isolated from the list.
16.00
FUNCTIONAL CHECK FOR SWITCHS FOR ALARM & TRIP CIRCUIT

This operation involves calibration check of each primary component of the alarm/ trip
circuit (pressure switch, temperature switch etc.) for its correct & precise actuation at the
preset value of the variable.
17.00
FUNCTIONAL CHECKING OF LOOPS / CIRCUITS :This operation involves actuation/ simulation of all initiating points (switches both process
as well as manual) and checking the operation of the valves for the correct functionality
along with the status indication /alarm on the shutdown/ alarm systems and/ or pressure
panels in the control room.
18.00
TOOLS TACKLES CALIBRATION & TESTING EQUIPMENT : The contractor shall make all necessary arrangements regarding tools, tackles, calibration
instruments & testing equipment required for proper execution of the work awarded to him.
A list of calibration & testing equipments to be maintained at the worksite/workshop of the
contractor within the project site during the complete execution of the job is given below.
This list is by no means complete and any additional test equipment and/or calibration
equipment found necessary the contactor shall arrange the same at no extra charge to the
owner/consultant.
a) Digital multi-meter / tester
b) Loop Tester/calibrators (portable)
c) Smart calibrator / configurator/ smart transmitter
d) Mercury / water manometer
e) Portable field calibrator (if necessary)
f) Precession calibrator manometer
g) Dead weight tester (hydraulic)
h) Standard pressure gauge
i) Thermostatic temperature bath
j) Standard test gauge for temperature.
k) Signal generator mA, mV and pulses
l) Manual hydraulic pump for hydro testing of impulse tubing
m) Decade resistance box
n) DC power supply
o) Meggar for insulation check
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p) Earth resistance meter (digital) with electrodes & cables.
Mechanical Items:
a)
Cranes, winches, chain pulley blocks etc. in required quantity and of suitable capacity.
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
Trailers with prime mover/tractor trailers.

D-Shackles, slings, wire ropes etc.
Transformer welding sets.
Water level, spirit level etc. for leveling and alignment.
Gas cutting sets.
D.G. Welding Machines.
Drilling/Grinding Machine
Jacks with spindles (for cable drums).
Pipe bending machine
Hydraulic crimping tools set.
Hand crimping tools set.
Air blower/vacuum cleaner.
Pump for hydro testing complete with associated piping, calibrated pr. gauges,
temporary fasteners, valves etc.
Earth resistance tester with leads and electrodes.
Clip on ammeters/tong testers.
Wooden sleepers of proper size and in adequate numbers.
Scaffolding materials as required.
Safety valve calibration test rip and hydraulic pump.
Any other tools tackles and facilities required to complete all the jobs as per TENDER
to the best engineering practices.
o)
p)
q)
r)
s)
t)
19.00
PRE - INSTALLTION CHECK

Prior to installation all instruments shall be visually checked to verify their compliance with
approved technical specifications. Functional test & /or calibration tests shall be performed
/carried out as per belowTransmitters
: Functional check, calibration
Direct Gauges /indictors
: Functional check and calibration
Receivers, controllers, recorders, : Functional check and calibration
indicators etc.
Pressure , temperature flow etc : Functional test, Calibration
switches thermostats
Level switches
: Functional test, Calibration
Gas / Flame detectors
: Functional test
Gas / Flame monitors
: Functional check response and zero range
19.01
All other items such as control / shut off / remote operated valves, level transmitter (DP type
/ displacer type/float type etc) and on line instruments shall be calibrated and function
checked before pre commissioning activities start.
19.02
The instrument contractor shall submit the calibration functional check and loop test reports
as per the prescribed calibration and test formats given by the consultant PDIL to the
successful bidder.
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CHECKING AND TESTING FOR MECHANICAL COMPLETION:

After completion of erection the following checks and tests shall be performed to ascertain
the mechanical completion of the instrumentation work.
a)
----b)
Process connections: All process primary connections impulse tubing and fittings including
those of manifolds of pressure gauges and transmitters shall be subjected to a hydraulic
test and the testing pressure to which the impulse / primaries are connected .After hydro
test process connections shall be drained and blown with air to remove water particles.
c)
Pneumatic tubing leak test: All pneumatic tubing connections and joints shall be subjected
to a pressure test by sealing a pressure in each loop and checking with soap solution on all
joints .Also including a pressure gauge in each loop the drop in seal pressure can be
observed and if no drop is noticed the connection may be passed.
d)
All pneumatic tubing and supply lines shall be blown with air for removing dust, dirt moisture
from the lines before taking up the above test procedures.
21.00
Pre commissioning for start up.
----
----
Visual check: Before testing of any instruments starts a visual check shall be made to all
instruments, equipment and their accessories to verify.
Paintings, greases oil etc. are done wherever required and covers of JB fixed properly.
All supports work is complete and the instruments and accessories fixed correctly.
Instruments, equipment and their connections have not been damaged during erection by
own or other contractors.
Instruments and equipment are free of dust, debries moisture or any other harmful matter.
The instrumentation shall be considered ready to be connected for process operation only
after completion of the following.
Check of the calibration of instruments and equipment calibrated before erection. in the
case of transmitters and receivers zero span (range) and the mid point will be rechecked.
Check for the proper functioning of control valves shut off valves and remote operated
valves as per the loop circuit.
Check set point of pressure switches, temperature switches, electronic switches and
operation of manual push buttons, limit switches etc, for alarm, shut down or start /open
/close sequence logics and other enable / inhibit interlocks.
Set pressure regulators of instrument air supply to ROVs.
Check of regular function of UPS and electrical supply to individual works.
Performance test of alarm and sequence logic / safety systems, various function check
push button stations, limit switches, electronic switches, pressure, temperature and other
switches, solenoid valves etc to verify proper operation of the systems.
Calibration check and pop-up test of safety / thermal relief valves.
FREE SUPPLY BY NRL :
Construction power, water shall be provided by NRL as given below
Free Water Inside Plant premises at single point
Free Instrument Air Inside Plant premises at single point
Power Single Phase 230 V/50 HZ NON-UPS Inside Plant premises at single point
Power Three Phase 440V NON-UPS Inside Plant premises at single point
Materials to be supplied by the contractor for the execution of jobs at his own cost, as
part of this specification -
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The procurement and supply in sequence and at the appropriate time of all materials and
consumables shall be entirely the contractors responsibility and his rates for execution shall
be inclusive for all these items. These are as but not limited to the following :A. All industrial gases like Oxygen, acetylene or inert gases, compressed air and all types
of welding electrodes, brazing rods, flux etc. for welding purpose with necessary facilities
for testing the welded joints.
B. All equipments with required accessories for Welding, pipe bending, tube bending, lifting,
installation, transporting material shall be in the scope of erection contractor.
C. PTFE tape and other pipe jointing compounds for threads and material for sealing of
cable entries to control room, local panels, insulation tapes, sealing compounds for
flame proof conduit fittings.
D. Bolts and nuts for supports, U-bolts with nuts, clamps for tubes and pipes, anchor bolts
for panels, expansion bolts (pinch anchor/raw bolts) of various sizes for fixing to
concrete structures. Polythene bags for protection of instruments against rain.
E. Paints, primers and solvents.
F. Plastic tags for identifications of tubes/wires at panel junction boxes.
G. All materials for minor civil works like grouting etc.
H. Structural steel, MS Plates, GI plates, flats, pipe etc. required for fabrication or
instruments supports and tray supports wherever required if listed in BOQ.
I.
Spool pieces, jigs, fixtures, blinds & other accessories for testing as needed.
J. Any other item not specified, but required for the completion of the job.
The contractor shall submit in sealed cellophane packets samples of all consumables like
bolts, nuts, lubricants, ferrules lugs and any other material included in their scope of supply
for approval of Engineer-in-Charge which then forms the standards for erection work.
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AT NRL, ASSAM
14.09.2015
--
HK
RA
SKT
21.07.2015
--
HK
RA
SKT
23.06.2015
--
HK
RA
SKT
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
FORM NO: 02-0000-0021F1 REV3
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CONTENTS
SECTION NUMBER
DESCRIPTION
1.00
Scope
03
1.01
Environmental Conditions
03
1.02
Area Classification & System Design Basis
03
2.00
General
03
2.01
Electronic Transmitters
04
2.02
Flow Measurement
06
2.03
Level Measurement
07
2.04
Pressure Measurement
08
2.05
Temperature Measurement
09
2.06
Control Valves / ROV
10
2.07
Safety Valves
12
2.08
Signal Transmission System
13
2.09
Local Instruments Installation
15
2.10
Pneumatic-Instruments Supply
15
2.11
Process Connection
15
2.12
Electric-Instruments Supply
16
2.13
Codes and Standards
17
2.14
Specific Requirements
19
2.15
Notes
Annexure I
Annexure II
SHEET NUMBER
EM163_INST_DESIGN_PHIL_Rev P.docx
20
21
23
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1.00
SCOPE
This document defines the Design Philosophy, Standards, Engineering practices to be
followed during detail engineering activities for the installation of 4 nos. of new Mounded
Bullet of capacity 1760.56 m3 each along with associated Utilities & Offsite facilities
inside the Numaligarh Refinary Limited Assam .
1.01
1.02
Environmental Conditions
Climate
[X]
Ref Process Design Basis
Relative Humidity
[X]
Atmosphere
[X]
Area Classification and System Design Basis

Plant Instrumentation design shall be:
[X] Intrinsically safe (Exia), if not available then FLAMEPROOF Exd
Certificated by statutory authorities like (For Imported components)
[X] BASEEFA
[X] EN (CENELEC)
[X] PTB
[X] FM
[X] UL
NOTES
1. Petroleum And Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur or Director General of Mines Safety (DGMS) in
India certificate shall be furnished for all intrinsically safe and Flame proof
enclosures.
2. For locally manufactured Flame proof enclosures, testing shall be carried out
by CMRI/ERTL in addition to certificate of Petroleum And Explosives Safety
Organisation (PESO)/ Chief Controller of Explosives (CCE), Nagpur
2.0
GENERAL
-Instrumentation Numbering Philosophy [X]
for Instrument Tag Nos.
-Control Room/Control Panel
-Satellite room requirement

- Field circuits design
[X]
[X]
[X]
Area Code Item Code Item

Number
e.g. Level Transmitter 45-LT3001.
New signals to be hooked-up to
the
new
Control
System
(Annexure-I) (I/O List shall be
provided for new signals)
Existing NRMT Control Room.
HAZARDOUS Area Zone-1 IIA/B T3 as
per IEC norms
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[X]
Electrical/ Electronic Instrument : IP-67

: IP-65
Sensors, RTD, T/C, etc
Local Gauges
: IP-55
Pneumatic Instrument
: IP-54
Solenoid Valves
: IP-67
EMC compatibility & electrical safety as
per latest IEC standard.
- Field instrument protection

- Equipments Electric rules
for control & acquisitions
- Installation Electric
[X]
[X]
Ex(ia), if unavoidable Ex(d).

IEC / ISA
[X]
IEC / ISA
- Multicables
[X]
Above ground in GI Cable Tray / Duct
[X]
If run in trench to be filled with sand

& covered
In GI pipe underneath culverts
[X]
- Safety valve rule
(Refer Mechanical)
[X]
[X]
[X]
[X]
- Electric Supply
- Engineering Std.
Unit for Measurement
[X]
[X]
[X]
English
- Temperature
[X] M.K.S.
[X]
C
- Flow-liquid
[X]
M3/Hr
- Gas
[X]
NM3/Hr at 0C and 1 Ata
- Steam
[X]
KG/Hr
- Mass
[X]
KG/Hr
[X]
[X]
[X]
[X]
0-100%
mm & Meter
Kg/cm2g
Kg/cm2 A / mmWC
Level - Process
Tank /Bullet
Pressure
Vaccum
Interconnection/Communication between
mounted near base of Bullet.
pkg.
[X]
API-RP-520
ASME-SEC.VIII & I
IBR for steam, BFW (Wherever
applicable)
Existing System for existing transfering
pumps
110 V AC Ungrounded UPS
All applicable International Std.
vendor
Insts./Radar/Servogauge
Panel
ISOLATED 4-20 mA analog signal powered

from main panel/PLC based Control system
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2.01
Electronic Transmitters
Type
[X]
[X]
Microprocessor based Smart type Universal

Hart Protocol with latest revision
The transmitter selection shall be such that
the operating maximum upper limit shall be
around 70% of the total measurement range
of the transmitter
Signal
[X]
4-20 mA D.C. (2 wire loop)

+ super imposed Digital
Precision
[X]
+/- 0.075% F.S. min. (except draft range)
Rangeability
[X]
1 : 100
Circuit
Enclosure Execution
[X]
[X]
EExi for hazardous area

Weather proof IP-67 min.
Body Material
Housing Material
Process Connection
Manifold (Supported on
2 Pipe mounting)
[X]
[X]
[X]
[X]
[X]
SS
Housing Die-Cast Aluminium Epoxy Painted
1/2 NPT F through oval flanges
Integral 3 Way Valves for Diff. Pr. Tr.
Integral 2 Way Valves for Pr. Tr.
Power Supply
[X]
2 Wire System
Electric Connection
[X]
1/2 ANSI B 2.1 NPTF SS

Plugged
Local Indicator
[X]
[X]
Radio Frequency Protection
[X]
Required - Digital
All flow transmitters shall have square root
extraction function
Yes
Programming Unit/
Calibrator
[X]
Yes , Universal type , HART
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2.02
Flow Measurements
i)
Orifice Plates - Nozzles

Orifice Plates
[X]
Square edged concentric type
[X]
normally AISI 316 unless special

materials are required for the service
Ratio of orifice to inside

pipe diameter
[X]
Maximum of 0.70 and minimum of

0.25
Calculation
[X]
ISO 5167 (Latest Revision)
Tapping
[X]
Integral Orifice for line size 1" and

below
[X]
Flange Tapping line for upto 14
[X]
[X]
Pipe Tapping for Over and above 14

As per Piping Material specification
Type
[X]
Special mass flow meters (Coriolis Type) (Note 7)
Accuracy
[X]
0.10% or better
Sensing element
[X]
straight/U-tube, matl. 316SS in general
Material of Orifice Plate
Flanges
ii)
Special Flow Meters
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2.03
Level Measurements
i)
Level Transmitters/Controllers
Type and Selection for
Bullets / LPG storage
Vessels
[X]
MB Lal and OISD requirement should be

considered (including SIL certification)
during the selection of the gauge type and
installation method. Also, atleast one
Level instrument should be of Servo type
(+/1 mm accuracy).
[X]
Atleast 2 independent system should be

provided for redundancy
[X]
The Control Room items (interfacing/ data

acquisition units/ HMI) shall be redundant
for each system.
Guided wave type level transmitter with
Temperature compensation having facility
to measure RVD and Temperature.
Electronics shall be capable of
measuring upper liquid and interface
level simultaneously.
[X]
Type and Selection for

other normal services
[X]
Servo with Intelligent Tank Data

Transmitter Including density and AV.
[X]
Direct Liquid Level measurement

All the vessels shall be provided with
atleast 2 nos. of Level transmitters of
same level reference. If same is used for
control purpose, PV of any one of 2 nos.
LTs shall be soft selectable from HMI for
the
controller
as
per
operator
requirement.
Level transmitter shall be either Radar or
DP type
If DP type transmitter is considered for
level measurement, only remote seal type
shall be used.
Internal
displacer
type
of
level
transmitters shall be avoided unless
application necessitates its use.
[X]
Interface level measurement: Atleast 2 nos.

of displacer type level transmitters shall be
provided for interface level measurement (if
any)
SS as a minimum
Body Material
[X]
Electric Circuits
[X]
Ex(ia) for Hazardous Area, Ex(d) for

servo gauges
Enclosure Execution
[X]
IP-65 min.
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Process Connections
[X]
Electric Connections
Installation
Inventory
Management
[X]
[X]
[X]
[X]
Manufacturer Std.
1/2 ANSI (NPT F), SS Plugged
Direct
With complete software package
ii )
Level Switches No Direct Level Switches. Switching shall be

configured from transmitted signals at PLC based Control System.
2.04
Pressure Measurements
i)
Direct Pressure Gauges

Element
[X]
Sensor Material
[X]
Industrial Bourdon gauge/diaphragm or

spring bellows type as per process
requirement
316SS min.
Dial
[X]
150 mm min.
Case
[X]
Stainless Steel case
Zero adjust
[X]
With micrometer pointer
Process connection
[X]
1/2 NPTM Bottom
Precision
[X]
+/- 1% F.S.
Glycerine filling
[X]
For vibrating locations
Other accessories
[X]
As required
[X]
Blow-out discs are required for all

pressure gauges except for instrument
air services
Integral 2 Way Valves
[X]
ii)
8with still well for radar and 6 servo

gauge
Pressure Switches - No Direct Level Switches. Switching shall be

configured from transmitted signals at PLC based Control System.
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2.05
Temperature Measurements
i) Field mounted gauge
Type
[X]
Dial
[X]
Enclosure Execution
[X]
[X]
IP-55
SS min
Element
[X]
Normally K type thermocouple as per

IEC584
Grounded
Type
[X]
[X]
[X]
Sheathed type with high purity

magnesium oxide insulation
Sheath diameter shall normally be 6mm
(1/4)
AISI - SS316 below 400 deg C design
temp.
Case and stem material
Bimetalic, heavy duty adjustable angle

connected type
150 mm min. Dials shall be of white,
non-rusting metal with black figures
ii) Field mounted sensor
[X]
Sheath Material
Temperature transmitter
Temperature transmitter
iii) Thermowell
Type
Required
[X]
[X]
Remote
Location - field
[X]
Single Bar stock

ASTM A 182 Gr.F316 or better as per
piping material specification
Well Material
[X]
Flange Material
[X]
Process Connection
[X]
[X]
Other
[X]
Wake frequency calculation

provided for all thermowells
[X]
Light Alloy Non incendiary(LM6)
Head Execution
[X]
IP-65
Electric connection
[X]
1/2 ANSI B 2.1 NPT(F)
iv) Head for RTD

Head Material
[X]
[X]
[X]
Duplex type (With dual entry)
ASTM A 182 Gr.F316 or better as per

piping material specification
1 1/2 ANSI B 16.5 RF
Bullet Thermowell shall be welded to the
Bullet
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v) Multi-point temperature Sensor to be connected to Radar LT
2.06
Standard
[X]
DIN 43760
Element
[X]
Pt 100 OHM at 0 deg C
[X]
Mineral Oxide insulated
Sheath Material
[X]
AISI - SS316 min
No of temperature
l
t
Installation
[X]
As per API STD 2543
[X]
In Thermowell
Nozzle
[X]
2 Flange 300#
Control Valves / ROV

Sizing
[X]
ISA S 75.01
Base Type
[X]
[X]
[X]
[X]
Process Connection
Leakage Class
[X]
[X]
Globe/ Butterfly for Control valve

Ball valve for On/Off valve
Fire Safe Full Bore for On-Off valve
Metal seat / Soft seated for ROV as
per seating class
1 1/2 ANSI B 16.5 RF
Globe valves Class IV leakage min as
per ANSI B16.104
Shutdown valves Class V metal to
metal min.
[X]
Body Material
[X]
Trim Material
[X]
[X]
Control Valve Opening %
[X]
Piping Connections
Minimum Rating
[X]
[X]
Actuator
[X]
As per process data and fluid under

service
As per process data and fluid under
service, however SS316 as a
minimum.
Special trim for cavitating/flashing
services
control valve % opening shall be at
minimum flow 10-20%,
for normal flow 50 to 70%,
for maximum flow 75 to 85%
Flanged
300 #
Pneumatic diaphragm type with
pressed
steel
diaphragm
case
wherever applicable.
In case of piston actuator complete
with air locks, air bottles & other
accessories to achieve desired air
failure position - for ROV
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[X]
Actuator sizing shall be done at 5

Kg/cm2
Shut off valves
[X]
Size and port equal to the line size
Positioner
[X]
[X]
[X]
[X]
SMART ElectroPneumatic along with

valve signature software
SS case gauges
For all except on-off valves
4~ 20 mA
I/P converter Output Signal

Range
[X]
3~ 15 Psi
Air Filter Regulator
[X]
Yes with
positioners
positioners
Accessories
Valve travel time
Valve Tubing
[X]
[X]
[X]
[X]
Solenoid
[X]
All mounted & tubed

Full travel time shall not exceed 10
OD for control valve size upto 4"
tubing to be used for valve sizes 6"
and above
IP-67, 1/2 NPTF cable entry (No flying
lead), Normally energized condition
and shall be de-energized to initiate
trip
AISI 316 S.S. body
I/P converter Input Signal

Range
[X]
Solenoid Valve enclosure
Limit Switch
Handwheel
Noise level limit
ROV Operation
[X]
[X]
[X]
[X]
[X]
[X]
gauges for individual

and Individual SMART
Ex (ia) for Hazardous area

Proximity sensor (P&F) for all valves
Side mounted
85 dBA for continuous service
MB Lal and OISD requirement should
be considered
Open/ close position status of each
ROV should be distinguishable at field
itself without opening the fire proof
enclosure (if any). If required
additional open/ close position
indicator to be provided near each
ROV
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Safety Valves
Sizing
[X]
API RP 520, 1990
[X]
ASME Sec. I & VIII
Type
[X]
Direct Spring Loaded
Bonnet construction
[X]
Plain closed bonnet for toxic and

inflammable gases as well as vapour
and liquids.
Exposed bonnet shall be specified for
steam service and in Boiler feed water
service above 200C.
Bonnet extension shall be used above
400C
[X]
[X]
Body and Bonnet Material
[X]
Lifting Lever
[X]
Test Gag
[X]
Bellows requirement
[X]
[X]
For all
for relief into closed flare and slowdown
systems, if the developed back-pressure
exceeds 10% of the set pressure
specified where leakage of gas from the
seals not permitted during normal plant
operation
Piping Connections
[X]
Flanged
Spring
[X]
Carbon steel for normal process

operating temperature of (-) 25C to
200C
Carbon steel is permitted above 200C
for open bonnets
Tungsten alloy or high temp. alloy steel
above 200C.
Stainless steel spring may be used for
services below (-) 25C.
[X]
[X]
[X]
Piping material Specification

Packed, for all except air and supper
heat steam
Blowdown
[X]
[X]
Centre Centre dimension

Thermal Relief Valve
[X]
[X]
Between 5% to 7%.
For steam services under Power Boiler
Code as per ASME the blowdown shall
be 3% - 4%.
API 526
For thermal relief of accumulated
liquids in pipelines and vessels 1x2
size valves shall be used in general.
Thermal relief valves shall also be
flanged
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2.08
Signal Transmission System

Multicables running
[X]
New Perforated GI duct
[X]
Galvanised Pipe Conduit if required for

Underground Cabling
Galvanised Pipe Conduit for trench
crossing
Flexible HDPE pipe for Fiber Optic cable
laying
[X]
[X]
Cable entry to control room
[X]
Multi Cable Transit (MCT) of Roxtec

make only shall be used for leak proof
sealing for cable entry to control room(s)
preferably above the false ceiling, if the
cables are run overground.
[X]
Cable Trays
[X]
For cables coming underground from

plant area shall be routed through MCT
located below the false floor level of
control room
Perforated GI tray
Secondary Cables
[X]
On cable tray
Signal and Power Cables
[X]
FRLS as per standard IEC 332-3 Part 3

Cat. A. Fire resistance cables whenever
specified shall be as per me 331 Cat. A.
Insulation Grade
[X]
[X]
600 V/1000 V
It shall meet insulation resistance, voltage
and spark test requirements as per BS5308 Part-2.
Cables
[X]
Electronic Instrument Signal Wiring shall

be twisted pairs - 15 twists or more per
meter.
1.5 mm2 Cu cable for single pair
signal/Thermocouple
extension/RTD
cable/ solenoid valves / flame detectors.
0.5 mm2 Cu cable for multipairs / 1.5
mm2 for multi-triad signal cable
[X]
[X]
Conductors
[X]
2.5 mm2 Cu cable (Power cable

as per IS-1554 Part I)
[X]
Conductors shall be 1.5mm2 for one and

two pairs and 1.0 mm2 for multiconductor
cable and shall be stranded, annealed
tinned copper.
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Insulation
[X]
[X]
PVC insulated, primary insulation of 85C

PVC as per IS-583.
Insulation shall have a minimum radial
thickness of 0.25mm. Insulation of core to
core shall withstand a r.m.s. AC test
voltage of min. 2000V.
Armouring
[X]
[X]
All cables armoured.

Armour over inner jacket shall be of
Galvanised steel wire/flat as per IS-1554
part I / lEC 502
Inner and outer jacket
[X]
Extruded flame retardant 90 ac PVC to

IS-5831
For signal and control cables, inner /
outer jacket colour shall be black.
However outer jacket colour shall be light
blue, for intrinsically safe application.
For thermocouple extension cables the
inner/ outer jacket colour shall be as per
IS-8784
Pair/Triad No. printed on each
core sequentially at 1 meter on core
[X]
[X]
Pair/Triad Identification
[X]
Shielding
[X]
[X]
[X]
Core Insulation
[X]
Pair/Triad for single pair signal cables.

Individual Pair/Triad & overall shielded for
Multipair signal/Triad cable
Overall for other control cables
Colour of core insulation shall be black blue
in pair and black, blue and brown in a triad.
Junction Boxes
Type
[X]
[X]
[X]
[X]
Weatherproof IP 65 with Mounting brackets,

hinged door for IS signals
Flameproof proof (EEx d) for non IS signal
Multipair cable bottom entry
Single pair cable side entry
Die-cast Aluminium & epoxy painted
Material
Cable Glands
Cable Glands type
[X]
[X]
[X]
With Junction Boxes

Stainless Steel
Jn. Box Colour
[X]
[X]
[X]
Double Compression type

Shrouds
Grey (Non IS) / Blue for IS loops
Note : Junction Boxes and cable glands will be certified according to CENELEC/IS Codes.
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2.09
Local Instruments Installation

Instrument Installation
[X]
Remote
Impulse Piping
[X]
[X]
Paving/platform/column
Material acc. to line spec.
[X]
Rigid 1/2 seamless pipe
Impulse Tubing
[X]
OD annealed seamless SS316
Fitting for rigid pipes
[X]
[X]
[X]
Material acc. to line spec.(Note)

Dimensions as per ANSI
Welded
[X]
[X]
Screwed where unavoidable

SS Compression (double ferrule) type
(Swagelok or equivalent)
Fitting for Tubes (Impulse)
Pneumatic Tubing and air supply [X]

tubing
Main Instrument air / branch
[X]
header (Note 2)
Stainless Steel AISI-304 (Double

Compression)
Main instrument air header in SS
Note: Pipe fittings shall be standardized in two ratings of 30000 lbs and 60000
lbs. Higher ratings wherever applicable as per pipe class.
2.10
2.11
Pneumatic Instruments Supply

Air Pressure
[X]
Min. 4 Kg/cm2 g
Max. 6 Kg/cm2 g
Dew Point
[X]
[X]
(-) 40C at atmospheric pressure

(-) 27C at operating pressure
Process Connection :
a) First tapping points for all pressure, d/p signals shall be 3/4 NPT. Mechanical piping
scope shall be upto 1st isolation valve(s). Subsequent reduction to 1/2 size and
impulse piping and connection shall be under the scope of instrumentation.
Mechanical scope shall be upto reduction to NPT size.
b) Wherever diaphragm seals have been used, the vessel or piping nozzle shall be 3
flanged. Flange rating shall conform to piping index.
c) All vessel or piping nozzles for temperature instruments shall be 1 1/2 flanged or 1
NPT(F) threaded.
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2.12
Electric - Instruments Supply

110V AC
50Hz.UPS
110V DC
24V DC*
110 V AC
Non UPS
230 VAC
50Hz
a)
Distributed Digital
Control system
[X]
[ ]
[ ]
[ ]
[ ]
b)
PLC
[X]
[ ]
[ ]
[ ]
[ ]
c)
Relay based
[ ]
Interlock & Shutdown system
[ ]
[X]
[ ]
[ ]
d)
Solenoid Valves
[ X]
[ ]
[ ]
[ ]
[ ]
e)
I/P, Transmitters,
Voltage
[ ]
[ ]
[X]
[ ]
[ ]
f)
Gas Detection System
[ ]
[ ]
[X]
[ ]
[ ]
g)
Analysers and
Analyser System
[X]
[ ]
[ ]
[ ]
[ ]
h)
Level
Gauge
illumination
[ ]
[ ]
[ ]
[ ]
[X]
i)
Mass flow meter
[X]
[ ]
[ ]
[ ]
[ ]
Note-a: 24 VDC wherever required shall be provided with Redundant Bulk Power
supply unit with diode O-ring.
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2.13
Codes and Standards
The following additional Standards shall be used/and taken into account during instrument
engineering and design.
OISD-GDN-144
Guideline on LPG Bottling plant (Design & fire protection facility)
IEC 13
Diagrams, Charts and Tables, Preparation of Logic Diagrams
IEC 534
Industrial - Process Control Valves
IEC 584
Thermocouples
IEC 605
Equipment Reliability Testing elements
IEC 611-12 Part 12 Graphical Symbols for Diagrams. Binary Logic

IEC 654
Measurement and Control equipment
IEC 751
Industrial Platinum Resistance Thermometer Sensor
IEC 801
Electromagnetic Compatibility for Industrial Process measurement

and Control Eqpt.
IEC 848
Preparation of Function Charts for Control Systems
IEC 902
Industrial Measurement and Control Terms and Definitions
ISA S-5 .1
Instrumentation Symbols and Identification
ISA S-5.2
Binary Logic Diagrams for Process Operation
ISA S-5 3
Graphic Symbols for Distributed Control/Shared Display

Instrumentation, Logic and Computer Symbols
ISA-S20
Instrumentation specification formats
ANSI/ISA S 5.1
Process Instrumentation Terminology
ANSI/ ISA S71.04 Environmental conditions

ANSI/ ISA S75.01 Control Valve Equations
ANSI/ ISA S75.02 Control Valve Procedure Capacity Test
ANSI/ ISA S75.03
Face-to-Face Dimensions for Flanged Globe Style Control Valve

Bodies
ANSI/ FCI 70.02
Quality Control Standard for Control Valve Seat Leakage
BS 6020
Instruments for the Detection of Combustible Gases
DIN 3582
Screwed Plugs, Tapped Holes, with Whitworth Part 2 Pipe Threads:

General Outlay of Types
DIN 43760
Measurement Standard for RTD.
DIN 19243
Measurement and Control Electrical Sensors, Electrical Position

Sensors and Signal Converters used for Intrinsically safe two-wire
DC System.
EN-50-014/020
Electrical Apparatus for Potentially Explosive Atmospheres
EN 54 Part I
Components of Automatic Fire Detection System Introduction.
EN 54 Part 5
Heat sensitive Detectors - Point Detectors containing a Static

Element.
ISO 3511.1
Process Measurement Control Functions and Instrumentation

Representation Part I: Basic requirements.
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ISO 3511.2

Representation Part 2: Extension of Basic Requirements.
ISO 3511.4

Representation Part 4: Basic Symbol for Process Computer,
Interface and shared Display/Control Systems.
ISO 4200
Plain End Steel Tubes, Welded and Seamless - General Table of

Dimensions and Masses per Unit Length.
ISO 5167
Measurement of Fluid by Means of Orifice Plates, Nozzles and

Venturi Tubes Inserted in Circular cross-section Conduits Running
Full.
API RP 520
Sizing, selection and Installation of Pressure relieving devices in

Refineries
API RP 521
Guide for Pressure Relieving and Depressuring System
API RP 2000
Venting Atmospheric and low pressure storage tanks
API- Chapter 5.4 : Accessory equipment for liquid meters Manual of
Chapter 6.2
Loading rack and tank truck metering system
Chapter 6.6:
Pipeline Metering Systems Measurement
Chapter 12:
Calculation of Standards Petroleum Quantities
2.1 & 12.2
Part 1 and 2
API-RP-550
Manual on Installation of refinery Instruments Part I and Control

System
ANSI - B 16.104
Control Valve seat leakage
ISA-S 75.01
Control Valve sizing
ISA S 18.1
Specifications and guides for the use of general

Annunciators.
IEC 529
Environmental Protection of equipment
ANSI B 2.1
Pipe threads
ANSI B 16.5
Steel pipe flanges, flanged valves and fittings
IEC 79.11/
Intrinsic safety code and practice
IEC-79.14
International Boiler Regulation
IS 2148
Flameproof enclosure of electrical apparatus
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2.14 Specific Requirements

2.14.1 HC Gas Detectors
Type
Enclosure
[X]
Infra-red multi-beam type
[X]
3 wire transmitters
[X]
Power supply -24 VDC
[X]
Detectors to be connected to
new PLC system
[X]
Hooter and beacon 110VAC (Grouped)
[X]
atleast SIL 2 certified.
[X]
Stainless Steel
[X]
Heat and Ionisation detector

for fire
[X]
Power through Fire Detection System
(Detector and Transmitter)
2.14.2 Fire Detectors

Type
2.14.5 Earthing system
a)
Panels, racks, cabinets, consoles

earth grid shelters etc. and all
Junction boxes with power more
than 110 V
[X]
Separate electrical
b)
Signal earth
[X]
Separate dedicated earth grid (Note 8)
c)
Barrier earth
[X]
(Only for Zener barriers, if applicable)
Separate dedicated earth grid
All rights reserved

AT NRL, ASSAM
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 20 of 23
2.15
Notes:
1) Integral manifold shall be used for DP type flow Transmitter. Piping & SS Tubing shall
be used for Impulse lines. SS tubing shall be used between integral manifold &
transmitter. Impulse line val ves shall be gate type.
2) 1/2 SS isolation valve for each pneumatically operated instrument shall be provided.
Main Header line shall be of minimum SS irrespective of the piping material
specification.
3) For Trip Solenoid Valves, FMR (Field Manual Reset) is required at field.
4) For flow, level, Pressure & Temperature instruments, only transmitters shall be
connected directly to system for monitoring, controlling & generating alarm in DCS.
Similarly for PLC shutdown loops also, only transmitters (4 20 MA) shall be used &
the same shall be connected to PLC as AI. No direct switches shall be used. For
pump seal vessel also, only level transmitter shall be used.
Three transmitters shall be used for critical closed loop control and for all trips.
5) Thermowell flange rating shall be 300# as a minimum or better as per piping/ rating.
Flange & thermowell material shall be ASTM A 182 Gr.F316 as a minimum or better as
per piping class. This philosophy is followed for licensed as well non-licensed units.
Thermowell shall be single bar stock. Duplex type thermocouples shall be used.
6) For split range control, two I/P converters shall be used.
7) Mass flow meter shall be provided with back pressure control with necessary block
& bypass valves. Back pressure control shall be carried out through separate
transmitter and control valve.
8)
PLC and DCS earth grids shall be separate, Earth grid shall be formed by integrating more
than one earth pit.
As a minimum two earth pits shall be connected to one grid.
9) 2 years operational spares shall be ordered separately as recommended by suppliers.

Mandatory spares, commissioning spares & consumables shall form part of main
instruments supply.
10) All limit switches shall be of Proximity type.
11) Local Panel lamps, pushbuttons & selector switches shall be ex-proof / IS type only
12) For split range control, two I/P converters shall be used.
13) Number of Gas Detectors to be finalised by during detail engineering.
14) Instruments shall have individual tapings from process lines. Independent tapping points
shall be provided for instruments related to Trip, Control /Monitoring and local. They shall
not be from the same tapping point from the main process line.
15) Ultrasonic type flow meter shall be used for measuring flare flow.
16) Fail safe position, leakage class, mechanical stopper if any shall be indicated in the
instrument data sheets.
17) All structural supports, Stanchion, Impulse lines shall be painted. Tag no painting (yellow
back ground with black lettering) shall be provided.
18) Multi & Branch cables shall be glanded & ferruled. Cable shrouds shall be provided for
cable glands.
19) Tag plates and name plates in cables, instruments, JBs shall be minimum SS.
All rights reserved

AT NRL, ASSAM
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 21 of 23
Annexure-I
New PLC system in existing NRMT Control room:
A new PLC system with existing Panel room and Operator Cabin room at field is required. Both the
control and shutdown philosophy shall be implemented in PLC system.
The control system scheme is attached herewith for reference. (Refer Annexure II)
The proposed system configuration is enclosed for reference.
Installation:
a. At field:
Operator Cabin Room: where the new signals from mounded bullet plant shall
be hooked-up.
One operator console for operation and control of all the process parameters like
level (2 Nos. i.e. one servo and one radar, ROVs, Deluge valves etc.).
The Engg cum operator console at NRMT control room and the console at
Operator cabin should be independent. Client Server configuration will not be
accepted.
b. At NRMT control room:
The NRMT panel room is also exhausted for new panels. However existing glass
partition to be extended suitably to accommodate new PLC panels (4 Panels
tentative).
There is no space for additional hardware console in NRMT.
Switches/PBs/Lamps etc. required for Hardware control to be mounted on the
existing control desk of NRMT Control Room by replacing existing
components/faci plate to maintain the aesthetics of existing configuration.
Auxiliary hardware console of the proposed control system (which will be hooked
up with the DI/DOs of control system of the satellite rack room via multi core/pair
cables). This console will consist of H/W selector switches/ push button for ROV
operation, indication lamp (open/ close feedback of ROVs/ valves), emergency
switch etc. as applicable. Operation and monitoring of ROVs/ deluge valves will
be carried from this console.
Redundant HMI/ workstation of the control system (which will be hooked up with
the control system of the satellite rack room via redundant FO cable network) for
GUI of the entire control/operation of the plant. One will be operator station and
other will be Operator cum Engineering station. The Operator cum Engineering
station will be server grade machine with redundant power supply and redundant
storage (RAID). Both the HMI will be independent. Failure of one HMI should not
affect the other HMI. Operation and monitoring of ROVs/ deluge valves including
all other field instruments will be carried from these HMIs through GUI.
Additionally entire system related engineering/ configuration will be carried out
from the Operator cum Engineering station
Redundant HMI/ workstation for TFMS. Atleast 2 independent system should be
provided for redundancy. Failure of one system should not affect the other
system.
All rights reserved

AT NRL, ASSAM
EM163-PNIN-0701-00
DOCUMENT NO
REV
SHEET 22 of 23
c. At TFMS:
For Inventory Management, TFMS is required by Operations. Hence One Radar
Level Transmitter for each Bullet shall be independently connected to the
existing TFMS system available at NRMT Control Room.
MODBUS connectivity via OFC required from TFMS connecting radar gauges
for mounded bullet to Refinery DCS (CCR).
At present no MODBUS connectivity for the existing TFMS system to/from the
new PLC system is envisaged.
Note:
One dedicated 5KVA feeder shall be provided from the existing/ new UPS by NRL.
New PLC System:

a. SIL 3 PLC with redundancy in all levels and with SOE. Power supply: 110 VAC, 50 Hz,
UPS. Availability/Adequacy of existing 110V UPS of NRMT should be checked. If the
same is not adequate, supply of new UPS should also be considered in consultation
with electrical department.
b. Redundant HMI/ workstation for GUI of the entire monitoring/ controlling/ operation of
the process parameters/ ROV etc.
c. Auxiliary hardware console where the indication/ on off switches/ selector switches for
ROV operation will be provided as mentioned earlier.
d. Supply voltage to SOV (solenoid operated valve): 110VAC. Accordingly suitable SOVs
should be selected.
e. Isolation of IO devices: All the field IOs (AI/AO/DI/DO) should be isolated from the
system IOs incorporating the followings:
Barriers for AI/AO.
Barriers/Interposing relays for DI/DO.
f. Fused TBs: All field DI/DOs should be connected via fused TBs only.
g. 3rd party connectivity (vendors scope):
MODBUS connectivity via OFC (with data driver) for proposed Control System
for hooking up with existing DCS. The distance is around 3 KM. FO cable
networking with MODBUS connectivity via OFC (with data driver) to be provided
by the vendor of PLC for this provision. Proposed system configuration is
enclosed for reference.
MODBUS connectivity via OFC required from TFMS connecting radar gauges
for mounded bullet to Refinery DCS (CCR).
All rights reserved
EM163PNIN070100
Page23of23
ANNEXUREII
Controlsystemschemeformoundedbullets
LevelXMTRs
(Servo)
LevelXMTRs(Radar2)
LevelXMTRs(Radar
1)
Analogprocess
value(AI)
Analogoutout(AO)
Valveopen/close
cmnd
Valveopen/close
feedback
Open/close/ESD
switches
FieldSide
DedicatdTFMS
NewPLC
(RedundantuptoI/O)
(SIL3)
(Inventorymanagementsystem)
Expansionofexisting
RedundantMODBUSconnectivity
withexistingDCS
A.AtNRMTcontrolroom:
1.DedicatedEngg.CumoperatorconsoleforPLCprogramming,operationandmonitoringofallthe
processparameterslikelevel(2Nos.i.e.oneservoandoneradars),ROVs,Delugevalvesetc.
RedundantMODBUS
connectivitywith
existingDCS
2.TFMS(expansionofexisting)forinventorymanagement.
Redundantcommunication
(PLCvendorspecific)
3.Hardwareconsole:Hardwareconsole:Thereisnospaceforadditonalhardware
console.Switches/PBs/LampsetcrequiredforHardwarecontrolshouldbemountedontheexisting
controldeskofNRMTControlRoombyreplacingexistingcomponents/faciaplatetomaintainthe
astheticsofexistingconfiguration
(PLCvendorspecific)
Newcabinetroom/SRR
Redundantcommunication
4.ExistingDCSconsole:.ExistingDCSconsolewillberetainedaccomodatingthenewsignalsviamodbus
connectivity.
TFMSconsole
WithTFMSpackage(Engg.Cum
monitoing)
FOcables
(new)
Expansionofexisting
Hardwareconsole
Lampindication
PB/Switches
Foroperation/monitoringofROVs
anddelugevalves
Engg.Cumoperatorconsole
WithPLCprog./Graphic/alarm
loggingpackage
Viewing/controlofallthe
parameters
Referpoint3
New
B.AtNRMTControlRoom/newcabinetroom
1.NewPLCpanels.
2.InterfacingdevicesofTankFarmManagementsystem(TFMS)(fornewsystem).
12Pair
signal
cables
Existing
D.Atoperatorcabin:
1.Oneoperatorconsoleforoperationandcontrolofalltheprocessparameterslikelevel(2Nos.i.e.one
servoandoneradar,ROVs,Delugevalvesetc.).
2.TheEnggcumoperatorconsoleatNRMTcontrolroomandtheconsoleatOperatorcabinshouldbe
indepenent.ClientServerconfigurationwillnotbeaccepted.
NRMT control room

NRMTcontrolroom
ExistingDCSconsole
Centralcontrolroom
CCRexistingDCS
Operatorcabin
Operatorconsole
WithGraphicpackage
Viewing/controlofalltheprocess
parameters/valvestatus
New
EM163-P
PNIN-7901-PA
ART B
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTB
DE
ETAIL EN
NGINEE
ERING O
OF
TECHNICAL
L SPECIF
FICATIO
ONS
OR PROC
CUREMENT AN
ND
FO
INSTALL
LATION / COMM
MISSION
NING OF
INST
TRUMEN
NTS
Job
b No
: EM
M163
Pro
oject
: IN
NSTALLA
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
Clie
ent
: NR
RL
24.09.2015
5
--
CLIENTS COM
MMENT INCO
ORPORATED
H
HK
RA
A
SKT
14.09.2015
5
--
CLIENTS COM
MMENT INCO
ORPORATED
H
HK
RA
A
SKT
21.07.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
FORM NO: 02-0000-0021

0
F1 REV3
EM163-E-7047
DOCUMENT NO
SHEET 1 OF 3
ENQUIRY SPECIFICATION
FOR
RADAR TYPE TANK LEVEL TRANSMITTER
(NON TFMS)
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
INSTALLATION OF LPG MOUNDED
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7047
COMMENTS INCORPORATED
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7047
ENQUIRY SPECIFICATION FOR
RADAR TYPE LEVEL TRANSMITTER
(NON TFMS)
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL. DRAWINGS/
NO. DOCUMENTS.DESCRIPTION
1
2
3
4
5
15
GENERAL CONDITIONS FOR

INSTRUMENTS
ENGINEERING SPECIFICATIONS FOR
INSTRUMENT SPECIFICATION FOR
(NON TFMS)
SPARES FOR RADAR TYPE LEVEL
TRANSMITTER
BOQ FOR RADAR TYPE LEVEL
TRANSMITTER
VESSEL DRAWING
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO.
/
DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7288
09
EM163-7047-ISP7288
02
EM163-7047-SP-7288
01
EM163-7047-BOQ7288
EM163-PNMV-DD45W-101/102/103/104
01
01
All rights reserved
EM163-E-7047
(NON TFMS)
DOCUMENT NO
SHEET 3 OF 3
LIST OF INSTRUMENTS (NON TFMS)
SL.
NO.
1
2
3
4
TAG NO.
45-LT-3002
45-LT-3005
45-LT-3008
45-LT-3011
FORM NO: 02-0000-0021F2 REV1
P & ID
QTY
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
01
01
01
01
All rights reserved
EM163-45- 102
Document No.
Sheet 1 of 1
Rev.
GENERALCONDITIONS
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %

Air temperature
380C
Relative humidity
85 %
Minimum Ambient Air Temperature
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
Maximum in one hour
90 mm
Wind
Wind code
Base wind pressure
Seismic Factor
Elevation
Average wind speed
36 km/hr
10
Maximum gust speed
140 km/hr
11
Site conditions
12
Precipitation Annual mean Max/ hr
08.07.2015
08.07.2015
For Enquire Issue
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES - 7288
DOCUMENT NO.
REV.
SHEET 1 OF 9
ENGINEERING SPECIFICATION
FOR
RADAR GAUGES
24.09.15
Issued for Enquiry
HK
RA
DDCPN
CISC
EFF
DATE
SKT
Issued for Enquiry
14-03-06
REV
REV
DATE
DHPV
PURPOSE
PREPD
REVWD
APPD

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
GENERAL REQUIREMENTS
3.0
INSPECTION , FACTORY
TESTS AND APPROVAL
4.0
PACKING
5.0
IDENTIFICATION AND
MARKING
6.0
SPARES
7.0
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
FORM NO: 02-0000-0021F2 REV1
NUMBER OF SHEETS
All rights reserved
ES - 7288
DOCUMENT NO.
REV.

RADAR GAUGES
SHEET 3 OF 9
1.00.00
General :
1.00.01
This general specification is applicable for the radar gauges of top vessel mounted
type.
1.00.02
This Engineering specification together with the Instrument specification attached

herewith define the requirement for the supply of radar gauges, its spares,
documentation and testing.
1.00.03
In the event of any conflict between Engineering specification and Instrument

specification the latter shall prevail.
2.00.00
General Requirements :
2.00.01
Gauges in general shall be of antistatic construction for Liquefied Gases, OIL

and other applications where Static build-up is likely.
2.00.02
Environmental Protection : Gauges shall have certified weatherproof , IP-65 or

better enclosure.
2.00.03
Gauges shall be suitable for storage, handling & outdoor installation in wet tropical
Coastal Climate.
2.00.04
The ambient conditions if not specified otherwise in data sheets shall be min
- 40 degrees & max 70 degrees Centigrade, Relative Humidity upto 100 %.
Instruments shall be suitable for such conditions.
2.00.05
EMI / RF immunity : The supplied equipment shall be CE marked or ATEX or

equivalent certified for immunity against Electromagnetic Interference & Radio
Frequency interference from / to nearby electrical apparatus in accordance with
EN 50081 , 50082 in industrial environment.
2.00.06
The process connection size shall be 8 ASME B16.5 flanged connection as

specified in individual Instrument specification sheets.
2.00.07
All flanges and their facings shall be as per ASME B 16.5
2.00.08
Flanges up to and including 600 # shall have raised face with concentric
serrations.
2.00.09
All flanges of rating 900 # and above shall have RTJ facing. All RTJ flanges shall
have groove corresponding to octagonal metal ring gaskets as per ASME B 16.20
2.00.010 In order to have antistatic construction Gaskets used if any shall be metallic or
SS304 with fibre filling for RF flanges. Ring Gaskets if any shall be octagonal
Rings of soft Iron.
2.00.011 Orientation of connection, rating, flange facing and flange face distance shall be as
indicated in individual Instrument specification sheets.
2.00.012 The material of construction shall be as per individual Instrument specification
sheets enclosed.
2.00.013 Electronics Casing / housing typically shall be Aluminium alloy ( non-incendive ), as
per vendor standard with protection class of IP-65 or better
2.00.014 Flanges shall be 316SS unless otherwise specified in data sheets.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 4 OF 9
2.00.015 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating
900 lbs. and above.
2.10.00
Electronics Enclosure & Cable Entries
2.10.01
In case of hazardous area applications, Gauges shall have Flame-proof / Ex-Proof

certified according to EN, FM or B IS. Endorsement / approval from CCOE ( Chief
Controller Of Explosives ) is required in case of Installation in India.
2.10.02
As a minimum certificate EExia II A / B T3 is expected. If certificate according to

IS - 2148 is furnished, it shall have certificate for temp class also.
2.10.03
Similarly for installation in other countries, certificates / endorsement shall be

available from concerned Local Statutory approval Authority as required.
2.10.04
Cable entries shall be with metallic plugs to prevent ingress of external matter.
2.10.05
Where specified flame-proof double compression cable glands shall be supplied.
2.10.06
Cable entries shall be NPTF, for Signal outputs & Power supply cabling.
2.10.07
Metallic plugs shall be provided at all cable entries to prevent ingress of external
matter till cabling at site is completed.
2.10.08
Cables entries shall be plugged to avoid damage during transit.
3.00.00
Operational Principle & main features
3.00.01
The device must use Frequency Modulated Continuous Wave (FMCW). Radar
technology which measures level based on elapsed time between send/receive of a
fixed frequency signal, (pulse or time domain) shall not be used for high performance
tank gauging. Incremental phase evaluation shall not be used since it can lead to
significant level gauging errors.
3.00.02
The radar gauge shall have a digital reference to ensure accuracy and stability.
Analog delay lines suffer from temperature and aging effects and shall not be used.
3.00.03
The RTG shall be capable of having dual, independent and galvanically isolated
gauge electronics, enabling built-in redundancy, dual level outputs or a combined
level gauging and alarm handling.
3.00.04
The RTG shall have a separate safety function suitable for use in Safety
Instrumented Systems (SIS). The function must be certified by a third party to at a
minimum meet Safety Integrity Level 2 (SIL 2) requirements as per IEC 61508.
3.00.05
The RTG subparts (antennas, electronics, housing etc.) shall be designed in such a
way that they can be freely interchanged, without recalibration.
3.00.06
The gauge shall be able to operate in a stand-alone mode (single gauge installation)
or in a network of up to at least 16 gauges and operator interface workstations in the
control room. Level update time shall not exceed one (1) second in the field data
concentrator. The standard fieldbus communication shall have a baud rate of at least
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES - 7288
DOCUMENT NO.
REV.

RADAR GAUGES
SHEET 5 OF 9
4800 Baud.
3.00.07
The RTG shall be equipped with dual memory banks enabling reprogramming and
configuration under continuous operation.
3.00.08
For high pressurized vessel and high accuracy applications, an optional pressure
transmitter for vapor space pressure measurement shall be incorporated into the
Radar gauging system. The pressure input shall be used by the RTG for automatic
compensation of the level indication in the field itself due to changes in vapor density.
3.00.09
The vendor shall provide at least one verification pin for the still-pipe to permit on-line
field verification of the level measurement while the tank is in operation. During
verification, the normal level reading shall also be available. A device for end-of pipe
measurement verification shall be provided.
3.00.10
The vendor shall provide an optional isolation valve at the gauge head to provide
increased safety.
3.00.11
A perforated steel pipe guided radar waves to ensures the safe measurements
undisturbed by the structures in the tank and possible boiling of the liquid gas.
3.00.12
The gauge shall be microprocessor based with inbuilt software for calculation of
densities, level; from Vessel / tank strapping tables; extensive diagnostics to detect
faults in the system, etc. and have safeguards to prevent damage to radar.
3.00.13
Typical accuracies expected are as specified otherwise in data sheets.
3.00.14
The transmitter shall have a local level indicator either inbuilt in the same casing.
3.00.15
Indicator at radar gauge casing shall have digital displays for level, calculated
volume, density, etc - in engineering units and diagnostic messages / alarms.
3.00.16
The transmitter may use optical or other types of encoders.
3.10.00
Outputs :
3.10.00
Following types of outputs are expected : signal, 4 ~ 20 mA DC output; RS 485

Serial output
( MODBUS RTU / PROFIBUS / FOUNDATION FIELDBUS as per data sheet ).
3.10.02
Four freely configurable potential free - galvanically isolated electromechanical

relays shall be available for Low, Very Low, Hi and Very High levels. Contact rating
0.5 Amps at 24 V DC.
3.20.00
Remote Indicators :
3.20.01
One additional IP-65 , weatherproof intrinsically safe certified field mounted

Remote indicator for mounting at the grade / ground level included in scope.
Digital display of Level Only shall be available on this Indicator.
3.20.02
3.20.03
This remote indicator shall be 4 ~ 20 mA loop powered indicator. Voltage Drop at

this indicator shall not exceed 1 Volt.
3.20.04
Cable entries shall be 2 nos., NPTF, one for incoming & other for outgoing.
Metallic plugs shall be provided to prevent ingress of external matter till cabling at
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 6 OF 9
site is completed.
3.30.00
Still well / pipe : Vendor shall furnish detailed dwgs of recommended still well /
pipes for correct installation of the instrument.
3.30.01
In case Still wells under equipment fabricator scope ( excluded from radar gauge
vendor scope ),equipment fabricated are to be supplied with necessary information
and vetted by OEM of radar gauge (OEM to spell out clearly all necessary
accessories for mounting the gauge).
3.30.02
Accessories like reflector kit, reference pin etc. shall be supplied along with the
radar.
4.00.00
Tank Farm Management System Software
4.00.01
If specified in data sheets, vendor scope shall include their proven software for
Tank farm management for inventory monitoring.
4.00.02
This software shall normally be loaded in Clients PC.
4.00.03
For this purpose all Servo gauges, if applicable, radar gauge shall be serially linked
& connected to the PC. Vendors software shall enable access to all data- level,
density , temperature, calculated values such as Volume being filled-in / pumpedout, total hold-up volume, filled capacity , etc.,
4.00.04
System shall also generate alarms at different configurable limits.
4.00.05
Configuration shall be through user-friendly menu driven templates.
4.00.06
Software shall generate dynamic Graphic pages showing all details of tanks with
dynamic level indication (increasing / decreasing, etc.,), all other operational data
concerning tanks & fluids.
4.00.07
Operator shall be able to access the different pages easily maximum in 2 steps.
5.00.00
Inspection , Factory tests and approval
5.00.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for
carrying out Inspection and test including tests to be conducted by independent
agencies. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be
conducted by vendors Quality Department and the results of tests shall be forwarded
along with the supply.
The manufacturer shall give clear 15 days notice informing readiness of the
instruments at manufacturers works. The vendor shall permit the authorised
representative of PDIL/OWNER to inspect the manufacture and assembly of the
instruments in various phases in compliance with mutually agreed quality assurance
plan, standards and specifications
The vendor shall make available to the authorised representative of PDIL /

OWNER the results of all the checks / calibrations conducted by them on the basis
of approved Quality Assurance Plan for PDIL/Owners inspection.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 7 OF 9
The vendor has to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the checks/calibration as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the written
permission of PDIL/ OWENER.
No instrument/accessory shall be shipped until all the required tests are successfully
completed and certified Cleared for despatch by the inspection authority.
5.00.02 The following physical checks, routine tests as a minimum shall be witnessed by PDIL /
owner inspection authority. The procedure & extent of test shall be governed by Quality
Assurance Plan mutually agreed and approved by Inspection Authority.
A. Physical Checks
1. Name Plate details
- Tag no.
- Model no.
- Range
- Execution (IP, IS, Exd etc.)
2. Process connection
B. Routine tests
1. Calibration check for accuracy, linearity, hysteresis and repeatability
2. Zero-shift
3. Hydraulic test.
5.00.03 Other Tests
Vendor shall submit following certificates from a approved laboratory or from statuary
bodies, as applicable.
1. Chemical Analysis
2. Huey test where applicable
3. Radiography/Ultrasonic examination of welded joints for rating 900# and above
5.00.04 Any other test applicable to particular equipment to establish its quality of
construction & performance.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 8 OF 9
6.00.0
Packing
Each radar gauges and its accessories shall be suitably packed and protected
from damage due to transportation, loading and unloading.
The radar gauges and their accessories along with spares shall be despatched as
a single consignment. Commissioning and 2 years operation spares shall be
packed separately with proper identification marking.
7.00.00
Identification and Marking
7.00.01
Self adhesive tapes or signs are not permissible for permanent marking of any
instrument.
7.00.02
All instruments shall have a tag plate in SS screwed to the radar gauges case
indicating make, model no., sl. no. , tag no., adjustable range, set range etc.
Besides the above each instrument to have a separate circular tag number plate in
stainless steel with engraved tag number and calibration range and attached
securely to the instrument with a soft stainless wire. The size of letters and figures
shall be minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm
thick.
7.00.03
All spare parts to be supplied along with the main consignment shall be fitted with
identification plate with the following data clearly printed and easily readable.
-Spare parts name, model no. as per purchasers Instrument spec. sheet.
-Serial no.
8.00.00
Spares : Spares shall be as per enclosed spares list.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES - 7288
DOCUMENT NO.
REV.

RADAR GAUGES
SHEET 9 OF 9
9.00.00
Documentation:
The following documents (Technical) are required to be submitted by the vendor
along with bid, after placement of order for approval purposes and final
documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION OF
DOCUMENT
Catalogue & technical literature of
level transmitter alongwith their

accessories, installation drgs,
sketch diagrams.
Deviation if any, from the technical
spec. giving justification for the
same.
Dimensional and sectional drawing
against each tag showing material
of construction of each part.
Chemical analysis and material
test certificates from an approved
laboratory.
Certificates from recognised
authority for (a) degree of
protection against environment (b)

Intrinsic safety/ Ex-proof
execution.
Instruction Manual for
maintenance.
Calibration and performance test
certificates.
Quality Assurance Plan.
After Placement of Order

ALONGWITH For Approval Final Documents
BID
/ Information
before Dispatch of
within 6 weeks consignment
Yes
Yes
Yes
Yes ( I )
Yes
Yes
Yes
Yes
Yes ( A )
within 2 weeks
Yes
Yes
Yes
( A ) for Approval
( I ) for Information
Sl. no. 1 to 7 shall be forwarded to PDIL / OWNER as per details outlined

in Enquiry / order
Sl. No. 8 shall be mutually finalised with Inspection Authority specified in
the order.
Number of sets along with bid for approval and as final documentation
shall be supplied as stipulated in the purchase order.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
LPG MOUNDED BULLETS AT NRL, ASSAM

TECHNICAL SPECIFICATION : EM163-7047-ISP-7288
RADAR TYPE LEVEL TRANSMITTER (NON TFMS)
1
GENERAL
PROCESS DATA
Tag no./ Quantity
2
3
4
5
6
7
Service
Eqpt No.
Eqpt Rating
Area Classification
Principle
Type
8
9
10
11
12
13
14
15
Process Fluid Lower

Temperature(C) Norm
Pressure
Norm
Dielectric constant
Viscosityy
Design Pressure
Design Temperature
Specific Gravity
16 Tank Type
17 Tank Height
PID No.
Process Fluid Upper

Max
Max
Tank Sketch No.

Tank Dia
TANK/VESSEL
SENSOR
18 Process
P
Connection
C
ti
Flange
Fl
Surface
S f
Fi
Finish
i h
19
20
21
22
23
24
Nozzle Projection
Still Well By
Nozzle I.D.
Still Well Size
Reflector/Reference Pin
Type of Application
Antenna Type
Operating Frequency
25 Temperature Inputs
26 Output Signal
27 Transmitter Type
28 Calibration Range
Display
TRANSMITTER
29
30 Mounting
31 Serial Links
Power Supply
Cable Entry
Enclosure Class/ Execution
Accuracy
32 Other Features
MATERIAL
ACCESSORIES
33 Body Flange
Electrical Housing
Gasket
Antenna
34
35 Still Well Pipe
36 Body and Wetted parts
37 Studs/Bolts/Nuts
38 O' Rings
39 Reflector/Reference Pin
40 Lightning Protection
41 Mounting Bracket
42 Additional Remote Indicator IP-65, Two cable entries
45-LT-3002,
/ 1 No.
45-LT-3005,
/ 1 No.
45-LT-3008,
/ 1 No.
45-LT-3011,
/ 1 No.
LPG
45-VV-101/ 102/ 103/ 104
VENDOR
OFFER
EM163-45-0021 (P1)/ 0022 (P2)
ZONE-1 IIA IIB T3 as per IEC Norms

FMCW
Non Contact Type Radar with Indicator and Transmitter, for measuring Level, Density, Tank
bottom
LPG
N/A
10-40 Deg C
55 Deg C
14.5 Kg/cm2 g
2.33 - 8.6Kg/ cm2 g
1.6-1.9
0.113-0.152 Cp
p
14.5 Kg/cm2g
-27 to 55 Deg C
0.5-0.57
Horizontal Cylindrical
EM163-PNMV-DD45-W-101
7000mm
LPG BULLET :TL ~ TL =52000mm

HEIGHT : Bullet I.D (7000mm) +Bullet
Thickness(42mm) + Mound
height(1000mm) + Dome upto top of Nozzle
(250mm) (Tentative)(Drawing Attached)
8",
RF(Tentative)
8" ANSI 300# RF(T
t ti ) (Note(N t 10 )
125 ~ 250 R
Ra
1250mm(Tentative)
193.68 mm (Tentative)
8" (Note- 9 ) Vendor to specify Schedule
Tank fabricator
Vendor to provide Reflector plate at end of still well pipe with reference pin
Continuous Level Measurement
Note-1
Note-1
2" Nozzle with 2" Thermowell for Multielement Averaging sensor
4 ~ 20 mA, 2 Channels freely assignable, 110 V, 50 Hz
Digital Pulse output for Level and Average
Temperature
Integral with Probe Dual Compartment
1/2" ANSI NPT(F) - 2 Nos. (SS Plugged)
0 - 8292mm (Note 1)
Integral Digital - LCD, in 0-100% , Additional Eexia / IP65
Loop Powered at grade level
On Dome - Top Mounted
LEVEL: 1 mm,DENSITY : 0 .005gm/cm3
RS 485 (Twisted Pair), MODBUS RTU
RS 485 Communication with Accessories required ie Booster amplifier, Repeaters etc. to be
provided as required .
Anti-Static Construction, Diagnostics, Maintenance prediction / information; Local as well as
R
t configuration
fi
ti facility,
f ilit iincluding
l di O
Li removall ffacility
ilit ffor RADAR LT,
LT One
O laptop
l t
Remote
On-Line
with Configuration and Software tools.
SA350 Gr LF2 Cl 1
SS316
SS with Weather-proof Hood

Spiral Wound SS 304 Graphite filled with SS
Centre Ring
SS316 / By tank vendor

SS316
SA 320 Gr L7 / SA194 Gr 4
PTFE
SS316
Required
Note-1
YES, DIGITAL, Loop powered with mounting accessories + SS Plugs
43 ISOLATION BALL VALVE
YES, 316 SS Wetted metal parts, Glass filled PTFE sealing and packings with hand lever,
Open & Close Indication
44 Cable Gland Type
1/2", SS 316 , Double Compression (Flame Proof)
45 Interconnecting Cable
Interconnecting Cable length between Transmitter and Local Indicator shall be Vendor's
scope. Vendor to specify length.
yes
46 Overfill Protection

RADAR TYPE LEVEL TRANSMITTER (NON TFMS)
VENDOR
OFFER
W & M approval, CMRI / CCOE approved (CENELEC, YES, SIL2 CERTIFICATION BY TUV
47 IS - 2148), SIL Certified, OISD
48
49 Model
Serial Number
By supplier
PURCHASE
50 Purchase Order Number
51 Price
Item No.
Notes: 1. VENDOR TO SPECIFY.
2.Tank drawing EM-163-PNMV-DD45-W-101/102/103/104 is attached for your reference.
3. Separate Local Indicator shall be provided one at grade and one on top of Mound Local Level Indication to show Pressure/Temperature also.
CERTIFICATION
4. Documentation shall include sets of installation , operation & maintenance manuals , wiring diagrams , authority approvals , certificates & manufacturers test and
guarantee certificates.
5. RADAR indicator shall have scale graduations in mm.
6. Vendor scope includes configuration of tanks data, calculations, supervision of Erection, Wiring, as well as Testing and Commissioning of whole system .
7. Vendor to confirm Nozzle Size/ Still Well Size.
8. Vendor to p
provide complete
software p
package.
p
g
9. Vendor to provide system Architecture, still well design drawings, typical arrangement drawing, etc along with the offer.
10. Bidder to coordinate with vendor supplying Radar Type Level Transmitter for installation and commissioning and hook up of level instruments in PLC without any extra cost.
11 Vendor to provide temperature compensation from multipoint averaging temperature transmitter i.e. 45-LT-3002 from 45-TT-3006, 45-LT-3005 from
45-TT-3007, 45-LT-3008 from 45-TT-3008 & 45-LT-3011 from 45-TT-3009. Vendor to coordinate with Temperaure assembly vendor.
12 Pressure Temperature Compensation is required for the Radar Transmitter .Vendor to provide slots accordingly.
1
0
P
No.
AK
AK
AK
Prepared By
RA
RA
RA
Checked By
SKT
SKT
SKT
Approved By
29.09.2015
14.09.2015
21.07.2015
DATE
INSTRUMENT SPECIFICATION
( NON TFMS)
COMMENTS INCORP
DRAFT ENQUIRY
Purpose
SPARE LIST FOR RADAR TYPE LT
EM163-7047-SP-7288
DOCUMENT NO.
REV
SHEET
OF
Please refer attached Bill of Quantity EM163-7047-BOQ-7288 for spare details
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 Years Operational spares
recommended by them.
Bill of Quantity For RADAR

EM163-7047-BOQ-7288
TYPE Level Transmitter
Rev 1 / 24.09.2015
Sl
Item
Item Description
Qty
No
<-------By Vendor----->
Radar
R d Type
T
Level
L
l transmitter
t
itt
Main Transmitter
45-LT-3002
Main Transmitter
45-LT-3005
Main Transmitter
45-LT-3008
Main Transmitter
45-LT-3011
Commissioning
g Spares
p
9
Spare 1
Recommended by the
vendor
Spare for 2 Years Operation

10
Model No / Part No
Spare 2
Recommended by the
vendor
Page 1 of 1
EM163-E-7147
DOCUMENT NO
SHEET 1 OF 3
FOR
RADAR TYPE TANK LEVEL TRANSMITTER
(TFMS)
WITH
MULTIPOINT TEMPERATURE ELEMENT
&
TEMPERATURE TRANSMITTER
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7147
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7147
(TFMS)
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL. DRAWINGS/
NO. DOCUMENTS. DESCRIPTION
1
INSTRUMENTS
2
3
(TFMS)
4
SPARES FOR RADAR TYPE LEVEL
TRANSMITTER
5
BOQ FOR RADAR TYPE LEVEL
TRANSMITTER
6
VESSEL DRAWING
7
10
11
12
13
14
15

MULTIPOINT
TEMPERATURE
ELEMENT (RTD) WITH TW
MULTIPOINT
TEMPERATURE
SPARE LIST FOR
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH TW
BOQ FOR MULTIPOINT
TEMPERATURE ELEMENT (RTD)
WITH TW
SKETCH FOR FOR MULTIPOINT
WITH TW
SPARE LIST FOR TEMPERATURE
TRANSMITTER
BOQ FOR TEMPERATURE
TRANSMITTER
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO. /
DOCUMENT NO
EM163-45-102
NO OF
PAGES
01
ES-7288
09
EM163-7147-ISP-7288
08
EM163-7147-SP-7288
01
EM163-7147- BOQ -7288
01
EM163-PNMV-DD45-W101/102/103/104
01
ES-7323
08
EM163-7161-ISP-7323
01
EM163-7161-SP-00
01
EM163-7161- BOQ
01
EM163-SK-7323-00
01
ES-7328
07
EM163-7162-ISP-7328
01
EM163-7162-SP-00
01
EM163-7162- BOQ
01
All rights reserved
EM163-E-7147
(TFMS)
DOCUMENT NO
SHEET 3 OF 3
LIST OF INSTRUMENTS TFMS

SL.
NO.
1
2
3
4
TAG NO.
45-LT-3001
45-TE-3005
45-TT-3005
45-LT-3004
45-TE-3006
45-TT-3006
45-LT-3007
45-TE-3007
45-TT-3007
45-LT-3010
45-TE-3008
45-TT-3008
FORM NO: 02-0000-0021F2 REV1
P & ID
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
QTY
01
01
01
01
01
01
01
01
01
01
01
01
All rights reserved
EM163-45- 102
Document No.
Sheet 1 of 1
Rev.
GENERALCONDITIONS
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %

Air temperature
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
Maximum in one hour
90 mm
Wind
Wind code
Base wind pressure
Seismic Factor
Elevation
Average wind speed
36 km/hr
10
Maximum gust speed
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
For Enquire Issue
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES - 7288
DOCUMENT NO.
REV.
SHEET 1 OF 9
FOR
RADAR GAUGES
24.09.15
Issued for Enquiry
HK
RA
DDCPN
CISC
EFF
DATE
SKT
Issued for Enquiry
14-03-06
REV
REV
DATE
DHPV
PURPOSE
PREPD
REVWD
APPD

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
INSPECTION , FACTORY
TESTS AND APPROVAL
4.0
PACKING
5.0
IDENTIFICATION AND
MARKING
6.0
SPARES
7.0
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
FORM NO: 02-0000-0021F2 REV1
NUMBER OF SHEETS
All rights reserved
ES - 7288
DOCUMENT NO.
REV.

RADAR GAUGES
SHEET 3 OF 9
1.00.00
General :
1.00.01
This general specification is applicable for the radar gauges of top vessel mounted
type.
1.00.02

herewith define the requirement for the supply of radar gauges, its spares,
1.00.03

2.00.00
2.00.01
Gauges in general shall be of antistatic construction for Liquefied Gases, OIL

and other applications where Static build-up is likely.
2.00.02

better enclosure.
2.00.03
Coastal Climate.
2.00.04
The ambient conditions if not specified otherwise in data sheets shall be min
- 40 degrees & max 70 degrees Centigrade, Relative Humidity upto 100 %.
Instruments shall be suitable for such conditions.
2.00.05

Frequency interference from / to nearby electrical apparatus in accordance with
EN 50081 , 50082 in industrial environment.
2.00.06
The process connection size shall be 8 ASME B16.5 flanged connection as

2.00.07
2.00.08
serrations.
2.00.09
SS304 with fibre filling for RF flanges . Ring Gaskets if any shall be octagonal
Rings of soft Iron.
2.00.011 Orientation of connection, rating, flange facing and flange face distance shall be as
indicated in individual Instrument specification sheets.
2.00.012 The material of construction shall be as per individual Instrument specification
sheets enclosed.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 4 OF 9
2.00.015 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating
900 lbs. and above.
2.10.00
2.10.01

2.10.02
As a minimum certificate EExia II A / B T3 is expected. If certificate according to

2.10.03
Similarly for installation in other countries, certificates / endorsement shall be

2.10.04
2.10.05
2.10.06
Cable entries shall be NPTF, for Signal outputs & Power supply cabling.
2.10.07
2.10.08
3.00.00
Operational Principle & main features
3.00.01
The device must use Frequency Modulated Continuous Wave (FMCW). Radar
technology which measures level based on elapsed time between send/receive of a
fixed frequency signal, (pulse or time domain) shall not be used for high performance
tank gauging. Incremental phase evaluation shall not be used since it can lead to
significant level gauging errors.
3.00.02
The radar gauge shall have a digital reference to ensure accuracy and stability.
Analog delay lines suffer from temperature and aging effects and shall not be used.
3.00.03
The RTG shall be capable of having dual, independent and galvanically isolated
gauge electronics, enabling built-in redundancy, dual level outputs or a combined
level gauging and alarm handling.
3.00.04
The RTG shall have a separate safety function suitable for use in Safety
Instrumented Systems (SIS). The function must be certified by a third party to at a
minimum meet Safety Integrity Level 2 (SIL 2) requirements as per IEC 61508.
3.00.05
The RTG subparts (antennas, electronics, housing etc.) shall be designed in such a
way that they can be freely interchanged, without recalibration.
3.00.06
The gauge shall be able to operate in a stand-alone mode (single gauge installation)
or in a network of up to at least 16 gauges and operator interface workstations in the
control room. Level update time shall not exceed one (1) second in the field data
concentrator. The standard fieldbus communication shall have a baud rate of at least
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES - 7288
DOCUMENT NO.
REV.

RADAR GAUGES
SHEET 5 OF 9
4800 Baud.
3.00.07
The RTG shall be equipped with dual memory banks enabling reprogramming and
configuration under continuous operation.
3.00.08
For high pressurized vessel and high accuracy applications, an optional pressure
transmitter for vapor space pressure measurement shall be incorporated into the
Radar gauging system. The pressure input shall be used by the RTG for automatic
compensation of the level indication in the field itself due to changes in vapor density.
3.00.09
The vendor shall provide at least one verification pin for the still-pipe to permit on-line
field verification of the level measurement while the tank is in operation. During
verification, the normal level reading shall also be available. A device for end-of pipe
measurement verification shall be provided.
3.00.10
The vendor shall provide an optional isolation valve at the gauge head to provide
increased safety.
3.00.11
A perforated steel pipe guided radar waves to ensures the safe measurements
undisturbed by the structures in the tank and possible boiling of the liquid gas.
3.00.12
The gauge shall be microprocessor based with inbuilt software for calculation of
densities, level; from Vessel / tank strapping tables; extensive diagnostics to detect
faults in the system, etc. and have safeguards to prevent damage to radar.
3.00.13
Typical accuracies expected are as specified otherwise in data sheets.
3.00.14
3.00.15
Indicator at radar gauge casing shall have digital displays for level, calculated
volume, density, etc - in engineering units and diagnostic messages / alarms.
3.00.16
3.10.00
Outputs :
3.10.00
Following types of outputs are expected : signal, 4 ~ 20 mA DC output; RS 485

Serial output
3.10.02

3.20.00
Remote Indicators :
3.20.01
One additional IP-65 , weatherproof intrinsically safe certified field mounted

Remote indicator for mounting at the grade / ground level included in scope.
3.20.02
3.20.03

3.20.04
Cable entries shall be 2 nos., NPTF, one for incoming & other for outgoing.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 6 OF 9
site is completed.
3.30.00
pipes for correct installation of the instrument.
3.30.01
In case Still wells under equipment fabricator scope ( excluded from radar gauge
vendor scope ),equipment fabricated are to be supplied with necessary information
and vetted by OEM of radar gauge (OEM to spell out clearly all necessary
accessories for mounting the gauge).
3.30.02
Accessories like reflector kit, reference pin etc. shall be supplied along with the
radar.
4.00.00
4.00.01
If specified in data sheets, vendor scope shall include their proven software for
Tank farm management for inventory monitoring.
4.00.02
4.00.03
For this purpose all Servo gauges, if applicable, radar gauge shall be serially linked
& connected to the PC. Vendors software shall enable access to all data- level,
density , temperature, calculated values such as Volume being filled-in / pumpedout, total hold-up volume, filled capacity , etc.,
4.00.04
4.00.05
4.00.06
dynamic level indication (increasing / decreasing, etc.,), all other operational data
4.00.07
5.00.00
5.00.01
carrying out Inspection and test including tests to be conducted by independent
agencies. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be
along with the supply.
plan, standards and specifications

FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 7 OF 9
permission of PDIL/ OWENER.
5.00.02 The following physical checks, routine tests as a minimum shall be witnessed by PDIL /
A. Physical Checks
- Tag no.
- Model no.
- Range
B. Routine tests
2. Zero-shift
3. Hydraulic test.
5.00.03 Other Tests
bodies, as applicable.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR GAUGES
ES - 7288
DOCUMENT NO.
REV.
SHEET 8 OF 9
6.00.0
Packing
Each radar gauges and its accessories shall be suitably packed and protected
from damage due to transportation, loading and unloading.
The radar gauges and their accessories along with spares shall be despatched as
a single consignment. Commissioning and 2 years operation spares shall be
packed separately with proper identification marking.
7.00.00
7.00.01
instrument.
7.00.02
All instruments shall have a tag plate in SS screwed to the radar gauges case
shall be minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm
thick.
7.00.03
-Spare parts name, model no. as per purchasers Instrument spec. sheet.
-Serial no.
8.00.00
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES - 7288
DOCUMENT NO.
REV.

RADAR GAUGES
SHEET 9 OF 9
9.00.00
Documentation:
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION OF
DOCUMENT

sketch diagrams.
same.
laboratory.

execution.
maintenance.
certificates.

BID
/ Information
before Dispatch of
Yes
Yes
Yes
Yes ( I )
Yes
Yes
Yes
Yes
Yes ( A )
within 2 weeks
Yes
Yes
Yes
( A ) for Approval

in Enquiry / order
Sl. No. 8 shall be mutually finalised with Inspection Authority specified in
the order.
Number of sets along with bid for approval and as final documentation
shall be supplied as stipulated in the purchase order.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

RADAR TYPE LEVEL TRANSMITTER (TFMS)
1
GENERAL
PROCESS DATA
Tag no./ Quantity
2
3
4
5
6
7
Service
Eqpt No.
Eqpt Rating
Area Classification
Principle
Type
8
9
10
11
12
13
14
15
Process Fluid Lower

Temperature(C) Norm
Pressure
Norm
Dielectric constant
Viscosityy
Design Pressure
Design Temperature
Specific Gravity
16 Tank Type
17 Tank Height
PID No.
Process Fluid Upper

Max
Max
Tank Sketch No.

Tank Dia
TANK/VESSEL
SENSOR
P
C
ti
18 Process
Connection
Fl
S f
Fi
i h
Flange
Surface
Finish
19
20
21
22
23
24
Nozzle Projection
Still Well By
Nozzle I.D.
Still Well Size
Reflector/Reference Pin
Type of Application
Antenna Type
Operating Frequency
25 Temparature Inputs
26 Output Signal
27 Transmitter Type
28 Calibration Range
Display
TRANSMITTER
29
30 Mounting
31 Serial Links
Power Supply
Cable Entry
Enclosure Class/ Execution
Accuracy
32 Other Features
MATERIAL
ACCESSORIES
33 Body Flange
Electrical Housing
Gasket
Antenna
34
35 Still Well Pipe
36 Body and Wetted parts
37 Studs/Bolts/Nuts
38 O' Rings
39 Reflector/Reference Pin
40 Lightning Protection
41 Mounting Bracket
42 Additional Remote Indicator IP-65, Two cable entries
45-LT-3001
/ 1 No.
45-LT-3004
/ 1 No.
45-LT-3007
/ 1 No.
45-LT-3010
/ 1 No.
LPG
45-VV-101/ 102/ 103/ 104
VENDOR OFFER
EM163-45-0021 (P1)/ 0022 (P2)
ZONE-1 IIA IIB T3 as per IEC Norms

FMCW
Non Contact Type Radar with Indicator and Transmitter for measuring Level,
Density, Tank bottom, Volume,Weight, Temperature.
LPG
N/A
10-40 Deg C
55 Deg C
14.5 Kg/cm2 g
2.33 - 8.6Kg/ cm2 g
1.6-1.9
0.113-0.152 Cp
p
14.5 Kg/cm2g
-27 to 55 Deg C
0.5-0.57
Horizontal Cylindrical
EM163-PNMV-DD45-W-101
7000mm
LPG BULLET :TL ~ TL =52000mm

HEIGHT : Bullet I.D (7000mm) +Bullet
Thickness(42mm) + Mound
height(1000mm) + Dome upto top of Nozzle
(250mm) (Tentative)(Drawing Attached)
8"
t ti ) (Note(N t 10 )
125 ~ 250 R
Ra
8", ANSI 300# RF(T
RF(Tentative)
193.68 mm (Tentative)
1250mm(Tentative)
8" (Note- 9 ) Vendor to specify Schedule
Tank fabricator
Vendor to provide Reflector plate at end of still well pipe with reference pin
Continuous Level Measurement
Note-1
Note-1
V, 50 Hz
4 ~ 20 mA
mA, 2 Channels freely assignable
assignable, 110 V
Digital Pulse output for Level and Average
Temperature
Integral with Probe Dual Compartment
1/2" ANSI NPT(F) - 2 Nos. (SS Plugged)
0 - 8292mm (Note 1)
Integral Digital - LCD, in 0-100% , Additional EExia / IP65
Loop Powered at grade level
On Dome - Top Mounted
LEVEL: 1 mm,DENSITY : 0 .005gm/cm3
RS 485 (Twisted Pair), MODBUS RTU
RS 485 Communication with Accessories required ie Booster amplifier, Repeaters
etc. to be p
provided as required
.
q
Anti-Static Construction, Diagnostics, Maintenance prediction / information; Local as
well as Remote configuration facility, including On-Line removal facility for RADAR LT
SA350 Gr LF2 Cl 1
SS316
SS with Weather-proof Hood

Spiral Wound SS 304 Graphite filled
with SS Centre Ring
SS316 / By tank vendor

SS316
SA 320 Gr L7 / SA194 Gr 4
PTFE
SS316
Required
Note-1
YES, DIGITAL, Loop powered with mounting accessories + SS Plugs
43 ISOLATION BALL VALVE
YES, 316 SS Wetted metal parts, Glass filled PTFE sealing and packings with hand
lever, Open & Close Indication
44 Cable Gland Type
1/2", SS 316 , Double Compression (Flame Proof)
45 Interconnecting Cable
Interconnecting Cable length between Transmitter and Local Indicator shall be

Vendor's scope. Vendor to specify length.
yes
46 Overfill Protection

VENDOR OFFER
W & M approval, CMRI / CCOE approved (CENELEC, YES

47 IS - 2148), SIL2 Certified, OISD
48
49 Model
Serial Number
By supplier
PURCHASE
50 Purchase Order Number
51 Price
Item No.
1. VENDOR TO SPECIFY.
Notes:
2.Tank drawing EM-163-PNMV-DD45-W-101/102/103/104 is attached for your reference.
3. Separate Local Indicator shall be provided one at grade and one on top of Mound Local Level Indication to show Pressure/Temperature also.
CERTIFICATION
4. Documentation shall include sets of installation , operation & maintenance manuals , wiring diagrams , authority approvals , certificates &
manufacturers test and guarantee certificates.
5. RADAR indicator shall have scale graduations in mm.
6. Vendor scope includes configuration of tanks data, calculations, supervision of Erection, Wiring, as well as Testing and Commissioning of whole system .
7. Vendor to confirm Nozzle Size/ Still Well Size.
8.
Vendor
package.
8 V
d tto provide
id complete
l t software
ft
k
9. Vendor to provide system Architecture, still well design drawings, typical arrangement drawing, etc along with the offer.
10. The Radar Type Level Transmitter shall be competable for hooking up with existing TFMS System (Emerson / Honeywell).
11. Multipoint Temperature Assembly along with necessary temperature interface shall be considered along with radar type level transmitter (TFMS).
12. Bidder to coordinate with NRMT TFMS vendor (Emerson/Honeywell ) for installation,commissioning & hook up of Radar Type Level Transmitter in NRMT
TFMS in all respects including license, software etc if required without any extra cost.
13. Bidder to coordinate with vendor supplying Radar Type Level Transmitter for installation & commissioning & hook up of level instruments without any extra
cost.
14 Pressure Temperature Compensation is required for the Radar Transmitter .Vendor to provide slots accordingly.
1
0
P
No.
AK
AK
AK
Prepared By
RA
RA
RA
Checked By
SKT
SKT
SKT
Approved By
24.09.2015
14.09.2015
21.07.2015
DATE
DRAFT ENQUIRY
Purpose
SPARE LIST FOR RADAR TYPE LT
EM163-7147-SP-7288
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 years Operation spares
EM163-7147-BOQ-7288
Bill of Quantity For RADAR

TYPE Level Transmitter
Sl
No
Rev 1 / 24.09.2015
Model No / Part No
<-------By Vendor----->
Radar Type Level transmitter
1
1
1
1
Item
Item Description
1
2
3
4
Main Transmitter
Main Transmitter
Main Transmitter
Main Transmitter
45-LT-3001
45-LT-3004
45-LT-3007
45-LT-3010
Commissioning Spares
Recommended by the vendor
Spare for 2 Years

Page 1 of 1
Qty
ES-7323
DOCUMENT NO.
REV
SHEET
1 OF 8

TEMPERATURE ELEMENT & THERMOWELL
20.07.2015
04.02.99
REV
DATE
HK
RA
SKT
ISSUED FOR IMPLEMENTATION
DDCPN
CISC
DHPV
PURPOSE
PREPARED
REVIEWED
APPROVED

ES-7323
DOCUMENT NO.
REV
SHEET 2
OF
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
INSPECTION, FACTORY TESTS

AND APPROVAL
PACKING
5.0
IDENTIFICATION & MARKING
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

ES-7323
DOCUMENT NO.
REV
SHEET 3
OF
1.00
General
1.01

herewith define the technical requirement for the supply of temperature elements,
thermowells, name plate marking, documentation, testing-inspection and packing.
1.02

specification the later shall prevail.
2.00
General Requirements
2.01
Thermocouple
2.01.01 The thermoelements or sensors shall be MgO packed metal sheathed mineral
insulated thermocouples whose thermoelectric properties and limits of errors for all
temperature elements shall conform to ASME MC 96.1 or IEC584.
2.01.02 The construction of the hot junction of thermocouples from mineral insulated cables
shall be made by welding the wire ends in inert dry atmosphere. The hot junction
shall be capped with same material of that of the sheath and insulation, taking all
precautions against ingress of gas/moisture inside the cap. The cap shall be leak
tested for water /moisture.
2.01.03 Unless specified otherwise in the Instrument specification Duplex element shall be
used as a standard.
2.01.04 Hot junction type shall be ungrounded type unless otherwise specified in the
instrument data sheet.
2.01.05 Time constant i.e. 90% change in temperature span without well for elements shall
be 3.5 seconds for ungrounded junctions. The same shall be < 1.0 seconds for
grounded thermocouples.
2.01.06 Inaccuracies due to drift in readings shall be 1C/ year.
2.01.07 Insulation material shall be high purity ( 99%) compressed Magnesium Oxide of
resistivity 1012 ohms /cm at 538C.
2.01.08 Nominal wire diameter shall be 0.19 x sheath O.D. in mm.
2.01.09 In case of high temperature areas MI thermocouples shall be brought to operating
level at ambient temperature before terminating into a junction box.
2.02
Resistance Temperature Detector (RTD)
2.02.01 The Resistance Temperature Detector characteristics shall conform to DIN 43760/
IEC 751 standards.
2.02.02 The Resistance detector element shall be three wire type in general, if not otherwise
specified in the instrument specification sheet.
2.02.03 The RTD element shall be encapsulated in impervious ceramic or glass bulb.
2.02.04 Platinum resistance element of resistance valve 100 ohms at 0C shall be used in
general, if not otherwise specified in instrument specification sheet.

ES-7323
DOCUMENT NO.
REV
SHEET 4
OF
2.02.05 The lead wires shall be Copper conductors with MI cable. Sheath material of MI cable
shall be 316 SS, if not otherwise specified in the instrument specification sheet. Silver
leads of 16 AWG shall be used if wires are specified as individually insulated through
bead insulators and in addition MgO powder packed in the instrument specification
sheet.
2.02.06 Clause numbers 2.01.04 and 2.01.08 for thermocouple are also applicable for RTD.
2.03
Thermoelements for skin temperature measurements
2.03.01 Wherever temperature elements for skin temperature measurement have been
specified in the instrument specification sheets, clause number 2.01 and 2.02 shall
be applicable except for shape, size and pad design. Such details shall normally be
given in the scope drawings indicated against each item and vendor shall prepare
final drawings on the basis of the same. If scope drawings are not available the
vendor shall prepare the same and submit for approval.
2.04
The scope as per enclosed instrument specification sheets may include either
Thermocouple or Resistance Temperature Detector(RTD) or skin temperature
elements or combination of any. Relevant portion of the general requirement (item
2.01 to 2.03) shall be applicable for the items covered in the instrument specification
sheets.
2.05
Head & Cover
2.05.01 Thermocouple/ RTD terminal head shall be of aluminium alloy epoxy painted.
2.05.02 The head cover shall be screwed type with SS chain and SS screws.
2.05.03 Insulation blocks shall be ceramic (Al2O3 56%-60%) or stelite (mag.silicate6.5%)
suitable for temperature 240C.
2.05.04 Terminal screw material shall be nickel plated brass/copper.
2.05.05 Thermo element head in hazardous areas if specified ex.proof / flame proof against
each item in the individual specification sheets then the same shall conform to
CENELEC or FM or BASEEFA or IS. IS - 2148 certification must be supplemented with
the temperature classification certification confirming to IS - 8239. However, any
ex.proof/flame proof certification requiring sealing of cable entry with sealing
compound or enclosures with sealed cable entry and flying leads are not acceptable.
2.06
Thermowell
2.06.01 Thermowells can either be flanged or screwed type as specified in the instrument
specification sheet.
2.06.02 The screwed type thermowell shall have 1 NPT (M) process connection & NPT(F)
for sensor connection.
2.06.03 The flanged thermocouple shall be 1 or as specified in the instrument specification
sheet.
2.06.04 Thermowells of length 600 mm and below shall be fabricated from bar stock. Above
600 mm length bar stock-bar stock combination and bar stock-pipe combination may
be used. All weld joints shall be radiographed.

ES-7323
DOCUMENT NO.
REV
SHEET 5
OF
2.06.05 The thermowell design shall be as per sketches mentioned against each item in the
instrument specification sheets.
2.07
Temperature element assemblies with spring loaded elements shall be used to

ensure positive contact between sheath tip and well bottom for minimum lag.
Corrosion resistant steel spring shall be isolated from terminals electrically to avoid
grounding.
2.08
Vendor shall submit thermo element assembly drawings developed at their end on
the basis of the drawings indicated against each tag in the instrument specification
sheets. If scope drawings are not available the vendor shall prepare the same and
submit to the Indentor for approval.
2.09
For steam, BFW & condensate services the thermowell shall be IBR certified. For items
of foreign origin the certification shall be done by Lloyds or any other IBR approved
authorities in specific IBR formats.
2.10
For corrosive services like UREA, wetted parts of stainless steel 316L grade and CrNi-Mo 25-22-2 alloy shall be used. For these materials chemical analysis and
corrosion tests (Huey test) shall be carried out as per ASTM A 262 practice C if
Huey test is specified in the instrument specification. The tests shall be carried out in
an approved laboratory.
2.11
Wherever NACE certificate requirement has been specified in Instrument specification,

the material composition & hardness tests shall be conducted only as per MR-0175 latest
edition. The tests shall be carried out in an approved laboratory.
2.12
Wherever temperatures Transmitters are specified in the individual specification sheets

the same shall be either loop powered or separately powered as per requirement
specified in the individual specification sheets. The transmitters shall have local digital
indication for the temperature range specified in each case.
2.13
Components made of copper and copper alloys exposed to atmosphere and coming in
contact with the operating fluid must not be used for ammonia & urea services.
2.14
Temperature Transmitters and local indicators in hazardous areas shall either be exproof or intrinsic safe conforming to area classification & execution specified against
each item in the individual specification sheets.
Ex-proof certification conforming to CENELEC,FM, BASEEFA and IS is preferred. IS 2148 certification must be supplemented with the temperature classification
certification confirming to IS - 8239. Intrinsic safe certification shall in general conform
to CENELEC standard EN 500014 and EN 50020, if not otherwise specified in the
individual specification sheet.
3.00
Inspection, Factory tests and approval
3.01
carrying out Inspection and test. In absence of any Inspection Agency the vendor
must submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in
such cases, shall be conducted by vendors Quality Department and the results of
tests shall be forwarded alongwith the supply.

ES-7323
DOCUMENT NO.
REV
SHEET 6
OF
The manufacturer shall give clear 15 days notice informing readiness of the instrument
at manufacturers works. The vendor shall permit the authorised representative of
PDIL/OWNER to inspect the manufacture and assembly of the temperature element
in various phases in compliance with mutually agreed quality assurance plan,
standards and specifications.
The vendor shall make available to the authorised representative of PDIL / OWNER
the results of all the checks/calibrations conducted before presenting for
PDIL/Owners inspection. Vendor to provide all the necessary facilities free of cost to
PDIL/Owners representative for carrying out the checks/calibration as per
standard/approved quality assurance plan. Under no condition inspection can be
waived off without the written permission of PDIL.
3.02
No temperature element and its accessories shall be shipped until all the required
tests are successfully completed and certified Cleared for despatch by the
inspection authority.
3.03
The procedure & extent of the following physical checks, routine tests shall be
governed by Quality Assurance Plan mutually agreed and approved by Inspection
Authority. The test procedures shall be in line with IEC 584, ASME - 220 / 230 / 230.
THERMOELEMENTS
A. Physical checks :
Visual inspection including dimensional check
B. Routine test
1. Insulation resistance
2. Check of seal
3. Nitrogen leak test for thermocouple inset (For MI sensors only)
4. Check of calibration & tolerance.
THERMOWELL
A. Routine inspection & test
1. Physical dimension checking
2. Pressure test
B. Other tests
1. Radiography for bore concentricity ( 10 % ), if not otherwise specified in the
individual specification sheets.
2. Radiography for thermowells of pressure rating 100 kg/cm2 g and above ( 100 % )
3. IBR (wherever applicable)
4. Huey Test (wherever applicable)
5. NACE (wherever applicable)

4.00
ES-7323
DOCUMENT NO.
REV
SHEET 7
OF
Packing
Each temperature element or alongwith assembly shall be suitably packed and
protected from damage due to transportation, loading and unloading.
The above items alongwith spares (commissioning spares and 2 years spares for
maintenance) shall be despatched as a single consignment.
5.00
5.01
instrument.
Each temperature element assembly i.e. the sensing element alongwith head
assembly shall have a separate circular tag number plate in stainless steel with
engraved tag no and protecting sheath immersion length I and attached securely to
the head assembly with a soft stainless wire. The size of letters and figures shall be
minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm thick.
5.02
Each thermowell shall have the following marking at position X or XX as shown in

the respective drawings.
(i) Tag no.
(ii) Thermowell model no. / manufacturers item no.
(iii) Material of construction
(iv) Immersion length
(v) Flange size / rating / facing / material
6.00
Spares
Complete thermoelement assembly of each type & range is included as spares in the
individual instrument specification sheets alongwith the main items.
However spare bare elements shall be as per enclosed spares list.

7.00
ES-7323
DOCUMENT NO.
REV
SHEET 8
OF
Documentation
alongwith bid, after placement of order for approval purposes and final documentation
before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
(A)
DESCRIPTION OF
DOCUMENT
ALONG
WITH BID
Consolidated list of drawing &

documents supplied by vendor.
temperature element & thermowell
alongwith their accessories.
Deviation if any, from the technical spec.
giving justification for the same.
against each tag showing material of
construction of each part.
Chemical analysis and material test
certificates from approved laboratory.
IBR certificate (wherever applicable)
NACE certificate (wherever applicable)
from approved laboratory.
Certificates showing chemical analysis,
corrosion test (Huey test), Ferrite
content on finished product, where
applicable from approved laboratory.
Certificates from recognised authority
wherever applicable for a) degree of
protection against environment.
b) ex. proof head, if applicable
c) ex.proof/Intrinsic safety for transmitter
Radiography films for thermowell where
ever applicable
Radiography films for bore concentricity
where ever applicable
Instruction Manual for maintenance.
certificates.
Quality Assurance Plan
for Approval
(I)
Yes
AFTER PLACEMENT OF ORDER

FINAL
FOR
DOCUMENTS
APPROVAL/
INFORMATION BEFORE
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes (I)
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
Yes
Yes
Yes(A)
(within 2 weeks)
for information.
Sl. no. 1 to 11 shall be forwarded to PDIL / OWNER as per details outlined in enquiry / order.
Sl. no. 12 shall be mutually finalised with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied
as stipulated in the purchase order.
EM163-7161-ISP7323
MULTIPOINT TEMPERATURE ELEMENT (RTD) WITH

THERMOWELL
DOCUMENT NO.
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
ORDER NO.
MANUFACTURER
:
:
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7161
1
2
3
4
5
6
ELEMENT
HEAD
HEAD EXTENSION
THERMOWELL
CERTIFICATION
PURCHASE
P&ID
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1
0
Tolerance Class
Wire Size
Element Configuration (Single/Duplex)
Sheath O.D / Material
Enclosure Class
Cable Entry Size
Blind Plug & Chain
Qty
45-TE-3005
P1 / 45-VV101
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3006
P1 / 45-VV102
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3007
45-TE-3008
Note:
P1 / 45-VV103
P1 / 45-VV104
Equaly distributed points (Last point placed approx. 50 mm

from the bottom of still well
CLASS A (IEC 751)
20 AWG
DUPLEX
Note 1 / Flexible Sheath ,SS316
Magnesium Oxide (Mineral Insulated)
Head Mount
Die Cast Aluminium with Epoxy coating
Zone 1 IIA IIB, T3 as per IEC
Ex ia
Weatherproof IP 66 or better
YES
1/2" NPT (F)
YES
YES with SS Chain
Note 1
Note 1
SS316
Note 1
Tapered
Single Bar Stock
RF/ 125~250 AARH
Note 1
Extension Type
Nipple Size
Extension Material
Extension Length (N)
Type (Tapered, Straight, Step down)
Construction
Flange Facing/Flange Face Finish
Instrument Connection Size
IBR
NACE
H2 SERVICE
PWHT
CCOE,BASEEFA,CENELAC
YES
Manufacturer
Model
Thermowell
Pressure
Temperature (deg C)
(Kg/cm2g)
Insertio
Process
Fluid
Lagging Ext
Element
n
Connectio
Length
Length
Length
Min Nor Max
Min
Nor
Max
n
'U'
Tag No
Line No./
Vessel No
24.09.15 ENQUIRY ISSUED

HK
RA
SKT
14.09.15 ENQUIRY ISSUED
HK
RA
SKT
21.07.15 DRAFT ENQUIRY
HK
RA
SKT VENDOR OFFER /
PURPOSE
DATE
PREP CHKD APPD
DEVIATION
Three wire
P
REV
RTD
PT-100
100 ohm at 0 deg C
NOTE 2
Approximately 500mm from base of mounting flange
Type
Configuration
Element Material
Resistance
Measuring Junction
Measuring Range
First Measurement Point Location
Measurement Point Distribution
Insulation Material
Type
Material
Area Classification
Ex. Protection
Ex. Approval/Certification
Spring Loaded
Terminal Block
SHEET 1 OF 1
TW/ Flange
Material
IBR
SS 316
SS 316
Note 2
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
1)Vendortospecify
2)Vendortospecify(I.D.7000mm+THK42mm+MoundHeight&NozzleHeight)
3)MultipointtemperatureelementshallcovertheentireBulletheight.Nos.ofelementsshallbesuchthatthespacingbetween2elements
doesntexceed1meterasperASTMD1066.
4)Multipointtemperatureelementwiththermowellshallbesuppliedascompleteassembly.
5) ThevesseldrawingforLPGMoundedbulletsisattchedforreference.Vendortospecifyanyspecialsupportrequired,ifany.
VENDOR'S
OFFER/
DEVIATION
SPARES LIST FOR

MULTIPOINT TEMPERATURE
ELEMENT (RTD)
EM163-7161-SP- 00
DOCUMENT NO
SHEET 1 OF 1
Please refer attached Bill of Quantity at EM163-7161-BOQ for spare details
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years Operation spares
FORM NO: 02-0000-0021F1 REV2
All rights reserved
EM163-7161-BOQ
Rev 1, 24.09.2015
Bill of Quantity
Sl
ITEM
TAG NO.
Qty
Model No / Part No
<-------By Vendor----->
No
MULTIPONT TEMPERATURE ELEMENT (RTD) WITH THERMOWELL

1
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
45-TE-3005
45-TE-3006
45-TE-3007
45-TE-3008
20% Spares for each Model & Range

2 Years Operation Spares
20% Spares for each Model & Range
Page 1 of 1
ES7328
DOCUMENT NO
SHEET 1 OF 7
FOR
TEMPERATURE TRANSMITTERS
00 20.07.2015
REV REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
All rights reserved
ES7328
DOCUMENT NO
SHEE 2 OF 7
CONTENTS
SECTION NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
All rights reserved
ES7328
DOCUMENT NO
SHEE 3 OF 7
1.00
General
1.01

herewith define the technical requirement for the supply of Temperature Transmitters, their
accessories, name plate marking, documentation, testing-inspection and packing.
1.02

specification, the later shall prevail.
2.00
2.01
Temperature transmitter shall have universal input for thermocouple / RTD and output
4-20mA for 2 wire system.
2.02
For all applications, the transmitter shall be supplied with smart electronics. The feature of
smart electronics shall include selectable analog/digital output mode, remote re-ranging,
self checking, diagnostics and configuration from hand held configurator or remote HART
maintenance system. The transmitter must have provision for upgrading the communication
protocol to Foundation fieldbus in future.
2.03
The transmitter shall have protection against reverse polarity connection.
2.04
The transmitter shall be unaffected due to radio frequency interference. The supplied
electronic part shall have susceptibility of less than 0.5% of span for a frequency range of
20-500 MHZ in field strength of 20 volts/meter.
2.05
Cable entries shall be plugged during transit to avoid damage.
2.06
Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature
transmitters.
2.07
Mounting accessories shall be suitable for 2 inch NB vertical pipe.
2.08
Digital output gauge shall be integral with electrical housing but there shall be partition
between electronics & output meter.
2.09
The electrical terminals shall be vibration proof. The transmitter terminals shall preferably
be located in a compartment separated from field electronics. Flying leads are not
acceptable.
2.10
Transmitters in hazardous areas shall either be ex-proof/flame proof or intrinsic safe

conforming to area classification, execution and execution standard specified against
each item in the individual specification sheets. Indian Standard (IS) certification IS 2148
for Ex-proof certification must be supplemented with the temperature classification
certification conforming to IS - 8239. Intrinsic safe certification shall conform to CENELEC
standard EN 50014 and EN 50020 if otherwise not specified in the individual specification
sheets.
2.11
3.00
3.01
Agency specified in the order and finalize with them the Quality Assurance Plan for
carrying out Inspection and test. In absence of any Inspection Agency the vendor must
submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in such cases,
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7328
DOCUMENT NO
SHEE 4 OF 7
shall be conducted by vendors Quality Department and the results of tests shall be
forwarded alongwith the supply.
at manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the instrument in various
phases in compliance with mutually agreed quality assurance plan, standards and
specifications.
The vendor shall make available to the authorized representative of PDIL / OWNER the
results of all the checks/calibrations conducted before presenting for PDIL/Owners
inspection. The vendor to provide all necessary facilities free of cost to PDIL/Owners
permission of PDIL.
3.02
completed and certified Cleared for dispatch by the inspection authority.
3.03
The following physical checks, routine tests, shall be in line with ISA S 55.1 The
procedure & extent of test shall be governed by Quality Assurance Plan mutually agreed
and approved by Inspection Authority.
A. Physical Checks
- Tag no.
- Model no.
- Range
B.
Routine Tests
1. Calibration check for Linearity, Accuracy, Hysteresis, Repeatability
2. Zero-shift
4.00
Packing
Each transmitter and its accessories shall be suitably packed and protected from damage due
to transportation, loading and unloading.
The transmitter and their accessories alongwith spares (commissioning spares and 2 years
spares for maintenance) shall be dispatched as a single consignment. Commissioning and 2
years operation spares shall be packed separately.
5.00
5.01
Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02
All instruments shall have a tag plate in SS screwed to the transmitter case indicating make,
model no., sl. no. tag no., adjustable range, set range etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved tag
number and calibration range and attached securely to the instrument with a soft stainless
wire. The size of letters and figures shall be minimum 4 mm and the plate should be 25 mm
diameter with 1-2 mm thick.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7328
5.03
DOCUMENT NO
SHEE 5 OF 7
All spare parts to be supplied alongwith the main consignment shall be fitted with identification
plate with the following data clearly printed and easily readable.
- Spare parts name, model number as per purchasers Instrument specification sheet.
- Serial no.
6.00
Spares
Complete untagged transmitter of each type & range is included as spare in the specification
sheet. In addition component spares shall be supplied as per enclosed spares list.
7.0
Documentation
Technical documentation
1.1
General
All the documentation such as graphic drawings and technical specifications shall be sent
to the Contractor who will reserve to approve it within 15 days; after this period, the
documents have to be retained approved.
The Contractor's approval will not relieve the Vendor of his responsibility for the final
performance of the supply.
Final issue of Project Documents shall be supplied in electronic format as specified
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be supplied
on paper.
1.2
Title block and heading

Each document originated by the Vendor shall be numbered according to Vendor
procedure.
1.3
Specification, Data Sheet and other documents.

All shall be produced with Microsoft Office products as Word, Excel or PowerPoint
access.
The files shall be delivered in a workable stand-alone format, without any special
features (links to other files, special fonts, macros, etc.), which may affect the
possibility of viewing and editing.
1.4
Drawings
Drawings will be made using AutoCAD version 12 or 14 or Latest.
Vendors are permitted to utilise other CAD software, but the produced files are to be
converted in AutoCAD format prior the delivery to Contractor.
Drawings files shall be delivered as single complete file, without any reference
attached, except when not practicable due to the dimension of referenced files. In this
case together with the reference files also the information necessary to manage the files
shall be given.
Together with the drawings files also the relevant files for plotting format HPGL or
HPGL2 are to be delivered.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7328
1.5
DOCUMENT NO
SHEE 6 OF 7
Scanned documents
The format of scanned documents shall be CCITT Group IV TIFF or Adobe PDF
Acrobat.
Quality control on file of scanned documents will be completed prior to delivery,
including:
Deskew
Despeckle
Hole Fill.
Resolution below 200 Dpi is not acceptable.
The following documents (Technical) are required to be submitted by the vendor along with bid, after
placement of order for approval purposes and final documentation before dispatch of consignment.
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

FOR APPROVAL/ FINAL
INFORMATION
DOCUMENTS
WITHIN SIX
BEFORE
WEEKS
DESPATCH OF
CONSIGNMENT
Yes (I)
Yes
1.

documents.
Yes
2.
Catalogue & technical literature

of Temperature transmitter
along with their accessories.
Yes
Yes
3.
Deviation if any, from the

technical spec. giving
justification for the same.
Yes
4.

test certificates from approved
laboratory.
Yes
5.
Certificates from recognized

protection against environment
(b) for Intrinsic safety/ Ex-proof
execution.
Yes
Yes
6.

maintenance.
Yes
7.
Calibration and performance

test certificates.
Yes
8.
Yes
Yes(A)
(within 2 weeks)
(A)
For Approval
FORM NO: 02-0000-0021F2 REV1
(I)
For information.
All rights reserved
ES7328
DOCUMENT NO
SHEE 7 OF 7
Sl. No. 1 to 7 shall be forwarded to PDIL/ OWNER as per details outlined in Enquiry/ order.
Sl. No. 8 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets along with bid for approval and as final documentation shall be supplied as stipulated in
the purchase order.
8.0
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to the
equipment proposed.
Technical information
The equipment offered as a basis shall be of standard production type it shall be based on modern
technology, be of a proven and referenced type and designed for continuous operation under the
specified operating conditions.
The Bidder shall quote for the materials requested according to the requirements of this
specification and of the individual job specifications. With bid shall be supplied the technical
documentation.
Deviations
The tender shall be in strict accordance with Purchaser's specifications.
However, the Vendor may quote, in addition and as an alternative, different materials from
those required in the specifications, provided these materials are suitable for the process
conditions specified in the individual job specifications.
Any deviation from the requirements listed in the general specification and in the individual job
specifications shall be clearly highlighted.
If no exceptions are listed, the tender - and the possible supply - shall be regarded as being in
full conformity with the Purchaser's requirements, and will be accepted after the tests and
checks have confirmed that the performance complies with the requirements of the tender
documents and order specifications.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM163-7162-ISP-7328
DOCUMENT NO.
FOR AVERAGING TEMPERATURE TRANSMITTER

PROJECT NO. :
PROJECT
:
EM163
PLANT
CUSTOMER
REQ. NO.
:
:
:
NUMALIGARH, ASSAM
NRL
EM163-E-7162
ORDER NO.
24.09.15
HK
RA
SKT
14.09.15
HK
RA
SKT
MANUFACTURE:
REV
21.07.15
DRAFT ENQUIRY
DATE
PURPOSE
HK
RA
PREP CHKD
SKT
APPD
1.
FUNCTION
2.
3.
4
5
TYPE
COMMUNICATION
SMART WITH LATEST HART PROTOCOL
POWER SUPPLY
POWER SUPPLY EFFECT
TRANSMITTER OUTPUT
12.5-30V DC, 2 WIRE LOOP POWERED

+/- 0.005% OF CALIBRATION SPAN PER VOLT
4-20 mA DC + HART/ DIGITAL
LOAD RESISTANCE
600 OHMS FOR DIGITAL COMM. AND 1250 OHMS FOR ANALOG OPERATION
8
9
INTEGRAL DIGITAL OUTPUT INDICATOR

ZERO & SPAN ADJUSTMENT
YES ,LCD DISPLAY, LINEAR SCALE, CONFIGURABLE IN ENGG. UNITS
UNIVERSAL PROGRAMMABLE FIELD MOUNTABLE TYPE SUITABLE

TO ACCEPT ALL TYPE OF T/C & RTD INPUTS 3 WIRE
CONTINOUSLY ADJUSTABLE FROM HAND HELD CONFIGURATOR OR PC

+/ - 0.075 % OF CALIBRATED SPAN OR BETTER (INCLUDING LINERARITY ,
HYSTERESIS AND REPEATABILITY)
10 ACCURACY
11 COLD JN. ACCURACY
12 UPDATE TIME
13 ISOLATION
+/- 0.5 deg C FOR T/C

0.5 secs adjustable in various steps of time constants
INPUT/OUTPUT/GND 500 V AC. MIN
14
15
16
17
18
19
20
21
22
AUTOMATC SWTCH OVER TO SENSOR 2

1/2" NPT (F) WITH SS/ALUMINIUM PLUG
ON 2" NB VERTICAL PIPE MOUTING WITH CLAMPS
0-95 % RH
UPTO 85 C
+/- 0..075 % OF UPPER RANGE LIMIT FOR 6 MONTHS
23
24
25
26
27
28
29
SENSOR BACKUP FN
ELECTRICAL CONNECTION
MOUNTING
HUMIDITY
AMB. TEMP. LIMIT
STABILITY
BURNOUT FEATURE
USER SELECTABLE FOR HIGH OR LOW
ENVIRONMENTAL PROTECTION CLASS

AREA CLASSIFICATION
IP-67 OR BETTER
EXECUTION
SELF TEST/ DIAGNOSIS
ELECTRICAL HOUSING
TRANSMITTER BODY MATL
LIGHTENING PROTECTION
BODY TRANSMITTER BOLTS/NUTS/SCREW MATL.
ACCESSORIES
(A) JUNCTION BOX
(B) MOUNTING ACCESSORIES
(C) CABLE GLAND
TEMP deg C
TAG NO.
QTY.
PID
NO.
VENDOR's OFFER / DEVITION
AVERAGING TEMPERATURE MEASUREMENT & TRANSMISSION
MIN
NOR
MAX
Ex-Proof & Intrinsically Safe to Hazardous Area Zone-1, Gr. IIA IIB, T3 as per IEC
EEx-ia
FEATURES SHALL BE INBUILT OF TRANSMITTERS
Matl.-Al.Alloy Protecting Paint-Epoxy Polyster as standard
SS 316
YES
YES ( SS 316 ) IF ANY
YES ( 2" NB VERTICAL PIPE MOUNTING WITH SS CLAMP & SS NUT BOLT)
2 Nos. 1/2" NPT SS 316, DOUBLE COMPRESSION TYPE, Ex- Proof
PRESSURE
RANGE
MIN/ MAX
(Design)
deg C
MODEL
NUMBER
Kg/cm g
UL/CALIB.
45-TT-3005
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3006
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3007
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3008
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
VENDOR'S OFFER/DEVIATION
NOTES :
1.
Vendor to specify
2.
For Sensor Details refer Doc No 1063-E-7061A-ISP-7323.
3.
Multipoint Temperature assembly along with necessary temperature interface shall be considered along with RADAR TRANSMITTER (TFMS) and non-TFMS Radar.
EM163-7162-SP-00
SPARES LIST FOR
DOCUMENT NO
SHEET 1 OF 1
NOTE :
FORM NO: 02-0000-0021F1 REV2
All rights reserved
Bill of Quantity For

Temperature Transmitter
Sl
Item
Item Description
EM163-7162-BOQ
REV 1 / 24.09.2015
Qty
1
Temp. Transmitter
45-TT-3005
2
3
4
Temp. Transmitter
Temp. Transmitter
Temp. Transmitter
45-TT-3006
45-TT-3007
45-TT-3008
1
1
1
Vendor to quote spares on propotionate basis so each
range and model covers the 20% spare for all main
transmitter. Vendor to give the quantity of each model
and range quoted as spare.
Model No / Part No
<-------By Vendor----->
No
Spare for 2 Years

range and model covers the 20% spare for all main
transmitter. Vendor to give the quantity of each model
and range quoted as spare.
Page 1 of 1
EM163-E-7052
DOCUMENT NO
SHEET 1 OF 3
FOR
SERVO TYPE LEVEL TRANSMITTER
WITH
MULTIPOINT TEMPERATURE ELEMENT
&
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24/09/2015
14/09/2015
21.07.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7052
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7052
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
S
NO
1
2
4
5
6
7
10
11
12
13
14
15
DRAWINGS/
DOCUMENTS.DESCRIPTION
GENERAL
CONDITIONS
FOR
INSTRUMENTS
ENGINEERING
SPECIFICATIONS
FOR LEVEL TRANSMITTER (SERVO
TYPE)
LEVEL
TRANSMITTER
(SERVO
TYPE)
SPARES FOR LEVEL TRANSMITTER
(SERVO TYPE)
BILL OF QUANTITY FOR
LEVEL
TRANSMITTER (SERVO TYPE)
VESSEL DRAWING
ENGINEERING
SPECIFICATIONS
FOR MULTIPOINT TEMPERATURE
MULTIPOINT
TEMPERATURE
SPARE LIST FOR
MULTIPOINT
WITH TW
SKETCH FOR FOR MULTIPOINT
WITH TW
ENGINEERING SPECIFICATIONS
FOR TEMPERATURE TRANSMITTER
SPARE LIST FOR TEMPERATURE
TRANSMITTER
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO. /
DOCUMENT NO
EM163-45-102
NO
OF
PAGES
01
ES-7289
08
EM163-7052-ISP7289
02
EM163-7052-SP-7289
01
EM163-7052-BOQ-7289
01
EM163-PNMV-DD45-W101/102/103/104
01
ES-7323
08
EM163-7061-ISP-7323
01
EM163-7061-SP-00
01
EM163-7061- BOQ
01
EM163-SK-7323-00
01
ES-7328
07
EM163-7062-ISP-7328
01
EM163-7062-SP-00
01
EM163-7062- BOQ
01
All rights reserved
EM163-E-7052
DOCUMENT NO
SHEET 3 OF 3
LIST OF SERVO TYPE LEVEL TRANSMITTER
SL.
NO.
1
TAG NO.
45-LT-3003
45-TE-3001
45-TT-3001
45-LT-3006
45-TE-3002
45-TT-3002
45-LT-3009
45-TE-3003
45-TT-3003
45-LT-3012
45-TE-3004
45-TT-3004
FORM NO: 02-0000-0021F2 REV1
P & ID
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
QTY
01
01
01
01
01
01
01
01
01
01
01
01
All rights reserved
EM163-45- 102
Document No.
Sheet 1 of 1
Rev.
GENERALCONDITIONS
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %

Air temperature
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
Maximum in one hour
90 mm
Wind
Wind code
Base wind pressure
Seismic Factor
Elevation
Average wind speed
36 km/hr
10
Maximum gust speed
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
For Enquire Issue
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
PROJECTS & DEVELOPMENT INDIA
ES- 7289
DOCUMENT NO.
REV.
SHEET 1 OF 9
FOR
SERVO GAUGES
14-03-06
REV
REV
DATE
Issued for Enquiry

EFF
DATE
FORM NO: 02-0000-0021F2 REV1
PURPOSE
03 ES-7289
DDCPN
PREPD
CISC
DHPV
REVWD
APPD
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
2.0
GENERAL
3.0
INSPECTION , FACTORY TESTS AND APPROVAL
4.0
PACKING
5.0
IDENTIFICATION AND MARKING
6.0
7.0
SPARES
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
03 ES-7289
NUMBER OF SHEETS
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 3 OF 9
1.00.00
General :
1.00.01
This general specification is applicable for the displacer servo gauges of top vessel
mounted type.
1.00.02
Float type with Capacitance sensor NOT to be used due to static discharge
problems associated with many fluids.
1.00.03

herewith define the requirement for the supply of Displacer type servo gauges, its
spares, documentation and testing.
1.00.04

2.00.00
2.00.01
Gauges in general shall be of antistatic construction for Liquefied Gases , OIL and
other applications where Static build-up is likely.
2.00.02

better enclosure.
2.00.03
Coastal Climate.
2.00.04
The ambient conditions if not specified otherwise in data sheets shall be min 4
degrees & max 50 degrees Centigrade , Relative Humidity min 10 & , max 95 % .
inst. shall be suitable for such conditions.
2.00.05

Frequency interference from / to nearby electrical apparatus in accordance with EN
50081 , 50082 in industrial environment.
2.00.06
The process connection size shall be min. 4 ASME B16.5 flanged connection if not
2.00.07
2.00.08
serrations.
2.00.09
SS304 with fibre filling for RF flanges . Ring Gaskets if any shall be octagonal Rings
of soft Iron.
2.00.011 Orientation of connection, rating, flange facing and Displacer /
flange
distance shall be as indicated in individual Instrument specification sheets.
2.00.012 The material of construction shall be as per individual Instrument
face
specification
sheets enclosed. As a minimum displacers of SS 304 / 316 are to be provided.
2.00.013 Wires shall be SS , PTFE coated for smooth operation.
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 4 OF 9
2.00.014 Displacer shall be attached to hook with feature that shall prevent displacer from
coming-out during operation.


2.00.017 Components made of copper and copper alloys exposed to atmosphere and
coming in contact with the operating fluid must not be used.

2.00.018 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating 900
lbs. and above.

2.10.00
2.10.01

2.10.02
As a minimum certificate EEx d (e) II A / B T3 is expected. If certificate according to

2.10.03
Similarly for installation in other countries , certificates / endorsement shall be

2.10.04
2.10.05
2.10.06
Cable entries shall be NPTF , for Signal outputs & Power supply cabling.
2.10.07
Cable entry & gland for temperature elements shall be as per vendor standard to suit
the cable from multi-element assembly to servo-gauge.
2.10.08
2.10.09
3.00.00

Operational Principle & main features -
3.00.01
The steel rope attached to the float is guided over a drum located in the transmitter
housing. This motor drives the drum to maintain tension in the rope. The two are
guided by servo mechanism.
3.00.02
Displacer of known weight is also utilised for determining the density of fluid and
interface level.
3.00.03
The gauge shall be microprocessor based with inbuilt software for temperature
compensation for calculation of densities, level ; volume from Vessel /tank strapping
tables; extensive diagnostics to detect faults in the system including snapping of
wire, jamming of wire, etc., and have safeguards to prevent damage to servo
system.
3.00.04
Typical accuracies expected are + 1mm of level ; + 0.05 gm / cc densities and

temperature unless specified otherwise in data sheets.
3.00.05
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 5 OF 9
3.00.06
Indicator at servo gauge casing shall have digital displays for level, calculated
volume , density , Temperature, interface level, etc - in engineering units and
diagnostic messages / alarms.
3.00.07
3.10.00
Outputs :
3.10.00
Following types of outputs are expected : Pulse output ; signal , 4 ~ 20 mA DC

output with HART ; RS 485 Serial output
3.10.02

3.20.00
Remote Indicators :
3.20.01
One additional IP-65 , weatherproof intrinsically safe certified field mounted Remote
indicator for mounting at the grade / ground level included in scope.
3.20.02
3.20.03

3.20.04
Cable entries shall be 2 nos. , NPTF , one for incoming & other for outgoing.
site is completed.
3.30.00
pipes for avoiding displacer swing.
3.30.01
Still well shall be with bottom support to prevent

equipment in case of snapping of wire.
3.30.02
Still wells under equipment fabricator scope ( excluded from Servo gauge vendor
scope ).
Temperature Elements :
Multi Spot Temperature Element Assemblies
4.10.00
4.10.01
displacer falling down into
4.10.01
Unless specified otherwise in data sheets , Servo Gauge vendor scope includes
supply of Multi Spot Temperature measurement Element assembly.
4.10.02
Temperature element assemblies shall be with 2 Flanged ( ASME / ANSI B 16.5 )

process connection. Ratings according to operating conditions. RF flanges shall
have concentric serrations.
4.10.03
Flange material ASTM A-105 for low pressure OIL applications.
4.10.04
Flanges for liquefied gases shall be 316 SS unless specified otherwise in data
sheets.
4.10.05
Normally these shall have their measuring tips at different levels.
4.10.06
Depending upon height of tank / equipment, typically one measurement at middle &
others at identical gaps above & below the centre are selected.
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 6 OF 9
4.10.07
The elements unless specified otherwise shall be ungrounded 3 wire Pt 100 Ohms
at 0 Deg C RTD ( Class B , DIN 43760 ) in 316SS sheath.
4.10.08
The sheathed elements shall be supplied in a common Flanged thermowell in case

of pressurised equipment.
4.10.09
In case of low pressure equipment / tanks, sheathed elements may be strapped tight
so that elements do not come / spring-out while handling / installation. They shall be
installed in Stillwell provided by equipment vendor,
4.20.00
Averaging type Temp. Element Assemblies :
4.20.01
If specified in data sheets , averaging type multi-element assemblies may be

provided.
4.20.02
Such assemblies shall measure the average temperature of the zone ,instead of
spot temperatures.
4.20.03
Except for this difference all other constructional details such as flanges ,
connections, etc., shall be similar to multi spot measurement assemblies.
5.00.00
5.00.01
If specified in data sheets, vendor scope shall include their proven software for Tank
farm management for inventory monitoring.
5.00.02
5.00.03
For this purpose all Servo gauges shall be serially linked & connected to the PC.
Vendors software shall enable access to all data- level, density , temperature,
calculated values such as Volume being filled-in / pumped-out, total hold-up volume,
filled capacity , etc.,
5.00.04
5.00.05
5.00.06
dynamic level indication ( increasing / decreasing, etc.,), all other operational data
5.00.07
6.00.00

The bidder shall furnish test/ inspection certificates & quality assurance plan adopted
by them with the bid. No third party inspection is foreseen
6.00.01 Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
Agency specified in the order and finalise with them the Quality Assurance Plan for carrying out
Inspection and test including tests to be conducted by independent agencies. In absence of any
Inspection Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality Department and the
results of tests shall be forwarded along with the supply.
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 7 OF 9

plan, standards and specifications.
representative for carrying out the checks/calibration as per standard/approved
quality assurance plan. Under no condition inspection can be waived off without the
written permission of PDIL/ OWENER.
No instrument/accessory shall be shipped until all the required tests are
successfully completed and certified Cleared for despatch by the inspection
authority.
6.00.02 The following physical checks, routine tests as a minimum shall be witnessed by
PDIL / owner inspection authority. The procedure & extent of test shall be governed
by Quality Assurance Plan mutually agreed and approved by Inspection Authority.
A. Physical Checks
- Tag no.
- Model no.
- Range
B. Routine tests
2. Zero-shift
3. Hydraulic test.
6.00.03 Other Tests
Vendor shall submit following certificates from a approved laboratory or from
statuary bodies, as applicable.
7.00.00
Packing
Each servo gauges and its accessories shall be suitably packed and protected from
damage due to transportation, loading and unloading.
The servo gauges and their accessories along with spares shall be despatched as a
single consignment. Commissioning and 2 years operation spares shall be packed
separately with proper identification marking.
8.00.00
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 8 OF 9
8.00.01
instrument.
8.00.02
All instruments shall have a tag plate in SS screwed to the servo gauges case
shall be minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm thick.
8.00.03
9.00.00
Spare parts name, model no. as per purchasers Instrument spec. sheet.
Serial no.
10.00.00 Documentation

SL.
NO.
1.
2.
3.
4.
5.
6.
7.

BID
/ Information
before Dispatch of
DESCRIPTION OF
DOCUMENT
sketch diagrams.
same.
laboratory.
execution.
maintenance.
certificates.
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
Yes
Yes
Yes
Yes ( I )
Yes
Yes
Yes
Yes
Yes
Yes
All rights reserved
ES- 7289
DOCUMENT NO.
REV.
SHEET 9 OF 9
8.
( A ) for Approval
Yes
Yes ( A )
within 2 weeks

in Enquiry / order
Sl. No. 8 shall be mutually finalised with Inspection Authority specified in the
order.
Number of sets along with bid for approval and as final documentation shall
be supplied as stipulated in the purchase order.
FORM NO: 02-0000-0021F2 REV1
03 ES-7289
All rights reserved
SERVO TYPE
TANK LEVEL TRANSMITTER
OP. DATA
GENERAL
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
1 TAG NO. /
: EM163
: NUMALIGARH, ASSAM
1 24/09/2015
: NRL
0 14/09/2015
:
P 21/07/2015
:
:
REV
DATE
QTY. / P&I
LT-3003 / 01 No. / P1
MOUNTING NOZZLE
STILL WELL
FLUID
PRESSURE ,Min./Nor./Max./Design Kg/cm2 g
TEMPERATURE Min./Nor. /Max./Design

SPECIFIC GRAVITY
11 VISCOSITY
12 TYPE
TRANSMISSION
AREA
MATERIALS
GENE
ERAL
PROCESS CONNECTION - SIZE ,

13 RATING,FACING
OPTIONAL
DOCUMENT NO.
REV.
COMMENTS INCORP
COMMENTS INCORP
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PRPD
RA
RA
RA
CHKD
SKT
SKT
SKT
APPD
LT-3006 / 01 No. / P1
LT-3009 / 01 No. / P2
LT-3012 / 01 No. / P2
TOTAL = 4 Nos.
LPG / 45-VV-101 / 45-VV-102 / 45-VV-103 /45-VV-104
DISPLACER, SERVO MOTOR
LPG BULLET: I.D. =7000mm TL ~ TL =52000mm HEIGHT: Bullet I.D
(7000mm) +Bullet Thickness(42mm) + Mound height(1000mm)+Dome upto
top of Nozzle (250mm) (Tentative) (Drawing attached)
2 SERVICE / LOCATION
3 PRINCIPLE
4 TANK DETAILS
5
6
7
8
9
10
EM163-7052-ISP-7289
6 ", 300 # RF TOP of Bullet Dome (Note- 8 )

6 " (Tentative) - In Bullet Vendor Scope (Note- 8 )
LPG
- / 2.33-8.6 / 14.5
/ 14.5
- / 10-40 /45
/ -27 to 55
0.5-0.57
0.113-0.152 Cp
SERVO OPERATED - For measuring Level, Interface level, Density,
Volume, Mass, Tank bottom
TOP, Flanged 6" ANSI 300# RF,Serrated face 125AARH
14
15
16
17
MEASURING RANGE
0 - 8292mm (Note-1)
ACCURACY
DISPLAY
OTHER FEATURES
LEVEL : + 1 mm, DENSITY + 0 . 005 gm /cm3

LOCAL - LCD type & Additional Loop powered at grade level
Anti-Static Construction,
Construction Diagnostics,
Diagnostics Maintenance prediction / information;
Local + Remote config. facility with communication Interface Unit
18
19
20
21
COMPENSATION - AUTOMATIC
Wire Expansion, Weight of wire & Displacer, Tank Deformation, Temp.
LIGHTNING PROTECTION
TEMPERATURE INPUTS
DISPLACER DIMENSION / MOVEMENT
YES
Displacer dia. & movement from max. level to min. level shall be within
limits so that displacer do not touch Still Well pipe internals.
22
23
24
25
26
27
28
BODY & WETTED PARTS

ELECTRICAL HOUSING
FLANGE MATERIAL
STUDS / BOLTS / NUTS MATERIAL
GASKET
" O " RINGS
DISPLACER / WIRE
AREA CLASSIFICATION
ENCLOSURE / EXECUTION
CERTIFICATION
TRANSMISSION OUTPUT
SS316
SS with Weather Proof Hood
SA350 Gr LF2 Cl 1
SA320 Gr L7 / SA 194 Gr 4
Spiral Wound SS-304 Graphite filled with SS Centre Ring
Vendor to specify
316 SS with PTFE coating
Zone -1 Gr. II A / II B, Temp. class - T3 as per IS / IEC
Weather proof IP 65/ Flame Proof
EExd (e) II A/B, T3
4 ~ 20 mA, 2 Channels freely assignable ,
Digital Pulse output forLevel and Average Temperature (Note-11)
RS 485 (Twisted Pair), MODBUS RTU,
110 V , 50 Hz ,
29
30
31
32
33 SERIAL LINKS
34 ALARM POINTS - H / L / LL
35 POWER SUPPLY
36 CABLE ENTRIES
37 CALIBRATION CHAMBER
38 ISOLATION BALL VALVE, API 608, 607 &
TESTING AS PER API 598 ( HP CLOSURE)
39
40
41
42
43
Addl. Remote Indicator IP-65 , 2 cable entries

CABLE GLAND TYPE
CABLE GLAND SIZE / MATERIAL
HYDRAULIC TEST PRESSURE Min / Max
CERTIFICATION
03 EM163-7052-ISP-7289
1 / 2 " NPT(F) with SS Plugs - 4 Nos.

YES (Note-1)
YES, 316 SS Wetted metal parts, Glass filled PTFE sealing and packings
with hand lever, Open & Close Indication
Yes, Digital, Loop powered, with mounting accessories + SS Plugs
Flame proof, Double Compression type
1 / 2 ", SS 304
As per process data.Displacers shall be tested at same pressure.
Weights & Measures Authority Approval; Cert. for Ball Valves
CMRI & CCOE approved ( CENELEC / IS-2148 ), SIL Certified, OISD
SHEET
1 OF 2
SERVO TYPE
TANK LEVEL TRANSMITTER
NOTES
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
NUMALIGARH, ASSAM
NRL
1 24/09/2015
0 14/09/2015
P 21/07/2015
DATE
REV
EM163-7052-ISP-7289
DOCUMENT NO.
REV.
COMMENTS INCORP
COMMENTS INCORP
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PRPD
RA
RA
RA
CHKD
SKT
SKT
SKT
APPD
VENDOR TO SPECIFY.
Documentation shall include sets of installation, operation & maintenance manuals, wiring diagrams, authority approvals, certificates & manufacturers test and
guarantee certificates.
Tank drawing EM-163-PNMV-DD45-W-101/102/103/104 is attached for your reference.
Separate Local Indicator shall be provided one at grade and one on top of Mound Local Level Indication to show Temperature also.
RS 485 Communication with Accessories required ie Booster amplifier, Repeaters etc. to be provided as required .
Servo Indicator unit shall have scale graduations in mm .
Interconnecting Cable length between Transmitter and Local Indicator shall be in Vendor's scope.Vendor to specify length.
Vendor to confirm Nozzle Size/ Still Well Size.
Vendor to provide system Architecture, still well design drawings, typical arrangement drawing, etc along with the offer.
10 Vendor scope includes configuration of tanks data, calculations, supervision of Erection, Wiring, as well as Testing and Commissioning of whole system .
11 Servo gauge shall have the provision for connection with TFMS. Howver, it will be connected to PLC (Control System), not TFMS.
12 Bidder to coordinate with vendor supplying Servo Type Level Transmitter for installation & commissioning & hook up of level instruments in PLC without any extra
cost.
13 Multipoint Temperature Assembly along with necessary temperature interface shall be considered with Servo Type Level Transmitter.
14 Pressure Temperature Compensation is required for the Servo Transmitter .Vendor to provide slots accordingly.
03 EM163-7052-ISP-7289
SHEET
2 OF 2
SPARE LIST FOR SERVO LEVEL TRANSMITTER
EM163-7052-SP-7289
DOCUMENT NO.
REV
SHEET
OF
NOTE: The vendor shall also indicate the additional/ applicable 2years Operational spares
EM163-7052-BOQ-7289
Bill of Quantity
Sl
Item
No
1
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
Fuse of each type & rating
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
Inner Electronic Assembly
1 No
1 No
Main Transmitter 45-LT-3006

Commissioning
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No

Commissioning
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
Spare 2 Years
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No

Commissioning
1 No
Spares
Measuring wire
1 No
Displacer SS 316
1 No
1 No
Stepping Motor
1 No
CPU Board
1 No
Interface Board
1 No
1 No
1 No
Spare 2 Years
Model No / Part No
<----------By Vendor---------------------->
Spare 2 Years
3
Qty

Commissioning
Spare 2 Years
Item Description
Rev 1 / 24.09.2015
ES-7323
DOCUMENT NO.
REV
SHEET
1 OF 8

20.07.2015
04.02.99
REV
DATE
HK
RA
SKT
DDCPN
CISC
DHPV
PURPOSE
PREPARED
REVIEWED
APPROVED

ES-7323
DOCUMENT NO.
REV
SHEET 2
OF
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

ES-7323
DOCUMENT NO.
REV
SHEET 3
OF
1.00
General
1.01

herewith define the technical requirement for the supply of temperature elements,
thermowells, name plate marking, documentation, testing-inspection and packing.
1.02

2.00
2.01
Thermocouple
2.01.01 The thermoelements or sensors shall be MgO packed metal sheathed mineral
insulated thermocouples whose thermoelectric properties and limits of errors for all
temperature elements shall conform to ASME MC 96.1 or IEC584.
2.01.02 The construction of the hot junction of thermocouples from mineral insulated cables
shall be made by welding the wire ends in inert dry atmosphere. The hot junction
shall be capped with same material of that of the sheath and insulation, taking all
precautions against ingress of gas/moisture inside the cap. The cap shall be leak
tested for water /moisture.
2.01.03 Unless specified otherwise in the Instrument specification Duplex element shall be
used as a standard.
2.01.04 Hot junction type shall be ungrounded type unless otherwise specified in the
instrument data sheet.
2.01.05 Time constant i.e. 90% change in temperature span without well for elements shall
be 3.5 seconds for ungrounded junctions. The same shall be < 1.0 seconds for
grounded thermocouples.
2.01.06 Inaccuracies due to drift in readings shall be 1C/ year.
2.01.07 Insulation material shall be high purity ( 99%) compressed Magnesium Oxide of
resistivity 1012 ohms /cm at 538C.
2.01.08 Nominal wire diameter shall be 0.19 x sheath O.D. in mm.
2.01.09 In case of high temperature areas MI thermocouples shall be brought to operating
level at ambient temperature before terminating into a junction box.
2.02
Resistance Temperature Detector (RTD)
2.02.01 The Resistance Temperature Detector characteristics shall conform to DIN 43760/
IEC 751 standards.
2.02.02 The Resistance detector element shall be three wire type in general, if not otherwise
specified in the instrument specification sheet.
2.02.03 The RTD element shall be encapsulated in impervious ceramic or glass bulb.
2.02.04 Platinum resistance element of resistance valve 100 ohms at 0C shall be used in
general, if not otherwise specified in instrument specification sheet.

ES-7323
DOCUMENT NO.
REV
SHEET 4
OF
2.02.05 The lead wires shall be Copper conductors with MI cable. Sheath material of MI cable
shall be 316 SS, if not otherwise specified in the instrument specification sheet. Silver
leads of 16 AWG shall be used if wires are specified as individually insulated through
bead insulators and in addition MgO powder packed in the instrument specification
sheet.
2.02.06 Clause numbers 2.01.04 and 2.01.08 for thermocouple are also applicable for RTD.
2.03
Thermoelements for skin temperature measurements
2.03.01 Wherever temperature elements for skin temperature measurement have been
specified in the instrument specification sheets, clause number 2.01 and 2.02 shall
be applicable except for shape, size and pad design. Such details shall normally be
given in the scope drawings indicated against each item and vendor shall prepare
final drawings on the basis of the same. If scope drawings are not available the
vendor shall prepare the same and submit for approval.
2.04
The scope as per enclosed instrument specification sheets may include either
Thermocouple or Resistance Temperature Detector(RTD) or skin temperature
elements or combination of any. Relevant portion of the general requirement (item
2.01 to 2.03) shall be applicable for the items covered in the instrument specification
sheets.
2.05
Head & Cover
2.05.01 Thermocouple/ RTD terminal head shall be of aluminium alloy epoxy painted.
2.05.02 The head cover shall be screwed type with SS chain and SS screws.
2.05.03 Insulation blocks shall be ceramic (Al2O3 56%-60%) or stelite (mag.silicate6.5%)
suitable for temperature 240C.
2.05.04 Terminal screw material shall be nickel plated brass/copper.
2.05.05 Thermo element head in hazardous areas if specified ex.proof / flame proof against
each item in the individual specification sheets then the same shall conform to
CENELEC or FM or BASEEFA or IS. IS - 2148 certification must be supplemented with
the temperature classification certification confirming to IS - 8239. However, any
ex.proof/flame proof certification requiring sealing of cable entry with sealing
compound or enclosures with sealed cable entry and flying leads are not acceptable.
2.06
Thermowell
2.06.01 Thermowells can either be flanged or screwed type as specified in the instrument
2.06.02 The screwed type thermowell shall have 1 NPT (M) process connection & NPT(F)
for sensor connection.
2.06.03 The flanged thermocouple shall be 1 or as specified in the instrument specification
sheet.
2.06.04 Thermowells of length 600 mm and below shall be fabricated from bar stock. Above
600 mm length bar stock-bar stock combination and bar stock-pipe combination may
be used. All weld joints shall be radiographed.

ES-7323
DOCUMENT NO.
REV
SHEET 5
OF
2.06.05 The thermowell design shall be as per sketches mentioned against each item in the
2.07
Temperature element assemblies with spring loaded elements shall be used to

ensure positive contact between sheath tip and well bottom for minimum lag.
Corrosion resistant steel spring shall be isolated from terminals electrically to avoid
grounding.
2.08
Vendor shall submit thermo element assembly drawings developed at their end on
the basis of the drawings indicated against each tag in the instrument specification
sheets. If scope drawings are not available the vendor shall prepare the same and
submit to the Indentor for approval.
2.09
For steam, BFW & condensate services the thermowell shall be IBR certified. For items
of foreign origin the certification shall be done by Lloyds or any other IBR approved
2.10
For corrosive services like UREA, wetted parts of stainless steel 316L grade and CrNi-Mo 25-22-2 alloy shall be used. For these materials chemical analysis and
corrosion tests (Huey test) shall be carried out as per ASTM A 262 practice C if
Huey test is specified in the instrument specification. The tests shall be carried out in
2.11

2.12
Wherever temperatures Transmitters are specified in the individual specification sheets

the same shall be either loop powered or separately powered as per requirement
specified in the individual specification sheets. The transmitters shall have local digital
indication for the temperature range specified in each case.
2.13
2.14
Temperature Transmitters and local indicators in hazardous areas shall either be exproof or intrinsic safe conforming to area classification & execution specified against
each item in the individual specification sheets.
Ex-proof certification conforming to CENELEC,FM, BASEEFA and IS is preferred. IS 2148 certification must be supplemented with the temperature classification
certification confirming to IS - 8239. Intrinsic safe certification shall in general conform
to CENELEC standard EN 500014 and EN 50020, if not otherwise specified in the
individual specification sheet.
3.00
3.01
carrying out Inspection and test. In absence of any Inspection Agency the vendor
must submit the quality Assurance Plan for PDIL/OWNERs approval. All tests, in
such cases, shall be conducted by vendors Quality Department and the results of
tests shall be forwarded alongwith the supply.

ES-7323
DOCUMENT NO.
REV
SHEET 6
OF
at manufacturers works. The vendor shall permit the authorised representative of
PDIL/OWNER to inspect the manufacture and assembly of the temperature element
in various phases in compliance with mutually agreed quality assurance plan,
standards and specifications.
The vendor shall make available to the authorised representative of PDIL / OWNER
the results of all the checks/calibrations conducted before presenting for
PDIL/Owners inspection. Vendor to provide all the necessary facilities free of cost to
PDIL/Owners representative for carrying out the checks/calibration as per
standard/approved quality assurance plan. Under no condition inspection can be
waived off without the written permission of PDIL.
3.02
No temperature element and its accessories shall be shipped until all the required
tests are successfully completed and certified Cleared for despatch by the
inspection authority.
3.03
The procedure & extent of the following physical checks, routine tests shall be
Authority. The test procedures shall be in line with IEC 584, ASME - 220 / 230 / 230.
THERMOELEMENTS
A. Physical checks :
B. Routine test
1. Insulation resistance
2. Check of seal
3. Nitrogen leak test for thermocouple inset (For MI sensors only)
4. Check of calibration & tolerance.
THERMOWELL
2. Pressure test
B. Other tests
1. Radiography for bore concentricity ( 10 % ), if not otherwise specified in the
2. Radiography for thermowells of pressure rating 100 kg/cm2 g and above ( 100 % )

4.00
ES-7323
DOCUMENT NO.
REV
SHEET 7
OF
Packing
Each temperature element or alongwith assembly shall be suitably packed and
protected from damage due to transportation, loading and unloading.
maintenance) shall be despatched as a single consignment.
5.00
5.01
instrument.
Each temperature element assembly i.e. the sensing element alongwith head
assembly shall have a separate circular tag number plate in stainless steel with
engraved tag no and protecting sheath immersion length I and attached securely to
the head assembly with a soft stainless wire. The size of letters and figures shall be
minimum 4 mm and the plate should be 25 mm diameter with 1-2 mm thick.
5.02
Each thermowell shall have the following marking at position X or XX as shown in

the respective drawings.
(i) Tag no.
(ii) Thermowell model no. / manufacturers item no.
6.00
Spares
Complete thermoelement assembly of each type & range is included as spares in the
individual instrument specification sheets alongwith the main items.
However spare bare elements shall be as per enclosed spares list.

7.00
ES-7323
DOCUMENT NO.
REV
SHEET 8
OF
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
(A)
DESCRIPTION OF
DOCUMENT
ALONG
WITH BID

Deviation if any, from the technical spec.
giving justification for the same.
certificates from approved laboratory.
IBR certificate (wherever applicable)
NACE certificate (wherever applicable)
from approved laboratory.
Certificates showing chemical analysis,
corrosion test (Huey test), Ferrite
content on finished product, where
applicable from approved laboratory.
Certificates from recognised authority
wherever applicable for a) degree of
protection against environment.
b) ex. proof head, if applicable
c) ex.proof/Intrinsic safety for transmitter
Radiography films for thermowell where
ever applicable
Radiography films for bore concentricity
where ever applicable
certificates.
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
INFORMATION BEFORE
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes (I)
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
x
x
Yes
Yes
Yes
Yes
x
x
x
x
Yes
Yes
Yes(A)
(within 2 weeks)
for information.
Sl. no. 1 to 11 shall be forwarded to PDIL / OWNER as per details outlined in enquiry / order.
Number of sets alongwith bid for approval and as final documentation shall be supplied

MULTIPOINT TEMPERATURE ELEMENT (RTD) WITH
THERMOWELL
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
ORDER NO.
MANUFACTURER
:
:
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7061
1
2
3
4
5
6
ELEMENT
HEAD
HEAD EXTENSION
THERMOWELL
CERTIFICATION
PURCHASE
P&ID
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Tolerance Class
Wire Size
Element Configuration (Single/Duplex)
Sheath O.D / Material
Enclosure Class
Cable Entry Size
Blind Plug & Chain
Qty
45-TE-3001
P1 / 45-VV101
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3002
P1 / 45-VV102
LPG
2.35
14.5
-27
10-40
55
2" 300RF
45-TE-3003
45-TE-3004
Note:
P1 / 45-VV103
P1 / 45-VV104
Equaly distributed points (Last point placed approx. 50 mm

from the bottom of still well
CLASS A (IEC 751)
20 AWG
DUPLEX
Note 1 / Flexible Sheath ,SS316
Magnesium Oxide (Mineral Insulated)
Head Mount
Die Cast Aluminium with Epoxy coating
Zone 1 IIA IIB, T3 as per IEC
Ex ia
Weatherproof IP 66 or better
YES
1/2" NPT (F)
YES
YES with SS Chain
Note 1
Note 1
SS316
Note 1
Tapered
Single Bar Stock
RF/ 125~250 AARH
Note 1
Extension Type
Nipple Size
Extension Material
Extension Length (N)
Type (Tapered, Straight, Step down)
Construction
Flange Facing/Flange Face Finish
Instrument Connection Size
IBR
NACE
H2 SERVICE
PWHT
CCOE,BASEEFA,CENELAC
YES
Manufacturer
Model
Thermowell
Pressure
Temperature (deg C)
(Kg/cm2g)
Insertio
Process
Fluid
Element
Lagging Ext
n
Connectio
Length
Length
Min Nor Max
Min
Nor
Max
Length
n
'U'
Tag No
Line No./
Vessel No
SHEET 1 OF 1
24.09.15 ISSUED FOR ENQUIRY

1
HK
RA
SKT
14.09.15 ISSUED FOR ENQUIRY
0
HK
RA
SKT
21.07.15 DRAFT ENQUIRY
P
HK
RA
SKT VENDOR OFFER /
DATE
PURPOSE
REV
PREP CHKD APPD
DEVIATION
RTD
Three wire
PT-100
100 ohm at 0 deg C
NOTE 2
Approximately 500mm from base of mounting flange
Type
Configuration
Element Material
Resistance
Measuring Junction
Measuring Range
First Measurement Point Location
Measurement Point Distribution
Insulation Material
Type
Material
Area Classification
Ex. Protection
Ex. Approval/Certification
Spring Loaded
Terminal Block
EM163-7061-ISP7323
DOCUMENT NO.
TW/ Flange
Material
IBR
SS 316
SS 316
Note 2
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
LPG
2.35
14.5
-27
10-40
55
2" 300RF
SS 316
1)Vendortospecify
2)Vendortospecify(I.D.7000mm+THK42mm+MoundHeight&NozzleHeight)
3)MultipointtemperatureelementshallcovertheentireBulletheight.Nos.ofelementsshallbesuchthatthespacingbetween2elements
doesntexceed1meterasperASTMD1066.
4)Multipointtemperatureelementwiththermowellshallbesuppliedascompleteassembly.
5) ThevesseldrawingforLPGMoundedbulletsisattchedforreference.Vendortospecifyanyspecialsupportrequired,ifany.
VENDOR'S
OFFER/
DEVIATION
SPARES LIST FOR

ELEMENT (RTD)
EM163-7061-SP- 00
DOCUMENT NO
SHEET 1 OF 1
NOTE :
FORM NO: 02-0000-0021F1 REV2
All rights reserved
EM163-7061-BOQ
Rev 1, 24.09.2015
Bill of Quantity
Sl
ITEM
TAG NO.
Qty
Model No / Part No
<-------By Vendor----->
No
MULTIPONT TEMPERATURE ELEMENT (RTD) WITH THERMOWELL

1
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
MULTIPOINT
TEMPERATURE
ELEMENT
(RTD)
WITH
THERMOWELL
COMMISSIONING SPARES
5
SPARE
45-TE-3001
45-TE-3002
45-TE-3003
45-TE-3004
20% Spares for each Model &

Range
2 YEARS OPERATIONAL SPARES

5
SPARE

Range
Page 1 of 1
ES7328
DOCUMENT NO
SHEET 1 OF 7
FOR
TEMPERATURE TRANSMITTERS
00 20.07.2015
REV REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
All rights reserved
ES7328
DOCUMENT NO
SHEE 2 OF 7
CONTENTS
SECTION NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
All rights reserved
ES7328
DOCUMENT NO
SHEE 3 OF 7
1.00
General
1.01

herewith define the technical requirement for the supply of Temperature Transmitters, their
1.02

2.00
2.01
Temperature transmitter shall have universal input for thermocouple / RTD and output
4-20mA for 2 wire system.
2.02
For all applications, the transmitter shall be supplied with smart electronics. The feature of
smart electronics shall include selectable analog/digital output mode, remote re-ranging,
self checking, diagnostics and configuration from hand held configurator or remote HART
maintenance system. The transmitter must have provision for upgrading the communication
protocol to Foundation fieldbus in future.
2.03
2.04
20-500 MHZ in field strength of 20 volts/meter.
2.05
2.06
Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature
transmitters.
2.07
2.08
2.09
The electrical terminals shall be vibration proof. The transmitter terminals shall preferably
acceptable.
2.10

conforming to area classification, execution and execution standard specified against
each item in the individual specification sheets. Indian Standard (IS) certification IS 2148
for Ex-proof certification must be supplemented with the temperature classification
certification conforming to IS - 8239. Intrinsic safe certification shall conform to CENELEC
standard EN 50014 and EN 50020 if otherwise not specified in the individual specification
sheets.
2.11
3.00
3.01
Agency specified in the order and finalize with them the Quality Assurance Plan for
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7328
DOCUMENT NO
SHEE 4 OF 7
at manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the instrument in various
specifications.
inspection. The vendor to provide all necessary facilities free of cost to PDIL/Owners
permission of PDIL.
3.02
3.03
The following physical checks, routine tests, shall be in line with ISA S 55.1 The
procedure & extent of test shall be governed by Quality Assurance Plan mutually agreed
and approved by Inspection Authority.
A. Physical Checks
- Tag no.
- Model no.
- Range
B.
Routine Tests
2. Zero-shift
4.00
Packing
5.00
5.01
5.02
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7328
5.03
DOCUMENT NO
SHEE 5 OF 7
- Serial no.
6.00
Spares
7.0
Documentation
1.1
General
All the documentation such as graphic drawings and technical specifications shall be sent
to the Contractor who will reserve to approve it within 15 days; after this period, the
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be supplied
on paper.
1.2

procedure.
1.3

access.
1.4
Drawings
shall be given.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7328
1.5
DOCUMENT NO
SHEE 6 OF 7
Scanned documents
Acrobat.
including:
Deskew
Despeckle
Hole Fill.
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

FOR APPROVAL/ FINAL
INFORMATION
DOCUMENTS
WITHIN SIX
BEFORE
WEEKS
DESPATCH OF
CONSIGNMENT
Yes (I)
Yes
1.

documents.
Yes
2.

of Temperature transmitter
along with their accessories.
Yes
Yes
3.

Yes
4.

laboratory.
Yes
5.

execution.
Yes
Yes
6.

maintenance.
Yes
7.

test certificates.
Yes
8.
Yes
Yes(A)
(within 2 weeks)
(A)
For Approval
FORM NO: 02-0000-0021F2 REV1
(I)
For information.
All rights reserved
ES7328
DOCUMENT NO
SHEE 7 OF 7
the purchase order.
8.0
METHOD OF TENDERING
General
equipment proposed.
documentation.
Deviations
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM163-7062-ISP-7328
DOCUMENT NO.
FOR AVERAGING TEMPERATURE TRANSMITTER

PROJECT NO.
PROJECT
PLANT
CUSTOMER
:
:
:
:
EM163
NUMALIGARH, ASSAM
NRL
24.09.15
ISSUED FOR ENQUIRY
HK
RA
SKT
REQ. NO.
EM163-E-7062
14.09.15
ISSUED FOR ENQUIRY
HK
RA
SKT
ORDER NO.
21.07.15
DRAFT ENQUIRY
HK
RA
SKT
DATE
PURPOSE
P
REV
MANUFACTUR:
1.
2.
3.
FUNCTION
AVERAGING TEMPERATURE MEASUREMENT & TRANSMISSION
4
5
6
TYPE
COMMUNICATION
POWER SUPPLY
POWER SUPPLY EFFECT
TRANSMITTER OUTPUT
LOAD RESISTANCE
UNIVERSAL PROGRAMMABLE FIELD MOUNTABLE TYPE SUITABLE

TO ACCEPT ALL TYPE OF T/C & RTD INPUTS 3 WIRE
SMART WITH LATEST HART PROTOCOL

+/- 0.005% OF CALIBRATION SPAN PER VOLT
4-20 mA DC + HART/ DIGITAL
600 OHMS FOR DIGITAL COMM. AND 1250 OHMS FOR ANALOG OPERATION
YES ,LCD DISPLAY, LINEAR SCALE, CONFIGURABLE IN ENGG. UNITS
8
9 ZERO & SPAN ADJUSTMENT
10 ACCURACY
CONTINOUSLY ADJUSTABLE FROM HAND HELD CONFIGURATOR OR PC

+/ - 0.075 % OF CALIBRATED SPAN OR BETTER (INCLUDING LINERARITY ,
HYSTERESIS AND REPEATABILITY)
11 COLD JN. ACCURACY

12
13
14
15
16
+/- 0.5 deg C FOR T/C
UPDATE TIME
ISOLATION
SENSOR BACKUP FN
MOUNTING
0.5 secs adjustable in various steps of time constants

INPUT/OUTPUT/GND 500 V AC. MIN
AUTOMATC SWTCH OVER TO SENSOR 2
1/2" NPT (F) WITH SS/ALUMINIUM PLUG
ON 2" NB VERTICAL PIPE MOUTING WITH CLAMPS
17 HUMIDITY
18 AMB. TEMP. LIMIT
19 STABILITY
0-95 % RH
UPTO 85 C
+/- 0..075 % OF UPPER RANGE LIMIT FOR 6 MONTHS
20 BURNOUT FEATURE
21 ENVIRONMENTAL PROTECTION CLASS
22 AREA CLASSIFICATION
USER SELECTABLE FOR HIGH OR LOW

IP-67 OR BETTER
23
EXECUTION
24 SELF TEST/ DIAGNOSIS
EEx-ia
FEATURES SHALL BE INBUILT OF TRANSMITTERS
25
26
27
28
29
Matl.-Al.Alloy Protecting Paint-Epoxy Polyster as standard

SS 316
YES
YES ( SS 316 ) IF ANY
Ex-Proof & Intrinsically Safe to Hazardous Area Zone-1, Gr. IIA IIB, T3 as per IEC
ELECTRICAL HOUSING
TRANSMITTER BODY MATL
BODY TRANSMITTER BOLTS/NUTS/SCREW MATL.
ACCESSORIES
(A) JUNCTION BOX
(B) MOUNTING ACCESSORIES
(C) CABLE GLAND
TEMP deg C
TAG NO.
QTY.
PID
NO.
PREP CHKD APPD VENDOR's OFFER / DEVITION
MIN
NOR
MAX
YES ( 2" NB VERTICAL PIPE MOUNTING WITH SS CLAMP & SS NUT BOLT)
1/2" NPT SS 316, DOUBLE COMPRESSION TYPE, Ex- Proof
PRESSURE
RANGE
MIN/ MAX
(Design)
deg C
MODEL
Kg/cm2 g
UL/CALIB.
NUMBER
45-TT-3001
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3002
P1
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3003
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
45-TT-3004
P2
-27
10-40
55
2.35/14.5
-27 to 60
NOTE 1
VENDOR'S OFFER/DEVIATION
NOTES :
1.
Vendor to specify
2.
3.
For Sensor Details refer Doc No 1063-E-7061-ISP-7323.

Multipoint Temperature assembly along with necessary temperature interface shall be considered along with Servo Gauge.
EM163-7062-SP-00
SPARES LIST FOR
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years operational spares
FORM NO: 02-0000-0021F1 REV2
All rights reserved
Bill of Quantity For

Sl
Item
Item Description
EM163-7062-BOQ
REV 1 / 24.09.2015
Qty
1
2
3
4
5
Model No / Part No
<-------By Vendor----->
No
Temp Transmitter
Temp.
45-TT-3001
Temp. Transmitter
45-TT-3002
Temp. Transmitter
45-TT-3003
Temp. Transmitter
45-TT-3004
range and model covers the 20% spare / min. 1 No. for
all main transmitter. Vendor to give the quantity of each
model and range quoted as spare.
Spare for 2 Years
range and model covers the 20% spare / min. 1 No. for
all main transmitter. Vendor to give the quantity of each
model and range quoted as spare.
Page 1 of 1
1
1
1
1
EM163-E-7053
DOCUMENT NO
SHEET 1 OF 3
FOR
PRESSURE GAUGE
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7053
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
DRAFT ENQUIRY
PURPOSE
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7053
PRESSURE GAUGE
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
DRAWINGS/

INSTRUMENTS
FOR PRESSURE GAUGE
FOR PRESSURE GAUGES
SPARE LIST FOR PRESSURE
GAUGE
BOQ FOR PRESSURE GAUGE
2
3
4
5
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO.
/
DOCUMENT NO
EM163-PNIN-0000
NO OF PAGES
01
ES-7303
08
EM163-7053ISP7303
EM163-7053-SP-00
04
01
EM163-7053-BOQ
02
All rights reserved
EM163-E-7053
PRESSURE GAUGE
DOCUMENT NO
SHEET 3 OF 3
LIST OF PRESSURE GAUGES
SL.
NO.
TAG NO.
P & ID
QTY
1
2
3
4
5
45-PG-3001
45-PG-3002
45-PG-3003
45-PG-3004
45-PG-3016
P1 (EM163-45-0021)
P1 (EM163-45-0021)
P2 (EM163-45-0022)
P2 (EM163-45-0022)
P4 (EM163-45-0024)
01
01
01
01
01
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
aligarh, Golaghat Distrrict
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
Nearest National Hiighway
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
mbient Air Temperature
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
eismic Facttor - 0.04
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions
Prevailing wind dirrection NE to

t SW
12
Precipitation Annual me
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
Forr Enquire Issue
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES-7303
PRESSURE GAUGES
DOCUMENT NO
SHEET 1 OF 8
FOR
PRESSURE GAUGES
00 20.07.2015
REV REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
All rights reserved
ES-7303
PRESSURE GAUGES
DOCUMENT NO
SHEE 2 OF 8
CONTENTS
SECTION NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
All rights reserved
ES-7303
PRESSURE GAUGES
DOCUMENT NO
SHEE 3 OF 8
1.00
General
1.01

herewith define the technical requirement for the supply of pressure gauges, their
1.02

2.00
The supply shall be strictly in line with the technical requirements specified in the
Instrument specification. In addition the supply must comply with the following.
2.01
In general, construction, design and testing of the pressure gauges shall be as per IS
3624, unless otherwise deviations stated in the enclosed Instrument specification.
2.02
All equipment shall be weather proof to IP-65, antifungus and tropicalised.
2.03
All the wetted parts, movements, casing shall be of stainless steel unless otherwise
specified deviation in the Instrument specification. No component and accessories
should be of copper and its alloys.
2.04
The dial shall be white, non rusting metal or plastic with black figures.
2.05
Blow out devices shall be provided for all ranges .
2.06
All gauge casing shall be of safety pattern design. Baffle/solid front between dial and
sensor shall be provided for ranges 25 kg/cm2 g and above. Below 25 kg/cm2 g is
optional.
2.07
IBR certificate shall be required for accessories like pig tail siphon for steam, condensate
& BFW services. For items of foreign origin the certification shall be done by Lloyds or
any other IBR approved authorities in specific IBR format.
2.08

2.09
2.10
Pressure gauges shall be capable of withstanding intermittent overpressures of 1.3 times

the maximum scale reading without damage or calibration shift of more than 1% of the
scale reading.
2.11
The standard measuring element shall be a seamless bourdon tube of AISI 316 stainless
steel, except where the process fluid requires the use of special material. Bourdon tubes
shall be welded to socket and tip and stress relieved as required.
2.12
The gauge pointer shall be adjustable without removing it from its shaft.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES-7303
PRESSURE GAUGES
2.13
DOCUMENT NO
SHEE 4 OF 8
Auxiliary components for pressure gauge

Over range protector (gauge saver) shall be provided where a pressure gauge cannot withstand
a protuberant pressure due to unavoidable operation. Over range protector whenever used shall
be of SS316, as a minimum
Pulsation dampener shall be provided for all pulsating services e.g. Reciprocating pump
discharge piping etc. Pulsation dampeners shall be of minimum SS 316 and have connection
1/2 NPT (F) on both ends. Dampener shall be provided with integral screw head needle valve to
adjust aperture externally.
Pigtail type siphon shall be provided for steam service. Siphons shall be made of minimum SS
316 having connections 1/2 NPT (M) on both ends.
3.00

The Routine and type tests requirement shall be as per IS 3624 as a minimum. Within
two weeks of receipt of the LOI/order the vendor must contact the Inspection Agency
specified in the order and finalize with them the Quality Assurance Plan for carrying out
Inspection and test. In absence of any Inspection Agency the vendor must submit the
quality Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be
alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the gauges and
its accessories at manufacturers works. The vendor shall permit the authorized
representative of PDIL/OWNER to inspect the manufacture and assembly of the gauges
and its accessories in various phases in compliance with mutually agreed quality
assurance plan, standards and specifications.
inspection.
The vendor to provide all necessary facilities free of cost to PDIL/Owners representative
for carrying out the checks/calibration as per standard/approved quality assurance plan.
Under no condition inspection can be waived off without the written permission of PDIL.
4.00
Packing
Each gauge and its accessories i.e. siphon, snubber, gauge saver etc. wherever
applicable shall be suitably packed and protected from damage due to transportation,
loading and unloading.
5.00
5.01
instrument.
Each gauge to have a separate circular tag number plate in stainless steel with
engraved tag no and range and attached securely to the gauge with a soft stainless
wire. The size of letters and figures shall be minimum 4 mm and the plate should be 25
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES-7303
PRESSURE GAUGES
6.00
DOCUMENT NO
SHEE 5 OF 8
mm diameter with 1-2 mm thick. This shall be in addition to manufacturers standard

name plate.
Spares
All untagged instruments in the individual instrument specification sheets are spare
instruments. In addition if Component Spares are required then the same shall be as per
enclosed spares list.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES-7303
PRESSURE GAUGES
7.0
Documentation
1.1
DOCUMENT NO
SHEE 6 OF 8
General
All the documentation such as graphic drawings and technical specifications shall be
sent to the Contractor who will reserve to approve it within 15 days; after this period, the
here under.
All the other Vendor documentation, such as Manual, Catalogues, etc. shall be
supplied on paper.
1.2

procedure.
1.3

access.
1.4
Drawings
shall be given.
1.5
Scanned documents
Acrobat.
including:
Deskew
Despeckle
Hole Fill.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES-7303
PRESSURE GAUGES
DOCUMENT NO
SHEE 7 OF 8
The following documents (Technical) are required to be submitted by the vendor alongwith bid, after
SL. NO.
DESCRIPTION OF
DOCUMENTS
ALONG
WITH BID
1.

Yes
For approval/
information
within six weeks
Yes (I)
2.

pressure gauges alongwith their
accessories.
spec. giving justification for the same.
construction of each part and
complete assembly.
certificates from an approved
laboratory
IBR certificate for siphon, where
applicable.
NACE certificate for wetted parts from
an approved laboratory, where
applicable.
Certificates from competent authority
for degree of protection against
environment.
certificates.
Yes
Yes
Yes
Yes (I)
Yes
Yes
Yes
Yes
Yes
Yes
x
x
x
x
Yes
Yes
3.
4.
5.
6.
7.
8.
9.
10.
11.
(A)
For Approval
(I)
Final documents
before dispatch of
consignment
Yes
Yes (A)
(Within 2 week)
For Information.
Sl. no. 1 to 10 shall be forwarded to PDIL/OWNER as per details outlined in enquiry / order.
Sl. no. 11 shall be mutually finalized with Inspection Authority specified in the order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as stipulated in the
purchase order.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES-7303
PRESSURE GAUGES
8.0
DOCUMENT NO
SHEE 8 OF 8
METHOD OF TENDERING
General
equipment proposed.
documentation.
Deviations
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM163-7053-ISP7303
DOCUMENT NO.
PRESSURE GAUGE
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
GENERAL
TYPE
MOUNTING
DIAL SIZE
DIAL COLOUR
CASE MATERIAL
BEZEL RING
ELEMENT MATERIAL
BLOW OUT PROTEC.
LENS
ACCURACY
OVER RANGE PROTEC.
ENCLOSURE PROTEC.
PRESSURE ELEMENT
BOURDON SIZE
MOVEMENT MATL.
PROCESS CONN.
POINTER TYPE
ZERO ADJUSTMENT
FACILITY
:
:
:
:
:
:
:
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7053
:
:
:
:
:
:
:
:
:
:
:
:
Direct reading
Local
150mm
Black numerals on white background
SS 304
SS 304
Refer against Indivisual tag
Required as per IS 3624
Shatter Proof Glass
1% on full scale
Required as per IS 3624 or Latest
IP 65 or better
:
:
:
:
:
110mm dia. (minimum)

SS 316
1/2" NPT(M) Bottom
Micrometer screw type
Required
QTY.
LINE NO./
EQUIPMENT NO
P&ID
45-PG-3001
01
45-VV-101
P1
45-PG-3003
45-PG-3004
45-PG-3016
01
01
01
01
VENDOR's OFFER / DEVIATION
TAG NO.
45-PG-3002
45-VV-102
45-VV-103
45-VV-104
45-VV-106
P1
P1
P1
P4
24.09.15
Clients Comment
Incorporated
HK
RA
SKT
14.09.15
Clients Comment
Incorporated
HK
RA
SKT
P 21.07.15
REV
DATE
DRAFT ENQUIRY
PURPOSE
HK
RA
PREP CHKD
SKT
APPD
VENDOR'sOFFER/
DEVIATION
OPTIONS
A1) PIG TAIL SYPHON ASTM A 106 Gr. B, 1/2" NB
Seamless pipe, Sch 80, Both ends Plain with IBR
A2) PIG TAIL SYPHON ASTM A TP 304 SS, 1/2" NB
Sch. 80s Seamless pipe, Both ends Plain with IBR
A3) PIG TAIL SHYPON ASTM A TP 347H SS, 1/2" NB
Sch. 80s, Both ends Plain with IBR
A4) PIG TAIL SYPHON Specify as required
B1) SNUBBER AISI 304 SS, 1/2 " NPT(F) Gauge side,
1/2" NPT(M) Process side, Rating & Temp. to suit service pressure,
Dampning : Adjustable
B2) SNUBBER Specify as required
C1) GAUGE SAVER AISI 304, 1/2" NPT(F) Gauge side,
1/2" NPT(M) Process side
C2) GAUGE SAVER AISI 304L, 1/2" NPT(F) Gauge side,
1/2" NPT(M) Process side
D) MOVEMENT DAMPING Specify as required
E) SAFETY PATTERN GAUGE
WITH BAFFLE WALL
F) NACE CERTIFICATE
FLUID
/ LINE /VESSEL
OP.MIN /
NOR / MAX
/DESIGN
K / 2( )
OP.MIN / MAX /DESIGN

TEMP. (OC)
: Required with SS Solid Front
OPTIONS
RANGE
KG/CM2(G)
ELEMENT
TYPE
ELEMENT
MATERIAL
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / G
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
LPG / L
2.35 / 6.51
/14.5
(-) 27 / 55
0-16
SEAMLESS BOURDON
SS316
C1
NOTES: Bourdon tube shall be seamless
SHEET 1 OF 1
VENDOR'sOFFER/
DEVIATION
SPARES LIST FOR

PRESSURE GAUGE
EM163-7053-SP-00
DOCUMENT NO
SHEET 1 OF 1
Please refer attached Bill of quantity at EM163-7053-BOQ for spare details
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 Years Operation spares
FORM NO: 02-0000-0021F1 REV2
All rights reserved
EM163-7053-BOQ
Bill of Quantity
Sl
No
1
2
3
4
5
Item
Item Description
PRESSURE GAUGES
45-PG-3001
45 PG 3001
45-PG-3002
45-PG-3003
45-PG-3004
45-PG-3016
Main Pr. Gauge

Main Pr. Gauge
Main Pr. Gauge
Main Pr. Gauge
Main Pr. Gauge
Rev 1/ 24.09.2015
Model No / Part No
Qty
<-------By Vendor----->
1
1
1
1
1
6
Spare - 3
Pressure
gauge, Seamless Bourdon
Spare - 4
Spare - 5
Range 0 to 16 Kg/Cm2 (g)
AISI 304 SS, 1/2 " NPT(F) Gauge side,

1/2" NPT(M) Process side, Rating &
Temp. to suit service pressure
GAUGE SAVER AISI 304, 1/2" NPT(F) Gauge side, 1/2"

NPT(M) Process side
SNUBBER
2 years Operational Spares
Spare - 6
Pressure
gauge, Seamless Bourdon
Range 0 to 16 Kg/Cm2 (g)
20% of
each
model /
range/
min. 1 no.
EM163-E-7044
DOCUMENT NO
SHEET 1 OF 3
FOR
PRESSURE TRANSMITTERS &
DIFF. PRESSURE TRANSMITTER
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7044
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
DRAFT ENQUIRY
PURPOSE
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved

PRESSURE TRANSMITTER &
EM163-E-7044
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL. DRAWINGS/ DOCUMENTS.DESCRIPTION

NO.
1
INSTRUMENTS
2
DIFFERENTIAL PRESSURE
TRANSMITTER
3
DIFFERENTIAL PRESSURE
TRANSMITTER
4
SPARE LIST FOR PRESSURE
TRANSMITTERS & DIFFERENTIAL
PRESSURE TRANSMITTER
5
BOQ FOR FOR PRESSURE
TRANSMITTERS & DIFFERENTIAL
PRESSURE TRANSMITTER
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO./
DOCUMENT NO
EM163-PNIN-0000
NO OF
PAGES
01
ES-7308
08
EM163-7044-ISP7308
02
EM163-7044-SP-00
01
EM163-7044-BOQ
01
All rights reserved

PRESSURE TRANSMITTER &
EM163-E-7044
DOCUMENT NO
SHEET 3 OF 3
LIST OF PRESSURE TRANSMITTERS
SL.
NO.
TAG NO.
P & ID
QTY
1
2
3
4
45-PT-3013 A/B/C
45-PT-3014 A/B/C
45-PT-3015 A/B/C
45-PT-3016 A/B/C
P1 (EM163-45-0021)
P1 (EM163-45-0021)
P2 (EM163-45-0022)
P2 (EM163-45-0022)
3 Nos.
3 Nos.
3 Nos.
3 Nos.
LIST OF LEVEL TRANSMITTERS
SL.
NO.
TAG NO.
P & ID
QTY
45-LT-3017
P4 (EM163-45-0024)
1 No.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions

t SW
12
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
Forr Enquire Issue
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES7308
PRESSURE & DIFF. PRESSURE
TRANSMITTER
DOCUMENT NO
SHEET 1 OF 8
FOR
PRESSURE AND
DIFFERENTIAL PRESSURE TRANSMITTERS
00 20.07.2015
REV REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
FOR ENQUIRY
PURPOSE
HK
PREPD
RA
REVWD
RA
APPD
All rights reserved
ES7308
PRESSURE & DIFF. PRESSURE TRANSMITTER
DOCUMENT NO
SHEET 2 OF 8
CONTENTS
SECTION NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
All rights reserved
ES7308
DOCUMENT NO
SHEET 3 OF 8
1.00
General
1.01

herewith define the technical requirement for the supply of Pressure and Differential
Pressure Transmitters, their accessories, name plate marking, documentation, testinginspection and packing.
1.02

2.00
2.01
Pressure Transmitters
2.01.01
Flanged integral type 2-valve manifold shall be used with transmitters having either
flanged or oval flanged adopter with 1/2 NPT (F) process connection. Otherwise, 1/2
NPT (F) screwed 2 valve manifold shall be used.
2.01.02
One complete bolt sets shall be provided for flanged connections at both ends.
2.02
Differential Pressure Transmitter
2.02.01
Flanged integral type 3-valve manifold shall be used with transmitters having either
flanged or oval flanged adopter with 1/2 NPT (F) process connection. Otherwise, 1/2
NPT (F) screwed 3 valve manifold shall be used.
2.02.02
One complete bolt sets shall be provided for flanged connections at both ends.
2.03
For all applications, the transmitter shall be supplied with smart electronics. The feature
of smart electronics shall include selectable analog/digital output mode, remote reranging, self checking, diagnostics and configuration from hand held configurator or
remote HART maintenance system. The transmitter must have provision for upgrading the
communication protocol to Foundation fieldbus in future.
2.04
Studs & nuts for flange adapter & oval flanges shall be of stainless steel if otherwise not
specified in the data sheet. If no special requirements are stipulated all gaskets/O rings
in contact with process fluid shall be of Teflon or equivalent. For liquid ammonia service
low temp application (sub-zero temp.), gaskets/O rings shall be EP-851 or equivalent.
2.05
2.06
20-500 MHZ in field strength of 20 volts/meter. The transmitter shall be vibration and
shock proof.
2.07
2.08
2.09
2.10
The electrical terminals shall be vibration proof. The transmitter terminals shall
preferably be located in a compartment separated from field electronics. Flying leads are
not acceptable.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7308
DOCUMENT NO
SHEET 4 OF 8
2.11
All transmitters without chemical seal shall have 1/2 NPT (F) connection.
2.12
The scope as per enclosed instrument specification sheets may include either Pressure or
Differential pressure Transmitters or combination of any. Relevant portion of the general
requirement (item 2.01 to 2.02) shall be applicable for the items covered in the instrument
specification sheets.
2.13

conforming to area classification, execution and execution standard specified against each
item in the individual specification sheets. Indian Standard (IS) certification IS 2148 for Exproof certification must be supplemented with the temperature classification certification
conforming to IS - 8239. Intrinsic safe certification shall conform to CENELEC standard EN
50014 and EN 50020 if otherwise not specified in the individual specification sheets.
2.14
2.15
Body pressure rating shall be 100 bar minimum and measuring capsules shall be able to
withstand pressure up to the body rating in either direction without damaging the instrument.
2.16
The body and other wetted parts material shall be SS 316L minimum. Other materials such
as hastelloy, Monel or tantalum may be used as per process requirement.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the Inspection Agency
Inspection and test. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be conducted by
vendors Quality Department and the results of tests shall be forwarded alongwith the
supply.
The manufacturer shall give clear 15 days notice informing readiness of the instrument at
manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the instrument in various phases
in compliance with mutually agreed quality assurance plan, standards and specifications.
inspection.Vendor to provide all the necessary facilities free of cost to PDIL/Owners
permission of PDIL.
3.02
3.03
The following physical checks, routine tests, shall be in line with ISA S 55.1 The procedure &
extent of test shall be governed by Quality Assurance Plan mutually agreed and approved
by Inspection Authority.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7308
DOCUMENT NO
SHEET 5 OF 8
A. Physical Checks
- Tag no.
- Model no.
- Range
3. Manifold
B.
Routine Tests

2. Zero-shift
3. Hydraulic test (1.5 Times of Design Pressure minimum).
4.00
Packing
5.00
5.01
5.02
5.03
- Serial no.
6.00
Spares
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7308
7.0
Documentation
1.1
DOCUMENT NO
SHEET 6 OF 8
General
here under.
supplied on paper.
1.2

procedure.
1.3
Specifications, Data Sheet and other documents.

access.
1.4
Drawings
shall be given.
1.5
Scanned documents
Acrobat.
including:
Deskew
Despeckle
Hole Fill.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7308
DOCUMENT NO
SHEET 7 OF 8
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

FOR APPROVAL/ FINAL
INFORMATION
DOCUMENTS
WITHIN SIX
BEFORE
WEEKS
DESPATCH OF
CONSIGNMENT
Yes (I)
Yes
1.

documents.
Yes
2.

of Pressure and Diff. pressure
transmitter along with their
accessories.
Yes
Yes
3.

Yes
4.

laboratory.
Yes
5.

execution.
Yes
Yes
6.

maintenance.
Yes
7.

test certificates.
Yes
8.
Yes
Yes(A)
(within 2 weeks)
(A)
For Approval
(I)
For information.
the purchase order.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7308
8.0
DOCUMENT NO
SHEET 8 OF 8
METHOD OF TENDERING
General
The Bidder shall present a list of previous applications (References) for equipment similar to
the equipment proposed.
documentation.
Deviations
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM163-7044-ISP-7328
DOCUMENT NO
FOR TRANSMITTER
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
ORDER NO.
MANUFACTURER
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7044
1.
2
3
4
5
6
7
8
9
10
11
12
13
FUNCTION
FILL FLUID
VERSION/COMMUNICATION
MEASUREMENT PRINCIPLE/TYPE
POWER SUPPLY
TRANSMITTER OUTPUT
LOAD RESISTANCE
14
15
16
17
18
MOUNTING
HUMIDITY
STABILITY
OVER PRESSURE
19
20
21
PROCESS CONNECTION
O' RING
ENVIRONMENTAL PROTECTION CLASS
AREA CLASSIFICATION

ZERO SUPRESSION/ ELEVATION
DAMPING
ACCURACY
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
TURNDOWN RATIO
STATIC PR. COMPENSATION
AMBIENT TEMPERATURE COMPENSATION
STATIC PR. SHIFT
AMBIENT TEMPERATURE SHIFT
AMB. TEMP. LIMIT
DRAIN OR VENT ARRANGEMENT
MATERIAL
1
0
P
REV
24.09.15
14.09.15
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
HK
HK
RA
RA
SKT
SKT
21.07.15
DRAFT ENQUIRY
HK
RA
SKT
DATE
PURPOSE
PREP CHKD
APPD
PRESSURE & DIFFERENTIAL PRESSURE MEASUREMENT &TRANSMISSION

SILICON OIL
SMART WITH HART PROTOCOL
CAPACITANCE/ PIEZOELECTRIC / SILICON RESONATOR

4-20 mA DC /DIGITAL HAVING LATEST HART PROTOCOL/SMART/INTELLIGENT
550 OHMS MINIMUM AT 24V DC
YES ,LCD DISPLAY, LINEAR/SQ. ROOT SCALE, CONFIGURABLE
IN ENGINEERING UNITS
CONTINOUSLY ADJUSTABLE FROM HAND HELD CONFIGURATOR OR BY PC
INBUILT 100% ZERO ELEEVATION AND 100% SUPPRESSION.
0-32 sec adjustable in various steps of time constants
+/ - 0.1 % OF CALIBRATED SPAN OR BETTER (INCLUDING
LINERARITY , HYSTERESIS AND REPEATABILITY)
1/2" NPT (F) WITH SS PLUG
ON 2" NB VERTICAL PIPE MOUTING WITH SS CLAMPS and BOLTS
0-95 % RH
+\- 0.1 % OF UPPER RANGE LIMIT FOR 6 MONTHS OR BETTER
a.) PR. TRANSMITTER: Minimum 1.5 TIMES OF DESIGN PRESSURE
b.) DP TRANSMITTER: AS PER ATTACH LIST
1/2" NPT(F)
PTFE
IP-67 or Better
Ex-proof & INTRINSICALLY SAFE TO HAZARDOUS AREA CLASSIFICATION Zone-1,
Gr. IIA IIB, T3 as per IEC.
100 : 1
YES
YES
VENDOR TO SPECIFY
VENDOR TO SPECIFY
-27 C TO 55 C
YES
A.) SENSOR(CAPSULE): SS316L/HASTELLOY C
B.) PROCESS COVER:SS316
C.) OTHER WETTED PARTS:SS316
EEx-ia
YES,WRITE PROTECTION SWITCH,NON VOLATILE MEMORY
SS 316
YES ,SS 316 / ABOVE 100 Kg/Cm2g SUS 610
CONFIGURABLE
YES
EXECUTION
SELF TEST/ DIAGNOSIS
TRANSMITTER BODY MATL /DRAIN & VENT VALVE MATL.
TRANSMITTER BODY, BOLTS/NUTS/SCREW MATL.
SQUARE ROOT EXTRACTION
OPTIONS
(A) MOUNTING ACCESSORIES
YES ( 2" NB VERTICAL PIPE MOUNTING WITH CLAMP & SS NUT BOLT)
(B)THREE VALVE MANIFOLD
YES, T-TYPE, SS316 MATERIAL
(C) CABLE GLAND
1/2" NPT SS 316, DOUBLE COMPRESSION TYPE, Ex- Proof
(D) TWO VALVE MANIFOLD
YES
Universal Handheld Configurator complete with all accessories i.e. Battery, Charger, Interfacing cable & carry case with with 1 GB memory
VENDOR's OFFER /
DEVITION
EM163-7044-ISP-7328
DOCUMENT NO
FOR PRESSURE TRANSMITTERS

PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7044
1
0
24.09.15
14.09.15
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
ORDER NO.
21.07.15
DRAFT ENQUIRY
MANUFACTURER
REV
DATE
PURPOSE
TAG NO.
QTY.
PID NO.
Nos.
LINE NO./
EQUIP. NO
FLUID
NOR /
NOR / MAX
MAX PR.
CALIB.
TEMP.
2
RANGE (Kg/cm2g)
Kg/cm
0
DEG( C)
(g)
BODY
RTG.
ELEMENT
MATERIAL
COVER/
BODY/WET OPTION
PARTS MATL
45-PT3013 A/B/C
P1
45-VV-101
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
45-PT3014 A/B/C
P1
45-VV-102
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
45-PT3015 A/B/C
P2
45-VV-103
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
45-PT3016 A/B/C
P2
45-VV-104
LPG/L
(-)27/55
2.35-6.51
/ 14.5
0-25
NOTE 3
SS316
SS316
A,C,D
NOTES :
1. Mounting Bracket for mounting on 2" pipe with U-clamp & bolts, Matl.SS.
2.Body rating selected by manufacturer shall be suitable for the given pressure & temp.
3. MANUFACTURER TO SPECIFY.
4. In case of High Temp. i.e more than 200 deg. C, Suitable 'O' Ring material to be quoted by the manufacturer.
5. Each transmitter shall be supplied with NPT SS plug for auxiliary electrical connection.
6. Vendor shall indicate full model codes for the transmitters offered and shall submit relevant decoding sheet also
7. Valve manifold & transmitter body shall be tested Hydraulically separately
HK
HK
RA
RA
HK
RA
SKT
SKT
SKT
PREP CHKD
APPD
MODEL
VENDOR's
OFFER /
DEVIATION
EM163-7044-ISP-7328
DOCUMENT NO
LEVEL TRANSMITTER (dP Type)

PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
:
:
:
:
:
ORDER NO.
MANUFACTURER
TAG NO.
LT-3017
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7044
24.09.15
ISSUED FOR ENQUIRY
14.09.15
ISSUED FOR ENQUIRY
REV
DATE
PURPOSE
QTY.
NOS
. PID NO.
LINE NO.
1
EM163-45- 45-VV-106
0024
FLUID
LPG/
WATER
MAX./
MAX./NOR NOR PR.
TEMP.
Kg/cm2
0
(g)
DEG( C)
(-)27/55
2.35-6.51
/ 14.5
BODY
C-C / RANGE
RTG./
(mmWC) / CALL. FLANGE
ELEMENT
RANGE
MATERIAL MATERIAL
800 / - /NOTE-3
1.5",
SS316
300#RF
HK
RA
HK
RA
PREP CHKD
DENSITY
FLUID
COVER/
IN Kg/m3 /
BODY/WET
PARTS MATL
VISC.
SS316
1000 / 0.756
SKT
SKT
APPD
OPTI
ON
MODEL
A,C
VENDOR's
OFFER /
DEVIATION
EM163-7044-SP-00
SPARES LIST FOR

TRANSMITTERS
DOCUMENT NO
SHEET 1 OF 1
NOTE: 1 The vendor shall also indicate the additional/ applicable 2 years spares recommended by them.
FORM NO: 02-0000-0021F1 REV2
All rights reserved
EM163-7044-BOQ
Bill of Quantity for Transmitter

Rev 1 / 24.09.2015
Model No / Part No
Sl
No
1
2
3
4
5
Item
Item Description
Qty
<-------By Vendor----->
PRESSURE TRANSMITTERS
45-PT-3013 A/B/C
45-PT-3014 A/B/C
45-PT-3015 A/B/C
45-PT-3016 A/B/C
45-LT-3017
Main Transmitter
Main Transmitter
Main Transmitter
Main Transmitter
Main Transmitter
3
3
3
3
1
Spare 1
Pressure
Transmitter
Vendor to quote spares on

propotionate basis so each range
and model covers the 20% spare for
all main transmitter. Vendor to give
the quantity of each model and
range quoted as spare.

Spare 2
Level Transmitter and model covers the 20% spare for
Latest version of Handheld Configurator complete with all accessories i.e.
Battery, Charger, Interfacing cable & carry case with 64 MB of internal memory
etc.
etc
2 years operational Spares
Spare 3
10
Spare 4

Pressure
Transmitter
Level Transmitter
Page 1 of 1
EM163-E-7022
DOCUMENT NO
SHEET 1 OF 3
FOR
SAFETY RELIEF VALVE
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
11.09.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7022
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
DRAFT ENQUIRY
PURPOSE
AK
AK
AK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7022
SAFETY RELIEF VALVE
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
2
3
4
5
6
DRAWINGS/
INSTRUMENTS
FOR SAFETY RELIEF VALVE
SAFETY RELIEF VALVE
SPARE LIST FOR SAFETY RELIEF
VALVE
BOQ FOR SAFETY RELIEF VALVE
SKETCH FOR SAFETY RELIEF
VALVE
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO. /
DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7234
09
EM163-7022-ISP-7234
03
EM163-7022-SP-7234
01
EM163-7022-BOQ-7234
EM163-7022-SK-7234
01
01
All rights reserved
EM163-E-7022
SAFETY RELIEF VALVE
DOCUMENT NO
SHEET 3 OF 3
LIST OF SAFETY RELIEF VALVE

SL.
NO.
1
2
3
4
5
TAG NO.
45-PSV-3001A/B
45-PSV-3002A/B
45-PSV-3003A/B
45-PSV-3004A/B
45-PSV-3007A/B
FORM NO: 02-0000-0021F2 REV1
P & ID
EM163-45-0021(P1)
EM163-45-0021(P1)
EM163-45-0022(P2)
EM163-45-0022(P2)
EM163-45-0024(P4)
QTY
02
02
02
02
02
All rights reserved
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions

t SW
12
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
Forr Enquire Issue
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES-7234
DOCUMENT NO
REV
SHEET 1 OF 9
FOR
SAFETY RELIEF VALVES
0
REV
05.02.1999
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2

PURPOSE
DDCPN
PREPD
CISC
REVWD
DHPV
APPD
All rights reserved

SAFETY / RELIEF VALVE
ES-7234
DOCUMENT NO
REV
SHEET 2 OF 9
CONTENTS
SECTION NUMBER
1.0
DESCRIPTION
GENERAL
SHEET NUMBER
2.0
CODES AND STANDARDS
3.0
SIZING AND DESIGN CRITERIA
4.0
5.0
INSPECTION, FACTORY TEST

AND APPROVAL
PACKING
6.0
7.0
SPARES
8.0
DOCUMENTATION
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
NUMBER OF SHEETS
All rights reserved

ES-7234
DOCUMENT NO
REV
SHEET 3 OF 9
1.00
General
1.01
This general specification together with the data sheets and inspection standards
attached herewith define the technical requirement for the supply of Safety / Relief
valves, spares, documentation, inspection-testing and shipping.
1.02

2.00
Codes and Standards
2.01
The pressure relieving devices design, manufacture, installation and testing shall be in
accordance with the following codes and recommendations and as specified in the
individual specification sheets:
a) ASME Boiler and pressure vessel code section I
- Design, manufacture and calculation for steam services in fired pressure
vessels.
b) ASME Boiler and pressure vessel code section VIII
- Design, manufacture and calculation for steam, gas, vapour and liquid services in
unfired pressure vessels
c) API-RP-520, part I and II sizing, selection & installation of pressure
system in refineries.
relieving
d) API standard 521 guide for pressure and depressurising system.

e) API standard 526 flanged steel safety relief valves.
- Design and manufacture as per ASME section VIII and orifice calculation as per
API -RP-520 part I and II , appendix C
f) API standard 527 commercial seat tightness of safety relief valves with metal
to metal seat.
g) API 2000 for sizing of pressure / vacuum relief valves on storage tanks.
h) ASME B16.5 steel pipe flanges, flanged valves and fittings.
i) ASME B46.1 surface textures.
j) Indian Boiler Regulations for valves on steam service, Paragraph 293.
k) ASME B16.34 for non destructive tests
3.00
Sizing and Design Criteria
3.01
The manufacturer shall furnish calculations in accordance with the code specified in the
individual instrument specification sheets. Each manufacturer to state its own K factor
and actual measurable area. In addition, approx. weight of each valve shall be specified.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

ES-7234
DOCUMENT NO
REV
SHEET 4 OF 9
All the above information shall be submitted at the time of bidding, approval after order
placement & alongwith final despatch.
3.02
The percent over-pressure and accumulation used in calculation for sizing of relieving
devices shall be considered as indicated in the individual specification sheet.
3.03
For Steam, BFW & condensate services the instrument shall be IBR certified. For items of
foreign origin the certification shall be done by Lloyds or any other IBR approved
authorities in specific IBR format.
3.04

edition. The tests shall be carried out in an approved laboratory
3.05
For corrosive services like UREA wetted parts of stainless steel 316L grade and Cr-Ni-Mo
25-22-2 alloy shall be used. For these materials chemical analysis and corrosion tests
(Huey test) shall be carried out as per ASTM A 262 practice C. The tests shall be carried
out in an approved laboratory.
3.06
All safety valves of inlet rating 900# and above shall be subjected to
radiography/ultrasonic test as per procedures outlined in ASME-B16.34 and mutually
agreed quality assurance plan, if not otherwise stated in the individual specification sheet
.
3.07
In general, safety / relief valves for thermal expansion (on liquids) shall be 3/4 x 1, NPT
ASME B 2-1 unless otherwise specified in specification sheet.
3.08
All valves except thermal relief ones shall be full nozzle type. All valves shall have the
facility of blow-down adjustment except thermal relief valves. Base/modified or seminozzle types shall be specified for thermal relief valves.
3.09
Lifting Levers shall be furnished for exposed spring bonnets on valves in steam and hot
water service, on air and hot water valves with closed bonnets. All the lifting levers shall
be packed type unless the valve is handling inert gas at ambient temperature.
3.10
Bonnets shall be plain closed ones for toxic or inflammable gases as well as for vapours
and liquids. Exposed spring bonnet shall be specified for steam service and in boiler feed
water service above 2000 C. Extension type of bonnet shall be used above 4000 C &
cryogenic service.
3.11
Balancing or Sealing Bellows shall be used under the following conditions or as specified
in the individual specification sheet.
a) When the back pressure exceeds 10% of the set pressure.
b) The back pressure is variable.
c) The valve is handling corrosive fluid.
3.12
Material Of Valve Body shall conform to the material specified in the enclosed individual
instrument specification sheets. In general valve body material and rating shall conform
to upstream line specification or specification of the vessel wherever it is mounted.
3.13
Material of nozzle and disc shall be, in general, SS 316 (A182 F316) and 17.4 pH or
316SS with stellite facing, for high pressure drop/abrasive services if not otherwise stated
in the individual instrument specification sheets.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

ES-7234
DOCUMENT NO
REV
SHEET 5 OF 9
3.14
Springs shall be carbon steel cadmium plated (rust proof) for normal process operating
temperature (-) 250 C to 2000 C and tungsten/ alloy steel for high temperature above 2000
C. Below (-) 250 C stainless steel may be used. Carbon steel (Rust proof) is permitted
above 2000 C when the bonnet is open.
3.15
Test Gag shall be furnished on all safety and relief valves and they shall be handed over
to owner after testing clearly labelled with the tag number of the valve they belong to.
3.16
The manufacturer must specify Cold Differential Set Pressure (CDSP) for each pressure
relieving devices at 250 C.
3.17
Rupture disc if specified used at inlet of safety valves shall have fragmentation free burst.
The stamped capacity of safety valves shall be derated by 20%, unless the combined
capacity of the rupture disc and safety relief valve is established by the disc
manufacturer.
3.18
The space between safety valve and rupture disc shall be vented during normal
operation. The disc holder shall be supplied with 4 telltale pressure gauge with SS
body, wetted parts, pipe nipple, excess flow valve. The excess flow valve and pressure
gauge shall have 1/2 NPT connections.
3.19
Burst sensors with rupture discs in hazardous areas shall either be ex-proof or intrinsic
safe confirming to area classification & execution specified against each item in the
Ex-proof certification confirming to CENELEC, FM, BASEEFA and IS is preferred. IS 2148 certification must be supplemented with the temperature classification certification
confirming to IS - 8239.
Intrinsic safe certification shall in general confirm to CENELEC standard EN 500014 and
EN 50020, if not otherwise specified in the individual specification sheet.
3.20
4.00
4.01
4.02
The manufacturer shall give clear 15 days notice informing readiness of the valves at
manufacturers works.
4.03
The vendor shall permit the authorised representative of PDIL/OWNER to inspect the
manufacture and assembly of the valves in various phases in compliance with approved
drawings, standards and specifications.
4.04
The vendor should make available to the authorised inspector the results of all the
checks/calibrations conducted before presenting for PDIL/Owners inspection.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

ES-7234
DOCUMENT NO
REV
SHEET 6 OF 9
4.06
The vendor to provide all necessary facilities free of cost to PDIL/Owners inspector for
carrying out the checks/calibration as per standard/approved quality assurance plan. In
no condition inspection can be waived off without the written permission of PDIL.
4.07
No assembly shall be shipped until all the required tests are successfully completed and
certified Cleared for despatch by the inspection authority.
4.08
The following tolerances are permitted for calibration:
b)
a) For valve calibration < 5 kg/cm2, +/- 2.8% of the calibrated value.
For valve calibration > 5 kg/cm2, +/- 3% of the calibrated value.
4.09
The following tests shall be carried out as a minimum for safety valves
(i)
Verification of cold differential test pressure 100% for all valves
(ii)
Hydraulic pressure tests for primary parts (Refer ANSI B 96.1 for terminology) shall be
tested at 1.5 times the set pressure.
(iii)
Pneumatic shell test for closed bonnet valves on secondary side shall be at 1.5 times
back pressure (or) 2 kg/cm2 whichever higher when back pressure is zero or not stated.
For positive back pressure test pressure shall be 1.5 times the back pressure.
(iv)
Seat leakage test for metal to metal seated safety valves shall be done in accordance
with API-527. For steam, soft seat, pilot valves and special cases where leakage test is
not covered in API-527, the procedure for testing in such cases shall be mutually
decided and recorded in the Quality assurance plan.
(v)
Foundry /forge shop test certificate to be provided for verification of body, bonnet, nozzle
for conformance to standards.
(vi)
Vendors test certificate for material conformance and pressure test to be
(vii)
IBR certificate wherever applicable. Refer clause no. 3.03
(viii)
Radiography/Ultrasonic inspection. Refer clause no. 3.06
(xi)
NACE certificate wherever applicable. Refer clause no. 3.04
(xii)
Corrosion test (Huey test) wherever applicable. refer clause no. 3.05
(xiii)
Sealing test on bellows ( as per manufacturers standard)
4.10
5.00
provided.
Test certificate verification for coefficient of discharge

Packing
Each safety / relief valve and its accessories wherever applicable shall be suitably
packed and protected from damage due to transportation, loading and unloading.
The safety / relief valves alongwith their spares shall be despatched as a single
consignment.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

ES-7234
DOCUMENT NO
REV
SHEET 7 OF 9
6.00
6.01
Each safety / relief valve shall be fitted with a stainless steel permanently fixed
name plate with the following minimum information:
-
Complete tag no of the valve as per inst. data sheet.

Manufacturers name
Valve model and serial no.
Inlet and outlet sizes with ratings
Body and trim material
Bellows material wherever required
Designated orifice with area in sq. cm.
set pressure in kg/cm2.
All valves are applied two coats of red oxide metal primer, prior to applying two final coats
of synthetic enamel paint. The second coat of synthetic enamel paint is applied just
before despatch.
7.00
Spares
Spares shall be as per enclosed spares list.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

8.00
ES-7234
DOCUMENT NO
REV
SHEET 8 OF 9
Documentation
SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
1.
Consolidated list of drawing

& documents.
Catalogue & technical
literature of safety valves
alongwith sizing calculation.
Dimensional and sectional
drawing against each tag
showing material of
Capacity chart for
safety/thermal relief valves
showing set pressure
effective area/for air
capacity, water capacity
against models offered.
Chemical analysis and
material test certificates from
Certificates showing
chemical analysis, corrosion
test (Huey test), Ferrite
content on finished product,
where applicable from an
approved laboratory.
NACE certificate (wherever
applicable) from an approved
laboratory.
Weight of safety / relief
valves.
maintenance.
test certificates including
calibration curve & Cold diff.
test pressure values.
Yes
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
FORM NO: 02-0000-0021F2 REV1

FINAL
FOR APPROVAL/
DOCUMENTS
INFORMATION
BEFORE
WITHIN SIX
DESPATCH OF
WEEKS
CONSIGNMENT
Yes(I)
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes
Yes
Yes
Yes
(approx. weight)
X
Yes(I)
Yes
Yes
Yes
All rights reserved

SL.
NO.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID
12.
IBR certificate for valves

for steam, BFW and
condensate services from
statuary bodies wherever
applicable.
Ultrasonic test certificates
for steel forgings and bars
wherever applicable
Liquid diepenetrant test
certificate for steel
castings and forgings.
15.
List of routine tests

performed on standard
valves and suggested on
special ones.
16.
Radiography inspection
certificate for steel
castings and forgings
Impact test results for LT
steel castings and forgings
Installation, operating and
maintenance manual (12
sets) including parts lists.
Transparency for each tag
no. dimensional drawings.
13.
14.
17.
18.
19.
20.
(A)
for Approval
(I)
ES-7234
DOCUMENT NO
REV
SHEET 9 OF 9

FOR APPROVAL/
FINAL DOCUMENTS
INFORMATION
BEFORE DESPATCH
WITHIN SIX
OF CONSIGNMENT
WEEKS
x
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information.
Sl. no. 1 to 19 shall be forwarded to PDIL/OWNER as per details outlined in Enquiry / order.
Number of sets alongwith bid for approval and as final documentation shall be supplied as
stipulated in the purchase order.
FORM NO: 02-0000-0021F2 REV1
All rights reserved

PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
LPG MOUNDED BULLETS
NUMALIGARH,ASSAM
NRL
EM163-E-7022
1. TAG NO./QTY. / P & I

2. SERVICE
GENERAL
3. LINE NO./VESSEL NO.

4. VALVE CLASSIFICATION
5. DESIGN PRESSURE/TEMPERATURE
6. BONNET TYPE
7. CALCULATION CODE
CON
8. BASIS FOR SIZING;OVER PR. SOURCE

9. INLET SIZE & RATING
10. OUTLET SIZE & RATING
MATERIAL
11. BODY & BONNET

12. NOZZLE & DISC
13. GUIDE
14. BLOWDOWN RING
15. SPRING
ACCESS.
16. BELLOWS
17. CAP
18. LIFTING LEVER
19. TEST GAG
20. PILOT BODY/ NOZZLE MATERIAL
21. FLUID/ FLUID STATE
22. RELIEVING CAPACITY
23. % ALLOWANCE OVER PRESSURE
24. % BLOWDOWN REQUIRED
25. OPERATING/SET PRESSURE
26. OPERATING/ RELIEVING TEMP.
1 24.09.2015
0 14.09.2015
P 21.07.2015
REV
DATE
EM163-7022-ISP-7234
DOCUMENT NO.
Issued for Enquiry

Issued for Enquiry
Draft Enquiry
PURPOSE
AK
AK
AK
PREP
RA
RA
RA
CHKD
45-PSV-3001A,B /02 /EM163-45-0021(P1)

LPG
8"-P-45-3016,3014-B1A / 45-VV-101
SAFETY RELIEF VALVE
14.5 Kg/Cm2g / (-)27 to 55 Deg. C
CLOSED
API 520 / ASME SECTION VIII
EXTERNAL FIRE
8" 300#RF
10"150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cadmium Plated Carbon Steel
SS316L
SCREWED
PACKED LIFTING LEVER
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40 / 65 C
45-PSV-3002A,B /02 /EM163-45-0021(P1)

LPG
8"-P-45-3020,3019-B1A / 45-VV-102
SAFETY RELIEF VALVE
14.5 Kg/Cm2g / (-)27 to 55 Deg. C
CLOSED
EXTERNAL FIRE
8" 300#RF
10"150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cadmium Plated Carbon Steel
SS316L
SCREWED
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40/ 65 C
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
'0.62-2.26 Kg/cmg
-
'0.62-2.26 Kg/cmg
-
13974.09 ft
249.6 cm(124.8cmforeachPSV)
42.19 inch (26 inch for each valve)
T
NOTE-1
13974.09 ft
T
NOTE-1
30.
31.
LATENT HEAT AT SET PRESSURE

COMPRESS. FACTOR
EXHAUST FLOW RATE
34.
35.
LIQ.PH.
SPECIFIC HEAT RATIO
33.
DENSITY AT SET CONDITION

VISCOSITY
37.
38.
39.
BACK PR.
2
36. ACCULUMATION % MAWP (Kg/cm g)
CONSTANT BACK PRESSURE

VARIABLE BACK PRESSURE
BUILD UP BACK PRESSURE
TOTAL BACK PRESSURE
41.
OPERATING PRESSURE TUBE SIDE
42.
NORMAL FLOW TUBE SIDE
44.
45.
46.
TUBE FAILURE
40.
43.
FLUID TUBE SIDE/ STATE

TUBE INTERNAL DIAMETER
EXPANSION FACTOR
SP. GRAVITY AT STD. CONDITION
47.
SP. GRAVITY AT OP. CONDITION
48.
LATENT HEAT OF VAPOUR
49.
50.
ORIFICE
EXHAUST FLOW RATE

MOL. WEIGHT/ SP. GRAVITY
32.
FIRE
PROCESS DATA PIPE/ SHELL SIDE
29.
GAS PHASE
27. STEAM CONDITION

28.
ENVIRONMENTAL FACTOR
EXPOSED WET AREA
51. CALCULATED ORIFICE AREA

52. SELECTED ORIFICE AREA
53. ORIFICE DESIGNATION
54. STEAM JACKET (YES/NO)
OPTION
55. JACKET CONN./ MATL.

56. WASHING CONN. (Y/N)
57. WASHING CONN. SIZE/MATL.
58. IBR/LLYOD'S CERTIFICATE

59. ULTRASONIC / RADIOGRAPHY TEST
NOTES
MODEL NO. :
SKT
SKT
SKT
APPD
1. Vendor to Specify.
2. LPG Bullet is horizontal , ID =7000mm , TL-TL : 52000 mm. Both ends of Bullet are hemispherical.
3. Vendor to submit safety valve sizing calculations and reconfirm the size.

PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
LPG MOUNDED BULLETS
NUMALIGARH,ASSAM
NRL
EM163-E-7022

2. SERVICE
GENERAL

6. BONNET TYPE
7. CALCULATION CODE
CON
CON

MATERIAL
11. BODY & BONNET

12. NOZZLE & DISC
13. GUIDE
14. BLOWDOWN RING
15. SPRING
ACCESS.
16. BELLOWS
17. CAP
18. LIFTING LEVER
19. TEST GAG
1 24.09.2015
0 14.09.2015
P 21.07.2015
REV
DATE
EM163-7022-ISP-7234
DOCUMENT NO.
Issued for Enquiry

Issued for Enquiry
Draft Enquiry
PURPOSE
AK
AK
AK
PREP
RA
RA
RA
CHKD
45-PSV-3003A,B / 02 /EM163-45-0022(P2)
LPG
8"-P-45-3030,3028-B1A / 45-VV-103
SAFETY RELIEF VALVE
14.5 Kg/Cm2g / (-)27 to 55 Deg. C
CLOSED
EXTERNAL FIRE
8" 300#RF
10" 150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cadmium Plated Carbon Steel (Rust Proof)
SS316L
SCREWED
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40 / 65 C
45-PSV-3004A,B / 02 /EM163-45-0022(P2)
LPG
8"-P-45-3039,3037-B1A / 45-VV-104
SAFETY RELIEF VALVE
14.5 Kg/Cm2g / (-)27 to 55 Deg. C
CLOSED
EXTERNAL FIRE
8"300#RF
10" 150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cadmium Plated Carbon Steel (Rust Proof)
SS316L
SCREWED
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40/ 65 C
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
62161 Kg/h
52.8 / 64 Kcal/kg
0.84
1.17
-
'0.62-2.26 Kg/cmg
-
'0.62-2.26 Kg/cmg
-
13974.09 ft
T
NOTE-1
13974.09 ft
T
NOTE-1
30.
31.

COMPRESS. FACTOR
EXHAUST FLOW RATE
34.
35.
LIQ.PH.
SPECIFIC HEAT RATIO
33.

VISCOSITY
37.
38.
39.
BACK PR.
2

TOTAL BACK PRESSURE
41.
42.
44.
45.
46.
TUBE FAILURE
40.
43.

EXPANSION FACTOR
47.
48.
49.
50.
ORIFIC
EXHAUST FLOW RATE

32.
FIRE
29.
GAS PHASE
27. STEAM CONDITION

28.
EXPOSED WET AREA

OPTION


NOTES
MODEL NO. :
SKT
SKT
SKT
APPD
2. LPG Bullet is horizontal , ID =7000mm , TL-TL : 52000 mm.Both ends of Bullet are hemispherical.

PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
LPG MOUNDED BULLETS
NUMALIGARH,ASSAM
NRL
EM163-E-7022

2. SERVICE
GENERAL

6. BONNET TYPE
7. CALCULATION CODE
CON
CON

11. BODY & BONNET
MATERIAL
12. NOZZLE & DISC

13. GUIDE
14. BLOWDOWN RING
15. SPRING
16. BELLOWS
ACCESS.
17. CAP
18. LIFTING LEVER
19. TEST GAG
1 24.09.2015
0 14.09.2015
P 21.07.2015
REV
DATE
45-PSV-3007A,B/02/EM163-45-0024(P4)
LPG
1"-FL-45-3078-B1A
SAFETY RELIEF VALVE (BELLOWS)
18 Kg/Cm2g /
90 Deg. C
CLOSED
EXTERNAL FIRE
1" 150#RF
2" 150#RF
ASTM A216 WCB
SS316
SS316
SS316
Cd Plated Carbon Steel (Rust Proof)
SS316L
SCREWED
YES
LPG/VAPOR
NOTE-1
21%
5-7 % OF S.P.
3.35-7.51 Kg/Cm2A /14.5 Kg/Cm2G
10-40 / 65 C
28.
30.
31.
EXHAUST FLOW RATE

COMPRESS. FACTOR
SPECIFIC HEAT RATIO
33.
EXHAUST FLOW RATE
34.
35.
LIQ.PH.
32.

VISCOSITY
39.
BACK PR.
37.
38.

TOTAL BACK PRESSURE
41.
42.
44.
45.
46.
TUBE FAILURE
40.
43.

EXPANSION FACTOR
48.
50.
EXPOSED WET AREA
ORIFIC

OPTION
'0.62-2.26 Kg/cmg
-
47.
49.


MODEL NO. :
NOTES
52.8 / 64 Kcal/kg
0.84
1.17
-
2
FIRE
29.
GAS PHASE
27. STEAM CONDITION
44.615 ft
0.7968 cm
0.196 inch
E
NO
NOTE-1
EM163-7022-ISP-7234
DOCUMENT NO.
Issued for Enquiry

Issued for Enquiry
Draft Enquiry
PURPOSE
AK
AK
AK
PREP
RA
RA
RA
CHKD
SKT
SKT
SKT
APPD
EM163-7022-SP-7234
SPARE PART LIST FOR

DOCUMENT NO
SHEET
1 OF 1
Please refer attached Bill of Quantity at EM163-7022-BOQ-7234 for spare details
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 years spares recommended
by them.
FORM NO: 02-0000-0021F1 REV2
All rights reserved
EM163-7022-BOQ-7234
Bill of Quantity
Rev 1/ 24.09.2015
Sl
No
1
Item
Item Description
PSV-3001A/B
Main Valve
Gasket
Commissionin 'O' RING
g Spares
Other Vendor Recommended Spares
2 Nos
2 Sets
2 Sets
Spare 2 Years Gasket

'O' RING
DISC INSERT
NOZZLE
SPRING
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Main Valve
PSV-3002A/B
2 Sets
2 Nos
Commissionin Gasket
g Spares
'O' RING
2 Sets

'O' RING
DISC INSERT
NOZZLE
SPRING
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Main Valve
PSV-3003A/B
2 Sets
2 Sets
2 Nos
Commissionin Gasket
g Spares
'O' RING
2 Sets

'O' RING
DISC INSERT
NOZZLE
SPRING
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Main Valve
2 Nos
Gasket
2 Sets

'O' RING
DISC INSERT
NOZZLE
SPRING
Main Valve
2 Sets
2 Sets
PSV-3004A/B
Commissionin
'O' RING
g Spares
Qty
45-PSV-3007A/B
Gasket
Commissionin
'O' RING
g Spares
'O' RING
DISC INSERT
NOZZLE
SPRING
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Nos
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
2 Sets
Model No / Part No
<----------By Vendor---------------------->
OVERALL DIMENSIONS OF
EM163-E-7022-SK-7234
DOCUMENT NO.
REV
PRESSURE SAFETY VALVES
OF 1
SHEET 1
INLET
TAG NO.
45-PSV-3001A
45-PSV-3001B
45-PSV-3002A
45-PSV-3002B
45-PSV-3003A
45-PSV-3003B
45-PSV-3004A
45-PSV-3004B
45-PSV-3007A
45-PSV-3007B
SIZE
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
RATING
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
OUTLET
SIZE
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
RATING
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
DIMENSIONS (MM)
A
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
B
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
C
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
WEIGHT IN Kg.
REMARKS
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
Note1
NOTE1: BY VENDOR
FORM NO: 02-0000-0021F3 REV2
All rights reserved
EM163-E-7058
DOCUMENT NO
SHEET 1 OF 3
FOR
DIAL THERMOMETERS
(BIMETAL THERMOMETER)
1
0
P
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
21.07.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7058
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
DRAFT ENQUIRY
PURPOSE
HK
HK
HK
PREPD
RA
RA
RA
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7058
DIAL THERMOMETERS
DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
2
4
5
6
DRAWINGS/
INSTRUMENTS
FOR DIAL THERMOMETERS
FOR DIAL THERMOMETERS
SPARE LIST FOR DIAL
THERMOMETERS
BILL OF QUANTITY FOR DIAL
THERMOMETERS
SKETCHES FOR DIAL
THERMOMETERS
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO./
DOCUMENT NO
EM163-45-102
NO. OF PAGES
01
ES-7321
08
EM163-7058-ISP7321
01
EM163-7058-SP-01
01
EM163-7058-BOQ
01
EM163-7058SK7321-00
02
All rights reserved
EM163-E-7058
DIAL THERMOMETERS
DOCUMENT NO
SHEET 3 OF 3
LIST OF DIAL THERMOMETERS (BIMETAL THERMOMETER)

SL.
NO.
TAG NO.
P&ID NO.
QTY
1.
45-TG-3005
P4
01
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM163-45- 102
Document No.
Sheet 1 of 2
Rev.
GENERALCONDITIONS
Site Location
Plant Location
State / Country
: Assam / India
: Golaghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
Barometric pressure
750 mm Hg
Air temperature
35 0C
Relative humidity
73 %

Air temperature
380C
Relative humidity
85 %
50C (Min)
Rain fall
: NH-39
Heaviest in a day
160 mm
Maximum in one hour
90 mm
Wind
Wind code
Base wind pressure
Seismic Factor
Elevation
Average wind speed
36 km/hr
10
Maximum gust speed
140 km/hr
11
Site conditions
12
08.07.2015
08.07.2015
For Enquire Issue
SKK/ VKS
SCA
SCA
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ES7321
TEMPERATURE GAUGES & THERMOWELL
DOCUMENT NO
SHEET 1 OF 8
FOR
00 02.01.2010
REV REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
FOR ENQUIRY
PURPOSE
SK
PREPD
SKT
REVWD
SKT
APPD
All rights reserved
ES7321
DOCUMENT NO
SHEE 2 OF 8
CONTENTS
SECTION NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
All rights reserved
ES7321
DOCUMENT NO
SHEE 3 OF 8
1.00
General
1.01

herewith define the technical requirement for the supply of Bi-metallic and Mercury in
steel/ gas filled type Dial Thermometers and thermowells, their accessories, name plate
marking, documentation, testing-inspection and packing.
1.02

2.00
2.01
Bi-Metallic Type Dial Thermometer
2.01.01
The Bi-metallic type Dial Thermometers shall be heavy duty precision type.
2.01.02
The thermometer shall be either rigid straight or rigid axial stem or swinging stem with
rotable head as specified against individual specification sheets.
2.01.03
The rotable head shall be rotable up to 360.
2.02
Mercury/Gas filled in Steel Type Dial Thermometer
2.02.01
The Mercury/ gas filled in Steel type Dial Thermometers shall be heavy duty precision type.
2.02.02
The filled liquid shall be mercury/ gas.
2.02.03
The Thermometer shall be rigid stem type.
2.02.04
The case compensation shall be as per SAMA classification.
2.03
Thermowell
2.03.01
Thermowells can either be flanged or screwed type as specified in the instrument

2.03.02
The screwed type thermowell shall have 1 NPT (M) process connection & NPT (F) for
sensor connection.
2.03.03
The flanged thermowell shall be either 1 or 1 or as specified in the instrument

2.03.04
Thermowells of length 600 mm and below shall be fabricated from bar stock. Above 600
mm length bar stock-bar stock combination and bar stock-pipe combination may be used.
Welding joints shall be radiographed.
2.03.05
The thermowell design shall be as per sketches mentioned against each item in the
2.04
The scope as per enclosed instrument specification sheets may include either Bimetallic
Type or Mercury/ gas filled in Steel Type Dial Thermometers. Relevant portion of the
general requirement (item 2.01 to 2.02) shall be applicable for the items covered in the
scope.
2.05
Vendor shall submit thermometer assembly drawings developed at their end on the basis of
the drawings indicated against each tag in the instrument specification sheets. If scope
drawings are not available the vendor shall prepare the same and submit to the Indenter
for approval.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7321
DOCUMENT NO
SHEE 4 OF 8
2.06
For steam, BFW & condensate services the thermowell shall be IBR certified. For items of
foreign origin the certification shall be done by Lloyds or any other IBR approved authorities
in specific IBR formats.
2.07
For corrosive services like UREA, wetted parts of stainless steel 316L grade and Cr-Ni-Mo
25-22-2 alloy shall be used. For these material chemical analysis and corrosion tests
(Huey test) shall be carried out as per ASTM A 262 practice C if Huey test is specified in
the instrument specification. The tests shall be carried out in an approved laboratory.
2.08
Wherever NACE certificate requirement has been specified in Instrument specification, the
material composition & hardness tests shall be conducted only as per MR-0175 latest
2.09
3.00
3.01
Inspection and test. In absence of any Inspection Agency the vendor must submit the
quality Assurance Plan for OWNERs approval. All tests, in such cases, shall be conducted
by vendors Quality Department and the results of tests shall be forwarded alongwith the
supply.
The manufacturer shall give clear 15 days notice informing readiness of the instrument at
manufacturers works. The vendor shall permit the authorized representative of OWNER to
inspect the manufacture and assembly of the instrument in various phases in compliance
with mutually agreed quality assurance plan, standards and specifications. The vendor
shall make available to the authorized representative of OWNER the results of all the
checks/calibrations conducted before presenting for Owners inspection. The vendor to
provide all necessary facilities free of cost to Owners representative for carrying out the
checks/calibration as per standard/approved quality assurance plan. Under no condition
inspection can be waived off without the written permission of OWNER.
3.02
3.03
The procedure & extent of the following physical checks, routine & type test shall be
Authority.
THERMOMETER ELEMENTS
A. Physical checks
B. Routine test
1. Leak test for Mercury in steel type Dial Thermometers.
2. Check for calibration
C. Type test
1. Response time
2. Vibration test
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7321
DOCUMENT NO
SHEE 5 OF 8
THERMOWELL
2. Hydro test (at minimum 1.5 times of Maximum Pressure)
B. Other tests
1. Radiography for bore concentricity (10%), if not otherwise specified in the
2. Radiography for thermowells of pressure rating 100 kg/cm2 g and above (100 %)
3. Die Penetration Test
4.00
Packing
Each thermoelement or alongwith assembly shall be suitably packed and protected from
damage due to transportation, loading and unloading.
maintenance) shall be dispatched as a single consignment.
5.00
5.01
Each temperature element assembly i.e. the sensing element alongwith head assembly
shall have a separate circular tag number plate in stainless steel with engraved tag no and
protecting sheath immersion length I and attached securely to the head assembly with a
soft stainless wire. The size of letters and figures shall be minimum 4 mm and the plate
should be 25 mm diameter with 1-2 mm thick.
5.02
Each thermowell shall have the following marking at position X or XX as shown in the
respective drawings.
(i) Tag no.
(ii) Thermowell model no. / Manufacturers item no.
6.00
Spares
Complete dial thermometer with well of each type & range is included as spares in the
individual instrument specification sheets. Other spares as per enclosed spares list.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7321
7.0
Documentation
1.1
DOCUMENT NO
SHEE 6 OF 8
General
here under.
supplied on paper.
1.2

procedure.
1.3

access.
1.4
Drawings
shall be given.
1.5
Scanned documents
Acrobat.
including:
Deskew
Despeckle
Hole Fill.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7321
DOCUMENT NO
SHEE 7 OF 8
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

same.
certificates from approved
laboratory.
IBR certificate (wherever
applicable)
applicable) from approved
laboratory.
Certificates showing chemical
analysis, corrosion test (Huey test),
Ferrite content on finished product,
where applicable from approved
laboratory.
Yes

authority for degree of protection
against environment.
certificates.
(A)
For Approval
(I)

FOR APPROVAL/
FINAL
INFORMATION
DOCUMENTS
WITHIN SIX
BEFORE
WEEKS
DESPATCH OF
CONSIGNMENT
Yes (I)
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
For information
Sl. no. 1 to 10 shall be forwarded to PDIL/ OWNER as per details outlined in enquiry/order.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7321
8.0
DOCUMENT NO
SHEE 8 OF 8
METHOD OF TENDERING
General
documentation.
Deviations
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM163-7058-ISP7321
DIAL THERMOMETERS
DOCUMENT NO.
SHEET 1 OF 1
CASE
GENERAL
PROJECT NO.
PROJECT
PLANT
CUSTOMER
REQ. NO.
ORDER NO.
MANUFACTURER
:
:
:
:
:
:
:
EM163
NUMALIGARH, ASSAM
NRL
EM163-E-7058
1
24.09.15
0
14.09.15
P
21.07.15
REV
DATE
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
DRAFT ENQUIRY
PURPOSE
HK
RA
HK
RA
HK
RA
PREP CHKD
SKT
SKT
SKT
APPD
1. ELEMENT/ TYPE
CYLINDRICAL BI-METTALIC SPIRAL / Flexible Dial Thermometer (Every angle construction)
2.
3.
4.
5.
6.
7.
8.
9.
STEM OR UNION THREAD

UNION CONNECTION TYPE
STEM & UNION MATERIAL
STEM DIAMETER
TRANSMISSION SHAFT & SLEEVE MATL.
SPRING & FRAME MATERIAL
SENSOR MATERIAL
CASE & RIN#
1/2" NPT(M)
ADJUSTABLE LENGTH , RIGID STEM
SS 316
6 MM
DIRECT ACTING
SS 304
STD BI-METAL
SS 304
10.
11.
12.
13.
14.
ENCLOSURE TYPE
GLASS
DIAL SIZE & COLOUR
SCALE LENGTH
SCALE GRADUATION
IP -65 or better
SHATTER PROOF GLASS
150 MM & BLACK NUMERALS WITH WHITE BACKGROUND
CIRCULAR 270 , SEGMENT
1 div. per C upto span of 100C , 2 div. per C above 100C upto of 300C,
5 div. per C above 300C upto of 400C , 10 div. per C above span of 400C
150 C span - Less than equal to 105 seconds up to 95% span and 50 seconds
from 95% to100% span.
Above 150 C - Less than equal to 180 seconds up to 95% span and 95 seconds
from 95% to100% span.
MICROMETER SCREW AT THE BACK, SS 304 MATERIAL
1% FSD.
15. RESPONSE TIME
OPTIONS
16. ZERO ADJUSTMENT

17. ACCURACY
VENDOR OFFER /
DEVIATION
TAG NO. QTY. P&ID NO.
45-TG3005
01
P4
SERVICE
DRAIN
VESSEL
FOR LPG
LINE NO./
EQUIPMENT
NO
45-VV-106
MIN/NOR./MAX.
PRESS.
TEMP.
Kg/cm 2 g
deg C
-/ 2.35/14.5
1. VENDOR TO CONFIRM TO ES-7321.

2. WAKE FREQUENCY CALCULATION TO BE PROVIDED.
RANGE
DEG C
(-27) / 10-27 to 60
40 /55
IMMERSION
LENGTH
"I. L." mm
400
THERMOWELL
PROCESS MATERIAL /
CONN.
SKETCH NO
1 1/2"
300#RF
ASTM A 182
Gr. F316 or
better /Note 1
VENDOR OFFER/
DEVIATION
SPARES LIST FOR

DIAL THERMOMETERS
EM163-7058-SP- 00
DOCUMENT NO
SHEET 1 OF 1
NOTE :
1. The vendor shall also indicate the additional/ applicable 2 Years Operational spares
FORM NO: 02-0000-0021F1 REV2
All rights reserved
EM163-7158-BOQ
Rev 1/14.09.2015
Bill of Quantity
Sl
No
1
ITEM
TAG NO.
TEMPERATURE GAUGE
45-TG- 3005
SPARE 1

Range or min. 1 No.
2 Years Operational Spares

3
Model No / Part No
<-------By Vendor----->
(
DIAL THERMOMETERS (BIMETAL
THERMOMETER)) WITH THERMOWELL
2
Qty
SPARE 2

Range or min. 1 No.
Page 1 of 1
EM163-7058SK7321-00
BIMETALIC THERMOMETER ASSEMBLY

SWINGING STEM
DOCUMENT NO.
SHEET 1
OF 2
Swing Head
( 0 - 180 Rotation )
150
Adjustable
Compression Joint
()
NPT M
Bulb 6 mm
NOTES :
1.
FOR MATERIAL OF CONSTRUCTION OF VARIOUS PARTS. FLANGE RATING & FACING

REFER SPECIFICATION.
2.
LENGTH I TO SUIT THERMOWELL.
3.
DIMENSIONS ARE TENTATIVE MAY VARY WITH EQUIPMENT SIZE & CAPACITY.
4.
ALL DIMENSIONS ARE IN MILLIMETRES. UNLESS OTHERWISE STATED.
1
0
P
24.09.2015
14.09.2015
20.07.2015
REV
REV DATE
EFF DATE
FORM NO: 02-0000-0021 F3 REV0

HK
HK
HK
RA
RA
RA
PURPOSE
PREPD
REVWD
SKT
SKT
SKT
APPD
All rights reserved
BIMETALIC THERMOMETER ASSEMBLY

SWINGING STEM
EM163-7058SK7321-00
DOCUMENT NO.
OF 2
200+/0.5
SHEET 2
8 mm +/- 0.2 mm
1
0
P
24.09.2015
14.09.2015
20.07.2015
REV
REV DATE
EFF DATE
FORM NO: 02-0000-0021 F3 REV0

HK
HK
HK
RA
RA
RA
PURPOSE
PREPD
REVWD
SKT
SKT
SKT
APPD
All rights reserved
EM163-E-7046
DOCUMENT NO
SHEET 1 OF 3
FOR
MAGNETIC TYPE LEVEL GAUGE
1
0
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7046
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
PURPOSE
AK
AK
PREPD
RA
RA
REVWD
SKT
SKT
APPD
All rights reserved
EM163-E-7046

DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
DRAWINGS/
INSTRUMENTS
FOR MAGNETIC TYPE LEVEL
GAUGE
FOR LEVEL GAUGE
SPARES FOR LEVEL GAUGE
BOQ FOR LEVEL GAUGE
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO.
/ DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7278
09
EM163-7046-ISP7278
EM163-7046-SP7278
EM163-7046-BOQ7278
01
01
01
All rights reserved
EM163-E-7046

DOCUMENT NO
SHEET 3 OF 3
LIST OF MAGNETIC TYPE LEVEL GAUGE
SL.
NO.
TAG NO.
45-LG-3016
FORM NO: 02-0000-0021F2 REV1
P & ID
EM163-45-0024(P4)
QTY
01
All rights reserved
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions

t SW
12
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
Forr Enquire Issue
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEET 1 OF 9
FOR
LEVEL GAUGES
00 07.07.2011
REV REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
FOR IMPLEMENTATION
PURPOSE
PREPD
REVWD
APPD
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 2 OF 9
CONTENTS
SECTION NUMBER
FORM NO: 02-0000-0021F2 REV1
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
8.0
METHOD OF TENDERING
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 3 OF 9
1.00
General
1.01
This Engineering specification is applicable for the transparent, reflex type and Magnetic
type level gauges.
herewith define the technical requirement for the supply of Level gauges, their
1.02

2.00
2.01
Chamber
2.01.1
The liquid chamber section (single or multiple sections) shall be made out of one piece of
solid block of carbon steel or stainless steel as per requirement. The material to be used
shall be suitably treated and chosen with care to meet exactly the physical and chemical
characteristics of the working condition.
2.01.2
The glass sealing gasket shall be suitable for the handled fluid. Both the sealing and the
cushion gaskets shall be designed to ensure uniform pressure on the glass.
2.01.3
Wherever combined sections are required to be used, they must not exceed four.
Deviations if any, are listed against each tag in the enclosed individual specification sheets.
2.01.4
The pressure rating shall be in accordance with the instrument individual specification
sheets. However, minimum pressure rating shall be 300 lbs or 40 kg/cm2 g.
2.02
Cover
The covers shall be made out of drop forged temperature resisting steel or from solid bar of
steel.
2.03
Glasses
2.03.1
The glasses shall be flawless, perfectly flat, toughened boro-silicate, polished to ensure
optimum transparency and thermally pre-stressed. They shall be suitable for use at high
temperature and pressure.
2.03.2
Glass section length of 280 mm (No. 7 of Klinger) shall be used as standard.
2.03.3
Reflex glasses wherever applicable shall be with moulded grooves at 90 deg. angles.
2.03.4
Glasses on steam services shall be protected by means of high quality mica shield.
For other erosive services kel-F shield may be used, if not otherwise stated in the
2.04
Illuminators
2.04.1
Illuminators shall be provided for all transparent gauges wherever specified in Instrument
specification sheet. All illuminators shall be suitable for area classification indicated in the
specification sheet. If Indian Standard IS 2148 certification is specified in the individual
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 4 OF 9
specification sheets for Ex. proof enclosures then IS - 2148 certification must be
supplemented with the temperature classification certification confirming to IS - 8239.
2.04.2
Power supply for lamps shall be 240V 10% AC 50 Hz, cable entry 1/2 NPT (F) complete
with cable gland. The cable glands, in general, shall be double compression type of SS316
, if not otherwise specified in the individual specification sheets. The lamp holder shall be
suitable for tropical condition and shall be designed to prevent unscrewing of the lamp due
to vibration. Lamps shall be under rated for extended lifetime and shall be included in
supply. The terminals should be suitable for 3 X 2.5 mm2 Cu conductors.
2.04.3
The diffuser must not cover more than two sections for transparent gauges and it shall be
suitable for the maximum working temperature.
2.04.4
The Illuminators shall be easily removable without interfering with the operation of the level
gauges.
2.05
MAGNETIC TYPE
2.05.01 Magnetic type level gauges shall be used for the measurement of all liquids, including
dangerous, toxic or flammable fluids where glass breakage would cause a hazard.
Magnetic type level gauges shall be considered for:
Cryogenic services
Fluids that attack glass (e.g., strong acids, alkalies, boiler feed water)
Light ends services
Toxic services
Pressures above 500 psig (3450 kPa) special consideration must be given to the design
of float for high pressure
2.05.02 Magnetic- type level gauges shall consist of a liquid chamber enclosing a float which is
magnetically coupled to a rotary wafer-type indicator. The liquid chamber shall be onepiece construction with a minimum internal diameter of 50 mm, provided with a bottom
flange for removal of the float, vent and drain connections. Indicator shall be adjustable
around the chamber with provisions to indicate float failure.
2.05.03 Magnetic level gauges shall be top or side mounted type and shall consist of a float with
extended rod and magnet at the end of extension, magnet tube / chamber and float guide
pipe. When the float moves up and down with the liquid level inside the vessel, the magnet
moves up and down inside the magnet tube/chamber which in turn operates the indication
mechanism.
2.05.04 The indication shall consist of bi-colour (red/white) magnetic rollers mounted on outside the
magnet chamber. As the float rises or falls with the liquid level each roller rotates 180 Deg
and so presents a contrasting colour.
2.05.05 The accidental rotation of rollers shall be prevented by the construction/design such as
edge magnetization.
2.05.06 Floats shall be designed and manufactured for the specific conditions specified on
datasheets. It shall be designed to be adequate for hydrostatic test conditions.
2.05.07 Floats shall be hermetically sealed, no vented or pressure equalized construction shall be
allowed.
2.06
Gauge Valves
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 5 OF 9
The gauge valves shall be connected at top and bottom through 3/4 NPT unions and the
body material of gauge valves shall be same as that of chamber. Valve trim and safety ball
shall be of stainless steel. Drain and vent valves shall also be of same material and shall be
furnished with 1/2 NPT (F) connection with plug for drain and vent pipe. Requirement of
both, either or none for vent and Drain valves including quantities shall be indicated in the
option column. Hand wheel material for all gauge/drain/vent valves shall be C.S.
Deviations, if any, are listed in the individual specification sheets.
2.07
Steam Jacketing
For heavier and slurry services like reduced crude oil, heavy vacuum gas oil, slop-cut, short
residue, vac. residue, Bitumen, urea service, etc. the level gauge shall be provided with
steam jacketing arrangement. The steam jacketing connections shall be 1/2 NPT (F).
2.08
Anti-Frosting Extension
Shall be mounted on opposite side of the illuminator where the minimum operating
temperature is below zero. The extension block shall be attached with visible width of glass
and thickness shall be selected on the basis of the temperature to ensure that extension is
always ice-free.
2.09
IBR certificate
For steam, BFW and condensate services the gauge shall be tested and certified by Indian
Boiler Regulation Authorities (IBR). For items of foreign origin the certification
shall be done by Lloyds or any other IBR approved authorities in specific IBR formats.
2.10
Wherever NACE certificate requirement has been specified in Instrument specification, the
2.11
The scope as per enclosed instrument specification sheets may include either Reflex level
gauge or transparent level gauge or combination of both. Relevant portion of the general
requirement (item 2.01 to 2.07) shall be applicable for the items covered in the scope.
2.12
3.00
3.01
Inspection and test. In absence of any Inspection Agency the vendor must submit the quality
Assurance Plan for PDIL/OWNERs approval. All tests, in such cases, shall be conducted by
vendors Quality Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the gauges at
manufacturers works. The vendor shall permit the authorized representative of
PDIL/OWNER to inspect the manufacture and assembly of the gauges in various phases in
compliance with mutually agreed quality assurance plan, standards and specifications.
results of all the checks/calibrations conducted by them, if any before presenting for
PDIL/Owners inspection.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 6 OF 9
3.02
The following physical checks and other tests shall be witnessed by PDIL / owner
inspection authority. The procedure & extent of test shall be governed by Quality
A) Physical Checks
1) Name Plate details
- Tag no.
- Model no.
- Range and C.C. distance visibility
- Execution (IP, Ex `d etc. for illuminators)
2) Process connection/Electrical connection.
3) Provision of all accessories as per specification.
4) Steam jacketing arrangement and their connection.
B) Other Tests
1) Liquid chamber hydraulic test at 1.5 times of the rated pressure (flange rating) or
kg/cm2 g whichever is greater.
40
2) Steam jacketing chamber hydraulic test up to 1.5 times the steam pressure being
used for heating purposes.
3) Functioning checking of illuminators.
4) IBR/ NACE Certification wherever applicable.
4.00
Packing
Each level gauges and its accessories shall be suitably packed and protected from damage
due to transportation, loading and unloading.
The level gauges alongwith spares for maintenance shall be dispatched as a single
consignment.
5.00
5.01
5.02
All level gauges shall have a tag plate in SS screwed to the level gauge case indicating
make, model no., Sl. no. , tag no., centre to centre distance etc. Besides the above each
number and attached securely to the instrument with a soft stainless wire. The size of
letters and figures shall be minimum 4 mm and the plate should be 25 mm diameter with 12 mm thick.
5.03
All spare parts to be supplied alongwith the main consignment shall be fitted with
- Spare parts name/model no. as per purchasers Instrument specification sheet.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 7 OF 9
- Serial no.
6.00
Spares
7.0
Documentation
1.1
General
here under.
supplied on paper.
1.2

procedure.
1.3

access.
1.4
Drawings
shall be given.
1.5
Scanned documents
Acrobat.
including:
Deskew
Despeckle
FORM NO: 02-0000-0021F2 REV1
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 8 OF 9
Hole Fill.
The following documents (Technical) are required to be submitted by the vendor alongwith bid, after
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

level gauges alongwith their
accessories.
Sketch showing steam jacketing
arrangement for applicable
gauges.
same.
applicable)
laboratory.
Material Test Certificates for
physical properties and chemical
composition from an approved
laboratory.
Functional test certificates.
Copies of relevant certificates for
Ex proof execution of illuminators
from competent authority
Instruction manual for
maintenance.
(A) For Approval
Yes

For approval/
Final documents
information within
before dispatch of
six weeks
consignment
Yes(I)
Yes
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
Yes
x
Yes
x
x
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
(I) For Information
Sl. no. 1 to 11 shall be forwarded to PDIL/ OWNER as per details outlined in enquiry / order.
in the purchase order.
FORM NO: 02-0000-0021F2 REV1
stipulated
All rights reserved
ES7278
LEVEL GAUGES
DOCUMENT NO
SHEE 9 OF 9
8.0
METHOD OF TENDERING
General
documentation.
Deviations
FORM NO: 02-0000-0021F2 REV1
All rights reserved
MAGNETIC LEVEL GAUGE (INTERFACE MEASUREMENT)
NRL
PROJECT
EM-163 INSTALLATION OF LPG MOUNDED BULLETS
PLANT
NUMALIGARH, ASSAM
DOC NO
NO.
EM163-7046-ISP-7278
STEAM
M
JACKETI
TING
TESTING
CHECK /
DRAIN & VENT
VALVES
GAUGE
PROCESS
S
CONDITION
NS
GENERAL
CLIENT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
TAG NO. / QTY
45-LG-3016 / 1 No.
SERVICE
P & ID No
LINE NO. / EQUIPMENT NO.
LPG + WATER
EM163-45-0024 (P4)
- , 45-VV-106
IEC ZONE 1, Gr IIA IIB,T3
LPG/WATER
2.33
8.6 / 14.5
2.33-8.6
10-40 / 55
14.5
kg/cm2 g
-27/55
Deg C
558/1000
kg/m3
0.152/cP
MAGNETIC TYPE FOR INTERFACE MEASUREMENT
ALUMINIUM, BI COLOUR (Red & White)
NA
800 mm
800 mm
2" 300#RF (125-250 AARH)
SIDE -SIDE
2" NB,SCH 40S/ SS 316
SS-316
SPIRAL WOUND SS 304
SS316
ASTM A-105
ASTM A193 Gr B7 / ASTMA194Gr2H
IP 65 OR BETTER
BALL VALVE
ASTM A-105
SS316
TEFLON
800#
-
32
AREA CASSIFICATION
FLUID (UPPER/LOWER)
PRESSURE Nor/Max(Kg/cm2 g)
TEMPERATURE Nor/Max C
DESIGN PRESSURE
DESIGN TEMPERATURE
DENSITY (UPPER /LOWER)
VISCOSITY
TYPE
INDICATOR TYPE (FLAPPER)
SECTIONS REQUIRED
C-C DISTANCE
VISIBLE LENGTH
PROCESS CONNECTION SIZE & FINISH
CONNECTION ARRANGEMENT
BODY OR CAGE SIZE /MATERIAL
SCALE MATERIAL
GASKET MATERIAL
FLOAT MATERIAL
FLANGE MATERIAL
STUD & NUT MATERIAL
INGRESS PROTECTION
TYPE
BODY MATERIAL
TRIM MATERIAL
GLAND PACKING
RATING
HYDROGEN SERVICE REQUIREMENT
33
SOUR & HIC SERVICE
34
IBR REQUIREMENT
35
STEAM JACKETING
36
MATERIAL & INLET / OUTLET SIZE
STEAM PARAMETER
37
NOTE
The Vendor shall determine required Float Dimensions.
Bottom Flange Connection shall be suitable for easy removal of Float for maintenance in case of failure.
The indicating System shall be hermetically sealed.
1
0
REV
24.09.15
14.09.15
DATE
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
DESCRIPTION
AK
AK
PREPD
RA
RA
CHKD
SKT
SKT
APPD
SPARE LIST FOR MAGNETIC TYPE LG
EM163-E-7146-SP-7278
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 years Operational
spares recommended by them.
Bill of Quantity
Sl
No
Item
Item Description

Spare 1
Spare 2
Spare 3
45-LG-3016
EM163-E-7046-BOQ-7278
Qty
MAGNETIC LEVEL GAUGE

1
2
3
4
5
6
7
Float of each type.

Body Gasket
Gland Packing for Isolation gauge
valve
2 years operational Spares
Spare 4
Float of each type.
Spare 5
Body Gasket
Spare 6
Gland Packing for Isolation gauge
valve
1 set
1 set
1 set
1 set
1 set
1 set
Rev 1 /24.09.2015
Model No / Part No
<-------By Vendor----->
EM163-E-7048
DOCUMENT NO
SHEET 1 OF 3
FOR
DISPLACER TYPE LEVEL TRANSMITTER
1
0
REV
PROJECT NO.
PROJECT
:
:
PLANT
CLIENT
ENQUIRY NO.
:
:
:
24.09.2015
14.09.2015
REV DATE
EFF DATE
FORM NO: 02-0000-0021F1 REV2
EM163
BULLETS
NUMALIGARH, ASSAM
NRL
EM163-E-7048
ISSUED FOR ENQUIRY

ISSUED FOR ENQUIRY
PURPOSE
AK
AK
PREPD
RA
RA
REVWD
SKT
SKT
APPD
All rights reserved
EM163-E-7048

DOCUMENT NO
SHEET 2 OF 3
LIST OF ATTACHMENTS
SL.
NO.
1
2
5
6
DRAWINGS/
INSTRUMENTS
FOR DISPLACER TYPE LEVEL
TRANSMITTER
FOR DISPLACER TYPE LEVEL
TRANSMITTER
SPARES FOR DISPLACER TYPE
LEVEL TRANSMITTER
BOQ FOR DISPLACER TYPE
LEVEL TRANSMITTER
FORM NO: 02-0000-0021F2 REV1
ATTACHMENT NO.
/ DOCUMENT NO
EM163-45-102
NO OF PAGES
01
ES-7287
07
EM163-7048-ISP7287
01
EM163-7048-SP7287
EM163-7048-BOQ7287
01
01
All rights reserved
EM163-E-7048

DOCUMENT NO
SHEET 3 OF 3
LIST OF DISPLACER TYPE LEVEL TRANSMITTER
SL.
NO.
TAG NO.
P & ID
QTY
45-LT-3013
EM163-45-0024(P4)
01
FORM NO: 02-0000-0021F2 REV1
All rights reserved
EM1
163-PNIN-000
00
Document No.
Sheet
S
1 of 1
Re
ev.
PR
ROJECTS & DEVELOPME
D
ENT INDIA LT
TD
G
GENERA
ALCONDITIONS
SITE METEROLO
M
OGICAL DA
ATA
Site Lo
ocation
Plant Loccation
: Numa
State / Country
C
: Assam
m / India
: Golag
ghat
Nearest Airport
: Jorhat
Nearest Sea Port
: Kolkata
arometric pressure
p
Ba
750 mm
m Hg
Air temperature
35 0C
R
Relative
hum
midity
73 %
M
Maximum
/ Design
D
Am
mbient condition
Air temperature
380C
R
Relative
hum
midity
85 %
M
Minimum
Am
T
e 50C (Min)
R
Rain
fall
: NH-3
39
Heaviest in a day
160 mm
m
M
Maximum
in
n one hour
90 mm
W
Wind
W
Wind
code
As per relevant
r
IS code
Ba
ase wind pressure
As per relevant
r
IS code
Se
eismic Facttor
As per IS:
I 1893 Se
Elevation
90 m ab
bove Mean
n sea level
Av
verage wind speed
36 km/h
hr
10
M
Maximum
gu
ust speed
140 km/hr
11
Site conditions

t SW
12
ean
M
Maximum/
hr
21.0
07.2015
21.07.2015
Forr Enquire Issue
HK
RA
SKT
RE
EV
REV
V DATE
EFF DATE
PURPOSE
PREPD
REVWD
A
APPD
ES-7287
DOCUMENT NO.
REV
SHEET
OF
FORM NUMBER 02-0000-0021 F1 REV O
LEVEL TRANSMITTER
05.02.99
REV
DATE

iIIMPLEMENTATIONCOMMENTS
PURPOSE
DDCPN
PREPARED
CISC
REVIEWED
DHPV
APPROVED

LEVEL TRANSMITTER
ES-7287
DOCUMENT NO.
REV
SHEET
OF
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

LEVEL TRANSMITTER
ES-7287
DOCUMENT NO.
REV
SHEET
OF
1.00 General
1.01 This general specification is applicable for the displacer type level transmitter with external
chamber or top vessel mounted type without chamber.
This Engineering specification together with the Instrument specification attached herewith
define the requirement for the supply of Displacer type Level transmitters, its spares,
1.02 In the event of any conflict between Engineering specification and Instrument specification
the later shall prevail.
2.00 General requirements
2.01 The displacer chamber for external mounted type shall have 1 1/2 ASME B16.5 flanged
connection or Butt weld type as per ASME B16.25 or as specified in individual Instrument
specification sheets.
2.02 All flanges and their facings shall be as per ASME B 16.5. All raised face flanges shall
have concentric serrated facing. All flanges of rating 900# and above shall have RTJ
facing. All RTJ flanges shall have groove corresponding to octagonal metal ring gaskets
as per ASME B 16.20.
2.03 Orientation of connection, rating, flange facing and centre to centre distance shall be as
indicated in individual Instrument specification sheets enclosed.
2.04 The vessel top mounted type without any external chamber shall have 4 ASME B 16.5
flanged connection or as specified in individual Instrument specification sheet.
2.05 The material of construction for external chamber, displacer, range spring, torque tube
shall be as per individual Instrument specification sheets enclosed. The construction shall
be with rotatable head and plain extension. In case the operating temperature is above
1500 C, radiating finned extension shall be provided.
2.06 The level transmission between displacer and transmitter shall be either through torque
tube or magnetic coupling.
2.07 The transmitters shall be intelligent SMART version with 4-20 mA DC analog output
superimposed with digital signal for maintenance through HART protocol. The transmitters
must have provision for upgrading the communication protocol to fieldbus in future.
2.08 Components made of copper and copper alloys exposed to atmosphere and coming in
2.09 All welded joints subjected to fluid pressure shall be X-rayed for pressure rating 900 lbs.
and above.
2.10 The transmitter shall have protection against reverse polarity connection.
2.11 The transmitter shall be unaffected due to radio frequency interference. The supplied
20 - 500 MHz in a field strength of 20 volts/ metre.
2.12 Cables entries shall be plugged to avoid damage during transit.

LEVEL TRANSMITTER
2.13
ES-7287
DOCUMENT NO.
REV
SHEET
OF
The external chamber, and other wetted parts in steam , BFW and condensate services
shall be tested and certified by Indian Boiler Regulation Authorities (IBR). For items of
foreign origin the certification shall be done by Lloyds or any other IBR approved
2.14 For corrosive services like UREA and wetted parts of stainless steel 316L grade and CrNi-Mo 25-22-2 alloy shall be used for these material chemical analysis and corrosion tests
(Huey test) shall be carried out as per ASTM A 262 practice C. The tests shall be carried
out in an approved laboratory.
2.15 Wherever NACE certificate requirement has been specified in Instrument specification, the
2.16 The electrical terminals shall be vibration proof . The transmitter terminals shall preferably
acceptable.
2.17 Transmitters and switches in hazardous areas shall either be ex-proof/flame proof or
intrinsic safe conforming to area classification, execution and execution standard
specified against each item in the individual specification sheets. Indian Standard(IS)
certification IS T2148 for Ex-proof certification must be supplemented with the
temperature classification certification conforming to IS - 8239. However, any
ex.proof/flame proof certification requiring sealing of cable entry with sealing compound
or enclosures with sealed cable entry and flying leads are not acceptable.
3.00 Inspection, Factory tests and approval
3.01 Within two weeks of receipt of the LOI/order the vendor must contact the Inspection
carrying out Inspection and test including tests to be conducted by independent agencies.
In absence of any Inspection Agency the vendor must submit the quality Assurance Plan
for PDIL/OWNERs approval. All tests, in such cases, shall be conducted by vendors
Quality Department and the results of tests shall be forwarded alongwith the supply.
The manufacturer shall give clear 15 days notice informing readiness of the instruments at
manufacturers works. The vendor shall permit the authorised representative of
PDIL/OWNER to inspect the manufacture and assembly of the level transmitter in various
specifications.
The vendor shall make available to the authorised representative of PDIL / OWNER the
results of all the checks / calibrations conducted by them on the basis of approved Quality
Assurance Plan for PDIL/Owners inspection.

LEVEL TRANSMITTER
ES-7287
DOCUMENT NO.
REV
SHEET
OF
3.02 The following physical checks, routine tests as a minimum shall be witnessed by PDIL /
A. Physical Checks
- Tag no.
- Model no.
- Range
B. Routine tests
2. Zero-shift
3. Hydraulic test.
3.03 Other Tests
bodies ,as applicable.
4. IBR for steam BFW & steam condensate services.
4.00 Packing
Each transmitter and its accessories shall be suitably packed and protected from damage
due to transportation, loading and unloading.
The transmitters and their accessories alongwith spares shall be despatched as a single
consignment. Commissioning and 2 years operation spares shall be packed separately
with proper identification marking.
5.00 Identification and Marking
5.01 Self adhesive tapes or signs are not permissible for permanent marking of any instrument.
5.02 All instruments shall have a tag plate in SS screwed to the transmitter case indicating
make, model no., sl.no., tag no., adjustable range, set range etc. Besides the above each
instrument to have a separate circular tag number plate in stainless steel with engraved
tag number and calibration range and attached securely to the instrument with a soft
stainless wire. The size of letters and figures shall be minimum 4 mm and the plate
should be 25 mm diameter with
1-2 mm thick.
5.03
All spare parts to be supplied alongwith the main consignment shall be fitted with
- Spare parts name, model no. as per purchasers Instrument specification sheet.

LEVEL TRANSMITTER
- Serial no.
6.00 Spares
ES-7287
DOCUMENT NO.
REV
SHEET
OF

LEVEL TRANSMITTER
7.00
ES-7287
DOCUMENT NO.
REV
SHEET
OF
Documentation
alongwith bid, after placement of order for approval purposes and final
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DESCRIPTION OF
DOCUMENT
Consolidated list of drawings &

documents.
accessories.
same.
Dimensional and sectional
drawing against each tag showing
material of construction of each
part.
laboratory.
Certificates showing chemical
analysis, corrosion test (Huey
test), Ferrite content on finished
product where applicable from an
approved laboratory.
IBR certificate (where applicable).
NACE certificate (where
laboratory.
execution.
maintenance.
certificates.
ALONGWITH
BID
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
INFORMATION BEFORE
DESPATCH OF
WITHIN SIX
WEEKS (6 sets) CONSIGNMENT
Yes (I)
Yes
Yes
Yes
Yes
Yes(I)
Yes
Yes
Yes
x
x
x
x
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A) (within 2
weeks)
(A)
for Approval
(I)
for Information
Sl. no. 1 to 11 shall be forwarded to PDIL/ OWNER as per details outlined in enquiry / order.
Sl. no. 12 shall be mutually finalised with Inspection authority specified in the order.
DISPLACER TYPE LEVEL

TRANSMITTER
PROJECT NO.
: EM-163
PROJECT
: INSTALLATION OF LPG MOUNDED BULLETS
PLANT
: NUMALIGARH, ASSAM
CUSTOMER
: NRL
OPTIONS
TRANSMITTER
PROCESS
DATA
DISPLACER
BODY
GENERAL
REQ. NO.
: EM163-E-7148
ORDER NO.
:
MANUFACTURER
:
1. TAG NO./ QTY.
2. SERVICE
3. P&I NO./ VESSEL NO.
4. AREA CLASSIFICATION
5. BODY / CAGE MATERIAL
6. NOZZLE SIZE/ORIENTATION
7. NOZZLE RATING & MATERIAL
8. NOZZLE C/C DISTANCE
9. CASE MOUNTING
10. TRANSMISSION
11. TORQUE TUBE MATERIAL
12. RANGE SPRING MATERIAL
13. DRAIN / VENT CONNECTION
14. DRAIN / VENT VALVE MATERIAL
15. VENT VALVE SIZE & RATING
EM163-E-7148-ISP-7287
DOCUMENT NO.
24.09.15
Issued For Enquiry
0 14.09.15
Issued For Enquiry
REV DATE
PURPOSE
45-LT-3013 / 1 No. FOR INTERFACE MEASUREMENT
AK
RA
SKT
AK
PREP
RA
CHKD
APPD
LPG / WATER
EM163-45-0024 (P4) / 45-VV-106
ZONE-1, IIA IIB , T3 as per IEC Norms
SS316
3" / Side-Side
300# / ASTM A105
800 mm
Note-1
LVDT / Torque Tube
SS 316
SS 316
1/2" NPT , Vent conn. shall be plugged
Body: A105 ; Trim: SS 316
1/2", 800# , Qty. 2 Nos.
16. DRAIN VALVE SIZE & RATING
1/2", 800# , Qty. 2 Nos.
17. DISPLACER LENGTH
Note-1
18. DISPLACER EXTENSION
Note-1
19. DISPLACER MATERIAL
SS 316
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
DISPLACER ROD MATERIAL

UPPER FLUID/ LOWER FLUID
SP. GR. UPPER/ LOWER
DENSITY UPPER/ LOWER
VISCOSITY UPPER / LOWER
PRESSURE
MIN./ NORM./ MAX.
TEMPERATURE MIN/NORM/MAX
TYPE
OUTPUT
SS 316
LPG / Water
-/558 / 1000 Kg/m3
0.152 / CP
30.
31.
32.
33.
34.
35.
36.
ACCURACY
OUTPUT ACTION: LEVEL RISE
ENVIRONMENTAL PROTECTION
EXECUTION
OUTPUT METER LINEAR
ELEC. POWER/ AIR SUPPLY
CABLE GLAND CONNECTION
- / 8.6 / 14.5- Kg/cm2g

- / 40/ 55 C
Smart with HART Protocol
CONTINOUSLY ADJUSTABLE EXTERNALLY, NON INTERACTING TYPE
4-20mA DC + LATEST HART PROTOCOL
+/ - 0.25 % OF CALIBRATED SPAN OR BETTER (INCLUDING
LINERARITY,HYSTERESIS & REPEATABILITY)
Output increases with level rise
IP 65 or NEMA 4X as minimum
EExd as per CENELEC / IEC
Integral Output meter
24V DC, Loop Powered
1/2" NPT(F) 2 Nos. (SS 316 Double Compression type)
37. ELEC. HOUSING
MATERIAL : ALUMINIUM ALLOY WITH EPOXY POLYESTER PAINTING.
38. RANGEABILITY
3:1
39.
40.
41.
42.
43.
Local and Remote

YES
CALIBRATION
IBR/ NACE CERTIFICATE
RADIOGRAPHY / ULTRASONIC
CORROSION (HUEY) TEST
HAND HELD CALIBRATOR
SKT
44. COOLING EXTN. /HEATING JACKET

45. WASHING CONNECTION
46. LOCAL INDICATION
47 LIGHTENING PROTECTION
Yes
REQUIRED
48 ADDITIONAL REMOTE INDICATOR

49 CMRI / DGMS & CCOE approved
49 MODEL NO. :
REQUIRED. DIGITAL, Loop Powered with mounting accessories, visible from Deadman
type valve + SS Plug, IP-65 with two nos. cable entries.
REQUIRED
Note-1
NOTES :
1. Manufacturer to specify.
2. Interconnecting Cable between Displacer Level Transmitter and Local Indicator shall be in Vendor's
scope. Vendor to specify length.
SPARE LIST FOR DISPLACER TYPE

LEVEL TRANSMITTER
EM163-E-7048-SP-7287
DOCUMENT NO.
REV
SHEET
OF
NOTE: 1. The vendor shall also indicate the additional/ applicable 2 Years Operational spares
recommended.
EM163-E-7048-BOQ7287
Bill of Quanity
Rev 1 / 24.09.2015
Sl
No
Item
Item Description
Qty
Model No / Part No
<-------By Vendor----->
45-LT-3013
1
Main Transmitter
2
3
COMMISSIONING SPARES
Gasket
Spare 1
DISPLACER
Spare 2
Spare for 2 Years Operation

Spare 3
1 SET
1 SET
EM163-PNIN-7901-PA
ART C
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTC
SPECIF
FICATIO
ONS FOR
R ERECT
TION MA
ATERIALS OF
TECHNICAL
L SPECIF
FICATIO
ONS
OR PROC
CUREMENT AN
ND
FO
INSTALL
LATION / COMM
MISSION
NING OF
INST
TRUMEN
NTS
Job
b NO
: EM
M163
Pro
oject
: IN
NSTALLA
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
ent
Clie
: NR
RL
24.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
14.09.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
21.07.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
FORM NO: 02-0000-0021

0
F1 REV3
ES-7337
DOCUMENT NO.
REV
SHEET
1 OF
INSTRUMENT VALVES
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

INSTRUMENT VALVES
ES-7337
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

INSTRUMENT VALVES
ES-7337
DOCUMENT NO.
REV
SHEET 3
OF 5
1.00
General
1.01
This Engineering specification together with the Technical specification attached

herewith define the technical requirement for the supply of instrument isolation
valve, air line valve, valve manifolds, marking documentation, testing-inspection
and packing.
1.02

2.00
2.01
Copper and its alloys shall not be used in fertilizer plants.
2.02
The instrument isolation valves shall be globle pattern forged / barstock with inside
screwed bonnet. The body and trim material, body rating and end connections
shall be as specified in the technical specification. The threadings shall be as per
ANSI B 2.1. The packing material shall be teflon unless otherwise specified. The
handwheel material shall be carbon steel zinc plated. Flow direction shall be
marked on the body. IBR certificate in form IIC, NACE certificate as per NACE
MR-0175-94 shall be furnished wherever required.
2.03
The air line valves shall be three piece full bore ball valves. Body material shall be
SS304 and trim material shall be SS 316 unless otherwise specified in technical
specification. The rating shall be 800#.
2.04
The 3-valve manifolds shall be designed for direct coupling to differential pressure
transmitters having 2 bolt flanges. The manifolds shall contain two main block
valves and an equalising by-pass valve. The valves shall be needle type. They
shall use self aligning 316SS ball seats. The manifold shall be suitable for
mounting on 2 pipe. Packing and O ring material shall be Teflon body material
shall be SS316 and minimum rating 100 kg/cm unless otherwise specified. The
process connection shall be 1/2 NPT(F). The manifolds shall be supplied with
mounting accessories (Cadmium plated) and bolts and nuts.
2.05
The 2 valve manifolds for pressure gauges shall be needle type with vend screw.
3.00
3.01
Within two weeks of receipt of the LOI/order the vendor must contact the
Inspection Agency specified in the order and finalise with them the Quality
Assurance Plan for carrying out Inspection and test. In absence of any Inspection
Agency the vendor must submit the quality Assurance Plan for PDIL/OWNERs
approval. All tests, in such cases, shall be conducted by vendors Quality
Department and the results of tests shall be forwarded alongwith the supply.
material at manufacturers works. The vendor shall permit the authorised
material in various phases in compliance with mutually agreed quality assurance

INSTRUMENT VALVES
ES-7337
DOCUMENT NO.
REV
SHEET 4
OF 5
The vendor shall make available to the

authorised representative of PDIL / OWNER the results of all the tests conducted
before presenting for PDIL/Owners inspection.
Normally the vendor shall have their own quality control requirements and
procedures for conducting the type tests. If the same is not acceptable by PDIL/
OWNER representative, the procedure & extent of type test requirement shall be
mutually discussed and agreed upon by vendor & PDIL/OWNER representative
and shall be covered in Quality Assurance Plan. Vendor must submit to the
Inspection authority all the results of the type tests conducted by them for their
approval. However, if the PDIL/OWNER representative is not satisfied with the
results, he may ask for witnessing the specific test(s) at vendors cost.
The vendor to provide all necessary facilities free of cost to PDIL/Owners
representative for carrying out the tests as per standard/approved quality
assurance plan. Under no condition inspection can be waived off without the
written permission of PDIL.
3.02
No material shall be shipped until all the required tests are successfully completed
and certified Cleared for despatch by the inspection authority.
3.03
The procedure & extent of the following physical checks, routine & type test shall
be governed by Quality Assurance Plan mutually agreed and approved by
Inspection Authority.
The following checks shall be carried out on 10% of each size of fittings selected
by the inspector.
4.00
Packing
Each valve shall be suitably packed and protected from damage due to
transportation, loading and unloading. Threaded fittings shall have plastic caps to
protect the threadings.
The valve and spare ferrules shall be packed separately by sizes and grades in
individual chlorine free water proof packets and tagged.
The above items shall be despatched as a single consignment.

5.00
5.01
Each valve shall have the following details punched at the sides easily visible.
- Valve size with part no.
- material
- rating
- threaded standard, if any (NPT)
- Manufacturers model no.
- IBR stamping for IBR fittings.
5.02
In addition each valve shall have a SS tag plate 25mm dia 1.2 mm thick securely
tied with soft annealed SS wire. The tag plates shall contain on both sides the part
no., size, material rating, threading standards where applicable. The size of
lettering and figures shall not be less than 4mm.

INSTRUMENT VALVES
6.00
ES-7337
DOCUMENT NO.
REV
SHEET 5
OF 5
Spares
Spares quantities are included in the main item quantity.
7.00
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

Catalogue/ technical literature
of all types of fittings, AD pots
etc. including cross-sectional
view, dimensions, weights etc.
Dimensional drgs. for each item
with technical details like
dimension, weight, material of
components etc.
laboratory.
applicable)
Nace Certificate (wherever
laboratory
Hydraulic test certificate
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
x
x
x
Yes(A)
(within 2 weeks)
Yes
x
for information
Sl. no. 1 to 8 shall be forwarded to PDIL/ OWNER as per details outlined in ITB/Order.
Number of sets along with bid for approval and as final documentation shall be supplied
ES-7334
DOCUMENT NO.
REV
SHEET
OF
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

ES-7334
DOCUMENT NO.
REV
SHEET 2
OF 6
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

ES-7334
DOCUMENT NO.
REV
SHEET 3
OF 6
1.00
General
1.01

herewith define the technical requirement for the supply of compression fittings/air
valves, marking, documentation, testing-inspection and packing.
1.02

2.00
2.01
2.02
The compression fittings of three piece construction shall be double ferrule

compression type (SWAGELOCK) suitable for using with metric tubings conforming
to ASTM-A-269 and rockwell hardness not exceeding 76 on 30T scale as to ensure
a minimum hardness difference of 5 to 10 between tube and fittings for better
sealing. Dimension shall conform to swagelock fittings catalogues.
2.03
Straight bodies, nuts and ferrules shall be from forged barstock 316SS conforming
to ASTM-A-276, ASTM-A-316 and ASTM-A-473.
2.04
Fittings shall be free from all burrs and loose scale which might become dislodged
in usage and all other defects which might affect their serviceability. All sealing
surfaces must be smooth to one micron.
2.05
The fittings shall be suitable for following service conditions

Pressure: 250kg/cm and temperature : 320c.
2.06
The tube fittings shall provide a leak-proof, torque-free seal at all tubing connection
and eliminate costly, hazardous leaks in instrumentation and process tubing. Nuts
and ferrules of particular size shall be interchangeable for each type.
2.07
The tube fittings shall be such that all the action in the fittings moves along the
tube axially instead of with a rotary motion. Since no torque is transmitted from the
fittings to the tubing, there is no initial strain which might weaken the tubing.
2.08
The tube fittings shall be such that no end preparation of the tubes is required
other than the tubes are cut square and joint is made by the compression of two
ferrules on the outside wall of the tube.
2.09
The tube fittings shall be such that they are easily installed without any special
tools.
2.10
The fittings shall be fully tightened in 1 turn after hand tight of nut.
2.11
The tube fittings when assembled with the respective tubings must withstand the
following forces and/or combination of forces.
- Internal pressure
- Tension
- Compression
- Torque
- Vibration
- Temperature variation

ES-7334
DOCUMENT NO.
REV
SHEET 4
OF 6
2.12
Calling in the tube end of the fittings shall be

prevented by special nut treatments applied during manufacturing.
2.13
All fittings shall have American national standard taper pipe threads (NPT) as per
ANSI B2.1. Spanner hold shall be metric.
2.14
Nomenclature of all tube fittings shall be as per ISA RP 42.1.
3.00
3.01
OWNER the results of all the tests conducted before presenting for PDIL/Owners
inspection.

3.02
3.03
by the inspector.
- Complete check of the threads with applicable gauges or profile projector
- Complete check of OD of the fittings and ferrules.
- Visual check under magnification of ferrule surfaces; body seats and threads.
- Dimensions.

ES-7334
DOCUMENT NO.
REV
SHEET 5
OF 6
Hydrotest:
The fittings when assembled with
appropriate SS tubing shall withstand an internal pressure of 375 kg/cm for atleast
one hour without any visible leakage.
Hardness test: The hardness of the ferrules shall be more than rockwell 76 on 30T
scale.
Reassembly : One percent of each type of leak tight assemblies shall be
deassembled and reassembled 25 times. After the twenty fifth assembly the
fittings shall pass hydrotest.
If specifically asked the vendor shall carry out following test
- Helium leak test
- Vibration checks
- Temperature cycling
- Pressure cycling
4.00
Packing
Each fitting shall be suitably packed and protected from damage due to
protect the threadings. Fittings and spare ferrules shall be packed separately by
sizes and grades in individual chlorine free water proof packets and tagged.
5.00
5.01
Each fittings shall be marked with the part no. If this is not feasible, the size of the
tubing and material shall be mentioned.
5.02
In addition each packet packings containing particular type of fittings/ferrules etc.

shall have a SS tag plate securely tied with soft annealed SS wire.
6.00
Spares

7.00
ES-7334
DOCUMENT NO.
REV
SHEET 6
OF 6
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

of all types of fittings, Air valves
components etc.
laboratory.
Test certificates (Hydraulic etc.)
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
x
x
x
Yes(A)
(within 2 weeks)
Yes
x
for information
ES-7341
DOCUMENT NO.
REV
SHEET
OF
S.S TUBES
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

S.S. TUBES
ES-7341
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

S.S. TUBES
ES-7341
DOCUMENT NO.
REV
SHEET 3
OF 5
1.00
General
1.01

herewith define the technical requirement for the supply of S.S. Tubes, marking,
documentation, testing-inspection and packing.
1.02

2.00
2.01
Tolerance in delivered quantities

Tolerance = 1 length / 1% whichever is less.
Tubes shall be delivered in coils of length 15-20 metres or standard length
of 4-7 meters as specified in the specification sheet.
Pipe shall be delivered in 5-7 meters of length properly capped at both ends.
2.02
Manufacture
The seamless stainless steel tubes as per ASTM-A-269 shall be made by the
seamless process. Tubes shall be cold finished. Tubes shall be white pickled free
from scale and soft annealed and suitable for bending. The finished tube should
be reasonably straight and free from dents and injurious defects and shall have
good finish and smooth ends.
2.03
Material composition of test requirements

The tubes shall conform to the requirements as to chemical composition as
prescribed below:
GRADE: SS304
Carbon (max)
Manganese (max)
Phosphorous (max)
Sulphur (max)
Nickel
Chromium
0.08%
2.00%
0.04%
0.03%
8.11%
18-20%
3.00
3.01

S.S. TUBES
ES-7341
DOCUMENT NO.
REV
SHEET 4
OF 5
The manufacturer shall give clear 15 days notice

informing readiness of the material at manufacturers works. The vendor shall
permit the authorised representative of PDIL/OWNER to inspect the manufacture
and assembly of the material in various phases in compliance with mutually
agreed quality assurance plan, standards and specifications.
inspection.
3.02
3.03
by the inspector.
3.04
Type-Test
Following type test (one per batch) shall be performed and certificates will be
furnished:
1) Material test: Chemical and physical properties.
2) Flaring test: The flaring test shall be performed on specimens from one
end of the tube with the help of the flering tool having on included angle
60.
3) Hardness test: Rockwell hardness shall not exceed 74 on the 30T scale and
88 on 15T scale. 5% tubes shall be tested for hardness.
4) Hydraulic Test: The tubes are subjected to hydrostatic test. The tubes
should withstand the hydrostatic test pressure of 1000 psi for a minimum period
of 15 seconds.
4.00
Packing
Each tube shall be suitably packed and protected from damage due to

S.S. TUBES
ES-7341
DOCUMENT NO.
REV
SHEET 5
5.00
5.01
The tubes bundles should be marked with following

- Name & brand of manufacturer
- Grade of material should be marked elegibly on a durable tag
securely attached to each bundle.
- Heat no.
- Part no.
6.00
Spares
OF 5

7.00
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

of S.S. Pipes.
Mill test certificate for each lot of
tubes for chemical composition
and physical properties.
Test certificates for type and
routine tests as per
specification.
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information
ES-734-
DOCUMENT NO.
REV
SHEET
OF
56
PIPE FITTINGS & ISOLATION VALVES
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

PIPE FITTINGS
ES-7340
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
1.00
General
DESCRIPTION
NUMBER OF SHEETS

PIPE FITTINGS
DOCUMENT NO.
REV
SHEET 3
OF 5
1.01
This Engineering specification together with the

Technical specification attached herewith define the technical requirement for the
supply of pipe fittings / flanges AD pots / condensate pots, marking,
1.02

2.00
2.01
2.02
The fittings shall be manufactured, tested and supplied strictly as per ANSI and
ASTM materials grade mentioned against each item.
Dimension
Rating
Material
Surface
Tolerance
Threading
Marking
Certification
ES-7340
: ANSI B 16.11
: ANSI Class 3000# and 6000# as specified.
: As indicated against each part no.
: The suface or seats (conical or spherical) shall
not have roughness and/or scoring ascertained
on sight or on touch.
: As per ANSI B 16.11
: AS per ANSI 2.1
: As per ANSI B 16.11
: Indian boiler regulation certificate in the form
of IIIC/NACE certificate as per NACE MR-0175-1994
wherever indicated.
2.03
All carbon steel and alloy steel fittings and AD/condensate pots shall be protected
against rusting using suitable paint.
3.00
3.01
inspection.

PIPE FITTINGS
ES-7340
DOCUMENT NO.
REV
SHEET 4
OF 5
and shall be covered in Quality Assurance Plan.

Vendor must submit to the Inspection authority all the results of the type tests
conducted by them for their approval.
However, if the PDIL/OWNER
representative is not satisfied with the results, he may ask for witnessing the
specific test(s) at vendors cost.
3.02
3.03
by the inspector.
4.00
Packing
Each fitting shall be suitably packed and protected from damage due to

5.00
5.01
Each fittings shall have the following details punched at the sides easily visible.
- Part no. / stock no.
- size
- material
- rating
- threaded standard, if any (NPT)
- IBR stamping for IBR fittings.
5.02
In addition each packings containing particular type of fittings/ferrules etc. shall

have a SS tag plate securely tied with soft annealed SS wire. The plates shall be
1.2 mm thick and at least 25 mm in dia. The tag plates shall contain on both sides
the part no./stock no., size, material rating, threading standards where applicable.
6.00
Spares
7.00
Documentation

PIPE FITTINGS
ES-7340
DOCUMENT NO.
REV
SHEET 5
OF 5
The following documents (Technical) are required

to be submitted by the vendor alongwith bid, after placement of order for approval
purposes and final documentation before despatch of consignment.
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

of all types of fittings, AD pots
components etc.
laboratory.
applicable)
Nace Certificate (wherever
laboratory
Hydraulic test certificate
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
x
x
x
Yes(A)
(within 2 weeks)
Yes
x
for information
ES-7335
DOCUMENT NO.
REV
SHEET
1 OF
CABLE TRAY
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

CABLE TRAY
ES-7335
DOCUMENT NO.
REV
SHEET 2
OF 5
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

CABLE TRAY
ES-7335
DOCUMENT NO.
REV
SHEET 3
OF 5
1.00
General
1.01

herewith define the technical requirement for the supply of cable tray, marking,
1.02

2.00
2.01
The material of construction for cable tray shall be Aluminium as per IS:737:1934
Grade 19000H2 or GI as specified in specification.
2.02
The tray shall be box type with webs for top cover screwing and of 2.5 meter
length.
2.03
Tolerance units shall be

Length
: 5mm
Width
: 2 mm
Height
: 1 mm
Bend
: 1 mm
Thickness
: 0.2 mm
Positive tolerance upto + 5% is acceptable for total quantity. Negative tolerance
is not acceptable.
2.04
The thickness of trays shall be uniform bend shall be smooth without too much of
reduction area at corners, (bending radious shall be approx. 600mm), free from
cracks, surface defects. Perforations shall be of staggered pattern with large
uniform holes for adequate ventilation.
2.05
Trays shall be supported at 2000mm intervals. The design of the cable tray shall
be such that apart from imparting sufficient mechanical strength under all
conditions, the deflection of the tray shall not exceed 3mm. The trays shall be
capable of withstanding the maximum permissible uniformly distributed loading.
The coupler plate and bolting shall also be designed suitably.
2.06
Each tray/section shall be supplied with holes drilled on the four sides for the
coupler plates / bolts for joining different lengths / sections. The trays shall be
supplied with coupler plates, boltsand nuts. All coupler nuts and bolts shall be of
SS.
3.00
3.01

CABLE TRAY
ES-7335
DOCUMENT NO.
REV
SHEET 4
OF 5
representative of PDIL/OWNER to inspect the

manufacture and assembly of the material in various phases in compliance with
mutually agreed quality assurance plan, standards and specifications.
inspection.
3.02
3.03
by the inspector.
4.00
Packing
Each tray shall be suitably packed and protected from damage due to
protect the threadings.
The tray and spare ferrules shall be packed separately by sizes and grades in
individual chlorine free water proof packets and tagged.

5.00
5.01
The packing shall clearly be marked on the outside (on top side and ends) in
indelible ink the following minimum details:
- part no.
- size of tray (Length x Width x Height)
- No. of trays / sections, total length
- material specification
- customers name
- manufacturers name

CABLE TRAY
6.00
ES-7335
DOCUMENT NO.
REV
SHEET 5
OF 5
Spares
7.00
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

of tray including cross-sectional
components etc.
laboratory.
Strength calculations for each
type of tray and coupler joint.
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information
ES-7338
DOCUMENT NO.
REV
SHEET
1 OF
JUCTION BOX & CABLE GLAND
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

ES-7338
DOCUMENT NO.
REV
SHEET 2
OF 6
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

ES-7338
DOCUMENT NO.
REV
SHEET 3
OF 6
1.00
General
1.01

herewith define the technical requirement for the supply of junction box and cable
glands, marking, documentation, testing-inspection and packing.
1.02

2.00
2.01
2.02
The junction boxes shall either be weather-proof and ex-proof type as specified in
technical specification..
2.03
The enclosure shall be as IS-2147 for weather-proof junction boxes and for
explosion proof it shall be as per IS-2148 suitable for the area classification
specified.
2.04
The entries should normally be from bottom unless otherwise specified and the
number of entries shall be as per technical specification..
2.05
The terminals shall be spring loaded, vibration proof clip on type (Weidmuller/
Phoenix), 2.5 mm. The terminals shall be mounted on DIN rail 46277/1 (vertical
mounting). The terminal material shall be melamin duroplast type as per DIN 7708
page 3 type 156 complete with end cover and clamps for each row. Terminals
colour shall be blue and certified for instrinsically safe circuits and manufacturers
standard colour for other circuits. Terminal numbers shall be marked on both
sides. Stickers/paint shall not be used for numbering.
2.06
Junction box material shall be Die cast aluminium LM6 or equivalent of minimum
5mm thick to withstand a load of atleast 80kg. Gasket should be neoprene rubber.
Mounting brackets (MS epoxy painted) and 4 nos bolts.nuts per JB shall be under
vendors scope of supply.
2.07
Junction box shall be provided with cadmium plated brass bar with non-loosening
screws for cable shields.
2.08
Junction boxes shall be provided with telephone plug and sockets. It should have
both internal and external earthing screws.
2.09
Depth of JB shall be as per manufacturers standard, but not less than 100mm for
2-3 cable entries and 150mm for more than 3 cable entries.
2.10
Ex-proof JBs shall have detachable cover which is fixed to be box by means of
cadmium plated triangular /hexagonal head screws. Weatherproof JBs shall have
doors which shall be hinged type and these shall be fixed with cadmium plated
countersunk screws.
2.11
Surface shall be prepared for painting. It shall be smooth and devoid of rust and
scale. Two coats primer and two final coats of epoxy paints shall be applied both
for interior and exterior surfaces. Colour shall be as specified in technical
specification.

ES-7338
DOCUMENT NO.
REV
SHEET 4
OF 6
2.12
Cable glands shall be double compression type

made from rolled aluminium bar, bushing shall be neoprene rubber, grommet type.
3.00
3.01
inspection.

3.02
3.03
4.00
Packing
Each junction box and cable gland shall be suitably packed and protected from
damage due to transportation, loading and unloading. Threaded fittings shall
have plastic caps to protect the threadings.
The junction box and cable gland and its accessories alongwith spares shall be
despatched as a single consignment.

ES-7338
DOCUMENT NO.
REV
SHEET 5
OF 6
5.00
5.01
Each junction box shall have SS nameplate firmly fixed on the front over through
SS screws. The following details shall be punched / engraved with letter sizes not
less than 4mm.
- part no.
- size
- terminal type/mode
- No. of terminals
- Enclosure certification
- Manufacturers name
- Manufacturers model no.
5.02
Each JB shall have 1 additional SS tag plate 25mm high x 100 mm long x 1mm
thick securely tied with soft annealed SS wire for tag no. of the JB.
6.00
Spares
7.00
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
DESCRIPTION OF
DOCUMENT

of all types of all types of JB,
glands etc. including
dimensional drawings.
components etc.
laboratory.
Test Certificate (IP/intrinsic
safe/exproof)
ALONGWITH
BID
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
Yes(A)
(within 2 weeks)

(A)
for Approval
2)
ES-7338
DOCUMENT NO.
REV
SHEET 6
OF 6
others for information
ES-73332
DOCUMENT NO.
REV
SHEET
OF
INSTRUMENT CABLE
26.02.02
REV
DATE
PURPOSE
PREPARED
REVIEWED
APPROVED

INSTRUMENT CABLES
ES-7332
DOCUMENT NO.
REV
SHEET 2
OF 7
CONTENTS
SECTION NUMBER
DESCRIPTION
1.0
GENERAL
2.0
3.0
4.0

AND APPROVAL
PACKING
5.0
6.0
SPARES
7.0
DOCUMENTATION
SHEET NUMBER
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
NUMBER OF SHEETS

INSTRUMENT CABLES
ES-7332
DOCUMENT NO.
REV
SHEET 3
OF 7
1.00
General
1.01

herewith define the technical requirement for the supply of signal, power, grouping
, extension/compensating cables, marking, documentation, testing-inspection and
packing.
1.02

2.00
2.01
Overall Drain wire shall be of annealed copper wire in continuous contact with
aluminium side of shield. No of strands, dia and cross sectional area shall be 7,
0.3mm and 0.5mm respectively.
2.02
Communication pair shall be placed in central position with the bundle of pairs.
Material of conductor shall be bare copper, no of strands-7, size-0.5mm insulation
PVC and colour-white.
2.03
Cables shall be supplied strictly as per the technical specification enclosed.

Relevant IS standards shall be applicable.
2.04
Tolerances in supply quantity and standard length on a drum shall be as follows:

- Vendor shall ensure that each drum shall have around 1000 meters (5%), if not
otherwise specified in the technical specification.
- Negative tolerance in total length is not acceptable.
- The positive tolerance in total length shall be limited.
Upto 1KM
Between 1 to 5 KM
Between 5 to 10 KM
Above 10 KM
2.05
+ 10%
+ 5%
+4%
+ 2.5%
Cable drum used shall be of high quality. Second hand drum or recycled drum is
not acceptable. The vendor shall submit a detail sketch of each type of drum
intended to be used for this order. It should indicate clearly the designed load of
the drum and the factor of safety considered for transportation and shipment.
Protective coating shall be applied on the outer surface of cable drum to protect
against rain/weather.
In case the cable is received at site in damaged drums, a penalty as indicated in
the special clause shall be levied.
2.06
Special clauses:
- In case at any stage during cable/laying/installation, if it is noticed that there is a
joint in a cable drum the entire cable with cable drum shall be replaced by vendor,
free of charge to the purchaser.

INSTRUMENT CABLES
ES-7332
DOCUMENT NO.
REV
SHEET 4
OF 7
- In case after receipt of material at site it is noticed

that the quality/condition of cable drums is not good, drum and cable shall be replaced free
of charge by the
vendor. The site engineers decision in this matter shall be treated as
final and binding on the vendor.
The general criteria for decision regarding quality of drum shall be :
- The flanges, nut bolts, inner mandrel and outer protection cover should be
intact without damage.
- The cable drum should freely roll and the drawing of cable out of drum be easy.
3.00
3.01
Department and the results of tests shall be submitted to the representative of
PDIL/OWNER during inspection.
inspection.
3.02
3.03

INSTRUMENT CABLES
ES-7332
DOCUMENT NO.
REV
SHEET 5
OF 7
TESTING AND INSPECTION PROCEDURE

- Dimensional check
- Type tests for physical properties of PVC compound as per IS 1554 PART-1, 1976
- Polyethylene insulation tests as per IS-6474 1984
- AC voltage test
The test shall be carried out at room temperature. AC voltage shall be
gradually increased and maintained at full value for specified time without
breakdown of insulation.
I) Between cores: 1500v for 10 minutes
ii) Between core and shield: 1000v for 1 minute
I) Between armour and shield: 500v for 1 minute
ii) Between adjacent shields: 125v for 1 minute
(for individual shielded cables only)
- Cable electrical parameter tests
I) Conductor resistance test
ii) Mutual capacitance test
iii) Mutual inductance test
iv) Insulation resistance test
v) Drain wire resistance including shield < 30 ohm/km
- Electrostatic Noise rejection ratio shall be over 76 db
- Spark test
Cable shall be subjected to AC voltages of 5000 volts.
- FRLS PVC tests for sheathing PVC compound.
I) Oxygen index : as per ASTM D2863.77
: 29 Min, at room temperature.
ii) Temp. index : As per ASTM D2863.77
: 250 deg c (min)
iii) HCL gas emission: As per IEC -754-1
: 20% (max.)
iv) Flammability: As per IEC 332 (part-1)

v) Smoke density: As per ASTM D2863.77
: 60% (max.)
vi) Armour test: As per IS 3975
Note:
a) The cables shall be submitted at manufacturers expenses to all the tests and
inspection required by this specification and standards mentioned herein.
b) Manufacturer shall obtain the approvals from the inspector for test house/
laboratories.

INSTRUMENT CABLES
ES-7332
DOCUMENT NO.
REV
SHEET 6
OF 7
c) One sample of each lot of production shall be

type tested in house or at a
laboratory approved/suggested by the inspecting agency
at manufacturers
expenses.
d) Certificates for PVC quality, galvanising of armour wire etc. to be furnished by
vendor.
4.00
Packing
Each cable drum shall be suitably packed and protected from damage due to
transportation, loading and unloading.
Sealing
Both the ends of the cable shall be sealed using PVC or Rubber caps,
additionally sealing tapes can be used if required. The caps should not be easily
removable during transportation. Main purpose of the sealing caps is to avoid
ingress of moisture during transportation and storage.
5.00
5.01
Marking on the cables

On the outer sheath of the cable, the PDIL code (part no.) shall be printed at 1
meter interval (letter size 3mm). The colour of marking ink shall be in contrast
with the outer sheath colour.
The pair numbers shall be printed on the multipair cables at 50mm interval (letter
size vendor to indicate.) Printing on tape is not acceptable.
Similarly the core numbers shall be printed on the multicore cables at 50mm
interval in case of unpaired cables (letter size vendor to indicate). The printing ink
to be used shall be of high quality and the marking should be visible inspite of
multiple handling.
5.02
Marking on the drum

2mm thick aluminium plate of dimension 300mm x 200mm shall be fixed with screws
on both sides of each drum. The following informations shall be punched/written by
dark ink on the plate.
- P.O. number and Mfrs job no.
- Name of supplier and name of customer
- Drum No.
- Length of cable in the drum
- Resistance in ohms (this is to be measured by sorting two cores at one end.)
- Code no./type (e.g. 2 pair x 1.5mm2)
- Weight of drum with and without cable.
The letter size shall be 20mm (height) and between two lines the gap shall be 10mm.
6.00
Spares

INSTRUMENT CABLES
7.00
ES-7332
DOCUMENT NO.
REV
SHEET 7
OF 7
Documentation
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
(A)
DESCRIPTION OF
DOCUMENT
ALONGWITH
BID

Catalogue/leaflets/ technical
literature giving details of
different cables manufactured
their specification, crosssectional details, dimensions,
RLC values, weights, bending
radius etc.
Certified cross-sectional
dimensional details of each type
of cable indicating tolerance
and minimum bending radius.
Test certificates of each cable
parameters dimensional details
and FRLS quality certificate for
the lot(s).
List of cable drum indicating
drum nos. with actual length in
each drum.
for Approval
(I)
Yes

FINAL
FOR
DOCUMENTS
APPROVAL/
BEFORE
INFORMATION
DESPATCH OF
WITHIN SIX
CONSIGNMENT
WEEKS
Yes
Yes
Yes
Yes
Yes
Yes(A)
Yes
Yes
Yes
Yes(A)
(within 2 weeks)
for information
EM163-PNIN-7901-PA
ART D
PROJEC
CTS & DE
EVELOPM
MENT
INDIA LTD
DOC
CUMENT NO
O
SHEET 1 of
o 1
1
REV
V
P
PARTD
BILL O
OF QUAN
NTITY
FOR
SU
UUPLY OF
O INSTR
RUMENTATION
N ITEMS AND ERECTIO
ON
ATERIAL
LS
MA
Job
b NO
: EM
M163
Pro
oject
: IN
NSTALLA
LETS
Plant
: NU
UMALIGA
ARH, ASS
SAM
ent
Clie
: NR
RL
24.09.2015
5
--
CL
LIENTS COM
MMENTS INCO
ORPORATED
D
H
HK
RA
A
SKT
14.09.2015
5
--
CL
LIENTS COM
MMENTS INCO
ORPORATED
D
H
HK
RA
A
SKT
21.07.2015
5
--
ISSUED FO
OR CLIENTS
S REVIEW
H
HK
RA
A
SKT
REV
REV DATE
E
EFF DAT
TE
PURPOSE
PRE
EPD
REVW
WD
APPD
FORM NO: 02-0000-0021

0
F1 REV3
PROJECT No. -EM163
BILL OF QUANTITY FOR SUUPLY OF INSTRUMENTATION ITEMS AND ERECTION MATERIALS
NUMALIGARH, ASSAM
(TENTATIVE)
PART /
ITEM
EM163-PNIN-BOQ-7001
Quantity
DESCRIPTION
No.
PREAMBLES ( THIS PREAMBLES ARE APPLICABLE FOR ALL BOQs APPEARING in THIS RFQ ):1) Vendor to submit erection material quantity as per installaion drawings attached elsewehere and fill in the BOQ accordingly
2) Inst. supports fabricated out of 2 MS pipe as per Drawings.
A.1
7047
FIELD INSTRUMENTS
4
nos
7147
Radar Type Level Transmitter (TFMS) with multipoint temperature element and
4 with TE & TT
nos
7052
Servo Type Level Transmitter (non TFMS) with multipoint temperature element and
4 with TE & TT
nos
7053
Pressure Gauge
nos
Radar Type Level Transmitter (non TFMS)
7044
Presssure Transmitter
12
nos
7022
Safety Valves
10
nos
7058
Bimetallic Temperature Gauge
no
7146
g
Level Gauge
g
Magnetic
no
7148
Displacer Type Level Transmitter
no
A.2
ERECTION MATERIAL
SEAMLESS PIPE
0103 SCH. 160, API 5L GR.B
Mtrs.
NIPPLE
0176 NPTM x PLAIN, SCH. 160, A105, 100MM LONG
0153 PLAIN x PLAIN, SCH. 160, A105, 100MM LONG
Nos.
Nos.
EQUAL TEE
0261 SW x SW x SW, 3000#, ASTM A105
Nos.
COUPLING
0004 SW x SW, 3000#, ASTM A105
Nos.
CAP
0624 NPTF, 3000#, ASTM A105
Nos.
GATE VALVE
0929 SW x SW, 800#, ASTM A105, 13% CR.TRIM
Nos.
FLANGE
0799 SW WITH STUDS, NUTS AND GASKETS, 300# ASTM A105
Mtrs.
BILL OF QUANTITY FOR SUUPLY OF INSTRUMENTATION ITEMS AND ERECTION MATERIALS
PROJECT No. -EM163

NUMALIGARH, ASSAM
(TENTATIVE)
PART /
ITEM
EM163-PNIN-BOQ-7001
Quantity
DESCRIPTION
No.
SEAMLESS TUBE
1088 1/2" OD x 0.065 THK, A269 TP304
Mtrs.
MALE CONNECTOR
0932 NPTM x OD, ASTM A105, COMPLETE WITH DOUBLE FERRULE
Nos.
FEMALE CONNECTOR
0962 NPTF x OD, ASTM A105, COMPLETE WITH DOUBLE FERRULE
Nos.
REDUCER
0562 3/4 NPTF x SW, 3000#
Nos.
PREPARATION OF INSTRUMENTATION STAND 2" PIPE including fabrication &

installation.
Nos.
STRUCTRAL WORK & FABRICATION FOR INSTRUMENT ITEMS LIKE

MOUNTING FRAMES FOR INSTRUMENTS, BASE FRAMES, ANY OTHER
REQUIRED FOR SUPPORTING INSTRUMENT ITEMS.
Ton
STRUCTURAL STEEL CONSISTING OF FOLLOWING item

1. 50 x 50 x 6THK ANGLE IRON
2. 50 x 6THK FLAT
3. 100 x 50 x 6THK CHANNEL
Ton
6MM THK. MS PLATE
CANOPIES :
MS rain protection cover for instruments like (PT, any other electronic instrument, etc
Nos.
JUNCTION BOX:
Nos.
CABLE
mtrs
CABLE TRAY
Nos.
EM163-PNINBOQ-7001
BILL OF MATERIALS
DOC. NO.
1 / 24.09.2015
HK
RA
RA
0 / 14.09.2015
HK
RA
RA
P / 21.07.2015
HK
RA
RA
Rev / DATE
PREPARED
REVIEWED
APPROVED
PROJJECTS & DEVELOPMENT

T
INDIA LTD
L
EM
M163 -TS-080
01
DO
OCUMENT N
NO.
RE
EV.
SHEET 1 of 32
PART
T-II TEC
CHNICA
AL
TE
ECHNIC
CAL SPE
ECIFICA
ATION
FOR
R
CTION SYSTEM
CATH
HODIC PROTE
P
M
ED BUL
OF
F LPG MOUND
M
LLETS
ED BUL
P
PROJEC
CT: INST
TALLAT
TION OF
F LPG MOUND
M
LLET
AT NRL, ASSAM
A
1
24.09.15
24.09.15
0
15.09.15
15.09.15
P
10.08.15
10.08.15
REV
REV. DATE
EFF. DATE
FORM NO: 02-0000-0021F
F1 REV4
ISSUED FOR ENQUIRY

E
ISSUED
D FOR CLIENT
TS COMMENT
TS
ISSUED
D FOR CLIENT
TS COMMENT
TS
PURPOSE
D
DKG
D
DKG
D
DKG
PREP
HS
H
H
HS
HS
H
H
HS
HS
H
H
HS
RE
EVWD
APP
PDD
All Rights Res
served
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2 of 32
CONTE
ENTS
SR. NO.
DESCRIPTIO
ON
SHEET NO.
N
1.0
Introducttion
2.0
Scope off Work
3.0
Detailed Scope of Work

W
4.0
Instructio
on to Bidde
er
5.0
Type of Contract
C
6.0
Codes & Standardss
7.0
System Implementa
ation
8.0
Basic Su
urvey for So
oil Resistivvity Measurement
9.0
System Details
D
10.0
Design Requireme
R
nt
11.0
Criteria For
F Protecttion
10
11.3 Sch
heme for Cathodic
C
Protection System.
S
10
11.3.2.1 CP Transsformer Re
ectifier Unit.
11
.11.3.2.2
2 Anode Disstribution Box.
B
12
11.3.2.3 Anode & Cathode

C
J.B.
12
11.3.2.4 Permanen
nt Reference Cell.
13
11.3.2.5 Cables
14
11.3.2.6. Monitoring
g J.B..
14
11.3.2.7. PDB
14
11.3.2.8 Anodes.
15
11.3.2.9. Surge Divverter.
16
11.3.2.10
0.Solid Sta
ate Polariza
ation Cell.
16
11.3.2.11
1.Measurement Juncction Box.
16
11.3.2.12
2.Earthing J.B..
16
11.4.1.14
4. Monolith
hic Isolating
g Joint.
16
11.3.2.15
5. Electrica
al Separation.
16
Miscellan
neous Poin
nts related to System
m Design.
17
12.0
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 3 of 32
13.0
Detailed Engineerin
ng Works to
t be perfo
ormed by Bidder
B
for C
CP
System of
o Mounded Storage Vessels
18
14.0
Earthing
20
15.0
CP Mate
erials
21
16.0
Description of Consstruction Work

W
21
16.1 Cab
ble Laying.
21
16.2 Permanent Re
ef. Cells.
21
16.3 Stra
aight Throu
ugh Joint fo
or Cables.
21
16.4 Cab
ble Connecction to Bullets.
22
17.0
Field Tessting and Commissio

C
oning
22
18.0
Commisssioning Re
equirementts
22
19.0
Material Inspection
n & Testing
g
25
20.0
Pre Com
mmissioning
g
25
21.0
Commisssioning
26
20.1. Perrmanent IC
CCP System.
26
22.0
Guarante
ee
27
23.0
Drawingss & Docum

ments
27
24.0
Instrume
ents, Tools and Spare
es
28
25.0
Schedule
e of Quanttities
29
LIST OF ATTACH
HMENTS
NU
UMBER OF
O
SHEETS
Data She
eet for Catthodic Prottection sys
stem of LP
PG Mounde
ed
Bullet
II.
TS- Basic Survey for

f Soil Re
esistant Me
easuremen
nt
III.
TS- Tran
nsformer Rectifier
R
Un
nit for CP System
S
17
IV.
TS- Rem
mote Monittoring Unit of TR Unitt for CP System
V.
TS- Ano
ode junction
n box for CP
C System
m
VI.
TS- Cath
hode junction box cu
um Test Sttation for CP
C System
m
VII.
TS-Cu/C
CuSo4 pe
ermanent Reference
e Electrode for C
CP
System
VIII.
TS- Refference Ele

ectrode ( Zinc)
Z
for CP
C System
m
I.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 4 of 32
IX.
ables for CP
C System
TS- -Ca
X.
TS - Mo
onitor Jn. Box.
B
for CP
P System
XI.
TS - PD
DB. for CP System
XII.
TS -Ano
odes for CP System
XIII.
TS -Surrge Diverte
er for CP System
S
XIV.
TS -Solid State Po
olarisation Cell for CP
C System
XV.
TS - Ea
arthing Jn. Box for CP
C System
TS - Mo
onolithic Iso
olation Joint. for CP System
XVII.
Master Vendor
V
Lisst for CP Syystem
XVIII.
Make forr Electrical Items. forr CP Syste

em
XVI.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
1.0
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 5 of 32
INTRODU
UCTION
Numaliga
arh Refinery Limited ( NRL ) situated in Assam State, has
s planned to
install 4 Nos. of Mounded
M
B
Bullets
for LPG. Forr proper fu
unctioning of Mound
ded
s
and economy point of vie
ew, the bu
ullets shall be protectted
bullets, both from safety
orrosion fo
or their long
g & trouble
e free operration. Thiss specificattion specifiies
against co
the requirrement of Basic Survvey, Desig
gn, Enginee
ering, Supply of Mate
erial, Testiing
of Cathod
& Comm
missioning, installatio
on and Monitoring
M
dic Protec
ction syste
em
complete in all resp
pects.
2.0
SCOPE OF
O WORK
K
The scop
pe of workk under th
his section
n shall consists of B
Basic Surv
vey, Desig
gn,
Engineering, Supp
ply of all Material, installatio
on, Testin
ng & Com
mmissionin
ng,
Monitorin
ng of the Ca
athodic Prrotection sy
ystem com
mplete in all respects for mound
ded
storage bullets,
b
all with
w semispherical en
nds within the plant.
The com
mplete imp
plementation of CP
P system should b
be carried
d out und
der
supervisio
on of NAC
CE Certifie
ed CP Eng
gineer with valid license for certifying
c
t
the
Design, Engineering
E
g, Procedu
ures and Commission
C
ning Resullts.
This speccification defines
d
the
e basic gu
uidelines to
o develop an Impres
ssed Curre
ent
Cathodic Protection
n (ICCP) system
s
forr the bulle
et required
d to be pro
otected. The
T
essed Currrent Catho
odic Protecction shall be minimu
um 30 yea
ars.
design liffe for Impre
All data required in
n this rega
ard shall be
b taken into consid
deration to
o develop an
acceptable design and for proper
p
eng
gineering of
o the sysstem. Com
mpliance with
w
these spe
ecificationss and/or approval of any of the
e Bidders documentts shall in no
case relie
eve the bid
dder of his contractua
al obligations.
The bidd
der should supply materials
m
sttrictly as per
p specifiications an
nd approvved
Vendors list attache
ed. Bidder shall give performan
nce guaran
ntee of min
nimum 5 yrs.
y
for CP Syystem.
3.0
DETAILE
ED SCOPE
E OF WOR
RK
3.1
Carrying out Basic Surveys, and

a other topograph
hical data ccollection from
f
site. This
T
p the bidde
er in design
ning and im
mplementin
ng the systtem efficien
ntly.
shall help
3.2
Developm
ment of De
etailed En
ngineering Documen
nt on the B
Basic Surv
vey Data and
optimize the
t ICCP System.
S
3.3
Site visit to
t decide the
t location
n of propos
sed Anode
e Bed, T/R unit, Test Station etcc.
3.4
Calculatio
on of Polyymeric An
node quan
ntities and their size
es based on maxim
mum
current re
equirementt and desig
gn life.
3.5
Sizing ca
alculation for
f T/R unit, Anode loop resistance and potential profile on the
protected
d structuress.
3.6
Submission of dettailed eng

gineering package
p
i
including
preparatio
on of deta
ailed
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 6 of 32
material/ equipment and consstruction drrawings forr Approval from owne

er/consulta
ant.
3.7
Procurem
ment of Material
M
an
nd equipments for complete
c
ICCP sys
stem includ
ding
incoming and outgo
oing cabless.
3.8
ngs for ca
able trays, fixing deta
ails, cable sizing, ca
able sched
dule,
Constructtion drawin
interconn
nection diag
gram, and cable tray
y details forr complete ICCP system.
3.9
Installatio
on details including location and
a
fixing details of T/R unit, junction box.
b
Anodes and
a controll equipmen
nts.
3.10
Installatio
on details of Anode
e bed, refe
erence ce
ell, junction
n box etc. of comp
plete
Impresse
ed Current Cathodic Protection
P
System.
3.11
The Bidd
der need to
o supply all
a materialls, consum
mables in h
his scope of supply and
provide all
a construcction toolss, tackles equipment
e
and perso
onnel nece
essary forr the
work.
3.12
etailed factory / laboratory testing procedures for critical

Preparation of de
equipmen
nts. Submission of te
est certifica
ate for equiipment insttalled.
3.13
Field-testting of ind
dividual co
omponents
s of C.P. System a
as per ap
pproved detail
engineeriing packag
ge. Final commissio
oning of in
nstalled syystem as per appro
oved
procedure
e.
3.14
Installatio
on and erecction of ICCP System
m.
3.15
Developm
ment of system
interferen
nce testing.
3.16
Energizin
ng, Testing and Comm
missioning
g of ICCP System.
S
3.17
After Com
mmissionin
ng of the C.P.
C
Syste
em, if it is found that structure
e to electro
olyte
potential achieved at some lo
ocation is in the rang
ge which iss below ac
cceptable limit
ode, then a supplem
mentary C.P. System
m need to be installe
ed to bring the
as per co
potential level at such location
ns within acceptable limit as me
entioned.
3.18
Preparation and Su
ubmission of
o As-built drawings, Operation
n &Mainten
nance manual.
3.19
Handling over and Training

T
off Owners Personnel
P
3.20
The locattion of the TR unit sh

hall be inside the MC
CC room (E
Electrical room). The
e AC
power su
upply to the
e CP TRU
U shall be provided
p
b the Own
by
ner/ contra
actor, howe
ever
the cable
e required shall be in
n the scope of CP co
ontractor. The CP co
ontractor shall
s
be provid
ded with the
t
permisssion to work
w
by the
e the own
ner/ contra
actor from the
Statutory Authorities (whereve
er required
d)
FORM NO: 02-0000-0021F

F2 REV3
t
testing
and
comm
missioning
procedurres
includ
ding
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Sheet 7 of 32
4.0
INSTRCU
UTIONS TO
O BIDDER
R
4.1
Every item of workk and supp

ply by BIDDER shall be subjecct to Engin
neer-In-cha
arge
scrutiny, supervision and approval. Any work carried out or ssupplies afffected with
hout
such app
proval shalll stand auttomatically
y rejected and
a his cla
aim for com
mpensation
n for
such unauthorized work
w
shall be null and void.
4.2
Owner/co
onsultant shall
s
have the
t right to
o inspect th
he following
g:
Worksho
op & production facilitties availab
ble with BIDDER or its tie up ag
gency.
Fabrication/testing of materia
al/equipme
ent to be supplied
s
b
by BIDDER
R or its tie
e up
ncy for C.P
P. system.
agen
It shall be bidderr's respon
nsibility to arrange access ffor ownerrs/consulta
ants
personne
el for such visits. All
A costs related with
w
travel,, boarding
g, lodging for
owners/cconsultants personne
el for such visits (if any) shall b
be borne by
y owner.
4.3
Licensed holder Ele

ectrical Co
ontractor is
s essentially required
d as per re
egulations laid
by electriical inspecctor of the state for electrical jobs. The Bidder sha
all arrange
e for
the same. Any approval
a
frrom electrical inspe
ector requ
uired for the electrical
installatio
on shall be in Bidder'ss scope.
4.4
Warrantyy
Bidder ne
eeds to re
eplace/rep
pair or rein
nstall free of cost a
any material/ equipm
ment
supplied or installed by him in
i case it fails to op
perate due to defective materia
al or
workmanship as pe
er requirem
ments of this
t
specifiication with
hin 12 (Tw
welve) mon
nths
from the date of isssue of com
mpletion ce
ertificate an
nd accepta
ance of the
e C.P. Sysstem
by Ownerr. Bidder shall replacce at his ow
wn cost if any
a item fo
ound defec
ctive or misssed
before ha
anding over the syste
em to owne
er.
5.0
TYPE OF
F CONTRA
ACT
The contrract under the above
e scope of work
w
shall be on LST
TK basis.
6.0
CODES & STANDA

ARDS
6.1
The syste
em design
n, performa
ance and materials
m
to
o be supplied shall conform
c
to
o the
requirements of the
e latest revvision of folllowing sta
andards
NACE Standard
S
R
RP-0285:
Recomme
ended Practice forr Corrosio
on Control of
Undergro
ound Storage Tank Systems
S
by
y Cathodic Protection
n
NACE Standard
S
RP-0177: Standard
d Recom
mmended Practice Mitigation of
Alternatin
ng Currentt and Ligh
htning Effe
ects on Metallic
M
Structures and
a
Corrosion
Control Systems.
S
OISD 11
13: Classiification of
o Areas for Electrrical Insta
allation at Hydrocarrbon
Processin
ng and Han
ndling Faccilities.
OISD 147
7: Inspectio
on and Saffe Practice
es during Electrical
E
In
nstallations
s.
FORM NO: 02-0000-0021F

F2 REV3
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ATHODIC PROTECTION
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OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
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Sheet 8 of 32
OISD 149
9: Design Aspects
A
for Safety in Electrical Systems.
OISD 150
0: Design and
a Safetyy Requirem
ments for LPG Mound
ded Storag
ge Facility.
DNV RP--B403: Reccommende
ed Practice
e Monitorin
ng of Catho
odic Protec
ction Syste
ems.
DNV RP--B401: Catthodic Systtem design
n.
IS: 8062: Code of Practice
P
forr Cathodic Protection
n of Steel S
Structures.
IS: 1554 Part I: PVC
C insulated
d (heavy du
uty) cabless.
IS: 7098 Part-I: PVC
C insulated
d PVC she
eath cable.
IS: 5571 Guide For Selection of Electric
cal Equipment For Ha
azardous Areas
A
IS: 5572 Classifica
Areas (O
ation of Hazardous
H
Other than
n mines) For Electrical
Installatio
ons: Areas having Fla
ammable Gases
G
and Vapors.
IS: 60079
9-Part 1 Fla
ame proof Enclosure
es For Elecctrical Appa
aratus.
Any otherr standard applicable
e for the eq
quipment being
b
used for CP Sy
ystem.
Indian ele
ectricity act and ruless framed th
here underr.
Fire insurrance regu
ulations
ons laid by Chief Elecctrical Insp
pector of Sttate.
Regulatio
ons laid by Chief Con
ntroller of Explosives.
E
.
Regulatio
on laid by Factory
F
Insspector of State.
S
Regulatio
Petroleum
m Act, 197
76(Govt. off India, Corrosion control in Pe
etroleum prroduction TPC
T
Publicatio
on No.5)
Any otherr standard applicable
e for the eq
quipment being
b
used for CP Sy
ystem.
6.2
In case of importted equipm

ments sta
andards off the country of orrigin shall be
applicable if these standardss are equiv
valent or sttringent than the app
plicable Ind
dian
Standard
ds.
6.3
The equ
uipment sh
hall also confirm to the provissions of India Electricity rules and
other statutory regu
ulations currently in fo
orce in the
e country.
6.4
In case of
o any con
ntradiction between various
v
referred stan
ndards / specificatio
s
ons /
datashee
et and statu
utory regullations the following order
o
of prriority shall govern:
Stattutory Regulations
FORM NO: 02-0000-0021F

F2 REV3
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OWNER : NRL,AS
SSAM
7.0
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 9 of 32
Data
a Sheets
Thiss Specifica
ation
Cod
des and Sta
andards
SYSTEM
M IMPLEME
ENTATION
N
All work to be perfformed an
nd supplies
s to be efffected as a part of contract shall
s
require specific revview of ow
wner or his
s authorize
ed represe
entative. Major
M
activvities
requiring review sha
all include but not be
e limited to the followiing:
8.0
Corro
osion survey data intterpretation
n report an
nd design b
basis for C.P.
C System
m.
C.P. System de
esign packkage.
Basicc engineerring packag
ge
Deta
ailed engine
eering pacckage.
Purcchase requisition for major
m
equipment.
Field
d-testing an
nd commisssioning procedure.
.As built
b
docum
mentation
BASIC SURVEY FO
OR RESIS
STIVITY MEASUREM
M
MENT
For this re
efer enclossed relevant specifica
ation.
9.0
SYSTEM
M DETAILS
S
All equip
pment sha
all be ne
ew and procured
p
from app
proved ma
anufacture
ers.
Equipmen
nt offered
d shall be
b field proven.
p
Equipment requiring specializzed
maintena
ance or operation
o
shall be avoided as far ass possible
e. Prototyype
equipmen
nt shall not
n
be acccepted. Equipment
E
shall con
nform to the releva
ant
specificattions enclo
osed with the
t
tenderr documen
nt. All equipment inclluding CPT
TR
Unit, Ano
ode Junctio
on Boxes cum Test Station, and
a
Cathod
de Junction Boxes etc.
e
shall be located
l
in safe non--hazardous
s areas. Where
W
it is essential to install the
t
equipmen
nt in hazarrdous area
a, such equ
uipment sh
hall be flam
meproof ty
ype and sh
hall
meet the requireme
ent of IS: 60079-1 or equivalentt Internatio
onal Standa
ard and sh
hall
o
suitable for gas group IIA
A/IIB, tem
mperature class T3 (200 C). Indigeno
ous
equipmen
nt shall be
e certified by CMRI or any oth
her recogn
nized testin
ng body and
a
shall be approved
a
b the conccerned stattutory auth
by
hority
An area around
a
bullets as perr Hazardou
us Area Cla
assification
n drg. ( To be preparred
by bidde
er during detail
d
eng
gg.) , as minimum to be con
nsidered as
a explosiion
hazardou
us area ( Gas
G Group IIA/II B, Zo
one -1, Tem
mp. class T
T3)
10.0
DESIGN REQUIRE
EMENT
Permanent Cathod
dic protecttion system
m by Imp
pressed Current sys
stem shalll be
mum 30 years
y
life. The syste
em shall cconsist of suitable nos.
n
designed for minim
automaticc transform
mer rectifier unit (B
Bidder sha
all calculatte the qua
antity), Po
ower
distributio
on Board((If required), Anode
e Junction
n Boxes with resis
stor, Cath
hode
Junction Boxes, Monitoring
M
Junction Boxes,
B
Ea
arthing Jun
nction Box
xes with Solid
S
State Polarization Cells,
C
Cu/C
CuSO4 & Zinc
Z
Refere
ence Electrrodes, & Pre packa
aged
FORM NO: 02-0000-0021F

F2 REV3
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ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
10 of 32
Polymericc conducctive polym

mer Anode Strings spaced
s
eve
enly and placed
p
on the
peripheryy of the ta
anks. Refe
erence cells and ano
odes (Ano
ode flex-15
500)) shall be
suitably lo
ocated at various
v
loccations nea
ar the tank surface.
11.0
CRITERIA
A FOR PR
ROTECTIO
ON
11.1.
The strucctures to so
oil potentia
al only shalll be used for effectivve cathodic
c protection
n off
potential on all parts of the tanks and sh
hall be eith
her equal o
or more ne
egative than (-)
0.85V witth referencce to Cu/Cu
uSo4.
11.2.
When anaerobic co
onditions and
a activity
y of sulpha
ate reducin
ng bacteria
a is presen
nt or
likely then
n the OFF potential shall
s
be eq
qual or morre than 0.95V. On no
n accountt the
OFF pote
entials sha
all be morre than 1.15V.The structure (bullets / tanks) will be
considere
ed protected when a A minim
mum 100 mV of Ca
athodic po
olarization.The
formation
n or decay of polariza
ation may be
b used to satisfy the
e criteria.
11.3.
Scheme for Catho

odic protec
ction (CP) System
11.3.1
Impresse
ed current Cathodic
C
p
protection
is to be considered fo
or preventiion of soil side
s
corrosion
n of mounded storage
e vessels.
Continuous distribu
uted close
e anode strings co
onsisting o
of Conductive polyymer
anodes shall
s
be insstalled. The
e quantity of strings shall be a
as per actu
ual calculattion,
ensuring uniform distribution of
o current but minim
mum 4 loop
ps per bulle
et. The strrings
f from natural air cooled,
c
Tra
ansformer--Rectifier u
unit (There shall be One
O
shall be fed
Working + One Standby T/R
R units forr the Moun
nd) of 50V
V/50A rating through one
common Anode Disstribution Box
B ( ADB)) & Anode
e Junction Boxes (AJ
JB) ,two ( One
O
on each end ) seperarate for each bulllet. T/R Units
U
( Wo
orking & Standby
S
) shall
s
have one
e common outgoing positive
p
he
eader cable
es; positivve header cable shalll be
terminate
ed to wall / structure mounted ADBs to be
b installed ( may be on retain
ning
wall of the
t
mound
d ) at each
h end alon
ng the axiss of bulletss. Positive header ca
able
shall interconnect each
e
end AJBs
A
of th
he bullet. As
A such A
Anode Strin
ngs get po
ower
from both
h end AJB
Bs. Joint of Anode Strings
S
from
m mound & electrica
al cables from
f
AJBs sha
all be placced outside
e the mou
und so tha
at the said
d joints rem
main availa
able
accessiblle for inspe
ection & repaires.
T/R Units shall have
h
one out going
g negative
e header cable, which shall be
interconn
nected by looping
l
arrrangementt to require
ed nos. of cathode junction bo
oxes
cum test station (CJJB). Each CJB cum test
t
station
n (CJB) sha
all be locatted at one end
along the
e axis of bu
ullet so tha
at each bullet can havve one CJB
B cum testt station (C
CJB)
for its dra
ainage con
nnection and
a
potential measurrement. Tw
wo drainag
ge cables and
two meassurement cables
c
from
m each bullet shall be
e terminate
ed to its CJ
JB.
Cables frrom 17 no
os of ref. electrodes
e
per bullet shall be tterminated
d in respecctive
CJB. 1 no.(25CX2.
n
.5 sqmm) or 2 nos. X(12CX2.5 sqmm) Cu conduc
ctor armou
ured
from each
h CJB shall be laid to
o monitiorin
ng Junction ox installed in Swittch room.
One stan
ndby T/R unit
u of the same 50V
V/50A rating shall be connected
d in paralle
el to
the opera
ating T/R Unit,
U
so tha
at initially when coatting condittion is good, always one
T/R unit can
c be ma
ade operating and the other ca
an be kept stand by in switched
d off
condition or hot sta
andby as per
p mode selected.
s
A
After
wardss when coa
ating condition
deteriorattes both T/R
T unit can work in parallel also. Powerr supply fo
or the T/R Unit
shall be drawn from
m the Electrical Pan
nel i.e.PMCC ( LPG
G Bullets) located in the
ectrical Ro
oom near Bullets
B
. Bidder
B
shall supply , lay , terminate requ
uired
same Ele
nos. of power
p
feed
der cables ( One 1( 3.5 x 35 Sq.mm) from said
d PMCC (L
LPG
FORM NO: 02-0000-0021F

F2 REV3
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ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
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O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
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BULLETS
OWNER : NRL,AS
SSAM
11.3.2
11.3.2.1
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
11 of 32
Bullets) to
o each T/R
R units..
Monitorin
ng of C.P. System performance shall be done by installation of perman
nent
reference
e cells in th
he vicinity of
o mounded Storage vessels. T
The referen
nce cell cables
and the measurem
ment cables from each
e
vesssel shall be routed
d through the
respective cathode
e junction box cum test station (CJB) to a sing
gle Monito
oring
B), which shall be located ne
ear the T//R Units and
a
have the
Junction Box (MJB
provision of measurrement of vessel to soil
s potentiial. Also fo
or monitorin
ng of vesse
el to
ntials at th
he T/R unit, monitorring cabless consistin
ng of referrence cell and
soil poten
measurem
ment cable
es shall be
e laid betw
ween MJB and T/R u
unit for co
onnection of
o at
least two reference cells to T//R Unit pan
nel.
e laying ca
able trays with
w tray su
upporting structures
s
a
along pipe
es on groun
nd &
For Cable
in Cable Trenches
T
& on wall etc.,has
e
to be installe
ed .
Thermit welding
w
sh
hall not be
e used, only mechan
nical mean
ns shall be
e used for the
connectio
on of draina
age cabless and measurement cables
c
to tthe vessels
s.
For ease of accessibility of sp
plice joint shall be kep
pt outside tthe mound
d
hall carryo
out detaile
ed enginee
ering, proccurement, installation
n, testing and
Bidder sh
commissiioning of the follow
wing majorr materialss/ equipme
ents as per
p the ab
bove
explained
d basic sch
heme for Cathodic
C
prrotection syystem for tthe buried bullets:
CP Trans
sformer Rectifier
R
U
Units
(TRU
U)
The C.P. Units shall have Automatic/Ma
anual conttrol mode sselector sw
witch and shall
s
be metal clad, com
mpact, suita
able for ind
door installlation, air n
natural coo
oled, dust and
vermin proof
p
. Th
he compon
nents of the
t
units shall be designed for maxim
mum
operating
g efficiencyy.
The supp
ply, Installa
ation, Testing and Commissio
C
oning of in
ndoor type
e CP T/R Unit
shall be included in
n Bidders scope.
s
The
ere shall be one worrking + one
e stand by T/R
for each bullet. Standby T/R units can be automa
atically use
ed in the event
e
of faiilure
of running
g T/R unit.
T/R units shall be fe
ed individu
ually, electrrical power from PMC
CC, using 3.5 x25 mm2,
m
Al power cable.
The CP TR
T Unit sh
hall be insstalled in non-hazard
n
dous (safe)) area. The CP TR Unit
shall be in
nstalled in a Indoor. There shall be one set
s T/R unitts (1Running+1Stand
dby)
for supplyying DC su
upply to An
nodes and Cathodes and it sho
ould be rate
ed for 50 V,
V 50
A. CP TRU
T
shalll be man
nufactured as per enclosed specification. Make
e of
equipmen
nt and com
mponent sh
hall be as per
p clause No. 15.1 o
of this spec
cification.
TRU shalll also have
e the follow
wing featurres:
a. Vo
oltmeter, Ammeters
A
s
shall
be witth 1% mea
asuring acccuracy on the
t full sca
ale.
b. All cables shall
s
be clearly
c
iden
ntified. DC
C cables A
AC cables
s shall run
n in
se
eparate PV
VC/GI conduits. The
ese could be single core or multi-core
m
with
armored to meet systtem requirrement an
nd shall be
e of 1.1KV
V grade PVC
P
FR
RLS insulated of Al/C
Cu conducttors.
c. Th
he unit sha
all be proviided with automatic
a
p
potential
ccontrol. A selector
s
sw
witch
forr auto/man
nual also shall be pro
ovided.
d. Cu
urrent con
ntrol to ind
dividual ta
anks/bullets shall be
e negative
e connections
thrrough suita
able contro
ol resistors
s in junction boxes to
o adjust the
e imbalancce in
cu
urrent requirement be
etween tanks.
e. Se
eparate dra
ain cables for each of the bulllet with suitable diod
des in juncction
bo
ox shall be provided to
t prevent equalizatio
on currentss to flow be
etween bullets
du
uring ON/O
OFF potential measurrements.
f. Su
uitable shu
unts in ano
ode junctio
on boxes shall
s
also be installe
ed to meassure
FORM NO: 02-0000-0021F

F2 REV3
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ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
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O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
12 of 32
ind
dividual an
node currents and als
so in nega
ative conne
ections to measure
m
d
drain
cu
urrent in ea
ach bullet.
g. Th
he potentia
al measuring circuit shall be ca
apable of working with
w Cu/CuSO4
an
nd zinc refe
erence cells. At any given time
e, system sshall be eitther contro
olled
byy one type
e of referen
nce cell and the oth
her type sh
hall be kept on stan
ndby
mo
ode.
h. To
o avoid ovverprotectio
on of the bullets, the
e control ssystem in TRU shall be
pro
ovided witth adjustable voltage and currrent limiting circuits
s and alarrms.
Po
otential free
e contact of
o one norm
mally open
n and one normally closed
c
shall be
wired to term
minal blockk for remo
ote alarm in Control room. A panel-moun
p
nted
eter shall be
b provide
ed to read the structu
ure to soil potential at
a the seleccted
me
co
ontrol refere
ence cell.
i. Su
uitable con
ntrol resisto
ors in Junction Boxess, to adjustt the imbala
ance curre
ents.
j. Po
otential fre
ee contaccts shall be wired
d to existting Control Room, to
an
nnunciate alarm
a
there
e.
k. Th
he T/R Unit
U
installed for Cathodic
C
P
Protection
nded Storrage
of Moun
Bu
ullets/Tankks shall have inbuiltt RMU fea
atures to M
Monitor all specified T/R
Un
nit Parameters, Ala
arms and Cathodic Protection Referen
nce Electrrode
Pa
arameters and comm
municate th
he Data to
o the Cen
ntral Comp
puter Netw
work.
Th
he T/R Un
nit RMU shall
s
be provided
p
b the m
by
manufacture
er, which can
Mo
onitor the specified
s
C Parame
CP
eters.
l. Th
he T/R Unit RMU Hardware shall be
b expand
dable for incorpora
ating
ad
dditional I/O
O Channels in future..
11.3.2.2
11.3.2.3
D
n Box.(AD
DB)
Anode Distributio
Positive haeder cable shalll be terminated in one
o
ADB.T
This ADB shall feed
d to
all AJB
i)
Exxplosion prroof Enclossure.( Gas group II A / II B.) & in
n LM6 con
nstruction.
ii)
Re
esistors witth shunts for
f current control to individual bullet.
iii)
Su
uitable explosion proo
of cable gla
ands for in
ncoming & outgoing cables.
c
iv)
Pro
ovision forr 30 % add
ditional (as spare ) in outgoing feeders fo
or future usse to
be
e kept.
Ground Beds
a. Su
upplier sha
all submit design
d
calc
culation off the groun
nd bed res
sistance ba
ased
on
n the meassured soil/ssand resistivity data
b. Th
he anodess shall be
b Longline Condu
uctive Po
olymeric anode
a
facctory
Prrepackaged
d.
11.3.2.4
Anode & Cathode Junction Box

CJB shall be CJB cum
c
Test station.All
s
reference
r
e
electrode
ccable one bullet shall be
terminate
ed in CJB cum Test station.Junction Boxxes (AJB & CJB) forr C.P. Sysstem
shall be as per in
n enclosed
d specifica
ation for junction
j
boxes spec
cification. The
e of AJB & CJB sh
hall be classified typ
pe as per Area clas
ssification and
enclosure
relevant IEC/NEC
I
c
codes
give
en in enclos
sed spec. Anode striings should
d be desig
gned
and grou
uped for each AJB in such a manner that
t
approximately uniform
u
an
node
current iss discharge
ed through
h each term
minal. While deciding
g no. of An
node leadss for
each AJB
B, at least two nos. of
o cable en
ntries and cable
c
term
minals or 30
0%, whiche
ever
FORM NO: 02-0000-0021F

F2 REV3
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ghts reserved
TECHNICA
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CA
ATHODIC PROTECTION
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MOU
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EM163-TS--0801
DOCUMENT
T NO
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V
Sheet 1
13 of 32
is higher should be
e kept spa
are at each
h AJB for connection
n of Anode
es .The sp
pare
cable enttries should
d b e close
ed with a th
hreaded plug.
The anod
de junction box sho
ould have power re
esistors in series with shuntss for
current distribution to individu
ual anode string circu
uit. The po
ower resisttors should
d be
CRESSO
OL or equivvalent makke, strip typ
pe with adjustable arm
m in series
s with shun
nt of
0.5% acccuracy. Th
he rating of
o resistor//shunt sha
all be decided keepiing in view
w of
voltage drop
d
and te
emperature
e rise. The
e junction box
b shall h
have at lea
ast 30% sp
pare
terminals.
Cathode junction box shall ha
ave powerr resistors in series w
with shunts
s to adjustt the
nt requirem
ment betwe
een bulletss. The pow
wer resisto
ors and shu
unts
imbalance in curren
shall be similar
s
to one
o being used in AJB
A
and de
escribed in
n above po
oint exceptt for
their currrent rating and of sa
ame make as AJB. The CJB shall also have suita
able
diodes in
n circuit to
o prevent equalizatio
on currentts to flow between bullets du
uring
ON/OFF PSP meassurement. The catho
ode junctio
on box sha
all also hav
ve 30% sp
pare
terminals.
The AJB and CJB shall
s
be of explosion proof type
e suitable ffor hazardo
ous area zone
z
1, gas gro
oup IIA/IIB and in LM
M-6 constru
uction.
For otherrs, refer enclosed rele
evant spec
cifications.
11.3.2.5
ent Refere
ence Cells
s for U/G Vessels
V
Permane
Cu/CuSO
O4 Perman
nent referrence cells
s shall be
e as per enclosed specificattion.
Permanent reference cells sh
hall be ins
stalled in the
t
sand ccushion su
urrounding the
vessel att a distancce of 150mm from the vesse
el for mon
nitoring of C.P. Systtem.
Minimum 16 nos. of
o referencce cells to be installe
ed for each
h vessel. Four
F
refere
ence
cells shall be place
ed in one row at ea
ach locatio
on and the
ere will be
e four rows of
e cells at fo
our equidisstant locatio
ons along the length of each ve
essel.
reference
Nearest row
r
facing
g CJB should be con
nsidered as
a first row
w of refere
ence cells and
consecutive rows shall be con
nsidered as
a second, third and ffourth rows
s respectivvely,
in each ro
ow referen
nce cells shall
s
be pla
aced at 45
50,1350, 2250 and 315
50 location
ns in
0
anti clockk wise dirrection con
nsidering 0 at 6 Oclock
O
possition. The
e identifica
ation
numbers of reference cell for each bulle
et shall sta
art with B and afterr B first suffix
b
numb
ber, second suffix sh
hall be row number off reference
e cell and third
t
shall be bullet
suffix sha
all be refere
ence cell angular
a
pos
sition as sh
hown below
w:
Bullet No
o. /
Row No..
FORM NO: 02-0000-0021F

F2 REV3
Iden
ntification Number
N
of Each Refe
erence Celll at Differe
ent Angular
Locatio
ons
0/3
3600
450
135
50
2250
3150
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TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
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BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
14 of 32

evant Spec
cification.
11.3.2.6
Cables
Cables fo
or C P Systtem shall be
b as per enclosed
e
specification.
11.3.2.7
Monitoring Junction Box (M

MJB)
i) MJB sh
hall have prrovision for measurement of ve
essel to ele
ectrolyte po
otentials fo
or all
vessels and
a
shall be
b installe
ed near the
e T/R Unitt . For me
easuremen
nt of vesse
el to
electrolyte potentialls multi-core cable (2
25-core x 2.5
2 mm2, C
Cu, one-run or 12-co
ore x
een CJB cum
c
Test S
Stations an
nd MJB. MultiM
2.5 mm2, Cu, two-rrun) to be laid betwe
core cablle (12-core
e x 2.5 mm
m2, Cu) to be laid alsso betwee
en MJB and T/R Unit for
measurem
ment of at least two reference cell potential at the T/R Unit. The
T enclossure
of MJB shall
s
be IP
P-55 as pe
er relevantt IEC/NEC
C codes. B
Bidder sha
all prepare the
layout/construction drawings and a prrototype of
o MJB sh
howing inte
ernal term
minal
ments and wiring
w
arra
angements and subm
mit to owner/consultan
nt for approval
arrangem
before fab
brication & procurem
ment of the same
ii) The mo
onitoring ju
unction boxx shall be non-flamep
n
proof type and shall be
b installed
d in
substation / Electriccal Room and
a shall be of 12 SW
WG sheet ssteel consttruction duly
epoxy painted.
iii) Also re
efer enclossed relevan
nt standard
d specifica
ations.
11.3.2.8
Power Distribution
D
n Board (P
PDB) ( If Required)
R
The Pow
wer distribu
ution boarrd (PDB) ,if
, require
ed for the
e CP System, shalll be
installed in non-cla
assified lo
ocations near a single or gro
oup of T/R Unit . The
enclosure
e of shall be
b IP-55 ass per relev
vant IEC/N
NEC codess. The Pow
wer distribu
ution
board (PD
DB) shall be
b compossed of one
e no.3 pha
ase, 4-wire
e 125A, inc
coming MC
CCB
and required numbers (includ
ding 20% spares)
s
of 1 phase, 6
63A-outgo
oing MCB. The
FORM NO: 02-0000-0021F

F2 REV3
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TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
15 of 32
incoming switch shall be 4-po

ole and outgoing switches shalll be 2- polle. The MC
CCB
and MCB
B shall be suitable
s
fo
or motor loa
ad applica
ation and sshall be as per appro
oved
make. 4 Nos. of 25
5 x 5 mm tinned cop
pper bus bar
b shall be
e used wh
hich should
d be
taped byy PVC tape
e of red, yellow and
d blue colors for identification
n of the th
hree
phases and
a black color
c
for ne
eutral. All single core
e cables shall be used red, ye
ellow
and blue colored for phase co
onnections and blackk colored fo
or neutral connection
c
n. All
cables te
erminationss shall be through Tinned
T
cop
pper cable lugs of matching
m
ca
able
size. All cable en
ntries to the
t
PDB panel sha
all be thro
ough Alum
minium sin
ngle
2,
compresssion glandss. One gland for 70m
mm 3-pha
ase, 3 -ccore Alumin
nium incom
ming
cable con
nnection shall be pro
ovided at left side bo
ottom of th
he panel, 4 glands to
o be
provided at right side bottom
m of the pa
anel for ou
utgoing cab
ble connec
ctions for 63A
PDB. The
e outgoing
g cables shall be 25
5mm2, 1-ph
hase, 3-co
ore Alumin
num condu
uctor
cables. Size
S
of the
e PDB Pan
nel enclos
sure shall be adequa
ate to acc
commodate
e all
compone
ents easily and shall be
b made of
o 12 SWG sheet stee
el. Two nos
s. hinged front
f
shutters shall
s
be provided.
p
T
The
shutters shall be
e screwed to the pa
anel enclossure
structure at the cen
nter in add
dition it sha
all have locckable han
ndles. Pain
nting detaills of
inside and outside surfaces of
o the PDB
B panel sha
all be as fo
ollows: Afte
er fabrications
the entire
e enclosurre shall be
e sand blasted to a SA2 surrface. An inorganic zinc
primer sh
hall then be
e sprayed to
t a total th
hickness of
o 3 mils. The finish coat
c
shall be
b of
polyamide cured epoxy in th
hree coats
s to achievve total thickness off 15 mm. The
finish coa
at shall be a dark gre
ey or yello
ow shade as
a per cho
oice of own
ner/consulttant.
BIDDER shall prep
pare the la
ayout/cons
struction drawings a
and a prototype of PDB
P
showing internal te
erminal arrrangemen
nt and wirring arrang
gements and
a
submiit to
owner/consultant fo
or approvall before pro
ocurementt/ installatio
on of the same
s
at site
e.
evant spec
cification.
11.3.2.9
Anodes
nded vesse
els: Anode
es employe
ed for C.P. System of mounded
d vessels shall
s
For moun
be Long Line cond
ductive polymer anod
de. The ge
eneral spe
ecifications
s of Long Line
L
conductivve polymerr anode are
e enclosed
d.
Type of Anode
A
sha
all be of Anode
A
Flex
x 1500-01 Type. Th
he Anode flex (1500
0) of
Raychem
m/equivelen
nt make sh
hall be insta
alled at 1,3
3,5,7,9,11 Oclock po
ositions at four
regular in
ntervals alo
ong the entire length of bullet making
m
a lo
oop from 1 to 11 Occlock
positions and like wire
w for 3 to
o 9 Oclock
k positionss and 5 to 7 Oclock positions. The
anodes should
s
not be installe
ed as indiv
vidual strin
ngs but a loop covering the en
ntire
dish end of the bulllet at one location an
nd exiting the mound
d for splicing with an
node
tail cable at the oth
her end. There shall be no com
mmon Ano
ode flex fo
or two or more
m
bullets.
Specific installation requireme

ents of String Anode shall be ass follows: Anod
de lead cab
ble shall be
e 1C x 10 mm2 , Cu cable
Anod
des shall be installe
ed in the sand cush
hion surro
ounding the
e vessel at
a a
dista
ance of 100
00mm (min
n.) from the vessel. Minimum
M
4 nos. ano
ode strings per
bulle
et shall be provided
p
(a
actual quantity shall be calculatted by ven
ndor).
Botto
om anode strings in between two conse
ecutive vesssels as well
w as for the
FORM NO: 02-0000-0021F

F2 REV3
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TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
16 of 32
vessels at both
h end of th
he mound shall be installed m
matching with
w the botttom
surfa
ace of the
e mounded
d vessels. Separatio
on distancce between
n consecu
utive
String anodes and betwe
een string anodes to mounded vessels shall
s
be as per
draw
wing.
Actual length of
o Anode Strings
S
sha
all be calcculated by bidder and furnished to
owne
er/consulta
ant for App
proval durin
ng detail en
ngineering stage.
A minimum 8 number
n
of Anode Fle
ex Splice Kits
K for eacch bullet of similar make
m
as th
he anode, too, shall be used
d for Anod
de Stringss. The splicing shalll be
perfo
ormed outsside the mo
ound, for fu
uture checcking/ moniitoring purp
pose.
Anod
des shall be fed from both the ends
e
of the
e loop spliccing
11.3.2.10 Surge Diiverter
For this, refer enclo

osed releva
ant specific
cation.
11.3.2.11 Solid Sta
ate Polarizzation Celll

osed releva
ant specific
cation.
11.3.2.12 Measure
ement Jun
nction Box
x
For this refer

r
enclossed releva
ant specific
cation.
11.3.2.13 Earthing
g Junction
n Box
osed releva
ant specific
cation.
11.3.2.14 Monolith
hic Isolatin
ng Joint
For this,
t
refer enclosed
e
re
elevant spe
ecification..
11.3.2.15 Electrica
al Separation
Each bu
ullet shall be
b electrica
ally isolated
d from the other bulle
et, pipeline
es, any burried
as given
n structuress in the viccinity and electrical/in
e
nstrumenta
ation earthing system
m.
Suitable
e Monolithicc isolating joints shalll be installed above g
ground in all
a piping
attached
d to each bullet
b
as pe
er OISD 15
50. These joints
j
shalll be suitable for
expected
d temperature range
e in the des
sign data.
The ressistance across th
he Monoliithic insullation join
nts shall be recorrded
immedia
ately before
e welding into the piipeline and
d shall not be less th
han one Mega
M
ohm. Monolithic Issolating jo
oints with contrast
c
co
olor paint shall be done
d
for easy
e
identifica
ations.
- To avoid surge acrross the inssulating joints use off spark gap
p surge arresters sho
ould
be envissaged for each
e
insula
ated joint.
-Safety & instrume
ent earthing installe
ed on the
e bullets shall be provided with
FORM NO: 02-0000-0021F
F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
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BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
17 of 32
polarizatio
on cells to avoid losss of cathod
dic protectiion currentt while maiintaining a low
resistance to earth
h. Polariza
ation cells shall be installed iin the earrthing of each
e
individuall bullet to ensure
e
elecctrical insu
ulation betw
ween the vvessels.
12.0
Miscellan
neous poiints relate
ed to Syste
em Design
n
1
12.1
The follow
wing criterria shall be followed to
t determin
ne the prottection leve
els :
Maxim
mum allowa
able vesse
el to soil po
otential witth respect to Cu/CuS
SO4 ref. Ce
ell:
- 1.50V (ON) or 1.10V (In
nstant OFF
F)
Minim
mum allowa
able vessell to soil pottential with
h respect to
o Cu/CuSO
O4 ref. Celll: 850mV
V (OFF) or
o -100mV polarizatio
on shift (O
Off) or -. Discretion to
o use any of
the criteria shall solely rest with Own
ner/Owner's Represe
entative.
Interfe
erence Critteria: +100
0mV positiv
ve shift
1
12.2
Design liffe of Anode = 30 yea

ars (minimum)
1
12.3
While de
eciding num
mber of modular typ
pe 50V/50A
A T/R unitss, conside
erations mu
ust
be given that no T/R
T unit is loaded mo
ore than 75%
7
of its rated outp
put voltage
e&
current capacity
c
throughout design
d
life while feed
ding load tto a single
e or group of
anode be
eds.
1
12.4
For contiinuous string/wire an

node the anode
a
currrent capacity shall be
e considerred
30mA/m & location of anode string
s
shall be as me
entioned in approved drawing.
1
12.5
Earthing of all Bullets, T/R Units, PD

DB, Junction Boxes need to be done by
connectin
ng the sam
me with pla
ant earthin
ng grids, wherever
w
p
plant earthing grids are
a
not availa
able nearb
by, a separrate earth pit
p approve
ed by owne
ant has to be
er/consulta
provided by Bidderr at no extrra cost on this account.
1
12.6
To avoid cable dam

mage in the
e long run, all cabless are to be
e laid in the
e cable tra
ays
whereverr possible; undergrou
und cable laying sho
ould be considered only
o
when no
cable trayys are ava
ailable nea
arby. All C.P. System
m cables ne
eed to be laid
l
at pow
wer
cable tra
ays, all mu
ulti core-m
monitoring cables ma
ay be laid in either electrical or
instrumen
ntation cab
ble trays whichever
w
is
s available
e.
1
12.7
The type of coating

g and opera
ating temp
perature of each mou
unded vess
sel should be
taken into
o considerration for all detail-engineering calculation
c
ns.
1
12.8
Whereve
er specific guideline
es are nott furnished
d for cath
hode struc
cture curre
ent
density or
o separattion distan
nce of anode from cathode structure and spaciing
between consecutive anode
es, a prote
ective currrent density for coa
ated catho
ode
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
1
12.9
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
18 of 32
structure shall be considered

c
d 50 A/m2 and the same
s
for b
bare catho
ode/inciden
ntal
2
structure shall be considered 10 mA/m .
If operating tempe
eratures off U/g or mounded
m
v
vessels
exxceed 30OC,
C protective
2
current density
d
sh
hall be co
orrected @ 0.5mA/m
m /deg.C. For vess
sel operatiing
O
temperattures above 60 C, minimum
m
prrotective potential
p
sh
hall be - 0.95mV (OF
FF)
w.r.t Cu/C
CuSO4 refference ele
ectrode. In
n any case
e the requirred protec
ctive potenttial
shall not exceed - 1.15Volts (OFF cond
dition) with
h respect to
o Cu/CuSO
O4 referen
nce
e.
electrode
1
12.10
Exd loccal AJB/CJJB suitable

e for classified hazardous area
a need to be provid
ded
near the
e end of the bulletts along the
t
longitu
udinal axiss as per scheme for
terminatio
on anode/ccathode/ re
eference cell/measur
c
rement cab
ble connec
ctions
13.0
Detailed Engineerring Works

s To Be Performed
P
By Bidde
er For C.P
P. System Of
Mounded
d storage Vessels
Following
g detailed engineerin
ng works are to be performed
d by Bidder based on
scheme and
a design
n basis:
List of materiials/equipm
ments to be procured from Indian market/forei
m
ign
markket.
Item wise lisst of ven

ndors witth their reference lists forr supply of
mate
erials/equip
pment.
Calculation and
d Preparattion of Bill of Quantitties for all C.P. syste
em materia
als
and equipment
e
t required.
Bill of quanttity along with de

etailed ca
alculations and pre
eparation of
speccifications, installation work procedu
ures & ffabrication/constructiion
draw
wings for fo
ollowing items:
C.P. System power

p
distrribution bo
oard (PDB): Total qu
uantity and
d connectiion
sche
eme showin
ng group of
o T/R unitts to be co
onnected w
with each C.P. Syste
em
PDB and connection deta
ails between owner'ss switch bo
oard and C.P. Syste
em
PDB.
Prep
paration & submissio
on for app
proval of Hazarodous Area Classificati
C
ion
drgs.
T/R unit: Tota

al quantityy, detailed
d circuit diagrams and theirr installatiion
draw
wings.
AJB//CJB/MJB: Total qua

antity and connection
c
n Scheme showing how
h
group of
anod
des, anod
de beds and vess
sels are to be cconnected with ea
ach
AJB//CJB/MJB.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 1
19 of 32
Also fabricatio
on drawin
ngs & sc
chematic drawings for internal termin
nal
arran
ngements and
a installa
ation draw
wings for a typical AJB
B/CJB/MJB
B.
Anod
des: Total nos. of Anode
A
strin
ngs and an
node string
g to anode
e lead cab
ble
joint details fo
or entire C.P.
C
System
m and the
eir layout arrangeme
ent drawin
ngs
show
wing no. off anode strrings in ea
ach bullet. Construction drawin
ngs and wo
ork
proce
edures forr anode to
o cable jo
ointing and
d also forr installatio
on of ano
ode
string
gs.
Desig
gn calculations show
wing: --
Cables: Total quantity

q
of cables and their layo
out drawing for each C.P. Statiion
as well
w as for entire C.P
P. System for +ve he
eader cables, -ve he
eader cable
es,
anod
de lead ca
ables, eartthing cable
es, drainag
ge cables,, power su
upply cablles
and multi-core
m
monitoring
g cables.
Cable to vesse
el joint: Tota
al quantity
y of joints and
a details of a typica
al joint.
h T/R unit is
T/R unit wise C.P. Systtem layout drawing showing how each
conn
nected with
h group of anode
a
strin
ngs/vessels through AJB/CJB/M
MJB.
Test points: All reference

e cells and anode strings should
d be marke
ed in a sing
gle
layou
ut drawing.
Overrall C.P. System

S
layout drawin
ng includin
ng all test points, anodes, ano
ode
bedss, AJB, CJB,
C
MJB,, cable ro
outes on a plot plan. All C.P.
C
Syste
em
mate
erials/equip
pment sha
all be marked prope
erly for easy identific
cation on all
appro
opriate dra
awings as well
w as on site.
Prep
paration of testing & commissio
c
ning proce
edure for C
C.P. System
m.
Prep
paration off construcction draw
wings with soft copies before
e starting of
insta
allation/proccurement work, Preparation of
o Soft & h
hard copie
es of as bu
uilt
draw
wings after completion
n of C.P. System
S
worrk shall alsso be furnis
shed.
Quan
ntified list of the major con
nstruction equipmen
nt, tools, tackles etc.
e
including Diesel engine pump sett for dewa
atering at cable/pipe
e trench the
t
SUPPLIER pro
oposes to use
u for exe
ecution of the
t work.
Bar chart
c
giving details how
h
SUPP
PLIER plan
ns to execu
ute the wo
ork within the
t
speccified time schedule.
s
Prep
paration & submission
s
n for appro
oval of Qua
ality Assura
ance Plans
s/Procedurre.
The Bidder shall estab

blish document and
d maintain
n an effec
ctive Quality
Assu
urance syystem as outlined in recogn
nized cod
des etc. and Quality
Assu
urance Pla
ans include
ed in Specifications etc. to en
nsure thatt the workk is
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
20 of 32
perfo
ormed in a planned, systematic
c manner to
t the bestt quality sttandards and
a
properly docum
mented to provide confidence
c
e that matterials sup
pplied and/or
workk executed
d and servvices perfformed by him confform to th
he applicab
ble
speccifications and all the require
ements off contract documen
nt and wo
ork
execcuted by him shall perform sattisfactorily over the e
entire period of its liife.
The Quality Assurance
A
Systems Plans/Pro
ocedures of the BIIDDER sh
hall
gene
by
erally cove
er the follo
owing asp
pects/details, which shall be furnished
f
SUPPLIER alo
ong with, his detail en
ngineering package.
i.
A Quality Asssurance Organization

n with currriculum vvitae of ke
ey personn
nel
respo
onsible forr the Qualitty Assuran
nce at site.
ii.
Com
mplete details pertaining to the responsibil
r
lity authoritty and acc
countabilityy of
the Quality
Q
Asssurance of the Bidderr at site.
iii.
Installation
Equipments, material,
m
E
Erection,
n, Testing
g and com
mmissionin
ng,
Quallity Controll Plans for quality tes
sting/inspecction etc.
iv.
QAP
P to be submitted by the
t succes
ssful bidder.
v.
Quallity Controll of processes such as

a welding, anode to cable jointing etc.
vi.
Conttrol Proced
dures/Plan
ns for calib
bration an
nd safe up
p-keep of instrumen
nts,
gaug
ges and sim
milar testing equipme
ents etc.
vii. Quallity audit & Maintenan

nce/record
ds/procedures etc.
viii. Othe
er relevant details.
Quallity Assura
ance Sysstem Plan
ns/Procedu
ures of th
he BIDDE
ER shall be
furnisshed in the
e form of a QA manu
ual. SUPPL
LIER shall be require
ed to proviide
expla
anation pe
ertaining to
o the deta
ails furnish
hed by him in acco
ordance with
w
proviisions contained in this
t
clause
e and any further de
etails, as sought
s
for by
owne
er/consulta
ant. In add
dition, all the
t
Qualityy Assurance Progra
ams/Plans as
per specificatio
s
ons enclossed with th
he Contracct shall be fully complied with by
the Bidder.
B
Preccautionary measuress to be tak

ken to pre
event fire hazard du
uring Therm
mit
welding and Pin Brazing of vessel for the pu
urpose of ccable to ve
essel joint as
i
n, operation
n & mainte
enance of C
C.P. System.
well as during installation
All other information as required in indiividual job specifications shall be furnish

hed
by Bidderr in his detail-enginee
ering package.
14.0
Earthing
Central earthing
e
system for bullets
b
shalll be designed and e
executed by
b the bidder.
Mounded
d bullets sh
hall be connected to
o a centra
al earthing system th
hrough sollid-
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
21 of 32
state pola
arization ce
ells, which
h shall be suitably
s
rated for the
e expected
d voltage and
a
currents. Two nos. solid-state
e polarization cell ratted for 5KA
A should be installed
d in
one earth
hing junctio
on box. Ind
dividual ca
able from each
e
bullett shall be connected
c
to
one end of polarization celll and the
e other en
nd of pola
arization cell
c
shall be
connected to earth
h bus bar. All polarrization ce
ells shall b
be housed
d in earthiing
junction box
b made of
o S.S. Sizze of earthiing cable shall
s
be minimum 1C
C X 35 sq.m
mm
unarmore
ed, PVC, Alluminium/
A
/ copper co
onductor.
Earthing network shall
s
be independen
ntly conne
ected and develope
ed. Requissite
numbers of earth piits are also
o included in Bidderss scope.
15.0
CP Materrials
The CP materials to be proccured from
m approve
ed manufaccturer/vend
dor list ha
ave
been ind
dicated in Make of
o Equipm
ment/Comp
ponent forr Cathodic
c Protectiion
System. Make of ite
em not me
entioned in the enclossed vendo
or list shall be subjectted
to owne
er/consulta
ant apprroval. All materia
als shall be ins
spected by
owner/co
onsultants representtative at ma
anufacture
ers work be
efore dispa
atch.
16.0
DESCRIP
PTION OF CONSTRUCTION WORK
W
16.1
Cable La
aying
The cab
ble conne
ections sh
hall be done
d
by mechanica
al means
s. Mechan
nical
connectio
ons shall be
b made above
a
grou
und only using
u
cable
e glands, lugs, nuts and
serrated washers. All grou
und electtrical conn
nection to
o the bu
ullet shall be
encapsulated.
All cabless shall be sized such
h that no excessive
e
voltage drrops occur which red
duce
the capaccity of the system. All
A cables shall
s
be inssulated and sheathed to withsttand
the preva
ailing site condition. Drain cables ( 1CX
X 50 mm2
2, Cu) and
d ground bed
feeder ca
ables shalll be armou
ured. Electrical cable
es ( shall be 1.1 KV
V grade, PVC,
P
FRLS , Al
A / Cu conductor.) for
f CP of bullets fro
om TR unitts in Electtrical Room
m to
Bullets , shall be la
aid in cable
e trays ov
verhead in below LPG pipe rac
cks. Cable
es in
ground , shall be la
aid buried in soft san
nd at a dep
pth of at le
east 0.5m, provided with
cable pro
otection tile
es or wind
ding tape as
a conside
ered suitab
ble for the
e area. All the
cables sh
hall be iden
ntified by cable
c
tag where
w
they come abovve ground.
D.C cable
es & A.C. cables
c
will run in sep
parate PVC
C / GI conduits.
16.2
Permane
ent Refere
ence Cells:
The perm
manent refe
erence cells shall be
e installed in naturall soil conditions as per
p
the reco
ommendattions of the cell manufaccturer. In
nstallations
s in high
hly
acidic/alkkaline soil and
a soil co
ontaminated by hydro
ocarbons shall be avo
oided
16.3
Straight through jo
oint for ca
able
As far ass possible any straig
ght throug
gh joint sha
all be avo
oided for any
a
cable run,
however for unavo
oidable situations the
t
straigh
ht through
h joint kit of Raych
hem
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
22 of 32
Equivalen
nt make may be conssidered forr jointing ca
able.
16.4
Cable Co
onnection to Bullets
s
All cable--to-vessel connectio
ons shall be
b made using
u
weld
ding, pin brazing
b
or by
mechaniccal means. Thermit welding or brazing to
t the vesssel shall not
n be use
ed.
The cab
ble connecctions sha
all be do
one by mechanica
m
l means. Mechaniccal
connectio
ons shall be
b made above ground only ussing cable glands, lu
ugs, nuts and
a
serrated washers.
w
All ground
d electrical connectio
on to the bullet shall be encapssulated
17.0
FIELD TE
ESTING AND COMM
MISSIONIN
NG:
1
17.1
System Testing
T
att Site
The system testing
g at site described
d
below shall be app
plicable fo
or Impresssed
Current CP
C system.
Field testts as per the
t
ownerr reviewed//approved field testing and co
ommissioniing
procedure
es prepare
ed by the Bidder
B
sha
all be carrie
ed out on tthe equipm
ment/system
ms
before th
hese are put
p into se
ervice. Acc
ceptance of
o the com
mplete installation sh
hall
contingen
nt upon insspection an
nd test resu
ults.
Bidder sh
hall carry out
o pre-com
mmissioning operatio
ons after co
ompletion of
o installatiion
of the syystem inclu
uding all pre-commi
p
ssioning checks,
c
se
etting of all equipme
ent,
control an
nd protection devicess. All site tests,
t
reliab
bility and p
performanc
ce tests sh
hall
be carried
d out by Biidder.
Before th
he CP sysstem facilities are pu
ut into ope
eration, ne
ecessary te
ests shall be
carried out to establish that all equipm
ment, devicces, wiring
g and conn
nection ha
ave
been corrrectly insta
alled, conn
nected and
d are in good working
g condition
n as requirred
for the in
ntended op
peration. Owner/Own
O
ners repre
esentative may witne
ess all tessts.
Intimation
n shall be given
g
at lea
ast one we
eek before commenccing the tes
sts.
18.0
COMMIS
SSIONNG REQUIREM
R
MENTS
1
18.1
Visual exxamination
n of all system components, checking
c
o
of all cable
e connections
and polarrity.
1
18.2
Checking
g of all perm
manent refference ce
ells with resspect to a portable re
eference Cell
C
before en
nergizing th
he system.
1
18.3
Measurements of natural
n
pote
entials at each
e
perma
anent mon
nitoring loca
ation.
1
18.4
Energizin
ng the systtem and cu
urrent adjustment to approxima
a
ate protection potentia
als.
1
18.5
Checking
g of the ele
ectrical isollation of ea
ach vessel
1
18.6
Measurements of ground
g
bed
d resistance
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
1
18.7
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
23 of 32
All tools, equipment and instruments req

quired for testing
t
sha
all be proviided by
Bidder. Generally,
G
t followin
the
ng minimum tests mu
ust be carrried out and results
should be
e recorded
d:
(
(i)
Visu
ual Inspection: Co
omparison with dra
awings, specifications, detailled
phyysical inspe
ection and,, if necessa
ary; by taking apart the compon
nent parts..
Tessting: Simu
ulation testss of equipm
ment to determine itss operation
nal fitness.
Cables
(
(ii)
able No.
Ca
Vo
oltage grad
de
Co
onductor crross sectio
on
Co
ontinuity ch
heck
Inssulation ressistance va
alues betw
ween each core & earrth, betwee
en cores.
Alll cables sh
hall be teste
ed by 500 V Megger.
Insulatin
ng Joint
(
(iii)
(
(iv)
Lo
ocation
Pip
pe to soil potential of both protected
p
and non-p
protected sides of the
t
inssulating joint before and
a after Energisatio
E
n of CP syystem.
Surge Diiverter
Lo
ocation / ide
entification
n number
Ra
ating
Tyype
Ch
heck for he
ealthiness
Ch
heck for pro
oper conne
ection
Polarizattion Cell
Lo
ocation / ide
entification
n number
Tyype
Ra
atings
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
(
(v)
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
24 of 32
Ch
heck for wiring
Ch
heck stand
dby currentt drain afte
er CP Sysstem Energ
gisation. (C
Current dra
ain
witth respect to voltage across the
e cell shall be recorded).
De
etails of gro
ounding prrovided for the polarizzation cell..
Anode
(
(vi)
(
(vii)
entification
n
Ide
Tyype
Ch
heck prope
er cable to anode spliicing
Ch
heck for acctual layoutt and comp
pliance with drawingss.
Re
esistance of
o each ind
dividual ano
ode and to
otal resistan
nce of ano
ode loop..
Cu
urrent outp
put of anode loop.
Cu
urrent outp
put of each anode
Referenc
ce Cell
Lo
ocation
Tyype of cell
Po
otential rea
ading
Insstalled on top
t / bottom
m level of bullet
b
tanks.
nction Boxxes.
Test Stattions / Jun
Lo
ocation / Ide
entification
n number.
Ch
heck for wiring as perr schematics.
Tyype of referrence cell
He
ealthiness of shunts and
a resisto
ors
Ch
heck the he
ealthiness of referenc
ce cell.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
19.0
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
25 of 32
MATERIA
AL INSPEC
CTION AN
ND TESTIN
NG
Owners/cconsultants represe
entative will
w visit th
he works during manufacture
e of
various equipment to
t assess the progre
ess of workk as well ass to ascerttain the quality
of raw materials
m
ussed all ne
ecessary assistance
a
shall be p
provided by
b Bidder and
vendor du
uring such inspection
n.
The minimum testiing and in
nspection requiremen
r
nts for all components/equipm
ment
shall con
nform to re
equiremen
nts as defined in the relevantt codes and standa
ards.
Detailed inspection
n and testing proced
dure along with acce
eptance crriteria shall be
al.
prepared by Bidder for Ownerrs approva
Test certiificates inccluding test records, performan
nce curves etc., shalll be furnish
hed.
All test certificates
c
s shall be endorsed
d with suffficient info
ormation to
t identify the
equipmen
nt to which
h certificate
es refer and
d must carrry project titles.
Owner re
eserves the
e right to ask
a for inspection of all or any item unde
er the conttract
and witne
ess all tessts and ca
arryout ins
spection or
o authorizze his representative
e to
witness te
ests and carryout
c
inspection. Bidder sha
all notify th
he owner / consultan
nt at
least 20 days
d
in advvance givin
ng exact details of te
ests dates a
and addres
ss of locations
where the
e tests wou
uld be carrried out.
The follow
wing minim
mum tests must
m
be ca
arried out and
a record
ded for all equipments
e
s:
g :
Checking
Inspection :
Testing
:
2
20.0
Visual inspe
V
ection, Com
mparison with
w drawin
ngs and sp
pecification
ns
D
Detailed
physical insp
pection & Dimensions
D
s measurement
S
Simulation
tests of equipmen
nt to dete
ermine its operation
nal
fiitness
MMISSION
NING
PRE-COM
The Bidder shall fin
nish the de
etailed field
d testing and
a pre-com
mmissionin
ng procedu
ures
oval. Field tests as per these approved
a
p
procedures
s shall be carried out on
for appro
the equip
pment / syystems be
efore these are put into servvice. Acceptance of the
complete installatio
on shall be continge
ent upon inspection and test results. Field
F
hall include
e but not be
e limited to
o the follow
wing:
testing sh
Bidder sh
hall carry out
o pre-com
mmissionin
ng operatio
ons after ccompletion of installa
ation
of the syystem including all pre-commissioning checks, se
etting of all
a equipm
ment,
control an
nd protecttive device
es. All site tests relia
ability and performan
nce tests shall
s
be carried
d out by Biidder.
Before the electrica
al facilities are put intto operation, necessa
ary tests shall be carrried
hat all equ
uipment, devices,
d
w
wiring
and connectio
on have been
b
out to esstablish th
correctly installed, connected
c
and are in
n good working cond
dition as intended forr the
required operation.
o
Owners / consulta
ants representative may witne
ess all tests. At leas
st one weeks
notice shall be given before co
ommencin
ng the testss.
All tools, equipmen
nt and insttrument an
nd instrum
ments required for te
esting shall be
provided by bidder.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
2
20.1
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
26 of 32
Anode Resistance
R
e Logging :
Resistancce Logging
g of anode strings sh
hall be done after com
mpletion off installatio
on of
anode be
ed and durring commissioning of
o CP Systtem. The p
procedure for
f same shall
s
be given by Bidderr as a part of commis
ssioning procedure d
during com
mmissioning of
CP system.
2
20.2
D
e Leads :
Holiday Detection
of Anode
To ensure
e the integ
grity of the insulation, the Bidde
er shall de
etect holida
ay of all an
node
lead cables. The sa
ame shall be
b conductted at the manufactu
m
rer works and
a witnesssed
by an autthorized re
epresentatiive from th
he ownerss side. The
e Bidder sh
hall provide
e an
approved
d holiday detection
d
in
nstrument complete with all acccessories
s for testing of
cables at the speciffied voltage
e.
al procedu
ures for the
e holiday detection
d
te
esting sha
all be in ac
ccordance with
The actua
the recom
mmendatio
on of the manufacture
er of the ho
oliday dete
ection instru
ument.
No repairr will be allowed
a
on the down
n hole ano
ode lead w
wires. Shou
uld holidayy be
detected, the entire
e cable and
d anode as
ssembly sh
hall be replaced.
2
20.3
Energisa
ation of T/R Unit :
After installation of each CP Station is complete, the Bidde
er shall ene
ergize the T/R
unit in the
e presence
e of the ow
wner/his re
epresentative to checck the func
ctioning off the
CP Syste
em.
2
21.0
COMMIS
SSIONING
2
21.1
Permane
ent ICCP System:
S
A brief co
ommission
ning proced
dure for a CP system
m of a Bulllet tanks is given be
elow
for general guidancce. Bidder shall
s
devellop detailed
d commisssioning pro
ocedure ass per
this guide
eline.
On comp
pletion of in
nstallation of
o Anode beds
b
and other
o
syste
ems as env
visaged in this
specificattion, they shall
s
be in
ndividually checked, tested and
d compare
ed againstt the
agreed sp
pecification
ns and pro
ocedure.
Electrical resistance
e of the bullets shall be checke
ed and reco
orded.
Before th
he bullets are put on
o charge by switching ON a
any of the
e CP statio
ons,
bullets to
o soil poten
ntial value
es at CJB/MJB of the system shall be measured
m
with
respect to
o Copper / Copper Sulphate refference ha
alf cell.
The TRU
U is then en
nergized and the outp
put of the TRU
T
shall then be so
o adjusted that
the sites of occurre
ence of lea
ast negativ
ve protectivve potentia
als are nott less nega
ative
than (-) 0.95 V (O
OFF) and sites
s
of oc
ccurrence of the m
most negattive protecctive
potential are not mo
ore negativve than (-) 1.1 V (OF
FF).
Care sha
all be exerccised to en
nsure that power supply rema
ains uninterrupted du
uring
the period
d of comm
missioning. In case off an interru
uption, the test in pro
ogress shall be
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
27 of 32
repeated after allow

wing time for polarization. Mo
ore sets o
of observations shall be
taken in any
a of the
e steps spe
ecified abo
ove, if advvised by the owners / consulta
ants
representtative.
Current readings
r
att all the CJJB shall be measured
d and recorded
Final records of te
esting and commissiioning including fina
al bullet to soil potential
readings shall be complied
d with inte
erpretation
n in consultation with
w
ownerrs /
consultan
nt are repre
esentative and subm
mitted.
If any de
eficiencies are found
d in the system,
s
the same sshall be re
ectified by the
Bidder, at
a no extra
a cost or time
t
sched
dule impacct, to the complete satisfaction of
owners / consultan
nts represe
entative. A set of PSP observations shall also be ta
aken
during the
e peak of the first drry season after comm
missioning
g the system into reg
gular
operation
n. Any deficciency foun
nd in the protection
p
o the bulle
of
et tanks sh
hall be rectified
by the Bid
dder at no extra costt.
If it is fou
und during commissioning thatt the sites of occurre
ence of lea
ast negative or
most neg
gative prote
ective pote
entials are less nega
ative than ((-) 0.95V (OFF)
(
or more
m
negative (-) 1.1 V (OFF) resspectively even afterr 72 hourss of opera
ation, then the
drainage point pote
entials sha
all be adju
usted depending up
pon Anode
e Ground Bed
currents in
i consulta
ation with owners
o
/ co
onsultantss representtative.
The curre
ent dissipated by indiividual Ano
odes shall be measured from th
he Anode lead
l
junction box
b and co
orrected fo
or equal dissipation to
t the exte
ent possiblle keeping the
total Grou
und Bed cu
urrent sam
me.
2
22.0
GUARAN
NTEE:
Bidder sh
hall guaran
ntee the proper perfo
ormance of
o the com
mplete imprressed currrent
cathodic protection
n system and
a
equip
pment provvided by him for a period off 24
months frrom the da
ate of comm
missioning of the PCP System.
The Bidder will mon
nitor the CP System for one ye
ear from the
e date of commission
c
ning
d
arissing shall be
b rectified
d at no extra cost.
and any defects
2
23.0
DRAWINGS AND DOCUMEN

D
NTS
2
24.1
GENERA
AL
After issu
uance of purchase
p
o
order,
succ
cessful bidd
der shall ssubmit six copies + CD
of all drawings/data
a/manuals//calculation
ns etc for review/app
proval, with
h identifica
ation
mber and de
escriptive title with p
project nam
me, owner and
on each document by a num
consultan
nt name.
2
24.1.1.
2
24.1.2.
All drawin
ngs and do
ocuments shall
s
be in English an
nd follow m
metric syste
em.
2
24.1.3.
Drawingss and documents furnished by

y bidder shall includ
de but not limited to the
following:
2
24.1.4.
Basis of system
s
design, desig
gn and sizing calcula
ations of the
e equipme
ents.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
28 of 32
2
24.1.5.
Bills of materials,
m
m
material
req
quisitions and
a purcha
ase requisittions.
2
24.1.6.
Fabricatio
on and insstallation de
etails of AJ
JB, CJB, te
est station etc.
2
24.1.7.
Connection scheme
e drawing for differen
nt type of ju
unction bo
oxes used in the cathodic
n.
protection
2
24.1.1.
Layout drawings sh
howing ano
ode, test station,
s
AJB, CJB, p
permanent reference cell
location etc.
e
2
24.1.2.
Cable schedule and

d cable layyout.
2
24.1.3.
Vendor drawings
d
and catalog
gues.
2
24.1.4.
Operation
n and main
ntenance manual,
m
Eq
quipment manufactur
m
rers docum
mentation
2
24.0
INST
TRUMENT
TS,TOOLS
S AND SPA
ARES
Bidder sh
hall provide
e a list of all
a instrum
ments, toolss and tacklles necess
sary for pro
oper
operation
n and main
ntenance of
o complete
e cathodic protection
n system and
a associa
ated
equipmen
nt along with prices.
Bidder sh
hall provide
e a list of spares
s
and
d consumables along
g with price
es, required
d for
proper operation and
a
mainte
enance of complete cathodic protection system fo
or 2
years.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 2
29 of 32
2
25.0
SCHEDULE OF QUANTITIES
De
Sr.
escription of Item
No.
1. i)D
Design( In
nclusive of
o detail engg.),
e
Supply,
Erection
n,
Te
esting,
co
ommission
ning of Imp
pressed Current
C
Cathodic Prrotection syystem for 4 Nos.
off Mounded
d Bullets fo
or LPG Sttorage,
co
omplete in all respeccts as per scope
off work & specificatio
s
ons as exp
plained
on
n LSTK basis. & inclusivve of
fo
ollowings.
i) Air cooled Transfformer Re
ectifier
Unit of ratin
ng 50V/ min.50A , - 2 Nos.
one working + one Sttand by)
(o
ii))Prepackag
ged , long Line Cond
ductive
Po
olymer Anode ANOD
DEFLEX 15
50001
1 Raychem
m/Equivale
ent make
-Q
Qty:As Req
quired (Buttmin.4striings
peerbullet)
iiii). Anode flex
f
Splice Kit
)Q
Qty:Min8Nos./Bullet
iv
v). Junction
n Boxes:
a)) Anode Diistribution Box (ADB))
Classified - 1 No.
unction Boxxes (AJB) for
b)) Anode Ju
classified arreas - 8No
os
c)) Cathode Junction Boxes
B
(CJB
B) cum
Te
est Station
n for classiffied areas. 4
Nos.
ng Junction
n Box (MJB
B) for
d)) Monitorin
no
on-classifie
ed areas
- 1 No.
v..) Cables:
a)) Positive and
a negativve header cable
:-1C X 50 mm2,Al
m
Arm
moured
b)) Drainage able :- 1C
C X 50mm2
2, Cu.
c)) Power Su
upply cable
e (PMCC to
o TR
Units). :- 3.5
5C X 25mm
m2, Al,Arm
moured
FORM NO: 02-0000-0021F

F2 REV3
Qty
C
Cost
Supply
Rem
mark
Installation
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
d)) Anode Intermediate

e cable : Frrom
ADB to Anode
A
Jun
nction Box :
1C
Cx50 mm2
2 (Cu)
e)) Earthing cable for Bullets.:B
1C X 35m
mm2, Al
f)) Anode ta
ail/ lead ca
able
1C X 10mm
m2, Cu Ano
ode tail/ le
ead
ca
able
g)) Referencce Cells to Test statio
on in
CJBs :- 1C X 6mm2, Cu
C
h)) Monitioring cable
Te
est Station
ns to Monitoring Box. :-12C
X 2.5mm2, Cu
C Monitoring cable (2
ured
Run per bullet) Armou
O
OR
25
5C X 2.5m
mm2, Cu Mo
onitoring cable
c
(1 run per bullet) Armo
oured
All cables shall
A
s
be 1..1KV Grad
de &
PV
VC/XLPE Insulated
.
- CaablesQty:AsRequired
vii). Weld Co
onnection:
a)) For 35/50
0mm2 Cab
ble- 16 Noss.(4
pe
er bullet
b)) For 6 mm
m2 Cable 8 Nos.(2 per
p
bu
ullet)
So4 perma
anent refere
ence
viii). Cu/CuS
ce
ells - 16 No
os./bullet
viiii). Instrum
ments for Operation
O
&
M
Maintenanc
e of C.P. System
S
- -Q
Qty:1
Lo
ot
ix
x). Painting
g of C.P. Syystem
eq
quipment .
X)). Explosio
on Proof Ea
arthing Jun
nction
Bo
ox (Nos.)
-Q
Qty:Min 1 no.
n per bullet
FORM NO: 02-0000-0021F

F2 REV3
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 3
30 of 32
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
Xi). Solid-Sttate type Polarization

P
n cells
(N
Nos.)
-Q
Qty:Min 1 no.
n for each ullet
(
XIi) . Surge Diverter- (Nos.)
-Q
Qty:As Req
quired
xiiv). Monolithic Isolating Joints

-Q
Qty:As Req
quired
X Earth pits
Xv).
p
-Q
Qty:Min 6 nos
n ,all con
nnected in
pa
arallel
Xv
vi) Zinc Re
eference Electrode
E
- 4
Nos. (1per bullet)
b
items
A)
A
Supplly
of
above
(In
nclusive of 10% commissiioning
sp
pares)
B)
Installlation
In
nstruments, Tools & Tackles
T
forr
prroper operation & ma
aintenance
e of
Cathodic Prrotection System &
e
ts.
asssociated equipment
1LOT
1LOT
DOCUMENT
T NO
REV
V
Sheet 3
31 of 32
XXXX
XX
XXXXX
1 Lot
i.
ii.
iii.
iv.
v.
EM163-TS--0801
Mandatory Spares for 2 Years

M
op
peration an
nd maintan
nace T/R Unit
U
1 Lot
D C Voltmete
er of each tyype
D C Ammete
er of each tyype
A C Voltmete
er of each tyype
A C Ammeter of each tyype
Co
orrosion voltmeter of each
e
type
1 no
1 no
1 no
1 no
1 no
FORM NO: 02-0000-0021F

F2 REV3
Bidde
er to
furn
nish
XXXXXX
XX
Listt of
Itemss with
Quanttities.
Spa
are
shall be
same
e as
XXXXXX
XX used
d in
offered
T/R Unit
XXXXXX
XX
XXXXXX
XX
XXXXXX
XX
All rig
ghts reserved
TECHNICA
AL SPECIFIICATION
CA
ATHODIC PROTECTION
N SYSTEM OF
O
UNDED BULLETS
MOU
PROJJECT:INSTA
ALLATION OF
F LPG MOUNDED
BULLETS
OWNER : NRL,AS
SSAM
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
xxiii.
Diodes
SC
CRs
D.C. Fuses fo
or output sid
de
HRC fuses fo
or Diodes
A..C fuses forr input side
D.C lighting arrestor
a
A C Circuit breaker MCB

B of each ra
ating
Ellectronic Co
ontrol Cardss each type
Filter Circuit Capacitor
C
Siignal Light assembly

a
fo
or annuncia
ation
R C Surge Diverter
Co
ontrol transsformer
Co
oarse Volta
age Control Switch
Fine Current control Switch
Fine Voltage control Switch
Au
uto Manual Mode Sele
ector Switch
h
To
oggle Switcches
Asssorted Gla
ass Cartridge Fuses
4 set
4 set
4 set
4 set
4 set
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
2 nos
20 set
EM163-TS--0801
DOCUMENT
T NO
REV
V
Sheet 3
32 of 32
Eachtype
andraating
Note:
1. Bidder to no
ote that quantity
q
ind
dicated in price sch
hedule is indicative & for tend
der
urpose onlly. Bidder shall calcculate/supp
ply the qu
uantity as per the approved
a
C
CP
pu
de
esign draw
wings/docum
ments submitted by bidder
b
afte
er award off order.
2. An
ny other spare
s
whicch are not specified
d here but required for safe and smoo
oth
op
peration of CP system
m shall also be quote
ed with unitt rate.
FORM NO: 02-0000-0021F

F2 REV3
All rig
ghts reserved
CATHODIC PROTECTION SYSTEM OF
MOUNDED BULLETS
PROJECT:INSTALLATION OF LPG MOUNDED
BULLETS
OWNER : NRL,ASSAM
EM163-TS-0801
DOCUMENT NO
REV
Sheet 1 of 2
DATA SHEET
FOR
CATHODIC PROTECTION SYSTEM OF LPG MOUNDED
BULLET
FORM NO: 02-0000-0021F2 REV3
All rights reserved
CATHODIC PROTECTION SYSTEM OF
MOUNDED BULLETS
PROJECT:INSTALLATION OF LPG MOUNDED
BULLETS
OWNER : NRL,ASSAM
1.0
EM163-TS-0801
DOCUMENT NO
REV
Sheet 2 of 2
SCOPE:
This Data sheets covers the minimum technical specification for Design of Cathodic
Protection System for LPG/ Propylene mounded bullet. CP VENDOR is requested to
fill up the missing information as called for in the Data Sheet.
2.0
DATA SHEET:
Parameter
Bullets (Nos.)
LPG BULLET
4
Bullet Diameter (Meters)
7.0
Bullet thickness (mm)
Bullet Coating
Bullet length (Meters)
52
Bullet Coating Thickness (mm)
-27OC to 55OC
Design Temp.
Design Life (Sacrificial)
N.A.
Design Life (Permanent)
30Years
Safety Factor
Operating Pressure, Kg/cm
1.3
2
Insulating Joints per bullet

Input Power Supply to T/R units
Average Soil Resistivity
As Required
240V (Single Phase)
Vendor to measure at site
Power Backup Requirement
No
Remote Control Required
No
Remote Monitoring Required
Yes
Cathodic Protection Current Density for PU coated

Bullet
C.P. Criteria
50 uA/m2
Structure to soil potential (P-S-P) to be
between (-) 850mV to (-) 1150mV with
reference to Cu/CuSo4 Reference
Electrode.
Note:- The above information is indicative only. Supplier shall refer Bullet
Specifications and others specifications enclosed elsewhere.
FORM NO: 02-0000-0021F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
BA
ASIC SU
URVEY
FOR
R
SOIL RESIST
TIVITY MEASU
UREMEN
NT
R
FOR
INS
STALLA
ATION OF
O LPG MOUND
DED BU
ULLETS
S
N
NRL,AS
SSAM
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
1.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 3
SC
COPE
This specification cove
ers the req
quirements
s for carryying basic survey for designing the
Ca
athodic Pro
otection System.
2.0
CO
ODES AND
D STANDA
ARDS
The
e basic su
urvey shalll be done in accorda
ance with the latest revisions of the follo
owing
Ind
dian standa
ards. Whe
erever applicable Ind
dian Standa
ards are n
not availab
ble, the relevant
IEC
C Standard
d shall app
ply:
a)
b)
c)
d)
Indian Standardss Institution

n (ISI)
Interna
ational Ele
ectro Techn
nical Comm
mission (IE
EC)
Americcan Standa
ards Institu
ution (ANS
SI)
British
h Standardss Institution (BS)
Wo
ork shall be
e carried out
o in accorrdance with all appliccable local laws and regulationss.
3.0
BA
ASIC SURV
VEYS :
Th
he following
g Basic Su
urveys shalll be carrie
ed out by va
arious metthods:
a. Soil Resistivity Survey 4 Point
P
Wenner Metho
od:
The Soil Resistivity Survey sh
hall be con
nducted within
w
the P
Plant/ Com
mplex for Bullets
B
and at evvery 2 km along pip
peline ROW
W at a depth of 1M, 2M, 3M,4
4M,5M,6M
M at a
matrix of 100 M in unpaved
u
areas by 4 point Wenner Metho
od and a co
ontour plott shall
be preparred.
b. Soil Resistivity Survey Soil Box Metthod
The Soil Resistivity Survey sh
hall be con
nducted within
w
the P
Plant/ Com
mplex for Bullets
B
and at evvery 2 km along pip
peline ROW
W at a depth of 1M, 2M, 3M,4
4M,5M,6M
M at a
matrix of 100 M in unpaved areas by soil box method
m
and a contour plot sha
all be
prepared.
c. Chemical Analysis
s of Samplles of Soill Water
wing param
meters of soil water extract at evvery 5 kmss along pip
peline ROW
W and
The follow
within the
e Plant/ Co
omplex for Bullets shall be analyzed for ssamples co
ollected a depth
d
of 1M 3M and 6M att a matrix of
o 250M in unpaved areas.
a
-
H
PH
Ca
arbonates as
a Ca CO3 mg / ltr.
Biccarbonatess as Ca CO
O3 mg/ ltr.
Ca
alcium as Ca
C CO3 mg
g/ ltr.
Ma
agnesium as
a Mg CO3 mg/ ltr.
Sodium as Na mg/ ltr.
Ch
hlorides as Cl mg/ ltr.
Sulphates ass SO4 mg/ ltr.
Siliica as SIO
O2 mg/t ltr.
Tottal Dissolvved Solids (TDS) mg// ltr.
Sulphate Red
ducing Baccteria
KM
MNO4 at 10
00 C mg / lttr.
Solubility of Soil
S in Distilled water %
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 3
.
4.0
RE
EPORT
On
n completio
on of the entire field
d and laboratory wo
ork, an intterim repo
ort incorporating
ressults generrated from surveys, additional
a
data colleccted, resullts of test carried
c
outt, etc.
sha
all be subm
mitted for commentss / approval. The fin
nal report iincorporatiing comme
ents /
misssing data shall be fu
urnished fo
or records. Contracto
or shall submit the re
eport along
g with
varrious drawings, graph
hs etc. pre
epared in connection with the w
work along with six prints.
.
5.0
INF
FORMATIO
ON REQUIIRED
Supplier shall provide fo
ollowing info
ormation:
5.1
5.2
hat will be used

u
for ca
arrying out soil
s resistivvity survey.
Insstruments th
Me
easuremen
nt location identificatio
on procedurre.
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 1 of 17
TECHNIC
CAL SPECIFICA
ATION
TRA
ANSFOR
RMER RECTIFI
R
IER UNIT
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
1.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 2 of 17
SC
COPE
al require
ements fo
or the De
esign,
This specificcation covvers the minimum Technica
Ma
anufacture,, Performa
ance, Supp
ply, Inspecttion, Testin
ng and com
mmissionin
ng of Air Cooled
Tra
ansformerss Rectifier Unit for CP
P System.
The
e Transforrmer Rectifier units shall
s
be a standard product off a manufa
acturer reg
gularly
eng
gaged in production
n of Cath
hodic Protection Power Supp
plies. The units sha
all be
sup
pplied in acccordance
e with the fo
ollowing sp
pecification
ns and data
a sheets.
2.0
CO
ODES AND
D STANDA
ARDS
e Design, Manufactu
uring, Tessting of Airr Cooled Transforme
T
er Rectifierr Unit and
d their
The
com
mponents shall be in accorda
ance with the latesst revisionss of the following
f
Indian
sta
andards, wherever
w
applicable. Where ap
ppropriate Indian Sta
andards are not available,
the
e relevant IEC
I
Standa
ard shall apply:
a)
b)
c)
d)
e)
f)
g)
Indian Standardss Institution

n (ISI)
Indian electricity Rules (IE rule)
Interna
ational Ele
ectro Techn
nical Comm
mission (IE
EC)
NACE
E standardss & recomm
mended prractice
Americcan Standa
ards Institu
ution (ANS
SI)
British
h Standardss Institution (BS)
OISD standard & CCOE no
orms
t the follow
wing:
This shall incclude but not limited to
IS: 2026
IS: 3700
IS: 4400
IS: 60898
IS: 13703
IS: 60947
IS: 3070
IS: 11548
IS: 694
IS: 3961
IS: 4800
IS: 11222
IS: 1248
IS: 6236
FORM NO: 02
2-0000-0021F2 REV3
R
Power Tra
ansformer
Essential rating and
d characte
eristics of Semi-Cond
S
ductor
devices.
Methods of measure
ements on
n semicond
ductor
Devices (General)
Electrical accessorie
es-Circuit breakers fo
or over currrent
Protection
n for house
ehold and ssimilar insttallation
Specificattion for Lo
ow voltage
es fuses for voltage
e not
exceeding
g 1000V AC
A or 1500V
V DC
Specificattion for Low
w voltage S
Switchgear & controll gear
Lightning arrestors for
f AC sysstems
Capacitorrs for surrge protecction for use
u
in Vo
oltage
system ab
bove 650V
V and up to
o 33kV
PVC insu
ulated unsh
heathed an
nd sheathe
ed cables//cords
for workin
ng voltagess up to and
d including 450/750 volts
v
Recomme
ended currrent rating for cables
Enameled
d round winding wires
Dial, sca
ales and indexes for indica
ating analogue
Measuring instrume
ents
Direct acting indica
ating analo
ogue electrical meassuring
instrumen
nts and the
eir accesso
ories
Direct rec
cording ele
ectrical mea
asuring ins
strument
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
IS: 2419
IS: 8573
IS
S: 3043
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 3 of 17
Dimension for pane

el mounted indicating and recorrding
electrical instrument
Digital ele
ectronic DC
C voltmeters and DC Electronicc
analogue to digital convertors
Code of practice
p
forr earthing
In case of conflicting
requireme
c
ents amon
ngst any of
o the abo
ove standards, the most
striingent requ
uirement shall
s
be folllowed.
3.0
TR
RANSFORM
MER
The
e Main Tra
ansformer will be the
e isolation type havin
ng separatte primary and secondary
win
ndings. An
n electrostatic shield, compo
osed of he
eavy copp
per foil, shall
s
be placed
p
bettween the two windin
ngs and grrounded to
o the rectifier cabinet, for this purpose a visible
v
lea
ad should be
b brought out from the coppe
er foil whicch shall be
e connecte
ed to any of
o the
mo
ounting stu
ud of the trransformerr core. Insu
ulation class of wind
ding shall be
b class F type.
The
e winding assemblyy shall be dipped in the therm
mo-setting vvarnish an
nd backed. The
Ca
abinet air temperatur
t
re will nott exceed 85
8 0 C at 110
1
% fulll load currrent at am
mbient
tem
mperature of up to 45
5oC. Transsformer full load efficiiency will n
not be less
s than 95%
%. The
auttotransform
mer shall be
b similar to
o main tran
nsformer except
e
it will have single winding
g and
tap
pping for manual
m
mod
de of contrrol.
4.0
ECTIFYING
G ELEMEN
NT
RE
Re
ectifier shalll be Silicon type of approved
a
make
m
with adequate cooling arrrangemen
nt with
mo
oisture and
d humidity resistant finish.
f
It sh
hall be mo
ounted on spindles or
o other su
uitable
sup
pports. The
e Power Rectification
R
n shall be through Diodes/SCR
Rs which shall be pro
operly
selected to have adequ
uate Safetyy Margin. Itt shall have
e configura
ation suitable for full wave
recctification.
The
e Thyristorrs/diodes shall
s
be mounted on heat sinkss which sh
hall prefera
ably be ma
ade of
exttruded alu
uminum. The
T
diodess shall be connecte
ed in Bridg
ge circuitrry for full wave
recctification. Adequate
A
filtering in the form of
o L-C filte
ering circuitt shall be provided
p
o the
on
outtput side to
o limit the ripple
r
content to less
s than 5% at
a rated ou
utput. The input &output of
the
e Rectifierr shall be protected
d by HRC
C fuses of
o suitable rating. Transient
T
s
surge
sup
ppressors shall also be provide
ed across DC
D output terminals and AC input terminals to
pro
otect the re
ectifier aga
ainst surge
es. Each diode and SCR
S
shall be provide
ed with su
uitable
surrge suppre
essers, and
d also with suitably designed sn
nubber circcuits.
The
e current and
a voltage
e ratings of Thyristorrs, diodes shall
s
be at least two times
t
the actual
a
ma
aximum de
evice curre
ent and miinimum tw
wo times th
he actual m
maximum voltage co
oming
acrross the de
evice respe
ectively.
5.0
A.C
C. INPUT
e transforrmer rectiffier units shall be designed to operate on 240
0V/415V+ 10%
The
single/three phase AC
C, 50 Hz + 5% pow
wer supplyy. Inrush ccurrent lim
miting reacttor of
suitable rating to be pro
ovided at input
i
line of
o the Main
n Transforrmer to avo
oid possibiility of
nuiisance tripping of MC
CB while cllosing circu
uit using MCB.
M
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
6.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 4 of 17
D.C
C. OUTPU
UT
The
e Transforrmer rectifier shall be
e designed to operate
e continuously at 110
0% rated output
o
currrent and 110% ra
ated outpu
ut voltage at input supply voltage 240V/415V single
s
pha
ase/three phase
p
AC without
w
dam
maging any
y compone
ents.
7.0
D.C
C. OUTPU
UT ADJUST
TMENTS
e D.C. outtput contro
ol shall be available in any of th
he following modes, with the help of
The
a selector
s
sw
witch.
8.0
8.1
MO
ODES OF OPERATIO
O
ON:
MA
ANUAL MO
ODE
Ou
utput voltag
ge at 36 eq
qual steps up to 110%
% rated vo
oltage shalll be availab
ble by mea
ans of
coa
arse and fine
f
tap ch
hanging sw
witches forr rated inp
put supply voltage and
a
110% rated
outtput curren
nt.
Tapping for output
o
volttage contro
ol shall be
e taken from a separrate Autotrransformerr. The
con
ntrolled ou
utput voltag
ge of the autotransfo
a
ormer shall be fed to
o main tra
ansformer input.
The
e output off the Main Transform
mer shall be
e rectified for
f D.C loa
ad supply.
8.2
AU
UTO MODE
E:
Either consta
ant currentt control or
o constantt pipe to soil
s potenttial control mode sha
all be
pro
ovided in Auto
A
mode as per datta sheet for Bullets.
8.2.1 AU
UTOMATIC
C VOLTAG
GE-CURRE
ENT CONT
TROL MOD
DE (AVCC
C MODE)
The
e output vo
oltage of th
he unit sha
all be adjus
stable to an
ny value frrom 0V to rated
r
voltage by
me
eans of a step
s
less vo
oltage setter potentio
ometer. The voltage rregulation shall be within
w
0.2
25V.
The
e output current
c
of the unit shall
s
also be
b adjusta
able to anyy value fro
om 0A to rated
currrent by means
m
of a step lesss currentt setter po
otentiometter. The current
c
sha
all be
reg
gulated within 1.0 A for bulletss.
The
e independ
dent curren
nt limit circcuit capable of proteccting the unit even un
nder dead short
circcuit acrosss output sh
hall be provided. The
e unit will be
b suitable
e of sustain
ning dead short
circcuit acrosss output ind
definitely without
w
deg
grading or damaging
g any intern
nal components
in this
t
mode.
8.2.2 AU
UTO REFR
RENCE MO
ODE
For Mounded
d Bullets operation off the unit in this mod
de shall be controlled
d by a reference
s
be in
nstantaneo
ous to suppress exxtremely fa
ast acting external stray
signal and shall
currrents if prresent. The
e output D.C. voltage
e of the un
nit in this m
mode shalll vary rightt from
0V to rated voltage
v
and
d form 0A to
t rated cu
urrent to maintain
m
the
e reference
e signal within
20 mV of the set value under all operating
o
conditions.
c
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 5 of 17
For Pipeliness operation of the unit

u
in this
s mode sh
hall be fullly automa
atic and will
w be
con
ntrolled byy the Referrence elecctrodes fee
edback. Th
he unit sha
all maintain the reference
voltage or P.S
S.P within 15mV off the set va
alue underr all the ope
erating con
nditions.
Suitable mettering arrangement shall
s
be provided to
o monitor a
all the extternal reference
signals as we
ell as intern
nal referen
nce signals
s independently.
In the
t event of
o failure of
o the refere
ence signa
als, the uniit will provide alarm All Reference
Fail and the output of the
t unit sh
hall get adjusted to a preset vallue which will
w be man
nually
om 0V to ra
ated voltag
ge
adjjustable fro
The
e independ
dent curren
nt limit circcuit capable of proteccting the unit even un
nder dead short
circcuit acrosss output sh
hall be provided. The
e unit will be
b suitable
e of sustain
ning dead short
circcuit acrosss output ind
definitely without
w
deg
grading or damaging
g any intern
nal components
in this
t
mode.
9.0
T/R
R UNIT WITH REMO
OTE MONIT
TORING FACILITY
F
T/R
R Units sh
hould be provided
p
w
with
transd
ducers for providing 4-20 mA
A output siignals
req
quired for remote mo
onitoring unit
u
(RMU)) interface
e for remotte monitorring of T/R
R Unit
outtput voltag
ge and current. Nece
essary term
minals are to be provvided at su
uitable loca
ations
of the T/R unit panel for easyy termination of onw
ward wirin
ng by others for re
emote
mo
onitoring pu
urpose.
Faccility will be
e provided
d for remote
e monitorin
ng of follow
wing signalls
1. Analog
g Parameters
a) PSP
b) DC O/P Voltage
V
c) DC O/P Current
C
d) AC Supply Voltage
e) AC Supply time Tota
aliser
2. Alarm Paramete
ers
a) Under Pro
otection
b) Over Prottection
e fail
c) Reference
d) AC Supply Fail
e) TR unit Door open
For details please referr specificattion for rem
mote monito
oring, attacched elsew
where.
10.0
T/R
R UNIT CO
ONTROL
The
e Transforrmer / Recctifier units electron
nic control circuitry sshould be able to accept
a
rem
motes as well
w as loccal referen
nce contro
ol signal fo
or setting o
of output current
c
/ output
o
voltage. The control signal for setting
s
sho
ould be se
elected ussing a sele
ector switcch for
rem
mote or loccal control.. At selecto
or switch in local possition, the potentiome
eter provid
ded in
T/R
R Units forr continuous currentt and volta
age adjusttment in auto mode should prrovide
loccal control reference
e signal byy manual adjustmen
nt to the p
potentiome
eter. At selector
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 6 of 17
switch in rem
mote posittion the electronic
e
circuitry
c
sh
hould be suitable to
o accept digital
d
refe
erence control signa
als through
h Ethernett link from central control room
m computer for
rem
mote settin
ng of outpu
ut current / voltage / PSP. In th
his case if Ethernet Link
L
fails th
he set
poiints should
d be maintained to the
t
presett values sttored in m
memory till communiccation
ressumes and
d new value
es are prog
grammed.
11.0
T/R
R UNIT IN INTERRUPTION
T/R
R units sho
ould be prrovided witth inbuilt Microproce
M
essor base
ed current interrupter with
GP
PS Receive
er with Exte
ernal Antenna for me
easuremen
nt of OFF P
PSP. The interrupter clock
sho
ould also accept
a
exte
ernal time synchroniz
zing signal from rem
mote monito
oring syste
em for
inte
errupted offf PSP reccording, syynchronizin
ng with other T/R uniits. The intterrupter should
be programm
mable to pe
erform inte
erruption in
n the time ratio
r
selecctive form 0-9999
0
secconds
in increment
i
of 0.1 secc. The curre
ent interrupter should
d have me
embrane ke
eypad and
d LCD
dissplay for prrogramming of day, date,
d
time, ON/OFF Time,
T
Syncchronization Signal etc.
12.0
DC
C OUTPUT
T RIPPLE
The
e filter circcuit shall be designed
d in such a manner that Ripple
e Factor does not exxceed
5%
% at rated lo
oad both in
n auto and
d manual mode.
m
13.0
INP
PUT OVER
RLOAD PR
ROTECTIO
ON
Pro
otection fro
om overloa
ads on the
e input sha
all be provvided by M
Miniature circuit breakker of
suitable ratin
ng on the
e input side. The trip point shall be
e unaffecte
ed by am
mbient
tem
mperature. The trip handles
h
of individual poles of circuit
c
brea
aker shall be
b mechan
nically
linkked so tha
at all lines are opene
ed when an
n overload
d occurs. In
n addition to above MCB,
HR
RC fuse of suitable ra
ating shall be connected beforre MCB so
o that A.C. input currrent is
limited to maxx. 10% exccess rated input current.
14.0
OU
UTPUT OV
VERLOAD PROTECT
TION
Pro
otection fro
om overloa
ad on the output
o
in auto mode for T/R un
nit having either
e
Auto
omatic
voltage-curre
ent control mode or Automatic reference
e mode will be provided by an
nother
clo
ose loop SCR
S
contro
ol circuitry giving auttomatic co
onstant currrent same
e as menttioned
(intterruption) except th
hat it will act as back up co
ontrol to m
main auto mode co
ontrol.
Separate PC
CB shall be
b used fo
or main au
uto mode control an
nd the bac
ck control. The
currrent limit for backup
p control iss to be se
et by two limit switch
hes marked Coarse
e and
Fine. The limits of the
e two switcches shall be algebra
aically add
ditive and shall
s
give equal
ste
eps of 2A each
e
up to 110% rate
ed current.
ne scale ca
alibrated in
n Ampere shall
s
be pro
ovided with
h each limit switches
s so that cu
urrent
On
limit can be set
s by operrator at anyy desired value
v
in 2A
A step. In a
any circumstances evven in
casse of shortt circuit the
e T/R unit output
o
currrent should
d not exce
eed the currrent limit set
s by
the
e backup control.
c
In addition to
o above electronic
e
c
current
lim
miting featu
ure HRC fu
use &
MC
CB of suita
able rating to be use
ed at posittive and ne
egative terrminals to disconnecct T/R
uniit quickly in
n case of over
o
loads in the outp
put circuit.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
15.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 7 of 17
VO
OLTAGE SURGE
S
PR
ROTECTIO
ON
Each silicon controlled
c
rectifier (S
SCR) and Diodes
D
sha
all be prote
ected from Voltage Surges
by means off R-C circuitry. Thesse R-C cirrcuits will be rated as recomm
mended by
b the
ma
anufacturerr of the SCR/Diode
S
es so thatt they will conduct heavily be
efore the Peak
Invverse Volta
age ratingss of the SCR / Diodes
s are reach
hed.
In addition, Lighting
L
Arrestors and Zener ba
arrier type
e or MOV ttype Surge
e Diverterss shall
C. input and
d D.C. outtput circuit of the Tra
ansformer Rectifier as
a per
be provided in the A.C
datta sheet.
16.0
CO
OOLING
The
e Transfo
ormer/Recttifier will be naturral air co
ooled, completely enclosed IP55
con
nstruction. The temperature of the transfo
ormer shall not be more than 85oC for am
mbient
tem
mperature of up to 45
5oC.
17.0
INP
PUT AND OUT PUT TERMINA
ALS
DC
C terminalss made off tinned pllated copp
per shall be
b located convenient to the cable
enttrance. The terminalss shall be suitable fo
or required
d cable size
es. Two ne
egative and two
possitive outpu
ut terminalls shall be provided.
AC
C terminalss shall be insulated to withstand 2000 vo
olts 50 Hz to the enc
closure, shall be
shielded to prevent acccidental con
ntact and shall
s
be sizzed to take
e required cable
c
sizess.
18.0
ETERS
ME
The
e transforrmer rectiffier units shall be equipped
e
with sepa
arate conttinuous reading
Voltmeter an
nd Ammete
er for the D.C
D outputt and the A.C
A input voltage, cu
urrent and
d PSP
me
easuremen
nt. All mete
ers shall be
b electron
nic digital type
t
with L
LED displa
ay arrange
ement
and
d should be
b able to
o indicate the curren
nt and volttage up to
o full rang
ges and ha
ave a
ressolution of one decim
mal place for
f DC Am
mmeter & Voltmeter
V
and 3 dec
cimal place
es for
PS
SP meter. Digit
D
size should
s
be 12.5
1
mm (m
minimum). All meterss shall be square
s
in shape
s
and
d accurate
e to within
n 2% at fu
ull load at ambient temp.
t
The
ey shall be
e Tempera
atures
com
mpensated
d to vary no
o more tha
an 1% per 10% temp
perature ch
hanges.
All AC & DC voltmeterss shall be provided
p
with
w separa
ate fuse and Toggle switch
s
whe
ere as
all Ammeterss shall be provided
p
w only To
with
oggle switcch.
19.0
AN
NNUCIATIO
ON
Each Transfo
ormer Rectifier shall be supplie
ed with a continuous
c
signal ligh
ht, which will
w go
on to this each
e
T/R unit should be given Annunciatio
A
on for
outt at loss off A.C. inputt. In additio
autto and ma
anual mod
de of operration by continuous
c
s signal lig
ght. T/R unit
u
should
d also
ind
dicate high temperature of insttrument ch
hamber ass well as th
he failure of each fu
use in
brid
dge rectifie
er and two DC outputt fuses by an independent LED
D for each.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 8 of 17
Audio / Visu
ual alarm for the fo
ollowing alarms with
h potential free conttact for re
emote
exttension:
i.
ii.
iii.
iv.
v.
Over Volttage (OV)

T/R ou
utput voltag
ge T/R ou
utput curre
ent Over Currrent (OC)
Input / Output MCB Trip
Diode / Output Fuse
F
Fail
Instrum
ment cham
mber high te
emperaturre
R Unit should be provided with transduce

er for 4-20 mA output for the fo
ollowing sig
gnals,
T/R
req
quired for remote
r
monitoring un
nit interface
e.
i.
ii.
iii.
T/R Output Curre

ent
T/R Output Volta
age
Pipe to
o Soil Pote
entials
Ne
ecessary te
erminals are to be provided
p
at suitable locations inside T/R
R Unit pan
nel for
termination of
o wiring req
quired for central
c
mo
onitoring an
nd control purpose.
18.1
AN
NNUNCIAT
TION FOR FUSE FA
AIL
T/R
R Unit sho
ould be pro
ovided witth Electron
nic Fuse fa
ail indicato
or. The fus
se fail indicator
sho
ould sense
e signals frrom each fuse
f
in serries with diiode in the
e rectifier circuit
c
as well
w as
eacch fuse in DC outputt circuit and
d on its faiilure, it sho
ould identiffy the fuse failed with
h help
of an independent LED
D for each fuse for lo
ocal visual alarm and
d potentiall free NO & NC
con
ntacts shou
uld be provvided for re
emote visu
ual alarm extension
e
fo
or remote monitoring
g.
18.2
NNUNCIAT
TION FOR HIGH TEM
MPERATU
URE
AN
T/R
R Unit sho
ould be pro
ovided with
h 2 nos. of
o thermosttats along with nece
essary Rela
ays &
pottential free
e NO & NC
C contacts for remote
e monitorin
ng & LED d
display forr local indiccation
of high temp
perature of
o instrume
ent chamb
ber. The thermostat
t
t should have
h
adjusstable
tem
mperature setting ran
nge from 45
5oC to 110
0oC.
20.0
EN
NCLOSURE
E
The
e enclosurre of T/R unit
u shall be
b plinth mounted
m
& outdoor h
having one
e compartm
ments
con
ntain Main Transform
mer, Auto-T
Transformer, DC cho
oke. Panel shall be of
o free standing
typ
pe and all cable
c
entrie
es shall be
e from the bottom
b
only.
The
e SCRs, Diodes, indicatin
ng meters, protecctive deviices, elec
ctronic co
ontrol
circcuits/contro
ol cords ettc. and sha
all be prov
vided with a Plexigla
ass viewing window. Both
the
e comparttments sh
hall be co
ompletely enclosed type ha
aving IP 65 for Bullets
B
con
nstruction.
The
e enclosure shall be
b made of
o minimu
um 12SWG
G (2.67 m
mm) sheett steel. Size of
encclosure sh
hould be specified
s
b Vendor.. An integrated/detachable sun/rain sha
by
ade of
suitable size to be provvided by ve
endor.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheett 9 of 17
The
e transform
mer rectifie
er shall be provided with
w the following acccessories.
Steel channel
c
un
nder the ba
ase for plin
nth mountin
ng.
Lifting lugs of sizze suitable for lifting complete
c
transformer rectifier unit.
u
Sunsh
hade / rain shade.
Lockable controll cabinet with
w viewing
g windows to IP55 ass a minimu
um.
Acccessibility shall be provided by
b hinged and removable fro
ont and ba
ack shutte
ers. A
Ple
exiglas view
wing windo
ows shall be
b provided at the fro
ont shutterr to allow th
he meters to be
rea
ad without opening th
he front shutter. One drawing pocket
p
shalll be made
e at inner side of
the
e front shutter. One holder
h
for 60
6 watt CF
FL connecction shall be provide
ed at a stra
ategic
poiint inside th
he cabinett to facilitatte proper illumination
n during op
peration and maintena
ance.
The
e enclosu
ure shall be supplied with an
a engravved warning label with the word
DA
ANGER. Two juncction boxe
es shall be provid
ded at bo
oth sides of the upper
u
com
mpartmentt, one for A.C cable
e entries and
a
other for D.C cable entrie
es. Gland plate
sho
ould be pro
ovided aga
ainst each junction box
b for fixin
ng single ccompressio
on cable glands
g
for AC/DC control
c
/ monitoring
m
c
cables.
Tw
wo 240 V, 6A Socke
et shall be
e provided
d at a
ategic poiint inside the cabin
net to fac
cilitate connection of soldering iron during
d
stra
ma
aintenance. After fabrication the
e entire en
nclosure sh
hall be epo
oxy paint/P
Powder Co
oating
of shade RA
AL 7032 Siiemens gre
ey with proper pre-treatment a
and primer applicatio
on as
perr standard Industrial Practice to
t achieve thickness of 120m.
21.0
NCLOSURE
E EARTHIING
EN
All normally dead
d
meta
allic parts shall
s
be ellectrically continuous
c
s. Earthing
g terminalss shall
be suitable for
f 35 mm
m2 cable co
onnections
s to powerr supply e
earthing an
nd two earthing
terminals sha
all be made
e for earthiing connec
ction to the
e local eartthing pits.
e earth connection
c
points shall be protected
p
a
against
co
orrosion. It
I shall no
ot be
The
neccessary to
o scrap th
he paint away
a
in orrder to ma
ake an efffective ea
arth conne
ection.
Pro
ovision shall also be made adjacent
a
to
o each gla
and plate for cable gland earthing
con
nnection. Enclosure
E
e
earthing
co
onnection stud size shall
s
not less than 12
2mm.
1 no.
n nickel plated
p
copp
per earth bus
b bar sha
all be proviided.
22.0
Ca
able Terminations
22.1
Ca
able glandin
ng and terrminating facilities
f
an
nd terminals shall be
e suitable for
f the spe
ecified
cab
ble type an
nd conductor size. Considerati
C
on and pro
ovision sha
all be take
en by the Bidder
B
on the equipm
ment desig
gn for the use
u of cablles with alu
uminum co
onductors. Cable glan
nds &
cab
ble lugs sh
hall be in th
he scope of
o supply fo
or CP syste
em installation contra
actor.
Terminal bloccks shall be
b arrange
ed and pos
sitioned to afford eassy access for carryin
ng out
extternal cablle termination, testin
ng, inspecttion and maintenanc
m
ce. There shall be ample
a
cle
ear space allowed
a
be
etween the
e terminal block and
d gland pla
ate for the
e spreading
g and
termination of
o external conductorss.
All terminal blocks
b
sha
all be shrouded or provided wiith transpa
arent coverrs. Pinch screw
s
typ
pe terminals are not acceptable
a
e.
Terminals forr different voltages
v
sh
hall be sep
parated by partitions.
Three positivve and thre
ee negative post types D.C ou
utput terminals shall be provide
ed for
E
post shall
s
be fittted with do
ouble nuts and washe
ers.
recctifier transsformers. Each
22.2
22.3
22.4
22.5
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 10 of 17
22.6
A terminal box
b
or ch
hamber with underline gland plate or entry pan
nel of suffficient
dim
mensions to
t terminatte the specified inco
oming and outgoing cables sha
all be provvided.
Dirrection of cable
c
entryy shall be frrom bottom
m.
22.7 Termination of
o single co
ore cabless shall through a non-magnetic gland platte and provvision
ma
ade for bon
nding and earthing
e
an
ny armor and/or
a
conccentric ground condu
uctors.
22.8 Ca
able termin
nal arrange
ements forr power an
nd control cables ma
ay be integ
grated pro
ovided
tha
at a barrier separatess the two.
22.9 Auxiliary wiriing shall have
h
copp
per conduc
ctors of th
he manufa
acturers standards sizing
s
(su
ubject to bu
uyers apprroval).
22.10 Suitable term
minals for two nos. ref. cell cables,
c
on
ne no. measurement cables and
a
a
selector switcch for perm
manent reff. cell to be
e provided for T/R un
nit panel fo
or connection to
PS
SP meter.
Wiring shall be
b crimped
d using selff-insulated
d compresssion type te
erminal blo
ocks which
h shall
be suitably id
dentified. Conductor
C
rs shall be
e fitted with
h sleeve fe
errules bearing the same
ide
entification as the terrminal to which
w
they are conne
ected. Minimum cond
ductor size
e shall
2
be 1.5 mm .
23.0
NA
AME PLAT
TE
A permanent
p
tly stampe
ed stainless steel me
etal plate shall be a
attached to
o outside of
o the
casse with the
e following information.
a.
b.
c.
d.
e.
f.
g.
h.
24.0
Manuffacturers name
n
AC inp
put voltage
e & currentt rating
AC fre
equency / Phase
P
Output DC volts and Ampss. Rating
Weigh
ht in Kg of T/R
T unit
Model number
Serial number
o Manufaccture
Year of
ECOMMEN
NDED LIST
T OF SPAR
RE PARTS
S
RE
e Bidder shall supplyy the follow
wing spares
s for T/R units
The
-
D C Voltmeter
D C Ammeter
A C Vo
oltmeter
A C Am
mmeter
Corrossion voltme
eter
Diodess
SCRss
D.C. Fuses
F
for output
o
side
HRC fuses
f
for Diodes
D
A.C fu
uses for inp
put side
D.C lig
ghting arre
estor
A C Circuit breakker MCB of
o each rating
Electro
onic Contro
ol Cards each type
Filter Circuit
C
Cap
pacitor
FORM NO: 02
2-0000-0021F2 REV3
R
No
os.
No
os.
No
os.
No
os.
No
os.
Se
et
Se
et
Se
et.
Se
et
Se
et
No
os.
No
os.
No
os.
No
os.
1
1
1
1
1
4
4
4
4
4
2
2
2
2
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
25.0
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 11 of 17
Signall Light asse

embly for annunciatio
a
on
R C Surge Diverrter
Contro
ol transform
mer
Coarse Voltage Control Sw
witch
Fine Current
C
con
ntrol Switch
h
Fine Voltage
V
con
ntrol Switch
h
Auto Manual
M
Mo
ode Selecto
or Switch
Toggle
e Switchess
Assortted Glass Cartridge
C
F
Fuses
No
os.
No
os.
No
os.
No
os.
No
os.
No
os.
No
os.
No
os.
Se
et
2
2
2
2
2
2
2
2
20
0
DA
ATA SHEE
ET OF T/R UNIT
A.C
C Input Voltage
: 240V
V/415V+ 10
0% Volt, 1/3
3 phase 50
0Hz+5
% Hz
A.C
C Input Current
: to be
e specified by Bidder
D.C
C Power Output
O
: to be
KV
VA Rating of
o transform
mer.
: To be
e specified
d by Bidderr
C Output Voltage
V
D.C
: 50V
D.C
C Output Current
C
: 50A
Current Ratin
ng of SCR
: to be
g of Diode
Current rating
: to be
Re
eference ce
ell
: Copp
per / Coppe
er Sulphatte Saturate
ed
eference ce
ell for contrrol
Number of re
: to be
eference EM
MF Setting
g
Re
: 0-300
00 mV
Re
egulation off Referencce
: to be
De
erating Facctor for Transformer
: 30 % excess cu
urrent capa
acity
De
erating Facctor for Diod
des / SCR
Rs
: 400 % excess current ca

apacity
(Minim
mum) for Bullets
Full Load Effiiciency of transforme
t
er alone : Not
N less tha
an 95%
r
alo
one
: To be
e specified
d by bidderr
Full Load Effiiciency of rectifier
Full Load Effiiciency of the
t unit
: not le
ess than 80 %
Full Load Pow
wer Factorr
: Not less than 0
0.85 (laggin
ng)
Inssulation Levvel
: 2.5 KV
K for 1 miinute at 50Hz
Peak Inverse
e Voltage Diodes
D
& SCRs
S
: To be
e specified
d by bidderr
Peak Transie
ent Revere
e Voltage Diodes
D
and
d SCRs
FORM NO: 02
2-0000-0021F2 REV3
R
: To be sp
pecified by
y bidder
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 12 of 17
Filttering Circu
uit
: L.C Filter
F
Rip
pple and Hum
H
: Lesss than 5% a
at rated loa
ad
Surge Diverte
ers for Diodes / SCR
Rs
: For Diodes
D
/ SC
CRs: RC circuitry
c
of rating
as advvised by m
manufacture
er of SCR &
Diode Metal oxid
de varistors /Zener
Diodes/R-C
T unit
For input of T/R
2 noss. Zener D
Diodes of voltage rating
300V RMS, sp
park over voltage 1000V
(Peak) or equivvalent apprroved type
e and
make
For output off T/R
Diodes of voltage rating

2 noss. Zener D
300V RMS, Sp
park over voltage 800V
e and
(Peak) or equivvalent apprroved type
make
Lig
ghtening Arrrestors
2 nos.. each at th
he input an
nd output of
o the
T/R unit
u
of vo
oltage ratin
ng 500V RMS
Maxim
mum 1.2/50
0 micro Se
econds im
mpulse
spark over vo
oltage 2.5
5 kV (P
Peak),
Maxim
mum disch
harge resid
dual voltag
ge at
5kA, 8/20
8
micro
o second impulse
i
cu
urrent
wave 2.5KV @1
1.5KA, Ma
aximum im
mpulse
nt discharrge capac
city 4/10 micro
curren
second impulse
e current wave 10
0 kA
(Peak), LAMCO
O L.T-2.8 or equivvalent
approvved make.
Zenerr Barrier Type, Volta
age rating 500V
rms Spark
S
over voltage 2500V
2
(pea
ak) at
Input and
a outputt
Pro
otection
MCB having the

ermal overrload and short
circuit protection
n with backup HRC fuses
for inp
put and outtput. Input MCB trip alarm
shall be
b extende
ed to facilitate for re
emote
indication of unit fail. Glass
G
carttridge
fuses in lamp circuit and auxiliary power
p
supplyy line off control circuit. Inrush
curren
nt limiting rreactor of suitable
s
ratting is
provid
ded at inpu
ut line to avoid nuissance
trippin
ng of MCB.
Me
eters / Instrruments
Digita
al Panel M
Meters (96 mm x 96 mm)
Accura
acy -2% 1 Digit of Full Scale 1 No
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 13 of 17
AC Vo
oltmeter, 0
0-400 Volts, Resoluttion 1
V
1 No. AC Amm
meter, Currrent Transd
ducer
Opera
ated, 0 99
9.9 A, Resolution 0.1 A,
1 No. DC Voltm
meter, 0-110 V, Reso
olution
0.1 V with
w built in
n 4-20 mA
A transduce
er
1 No. DC Amm
meter, 0-10
00 A with shunt
25 A / 75 mV forr Bullets, Resolution
R
0.1 A
with built in 4-20
0 mA transd
ducers.
o. Corrossion Voltm
meter, 9--0-9V,
1 No
0.001V
V Resoluttion with built
b
in 4-2
20mA
transd
ducer.
Vissual indicattions
: The following
f
V
Visual signal light
Indica
ators shall b
be provided.
a) AC
A Mains O
ON
b) Auto
A
Mode
c) Manual
M
Mod
de
d) Unit
U in AVC
CC mode
e) Over
O
Curren
nt Alarm
f) Over
O
Voltag
ge Alarm
g) Over
O
Tempe
erature
h) All
A reference
e fail
i) Reference
R
ccell 1 lowest
j) Reference
R
ccell 2 lowest
k) Reference
R
ccell 3 lowest
l) Reference
R
1 fail
m) Reference
R
2 fail
n) Reference
R
3
3fail
o) In
ndividual Fuse failure
e LED indiccation
Identiffying failure
e of each Diode
D
and
DC Ou
utput Fuse
e with audio
o alarm.
her Accesssories
Oth
(a) Integral Sun and Rain shade

s
(b) On
ne holder fo
or 60 Wattt CFL
(c) Tw
wo 240V, 5A
A socket fo
or Mainten
nance
operattion.
(d) Glass Viewin
ng Window
w
Co
ooling
The cabinet is n
natural air cooled an
nd the
tempe
erature risse not ex
xceeding 45oC
above
e the am
mbient. The
T
maxximum
tempe
erature rise
e shall be up
u to 850 C.
C
Me
easuremen
nt and conttrol termina
als
Shrouded termin
nal blocks
s of properr size
shall be
b provide
ed in the control jun
nction
box an
nd on the D
DC Board.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 14 of 17
Climate Cond
ditions
: Moderate to
o heavy rainfall during
d
Monso
oon and re
elative hum
midity of 100%.
Enclosure
Comp
pletely encllosed. Plin
nth Mounte
ed, IP
65 fo
or Bulletss, construction with
h an
integra
ated sun sshade. The
e top cabinet is
made from 12
2SWG mild steel. The
contro
ol cabinetss have hin
nged frontt and
rear doors
d
and a
are pad lo
ockable. A glass
viewin
ng window is provide
ed for frontt door
for re
eading of all the meters without
w
openin
ng the doo
or.
The enclosure iss also prov
vided with lifting
lugs of
o size and location su
uitable for lifting
the co
omplete recctifier unit.
Dim
mension off TR Unit
: To be
e specified
d by Bidderr
We
eight of TR
R Unit
: To be
e specified
d by Bidderr
Inp
put and Ou
utput Termiinals
Three Positive and three

e negative
e DC
Post tyype termin
nals made of tinned plated
p
coppe
er with double nuts and washerrs are
provid
ded in the D
DC junction
n box.
AC terminals insulate
ed from the
enclossure to witthstand 20
000 volts, 50Hz
are prrovided in tthe AC junction box.
Remo
ote
Con
ntrol
Te
erminals
are
ELME
EX/TOSHA
A Make Multiple Term
minals,
Shrouded Type
Ca
able entriess
For An
node, Cath
hode, Pow
wer, Contro
ol and
measu
urement ca
ables throu
ugh cable gland
plate at
a the botto
om of the T/R
T unit.
Surface Coatting and Pa

ainting
Painting Schedu
ule
- Surfface prepa
aration SA 2
- Hot dipped ga
alvanizing to
t 100um
- Firsst coat of ziinc rich epoxy primerr
- Two
o coats of e
epoxy pain
nt
- Tota
al painting thickness--120 micro
ons.
- Colo
or scheme
e
- lightt grey shad
de 631 IS: 5
- Bakked Epoxy paint/Powder Coatin
ng of
shade 631 IS: 5 with pro
oper pretrea
atment and
d primer ap
pplication.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 15 of 17
Na
ame Plates and Labels
All co
omponent identification labels shall
be scrreened/ alu
uminum an
nodized.
- A sta
ainless ste
eel rating plate
p
along
g with
manuffacturers name, ad
ddress, da
ate of
manuffacture, model number,
n
serial
numbe
er, weight etc. will be
e provided..
- A DA
ANGER lab
bel on the Rear Doorr.
Ovver Voltage
e Setting
0-50V
V in 25 ste
eps of 2V each with
h two
selector switche
es with an
n accuracyy of +
10% in
n AUTO M
Mode.
COAR
RSE: 0, 10V
V, 20V, 30
0V, 40V, 50
0V
FINE: 0, 2V, 4V,, 6V, 8V, 10V
The two swittches are
e algebra
aically
additivve but ma
aximum do
oes not exxceed
50V.
Ovver Currentt Setting
0-50A
A in 25 ste
eps of 2A each with
h two
selector switche
es with an
n accuracyy of +
10% in
n AUTO M
Mode.
COAR
RSE: 0, 10A
A, 20A, 30
0A, 40A, 50
0A
FINE: 0, 2A, 4A,, 6A, 8A, 10A
e algebra
aically
The two swittches are
aximum do
oes not exxceed
additivve but ma
50A.
Mo
odes of Autto Operatio
on
(i) AUTO Ref Mode:

In thiss mode of o
operation Auto
Prottected
structu
ure to ssoil potential (PSP
P) is
sense
ed with respect to CU-C
CuSO4
. The
(Saturrated) refe
erence to electrodes
e
electro
onic contro
ol circuit scans
s
up to
o two
reference electrrodes for actual
a
PSP
P and
matically selects the minimum
autom
negatiive value of actual PSP obttained
from any
a of the two refere
ence electrrodes.
The desired S
SET PSP
P referencce is
compa
ared with the minimum selected
value of actual P
PSP and th
he output power
p
of the CPTR is set autom
matically so
o that
the measured
m
value always rem
mains
close to the SET
T PSP valu
ue.
UTO AVCC
C MODE
(ii) AU
In thiss mode of operation Output vo
oltage
& currrent can be
e varied co
ontinuouslyy by a
potenttiometer depending upon the
Coarsse and Fine switch settings.
s
Control
of output voltage and current
c
thrrough
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 16 of 17
SCRs and Electtronic Con

ntrol circuittry so
that output
o
of the unit is mainttained
consta
ant irrespe
ective of cu
urrent drain
n and
supplyy line voltage variatio
ons.
Outpu
ut
voltag
ge
varia
able
byy
a
potenttiometer in the range
r
0-5
50 V
depen
nding on COARSE & FINE limit
setting
gs.
Outpu
ut voltage adjustable in steps of 1V
& 2V by
b COARSE & FIN
NE voltage
e limit
switch
hes. Two sswitches are
a algebra
aically
additivve, with a m
maximum 50V.
5
Outpu
ut current a
adjustable in steps of
o 1A
& 2 A by COA
ARSE & FINE cu
urrent
limit switches.. Two switches are
algebrraically, ad
dditive with
h a maximu
um of
50 A respectivel
r
y.
26.0
TE
ESTING OF
F T/R UNIT
T:
All T/R units shall be te
ested by co
ontractor and
a inspeccted by purrchaser/his
s represen
ntative
beffore dispa
atch. Testiing shall be conducted in accordance
e with cod
des, stand
dards,
app
proved QA
AP and encclosed specifications.
Bid
dder /vendo
or shall pro
ovide all th
he necessa
ary facilities to carry out all testts of CP TR
R unit
in his
h premise
es at his expenses.
27.0
DR
RAWINGS / DOCUMENTS:
awings / do
ocuments shall be fu
urnished byy bidder fo
or approval before starting
Following dra
n/manufactturing. App
proved dra
awing afterr incorpora
ation of co
omments (if any
of fabrication
from OWNER
R shall be furnished
f
i 6 copies
in
s along with reproduccible during
g the delive
ery of
T/R
R units.
Fabriccation draw
wings, GA drawings and
a data sheet
s
of T//R unit giving dimenssions,
rating, weight, in
ncluding insstallation / foundation
n arrangem
ment details.
Front view and typical
t
secctions of T//R unit pan
nel with arrrangemen
nt of equipment,
ol, protectio
on and mettering.
contro
Data sheet
s
of all accessoriies and circ
cuit element of T/R U
Unit including rating.
Schem
matic and wiring
w
diag
gram of T//R unit circcuitry givin
ng auto / manual
m
mo
ode of
contro
ol including circuit dettails of all control
c
carrds.
28.0
INS
STRUCTIO
ON BOOK
e instructio
on book/ operationa
o
al manual in 10 hard
d copies+ soft copy in CD sha
all be
The
pre
esented in such manner as to enable
e
it to
o be used by
b personn
nel who are
e unfamilia
ar with
the
e operation
n and main
ntenance of
o the T/R unit.
u
The in
nstruction book/ ope
erational manual
to be
b furnishe
ed along with
w supply of T/R unit.
The
e instructio
on book/ operational manual sh
hall contain
n the follow
wing:
A description of th
he T/R unit.
-
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Sheet 17 of 17
Instructiion for the

e installatio
on, testing commissiioning and
d safe
operatio
on and maiintenance.
The
e informatiion shall be
e presente
ed as follow
ws:
1.
Index of contents
c
General description
d
giving brie
ef description of the T
T/R and its
s use.
2.
Detailed description
d
n of T/R unit
3.
This desccription sh
hall include
e the tech
hnical characteristics
s, physical and
mechaniccal limitatio
ons, and item
i
wise the comp
ponents, accessoriess and
spare parrts.
4.
Descriptio
on of the operation
o
of
o the T/R unit. This d
description
n shall be clear,
concise and
a
in a logical sequence,
s
using scchematic diagram,
d
w
wiring
diagram and
a fabrica
ation drawing.
5.
Procedure
es for testing and adjjusting the
e T/R unit :
The comp
plete proced
dure for testing and adjusting
a
the T/R uniit during
Operation
n, periodic maintenan
nce and ovverhaul sha
all be cove
ered.
6.
Maintenance instrucctions :
This section shall be
e divided in
nto two parts:
a. Preventive main
ntenance which
w
sha
all indicate
e the periodic inspe
ection
require
ed the insp
pection pro
ocedure an
nd clearing procedure
es.
b. Break down ma
aintenance
e which shall includ
de instructtion for trrouble
shooting of the removal and
a
replaccement of all parts liisted as spares
shall be
b given.
7.
Spare Parts.
The instruction boo
oks shall be given all the ne
ecessary details
d
so as to
procure all
a the spare
e parts from
m the man
nufacture o
or from ope
en market.
8.
Each instruction book shall be
e accompa
anied with one set off final approved
Drawing / Documen
nts.
29.0
CO
OVERING OF
O THE IN
NSTRUCTION BOOK
KS/ OPER
RATIONAL
L MANUAL
LS
The
e instructio
on book/ operationa
o
al manuals
s shall be presented in a stiff covered binder
b
with the follow
wing inform
mation prin
nted on the
e cover:
The clie
ents name
The loca
ation of the
e installatio
on
The nam
me of the in
nstallation
The title
e of the instruction bo
ook
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
TECHNIC
CAL SPECIFICA
ATION
T
TRANSF
FORMER
R RECT
TIFIER UNIT
U
RE
EMOTE MONITO
ORING
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION SYSTEM OF
O
MOUN
NDED BULLETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUN
NDED
B
BULLETS
OWNE
ER : NRL,AS
SSAM
1.
E
EM163-TS-08
801
D
DOCUMENT
NO
REV
SHEET 2 of 3
SC
COPE
e T/R Unitt installed for Cathodic Protec
ction of Mo
ounded Storage Bulllets/Tanks shall
The
havve inbuilt RMU feattures to Monitor
M
all specified T/R Unit Parameters, Alarmss and
Ca
athodic Pro
otection Re
eference Electrode
E
Parameters
P
s and com
mmunicate the Data to
t the
Ce
entral Computer Netw
work. The T/R Unit RMU shall be provid
ded by the
e manufaccturer,
which can monitor
m
the specified CP Param
meters. The
e T/R Unitt RMU Hardware shall be
exp
pandable for
f incorpo
orating add
ditional I/O
O Channelss in future.. The T/R Unit RMU shall
me
eet all the specificatio
s
on requirem
ments conttained here
ein.
2.
MO
ONITORING FEATURES
e T/R Uniit shall have Monito
oring Circu
uit, which should
s
mo
onitor the Analog Siignals
The
con
nfigurable in real tim
me as userr defined schedule.
s
The resolu
ution shou
uld be 12 bit
b for
ana
alog input channels. The Volta
age Range
e should be
e calibrated to suit th
he Analog Input
Sig
gnal requirrement. All inputs Analog
A
Sig
gnals shou
uld be iso
olated to 3000Vrms
3
. The
Mo
onitoring Rate
R
should
d be progrrammable from 01 Reading
R
pe
er Second to 01 Reading
perr 99 Days.
The
e T/R Unit shall monitor the following ope
erating and
d cathodic protection parameters
listed as follo
ows:
2
2.1
The
e T/R Unit should mo
onitor the Analog
A
Output DC Vo
oltage and
d Current Signals
S
in re
eal
tim
me as per user
u
defined schedule
e and shou
uld generatte alarms iin case of Over
O
Volta
age
and
d Over Current Cond
ditions.
2
2.2
Each T/R Un
nit should monitor
m
the
e Referenc
ce Electrod
de Analog Signals frrom the Field in
al time as per
p user de
efined sche
edule and should gen
nerate an a
alarm in ca
ase of Ove
er and
rea
Under Protecction Conditions. The
e input Imp
pedance off the Monittoring Circu
uit shall be
e high
ough to measure
m
th
he Referen
nce Electrrode Analo
og Signalss without loading.
l
A the
All
eno
Re
eference Electrode in
nstalled to monitor protective
p
potentials of Bullets
s/pipeline and
a
it
sho
ould be disstributed to
o the everyy T/R Unit installed to
t be monitored by connecting
c
them
to the
t T/R Un
nit RMU.
The
e CP Con
ntractor sh
hould insta
all Perman
nent Type Cu/CuSo4
4 Referenc
ce electrode of
app
proved ma
ake and exxtend the signals
s
to the T/R uniit through a Monitorin
ng Junction box
using Multi co
ore Cable of size 2.5
5 Sq mm Cu
C PVC inssulated and PVC she
eathed arm
mored
cab
ble. Supply and insstallation of
o Reference Electro
odes, conn
necting ca
able shall be in
sco
ope of CP Contractorr.
2
2.3
The
e T/R Unit should monitor th
he status of 05Nos Digital Issolated Ala
arms inputts for
Re
ectifier overr Cabinet over
o
Temp
perature, Oil
O Tank ove
er Temperrature, Fus
se Fail and Input
MC
CB Trip, AC
A Input Failure. In case
c
of Allarm the T/R
T Unit R
RMC should
d generate
e and
upd
date the Data on the Network as
a per Use
er defined schedule.
s
3.
GE
ENERAL FEATURES
F
S OF REMOTE MON
NITORING UNIT (RM
MU)
Sta
and Alone RMU for TR
T Unit
Issolated Ana
alog Input Channels for Remotte Monitoring and Da
ata Logging
g
Issolated Dig
gital I/O Ch
hannels forr Alarms an
nd Interrup
ption Contrrol
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION SYSTEM OF
O
MOUN
NDED BULLETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUN
NDED
B
BULLETS
OWNE
ER : NRL,AS
SSAM
E
EM163-TS-08
801
D
DOCUMENT
NO
REV
SHEET 3 of 3
Ethernet
E
Co
onnectivity for local control
c
Ethernet/RS
E
S 485 conn
nectivity for Commun
nication
In
nput/ Outpu
ut Short Ciircuit Prote
ection
AC/DC
A
Surg
ge Protection
Pluggable
P
c
cards
for ea
asy mainte
enance
Dual
D
Processsor for Fa
ast Monitorring with sp
peed of 250 kilo samples per se
econd
Single
S
Inputt Power Su
upply
4.
RE
EMOTE MO
ONITORIN
NG UNIT (R
RMU) DIGIITAL CONDITIONING UNIT FE
EATURES
Signal
S
Inputt Power Su
upply
Output
O
4-20
0mA
In
nput 0-100% VDC/AD
DC/PSP
Natural
N
Air Cooled
C
DIN
D Rail Mo
ounting
Easy
E
to Rem
move/Repllace
In
nput/ Outpu
ut Protectio
on
Electronic
E
S
Short-Circu
uit Protectio
on
AC/DC
A
Surg
ge Protection
Weather
W
Prroof-NEMA
A 4 Constru
uction
Natural
N
air Cooled
C
(Ind
door)
Epoxy/PU
E
F
Finish
5.
EN
NCLOSURE
ES AND OPERATIN
O
NG ENVIRO
ONMENT
The
e T/R Unit should ha
ave a separate airtigh
ht housing of RMC Ellectronic to
o keep it
mo
oisture and
d dust free. The T/R RMC
R
Circu
uit should be
b robust a
and shall be operating
g at
tem
mperaturess between 400 C to + 700 C att 90% Rela
ative Humid
dity.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 4
TE
ECHNIC
CAL SPE
ECIFICA
ATION
ANODE JUNC
CTION BOX
B
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 4
1.0 SCOP
PE
s
n covers the
t minimu
um technic
cal requirements for the design
n, manufaccturer
This specificatio
and Su
upply of An
node Junction Boxess for ICCP system.
The ju
unction boxxes should
d be a stan
ndard of th
he manufa
acturer regularly used
d for impre
essed
curren
nt cathodicc protection
n system. This spec
cification confers req
quirement for type, rating,
r
manuffacture and
d testing off different types
t
of junction boxxes. The W
Weather pro
oof junction
n Box
& Flam
meproof Ju
unction Bo
ox shall be
e used for bullets respectively. Junction boxes sha
all be
supplie
ed in accordance witth the follow
wing speciifications and
a data sh
heets.
2.0 CODE
ES AND STANDARD
DS
The Weatherpro
W
oof & Flam
meproof Ju
unction Bo
oxes shall be in acccordance with the latest
revisio
ons of the fo
ollowing In
ndian stand
dards, whe
erever appllicable.
a)
b)
c)
d)
Indian sta
andards in
nstitution (ISI)
Internatio
onal electro
o technical commission (IEC)
American
n standard
ds institutio
on (ANSI)
British sttandards in
nstitution (B
BS)
Where
e appropria
ate Indian standard
s
a not ava
are
ailable, the relevant IE
EC standards shall apply.
a
3.0 DATA
A SHEET:
DC Input
I
Volta
age
DC Input
I
Curre
ent
Shun
nt type
Shun
nt Rating
Resiistor Rating
g
50V Maximum
m
50 A Maximum
m
Mag
ganin Alloy
To be
b Specifie
ed
Cressol Type Strip Wou
und (To be calculated
d by CP
conttractor)
Diod
de Rating
To be
b Specifie
ed
Bus bar
Tinn
ned Coppe
er Bus Bar - 50 mm x 6 mm for bullets
Term
minal Boarrd material
08 mm
m thick FRP
F
Num
mber of open/ outp
put / As required
r
(3
30% spare terminals shall be prrovided)
circu
uits
Inpu
ut Terminals
02 Nos.
N
10 mm
m Dia. Staiinless Stee
el stud with
h double nu
ut,
sprin
ng and plain washer.
Outp
put Termin
nals
As required
r
Dime
ension
To be
b specified
d by bidde
er
Enclosure Ratting for bullets Explosion Proof Zone 1-- Gas Grou
up IIA & IIB
B Tempera
ature
Classs T3
Cable entries
Cable entries are
a through FLP Cab
ble Glands.
Insulation Leve
el in betwe
een
3 kV
V & 2 kV fo
or 1 minute
e at 50 HZ
Z for Bullets
s.
term
minals & bo
ody
Surfface Painting
Firstt coat of Ziinc rich epoxy primerr
Intermediate Cost
C
of Epo
oxy
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 4
Two
o Coats of Polyamide
e epoxy paint
Tota
al painting thickness 200 micron(minimum
m)
Colo
our Schem
me for bullets
Stattion Termin
nals
Insu
ulator insside Juncction
Box
Nam
me plates and
a Labels
Enclosure
Quantity
Makke
Outp
put circuit Configurat
C
tion
Yello
ow paint Shade
S
SS 316
3 Nuts & Bolts
DMC
C
All in
nternal com
mponent id
dentification Labelling
g is done using
u
perm
manent Screening /m
marker
Nam
me plate sh
hall be engraved whitte lettering in black
Man
nufactures name, Add
dress, Date
e of Manuffacture, CM
MRS
No. Model No.., Serial No
o., Weight etc. shall be
b provided on
shuttter
Com
mpletely enclosed,
e
Outdoor type, Wa
all / Struccture
Mou
unted of folllowing typ
pes:
a Flamep
a.
proof type Exd Natural Air Coo
oled, dust and
vermin proof IP 65 Consttruction. The
T
cabine
et is
made from
f
Die cast Alum
minium Allloy-LM-6, with
threade
ed SS Plate
P
inse
erts and SS Do
ouble
compre
ession FLP
P Cable Gla
ands.
b Dust & vermin proof, nattural Air Cooled,
b.
C
IP
P 55
constru
uction. The
e cabinet is made
e from LM
M 6
constru
uction die Cast
C
constrruction
The cabinet shall
s
have hinged fro
ont doors with neoprene
gaskket and shall be Pad Lockable.
As Required
R
Refe
er list of Ap
pproved Ve
endors
Ano
ode Bus ou
utput distrib
buted into 20 circuits
s and 04 spare
circu
uit in line with
w Curren
nt Measurin
ng Shunt &Resister
&
4.0 CONS
STRUCTIO
ONAL FEATURES FO
OR ANODE JUNCTIION BOX
Anode
e lead cable from disttributed an
node groun
nd beds sh
hall be term
minated to the
t junction box
and fu
urther exte
ended to T/R
T Units. The
T
junctio
on box should have a tinned copper bu
us bar
50mmx6mm for connection of positivve headerr cable from
m the transformer re
ectifier unitt. The
numbe
er of anode
e circuits should
s
be as per abo
ove data sheet.
s
The anode lea
ad cable iss feed
from output
o
circcuit throug
gh a shunt of suitable rating and an
n adjustab
ble strip wound
w
CRES
SSOL type ZO resisto
or of suitab
ble rating. All termin
nals should
d be SS-30
04 materia
al and
size M-8
M (08mm
m) nut, bo
olts, spring washer. The term
mination b
boards sho
ould be Fabric
F
reinforrced Polyester of min
nimum 08 mm
m thickness. The enclosure
e
should be fabricated
d from
LM-6. The consttruction sh
hould be Flameprooff, Air-coole
ed, Dust an
nd Vermin proof. Jun
nction
box sh
hould have
e a card po
ocket insid
de the doorr. Degree of protection should be IP65 as
a per
IS: 2147/1962. The enclo
osure shou
uld be stand-alone/w
wall mountted type with
w
canop
py for
rainwa
ater protecction. The gasket sh
hould be of neoprene
e rubber. The enclo
osure shou
uld be
provided with fro
ont excesss door witth pad and
d panel ke
ey locking arrangem
ment. Contrractor
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 4 of 4
needs to fabrica
ate and takke approva
al of ownerr/consultan
nt then pro
oceed with manufacturing.
The junction boxx should be
with details.
e provided with stainlless steel nameplate
n
5.0TESTING & INSPECTION:
Weath
her Proof & Flameproof Junctio
on Boxes shall be in
nspected b
by owner before
b
disp
patch,
testing
g shall be
e conducte
ed in acccordance with
w
codess and sta
andards sp
pecified in
n this
docum
ment, as per
p
routine tests done
d
by manufactu
m
rer and a
additional tests don
ne by
manuffacturer..
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 4
TE
ECHNIC
CAL SPE
ECIFICA
ATION
CAT
THODE JUNCTI
J
ION BO
OX CUM TEST S
STATION
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 4
1.0 SCOP
PE
This specificatio
s
on covers the
t minimu
um technic
cal require
ements for the design
n, manufaccturer
and Supply
S
of Cathode
C
Ju
unction Boxxes for ICC
CP System
m.
The ju
unction bo
oxes shoulld be a standard pro
oduct of the manufa
acturer reg
gularly use
ed for
impressed curre
ent cathod
dic protection system
m. This sp
pecification
n confers requirement for
type, rating, ma
anufacture and testin
ng of diffe
erent typess of junctio
on boxes. Weather proof
junctio
on Box & Flameproo
of Junction
n Box shall be used
d for pipeline & bulle
ets respecttively.
Junctiion boxes shall be supplied
s
in
n accordan
nce with th
he following specifica
ations and
d data
sheetss.
2.0 CODE
ES AND STANDARD
DS
The Weatherpr
W
roof & Fla
ameproof Junction
J
boxes
b
shall be in acccordance with the latest
revisions of the following Indian
I
stan
ndards, wh
herever app
plicable.
a) Indian stan
ndards insttitution (ISI)
b) Internation
nal electro technical commissio
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
ndards insttitution (BS
S)
Wherre approprriate Indian standard
d are not available,, the relevvant IEC standards
s
shall
applyy.
3.0 DATA
A SHEET:
D Input Voltage
DC
V
DC Input Curre
ent
Outp
put Circuit Rating
Shunt type
Shunt Rating
Diod
de Rating
Bus bar
Num
mber of open/ In
nput/
outp
put / looping circuits
Term
minal Boarrd material
Inpu
ut/ Looping
g Terminalss
50V
V Maximum
m
50 A Maximum
m
50V
V/50A
Mag
ganin Alloy
y
To be
b Specifie
ed
To be
b Specifie
ed
Tinn
ned Coppe
er Bus Bar - 50 mm x 6 mm for bullets
As required
r
(3
30% spare terminals shall be prrovided)
06 mm
m thick FRP
F
02 Nos.
N
10 mm Dia. Sta
ainless Ste
eel stud with double nut,
sprin
ng and pla
ain washer..
Outp
put Termin
nals
As required
r
Dimension
To be
b specified by bidde
er
Enclosure Ratting for bullets Explosion Proof Zone 1-- Gas Grou
up IIA & IIB
B Tempera
ature
Classs T3
Cab
ble entries
Cab
ble entries are through FLP Cab
ble Glands
s
Insu
ulation Levvel in betw
ween 3 kV
V & 2 kV fo
or 1 minute
e at 50 HZ
Z for Bullets
s
term
minals & bo
ody
Surfface Painting
Firstt coat of Ziinc rich epoxy primerr
Intermediate Cost
C
of Epo
oxy
Two
o Coats of Polyamide
e epoxy paint
Tota
al painting thickness 200 micron(minimum
m)
FORM NO: 02
2-0000-0021 F2
2 REV3
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
Colo
our Schem
me for bullets
Stattion Termin
nals
Insu
ulator insside Juncction
Box
Nam
me plates and
a Labelss
Enclosure
Qua
antity
Makke
Outp
put circuit Configurat
C
tion
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 4
Yello
ow paint Shade
S
SS 316
3 Nuts & Bolts
DMC
C
All internal component
c
t identifica
ation Labe
elling is done
d
usin
ng permane
ent Screen
ning /marke
er
Nam
me plate sh
hall be eng
graved whitte lettering
g in black
Man
nufactures name, Address,
A
Date of Manufacture,
CMR
RS No. Model
M
No., Serial No
o., Weightt etc. shalll be
provvided on sh
hutter
Com
mpletely enclosed,
e
Outdoor type, Wa
all / Struccture
Mou
unted of folllowing typ
pes:
a Flamep
a.
proof type Exd Natural Air Coo
oled, dust and
vermin proof IP 65 Consttruction. The
T
cabine
et is
made from
f
Die cast Alum
minium Allloy-LM-6, with
threade
ed SS Plate
P
inse
erts and SS Do
ouble
compre
ession FLP
P Cable Gla
ands.
b Dust & vermin proof, nattural Air Cooled,
b.
C
IP
P 55
constru
uction. The
e cabinet is made
e from LM
M 6
constru
uction die Cast
C
constrruction
The cabinet shall
s
have hinged fro
ont doors with neoprene
gaskket and shall be Pad Lockable.
As Required
R
Refe
er list of Ap
pproved Ve
endors
FOR
R BULLETS:
Thiss JB works
s as cJB cum
c
test sttation all cables
c
from
m Cu
and Zn refere
ence electtrode and cathode cable
c
shalll be
minated in the
t box
term
4.0 Catho
ode cum Test
T
junctio
on Boxes:
Draina
age(2 nos.)), and reference elecctrode(17nos) cable from
f
the Bullet are te
erminated to
t the
cathod
de cum tesst junction box and further
f
exttended to T/R Units.. The junction box should
have a Tinned Copper
C
buss bar 50mm x 6mm for connecction of ne
egative hea
ader cable
e from
the tra
ansformer Rectifier unit.
u
The number
n
of cathode circuits
c
sho
ould be 01 + 01 including
spare. The catho
ode lead cables
c
feed
d from outp
put circuit through a suitable shunt
s
of su
uitable
rating and adjusttable strip wound Re
eputed mak
ke type ZO
O resistor o
of suitable rating.
r
All terrminals sho
ould be SS
S-304 mate
erial and siize M-8 (08
8mm) nut, bolts, sprin
ng washerr.
The enclosure should
s
be fabricated
f
from die Cast
C
Alum
minium Allo
oy LM 6. The
T constru
uction
shall be
b Flameprroof & Wea
atherproof for bullets
s & pipeline
es respectively. Air-co
ooled, Dusst and
Vermin
n proof. Ju
unction boxx should have a card
d pocket in
nside the d
door. Degre
ee of prote
ection
should
d be IP 65 for bullets .
The te
ermination boards sho
ould be Fa
abric reinfo
orced Polysster of minimum 06 mm
m thickne
ess.
The enclosure
e
should be
e stand a
alone / wa
all mounte
ed type w
with canopy for rainwater
protecction. The gasket
g
sho
ould be of neoprene
n
rubber.
r
The
e enclosurre should be
b provided
d with
FORM NO: 02
2-0000-0021 F2
2 REV3
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 4 of 4
front excess
e
doo
or with bolte
ed arrange
ement openable with Allen key.. Contracto
or needs to
o take
prior approval for GA dwg & data sheet
s
beffore proce
eeding with
w
fabriccation
works//manufactu
uring.
The junction boxx should be
e provided with stainlless steel nameplate
n
with details.
5.0 TESTING & INS
SPECTION
N:
her Proof & Flamep
proof Juncction Boxe
es shall be
b inspectted by pu
urchaser before
b
Weath
dispatcch. Testin
ng shall be
b conducted in accordance with latesst codes, standardss and
enclossed specificcations.
FORM NO: 02
2-0000-0021 F2
2 REV3
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 2
TE
ECHNIC
CAL SPE
ECIFICA
ATION
REFER
RENCE ELECTR
E
RODE CU-CU
USO4
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV4
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 2
1.0 SCOP
PE
This specificatio
s
on covers the minim
mum techn
nical requ
uirements for supply
y of permanent
referen
nce electro
ode for cathodic prote
ection systtem.
The pe
ermanent reference electrode shall be a standard product o
of a manuffacture reg
gularly
engaged in prod
duction. Th
he permane
ent referen
nce electro
ode shall b
be supplied
d in accord
dance
with th
he following
g specifica
ation and data sheets
s.
2.0 CODE
ES AND ST
TANDARD
DS
The permanent
p
reference electrode
e shall be in accorda
ance with tthe latest revisions of
o the
follow
wing Indian standardss, whereve
er applicable. Where appropriatte Indian standard
s
arre not
availa
able, the re
elevant IEC
C standardss shall app
ply.
dian standa
ards institu
ution (ISI)
a) Ind
b) Inte
ernational electro tecchnical com
mmission (IEC)
(
c) Am
merican sta
andards insstitution (A
ANSI)
d) British standa
ards institu
ution (BS)
Where
e appropria
ate Indian standard
s
a not ava
are
a
3.0 DATA
A SHEET:
Type
Cop
pper/Copper Sulphatte (Cu/Cu S
S04)
Make
Borrin U.S.A/ MC
M Miller
Model
Borrin U.S.A/ MC
M Miller
Dimensio
ons
Diameter: 4.0
0 cm mm
ngth: 18.0 cm
c
Len
Lead wirre
2.5 Sq mm. CU
C Cable, Lead wire, 1.5 long
Tempera
ature
0 to
o 55 Degre
ee C
Stability
+/- 10 mill voltts with 3.0 micro amp

ps load
Tube Ma
aterial
Spa
ace age ce
eramic tube
e with Yello
ow cap
Application
Forr External CP
C Only
4.0 TEST CERTIFIC

CATES:
The te
esting sha
all be cond
ducted in accordanc
a
e with cod
des and sttandards enclosed
e
in
n this
docum
ment, as pe
er routine testes
t
done by manu
ufacture. Te
est certifica
ate shall fu
urnish.
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TEC
CHNICA
AL SPEC
CIFICAT
TION
REFE
ERENCE
E ELECT
TRODE (ZINC)
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
FORM NO: 02-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
1.0
SC
COPE
1.1
Thiis specificcation covvers the minimum

m
technical requireme
ents for the
t
design
n,
ma
anufacturing and Sup
pply of Refe
erence Ele
ectrode (Zin
nc).
The
e Zinc Re
eference Electrode
E
s
should
be a standarrd product of the Manufacture
er
reg
gularly eng
gaged in production. The Zinc Reference
e Electrode
e shall be supplied in
acccordance with
w the following spe
ecifications
s and data sheets.
2.0
CO
ODES AND STANDAR
RDS
2.1
The
e Zinc Refference Ele
ectrode sh
hall be in accordance
a
e with the latest revis
sions of the
following Indian standards, where
ever applica
able. Where approprriate Indian
n Standards
are
e not availa
able, the re
elevant IEC
C standards shall app
ply.
a) Indian
I
stan
ndards insttitution (ISII)
b) Internation
I
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
S)
Wh
here appro
opriate Ind
dian standard are no
ot available, the relevant IEC
C standard
ds
sha
all apply.
3.0
ATA SHEET
T
DA
Mo
odel
Sensing Area
a
Ele
ectrode
Ele
ectrode Composition
Ele
ectrode con
nfiguration
Ele
ectrode Connection
Inssert type
Inssert plating
Cable
Cable Conne
ection
Cable Length
h
Tecchnical Lite
erature/
cattalogue
Bacckfill Mixtu
ure
Dim
mensions
Gro
oss Weight
Quantity
Ma
ake
FORM NO: 02-0000-0021 F2 REV3
To be specified
To be specified
Ele
ectrolytic Grade
G
Zinc Metal
Basic Zinc metal 99.99 %
Sin
ngle Rod Centre
C
Con
nnected
Threaded He
ead with nu
uts fitting te
ermination
Mild Steel witth TOR Ro
od of 8 mm
m dia.
Ele
ectro galva
anized
06 Sq. mm Unarmored
U
, Cu, XLPE
E/PE insula
ated
Epoxy Resin Seal
As required
To be furnish
hed by Bid
Gyypsum 75%
% + Benton
nite 20 % + Sodium Sulphate
S
5
%
150
0 mm (L) 40
4 mm X 40 mm (Min
nimum)
To be Specifiied
As Required
Ple
ease Referr Approved
d Vendors list
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
4.0
INS
SPECTION
N & TESTS
S:
4.1
The
e testing shall
s
be conducted in
n accordan
nce with co
odes and sstandards enclosed
e
in
thiss documen
nt, as per routine tessts done by
b the man
nufacture. Test Certificate sha
all
furn
nish.
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
TECHNICAL
L SPECIFICA
ATION
THODIC PRO
OTECTION SYSTEM
S
OF
F
CAT
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG MOUNDED
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DOCUMENT NO
REV
Sheet 1 o
of 6
TEC
CHNICA
AL SPEC
CIFICAT
TION
CABLES
S
FO
OR CATHODIC PROTE
ECTION SYSTE
EM
FORM NO
O: 02-0000-0021
1 F2 REV3
All rights rreserved
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 2 o
of 6
1.0
SCO
OPE
1.1
This standard
d covers the technical requirements of design,
manu
ufacture, te
esting at works
w
and dispatch
d
in
n well packked conditio
on of
powe
er and control cabless.
2.0
STANDARDS TO BE FO
OLLOWED
D
2.1
The design, manufactu

m
re and te
esting of cables co
overed by this
stand
dard shalll comply with the latest isssue of fo
ollowing In
ndian
stand
dards.
IS: 7098 Part (I)
Cro
oss linked
d polyeth
hylene in
nsulated PVC
she
eathed cab
bles for wo
orking voltages upto and
inclluding 1100 volts.
IS: 1554 Part (I)
PVC
C insulate
ed (heavy duty) elecctric cables
s for
worrking voltag
ges up to and
a including 1100 volts.
v
IS: 1554 Part (II)
PVC
C insulate
ed (heavy duty) elecctric cables
s for
worrking volta
ages from 3.3 kV up
p and inclu
uding
11 kV.
IS: 7098 Part (I)
Cro
oss Linke
ed polyethylene in
nsulated PVC
she
eathed cab
bles for wo
orking volta
ages up to
o and
inclluding 1100 Volts.
IS: 7098 Part (II)
Cro
oss Linke
ed polyethylene in
nsulated PVC
she
eathed cab
bles for wo
orking volttages form
m 3.3
kV up to and including 33
3 kV
IS: 7098 Part (III)
Cro
oss
Lin
nked
po
olyethylene
e
insullated
The
ermoplastic
c sheathe
ed cabless for worrking
volttages up to
o 66 kV an
nd up to 22
20 kV
IS: 692
Pap
per insula
ated lead sheathe
ed cables for
elecctrical supply
IS: 694
PVC
C insulated
d cables fo
or working voltages up
u to
inclluding 1.1 kV
IS: 5831
PVC
C sheath and
a insulattion for electric cables
2.2
The design and operatio

onal features of the cables
c
offe
ered shall also
comp
ply with th
he provisio
ons of late
est issue of the Ind
dian Electtricity
Rules.
2.3
Wherever any requireme

ent, laid down
d
in this standarrd, differs from
that in Indian Standard
d Specifica
ations, the
e requirem
ment spec
cified
herein shall pre
evail.
FORM NO
O: 02-0000-002
21 F2 REV3
All rights reserved

r
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
B
BULLETS
OWNER
R : NRL,ASS
SAM
3.0
SERVIC
CE CONDIITIONS
3.1
Ambien
nt Conditio
ons
3.2
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 3 o
of 6
Maximum Ambien
nt Temp
50 oC
Minimum
m Ambientt Temp
5 oC
Design Ref. Temp

p
45 oC
Relative
e Humidity
100%
Altitude above Sea

a Level
<1000m
System
m Details
These shall
s
be 3 Phase
P
415
5 V +/- 10%
%, and 50 Hz
H +5%, -5
5%.
4.0
OPERA
ATING REQ
QUIREMENTS
The cables shall be suitab
ble for op
perating co
ontinuouslyy at the rated
r
capacityy as speciffied in rele
evant IS un
nder the am
mbient con
nditions witthout
exceediing the permissible temperatur
t
re rise and
d without a
any detrime
ental
effect on any part.
5.0
RAL DESIG
GN AND CONSTRUC
C
CTIONAL FEATURE
ES
GENER
5.1
The de
esign, manufacture and workmanship of cabless shall be in
accorda
ance with the latest standard
s
prractice.
5.2
All mate
erials to be
e used shall be new, unused an
nd of the be
est quality.
5.3
Conduc
ctors
The po
ower cable
es shall be
e of stranded Aluminum / co
opper roun
nd or
shaped conducto
ors and control
c
ca
ables shall be of a
annealed high
conducttivity stran
nded copp
per round conductorrs. The co
onductors shall
comply with the re
equirementts of IS: 81
130.
5.4
Insulatiion
The co
onductor in
nsulation shall
s
be XLPE
X
type
e and sha
all comply with
relevantt IS.
5.5
Fillers
The cables shall have suittable fillers
s whereve
er required
d, laid up with
conducttors to provvide substantially circ
cular crosss section b
before the inner
i
sheath is applied.
5.6
Inner Sheath
S
Inner sheath sha
all be ST1
1/ST2 type
e compound applied
d by extru
usion
processs.
5.7
Armourring
All power and con
ntrol cables shall be armoured as specifiied. The single
core cables shall be armourred with ha
ard drawn Aluminum
A
taps / wire
es or
her suitablle nonmag
gnetic matterial. All other cables shall have
h
any oth
galvanizzed steel wire
w / strip armoring conforming
c
g to IS: 397
75.
FORM NO
O: 02-0000-002
21 F2 REV3
All rights reserved

r
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
B
BULLETS
OWNER
R : NRL,ASS
SAM
5.8
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 4 o
of 6
Outer Sheath
S
The ou
uter sheath shall be ST2 type, FRLS
S compoun
nd applied
d by
extrusio
on process and su
uitable to withstand
d atmosph
heric pollu
ution,
resistan
nce to term
mites, fire re
etardant an
nd coloured black.
5.9
Screening
Screeniing over conductor and insu
ulation sha
all be pro
ovided as per
relevantt standard unless sp
pecified otherwise. The
T
screen
ning for co
ontrol
cables if specifie
ed shall be
b of aluminum, Mylar
M
or e
equivalent and
ain wire which
w
sha
all be co
ontinuous and
provided with tinned dra
nently conn
nected to th
he screen.
perman
5.10
Identification
dividual co
ores of ca
ables shall be colou
ured as pe
er relevant IS.
The ind
Where it is not po
ossible to distinguish
d
the cores by colour, coloured strip
shall be
e applied on
o the core
es or core nos, shall be marked
d on each core
at regular interva
als. All cab
bles shall carry the manufactu
urers nam
me or
trade mark,
m
the cable
c
size, voltage rating
r
and year of m
manufacturre at
intervalss not exce
eeding 100
0 meters. Running
R
m
meter
markkings shall also
be provvided throughout the length of th
he cable.
5.11
Dimens
sion
The ove
erall dia. an
nd dia. und
der armourr of the cab
bles shall b
be indicate
ed by
the vendor in the technical particulars
p
. These sh
hall be gua
aranteed with
w a
tolerancce of + 5% but not exxceeding 2 mm.
5.12
The cutt ends of th

he cables shall
s
be se
ealed by means
m
of no
on-hygrosc
copic
materials.
6.0
SPECIA
AL PURPO
OSE CABL
LES
6.1
Flame Retardant
R
t Low Smo
oke Cables
s
Flame retardant low smoke
e cables, where spe
ecified, sh
hall have outer
o
aving follow
wing values
s.
sheath of PVC ha
Minimum
m oxygen index - 29%
Minimum
m tempera
ature indexx - 250OC
Maximu
um acid ga
as generatio
on - 20%
Maximu
um smoke density ratting - 60%
6.2
Heat Re
esistant Cables
C
Heat resistant cab
bles where
e specified shall be of
o silicon ru
ubber insullated
laid circcular with asbestos worming
w
and
a
overalll glass fibe
er braided and
varnishe
ed. Silicon
n rubber inssulating co
ompound shall
s
confo
orm to IS: 6380
6
and the constructiional features shall conform
c
ge
enerally to IS:9968.
FORM NO
O: 02-0000-002
21 F2 REV3
All rights reserved

r
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 5 o
of 6
7.0
CABLE
E DRUM
7.1
The cab
bles shall be supplie
ed in non-rreturnable wooden d
drums (or steel
drums if specifiied) of heavy
h
con
nstruction. The wo
ood used for
construction of th
he drums shall
s
be properly se
easoned, ssound and free
from de
efects.
7.2
Cables shall be supplied in specifie

ed drum le
engths. W
Where no such
indicatio
on is given
n standard drum lengths may be
e offered.
7.3
The tole
erance on each drum
m of cable shall not exceed
e
+2.5%. Howe
ever,
no nega
ative tolera
ances are acceptable
a
e.
7.4
All cable drums shall

s
have stenciled data as pe
er relevantt IS as we
ell as
the purcchasers orrder no., ite
em no. & drum
d
no.
8.0
TESTS AND INSP

PECTION
8.1
The following tests shall be carried out on the ca

ables as pe
er relevant IS.
i)
Routine
e Tests
ii)
Accepta
ance tests - On repre
esentative length of each
e
size
iii)
Type tests
8.2
In addition, the following tessts shall be

e carried out on all firre retardan
nt low
smoke cables
c
as per IS or as
a per the following
f
standards:
i)
Oxygen
n and temp
perature ind
dex test as
s per ASTM
M-D-2863
ii)
Acid gas emission

n test as pe
er IEC-754
4 Part-I
iii)
A
843
Smoke density tesst as per ASTM-D-28
iv)
ability test as per IEC

C-332 Part--I or IS-108
810
Flamma
8.3
The ab
bove menttioned testts shall be carried out in the
e presenc
ce of
purchassers repre
esentative. In addition the cablles shall b
be subjecte
ed to
stage in
nspection at
a works an
nd inspectiion at site for
f final accceptance.
8.4
These tests
t
and inspection shall, how
wever, not absolve th
he vendor from
their responsibilityy for making good any defecct which m
may be notticed
uently.
subsequ
9.0
SIZING OF CABL
LES:
- On all cables
c
ecified on one
o cable drum
d
of ea
ach size
- Wherever spe
The min
nimum size
e of various cables are as per following,
f
h
however biidder
shall re
ecommend sizes for various type of cables which
h is subject to
ownerss/consultan
nts approvval:
1. Posiitive & Neg
gative Header Cable : From th
he TRU to
o the cath
hode
Juncction Boxx and An
node Disttribution Box
B
: 1C
Cx50mm2 (Al)
1Cx50mm2 (All/Cu) Armo
oured
2. Drainage Cablle: From th
he cathode
e Junction Box
B to the bullet:
1Cx50 mm2 (C
Cu)
FORM NO
O: 02-0000-002
21 F2 REV3
All rights reserved

r
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUNDED BULLE
ETS
PROJEC
CT:INSTALL
B
BULLETS
OWNER
R : NRL,ASS
SAM
EM163-TS-0801
DO
OCUMENT
NO
1
REV
Sheet 6 o
of 6
3. Anode Interme
ediate cab
ble : From anode Distribution Box to An
node
Juncction Box : 1Cx50 mm
m2 (Cu)
4. Anode Tail Cable:
C
Fro
om the Anode
A
Jun
nction Boxx to Anode :
2
1Cx10mm (Cu
u)
5. Mea
asurement Cable an
nd Refere
ence Elecctrode Cab
ble: From the
Refe
erence elecctrode to CJB
C cum Test
T
Staion:1Cx6 mm
m2 (Cu)
6. Mon
nitoring Cable:
C
Fro
om the CJB
C
cum
m Test S
Staion to the
MJB
B(installed in safe are
ea) 12Cx2.5 mm2 (2
2 run/bulle
et) or 25C
Cx2.5
2
mm (1 run/bullet) Armou
ured
7. Eartthing cable
e: From th
he earthin
ng connecttion of the
e bullet to
o the
Pola
arisation Ce
ell 1Cx35m
mm2 (Cu)
8. Pow
wer Cable: From the PMCC Pa
anel to the TRU 3.5
5C x 25 sq mm
(Al) Armoured.
Cable size
s
for anyy other purrpose subje
ect to owne
er/consulta
ant approval.
Cable with
w coppe
er conducto
or of equiv
valent size in place o
of Al condu
uctor
cable may
m also be
e provided.
The cab
bles for pa
anel wiring
g shall be of unarmo
oured type
e with stran
nded
copper Conducto
or and insu
ulation. Ca
able sizes shall be to suit current
requirem
ment but not less tha
an 2.5 mm2
2.
LSTK Contractor
C
shall furn
nish cable size selecction base
ed on volta
ages
drop ca
alculation and curre
ent capacitty for own
ners/consu
ultants re
eview
/approvval before procureme
p
nt.
10.0
DEVIAT
TIONS
Deviatio
ons, if anyy, from this standard
d shall be
e clearly in
ndicated in
n the
offer with
w
reasons thereo
of. Deviatio
ons, from the data
a indicated in
specificcation shee
et shall be shown clea
arly by enccircling and
d indicating
g the
revised data in sp
pecification sheet.
FORM NO
O: 02-0000-002
21 F2 REV3
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
ONITORIING JUN
NCTION
N BOX
MO
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
FORM NO: 02-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
1.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
SC
COPE

m
technical requireme
ents for the
t
design
n,
ma
pply of Mon
nitoring Jun
nction Box.
The
e monitoriing junctio
on box sh
hould be a standard
d product of the manufacture
er
n
reg
gularly use
ed for Imprressed currrent Catho
odic protecction syste
em. This specificatio
s
con
nfers requiirement for type, rating, manuffacture and testing o
of monitoriing junction
boxx. The monitoring junction boxx shall be supplied
s
in
n accordan
nce with th
he following
spe
ecificationss and data sheets.
2.0
CO
ODES AND STANDAR
RDS
The
e Junction
n Box shalll be in acccordance with the latest revissions of th
he following
Ind
dian standa
ards, where
ever appliccable:
a) Indian
I
stan
b) Internation
I
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
S)
Wh
here appro
opriate Ind
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Circuit Configuration
asurement
Mea
Num
mber
of
Inpu
ut/output/
Term
minals
Term
minal
Board
Mate
erial
Insu
ulation le
evel in
betw
ween
te
erminals
and body
Cab
ble Entries
Inpu
ut/looping
Term
minals
Outp
put Termin
nals
Enclosure
Busbar
Degree of Prottection
Mou
unting
Gassket
FORM NO: 02-0000-0021 F2 REV3
Cable from
m bullet Re
n/out cables
s
As Require
ed
10mm FRP
3KV for 1 minute at 50Hz
5
As per deisgn
02nos. 10mm dia. Stainless
S
stteel stud w
with double
e nut, sprin
ng and
plain wash
her
As Requirred, 10mm
m dia. Sta
ainless ste
eel stud with
w
double
e nut,
spring and
d plain was
sher
Completely enclos
sed, Indo
oor type, Natural Air Cooled.
e
s
shall
be prrovided with two term
minals
weatherproof. The enclosure
for earthing.
Tinned Co
opper Busb
bar-50mmX
X6mm
IP-65 as per
p IS: 2147
7/1962
Back Plate
e Wall/Stru
ucture Mou
unted
Neoprene Rubber
All rights reserved
r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
Dimension
Cab
ble entries
Surfface Painting
To be Spe
ecified
Cable entrries through cable gla
ands
First coat of
o zinc rich
h epoxy priimer Interm
mediate co
oat of epoxxy Two
coats of polyamide
e epoxy paint
p
Tota
al painting thicknesss 200
micron (minimum)
Colo
our scheme
e
Yellow paiint shade
Station termina
als
SS 316 Nu
uts & Bolts
s
Juncction boxx inside DMC
insulator
Nam
me plates and All interna
al compone
ent identification labe
elling shall be done using
labe
els
permanent screening
g/marker. Name platte shall be Engraved
d white
lettering in black Manufaccturers na
ame, add
dress, da
ate of
ure,., mode
el number,, serial num
mber, weig
ght etc. sh
hall be
manufactu
provided on
o shutter.
Qua
antity
As require
ed
Makke
Refer List of Approve
ed Vendorrs
4.0
INS
SPECTION
N & TESTS
S:
Jun
nction Boxes shall be
e inspected
d by owner/consultan
nt before d
dispatch. Testing
T
sha
all
be conducted
d in accord
dance with codes and
d standards enclosed
d in this do
ocument, as
a
ests done by
b manufaccturer and additional tests done
e by manufacturer.
perr routine te
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
WER DIS
STRIBUT
TION BO
OARD
POW
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
FORM NO: 02-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
1.0
SC
COPE
1.1

m
technical requireme
ents for the
t
design
n,
ma
pply of Pow
wer Distribu
ution box.
The
e Power Distribution box sho
ould be a standard
er
n
reg
gularly use
ed for imprressed currrent catho
s
con
nfers requirement fo
or type, rating, manu
ufacture and testing of differe
ent types of
o
Pow
wer Distrib
bution box.. Power Distribution
D
box shall be supplie
ed in accorrdance witth
the
e following specifications and da
ata sheets.
2.0
CO
ODES AND STANDAR
RDS
2.1
The
e Power Distribution
D
n box shall be in ac
ccordance with the la
atest revis
sions of the
following Indian standards, where
ever applica
able:
a) Indian
I
stan
n (IEC)
b) Internation
I
c
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
S)
Wh
here appro
opriate Ind
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Sysstem
Construction
Bussbars
Cable entry
Paint
Me
easuring Instruments
Wirring
FORM NO: 02-0000-0021 F2 REV3
415
5 V 3Ph 4 wire 50 Hzz AC
Flo
oor mounte
ed Fixed tyype double front
com
mpartmenttalized dusst and verm
min proof suitable for
IP 55 protection
ame : 2.0 mm
Fra
Do
oors : 1.6 mm
m
Co
overs : 1.6 mm
Base Channe
el : 3.0 mm
m
250
0 A copperr : 50 mm X 6 mm & N
Earth Bus shall be of Copper
C
50 m
mm X 6 mm
m
Bus bars sha
all be suppo
orted on S
SMC/DMC insulators
Bus bars sha
all have hea
at shrinkab
ble PVC sleeve with
Co
olor bands at regular interval forr phase ide
entification
All incoming & Outgoing
g cable en
ntries shall be at
botttom
Ou
utside : Epo
oxy light grrey shade RAL 7032 of IS : 5
Insside : (MTG
G plate, gla
and plate, sside plate, side
parrtitions, sid
de covers trolley)
t
: Gllossy white
e
All meters sh
hall be of 24
40-degree taut band scale and
size shall be 96 mm x 96
9 mm for I/Cs
Min
nimum pow
wer wiring shall be off 2.5 Sq mm
m
All rights reserved
r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
Ga
asket
Name Plates
Ferrruling
Quantity
Ma
ake of components
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
min
nimum con
ntrol wiring shall be o
of 1.5 Sq mm
m for
con
ntrol circuitt and CT/P
PT circuit.
Wiring shall be
b done wiith FRLS g
grade wire of 1.1 kV
gra
ade
All doors and
d covers wiill be provid
ded with neoprene
rub
bber gaske
ets
Each feeder will
w be provided with Al anodize
ed
nam
meplate with white le
etter on bla
ack background
havving FDR No.,
N rating tag No., F
Feeder deta
ail
Each control wire will be provided
d ferrule at both endss.
Ferule at con
ntractor sha
all be TC-2
2 and terminal strip it
sha
all be C1-C
C16 i.e. cro
oss Ferrulin
ng
As required
Re
efer list of Approved
A
V
Vendors
4.0
INS
SPECTION
N & TESTS
S
4.1
Pow
wer Distrib
bution Boa
ard shall be
b inspectted by owner/consulltant beforre dispatch
h,
tessting shall be conduccted in acccordance with
w codes and stand
dards enclo
osed in thiis
doccument.
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
TE
ECHNIC
CAL SPE
ECIFICA
ATION
ANOD
DE
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 3
1.0 SCOP
PE
This specification
n covers the minimum
m technical requirements for the
e design, manufacture
m
er and
Supplyy of Longline continuou
us Conducttive Polyme
eric Anodefflex, factoryy prepackag
ged with ca
alcined
petrole
eum coke brreeze.
The ma
agnesium Anode
A
shall be a standard of the manufacture
m
er regularly engaged in
n production
n. The
Anode shall be su
upplied in acccordance with
w the follo
owing specifications an
nd data she
eets.
2.0 CODE
ES AND STANDARD
DS
The An
nodes shall be in accordance with
w
the lattest revisio
ons of the following In
ndian stand
dards,
wherevver applicab
ble.
a)
b)
c)
d)
Indian standarrds institutio

on (ISI)
Inte
ernational electro
e
techn
nical commission (IEC)
Am
merican stan
ndards instittution (ANS
SI)
Brittish standarrds institutio
on (BS)
Where
e appropria
ate Indian standard
s
a not ava
are
a
3.0 DATA
A SHEET:
Anode Typ
pe
Model
Conductive
e Polymer OD
O
Anode Len
ngth
Anode Maxximum Currrent Outputt
Conductive
e Polymer Volume
V
Ressistivity
Anode We
eight
Anode Dessign Life at Maximum Current
C
Outtput
Max length
h of each an
nodeflex strring
Anode Ope
erating Current Outputt
Maximum permissible
e potential attenuation
a
a
within the anode
Adhesive seam
s
bond strength off nylon
jacket
Anode Dessign Life at Operating Current
C
Outtput
Anode tail Cable Prim
mary Insulatiion
Anode tail Cable Seco
ondary Insu
ulation
Anode to Cable
C
Conn
nection
Coke breeze requirem
ment
Coke breeze fix carbo
on
Coke breeze resistivitty
Make
Long
L
Line Conductive
C
P
Polymer An
node
Anodeflex
A
1500 of RAY
YCHEM make
0.5Inch
0
(13m
mm) minimu
um
To
T be speciffied by bidd
der
52mA/m
5
1.1
1 to 1.9 oh
hm-cm
1.Kg(
1
Min)
20Yrs.
2
300
3 m
To
der
1%
800N/25mm
8
m
50Yrs.
5
(Miniimum)
XLPE
X
PVC
P
FRLS
To
der
1.15Kg.
1
/m
99.7%
9
0.05
0
to 15 ohm-cm
o
Tyco
T
adhes
sives USA (formerly Raychem)
R
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 3
4.0 TEST
T CERTIFC
CATES
The tessting shall be
b conducted in accorrdance with
h codes and
d standardss specified in
i this docu
ument,
as per routine tessts done by manufacturer and add
ditional testts done by manufacturrer. The folllowing
um tests sha
all be performed by bid
dder.
minimu
a.
b.
c.
d.
e.
Anode Co
omposition per lot
Anode we
eight - Net / Gross
Anode Su
urface Finish check
Anode to Cable Jointt Resistancce
ackfill Comp
position by weight.
w
Anode ba
FORM NO: 02
2-0000-0021F2 REV3
R
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 2
TE
ECHNIC
CAL SPE
ECIFICA
ATION
SURGE DIIVERTE
ER FOR INSULA
ATING J
JOINTS
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021 F2 REV3
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 2
1.0 SCOP
PE
This specificatio
s
on covers the minimum technic
cal require
ements for Supply off Surge Divverter
for Ca
athodic Pro
otection Syystem.
The surge
s
Dive
erter shall be a standard product of the manufactu
urer regula
arly engag
ged in
produ
uction. The Surge Diverter shall
s
be supplied in accordance with
h the follo
owing
speciffications and data sh
heets.
2.0 CODE
ES AND STANDARD
DS
The Surge
S
Dive
erter shall be in acco
ordance with
w the late
est revisions of the following
f
Indian
stand
dards, whe
erever applicable. Wh
here appro
opriate Ind
dian standa
ard are no
ot available
e, the
releva
ant IEC sta
andards sh
hall apply.
a) Indian sta
andards insstitution (IS
SI)
b) International electro
o technical commissio
on (IEC)
c) American standardss institution
n (ANSI)
d) British sta
andards insstitution (B
BS)
Wh
here appro
opriate Ind
dian standa
ard are no
ot available
e, the rele
evant IEC standards shall
app
ply.
3.0 DATA
A SHEET:
Sr No Item Desc
cription
1 Lightning impulse Current (10//350) Iimp
2 Nominal Discharge
D
C
Current
(8//20) In
100% Ligh
htning impulse sparkkover voltag
ge
3 Uas 100
4
5
6
7
Power freq
quency spark over vo
oltage (50 HZ)
Uaw
Degree off protection
n
Length of Enclosure
e
Diameter of enclosu
ure D
8 Enclosure
e material
9 Cable Len
ngth
10 Make
EXFS
50 KA
100
0 KA
< 2.5
2 KV
< 1.2 KV
IP 65/
6 Explossion proof
90 mm
63 mm
Die
e Cast zincc with
Moisture proo
of
100 mm
DEH
HN ,Neumarkt G
Germany/ OBO
O
Germ
many
4.0 TEST CERTIFIC

CATES:
The te
esting shall be cond
ducted in accordance
a
e with cod
des and sttandards specified
s
in
n this
docum
ment, as pe
er routine te
est done by
b manufac
cturer. Tesst certificate
e shall be furnished.
f
FORM NO: 02
2-0000-0021 F2
2 REV3
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
SO
OLID ST
TATE PO
OLARIZ
ZATION CELL F
FOR
CATHO
ODIC PROTEC
CTION SYSTEM
S
M
FORM NO: 02-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
1.0
SC
COPE
1.1

m
technical requireme
ents for the
t
design
n,
ma
pply of Solid
d State Po
olarization Cell.
C
The
e Solid State Polarrization Ce
ell shall be
b a stand
dard produ
uct of the contracto
or
reg
gularly use
ed in produ
uction. The
e Solid Sta
ate Polarizzation Cell shall be supplied in
acccordance with
w the following spe
ecifications
s and data sheets.
2.0
CO
ODES AND STANDAR
RDS
2.1
The
e Solid Sta
ate Polarizzation Cell shall be in
i accorda
ance with tthe latest revisions
r
o
of
the
e following
g Indian standards,
s
wherever applicab
ble. Where
e approprriate Indian
Sta
andard is not
n available, the rele
evant IEC standards
s
s
shall
applyy.
a) Indian
I
stan
b) Internation
I
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
S)
Wh
here appro
opriate Ind
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Ste
eady State
Rating
DC
C Blocking
Sho
ort Duratio
on fault Current
Lightening Su
urge Curre
ent
ratiing
Am
mbient Tem
mperature
Encclosures
Mo
ounting
Number of re
epeated
ope
eration
Quantity
Ma
ake
4.0
40 A Nomina
al
Op
ptimal highe
er ratings of
o Custom built
3.0
0 V Negativ
ve to 1.0 V Positive
5 kA/
k 5000 A @ 30 Cyccles
500
000 A Cres
st for 8 to 20
2 secon
nds
-45
5 C to 75 C
IP 55 Enclosu
ure for Non
n Hazardous Applica
ations
The
e cell is ma
ade to mou
unt on a fla
at surface
Virrtually unlimited und
der maximum ratings
s, provided
the
e operation
ns are not immediately repetitive.
As required
Da
airyland US
SA/ As per Approved list
SO
OLID STAT
TE POLAR
RIZATION CELL
C
REP
PLACEME
ENT
The
e device provides DC
C blocking when absolute volta
age across the termin
nals is 3.0 V
neg
gative to 1.0 V positive. The Device
D
furth
her provide
es groundiing (or cou
upling) patth
for steady sta
ate AC cu
urrent of a Magnitude
e 40 A. so
olid state d
design elim
minates the
ma
aintenance requireme
ents and th
he potentia
ally hazardo
ous electro
olytes asso
ociated witth
KO
OH type po
olarization cells and have a higher DC blocking
b
vo
oltage. The device is
i
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
ma
ade of solid
d state com
mponents, which have an instan
ntaneous rresponse with
w respecct
to voltage,
v
thereby initia
ating voltag
ge clampin
ng immedia
ately when
n the voltag
ge attemptts
to exceed
e
the
e blocking level seleccted.
5.0
TY
YPICAL AP
PPLICATIO
ON
6.0
Blocking Stray DC
D voltage
e
o cathodiccally prote
ected equ
uipment frrom utility grounding
DC issolation of
system
ms.
Over voltage
v
Prrotection fro
om AC fau
ults
Lightin
ng and Sw
witching Tra
ansients fo
or Monolithic isolation
n joints
AC Vo
oltage mitig
gation
TEST CETIFICATES:
The
e testing shall
s
be conducted in
n accordan
nce with co
odes and sstandards enclosed
e
in
thiss specification. Test Certificates
C
s shall be furnished as
a per routine tests & additiona
al
tesst done by manufactu
urer.
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
ARTHIN
NG JUNC
CTION BOX
B
EA
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
FORM NO: 02-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
1.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
SC
COPE
m
technical requireme
ents for the
t
design
n,
ma
pply of Eartthing Juncttion Box.
The
e earthing junction box should be a stand
dard produ
uct of the m
manufacturrer regularly
use
ed for Imp
pressed cu
urrent Cath
hodic prote
ection system. This specification conferrs
req
quirement for type, rating,
r
man
nufacture and testing of differrent types of earthing
junction box. The Earrthing Juncction Box shall be supplied in accordance with the
following specifications and data sheets.
s
2.0
CO
ODES AND
D STANDA
ARDS
The
e earthing
g junction box shall be in acc
cordance with
w
the la
atest revisions of the
following Indiian standards, where
ever applicable:
a) Indian
I
stan
b) Internation
I
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
S)
Wh
here appro
opriate Ind
C standard
ds
sha
all apply.
3.0
DA
ATA SHEET
- Earthing Circuits
- Earthing Device
- Circuit Coonfiguration
2 Nos. per bullett

s
polarrization cell of 5KA
Solid state
Earthing of th
he bullets
s is done
gh
polarrization
throug
cell.
The
earthin
ng cable from eac
ch bullet is
i
conne
ected to the
e central earthing grid
throug
gh polariza
ation cell.
Terminal Board Material
:
DMC/S
SMC
n level in between
3kV fo
or 1 minute at 50Hz terminalls
Insulation
:
and bo
ody
Busbar
Tinned
d Copper B
Busbar-50m
mmX6mm
:
Input Terrminals
for the
e cable from
m :
2
Nos.,
10mm
m dia , Staiinless the bullet Stee
el
stud with
w
double nut, Spring
S
and
plain washer
w
Output Te
erminals to
o the earthing pit :
2 Noss., 10mm dia , Stainless Stee
el
stud with
w double
e nut, sprin
ng and plain
washe
er
Enclosure
e complete
ely enclose
ed outdoorr type Walll/Structure Mounted, Natural Air
A
Co
ooled IP6
65 Construction. Th
he cabine
et
sh
hall be mad
de from CRCA shee
et steel witth
S.S. platess inserts and S.S. double
FORM NO: 02-0000-0021 F2 REV3
:
:
:
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
Enclosure
e Material
Enclosure
e Protectio
on
Degree of
o Protectio
on
Cable entries
g cable from
m the bulle
et
Incoming
Outgoing
g cables to earthing grid
g
Surface Painting
P
Color sch
heme
Name pla
ates and le
evels
Quantity
Make
4.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
co
ompression
n FLP ccable gla
ands. The
ca
abinet shalll have hin
nged front doors witth
ne
eoprene gasket a
and shall be Pad
loc
ckable.
2.0
0mm thickk CRCA ste
eel enclosu
ure
Ex
xplosion Proof
P
Zone
e 1-Gas Group
G
IIA &
IIB
B Tempera
ature Classs T3.
IP
P-65
Th
hrough FLP
P double ccompressio
on glands.
1CX35
5sq.mm
1CX35
5sq.mm
First coat off zinc rich e
epoxy prim
mer
Inttermediate
e coat of ep
poxy
Tw
wo coats of polyamid
de epoxy pa
aint Total
pa
ainting thickness 200 micron(minimum)
Ye
ellow paintt shade
alll internal component identification labeling
sh
hall be done
d
using perman
nent using
pe
ermanent screening
g/ screening/marker.
Na
ame plate
e shall b
be Engra
aved whitte
letttering in black. M
Manufacture
ers name
e,
ad
ddress, date of manufacture, CMRS
C
No.,
mo
odel numb
ber, serial number, weight etcc.
sh
hall be provvided on sh
hutter.
As
s required
Re
efer List off Approved
d Vendors
INS
SPECTION
N & TESTS
S:
e earthing Junction Box shall be inspec
cted by ow
wner/consultant beforre dispatch
h,
The
tessting shall be conduccted in acccordance with
w codes and stand
dards enclo
osed in thiis
doccument, as per routtine tests done by contractorr and additional testts done by
b
con
ntractor.
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 1 o
of 3
TECHNICA
AL SPE
ECIFICA
ATION
ONITORIING JUN
NCTION
N BOX
MO
FO
OR CAT
THODIC
C PROTE
ECTION
N SYSTE
EM
FORM NO: 02-0000-0021 F2 REV3
All rights reserved
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
1.0
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 2 o
of 3
SC
COPE

m
technical requireme
ents for the
t
design
n,
ma
pply of Mon
nitoring Jun
nction Box.
The
e monitoriing junctio
on box sh
hould be a standard
er
n
reg
gularly use
ed for Imprressed currrent Catho
s
con
nfers requiirement for type, rating, manuffacture and testing o
of monitoriing junction
boxx. The monitoring junction boxx shall be supplied
s
in
n accordan
nce with th
he following
spe
ecificationss and data sheets.
2.0
CO
ODES AND STANDAR
RDS
The
e Junction
n Box shalll be in acccordance with the latest revissions of th
he following
Ind
dian standa
ards, where
ever appliccable:
a) Indian
I
stan
b) Internation
I
c
n (IEC)
c) American
A
s
standards
institution (ANSI)
d) British
B
stan
S)
Wh
here appro
opriate Ind
C standard
ds
sha
all apply.
3.0
ATA SHEET
T:
DA
Circuit Configuration
asurement
Mea
Num
mber
of
Inpu
ut/output/
Term
minals
Term
minal
Board
Mate
erial
Insu
ulation le
evel in
betw
ween
te
erminals
and body
Cab
ble Entries
Inpu
ut/looping
Term
minals
Outp
put Termin
nals
Enclosure
Busbar
Degree of Prottection
Mou
unting
Gassket
FORM NO: 02-0000-0021 F2 REV3
Cable from
m bullet Re
n/out cables
s
As Require
ed
10mm FRP
3KV for 1 minute at 50Hz
5
As per deisgn
02nos. 10mm dia. Stainless
S
stteel stud w
with double
e nut, sprin
ng and
plain wash
her
As Requirred, 10mm
m dia. Sta
ainless ste
eel stud with
w
double
e nut,
spring and
d plain was
sher
Completely enclos
sed, Indo
oor type, Natural Air Cooled.
e
s
shall
be prrovided with two term
minals
weatherproof. The enclosure
for earthing.
Tinned Co
opper Busb
bar-50mmX
X6mm
IP-65 as per
p IS: 2147
7/1962
Back Plate
e Wall/Stru
ucture Mou
unted
Neoprene Rubber
All rights reserved
r
T
TECHNICAL
L SPECIFICA
ATION
CAT
THODIC PRO
OTECTION SYSTEM
S
OF
F
MOUND
DED BULLE
ETS
PROJEC
CT:INSTALL
LATION OF LPG
L
MOUND
DED
BULLETS
R : NRL,ASS
SAM
OWNER
EM
M163-TS-080
01
DO
OCUMENT N
NO
REV
Sheet 3 o
of 3
Dimension
Cab
ble entries
Surfface Painting
To be Spe
ecified
Cable entrries through cable gla
ands
First coat of
o zinc rich
h epoxy priimer Interm
mediate co
oat of epoxxy Two
coats of polyamide
e epoxy paint
p
Tota
al painting thicknesss 200
micron (minimum)
Colo
our scheme
e
Yellow paiint shade
Station termina
als
SS 316 Nu
uts & Bolts
s
Juncction boxx inside DMC
insulator
Nam
me plates and All interna
al compone
ent identification labe
elling shall be done using
labe
els
permanent screening
g/marker. Name platte shall be Engraved
d white
lettering in black Manufaccturers na
ame, add
dress, da
ate of
ure,., mode
el number,, serial num
mber, weig
ght etc. sh
hall be
manufactu
provided on
o shutter.
Qua
antity
As require
ed
Makke
Refer List of Approve
ed Vendorrs
4.0
INS
SPECTION
N & TESTS
S:
Jun
nction Boxes shall be
e inspected
d by owner/consultan
nt before d
dispatch. Testing
T
sha
all
be conducted
d in accord
dance with codes and
d standards enclosed
d in this do
ocument, as
a
ests done by
b manufaccturer and additional tests done
e by manufacturer.
perr routine te
FORM NO: 02-0000-0021 F2 REV3
All rights reserved

r
TECHNICA
AL SPECIFIC
CATION
ATHODIC PR
ROTECTION
N SYSTEM OF
O
CA
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 2
MASTER VEN
NDOR LIST
L
FOR CA
ATHODIIC PROTECTIO
ON SYST
TEM
FORM NO: 02
2-0000-0021F2 REV4
R
All rights reserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 2
CAT
THODIC PROTECTI
P
ION VEND
DOR LIST
VENDORS
Sr. No.
1
M/s Rayychem RPG

G Ltd
2
4
M/s Con
nsultech
M/s Corrrosion Con
ntrol Servicces (Bomb
bay) Pvt Ltd
d
M/s Corrrtech Interrnational Pvt

P Ltd, Ahm
medabad
M/s CTS
S Private Limited
L
7.
M/s BsssTech CP (I)

( Pvt Ltd, Mumbai
8.
Undergrround pipe
eline & NDT
TS (P) Ltd.
FORM NO: 02
2-0000-0021F2 REV3
R
All rights rreserved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 1 of 3
MAKE OF EQUIPMEN
NT / CO
OMPONE
ENT
ATHODIIC PROTECTIO
ON SYST
TEM
FOR CA
FORM NO: 02--0000-0021F2 RE

EV3
All rights reseerved
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 2 of 3
CATHODIC PRO
OTECTION
N MAKE OF
O EQUIPM
MENT / CO
OMPONEN
NT
Sr.
No.
1
DES
SCRIPTION OF MAT
TERIALS
Transform
mer Rectifie
er unit
Test Statio
ons/ Anode
e Junction Box/ Cath
hode
Junction Box
B
Refere
ence Electtrode Junc
ction
Box (REJJB) /
Earthing Junction
J
Bo
ox (EJB)
Surge Divverter for MIJS

M
Monolithicc Isolating Joints

J
Cables
6
7
Zinc Grounding Elecctrode/ Celll/ Zinc Rib

bbon
Anode
Digital Mu
ultimeter
DC clip-on
n meter
C.P. Syste
em Power Distributio
on Board
(PDB)
FORM NO: 02
2-0000-0021F2 REV3
R
MANUFACTURERS
S / VENDO
OR
Advvance Elecctronic Sys
stems
Rayychem
Krisstons Systtems
FCG
FEPL
Flexpro
Balliga
DEHN Germa
any
OB
BO Betterm
man Germa
any
AES
IGP
P, Chennai
Alfa
a Engineerring
SR
RL Italy
Zun
nt Italy
RM
MA Italy
NETCO
ASIAN
Finolex
NIC
CCO
CC
CI
Uniiversal
KEC
Suyyog cabless,
Icon cables,
Torrrent
Ravvin Cabless
RR
R Cables
Sarrgam Meta
als Chenna
ai
Scientific Mettals Karaik
kudi
Becckmann
Fluke
Mo
otwane
HC
CK (Germany)
Kyo
oritsu Elecct (Japan)
Asssociated Switchgears
s & Projectts
Ltd. /
Auttomatic controls
Corrporation/C
Controls
& Schematics
S
s Pvt. Ltd.//Control &
Sw
witchgear C
Co. Ltd./Ele
ecmech
corrporation/H
Havells Ind
dia Limited
/Hin
ndustan Co
ontrol & Eq
quipment Pvt.
P
All rights reserved
r
TECHNICA
AL SPECIFIC
CATION
CA
ATHODIC PR
ROTECTION
N SYSTEM OF
O
MOUNDED BULL
LETS
PROJE
ECT:INSTAL
LLATION OF
F LPG MOUNDED
BULLETS
OWNE
ER : NRL,AS
SSAM
EM163-TS
S-0801
DOCUMEN
NT NO
RE
EV
Shee
et 3 of 3
Ltd./ Reunion
n Electrical Manufactu
urers
Pvtt. Ltd
10
Long Line
e Conducttive Polym
mer Anode
e
Flex x 150
00
Rayychem
11
Anode flexx Splice Kiit
Rayychem
12
13
Cu/CuSO4
4 permane
ent reference cells
Reference
e Electrode
e (Zinc) /
Zinc Reference Cell
Solid-State type Polarization cells
c
Monitoring
g Junction Box (MJB)
Remote Monitoring
M
U
Unit
Borrin USA/Mcc-Miller/Ha
arco
14
15
16
FORM NO: 02
2-0000-0021F2 REV3
R
Borrin USA/Mcc-Miller/Ha
arco
Daiiry Land/ R
Rustrol /Kirrk/ Corrpro
Rayychem/AES or equiv
valent
Rayychem/AES
All rights reserved

r
LPG MOUNDED BULLETS, NRL REFINERY
Document No.
Sheet 1 of 1
Rev.
PIPING
TECHNICAL PART VOLUME - II
PIPING
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
LPG MOUNDED BULLETS, NRL REFINERY
Document No.
Rev.
PIPING
Sheet 1 of 1
CONTENTS
SN
Item
Page No
1.0
Piping Material Specification & Valve Material Specifications
2.0
Minimum Allowable Nozzle Loading For Mounded Bullet
12
3.0
Equipment layout for the New Mounded Bullets
15
4.0
PDIL Standards for Piping

4.1 ES 6005
16
4.2 ES 6006
33
4.3 ES 6007
40
4.4 ES 6010
44
4.5 ES 6011
59
4.6 ES 6101
67
4.7 ES 6102
72
4.8 ES 6103
77
4.9 ES 6104
82
4.10 ES 6105
86
4.11 ES 6606
90
4.12 ES 6018
98
4.13 PDS - P- 001
114
4.14 PDS P 011
115
4.15 PDS P 012
117
4.16 PDS P 01-65
121
4.17 PDS P123
168
4.18 PDS P 101
178
4.19 PDS P 103
181
Allrightsreserved
Document No.
Sheet 1 of 3
Rev.
FORMOUNDEDBULLET
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
Document No.
Rev.
Sheet 2 of 3
Allrightsreserved
Document No.
Rev.
Sheet 3 of 3
Allrightsreserved
Document No.
Sheet 1 of 1
Rev.
PIPINGMATERIALSPECIFCATION
&
VALVEMATERIALSPECIFICATION
05.08.2015
05.08.2015
First Issue
AK
SKM
SKM
REV
REV DATE
EFF DATE
PURPOSE
PREPD
REVWD
APPD
ANSI
CLASS
150#
CORROSION
1.5 MM
ALLOWANCE
-29.0
38.00
93
149
204
260
316
343
371
PRESS.KG/CM2 G 20.03
TEMP. DEG.C
20.03
18.28
16.17
14.06
11.95
9.84
8.78
7.73
40
36
E R R R R R
34
E TEES B. W.
DRAINS
1.5" & BELOW
SW COUPLING
H H. COUPLING
2" & ABOVE
BUTTWELDED
P PIPE TO PIPE
ON LINES < 1.5"

ON LINES > 2.0"
VENTS
TEMP. CONN.
PRESS. CONN.
AS PER P&ID OR 0.75"
ON LINES < 1.5"

1.5"
FLANGED
0.75"
E R R R R R R R R
26
E R R R R R R R R R
24
22
R REINFORCED
R R R R R R R R R R
S SOCKETLETS
E R
R R R R R R R R R R
18
E R R
R R R R R R R R R R
16
E R R R
R R R R R R R R R R
14
12
T TEES SWW / SCRD
ON LINES > 2.0"
32
30
W WELDOLETS
SW NIPPLE WITH VALVE TO SPEC
20
E R R R R
R R R R R R R R R R
E R R R R R
R R R R R R R R R R
10
E P R R R R R
R R R R R R R R R R
8.0
E P P R R R R R
R R R R R R R R R R
6.0
5.0
P P P R R R R R
R R R R R R R R R R
4.0
P P P R R R R R
R R R R R R R R R R
3.00
P P P R R R R R
R R R R R R R R R R
2.00
T E
H H H H H H H H
H H H H H H H H H H
1.50
T H
H H H H H H H H
H H H H H H H H H H
1.00
T T
T H
H H H H H H H H
H H H H H H H H H H
0.75
T T T
T H
H H H H H H H H
H H H H H H H H H H
0.50
3.5
2.50
1.25
0.25
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.5
4.0
5.0
6.0
8.0
10
12
14
16
18
20
22
24
26
30
32
34
36
40
42
44
48
PIPE JOINTS
E R R R R R R
E R R R R R R R
20
BRANCH CONNECTIONS
25
E R R R
15
BRANCH PIPE
DESCRIPTION
FLANGED (BUT TO BE KEPT MINIMUM)
42
10
SIZE
44
E R R
10
15
20
25
30
RUN PIPE
PIPING MATERIAL SPECIFICATION

A1A
SHEET 1 OF 3
ITEM
48
R R R R
MAINTE. JOINTS ALL
E
E R
30
NON CORROSIVE/ FLAMMABLE / NON FLAMMABLE/ NON LETHAL -PROCESS & HYDROCARBONS; LUBE OIL BEFORE FILTER;
AMMONIA, STEAM & CONDENSATE (NON IBR); UTILITIES- INST AIR(BEYOND A3A), PLANT AIR, NITROGEN, CARBONDIOXIDE;
WATER - BEYOND A3A AND A10A; IN OFFSITES ONLY BEYOND A10A;
ITEMS
S
NO.
PIPE
PIPES
FLANGE
FLANGES
TYPE
FITTING
FITTINGS
FITTING
FITTINGS
LOW
HIGH
SCH / THK /
RATING
SEAMLESS
SEAMLESS
SEAMLESS
SEAMLESS
E.FS.W
E.FS.W
NIPPLE, SEAMLESS
PE
PE
BE
BE
BE
BE
PBE
00
01
02
03
16
40
00
500
000
000
000
000
000
500
00
01
02
14
36
48
01
750
500
000
000
000
000
500
S160
XS
XS
STD
STD
XS
M
SW
WN
WN
WN
BLIND
BLIND
BLIND
FIG.8 FL
SPCR & BLN
SPCR & BLN
RF
RF
RF
RF
RF
RF
RF
FF
FF
FF
SW
SW
BW
BW
00
00
26
02
00
26
02
00
10
26
00
01
02
16
500
500
000
000
500
000
000
500
000
000
500
000
000
000
01
24
48
24
24
48
24
08
24
48
00
01
14
48
500
000
000
000
000
000
000
000
000
000
750
500
000
000
300
150
150
300
150
150
300
150
150
150
6000
3000
SCRF
SCRF
BW
PBE
00
01
02
00
500
000
000
500
00
01
48
03
750
500
000
000
6000
3000
DIAMETER RANGE
END /
FACING
ALL
EXCEPT
CAP
CAP
CAP
SWAGE
FACE FINISH /
RADIUS
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
R = 1.5D
R = 1.5D
DIMENSION /
DESIGN /
STANDARD
MATERIAL
DESCRIPTION
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
ASTM A 106 GR. B

ASTM A 106 GR. B
ASTM A 106 GR. B
ASTM A 106 GR. B
ASTM A672 GR.B60 CL 12
ASTM A672 GR.B60 CL 12
ASTM A 106 GR. B
B - 16.5
B - 16.5
B - 16.47 - B
B - 16.5
B - 16.5
B - 16.47 - B
B - 16.5
ASME B16.48
ASME B16.48
B - 16.11
B - 16.11
B - 16.9
B - 16.9
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A 105
A 105
A 105
A 105
A 105
A 105
A 105
A 516 GR 70
A 105
A 105
A234 GR.WPB
A234 GR.WPB - W
B - 16.11
B - 16.11
B - 16.9
BS - 3799
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A234 GR.WPB
A 105
PIPING MATERIAL SPECIFICATION NUMALIGARH REFINERY LTD.
A1A
CODE
NOTE
SHEET 2 OF 3
ITEMS
S
NO.
GASKET
VALVE
STUDS
GASKET
BOLTING
VALVES
TYPE
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
DIMENSION /
DESIGN /
STANDARD
MATERIAL
DESCRIPTION
NOTE
CODE
BODY: A105, TRIM: STELLITED,

STEM: 13% CR STEEL
BODY: A105, TRIM: STELLITED
51001
B16.11
800
800
API - 602 / ISO

15761
BS EN ISO 15761
BS EN ISO 15761
52001
53001
B16.11
B16.11
500
800
BS EN ISO 15761
BODY: A105, TRIM: 13% CR STEEL
58099
B16.11
16
000
150
125 AARH
BS EN ISO 17292
000
42
000
150
125 AARH
API - 600 / ISO

10434
02
000
16
000
150
125 AARH
BS - 1873
RF
02
000
24
000
150
125 AARH
BS - 1868
PLUG
RF
00
500
24
000
150
125 AARH
BS - 5353
PLUG
RF
00
500
36
000
150
125 AARH
BS - 5353
BUTTERFLY
WAF
03
000
24
000
150
125 AARH
BS EN 593
BUTTERFLY
WAF
26
000
48
000
150
125 AARH
BS EN 593
BODY: A216GRWCB, 13% CR. STEEL

56315
TRIM
B - 18.2
B - 18.2
A193 GR. B7
A194 GR. 2H
SS316 SPR.WND + GRAFIL
GATE
SW
00
250
01
500
800
GLOBE
CHECK
SW
SW
00
00
250
250
01
01
500
500
NEEDLE
SW
00
500
01
BALL
RF
00
500
GATE
RF
02
GLOBE
RF
CHECK
BOLT STUD
NUTS
BODY: A105 / A216GRWCB, TRIM:

BODY, SEAT: RPTFE
TRIM
TRIM
TRIM
BODY, PLUG: HARDENED
TRIM
SPIRAL
00
500
24
000
150 / 5 MM
B-16.20 / B 16.5
SPIRAL
26
000
48
000
150 / 5 MM
B-16.20 / B 16.47B SS316 SPR.WND + GRAFIL + I. RING
SPIRAL
00
500
24
000
300 / 5 MM
B-16.20 / B 16.5
FLGD
00
500
01
500
THRMODNMC
MNF'STD
B: A105; T: 13% CR; SS304
SW
BW
BW
00
02
16
500
000
000
01
14
24
500
000
000
Y TYPE
T TYPE
T TYPE
MNF'STD
B: A105; INT; SS304

B: A234 GRWPB; INT: SS304
B: A234 GRWPBW; INT: SS304
TRAP
PERM STR
PERM STR
PERM STR
150 /
125AARH
800
A1A
54301
51301
52301
53301
55301
55315
56301
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
WAFL TO
B16.5
FLANGED
TO
B16.47B
SHEET 3 OF 3
ANSI
CLASS
300#
CORROSION
1.5 MM
ALLOWANCE
-29.0
38.00
93.00
149
204
260
TEMP. DEG.C
52.02
47.8
46.05
44.64
42.53
316
343
40.07
371
38.66 37.26
399
427
35.5
28.82
48
30
NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHAL - HYDROCARBONS, AROMATICS, AMMONIA,
SWEET GAS, FLUSHING OIL AND OTHER UTILITIES -MP CONDENSATE, INSTRUMENT
AIR, PLANT AIR, NITROGEN, AMMONIA GAS ETC. ABOVE CLASS 'A1A'.
44
42
40
BRANCH CONNECTIONS
DESCRIPTION
32
FLANGED (TO BE KEPT MINIMUM)
30
2" & ABOVE
BUTTWELDED
ON LINES < 1.5"

ON LINES > 2.0"
VENTS
TEMP. CONN.
PRESS. CONN.
ON LINES < 1.5"

1.5"
FLANGED
24
P PIPE TO PIPE
E R
22
R REINFORCED
E R R
20
S SOCKETLETS
E R R R
18
E R R R R
16
E R R R R R
14
T TEES SWW / SCRD
ON LINES > 2.0"
0.75"
26
H H. COUPLING
W WELDOLETS
SW NIPPLE WITH VALVE TO SPEC
E R R R R R R
12
E R R R R R R R
10
E R R R R R R R R
8.0
E R R R R R R R R R
6.0
20
SW COUPLING
5.0
E R R R R R R R R R R R
4.0
E P P R R R R R R R R R R R
3.00
10
DRAINS
1.5" & BELOW
3.5
2.50
E P P P P R R R R R R R R R R R
2.00
T E H H H H H H H H H H H H H H H
1.50
T T T H H H H H H H H H H H H H H H H
1.00
T T T T H H H H H H H H H H H H H H H H
0.75
T T T T T H H H H H H H H H H H H H H H H
0.50
1.25
0.25
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.5
4.0
5.0
6.0
8.0
10
12
14
16
18
20
22
24
26
30
32
34
36
40
42
44
48
PIPE JOINTS
15
BRANCH PIPE
E TEES B. W.
10
15
20
25
30
RUN PIPE

B1A
SHEET 1 OF 3
SIZE
ITEM
MAINTE. JOINTS ALL
25
36
34
ITEMS
S
NO.
PIPE
PIPES
FITTINGS
FLANGE
FITTING
FLANGES
FITTING
FITTINGS
TYPE
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
SEAMLESS
SEAMLESS
SEAMLESS
SEAMLESS
E.FS.W
E.FS.W
E.FS.W
E.F.G.W.
NIPPLE, SEAMLESS
PE
PE
BE
BE
BE
BE
BE
BE
PBE
00
01
02
03
16
20
24
24
00
500
000
000
000
000
000
000
000
500
00
01
02
14
18
20
24
24
01
750
500
000
000
000
000
000
000
500
S160
XS
XS
STD
XS
XS
CALC
14.0
M
SW
WN
BLIND
FIG.8 FL
SPCR & BLN
RF
RF
RF
FF
FF
00
02
00
00
10
500
000
500
500
000
01
24
24
08
24
500
000
000
000
000
300
300
300
300
300
ALL
SW
SW
BW
BW
00
01
02
16
500
000
000
000
00
01
14
24
750
500
000
000
6000
3000
SCRF
SCRF
BW
PBE
00
01
02
00
500
000
000
500
00
01
24
03
750
500
000
000
6000
3000
EXCEPT
CAP
CAP
CAP
SWAGE
FACE FINISH /
RADIUS
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
R = 1.5D
R = 1.5D
DIMENSION /
DESIGN /
STANDARD
MATERIAL
DESCRIPTION
CODE
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
B - 36.10
ASTM A 106 GR. B

ASTM A 106 GR. B
ASTM A 106 GR. B
ASTM A 106 GR. B
ASTM A672 GR.B60
ASTM A672 GR.B60
ASTM A672 GR.B60
ASTM A672 GR.B60
ASTM A 106 GR. B
B - 16.5
B - 16.5
B - 16.5
ASME B16.48
ASME B16.48
ASTM
ASTM
ASTM
ASTM
ASTM
A
A
A
A
A
B - 16.11
B - 16.11
B - 16.9
B - 16.9
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A234 GR.WPB
A234 GR.WPB - W
B - 16.11
B - 16.11
B - 16.9
BS - 3799
ASTM
ASTM
ASTM
ASTM
A 105
A 105
A234 GR.WPB
A 105
B1A
CL
CL
CL
CL
NOTE
12
12
12
12
105
105
105
105
105
SHEET 2 OF 3
ITEMS
S
NO.
VALVE
VALVES
7
8
GASKET STUDS
BOLTING
TYPE
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
DIMENSION /
DESIGN /
STANDARD
GATE
SW
00
250
01
500
800
API - 602 / ISO

15761
GLOBE
SW
00
250
01
500
800
BS EN ISO 15761
CHECK
SW
00
250
01
500
800
NEEDLE
SW
00
500
01
500
800
BALL
RF
00
500
16
000
300
125 AARH
BS EN ISO 17292
GATE
RF
02
000
24
000
300
125 AARH
API - 600 / ISO

10434
GLOBE
RF
02
000
12
000
300
125 AARH
BS - 1873
CHECK
RF
02
000
24
000
300
125 AARH
BS - 1868
PLUG
RF
00
500
24
000
300
125 AARH
BS - 5353
BOLT STUD
NUTS
SPIRAL
TRAP
PERM STR
PERM STR
PERM STR
00
500
24
000
FLGD
00
500
01
500
SW
BW
BW
00
02
16
500
000
000
01
14
24
500
000
000
BS EN ISO 15761

STEM: 13% CR STEEL
STEM: 13% CR STEEL
BS EN ISO 15761

BODY, SEAT: RPTFE
TRIM
TRIM
TRIM
B - 18.2
B - 18.2
A193 GR. B7
A194 GR. 2H
B-16.20 / B 16.5
THRMONMC
MNF'STD
B: A105; T: 13% CR; SS304
Y TYPE
T TYPE
T TYPE
MNF'STD
B: A105; INT; SS304

300 / 5 MM
300 /
125AARH
800
MATERIAL
DESCRIPTION
B1A
CODE
NOTE
51001
B16.11
52001
B16.11
53001
B16.11
58099
B16.11
54401
51401
52401
53401
55401
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
SHEET 3 OF 3
ANSI
CLASS
150#
CORROSION
1.5 MM
ALLOWANCE
TEMP. DEG.C
38.00
50.00
100
10.55
10.55
10.55
150
186
10.55 10.55
E TEES B. W.
DRAINS
1.5" & BELOW
SW COUPLING 3000 LBS
H H. COUPLING
2" & ABOVE
BUTTWELDED
P PIPE TO PIPE
ON LINES <= 1.5"

ON LINES >= 2.0"
VENTS
TEMP. CONN.
PRESS. CONN.
ON LINES < =1.5"

1.5"
FLANGED
0.75"
34
E R R R R R R
32
E R R R R R R R
30
E R R R R R R R R
26
E R R R R R R R R R
24
22
R R R R R R R R R R
S SOCKETLETS
E P
R R R R R R R R R R
18
E R P
R R R R R R R R R R
16
E P R P
R R R R R R R R R R
14
12
W WELDOLETS
20
E P P R P
R R R R R R R R R R
E R P P R P
R R R R R R R R R R
10
E P R P P R P
R R R R R R R R R R
8.0
E P P R P P R P
R R R R R R R R R R
6.0
P P P P P P P P
R R R R R R R R R R
4.0
P P P P P P P P
R R R R R R R R R R
3.00
P P P P P P P P
P R R R R R R R R R
2.00
T E
H H H H H H H H
H H H H H H H H H H
1.50
T H
H H H H H H H H
H H H H H H H H H H
1.00
T T
T H
H H H H H H H H
H H H H H H H H H H
0.75
T T T
T H
H H H H H H H H
H H H H H H H H H H
0.50
SW HVY NIPPLE WITH GATE VALVE TO SPEC
25
36
E R R R RRR
R REINFORCED
T TEES SWW / SCRD
ON LINES >= 2.0"
40
5.0
3.5
2.50
1.25
0.25
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.5
4.0
5.0
6.0
8.0
10
12
14
16
18
20
22
24
26
30
32
34
36
40
42
44
48
PIPE JOINTS
E R R R
E R R R R
20
BRANCH CONNECTIONS
42
15
BRANCH PIPE
DESCRIPTION
FLANGED (TO BE KEPT MINIMUM)
44
E R R
10
SIZE
48
10
15
20
25
30
RUN PIPE

A3A
SHEET 1 OF 3
ITEM
MAINTE. JOINTS ALL
E
E R
30
NON CORROSIVE UTILITIES (ABOVE GROUND) CATEGORY "D" FLUID - COOLING WATER, INSTRUMENT AIR(2" & ABOVE),PLANT AIR, INERT GAS, CARBON DI OXIDE
(DRY), NITROGEN, CONDENSATE & BOILER FEED SUCTION (NON IBR),COOLING WATER(UNDERGROUND). THIS CLASS DOES NOT COVER THE FIRE WATER SERVICE. FOR
SIZES ABOVE 30", TEMPERATURE AND PRESSURE RATINGS SHALL BE 70 DEG.C & 7.0 KG/CM2G RESPECTIVELY.
ITEMS
S
NO.
PIPE
PIPES
FITTINGS
FLANGE
FITTING
FLANGES
DIAMETER RANGE
END /
FACING
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
C.WELDED
C.WELDED
WELDED
WELDED
WELDED
WELDED
PE
BE
BE
BE
BE
BE
00
02
08
16
20
26
500
000
000
000
000
000
01
06
14
18
24
48
500
000
000
000
000
000
HVY
HVY
6.00
8.00
10.0
12.0
SW
SW
WN
SO
SO
BLIND
BLIND
FIG.8 FL
SPCR & BLN
SPCR & BLN
RF
RF
RF
RF
FF
RF
FF
FF
FF
FF
00
00
02
02
26
00
26
00
10
26
500
500
000
000
000
500
000
500
000
000
01
01
24
24
48
24
48
08
24
48
500
500
000
000
000
000
000
000
000
000
150
300
600
150
150
150
150
150
150
150
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
125 AARH
SW
BW
BW
00
02
08
500
000
000
01
06
24
500
000
000
3000
STD
M
R = 1.5D
R = 1.5D
SCRF
BW
BW
BW
BW
PBE
SW
00
02
08
16
16
00
00
500
000
000
000
000
500
500
01
06
48
48
48
03
01
500
000
000
000
000
000
500
3000
STD
M
M
M, M
STD, STD
3000
ALL
DIMENSION /
DESIGN /
STANDARD
MATERIAL
NOTE
DESCRIPTION
IS-1239-I
IS-1239-I
IS-3589
IS-3589
IS-3589
IS-3589
IS-1239 BLACK
IS-1239 BLACK
IS-3589 GR.330
IS-3589 GR.330
IS-3589 GR.330
IS-3589 GR.330
B - 16.5
B - 16.5
B - 16.5
B - 16.5
AWWA-C207 CL.D
B - 16.5
AWWA-C207 CL.D
ASME B16.48
ASME B16.48
MANF' STD
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
B - 16.11
B - 16.9
B - 16.9
ASTM A 105
ASTM A234 GR.WPB
ASTM A234 GR.WPB-W
B - 16.11
B - 16.9
B - 16.9
ASTM A 105
ASTM A234 GR.WPB
ASTM A234 GR.WPB
IS-3589 GR.330
IS-3589 GR.330
ASTM A 105
ASTM A 105
A
A
A
A
A
A
A
A
A
A
CODE
105
105
105
105
105
105
285 GR.C
105
105
285 GR.C
EXCEPT
FITTING
FITTINGS
TYPE
CAPS
CAPS
CAPS
MITRES
REDUCERS
SWAGE
UNION
R = 1.5D
BS-3799
BS-3799
A3A
SHEET 2 OF 3
ITEMS
S
NO.
VALVE
VALVES
TYPE
STUDS
GASKET
BOLTING
GASKET
LOW
HIGH
SCH / THK /
RATING
FACE FINISH /
RADIUS
DIMENSION /
DESIGN /
STANDARD
GATE
SW
00
250
01
500
800
API - 602 / ISO

15761
GLOBE
SW
00
250
01
500
800
BS EN ISO 15761
CHECK
SW
00
250
01
500
800
BS EN ISO 15761
NEEDLE
SW
00
500
01
500
800
BS EN ISO 15761
BALL
RF
00
500
16
000
150
125 AARH
BS EN ISO 17292
GATE
RF
02
000
24
000
150
125 AARH
API - 600 / ISO

10434
GLOBE
RF
02
000
16
000
150
125 AARH
BS - 1873
CHECK
RF
02
000
24
000
150
125 AARH
BS - 1868
WAF
03
000
24
000
150
125 AARH
BS EN 593
BUTTERFLY
DIAMETER RANGE
END /
FACING
MATERIAL
NOTE
DESCRIPTION

STEM: 13% CR STEEL
STEM: 13% CR STEEL
51001
B16.11
52001
B16.11
53001
B16.11
58099
B16.11

BODY, SEAT: RPTFE
TRIM
TRIM
TRIM
TRIM
BOLT STUD
B - 18.2
A193 GR. B7
NUTS
B - 18.2
A194 GR. 2H
M/C BOLT
B - 18.2
BOLT: A307GR.B; NUT: A563GR.B
B-16.20 / B 16.5
B-16.20 / B 16.5

THRMODNMC
MNF'STD
B: A105; T: 13% CR; SS304
Y TYPE
T TYPE
T TYPE
MNF'STD
B: A105; INT; SS304

SPIRAL
SPIRAL
TRAP
PERM STR
PERM STR
PERM STR
00
26
500
000
24
48
000
000
FLGD
00
500
01
500
SW
BW
BW
00
02
08
500
000
000
01
06
24
500
000
000
150 / 5 MM
150 / 5 MM
300 /
125AARH
800
M
M
CODE
A3A
54321
51321
52321
53321
56321
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
FLANGED
TO B16.5
WAFL TO
B16.5
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Examination Requirements
3.4
Extent of Required Examination
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3.5
5.
4.0
Supplementary Examination
Examination Personnel
5.0
Examination
6.0
Types of Examination
6.1
General
6.2
Visual Examination
6.3
Magnetic Particle Examination
6.4
Liquid Penetrant Examination
6.5
Radiographic Examination
6.6
Ultrasonic Examination
6.7
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B 31.3 - 1999.This standard is meant for easy reference by the Inspector to all
requirements of inspection, examination and testing of welding of pipes at one
place and should not be used as purchase requirements for an enquiry or an
order.
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2.1
General
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This Standard distinguishes between examination (see para 3.0) and inspection.
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Inspector.
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It is the Owner's responsibility, exercised through the Owner's Inspector to

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inspect the piping to the extent necessary to be satisfied that it conforms to all
applicable examination requirements of the Code/Standard and of the
engineering design.
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The qualifications of the Owner's Inspector shall be at the discretion of the

Owner.
3.0
EXAMINATION
3.1
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Rights of the Owner's Inspector

The Owner's Inspector shall have access to any place where work concerned
with the piping installation is being performed. This includes manufacture,
fabrication, heat treatment, assembly, erection, examination and testing of the
piping. They shall have the right to audit any examination, to inspect the piping
usi,ng any examination method specified by the engineering design and to
review all certifications and records necessary to satisfy the Owner's
responsibility stated in para 2.2.
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Responsibility for Inspection
Examination applies to quality control functions performed by the manufacturer

(for components only), fabricator or erector. Reference in this Standard to an
examiner is to a person who performs quality control examinations.
3.2
Responsibility
for Examination
Inspection does not relieve the manufacturer, the fabricator or the erector of the
responsibility for:
(a)
providing materials, components and workmanship in accordance with the

requirements of the specification and of the engineering design.
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performing all required examinations; and
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Examination Requirements
3.3.1
General
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Prior to initial operation each piping installation, including components and

workmanship shall be examined in accordance with the applicable
requirements of para 3.0. The type and extent of any additional examination
required by the engineering design and the acceptance criteria to be applied
shall be specified. Joints not included in examinations required by para 3.4 or
by the engineering design are accepted if they pass leak test/pressure test as
per ES 6006.
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For P-Nos. 3, 4 and 5 materials, examination shall be performed after

completion of any heat treatment.
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For a welded branch connection the examination of and any necessary

repairs to the pressure containing weld shall be completed before any
reinforcing pad or saddle is added.
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Defective Components
and workmanship
An examined item with one or more defects (imperfections of a type or

magnitude exceeding the acceptance criteria of this Standard) shall be
repaired or replaced; and the new work shall be reexamined by the same
methods, to the same extent and b:f the same acceptance criteria as required
for the original work.
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Acceptance criteria shall be as stated in the engineering design and shall at

least meet the applicable requirements stated below, in para 6.6.2 for ultrasonic
examination of welds.
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3.3.4
Progressive
Sampling for Examination
When required spot or random examination re\(eals a defect:

(a)
two additional samples of the same kind (if welded or bonded joints, by
the same welder, bonder, or operator) shall be given the same type of
examination; and
(b)
if the items examined as required by (a) above are acceptable, the

defective item shall be repaired or replaced and reexamined as
specified in para 3.3.3 and all items represented by these two additional
samples shall be accepted; but
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if all the items examined as required by (c) above are acceptable, the
defective item(s) shall be repaired or replaced and reexamined as
specified in para 3.3.3 and all items represented by the additional
sampling shall be accepted; but
(e)
if any of the items examined as required by (c) above reveals a defect,

all items represented by the progressive sampling shall be either;
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repaired or replaced and reexamined as required; or
2)
fully examined and repaired or replaced as necessary and

reexamined as necessary to meet the requirements of this
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if any of the items examined as required by (a) above reveals a defect,

two further samples of the same kind shall be examined for each
defective item found by that sampling; and
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Piping in Normal Fluid Service shall be examined to the extent specified

herein or to any greater extent specified in the engineering design. Acceptance
criteria are as stated in para 3.3.2 and in Table 3.3.2 for Normal Fluid Service
unless otherwise specified.
(a)
Visual Examination
At least the following shall be examined in accordance with para 6.2 ;
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1)
sufficient materals and components, selected at random, to

satisfy the examiner that they conform to specifications and are
free from defects;
2)
at least 5% of fabrication. For welds, each welder's and welding

operator's work shall be represented.
3)
100% of fabrication for longitudinal welds, except those in

components made in accordance with a listed specification. See
para 3.5.1(a) for examination of longitudinal welds required to
have a joint factor Ej of 0.90.
4)
random examination of the assembly of threaded, bolted and other

joints to satisfy the examiner that they conform to the applicable
requirements of assembly and erection as per para 7.0 of ES
6004. When pneumatic testing is to be performed, all threaded,
bolted and other mechanical joints shall be examined.
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random examination during erection of piping, including checking

of alignment, supports and cold spring;
Not less than 5% of circumferential butt and miter groove welds

shall be examined fully by random radiography in accordance with
para. 6.5 or by random ultrasonic examination in accordance with
para 6.6. The welds to be examined shall be selected to ensure
that the work product of each welder or welding operator doing the
production welding is included. They shall also be selected to
maximize coverage of intersections with longitudinal joints. When a
circumferential weld with an intersecting longitudinal weld(s) is
examined, at least the adjacent 38 mm ( 1% in.) of each
intersecting weld shall be examined. In-process examination in
accordance with para 6.7 may be substituted for all or part of the
radiographic or ultrasonic examination on a weld-for-weld basis if
specified in the engineering design or specifically authorized by the
Inspector.
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examination of erected piping for evidence of defects that would

require repair or replacement and for other evident deviations from
the intent of the design.
Other Examination
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3.4.2
Not less than 5% of all brazed joints shall. be examined by

in-process examination in accordance with. para 6.7, the joints to
be examined being selected to ensure that the work of each brazer
making the production joints is included.
Certificates and Records
The examiner shall be assured, by examination of certifications, records,

and other evidence that the materials and components are of the
specified grades and that they have received required heat treatment,
examination and testing. The examiner shall provide the Inspector with a
certification that all the quality control requirements of the Code and of
the engineering design have been carried out.
Examination -- Category D Fluid Service
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Piping and piping elements for Category 0 Fluid Service as designated in the
engineering design shall be visually examined in accordance with para 6.2 to
the extent necessary to satisfy the examiner that components, materials and
workmanship conform to the requirements of ASME B 31.3 Code, this standard
and the engineering design. Acceptance criteria are as stated in para. 3.3.2
and in Table 3.3.2 for Category 0 fluid service, unless otherwise specified.
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3.4.3
Examination -- Severe Cyclic Conditions

Piping to be used under severe cyclic conditions shall be examined to the
extent specified herein or to any greater extent specified in the engineering
design. Acceptance criteria are as stated in para. 3.3.2 and in Table 3.3.2, for
severe cyclic conditions, unless otherwise specified.
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The requirements of para 3.4.1(a) apply with the following exceptions
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All fabrication shall be examined.
2)
All threaded, bolted and other joints shall be examined.
3)
All piping erection shall be examined to verify dimensions and

alignment. Supports, guides and points of cold spring shall be
checked to ensure that movement of the piping under all
conditions of startup, operation and shutdown will be
accommodated without undue binding or unanticipated
constraint.
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All circumferential butt and miter groove welds and all fabricated branch
connection welds comparable to those shown in Fig.3.5.4E of ES 6004
shall be examined by 100% radiography in accordance with para 6.5 or (if
specified in the engineering design) by 100% ultrasonic examination in
accordance with para 6.6. Socket welds and branch connection welds
which are not radiographed shall be examined by magnetic particle or
liquid penetrant methods in accordance with para 6.3 0r 6.4.
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In-process examination in accordance with para 6.7, supplemented by

appropriate nondestructive examination, may be substituted for the
examination required in (b) above on a weld-for-weld basis if specified in
the engineering design or specifically authorized by the Inspector.
(d)
Certification and Records
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The requirements of para 3.4(t) apply.
3.4.4
Examination
-Category
M Fluid Service
Piping to be used under Category M Fluid Service shall be examined to the

extent specified herein or to any greater extent specified in the engineering
design.
(a)
Visual Examination
1)
All fabrication shall be examined.
2)
All threaded, bolted and other mechanical joints shall be examined.
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Other Examination
1)
The random radiography/ultrasonic examination requirement of

para 3.4.1(b)(1) apply except that at least 20% of circumferential
butt and mitre welds and of fabricated lap and branch connection
welds comparable to those shown in Fig. 3.5.4(E) and 3.5.5
sketches (d) and (e) shall be examined.
2)
The in-process examination alternative permitted in para 3.4.1

(b)(1) may be specified on a weld-for-weld basis in the engineering
design or by the inspector. It shall be supplemented by appropriate
non-destructive examination.
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Any of the methods of examination described in para 6.0 may be specified by the
engineering design to supplement the examination required by para 3.4. The
extent of supplementary examination to be performed and any acceptance
criteria that differ from tHose in para 3.3.2 shall be specified in the engineering
design.
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3.5.1
Spot Radiography
(a)
Spot radiography for longitudinal groove welds required to have a weld

joint factor Ej of 0.90 requires examination by radiography in accordance
with para 6.5 of at least 300 mm in each 30 m of weld for each welder or
welding operator. Acceptance criteria are those stated in Table 3.3.2 for
radiography under Normal Fluid Service.
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Circumferential Butt Welds and Other Welds

It is recommended that the extent of examination be not less than one
shot on one in each 20 welds for each welder or welding operator. Unless
otherwise specified, acceptance criteria are as stated in Table 3.3.2 for
radiography under Normal Fluid Service for the type of joint examined.
Progressive Sampling for Examination
The provisions of para 3.3.4 are applicable
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Longitudinal Welds
(d)
Welds to Be Examined
The locations of welds and the points at which they are to be examined by
spot radiography shall be selected or approved by the Inspector.
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Hardness Tests
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The extent of hardness testing required shall be in accordance with following

para except as otherwise specified in the engineering design.
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Hardness tests of production welds and-Df hot bent and hot torrne.d.-pjpingare
intended to verify safisfactory heat treatment. The hardness limit applies to the
weld and to the heat affected zone (HAZ) tested as close as practicable (with in
2-3 mm) to the edge of the weld.
(a) Where a hardness limit is specified in Table 3 at least 10% of welds, hot
bends and hot formed components in each furnace heat treated batch and
100% of those locally heat treated shall be tested.
(b) When dissimilar metals are joined by welding the hardness limits specified
for the base and welding materials in Table 3 shall be met for each
material.
Examinations
to Resolve Uncertainty
Any method may be used to resolve doubtful indications. Acceptance criteria

shall be those for the required examination.
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EXAMINATION PERSONNEL
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Personnel Qualification and Certification
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Examiners shall have training and experience commensurate with the needs of
the specified examinations. The employer shall certify records of the examiners
employed, showing dates and results of personnel qualifications and shall
maintain them and make them available to the Inspector.
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Specific Requirement
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For in-process examination, the examinations shall be performed by personnel

other than those performing the production work.
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EXAMINATION PROCEDURES
Any examination shall be performed in accordance with a written procedure that
conforms to one of the methods sp.ecifiedin para 6.0, including special methods
(see para 6.1.2). Procedures shall be written as required in the ASME BPV
Code, Section V, Article 1, T-150. The employer shall certify records of the
examination procedures employed, showing dates and results of procedure
,qualifications and shall maintain them and make them available to the Inspector.
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TYPES OF EXAMINATION
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General
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Methods
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Except as provided in para 6.1.2, any examination required by this Standard,

by the engineering design or by the Inspector shall be performed in accordance
with one of the methods specified herein.
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If a method not specified herein is to be used, it and its acceptance criteria

shall be specified in the engineering design in enough detail to permit
qualification of the necessary procedures and examiners.
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100% Examination: complete examination of all of a specified kind of item in a

designated lot of piping.
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Random Examination: complete examination of a percentage of a specified

kind of item in a designated lot of piping
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Spot Examination: a specified partial examination of eac,h of a specified kind of

item in a designated lot of piping. e.g. of part of the length of all shopfabricated welds in a lot of jacketed piping.
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Random Spot Examination: a specified partial examination of a percentage of

a specified kind of item in a designated lot of piping.
Visual Examination
6.2.1
Definition
6.2.2
Visual examination is observation of the portion of components, joints and

other piping elements that- are or can be exposed to view before, during or
after manufacture, fabrication, assembly, erection, examination or testing. This
examination includes verificati9n of Code and engineering design
requirements for materials, components, dimensions, joint preparation,
alignment, welding, bonding, brazing, bolting, threading or other joining
method, supports, assembly and erection.
Method
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The following terms apply to any type of examination
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Visual examination shall be performed in accordance with the BPV Code,

Section V, Article 9. Records of individual visual examinations are not
required, except for those of in-process examination as specified in para 6.7.
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Magnetic Particle Examination

Magnetic particle examination of welds shall be performed in accordance with
ASME BPV Code,
Section V, Article
7. Magnetic particle examination is not
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Liquid penetrant examination of welds shall be performed in accordance with

ASME BPV Code, Section V, Article 6.
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Radiographic Examination
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Radiography of welds shall be performed in accordance with ASME BPV Code,

Section V, Article 2.
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Extent of Radiography
(a)
100% Radiography
This applies only to girth and miter groove welds and to fabricated branch
connection welds comparable to Fig.3.5.4E, unless otherwise specified in
the engineering design.
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for sizes ~ NPS 2Yl, a single elliptical exposure encompassing the

entire weld circumference;
2)
for sizes> NPS 2%//,the l,asserof 25% of the inside circumference

or 152 mm.
6.6
Ultrasonic
6.6.1
Method
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This requires a single exposure radiograph in accordance with para 6.5.1

at a point within a specified extent of welding. For girth, miter and branch
groove welds the minimum requirement is :
For longitudinal welds the minimum requirement is 152 mm of weld

length.
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Random Radiography
Examination
Ultrasonic examination of welds shall be performed in accordance with ASME

BPV Code, SectionV, Article 5, except that the alternative specified in (a) and
(b) below is permitted for basic calibration blocks specified in T-542.2.1 and
T-542.8.1.1.
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(a)
When the basic calibration blocks have not received heat treatment in
accordance with T-542.1.1(c) and T-542.8.1.1, transfer methods shall be
used to correlate the responses from the basic calibration block and the
component. Transfer is accomplished by noting the difference between
responses received from the same reference refiecturin the basic
calibration block and in the component and correcting for the difference.
(b)
The reference reflector may be a V-notch (which must subsequently be

removed), an angle beam search unit acting as a reflector or any other
reflector which will aid in accomplishing the transfer.
(c)
When the transfer method is chosen as an alternative, it shall be used, at

the minimum:
1)
for sizes < NPS 2/1,once in each 10 welded joints examined.
2)
for sizes> NPS 2/1and < NPS 18/1,once in each 1.5 m of welding
examined.
3)
for sizes> NPS 18" once for each welded joint examined.
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Each type of material and each size and wall thickness shall be
considered separately in applying the transfer method. In addition, the
transfer method shall be used at least twice on each type of weld joint.
(e)
The reference level for monitoring discontinuities shall be modified to

reflect the transfer correction when the transfer method is used.
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Acceptance
Criteria
A linear-type discontinuity is unacceptable if the amplitude of the indication

exceeds the reference level and its length exceeds:
(a)
6 mm for Tw~ 19 mm
(b)
Tw/3
(c)
19 mm for Tw> 57 mm
for 19 mm < Tw< 57 mm
6.7
In-Process Examination
6.7.1
Definition
In-process examination comprises examination of the following, as applicable:

(a)
joint preparation and cleanliness;
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fit-up, joint clearance and internal alignment prior to joining;
(d)
variables specified by the joining procedure, including filler material; and
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(for welding) position and electrode;

(for brazing) position, flux, brazing temperature, proper wetting and
capillary action;
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(e)
(for welding) condition of the root pass after cleaning - external and
where accessible, internal - aided by liquid penetrant or magnetic particle
examination when specified in the engineering design;
(1)
(f)
(for welding) slag removal and weld condition between passes; and
(g)
appearance of the finished joint.
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The examination is visual, in accordance with para 6.2, unless additional
methods are specified in the engineering design.
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ACCEPTANCE
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CRITERIA
FOR WELDS
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Criteria (A to M) for T vpes of Welds, for Service Conditions and for Required Examination Methodsr(Note (1 )l
Normal Fluid Service
Severe Cvclic Conditions
Cateaorv D Fluid Service
Methods T' 'pes of Weld
Methods
TvDes of Weld Method
T IDes of Weld
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Undercutting
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CRITERION VALUE NOTES FOR TABLE 3.3.2
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Criterion
Measure
Symbol
"
CD
C.
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Acceptable Value Limits rNote (6)1
Extent of imperfection
Zero (no evident imperfection)
CD
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Depth of incomplete penetration
~ 1 mm and ~ 0.2 Tw
Cumulative length of incomplete penetration
~ 38 mm in any 150 mm weld length
Depth of lack of fusion and incomplete

penetration
~ 0.2 Tw
Cumulative length of lack of fustion and

incomplete penetration [Note (7)]
~ 38 mm in any 150 mm weld length
Size and distribution of internal porosity
See ASME BPV Code, Section VIII, Division 1,

Appendix 4
Size and distribution of internal porosity
For Tw~ 6 mm limit is same as D

For Tw> 6 mm limit is 1.5 x D
Slag inclusion, tungsten inclusion or elongated

indication
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component surfaces
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1(1) Criteria given are for required examination. Mqre stringent criteria may be specified in
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Longitudinal groove weld includes straight and spiral seam. Criteria are not intended
to apply to welds made in accordance with a standard listed in Table A-1 or Table
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(3) Fillet weld includes socket and seal welds and attachment welds for slip-on flanges.
branch reinforcement and supports.
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(b) For thickness> 2 mm and < 6 mm : 2.5 mm
For external reinforcement and for greater thicknesses, see the tabulation for Symbol
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PRESSURE TESTING OF PIPING
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All installed piping after completion of the applicable examinations, but prior to
initial operation shall be pressure tested to ensure tightness in accordance with the
requirementsof this specification. However, piping built, in conformance with the
ASME Boiler & PV code or Indian Boiler Regulation shall be pressure tested in
complianceof such code or regulations.
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Piping systems open to atmosphere, such as drains, vents, outlet piping for relief
valves discharging to atmosphere and underground sewers shall not require any
pressuretesting. These lines shall be examined visually to determine that all joints
are propertymade up.
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If the test pressure would produce a nominal pressure stress or longitudinal

stress in excess of yield strength at test temperature, the test pressure may be
reduced to the maximum pressure that will not exceed the yield strength at
test temperature.
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(b) Test Fluid Expansion

If a pressure test is to be maintained for a period of time and the test fluid in
the system is subject to thermal expansion, precautions shall be taken to
avoid excessive pressure.
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(c) Preliminary Pneumatic Test
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may be made prior to hydrostatic testing to locate major leaks.
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Other Test Requirements
(a) Examination for Leaks

Test pressure during leak/pressure test shall be maintained for at least 10
min. and all joints and connections shall be examined for leaks.
(b) Heat Treatment
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Leak te~ts shall be conducted after any heat treatment has been completed.
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The possibility of brittle fracture shall be considered when conducting leak

tests at metal temperatures near the ductile-brittle transition temperature.
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(a) PipingSubassemblies
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test need not be tested.
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The final weld connecting piping systems or components which have bee'
successfully tested in accordance withthis engineering standard need not be>
leak tested providedthe weld is examined in process in accordance withpara
344.7 of ASME B 31.3 (para 6.7 of ES:6005)
and passes with 100%
radiographic examination in accordance with para 344.5 of ASME B 31.3
(Para 6.5 of ES 6005) or 100% ultrasonic examination in accordance with
para 344.6 of ASMEB 31.3 (Para 6.6 of ES 6005).
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3.1
All joints, including welds and bends. shall be left uninsulated & exposed for
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examination during leak testing, except' that joints previously tested may be
insulated or covered. Alljoints may be primedand painted only after leak testing.
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(a) The internal line shall be leak tested on the basis of the internal or external
design pressure, whichever is critical.This test must be performed before the
jacket is completed if it is necessary to provide visual access, to joints of the
intemalline.
(b) The jacket shall be leak tested on the basis of the jacket design pressure
unless otherwise specified in the engineeringdesign.
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Externally Pressured Piping

Piping subject to external pressure shall be tested at an internal gauge pressure
1.5 times the external differential pressure, but not less than 105 kPa (15 psi).
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Special Provisions for Testing
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Major equipment, such as compressors, pumps, vessels and exchangers shall be

isolated from pipe line during hydrostatic test. When necessary for practicability.
exchangers and vessels may be included with the connected piping provided the
piping test pressure is within the allowable cold pressure limits of the equipment.
3.3
All air present in the system to be tested shall I;)evented while admitting the test
fluid.
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Lines containing check valves shall have source of test pressure on the up-stream
side.
3.7
Valves shall not be subjected to a test pressure in excess of manufactures

allowable test rating. When permitted, the installed valves shall be kept open.
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Relief valves shall be excluded from the test and shall be suitably blanked off.
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Orifice plates in horizontal lines shall not be installed till completion of test.
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Control valves shall not be field tested. All flanged control valves shall be removed
before hydraulic testing of the pipe lines. Welded end control valves shall be welded
after hydraulic test, cleaning and blowing.
Indicating 'pressure gauges mounted locally may be tested /with the lines provided
the test pressure is not in excess of their scale ratings.
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Instrument take-off piping up to the first block valve shall be tested with piping to
which it is connected. Testing of remainder of lead line ,upto instrument can also be
done at the same time provided instruments are blocked 9ft from source of pressure
and vented to atmosphere.
3.10
The test shall be carried out at ambient temperature and the water temperature shall
not be less than loCo
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HYDROSTATIC LEAK! PRESSURE TEST
4.1
Test Fluid
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The fluid shall be water unless there is the possibility of damage due to freezing or to
adverse effects of water on the piping or the process. In that case another suitable
nontoxic liquid may be used. If thd liquid is flammable, its flash point shall be at least
49C and consideration shall be given to the test environment. Hydrocarbons shall
not be permitted for Oxygen service.
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Instruments, expansion joints, filters etc., for which the maximum permissible cold
test pressures are lower than the specified hydrostatic test pressure for piping, shall
be isolated and excluded from the test.
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Pipir.g designed for vapour and gas shall be provided with additional temporary
supportsif necessary, to support the weight of test fluid.
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Hydraulic testing of ferritic material shall preferably be carried out using suitably
inhibited water, which permits an extended period between the start of testing and
drying of components. Alternatively, uninhibited water may be used but the permitted
period between the start of testing and drying of components is reduced.
Hydraulic testing of austellitic material shall preferably be carried out using
de-ionized water, chlorine c.ontent of water shall not exceet 5 ppm.
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Water Quality
4.3.1 Ferriticparts and ferritic parts associatedwith non-ferrou5-parts :
The water shall be towns main supply free from oil and suspended mater. If this
water is to be inhibited, one of the inhibitors as specified below shall be added.
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Water shall be deionized water having a conductivity not greater than 1 micro
mho/cm at 25C. In case of works testing of unerected components, towns main
water free from oil and suspended matter may be used.
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The period between the start of testing and drying a component shall not be longer
than 48 hours in case of inhibited water and 4 hours in case of uninhibited water.
Where difficulty may be experienced in draining and therefore' in achieving the
drying specified above, drying shall be accomplished in as short a time as is
practicable.
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4.4
Test Pressue
Except as provided in para 4.5, the hydrostatic test pressure at any point in a metalF
piping system shall be as follows:
II
(a) Not less than 1% times the design pressure;

(b) For design temperature above the test temperature, the minimum test pressure
shall be calculated by following equatiPn except that the value of Sr / S shall not
exceed 6.5 ;
Pr = J.5PSr
S
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P = internal design gauge pressure

Sr = stress value at test temperature
S = stress value at design temperature
(c) If the test pressure as defined above would produce a stress in excess of the
yield strength at test temperature, the test pressure may be reduced to the
maximum pressure that will not exceed the yield strength at test temperature.
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PDIL
PRESSURETESTING OF PIPING
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(a) Where the test pressure of piping attached to a vessel is the same as or less
that the test pressure for the vessel, the piping may be tested with the vessel
at the piping test pressure.
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(b) Where the test pressure of the piping exceeds the vessel test pressure, and it
is not considered practicable to isolate the piping from the vessel, the piping
and the vessel may be tested together at the vessel test pressure, provided the
owner approves and the vessel test pressure is not less than 77% of the piping
test pressure calculated in accordance with para 4.4(b).
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1"8
Lines at Atmospheric Pressure

All liquid lines at atmospheric pressure (~ 1 Kg./cm2g)shall be tested hydrostatically
at 2 Kg/cm2g.
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5.0
PNEUMATIC LEAK! PRESSURE TEST
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Piping may be tested pneumatically if these cannot be safely filled with water or
where traces of water cannot be tolerated or if these have been previously tested
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Pneumatic testing involves the hazard of released energy stored in compressed gas.
Particular care must therefore be taken to minimize'.the chance of brittle failure
during a pneumatic leak test. Test temperature is important in this regard and must
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be considered when the designer chooses the material of construction.
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Pressure Relief Device
A pressure relief device shall be provided, having a set pressure not higher than the
test pressure plus the lesser of 345 kPa (50 psi) or 10% of the test pressure.
Test Fluid
The gas used as test fluid, if not air, shall be nonflammableand nontoxic.
Test Pressure
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The test pressure shall be 110% of design pressure.

Procedure
The pressure shall be gradually increased until a gage pressure which is the lesser
of one-half the test pressure or 170 kPa (25 psi) is attained, at which time a
preliminary check shall be made, including visual examination of joints. Thereafter,
the pressure shall be gradually increased in steps until the test pressure is reached,
hol~ing the pressure at each step long enough to equalize piping strains. The
pressure shall then be reduced to the design pressure before examining for leakage
in accordance with para 2.2.
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Lines at Atmospheric Pressure

All gas lines at atmospheric pressure ( ~ 1 Kg/cm2g)shall be tested pneumatically
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Lines in vacuum services shall be hydrostatically tested at a minimum internal

pressure of 1.5 Kg/cm2g unless limited to a lower value by design. Where it is not
possible to test hydrostatically, the pipe lines shall be tested pneumatically at'1
Kg/cm2g.
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SENSITIVE LEAK TEST

The test shall be in accordance with the Gas and Bubble Test method specified il.
the BPV Code, Section V, Article 1O, or by another method demonstrated to have
equal sensitivity. Sensitivity of the test shall be not less than 10-3atm.ml/sec under
test conditions.
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B
:>
'8
I~
i 5
a) The test pressure shall be at least the lesser of 105 kPa (15 psi) gage, or ?C>%
or the design pressure.
- //
I~
1'0..
b)
I~
s:!
-0
c:
"0
c:
<0
:::J
jg
8.0
i~
1=
I ,
i-g
1=
I ~a.
0
REPAIRS OR ADDITIONS AFTER LEAK TESTING

If repairs or additions are made following the leak test, the ,affected piping shall be
retested, except that for minor repairs or additions the owner may waive rete".
requirements when precautionary measures are taken to assure soun.
construction.
I;
I ,-
The pressure shall be gradually increased until a gage pressure the lesser of
one-half the test pressure or 170 kPa (25 pai) is attained, at which time a
preliminary check shall be made. Then the pressure shall be gradually
increased in steps until the test pressure is reached, Hie pressure being held
long enough at each step to equalize piping strains.
9.0
TEST RECORDS
QJ
c(!
.!!I
u
QJ
'eo.
j'O
ril Ii~
a.
QJ
~I
.-
N
c:
C;
C)
C)
C)
Cj'
CI:
W
CD
~
~
.,Z
~
~
""
:;
.!!!
c:
Records shall be made of each piping ~ystem during the testing, including:
a)
b)
c)
d)
e)
f)
Date of Test
Identification of the piping tested.
Test Method
Test Pressure and duration
Certification of results by examiner
Approval by the Inspector
"0
II)
:c
I-
~r
ES - 6007
ISSUE : JAN. 98
1 OF 4
LEAK TESTING OF PROCESS PIPING
JAN.98
REV.
DATE
FOR IMPLEMENTATION AND

COMMENTS IF ANY
PURPOSE
DKM\DAYTODAY\STANDARD\ES6007COVER.LWP
PREPARED
REVIEWED
APPROVED
PDIL
ES : 6007
ISSUE : JAN.98
SHEET 2
OF 4
1.0
SCOPE
1.1
The leak test is not a substitute for the pressure (strength) test. Leak-testing
shall be conducted for detection of leakage and to insure a tight and leak free
system for operation.
1.2
Leak-testing shall be carried out when specified in the piping specification and
generally shall include the following services:
a)
b)
c)
d)
e)
f)
g)
Toxic or Flammable Gases.

Toxic or flammable liquids.
Explosive Acid System
Strong Acid System
Refrigeration System
Oxygen System
Anhydrous System
1.3
In all cases, where leak-testing is specified, the type of test to be conducted

shall be determined by the PDIL. All leak-testing shall be conducted at
ambient temperatures (between 15O to 30O C) in cresence of PDIL Authorised
Inspector.
1.4
Before any leak-testing is performed, the piping shall have been cleaned and
inspected for clean liness. All lines which would be subjected to leak-testing
shall be blown out with dry, compressed air, prior to testing.
2.0
TEST METHOD
2.1
The following test methods shall be included in this specification:

a)
b)
c)
d)
Ammonia with leak detector

Halide Leak Detector
Pneumatic with soap indicator
Vacuum
3.0
TEST PRESSURE
3.1
The test pressusre, applicable in the cases of leak detection by means of

Ammonia, Haldia and Pneumatic with soap indicator methods shall be half of
the allowable working pressure in the system but not exceeding 3.5 Kg/cm2g.
DKM/DAYTODAY\STANDARD\MECH\ES6007.LWP
PDIL
ES : 6007
ISSUE : JAN.98
SHEET 3
OF 4
3.2
The maximum operating pressure of a system shall necessarily be the

maximum allowable pressure of the weakest link in the system which is to be
determined after investigating all the Rupture discs, Instruments, Seals,
Bellows, Expansion Joints Pumps, Blowers and Compressors etc. As the
pressure is being established, the system shall be checked for gross leaks,
holding at the test pressure for at least an hour. All gross leaks shall be
specified until the pressure remains sustantially constant without further
addition of air.
4.0
TEST PROCEDURE
4.1
Ammonia with Leak Indicator

Ammonia vapour shall be introduced into the piping with all ends closed until
the specified test pressure is reached and maintained. Leaks shall be located
by burning Sulphur, sticks or rags soaked in commercial Hydrochloric Acid
close to the joints, when a cloud of smoke would indicate a leak.
Alternatively, all the joints, glands, seals, valve bonnets etc. shall be liberally
applied with a mixture of Phenophthalcin solution, Glycerine, water and
Titanium Oxide made upt to a paint consistency, when a pink colouration
would indicate a leak.
4.2
Halide Leak-detector
After estimating the capacity of the system, misture of Freon 12 (or equivalent)
and air shall be introduced into the piping with all ends closed, until the test
pressure is reached. Approximately one ounce of refrigerent for a every cubic
meter colume of piping shall be required. The general area then should be
tested for leaks by means of a General Electric type H-I leak detector set.
All joints, packing glands and seals shall be tested with the probe held about
15 mm from the surface being tested and at a rate of 15 mm per second. In
case, General Electric leak detectors are used the amount of refrigerent to be
used and the test procedure shall be in accordance with the suppliers
recommendations.
4.3
Pneumatic with Soap Indicator
PDIL
ES : 6007
ISSUE : JAN.98
SHEET 4
OF 4
After closing all open ends, the system shall be filled with air compressed to
an maintained at specified test pressure while under pressure, each joint,
welded or screwed, shall be coated with aprepared soap solution. Leakage will
be indicated by formation of soap bubbles. Masking tape shall be applied over
all flanged joints before applying the soap solution.
The composition of the soap solution shall be follows:
1 oz. Powder Soap
16 oz. Water
8 oz. Glycerine
4.4
Vacuum Test
Leak testing for sub atmospheric pressure system shall be conducted with the
Refrigerent or Ammonia Vapour at atmospheric conditions provided around
the joint in a suitable sponge rubber sealed casing and the system shall be
partially vacnated. The cacuum reached in the system shall be half the
operating vacuum but not less than 150 mm of water. Leaks would be
indicated at the exchauster discharge either by Halids detectors or by
burning Sulphur sticks or rags soaked in Hydrochloric Acid.
5.0
RETESTS
When a leak is detected, the same shall be marked, repaired and the test
shall be repeated until the system is free of leaks.
6.0
TEST RECORDS
Records shall be maintained for each piping system being subjected to leaktestisng. The records shall include:
a)
b)
c)
d)
e)
Date of test
Identification of the piping tested
Test method
Test pressure
Approval by the Inspector
FEB. 78
ES
6010
P.D.I.L.
pJl
Qualification of Welding Procedure And 'Welder
BARODA
Performance
1.0
SCOPE
--
1.1
covers welding
This specification
operator performance qualification
1.2
Qualification
SHEET 1 OF
For Piping
procedure qualification
and welder and welding
for steels and Nickel alloys piping systems.
tests covered by this specification
shall be conducted
in presence of POlL
Representatives.
1 3
Welding
technique
and filler materials used for qualification
shall be in accordance with
our ES 6004, 6005.

This specification is generally in accordance with
ASME Code 011 Boin::;:;; and Pressure Vessels.
2.0
2.1
2.2
PROCEDURE
and SECTION IX of
QUALIFICATION
Scope of procedure qualification tests is to check whether with a given base material,
filler material and joint position, the welding PTQcedure can ensure the required characteristic for the joint concerned (for the various thicknesses to be welded). Therefore
the main elements which are involved
in the qualification
of a given procedure are
as follow" :
-
base material
filler material
joi nt position
thickness to be welded
welding
technique
For the base
material
separate qualilication
and parameters.
the following
0 - C.-Mo steel with 2 :::% Cr

E
F
G
H
groups
are
co:1sidered
and for each of them a
is required:
A - Carbon steel
G - Carbon - Moly steel (0.5%
C - Cr-Mo steel with % Cr ,2
M)
,
:::;
Cr-Ni austenitic steels

IT Carbon steels
Ni-Steels
Ni-Alloys.
Separate qualification is required

oned groups. Separate 4ualification
2.3
ANSI-B-31.3
For each type and make of

qualification shall be required.
for every material not included in the above-mentiis also required for joints betwp.en dissimilar materials.
electorode
or
However, this requirement may be waived if

from approved list as prepared by POlL
-'
wire (or
combination
thereof)
Separate
the electrodes or filler wires are selected
15
p8d
ES
6010
PoDoLL.
Qualification
BA:'iODA.
:: 4 Procedure qualification
il
rolled pipe with
of Welding Procedure And Welder

Performance
For Piping
shall be made for the three
pipe
with
its uxis
horizontal
c - fixed
pipe
with
its axis
vertical
for position
The qualification
a deviation
tions
a qualification
not
morethan
is required
Usu,Jlly. qu"lification
main welding
OF 15
positions:
its axis horizontal
b - fixed
with
following
SHEET 2
"b"
is valid
also for
position
15 degrees from the horizontal

for
position
"a"
and also
for a pipe
plane, For larger devia-
"C",
test welds are in position
"b"
and "c",
2,5
Each qualification
covers a given thinckness range, according to para 2,8,1 (where
11Cccssary. saparate test welds on more thickness will therefore be made). for auto!l1iJtic or semiautomatic
welding, a separate qualification
for the minimum size to
be Wdul::u may desired,
2.G
T(~5t
Technique
Weld
2.G.1 For procedure

qualifications,
chJraclenstics :
- nwttrial
test
welds shall be made on pipe studs with following
of the same type as used in the work:
- size iJnd thickness
suitable
to the
thickness
,
range
for which
required (see
para 2.8,1). For arc welding,
size lessthap
less than 9.5 mm are generally not recommended.
th'e qualification
is
ON 125 and thickness
- Length of test pipe shall be sufficient

to carry out the tests as shown at para 2,7.
Preferably 150 mm length pieces shall be selected.
2.6.2 End preparation and piece alignment shall be same as in piping work. Both pieces to
be welded shall be clamped together so as to prevent shifting during weld shrinkage.
2.6.3 The pieces to be welded shall be fixed in the position for which the qualification is
desired as in para 2.4 and SII..,11not be removed from such position before completion
of welding.
;
2.6.4
Filler
material, welding
equipment and technique (including any preheating and heat
treatment) shall be the same as used in actual pi"ping job,

During the execution of the welding, the following date shall be taken for each
(lna recorded I-oroperiy :
pass
- current
- arc voltage ( for automatic welding only)
- welding
speed
size, trade
( for automatic welding only)

lot number of electrodes or
name and
( if used)
- number of passes
- flow rate and type of inert gas ( if used)
- type of protective
gas inside the pipe (~f used

~._'~~
).
WIleS, as well
as type of flux
STANDARD
ENGINEERING
ES
6010
P .D.LL.
pJd
Qualification
BARODA

Performance
For Piping
SHEET 3 OF 15
This record shall also show the data concerning preheating and heat treatment, if
illlY.
2.6.J
A recording
of heat treatment
( if any)
Any test weld shall be suitab1y marked
shall bcl made.
and stamped by the Inspector cn the places
where the specimens are to be removed ( Ref, PDS : MT-202

2.7
2.7.1
Tests to
be
made
for
procedure
).
qualification
"Standard" test shall be performed in all cases. In addition to these "standard"

tests,
other tests are required for low alloy and alloy steels, for low-operating-temperature
piping CJnd fOr automatic or sellilautomatic welding.
The zones where
the
specimens
are
to be cut, shall be practically free of defects
, r<ldiography examination oi ,l,e pipe may help);

silJl1 be done to prepare test sample.
2.7.2 Stilndard les,s
.
for thickness below 10mm
otherwise,
the two
test welding
visual examination
x .rilY examination
- two reduced section tenslcn

-- two face bends
- two root bends
tests
Where the pipe size does not allow to carry out all the test with the one test weld
the specimens srJdd be out from the second test welds.
2.7.3
Standard Tests for thickness
10 mm and over:
visual examination
X-ray examination
tliVOreduced section tension tests
,.
four side bends
Where thickness of test pipe is less than 19 mm, the two side bends may be replaced
by tWO face bends and two root bends, as per clause 2.7.2
2.7.4
Besides standard tests, the following ~hall be made for Cr-Mo steels:
- macro examination
Hardness
test;:;
2.7.5 Besides standard tests, the following

and Nickel alloys:
2.7.6
Dye penetrant
tests shall
exCJmination ( possibly also on intermediate
Besides standard tests. the following

temperature below - 10C.
tests
- Charpy V-notbh impact test at specifisd

subjected to heat treatment
~~
".
be made for austenitic

runs
stainless steels
).
shall be made for piping with operating
temperatl,lre, when the welded joints are not
p8d
ES 6010
P.D.I.L.
Qualification of Welding Procedure And Welder

Performance For Piping
BAI10DA.
SHEET4 OF15
2.7.7
Besides standard
matic welding:
tests,'
the
followi ng tests shall be made for automatic
- Charpy V-notch
impact test
- macro examination
at ambient
temperature
- chemcal analysis on the weld for determination

determination of Cu.
- All-Well-Metal
2.7.8
( if required)
of C, Mn, Si and for short arc, for
Tension test, if required.
When the filler material is not of approved

besides the standard tests:
- All-Weld-Metal
quality, the following
tests shall be m<1de
Tension test
- Charpy V-notch impact test ( if required)

- Chemical analysis (for
low-alloy
and alloy steels only ) for the
the alloy eleme'll::;.
In particular
cases,
chardCltm::.tics
or semiauto-
further
(ferrite
special
tests may
percent, corrosion
be
required
to
determi nation of
assertain
pmticul()rs
resistance, tendency to cracks etc.)
,
28
2.8.1
Exter t of Procec'ure
Tests made on pipe
Qualification
with
thickness
given thickness
ranga
"S"
which
the procedure
type to be qualified.
(a)
and
diamater
rp, qu~lifY
either
upon "s"
to the following:
the
and
Manual shielded
matal arc welding or automatic
welding
inert -gas tUngesten-are welding or oxy-acetylene welding) :
procedure
1>. values,
in a
or upon
(root pass made by
S::: 2s
When rp < 125 mm, S shall be < 19 mm.
(b)
Complete oxy-acetylene welding or inert-gas tungsten-arc

matic shielded metal arc weldirtg :
sJ2 ~S~
2.8.2
"s"
depends
accordollg
welding or semiauto-
s.
When changes
of the
dure, a new welding
following
types are made with respect to the qualiii,;u proceprocedure qualification
shall usually be made.
a) Change in type of filler material. A new qualification is particularly required. when,

although the chemical composition
of the weld metal remains unchanged, the
electrode coating type changes
(such
as from high-cellulose coating electrode E
6010-11
or E 7010-11,
into low hydrogen coating electrodes E 6015-16 or E
7015-16)
or in the submJlged
are welding,
b) Change in base material from one group to

c) Change in the position
the qualification.
.. .-.
flux
composition
is changed.
another.
of the pipes to.- be welded,
into position
not covered by
..
,-: 4' ,.. ,
ENGINEERINGSTANDARD
JBl
P.D.I.L.
ES
6010
BARODA
Performance
d) Remarkable changes in the following
SHEET 6 OF
For Piping
items:
- End preparation
- Piece alignment
- Welding variables
-
Preheating
temperature
- Postweld' heat treatment procedure or temperature

- Composition of inert gas ( if used)
- Presence and composition
of protective gas in pipe inside (if used).
e) Change in welding process or in welding technique (upward or downward).

f) Thickness not covered by qualification.
3.0
WELDER
3.1
Qualification
3.1.1 Welder
PERFORMANCE
QUALIFICATION
Type
performane
perform
qualification
tests have the purpose to ascertain welder ability to
the required
characteristics,
using a given welding pro::edure
qualified)
and a given filler material, in given position, a given thickness.
welds
( previously
with
There shall be different welder Qualification types. depending upon the following factors:
- Welding process
- Filler material
- Thickness to be welded
- Welding position
3.1.2 For each welding process listed hereinafter
a separate procedure qualification is required
a) Shielded metal arc welding.

b) Oxy-acetylene
welding.
c) Inert-gas tungsten-arc welding (TIG.)
d) Semiautomatic
welding
protective gas.
3,1.3 The filler
material
is subdivided
into several groups and for each of them a separate
qualification
is normally
required (except when otherwise specified)~
For the use of
filler materials belonging to the same group, only one rate qualification may~ be made
for any of them (however, a separate
qualification
is required
for the electrodes
used with downward technique). Such groups are defined in the two following tables.
ELECTRODES
Group
. ',' ~
~; ,::'-;'
Coating
Type
1.
2.
High-cellulose
Low- hydrogen
3.
4.
5.
Low-hydrogen
Low-hydrogen
Neutral or high-titania
~omposition
of Weld Metal
Carbon or Carbon-Moly
Steel (0 '5%' No~
Carbon or Carbon-:-Mo.IY Steel

or Ni Steel with % Ni < 2
Cr-Mo Steels with % Cr ::: 5

Cr-Ni Austenitic Steel
Cr-Ni Austeflitic Steel
15
p8d
ES 6010
P.D.I.L.
BAHODA.
Qualification

Performance
For Piping
SHEET 6 OF 15
Where not otherwise specified,

Group 2 qualification involves the performance of
root pass with high-cellulose electorode and covers Group 1 qualification (thewhole
welded by high cellulose electrode ).
Where not otherwise
specified,
Group 3, 4, 5 qualification concerns filling only.
- Qualification for Group 4 is valid also for Group 5 but not viceversa.
- A separate qualirication is required for evt::IY elt>I.:Llodetype not included in this
Table. Qualification for 7% Cr 9% Cr steel covers anyway Group 3.
WIRES
Group
11
12
13
Composition
of Deposited
Metal
Carbon or Carbon-Moly Steel (0.510

Cr-Mo Steels with % Cr ::: 5
Cr-Ni Austenitic Steel
Mo)
- Welding process shall be specified in qualification record.

- A separate qualification is required for every wire type not included in this Table.
Qualification for 7% Cr and 9% Cr Steel covers anyway Group 12 and 11.
3.1.4 Where root pass and filling are made with different welding processes (i. e. TIGGroup 12 and electrodes Group 3) qualification either for the complete weld ( by
one welder), or for root pass only and filling only ( by different ,welders with the
same test weld), may be obtained. This applies for Group 3, 4, 5, 11, 12, 13.
As for performance qulification
for filling only, test' 'field with backing ring
may be made.
3.1.5 A welder qualified for filling on Cr-Mo steel (with low-hyd.rogen electrode) may be
LJllowedto perform filling with low-hydrogen electrodes of Group 2.
3.1.6 Each qualification covers a thickness
which the test weld has been made
in par. 34.1.
range depending upon the pipe thickness on

in accordance
with the requirements otlined
3.1.7 Qualification for Groups 3, 4, 5 on thicknesses

morethan 5 mm. may be accepted
also for lower thicknesses
whe'" the welder has previously obtained qualification on
such thicknesses for Group 2.
3.1.8 For gas metal-arc semiautomatic welding, a separate qualification can be required
for the minimum pipe size to be welded.
3.1.9 Separate test welds shall be made in the following welding positions:
fixed pipe with its axis horizontal

fixed pipe with its axis vertical
Qualification for fixed pipe with its axis horizontal covers also rolled pipe, or pipe
with angular deviation not more than 15 degrees ficm the horizontal plane.
ENGINEERING
STANDARD
ES
P.D.LL.
fBl
BARaDA
3.2
Welding
Uucwtication

Performance
For Piping
6010
SHEET 7 OF
Technique.
3.2.1 Test welding for welder performance

witl! following characteristics:
_. Material of tJ composition
qualification
shall be
made on pipe sections
similar to that of the filler material.
- Thickness suitable to the thickness range for which the qualification is requested
( in accordance
with para 3.4.1 ) and suitable size (for bend tests). As a rule
te5t welds will be performed on ON 150 size ( or over) with thickness>
5 mm
and/or ON 50 (or less) for thickness < 5 mm.
-
100 mm length
3.2.2 EmJ preparation
(after
bevelling)
for each pipe section.
and pipe section coupling for welding shall be as in the work.
3.2.3 The pipe sections to be welded shall be placed and fixed in the position for which
qualification is desired. They shall not be removed from such position before COmpletion of welding.
3.2.4 Filler material, welding equipment and technique
blJ sill.ilar to those used in the work.
(including
preheating if any)
shall
3.2.5 As i1 rule, a complete test weld (on the whole circumference, shall' be made for
each position or qualification type, unles otherwise specified for size greater than ON 200.
3.2.6 All test weld shall be marked
specimens are to be removed.
3.3
Tests to be made
and stamped by the Inspector at the points where the
for welder performance
qualification
3.3.1 According to the thickness of the pipe on which the test weld has been performed
iJnd to the wtJlding process used the following tests shall be done:
3.3.2 For oxy-acetylene
welding:
- Visual examination
- One face bend
- Three root bends
- X-ray examination ( if required)
For small size pipes, reduced with specimens may be used.
3.3.3 For metal are welding
Visual examination
- X-rt1Yexamination
- Two face bends
- Two root bends
on thicknes~,es below 10 mm :
15
ES 6010
P.D.I.L.
{J8Ii
Qualification
BARODA.
of Welding
Performance
When pipe
required
Welder
SHEET 8
OF 15
is below 5 mm and pipe size is below ON 65 and the welder
thickness
is already qualified
visual examination
Procedure And
For Piping
for higher thicknesses

with the same filler material, a complete
(also
inside, after sectioning')
and/or X-ray examination
(if
by the Inspector).
3.3.4 For metal arc welding
may be enough.
on thicknesses
10 mm and over:
- Visual examination
- X-ray examination
- Four side bends
If root are filling
passes are not made with the same filler material or' with the
same welding process, two of the side, bends shall be replaced by two root bends.
For thicknesses
below 19 mm the side bends may be replaced' with face and root
bends ( as provided
in Par 3.3.3).
3,3.5 For metal arc welding on pipe with its axis vertical, instead of four bends tests as
per Par. 3.3.3 and 3.3.4, ~[only two of them made, provided that the root pass and
the filling passes are made with the same type of filler material.
33.6 Where the required X-ray examinations
are not practicable, it shall be replaced with
two bend load fractureJ[ tests on each test weld. In such case all, Dend tests shall
be made.
3,3.7 The presence of fish eyes is not a reason for test rejection. Therefore, in the case of
welding of carbon steel, it is advisable to hold the bend and,'fractur~ test specimens
at a temperature of 200 to 300C for not less than 8 hours; iil order to allow the
elimination of the diffusible hydrogen.
3,3,8 Where a welder fails in one or more tests, as a rule he 'shall carry out two further
similar test welds, on which
all the qualification
tests shall be made. Should 'same
results be still negative, the welder may undergo a new qualification examination only
after an adequate training,
Other tests (e. g. dye penetrant for Nickel alloys, impact tests for low-operatingtemperature piping)
can be required in particular cases, to be considered each
time
3,1]
separate
Iy.
Range of qualification
for we!der
performance.
3.4.1 The weld test made on pipe with thickness "5" qualifies the welder for a gIven ~hickne5s
range "S" which depends upon either the value of "5" or the type of welding
process, as follows:
a) Shielded
"
...
..'
,".,
.
r. -
metal are welding:

for
::: 2s
s ::: s
5 mm ::: S ::: 25
S ~ 5 mm
< 5 mm
for 5::: s ::: 19 mm

for
s > 19 mm
"'
-,
. ..
.' '..
STANDARD
ENGINEERING
p8d
ES 6010
P.D.I.L.
Qualification
BAkODA.
b) Oxy-acetylene

Performance
For Piping
SHEET 9
OF 15
welding, or CO2 gas welding, or inert gas welding:
for s > 2.5 mm

for s :5 2.5 mm
2.5 mm :S S :S s
S = s
The qualification for TIG welding shall

pJSS made by TIG.
3.4.2 If during the work, the following
the welder shall be requalified.
iI) A change of welding
be also valid for all thicknesses for the root
changes
are made (to the qualified procedure)
process or welding technique
b) A change of filler material

indicated in par. 3.1.3.
involving
passage
(upward or downward).
from one to another of the groups
c) A change of base material, requiring a change of filler material from one to another
of the groups mentioned at par 3.1.3.
J.4 3 Renewal of qualification
<l) The welder
has not
in the following cases may be desired if :

used the specific process for three months or more ( in this
C<lse it will be sufficient to repeat the qualification for one thickness , only, and thus
the whole thickness range of the preceding qualification will be, covered ).
b) The welder has left the Company where he was employed at time of qualification.
c) There are reasons
qualification.
4.0
TEST
PROCEDURE
'U
Operation
to question
AND
his ability
in perforr:nin'g welds according to his
TECHNIQUE
sequence on testweld
4.1.1 Visual examination shall be made during and at the end of welding for preparation of
test sample for welding procedure and welder's performance qualification tests.
4.1.2 X-ray examination and if requiredt dye penetrant examination are performed. In particular cases X-ray examination is made after post-weld heat treatment.
'...1.3 Postvlield heat treatment,
to those followed during
where required,
the work.
is then
carried
out,
with procedure
similar
During such heat treatment, temperature recording over 300C shall be made, and
relevant recording chart shall be signed by POlL Inspector.
4 1.4 Specimens for the destructive tests as indicated for each case ( for the various qualification types ), shall then be removed. Such removal shall be made at the positions
as shown in PDIL : MT : 202.
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ENGINEERING
STANDARD
ES
P.D.I.L.
p8d
Qualification
BARODA
Each
the
specimen
shall be suitably
SHEET 10 OF
marked by stamping and shall also be stamped
by
Inspector.
4.1.5 The certified

be compiled.
4.2

6010
results of tension,
impact
tests and of chemical analysis, if any, shall
Test technique
4.2.1 The destructive
test procedures shall be as outlined below:
<I) Face Bend:

The specimen is shaped and sized as shown in PDS : MT : 200 and machined at
root surface to the required thickness; at face surface, only the weld reinforcement
is ground flush with the base metal. If the specimen has been flame cut, it is
recommended to grind off the cut surfaces. Corners shall be rounded off.
The specimen
is subjected
to a 180"
guided
bend
with its face outwards,
using
the equipment shown in PDS : MT : 201 and its convex surface is then examined.
In particular cases, where there is a difference of characteristic between base
metal and filler material, or between two different base metals, the specimen shall
be cut longitudinally
b) Root
to the weld.
Bend:
The specimen is shaped and sized as shown in PDS : MT : 200 and machined at
the face surface to the required thichness; at root surface, only weld reinforcement
is ground off flush with base metal.
If specimen
was flame cut, it is recommended
to grind off the cut serfaces.
Corners shal,l be rounded. off. Specimen is subjected to 1800 guided bend with
root outwards, using equipment. as shown in PDS : MT : 201 and convex surface
is then examined. In particular cases, the sepecimen shall be cut longitudinally
;
c) Side Bend:
The specimen is shaped and sized as shown in PDS : MT : 200 machined on
both opposite sides corresponding to surfaces along which the weld was cut, and
weld reinforcements at face and root are gruond off flush with base metal. Corners shall be rounded off.
Specimen
described
is subjected
to 1800 bend along axis of weld, using the equipment
in PDS : MT : 201 and convex surface is then examined.
d) Reduced Section
Tension Test:
The specimen, shaped and sized as shown in PDS : MT : ~OOis fl.attened on
..1
15
{J8d
P.D.I.L.
BARODA.
ES 6010
I
'

Performance For, Piping
face and root just to have flat surface

machined along this length.
.'
SHEET 11 OF 15
in the reduced section. Side surfaces are
Specimen is ruptured under tensile load by a special equipment. Teflsile strength

is then computed (dividing the maximum load before rupture, by the cross-sectional area of specimen surface at the rupture point as measured before load is applied).
e) Fracture
Test:
The specimen is shaped and sized

cut at sides of weld by hacksaw.
as shown in PDS : MT : 200 with notches
The specimen is fractured by bending, so that onD notch is in tension and the
other is in compression (bend test equipment shown in PDS : MT : 201 may be used).
Practure surfaces are then examined.
'
f) Charpy U-Notch
Impact
Test:
The specimen is sized and shaped as shown in PDS: MT : 211 and notch cut,
in the weld zone.
For each test-weld a minimum of three specimens, or a ,nultiple of 1hree, is required
Specimen surfaces shall be obtained by machining.
'
Specimen is subjected to fracture at required temperature (within five seconds
from extraction from cold bath, if any) by Charpy type machine (pendulum type).
g) Charpy
V-Notch
Impact Test:
Specimen is shaped and sized as shown in PDS : MT : 211. Other requirements

are similar as described above for charpyU-notch test.
h) All-Weld-Metal
Tension Test (parallel to weld axis) :
The specimen is machined to i dimension as shown in PDS : MT : 212, after" it

has been cut from a weld seam. deposited between two pi ates with 19 mm
thickness or more. If ~elded joints are to be heat treated, specimen shall also be
heat treated betore machining. Specimen is subjected to tension by the proper
equipment until rupture.
Tensile stre~gth as ~ell as yield point (corre.sponding to a deformation e'qual to

0.2% of gauge length), percent elongation and area reduction are detetmined.
i) Macro Examination:
",' "
A cross section of the joi nt is properly polished and etched by suitable, e~chants,
according to the material concerned. The appearance of the etched 'surface OJ'sthen
examined.
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ENGINE'ERIN,G:STANDA.R0
ES 6010
P.D.I.L.
pJl
Qualification of,Welding Procedure .And Welder

PerformanceFo.r ,Pip.jng
BARODA
j) Chemical
Analysis:
Chemical analysis
exam nation.
4,2,2 Non-destructive
a) Visual
SHEET 12 OF 15
is made
on
metal
tests for qual ification
chips machined from the test piece under
l)re as follows:
Examination:
It shall be done to check root

nsions, surface defects,
b) X-ray
penetration,
undercuts, weld appearance
and dime-
examination:
The whole test weld shall be radiographed,

Each radiographic film shall be properly marked for identification.
Dye-penetrant
c)
Examination:
Examination shall be performed on the whole test weld. Weld surface shall be
examined and any defects detected.
d) Brinell
Hardness:
Test shall be made after any heat treatment, on the w~ld metal, on the heat affeoted zone and on the base material.
Surface where test is performed shall be suitably flattened and polished,
e) Vickers
Hardness
( HV 30 )
Test shall be generally performed on the specimens prepared for macro examination
on weld metal, on heat affected zone, and on base metal, by suitable equipment,
after heat treatment ( if any).
4,3
Test
Result
Evaluation
4,3,1 Evaluation of tests mentioned

4.3.2 Conditions
a) Face,
for acceptance
Root
and
Side
under 4,2 shall be made as specified bellow;
of destructive
tests:
Bend:
After bending, on convex surface there shall be no open defects (caused by cracks
inclusions, blowholes etc.) exceeding 3 mm measured in any directions, excepted
those cracks occurring on the corners which are not caused by slage or other
internal defects,
b) Reduced
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If rupture occurs on the weld, the tensile strength shall not bEt):lower::,than the
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BARODA,
ES 6010

SHEET 13 OF 15
specified tensile strength of the base metal (if m{lterials of different specified
tensile strength are used, the specified tensile strength of the weaker of the two
is considered). If .the specimen breaks in the base metal, the tensile strength shall
not be more that 5 per cent below the specified t<:lI"ile strength of bas metal.
c) Fracture
Test:
Acceptability of any defects existing on

extent specified as follows:
- blowholes: max. dimension 1.6 mm
max. number 6
slag inclusions:
length:::; 3 mm
width $ 0.8 mm
- lack of penetration or fusion:

d) Charpy
U-Notch
fracture sur face shall not exceed the
Impact
none.
Test
The average of the values taken in 3 sets of tests, and at least two of such
values, shall be
not
lower than "III" and morE,over no value shall be lower than
"n". If this should not occur, and provided ~either the average nor more than "n",
two further sets of three specimens each (also taken from other similar testwelds)
will be allowed, e!l1Utne total average of all the values ,obtained' ( including those
of the first set of three tests)
shall be not lower than "m".
The values of "m" and"
thickness "a",
"a" (mm)
"m"
10
7.5
<5
n"
are
listed
below
as a 'function of the specimen
,"n"
(kgm/sqcm)
(kgm/sqcm)
42
4.6
5.5
2.8
3.1
3.9
In particular cases, different values may be specified for "m" and "n",
e) Charpy
V-Notch
Impat
Test:
Wilat is spe(,ified for charpy U Notch Impect Test applies except the values "m"
and "n", which are listed below as a function of the spection thickness "a",
"a"
(mm)
"m"
"n"
(kgm/sqcm)
10
7.5
$5
3.5
3.9
4.6
(kgm/sqcm)
2
2.2
2,8
In particular cases, different values mdY bE: specified, ror "m" and "n".
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ES 6010
P.D.I.L.
BARODA.
Qualification
f) All-Weld
Metal

Performance
For Piping
Tension
SHEET 14 OF 15
Test..
The values shali be not lower than those specified for filler material considered.
g) Macro-Examination:
Macro examination shall show no cracks, in-complete fusion and penetration.
Welding passes shall show to be correctly located and penetrating each other.
h) Chemical
Analysis:
The values ascertained shall conform to those required. For submerged-arc

matic welding on carbon steel. the ratio MnfSi shall be not less than 2.
4.3.3 Conditions
a) Visual
for acceptance
of
non-destructive
auto-
tests:
Examination:
The requirements specified in 3.3 and 3.2 of the concerned welding specification
shall be met with, as to penetration, undercutting, appearance and dimensions of
weld, surface defects.
b) X-ray
Examination:
Any defects, evidenced

c) Dye-Penetrant
Dye-penetrant
d) Brinell
by X-ray examination,
Examination:
examination
and Vickers
Brinell hardness
DOCUME=NTS
5.1
Documents
required
5,1.1 Upon qualification,

shall be prepared.
shall not exceed the values indicated
Documents
required
defects.
in the welding specification.
in pa~icular cases.
for procedure
qualificatinn
a Record on form similar to QW-483
It shall be counter-signed
5.2
shall not evidence any cracks or other surface
Hardness:
or the values prescribed

5.0
shall not exceed the limits specified.
by the Representatives
for welder
or welding
of ASME Code Section IX
of POlL and the fabricator.
operator
proformance
qualification.
5.2.1 Upon qualification, a Record strnilar to form QW-484 of ASME Code Section IX
(for welders or welding operat<?,rs,respectively) shall be prepared.
,.
'------
---
----
-----
ENGINEERINGSTANDARD
ES 6010
P .D.I.L.
pll
BARODA
Qualification

Performance
For Piping
SHEET 15 OF 15
Record shall be counter-.Signed by the Representatives of PDIL and the fabricators.
5,22 All qualification records of the welders belonging to a particular Employer and working
in the sarpe erection field shall be held in a special welder Register, to ba submitted
to the Rej,Jresentatives of POlL, until completion of welding work.
5.2.3 Each welder entrusted with field welding for prefabrication
have a special card with following information:
Name of welder
Stamp of welder
- Filler materials for which the
or erection of piping shall
qualification applies
- Employer
- Field where the Card has been issued
Thickness range covered by qualification
Any restrictions
Signature of MCI Representative and date. The card shall have the welder photo,
or shall be kt:pt together with an indentity card with photo.
5.2.4 Both welders and welding operators shall always wear their own indentification card
and shall show same on request of the Representatives of PDIL.
'
POlL may not alloy at the construction field those welders or "'{elding operators found
without the identification card or with a card no correspondin'g to the type of welnieg
they are entrusted with.
6.0
REFERENCE
STANDARDS
ASME Code on Boilers and Pressure Vessels, Section IX.
- ES:6004: Welding Specification-CarbonSteel & Alloy Steel Piping.

- ES:6005: Welding Specification-AusteniticStainless Steel Piping:
- PDS:MT200 : Weld Test Specimens
for Ferrous Materials.

- PDS:MT201 : Guided Bend Test 'Jids.
PDS:MT202 : Pipe Welding Procedure Performance Qualification

Removal of Specimens.
POS:MT211 : Standard Specimens for Impect Test.
PDS:MT212 : Standard
Test Joint &
Tensile Specimens.
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DKM\DA YTODA
FORiMPLEMENTATION
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installation, testing and commissioning of all carbon steel, alloy steel stainless
steel, aluminium and aluminium alloy piping.
The piping shall be erected as shown on the purchasers drawings and in
accordance with the purchaser's specification and specific instructions issued
to the Contractor by the Owner at site.
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The scope of work shall also include the following:

(a)
Fabrication and installation of steam jacketted piping and steam tracing

of pipe lines as indicated in the drawings and as per Purchaser's
specification.
(b)
Purging of inside of pipes with inert gas in case of TIG welding.

Threading and machining of pipes.
(c)
Installation of orifices, thermo-wells, expanation joints, control valves

and other specification,
(d)
Cutting of g:-skets from sheet.
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Instal!aUo;l and setting of supports, spring h,mgers, vibration dampers

for special supports if any anchors, provision of cold pull etc.
Installation of temporary and permanent line strainer and steam trap
assemblies.
(g)
Heat treatment,
specified.
(h)
Manufacture of pipe supports like pipe clamps, U-bolts, hanger-rods,

saddle supports etc. not supplied by POlL/Clients. Only pipe trunions of
materials same a~ the of pipe, (other than Carbon Steel) and spring
supports shall be supplied by POlL/Client.
(i)
Hydraulic testing, vleaning, pickling and passivating of pipelines. These

will also include isolation of pipes from equipments etc. The work may
also include, cutting of pipes and welding of cover plates or caps for the
purpose of isolation & instalation of temporary supports necessary for
hydraulic testing.
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The scope of work of contractor shall include site fabrication, inspection;
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ISSUE: JAN. '98
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ES 6011
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GENERAL SPECIFICATiON
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radiography
2.0
SPECIFICATiON AND DRAWINGS
2.1
Drawings:
and
other, non-destructive
tests
as
The drawings included with and made a part of this specification indicate
information available to-date. These drawings have been checked and
approved but are subject to modifiactions due to any change in equipment
purchases which are not yet finalised or due to some interferenceor for better
perform?lnceand economy.
I"
ENGINEERING 3TANDARD
GENERAL SPECIFICATION
PDIL
ES6011
ISSUE: JAN. '98
FOR
ERECTION OF PIPING
SHEET 2 OF7
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3.0
Reference
Following
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Standard
standqrds
form part of this specification:
(a)
Indian Boiler Code & Regulations.
c
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(b)
Process Piping, ASME-B-31.3
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(c)
General Piping Specification
(d)
POlL Engineering
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Standards
ES:2009
--
ES:2010
--
Protection
and storage requirements
ES:2401
--
Procedure
for storage & issue of & pipe fittings
ES:2404
--
Cleaning & Blowing of pipe lines
ES:6004
--
Welding of Carbon Steel & low alloy steel piping.
ES:6005
--
Welding of Stainless Steel piping
ES:6006
--
ES:6007
--
ES:6008
--
ES:6012
--
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ES:6016
--
ES:6021
--
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Protection and storage requirements - Pipe and

Fittings
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for Electrodes
Pressure testing of piping

leak
testing of piping.
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Specification for Steam Jacketed Piping
ES:6201
--
PVC Piping Installation
PDS:P 001
--
Tolerances
PDS:P 123
--
for fabricated
piping.
Vent, drain, steam trap and Instrument tapping
Indian Standards:
IS:554
4.0
4.1
--
Specification
of threads.
SUPPLY OF MATERIALS
, Following will be supplied
(a)
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Fusion welds of pressure-pipes- Inspection
Assemblies.
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Steam tracing design and inst,allation.
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Safety Valve installation & piping.
ES:6030
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steel piping.
Requirement.
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Pickling and passivating of stainless
by the purchaser unless otherwise
agreed:
All Pre-fabricated Pipes (wherever available), pipes in random and

double random lengths.
.
(b)
All fittings including elbows, tees, reducers, weldolets, laterolets and

unions, couplings, flanges, blank flanges etc.
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ES 6011
FOR
ERECTION OF PIPING
POlL
ISSUE: JAN.'98
SHEET 3 OF 7
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Allvalves, steam traps, strainers, sight glass!3s,drain funnels etc.

Asbestos gaskets in the form of .sheets, jacketted asbestos and metallic
gaskets.
Instrumentinserts and connections.
Orifices, nozzles, thermo wells and other specialities.
Q)
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(g)
Bolts, Nuts and Fasteners
(h)
All materials required for Jacketed

(excluding tie wires).
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Special supports like pipe trunions and spring supports.
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Wrapper/reinforcement plates if any required for support.
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4.2
If the contractor decides to do purl of fabrication work in his sllop to reduce cost
of fabrication arid to expedite completion of job it will be his responsibility to take
materials to his works and despatch to site.
4.3
All welding electrodus/consumables accessories shall be Contractor's supply.
4.4
It will be the Contractor's responsibimy to arrange for all necessary erection

tools, tackles and accessories for erection, testing and site fabrication of the
pipe including pipe bending equipment, pipe threading and machining, stress
relieving and radiography equipment.
.
4.5
The storage and protection of pipe and fittings after withdrawal from stores shall
be in accordance with ES:2009 and shall be the responsibility of the contractor.
In case any of them is damaged due to negligence on the part of contractor the
cost of replacement/rectification shall be borne by the contractor.
5.0
PRICE
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5.1
The price shall be quoted on a total lulllPsum basis for the complete scope of
work as enumeiated above based on the Purchaser's drawings and Bill of
Materials forming part of thi~ specification. The quantities indicated in the above
documents are preliminary and are subject to variations upto + 10%. A firm unit
price shall be quoted at the Contractors option based on the estimated
quantities for each category and the adjustment in the lumpsum price for the
total variations would be worked out on the basis of this unit price.
6.0
FABRICATION
6.1
All welding work shall be done in accordance with Purchasers Specification,

ES:6004 and ES:6005, Welds which are made after blowing/cleaning operation
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of pipe lines shall have root runs with TIG/MIG.
6.2
All steam Jackets for Piping as indicated in the drawings or isometrics shall be
fabricated and the fabrication shall be carried out in accordance with ES:6030.
6.3
Steam tracing installation on piping as indicated in the drawings shall be done in
accordance with E.,$:6016.
"
piping and steam traced piping
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ES 6011
FOR
ERECTION OF PIPING
POlL
ISSUE: JAN. '98

SHEET 4 OF 7
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Safety valve installation & connected piping shall be,as per ES:6012.
6.5
Bending
6.4.1
Carbon steel shall be bent hot or cold. Alloy steel and stainless steel pipes shall
be bent cold. All bends in alloy steel piping shall be suitably heat - treated after
bending to result in hardness of 220 BHN maximum.
6.4.2
While bending the pipes, the pipes shall be packed with Sulphur free high
temperature silica and of adequate finness. Care should be taken to pack the
pipes by vibration using suitable mechanical or manual means.
6.4.3
Bending methods and equipment shall be such as to ensure bends free from
wrinkles, bulges and kinks. Minor bulges & wrinkles may be removed by means
of local heating and use of hanger or flatters.
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6.4.4
Tolerances shail be as per PDS:P:001.
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6.4.5
All hot bends shall be cleaned by means of rotary cleaner, shot blasting or
Pickling as approved.
6.5
T.hreading
6.5.1
Threading of pipe s~c;allpreferably be done after bending and heat treatment if

any. Where subsequent threading is difficult and threads are cut first they shall
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6.5.2
Threads shall be concentric with outside of pipe and shall conform to 18:554
unless, otherwise specified in the drawing.
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7.0
SCRE\tVED JOINTS
7.1
For the screwed joints on pipe materials like stainless steel to stainless steel,
alloy steel to alloy steel and aluminium to aluminium no pipe joint compound
shall be used. Such ScrewedJoints, having an operating temperature of 200C
or less, shall be madeup using Teflon thr~ad seal tape.
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7.3
Threaded carbon steel connections shall be seal welded if the line is carrying
the following:
(a)
Toxic Materialssuch as Phenol, Chlbrine etc.
(b)
Highly corrosivematerial.
(c)
Hydrogen
(d)
Valuable and Poisonousmaterials such as vetrocoke solution, volatile

hydrocarbons.
Threaded connections requiring seal-welding shall be screwed up tight with

clean threads and seal-welding shall cover exposed threads or 10 mm
minimum.
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FOR
ERECTION OF PIPiNG
POlL
ES 6011
ISSUE: JAN. '98
SHEET 5 OF 7
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For other pipe materials like carbon steel to carbon steel or brass to brass etc. a
pipe joint compound suitable for specified service'shall be used, except whenonly welding or brazing is specified. Some of the recommended compounds
are:
Cooling water above ground
--
Compressed Air
-Thinned refined lacquer.

Aluminium Stearate Powder
Demineralizer water
--
Red lead & linseed oilpaste
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8.2
Slopes of piping specified on drawings shall be maintained. Where no slope is

required and where the required slope approches the horizontal, the piping
shall be checked for sag with a level not less than 300 mm long, equipped with
graduated bubble vial level gauge. All low points where liquid may be
entrapped shall either be removed or shall be provided' with valved drain where
required by POlL/Client.
8.3
Where cold springing for piping is specified on the drawings, the expansion
loop for which it is specified shall be erected with metal fillers of the specified
thickness inserted between the expansion element and connected piping. All
connected piping and all pipe supports anchors and hangers for the expansion
element and connected piping shall be, erected and adjusted with the metal
fillers in place. The metal fillers shall be then be removed and joints between
the expansion elements and connected piping shall be completed. It is
extremely important to ensureJthat the fillers are held firmly during erection and
are not removed unit! erections i~ complete between anchor points. Care shall
be taken while placing or removing the filler pieces to avoid injury to the metal
faces of the joint.
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Except where cold springing is called for on the drawing, all assembled piping
shall be installed in place without springing or forcing and so as to clear all
opeing and equipment. Excessive cutting or otherwise weakening of structural
members to facilitate installation of pipes shall not be permitted. Before cutting
qny structural members, permission of POlL/Client shall be obtained.
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9.0
SUPPORTS
9.1
When supporting" pipe, subject to thermal expansion, hanger rods shall be set
at slight angle so that when supported pipe expands rods will be plumb.
9.2
All supports shall be executed is accordance with the Purchaser's drawings

and standards.
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ES 6011
FOR
ERECTION OF PIPING
PDIL
ISSUE: JAN. '98

SHEET 6 OF 7
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10.0
VALVES
10.1
Valves should be lifted by the body or the lugs on the bonnet. They should not be handled by the hand wheel or the actuator or even dragged along the
ground.
10.2
The line and the valve should be thoroughly cleaned. Care shall be taken so
that no chips or weld drops are left in order to avoid seat damage. Control
Valve of welding ends should be welded after hydraulic test, cleaning and
blowing of the iine. Venturi type orifice shall also be weleled in position only
after blowing.
10.3
The valve flanges shall be parallel as the valves can not correct any
discontinuity. Contractor shall check the face to face dimensions of valves
before doing pre fabrication work, ~imensions shown in isometric have to be
checked at site,
10.4
Globe, Check and Gate valves with bypass or pressure relief system should be
installed according to the arrow on the body.
10.5
The valves should t:e installed in a vertical position wherever possible, having
the hand wheel 8~ top. This particularly concerns large dia gate valves.
Actuators can not operate in all positions.
11.0
EXPANSION JOINTS
11.1
Expansion joints shall be the last unit installed' in any piping system. The
installation
of
expansion
joints
shall
be
in
accordance
with
POlL/Manufacturer's instructions.
11.2
Before installation of any expansion joints all piping shall be accurately aligned
without restraint and shall be properly anchored and guided. Expansion joints
shall be cleaned with a rag or better with compressed air blow so that no
foreign matter shouid remain in bellow corrugations to interfere with the proper
flexing of the bellows.
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by the manufacture.
never be extended or
drawings with (2=,

2,mm) including cold springing.
11.4
No adjustment shall be made to the tie rods provided by the manufacturerto

control alignment and end thrust, these tie rods shall remain part of the unit.
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They should
compressed to make up deficiencies in pipe length, or effect to accomodate

piping which is not properly aligned unless such installation tolerances have
been specified by POlL' and taken care of by the manufacturer. The space
allowed in the piping for an insertion of an expansion joint is specified on
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It is important that expansion joints be installed at the proper lengths as

recommended
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ES 6011
FOR
ERECTION OF PIPING
PDIL
ISSUE: JAN. '98

SHEET
7 OF 7
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11.5
It is absolutely forbidden to sling expansion joints by means of the rods, tie bars
angles, shipping expeditents and of course on the bellow corrugations and
external 'Shrouds'. All expansion joints must be alinged on the end pipes orflanges or on the middle pipe. An extension joint must be handled with care to
prevent any shock, denting or welding shot and spatters.
11.6
During welding of expansion bellow joints, care shall be taken to ensure that
lead earth cable is not placed on the expansion joints. Any arc weld shot or
spatter shall be avoided as it may lead to leak in corrugations.
11.7
Space bars supplied by the manufacture for shipping purpose shall not be
adjusted or removed from expansion joints until after joints are in place and/or
until the line is tested. Spacer bars must be removed before the line is put in
service.
12.0
CLEANING
12.1
Cleaning Prior to Erection
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All field fabricated piping shall be cleaned after the completion of

fabrication. 1\:1burrs, welding particles and weld spatter shall be removed
by means of chipping, reaming or filling. The. piping shall be thoroughly
flushed with water to remove. any foreign material. The. open ends of pipe
shall be s~itably closed or plugge.d.
(I)
All nozzles of under ground lines shall be blanked by blind fJange.sor by

tack welding caps/p!ates to avoid ingre.ss of dirt, sand etc. as per
ES:2404.
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12.2
Pickling and passivating of stainless steel pipe. after we.lding shall be as pe.r
ES:6008. In case of pipe welds with root run/complete made. with TIG/MIG
welding, no pickling shall be done but the lines shall be cle.aned as per ES:2404.
12.2.1
All weld joints of S.S.Pipe shall be. pickled/dressed up by grinding from outside.
13.0
TESTING
13.1
All installed piping shall be tested either by pressure testing or by leak te.sting in
accordance with the Purchaser's specifications ES:6006 and the pressure
would be in accordance with the schedule of test pressures.
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Preliminary cleaning shall be done for shop-fabricated piping, valves and

fittings.
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DKM\DA YTODA Y\ST ANDARD\MECH\ES6011.L WP
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ES : 6101
PDIL
ISSUE. : APR. 99
TECHNICAL NOTES FOR PIPES
SHEET 1 OF 5
1.0
GENERAL
1.1
Scope : This specification defines the responsibility of the supplier and covers
supplementary requirements relating to manufacturing, fabrication, inspection,
testing, painting, packing and despatch etc. This specification shall be read in
conjunction with relevant codes and enquiry documents. The vendor must
contact PDIL for clarification. As a general rule the most stringent requirement
shall govern and PDILs option shall be binding.
1.2
For pipes of NB > 2 and thk. > 2.9 mm, the ends shall be beveled as per
ANSI B 16.25.
1.3
The pipes shall be supplied in random length of 4 to 7 mtrs.
1.4
Total length allowance shall be + 1% or one length whichever is less.
1.5
All the standards referred shall be of latest edition.
1.6
In case of conflict between different specifications and technical condition of

supply, the vendor shall contact PDIL for any clarifications/confirmation,
otherwise it shall be assumed that all clauses are clear to the vendors.
1.7
The quantities mentioned are tentative, may vary + 25% and will be decided
at the time of placement of order. The price shall be firm for these variation.
2.0
GENERAL INSTRUCTIONS FOR BIDDING PURPOSE ONLY
2.1
Each sheet of technical condition of supply and specification sheets shall be

duly signed and stamped by competent authority and shall be enclosed
alongwith offer without which the offer shall be considered incomplete.
2.2
The price shall be quoted on the zerox copy of the same sheet of the bill of
material attached with the enquiry specification and any deviation from the
required specification shall be marked therein. Prices typed on other format
shall not be considered for evaluation and rejected without any reference.
2.3
Any deviations from the clause stipulated, in the codes and other enquiry
documents shall be clearly mentioned in a separate Deviation Listwith
proper ref.no. In the absence of any such indications, it shall be assumed
that the offer complies with all the requirements in totality and such
assumptions shall be strictly binding on the supplier.
2.4
All testing charges shall be included in individual prices of the items. If third
party inspection charges are not indicated, it shall be assumed that it is
included in the offer. If third party inspection charges are extra, it shall be
indicated as percentage basis of individual item. In no case third party
inspection charges shall be indicated as lumpsum amount.
ES : 6101
PDIL
ISSUE. : APR. 99
SHEET 2 OF 5
3.0
MATERIAL
3.1
All materials, whatsoever, required to complete the supply shall be procured

by the supplier and all such materials shall be covered with due identifiable
material test certificates.
3.2
For pipes to A 312 TP 316L + G510 (CR.UR 510), ferrite content shall be
0.6% max.
3.3
Carbon content for carbon steel pipes shall be maximum 0.25%.
4.0
TESTING
4.1
In case of seamless & welded pipes, parent material including weld and heat
effected zone for low temperature service shall be impact tested (on charpy v
notch) at the lowest design temperature in accordance with requirements of
code/ specification.
4.2
Intergrannular corrosion test shall be carried out on urea grade S.S. pipes to
ASTM A 312 TP 316L + G510 (CR.UR.510) on parent material, welds and
heat affected zone as per Snam Progettis Specn. G 510 (CR.UR.510), Rev.1.
4.3
Hydrostatic test shall be carried out on each random length of pipe as per
ASTM A 530 for pipes to ASTM specification, as per API 5L for pipes to API
5L specification, as per IS:1239 for pipes to IS:1239 and as per I.B.R.
specification for pipes under IBR.
4.4
Transverse tension test shall be carried out on pipes of nominal size 8 and
above and thickness of Sch.120 and above as per supplementary
requirements of respective standards.
4.5
Check analysis shall be carried out as per ASTM-A-530. for pipes as per
ASTM-A-312 and pipe size > 8 and thickness > Sch 120, CHECK analysis
shall also be carried out as per supplementary requirement S 1 of
ASTM-A-312.
4.6
For seamless pipes, each length of pipe with following specifications shall be
ultrasonically tested as per ASTM E 213 or ASTM A 388.
(a) Size upto 4 inches and Sch > 120
(b) Size > 5 inches and thk. > 12 mm.
Any defects producing signal greater than the appropriate reference groove
shall be unacceptable. The allowable defect shall be longitudinal flat bottom
groove on the outside or inside surface of the pipes and length not greater
than 25 mm, width not greater than 1.6 mm and depth not greater than the
smaller of 1 mm or 5% of the wall thickness.
5.0
INSPECTION
PDIL
ISSUE. : APR. 99

ES : 6101
SHEET 3 OF 5
5.1
Inspection authority means the inspection agencies approved by the

Owner/PDIL. Approved inspection agencies are M/s.Lloyds/TUV/Japan
Inspection Agency etc. for overseas vendors for both IBR & Non-IBR items.
However, PDIL will be inspection agency for Non-IBR items and chief
inspector of boilers for IBR items for Indian vendors.
5.2
Pipes for Steam Services shall be tested in accordance with requirements of

IBR Form IIIA by IBR Authority.
5.3
The inspecting authority shall be provided free access at all possible times to
those parts of suppliers work engaged in production and testing of materials
ordered.
5.4
The inspecting authority shall have the right to select random samples for
check test and reject materials, if samples furnished as above and tested as
per the specifications fail to meet the requirement specified.
5.5
All the items shall be inspected and tested in the presence of one or more
representatives of the purchaser during various stages of manufacturing
starting from identification of raw material up to completion. Material shall be
considered acceptable for despatch only after final certificate of acceptance
is issued by the Inspector.
5.6
Testing performed in the presence of the purchasers representatives shall

not relieve the supplier of their own responsibilities and guarantees and any
other contractual obligations.
6.0
DOCUMENTATION
6.1
The pipe shall be supplied with 8 copies of the mill test certificates indicating
the following and duly signed by the inspecting authority alongwith supply of
materials. In addition 4 copies shall be sent to PDIL.
a) Purchase order no.
b) Material specification and grade
c) Size and sch.no./thickness
d) Quantity
e) Heat and lot No.
f) Results of Chemical analysis
g) Mechanical test results (as per applicable clause)
h) Hydrostatic test results
i) Non-destructive test results (as per applicable clause)
6.2
Pipes under IBR shall be supplied with 8 copies of IBR certificates in form
IIIA duly signed by inspecting authority alongwith supply of materials. In
addition to above 4 copies of these certificates shall be sent to PDIL.
7.0
MARKING
7.1
Marking on pipe shall be as per the relevant standard. The minimum

requirements of marking information shall be ASTM or API designation, size
ES : 6101
PDIL
ISSUE. : APR. 99
SHEET 4 OF 5
and Sch.No./thickness on each meter of standard pipe length in addition to

the requirement of relevant code.
7.2
For all pipes of size 2 and above, marking shall be done by paint stenciling
using a weather resistant paint which has a guaranteed life time against rust
and moderate handling for not less than 3 years. If necessary the surface
shall be sand blasted to SA 2.5 according to ISO 55900 and primed before
marking is applied.
7.3
A transparent coating may be applied after marking, if necessary, to fulfill the

requirements of 3 years resistance to damage.
7.4
For pipe equal to size 1 inch or less, marking shall be done on pipe or by
die stamping on a metal tag fixed to the pipe by compression method.
7.5
In addition each length of pipe shall be given a 20 mm wide colour code strip
for the entire length. according to colour coding of pipe material as per sheet
5 of this standard.
7.6
For pipes covered under IBR inspection identification mark IBR shall be
stamped at both ends inside or outside of each random length of pipe.
Additional red colour strip of 20 mm width shall be marked for the entire
length of pipe.
7.7
Part no. appearing against each item of bill of material shall be marked on
both ends of each random length of pipe by paint stenciling and should be
able to withstand sea transport, handling and storage.
8.0
PRESERVATION AND PACKING
8.1
Pipes up to size 4 shall be packed separately by sizes and material grades

and clearly tagged for idenditication. However pipes above 4 can be shipped
in crates or shipped loose.
8.2
All ends shall be capped or plugged. One coat of approved anti rust paint
shall be applied on the surface of the pipe except s.s.pipes.
8.3
Pipes shall be adequately protected from both inside and outside to avoid
mechanical damage during transit and storage. For transportation overseas,
protection and packing shall be adequate to prevent damage from sea
atmosphere.
9.0
GUARANTEE
9.1
All items shall be guaranteed against poor workmanship and defective

material as per the warranties and Guaranties clauses mentioned in the
commercial terms and conditions of ITB.
SL.NO.
MATERIAL
PIPING STANDARD
COLOUR
1.
C.S.
API 5L GR.B
Yellow
2.
C.S.
API 5L GR.B (IBR)
Yellow & Red
3.
C.S.
ASTM-A-106 GR.B
ASTM-A-672
Blue
4.
C.S.
ASTM-A-106 GR.B (IBR)
Bluw & Red
DKM\DAYTODAY\STANDARD\MECH\ES6101.LWP
ES : 6101
PDIL
ISSUE. : APR. 99
SHEET 5 OF 5
5.
L.T.C.S.
A-333 GR.1
A-671 GR.CC-60
Red
6.
Mo
A-335 GR.P-1
Green
7.
Mo
A-335 GR.P-1 (IBR)
Green & Red
8.
1 Cr.
Mo
A-335 GR.P-11
Lilac
9.
1 Cr.
Mo
A-335 GR.P-11 (IBR)
Lilac & Red
10.
2 Cr.
1 Mo
A-335 GR.P-22
Brown
11.
2 Cr.
1 Mo
A-335 GR.P-22 (IBR)
Brown & Red
12.
S.S. 304
A-312 GR.TP-304
A-358 GR.TP-304
White
13.
S.S.304L
A-312 GR.TP-304L
Slate
14.
S.S. 321
A-312 GR.TP-321
Alluminium
15.
S.S. 347
A-312 TP-347H
Grey
16.
S.S.316
A-312 GR.TP-316
Black
17.
S.S.316L
A-312 GR.TP-316L
A-358 GR.TP-316L
Red
18.
S.S.316L
+ G 510
A-312 GR.TP-316L
+ 510
Black & Red
DKM\DAYTODAY\STANDARD\MECH\ES6101.LWP
ES : 6606
FEB'99
DOCUMENT NO
ISSUE
SHEET 1 OF 8
CASING INSULATORS AND END SEALS
1
0
REV
29.08.2008
FEB'99
REV DATE
FEB'99
EFF
DATE
FORM NO 02-0000-0021F1 REV2

ES 6606
Converted in MS WORD
FOR ISSUE
PURPOSE
PCC
PREPD
REVWD
HSW
APPD
rights reseved
ES : 6606
FEB'99
DOCUMENT NO
ISSUE
SHEET
2 OF 8
CONTENTS
SECTIONS
PART - I
PAGE NUMBER
CASING INSULATORS
1.0 SCOPE
2.0 FUNCTION
3.0 DESIGN
4.0 MATERIAL
5.0 INSPECTION AND TESTING
PART - II
CASING END-SEALS
1.0 SCOPE
2.0 FUNCTION
3.0 DESIGN
4.0 MATERIAL
PART-III
SUPPLEMENTARY REQUIREMENTS
NOTES:
This document shall be used with relevant information contained in the documents
listed below ( in order of Priority).
Letter for invitation of bid or succeeding official confirmed order.
This document.
3. Codes and Standards referred in the above mentioned documents and in this
document.
FORM NO 02-0000 .0021F2 REVI
E5-66D6
All rights reserved
ES : 6606
FEB 99
DOCUMENT NO
ISSUE
SHEET 3 OF 8
PART I - CASING INSULATORS

1.0
SCOPE
This specification covers the minimum requirements of design, material,
manufacture and supply of casing, insulators intended to be used for cased
pipeline crossings.
2.0
FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing pipe
and electrically isolate the carrier pipe from the casing pipe at the cased crossings.
The casing insulators shall :
Resist cold flow and will not soften at design temperature.
Resist corrosion.
Resist mechanical damage while being pulled into the casing.
Have high electrical insulating value and low water absorption, thus
preventing leakage and maintain electrical isolation between carrier and
casing pipes.
Have high compressive strength in order to assure a permanent support to
the carrier pipe.
3.0
DESIGN
The arrangement of insulator shall be generally in accordance with Figure in sheet
8. It shall be made in segments duly held together with cadmium plated bolts and
nuts, to be supplied with casing insulators.
The number of segments shall be two for pipe diameters upto 12" (generally). For
larger diameters, the number of segments may be more than two, but their number
shall be kept minimum.
The skid height shall be such that it is slightly less than the value obtained by
following formula
Casing internal diameter - Carrier outer diameter

2
Manufacturer shall obtain prior approval from Owner / Consultant on casing
insulators drawings / designs.
4.0
MATERIAL
Casing insulators shall be made of injection moulded high density polyethylene or
other material equivalent or superior as approved and shall meet the following
specifications :
FORM NO. 02-0000-0021F2 REV1

E5-6606
All opts reserved
Property
5.0
Value
ES : 6606
FEB 99
DOCUMENT NO
ISSUE
SHEET 4 OF 8
ASTM Test Method
Dielectric Strength
450-500 Volts/Mil
D-149
Compressive strength
3200 psi
D-695
Tensile strength
3100-5000 pai
D-638.D-651
Impact strength
4.0 ft.lb./inch of notch
D-256
Water Absorption
0.01%
D-570

Manufacturer shall furnish material test certificates of the components used in the
assembly of casing insulators as per the requirement of clause 4.0 of this
specification.
FORM NO: 02-0000-0021F2 REV1

5-6636
All rghls rese r ved
4p.
41
/LA

L
ES : 6606
FEB ' 99
DOCUMENT NO
ISSUE
SHEET 5 OF 8
PART II - CASING END SEALS

1.0
SCOPE
This specification covers the minimum requirements of design, material,
manufacture and supply of casing end seals insulators intended to be used for
cased pipeline crossings.
2.0
FUNCTION
Casing end seals are intended to be used for sealing the annular space between
casing pipe and carrier pipe at casing ends so as to prevent ingress of moisture
and water.
3.0
DESIGN
The seals shall be suitable for the casing and carrier pipe diameters as applicable
for each case.
The casing end-seal shall be flexible to cater for the expansion and contractor of
carrier and casing pipes and shall be able to tolerate both angular and concentric
misalignment of casing pipe without loss of sealing efficiency.
The design of the casing end-seals shall permit easy installation of the seal to the
cased pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated life of
the buried pipeline.
Manufacturer shall obtain prior approval from Owner / Consultant on casing end
seals design / drawings.
4.0
MATERIAL
The casing end-seals shall be made of heat shrink high density radiation cross
linked polyethylene with an adhesive having a melt point suitable for the pipeline
service temperature and ambient temperatures foreseen during construction. Endseals material shall be resistance to heat, cold vibration, impact ,abrasion,
corrosive fluids, disbonding, organic and bio-deterioration. Manufacturer shall
confirm compatibility of end seals with carrier pipe coating.
Casing end seals shall meet following minimum property requirements :
FORM NO 02-0000-0021F2 REVS

ES-6606
All rights reserved
Property
Minimum Value
ES : 6606
FEB99
DOCUMENT NO
ISSUE
SHEET
OF
Test Method
Backing (Sleeve and closure patch)

Tensile strength
2200 psi
ASTM D-638
Ultimate Elongation
400%
ASTM D-638
Heat Shock
No visual cracks
ASTM D-2671
flow or drips
(at 225C,4 hrs)
Adhesive
Ring and Ball softening
90C
ASTM E-28
60 c C-25 pai
ASTM D-1002
point
Lap Shear
23C - 250 pai

(2 inch/min)
c) System(as applied)
Peel strength
5 pli
(To casing & carrier
(10 inch/min.)
ASTM D-1000
pipe and closure patch)

Manufacturer shall furnish material test certificate of the components used in the
assembly of casing end-seals as per the requirements of this specification.
FORM NO 02 . 0000-0021F2 REV1

E $.6606
All rights reservecs
ES : 6606
FEB'99
DOCUMENT NO
SHEET
ISSUE
OF
PART III - SUPPLEMENTARY REQUIREMENTS

1.0
The manufacturer shall replace, at no extra cost. any material not conforming to
the material and performance requirements of this specification.
2.0
Manufacturer shall submit detailed specification of the materials used in the

assemblies, alongwith instructions for handling, use and installation of the material
for OWNER's approval prior to procurement.
3.0
Manufacturer shall submit all the documents. test reports, records and other
information in six copies to the OWNER for record after approval as per clause
2.0 above.
FORM NO 02 . 0000. 0021F2 REVI

ES-6606
All rights reserved
1,4s.
PDIL
FEB99
ES : 6606
DOCUMENT NO
ISSUE
SHEET 8 OF 8
FORM NO 02 . 0000 . 0021F2 REVI

ES.6606
All nights reserved
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ES 6018
ISSUE: JAN. '98
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PDIL
ISSUE: JAN.'98
UNDERGROUND PIPING
..
SHEET 1 OF 15
[-.-
150..
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1.0
SCOPE
1.1
This specification covers the requirements

underground Carbon Steel burried piping.
2.0
REFERENCE STANDARDS
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Tolerance for piping fabrication.
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Welding specifications
ES 6006
Pressure Testing of pipes.
ES 6009
Protective coating for underground
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Fusion welds of pressure pipes - Inspection requirement
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PROTECTIVE COATING
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STORAGE AND HANDLING
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Storage
-11.1
Pipes shall be stored on firm and well drained ground.
-: 12
The pipes shall be stacked/stored

them out of contact with ground.
J.1.J
Pipe fittings and valves upto size 6'/ shall be stored indoors.
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Pipe fittings and valves above size 6" may be stored outside
on wooden
sleepers on firm and well drained ground. Fittings shall be stacked such that
ingress of rain water is avoided and are in self draining position.
-1.1.5
The valves shall be stored in closed position except those with non metallic
seats (for instance butterfly valves).
J.I.6
Gate valves shall be stored in upright position while butterfly valves shall be
kept with fiange facing resting on wooden sleepers. All valves shall be
covered with tarpulin/polythene sheets.
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Protective coating of pipes shall be in accordance with ES 6009.

Wherever specified, cathodic protection
specified in NIT shall also be provided.
as per the specification/procedure
on timber/packs of'sand bags/steel to keep

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Rubber-lined valves shall be stored in shade and protected from exposure to

direct sunlight.
..1.1.8
Valves end coverings shall be retained in pl.ace until removal is necessitated

for erection. All the valves shall be inspected and cleaned after end coverings
0.
are removed for erection.

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Valves spindle shall be cleaned and lubricated prior to commissioning.
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ISSUE:JAN.'9~
POlL
UNDERGROUND PIPING
SHEET 2 OF 1~
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Valves shaH be lifted by slinging around the- body or lifting lugs provided on
the body. Valves shall not be handled from hand wheels/actuators and also
shall not be dragged.
a.
4.2
Handling
4.2.1
Pipes/pipe fittings and valves shall not be allowed to drop or strike any
objects which shall damage the same.
~~
4.2.2
While handling pipes and fittings, care shall be exercised to avoid distortion,
flattening, denting, scoring or any other form of damage-.
!-
4.2.3
To the extent feasible, mechanical lifting tools and tackles shall be used for
handling pipes to avoid any scoring/scratching.
-+.2.4
After application of protective coating, no bracelinks/ropes of any description

shall be used for lifting or handling of pipes. After application of protective
coating, for handling the pipes, lifting hooks made of belt length or plates
curved to match the curvature of pipes or any similar device providing enough
bearing area to avoid damage to the protective coating shall be used. After
application of protective coating, pipes shall be lifted and lowered by use of
cranes except for areas which are unaccessibl~ for cranes.
4.2.5
Dragging of coated or uncoated pipes is prohibited.
4.2.0
In stringing pipe along the right of way, gaps shall be left between adjacent
length of pipes at regular intervals and at well defined places to permit free
passage of personnel or vehicle during the time interval between stringing
-and other construction operations.
5.0
SPECIFICATION
5.1
Layout of the trenches including slope shall conform to piping layout drawings.
5.2
The cross section of trer{ches shall conform to Fig.1. The depth of the trench
at certain locations may have to be increased in consultation with POlL.
5.3
Excavation shall be carried out with conventional tools and machinery. The
excavation in rocky areas shall be carried out by controlled blasitng and/or
5.4
5.5
Soil removed during excavation shall be properly stacked and shall be used
for back filling, if it meets the requirements laid down in this standard for back
filling material.
5.6
Finished trench shall be free of rocks, hard clods, roots and/or other debris
which would damage the coating, when the pipe is lowered into the trench.
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AND CONSTRUCTION
OF TRENCHES
use of drilling, rock ploughs, rippers e~c.

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Adequate and abundant caution shall be exercised prior to and during the
blasting to prevent any damage to the property or injury to personnel. All rock
scattered due to blasting
shall be removed to the satisfaction of POlL.
.
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ENGINEERING
ES 6018
STANDARD
ISSUE: JAN.'98
POlL
UNDERGROUND PIPING
SHEET 3 OF 15
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After excavation, bed depth of 75 mm below the bottom of the pipe as shown
in Fig.1 shall be ensured.
5.S
While constructing the trench at rail/road crossifl9, danger signals shall be

provided on both sides of rail/road in accordance
with Railway/State
regulations. Signals shall be 10Gateda minimum of 100 meters from pipe line
crossing and shall be readable from 30 meters. Barricades or guard rails may
also be provided for protection of general public due to the hazardous location
of the crossing.
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Clearance between the pipe and any other underground structure shall be
provided as indicated below, clearance between two adjacent pipes shall also
be as indicated below and decided considering the higher size pipe.
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300
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Where drain is encountered, the trench shall be dug so that the pipe line may
be laid over or under such drain with a minimum clearance of 100 mm and to
such depths as may be required due to site conditions. When any drain is
.damaged, it shall be repaired immediately (See Fig.6).
The pipe line may pass through deep washes and creeks where supports shall
be provided in consultation with POll. The controlling factors will be length of
span, conditions of banks and hazards of leaving the line exposed. Maximum
unsupported span for various sizes are shown in Table-1. It shall be checked
that the combined stress due to internal pressure and external loads are within
permissible limits.
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Pipe Size
in inches
Span in Metre
6
8
10
12
14
15
16
18
19
19
TABLE - 1
Pipe Size
Span in Metre
in Inches
16
18
20
22
24
21
24
24
25
25
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ENGINEERING
ISSUE:JAN.'98
POlL
1
-
The crossings at railway tracks and roads shall be in accordance with the
requirements of Railways or local Governament authorities./ Pipe casing or
other suitable arrangement like culverts etc. shall be provided at crossing of
roads, railway tracks, canals etc. as indicated in the drawings.
5.14
In all cases where trench has been cut across public or private roads and back
filling of the trench is not completed, temporary bridge work of full width of
road and of adequate strength shall be installed to ensure safety of traffic.
5.15
Crossing/diversion shall be provided wherever necessary in the opinion of

POlL to permit property owner to travel or move his stock and property.
5. t (j
The dimensions of the trench may have to be locally increased

welding of pipe. Field joints should be kept to a minimum.
0.0
DEWATERING
O. I
Adequate arrangement for dewatering of trenches shall be made by the

contractor. The water thus pumped/bailed out ~nall be drained to a safe
location as directed by POlL.
0.2
. The trenches shall be made free of water while preparing the bed, laying of
pipes, backfilling and welding of field joints.
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LAYING OF PIPE
7.1
Laying of pipes in the trench shall be started only after the layout, depth and
slope of the trench have been approved by POlL.
7.2
Pipes shall be visually examined to ensure that the internal surface of the pipe
is clean. No earth or rock shall remain inside the pipe. The weld preparation
and adjacent pipe shall be free from dust, scale, paint and foreign material for
a distance of 2T + 50 mm where T is the thickness of the pipe.
7.3
The pipes shall be visually examined for any damage to the protective /
coating. In case any damage is observed the same shall be further examined
by spark testing to establish the extent of damage. The damaged area shall
be repaired to the satisfaction of POlL.
7.4
The open ends of sections of laid pipe shall be covered with minimum 3 mm
thk. steel plates to prevent the ingress of water, skids, animals or other
material which would interfere with the final cleaning of the pipe.
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From safety point of view, diesel driven pumps shall be preferred.
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0.3
SHEET4 OF 15
5.13
II ~2
PIPING
Where spans are greater length than those indicated in Tab!e-1, intermediate
supports shall be provided. However, in no case the unsupported length of
pipe shall be more than that indicated in Table-1.
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UNDERGROUND
5.12
ES 6018
STANDARD
The covers shall be securely attached to the pipe and shall not be removed
until the pipes are to be joined by welding.
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D-
ENGlNEERING STANDARD
ISSUE:JAN.'98
POlL
7.6
Concrete anchor blocks shall be provided at all turning points for pipe sizes 8"
and above to absorb water hammer and pipe vibrations.
7.7
Anchor blocks at suitable interval should be provided to take care of buonacy

force coming on the pipe when the pipe is passing on the river bed or through
water.
s.n
INSTALLATION OF CASINGS PIPE
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The material of casing pipes shall be Carbon Steel.
S.l
The thickness of casing pipe shall be calculated in accordance

Annexure-I of this standard or as indicated in the drawing/work order.
S.2
The interior surface of the casing pipe must be free of rocks, dirts, clods or
other material which could damage the coating on the carrier pipe.
8.3
Casing shall be installed in accordance with figures 2 & 3 and shall meet the
requirements of Railway and local Government authorities.
SA
Casing to be installed by boring. The boring'sha.1I be done with a machine

which will feed the casing into the bored hole directly following the cutter head
on the auger simultaneously with the boring oper-ation. The diameter of the
cutter head on the auger shall not be more than 20 mm larger than the outside
diameter of the casing. The trench excavated for boring operation shall be at
least 3000 mm away from the edge of road/rail track.
S.5
Casing ,may also be installed across highways or roads by trenching.

However, when this. method is used, the trench across the road shall be
back-filled immediateiy after the casing is in place. The back fill shall be
thoroughly compacted acrdss the entire road bed. The top 300 mm of the back
fill shall be gravel or crushed rock.
8.6
Casing shall have minimum clearance

structures.
8,7
As soon as the casing is in place, the vent pipes shall be installed, the insid~
of the casing cleaned out and both ends capped.
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All rules and regulations laid down by railway and or other related Government
authorities shall be complied with while laying the pipe through rail/road
crossing.
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UNDERGROUND PIPING
7.5
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ES 6018
with
of 300 mm from other underground
The area shall be cleaned up before moving away from the work site.
9.0
WELDING
<).1
Welders to be deployed for welding shall be tested for procedure

qualification in presence of POlL at si~e strictly as per ASME Sec. IX.
9.2
Welding shall be in accordance with ES6004.
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ENGiNEERiNG STANDARD
ES 6018
ISSUE: JAN.'98
POlL
UNDERGROUND PIPING
SHEET 6 OF 15
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Alignment and welding set up of pipe joints shall be as per ASME B 31.3 and
shall be inspectecfby POlL before starting the welding.
().4
Inspection and inspection requirements
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CLEANING AND FLUSHING
IO.I
The pipe line shall be, section by section, thoroughly cleaned by manual
means/compressed air/mechanical means. such as pigging/water as may be
permitted.
10.2
Normally the complete system/installation

shall be flushed/cleaned with the
system fluid after the system Pumps/Compressors
are taken on line. However,
the suitability of the system fluid for flushing shall have POlL approval.
10.)
Adequate and suitable arrangements

made before starting the flushing.
10.4
During flushing/cleaning of the piping system with system pumps/compressors

on line, the complete installations shall be examined for possible leaks.
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11.0
HYDRAULIC TESTING
1\.1
The procedure for Hydraulic testing shall be iri, accordance with ES:6006
except that the specified test pressure shall be maintained on the line for a
period of one hour or time taken for inspection whichever is more and no drop
in pressure should occur. It is pressumed that all field joints are exposed for
visual inspection during hydraulic test.
11.2
The spool pieces before application of protective coating shall be subjected to

hydraulic test.
113
In case, due to site conditions, Hydraulic testing of the complete system is not
feasible, the field joints in trenches shall be 100% radiographed.
12.0
BACK FILLING & CLEAN UP
E
D.
12.1
Back filling of the trench shall be started after inspection and approval of POlL.
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12.2
Before pipe is laid in the trench, sub-grade shall be made by back filling with
approved material for a depth of 75 mm from the bottom of the pipe and /
compaced by ramming/tamping.
.
12.3
All trenctJes shall be back-filled by hand from bottom of the trench upto 300
mm above the top of the pipe with back-fill material free from cinder, ashes,
refuse, vegetable or organic material, boulders, rocks, stones or other such
material which may damage the protective coating of the pipe. The back filling
shall be carried out in layers of 75 mm and thoroughly compacted by tamping.
Back-fill material shall be deposited in the trench for its full width. The back fill
material may be excavated earth, river sand, fine stone dust, sandy soil, etc. In
case, adequate quantity of excavated earth is not available, back-fill material
shall be hauled from other places by the contractor.
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for disposal of the flushing fluid shall be
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ES 6018
STJrnUARD
ISSUE:
UNDERGROUND
-----'
PIPING
.. '
JAN.'98
SHEET 7 OF 15
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12.4
From 300 mm above the top of the pipe and upto grade level, material
containing boulders upto 80 mm in their largest dimension may be used. The
back-fill material may be filled by hand or by other approved mechanical
methods and shall be thoroughly compacted.
12.5
While back-filling and compacting, care shall be taken to avoid any injury to the
pipe and the protective coating.
12.0
Wherever excavated earth is used for back-filling, the degree of compactness

shall not be less than 90% protector density as per IS 2720 Part 7 and Part 8.
12.7
The back-fill above the grade level shall be completed as indicated in FigA & 5
as applicable.
12.8
Settlement of back-fill in the trench shall be achieved by means of flooding,

puddling, tamping or jetting. Poking with metal rod is not permitted.
12. C)
During and/or after completion of back-filling, the excess excavated material

shall be carted away as per direction of POlL. The area shall also be dressed
and cleaned. All debris, erection waste etc. shall also be removed by the
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MISCELLANEOUS
. The pipes and its branches emerging above the ground level shall be blanked
with M.S. blanks fillet welded to them. These blanks shall be removed only at
the time of connecting these lines to above ground piping.
13.2
The elevation of projected portion shall be as per piping drawing and shall be
kept free from any protective coating for a distance of 150 mm from top
elevation.
14.0
In case of cooling water lines, if it is difficult to drain out the water and dry out
the line completely, the test'water shall be allowed to remain in the header after
adding the inhibitor like hexametaphosphate.
15.0
Valve pits shall be constructed as per drawing and construction shall be such
as to prevent ingress of sub-soil water.
I
DEVIATIONS
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16.1
Record of deviation/alteration
by the Contractor.
16.2
After
from the construction drawings shall be recorded
the completion of the work, as built drawisngs
shall be made by the
Contractor and submitted to POlL incorporating all the deviations/alterations. .
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ES 6018
ISSUE: JAN.'98
POlL
'
UNDERGROUND
PIPING
SHEET 8 OF 15
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17.0
MEASUREMENTS
17.1
Trench Earth Work
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For the purpose of measurement
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Cross section of the trench shall be considered
b)
Length of the trench shall be on the basis of dimensions

layout drawing including the valve face to face distance.
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17.2
as per Fig.1.
given in piping
Piping System
<J)
<l>
I a
a)
The piping measurement shall be computed from the piping layout

drawings and actual measurements taken for deviation/modifications
made during execution.
b)
In case the erection of valves and specified special components is

being measured separately, the erection dimensions of such items shall
be excluded while computing the erected piping measurement.
c)
The measurements shall be along centre line of piping system from end
~
.2
0
.r:
<J)
(;
"0
<l>
U
:J
"0
0
Co.
to end and shall include all fittings like flanges. bends, elbows, tees,
reducers, instrument tappings etc., but shall exclude such items as per
para 17.2 (b).
"0
1>
0..
0
u
OJ
D
d)
I ~
I g
i
I
I
the measurement
shall be from the root of the
u
c
"
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;=;
c;:
For branch connections

branch.
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E
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t=
,.
ENGINEERING
ES 6018
STANDARD
ISSUE:JAN.'98
POlL
UNDERGROUND
PIPING
SHEET 9 OF 15
GROUND LEVEL
I~UII::
~0
c0
:::::::::::\
::>
/'
'>".J
110 P"""""""""""
Vi
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E
n;
0.
C
~
~
QJ
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!
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g
!
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I
N (MIN.)
N1
N2
3
4
700
700
1100
1100
225
225 .
300
300
700
1100
275
300
800
1200
300
300
10
12
14
16
18
.20
24
60
32
36
40
44
48
56
64
72
80
800
800
800
900
900
900
1000
1000
1100
1100
1200
1200
1300
1400
1500
1600
1700
1200
1200
1200
1300
1300
1300
1400
1400
. 1500
15d'0
325
350
375
375.
400
425
450
500
550
600
325
350
375
375
400
425
450
500
550
600
1600
675
675
. 1600
1700
1800
1900
2000
2100
750
800
900
1000
1100
1200
750
800
900
1000
1100
1200
: ~
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1:
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g
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0
0..
'0
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'6
c
C
QJ
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0.
0
a;
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VI
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a:
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a.
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1-
PIPE SIZE
IN INCHES
'6
I B
FIG. 1
I ~.
II ~~
I.
-.-~~----._-
NORMAL
EXCAVATION
ROCK
EXCAVATION
NOTE:
1.
2.
3.
4.
5.
N1 Apples for plant piping.

N2 Apples for cross country p1ping.
The dimension '8' shall correspond to the diameter of end pipe.
The dimension 'N' shall correspond to largest diameter pipe.
Distance between two pipes shall be as per CI. 5.9.
ES 6018
ISSUE: JAN.'98
UNDERGROUND PIPING
PDIL
.'
I SHEET 10 OF 15
High way Right of way

( Typical)
.J
0>1
::2'
0
Cl.
'"5
~I
Vent pipe ( 5)
:s
:;;
'"
(f)'
'01
w'
Pavement
~
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<:>
0
0
N
:S
min.or 3S specified
I" by high way regulations.
100~
mi~ r
-,
I
'"
i
I
.
I Caslna
Insulator
Carrier Pipe
~
"
5 m max. spacing
..
i
!
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l
Casing Pipe
--------------------------------------------------------~
I
I
I
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!
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500
I
...
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i::
,
S.S.Wire Mesh
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(20 Mesh)
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-'
SEC. Y - Y
~
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FIG.
-'
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1.
Casiing pipe shall be sealed at both ends-
2.
In refilling the trench excavated for the pipe line, adjacent to road and across I
roads where trenching is permitted. the trench shall be promptly back filled in a
proper and workman like manner.
3.
Casing pipe shall be 100 mm bigger than the carrier pipe-
4.
All dimensions are subject to individual state high way specification.
5.
Vent pipes shall be provided only in case of gases and volatile liquids such
as Ammonia. Naphtha etc.
WAY I ROAD CROSSINGS
NOTES:
a:
C
?:
Ci
0a
a.
HIGH
t"J
"'5
c
c
!:!)
c
fl
:;
u
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~ PDIL
ISSUE: JAN.'98
UNDERGROUND PIPING
'
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0
Cl.
ES 6018
ENGINEERiNG 5TANDARD
.-
SHEET 11 OF 15
Rail Road
Right of way
( typical)
a
c
0
u;
</)
E
a;
<:I-
z
~
a
a
~
~
5
;
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Seal
</)
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c:.
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300-1
- - - - - - - - - - - ---j- - - - -=-==--=---~ I ~=-- --~- ~-
~
\
"-
\ Carrier Pipe
</)
FIG- 3. RAIL ROAD
"0
'"
U
I
4-----
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>-4
Casing Insulator
4.5 m max. spacing
CROSSINGS
::>
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a
a.
~
1200
.y
5.S Wire Mesh

( 20 Mesh)
D
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Ci
a
u
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.2
.y
DETAIL - A
0
c
DETAIL X
.-SEC.
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.,
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0
c.
NOTES:
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6
c
1.
Casing pipe shall be sealed at both ends.
2.
Pipe line shall not be laid under rail road tracks nearer than 2 m from any rail
joint.
3.
The trench on each side of the track shall be promptly refilled in a proper and
workman like manner.
4.
No pipe shall be placed on, under or with!n 16 m of any bridge culvert or

structure.
5.
Casing pipe shall be 100 mm bigger than carrier pipe.
6.
Where in the opinion of the railway authorities. drainage ditches or other

conditions require the pipe and casing to be burried to a greater depth. pipe shall
be so installed.
7.
In all case the specifications of Indian Railways shall govern.
8.
Vent pipes shall be provided only in case of gases and volatile liquids
such as Ammonia. Naphtha etc.
C
QJ
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Tlus document
--
IS the poil!,'"
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Prl;I'::C!:;
ImJIJ L"l"li~d
.:!. Development
t I '()II.)
JI1J
not t,) be copied
or reproduced
or sho'Nn
10 In:rd ,:Jr;:es
','"Ihout
(t,e wntlen
permission
of POlL.
[II
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,-
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N
U1
a
N
U1
a
-a
c-
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Back filling as
per CI-12.4
r-
18
Pipe Line
j
m
z\
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:2:
m
m
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CJ)
-4
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C,
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CJ
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Back filling
perCI-12.3
c
z
c
m
as
:;t1
....
FIG.4
G)
BACK FILL
:;t1
FIG. 5 BACK FILL ON SLOPING GRO
Grade
\ \ \ \ \ \ \ \ \
Bottom of Drain
Channel iron or secti~

of pipe strong enough
to support the drain
bottom
Sand cement filled bags
FIG. 6 DRAIN REPAIR
a
c
z
C
-0
-0
z'
G)
en
:r en
m en m
m c: en
-! fTl.
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(
m
0
co
ES 6.018
ISSUE:JAN.'98
UNDERGROUND
POlL
I
I ~
I ~
I
PIPING
SHEET 13 OF 15
ANNEXURE-1
Strength Calculation of underground Metallic Pipes
~in
V>
E
a;
a.
1.2
Following steps specifies the. procedure for checking the strength

of
underground
steel pipes and underground steel casing pipes (i.e. Burried
Pipes ).
~.()
Loads over Burried Pipes
8-
2.1
Live load (Wd in Kg/cm2 shall be obtained as indicated below:
c:
2
i ~
0
".
5
:0
"'"
S
.9
;;
0
Height of cover (m)
--
0.3
0,6
1.2
1.8
2.4
3.0
.c.
V>
Load of truck
--
0.8
0.5
0.23
0.15
0.08
0.08
(;
'0
OJ
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:0
'0
0
Load of locomotives
2.6
2.0
1.5
1.3
1.0
0.7
a.
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'0
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0
U
i!J
D
Wd
.9
0
c:
;2
;:0
-'
'0
HP x 10-4 where H = Height of cover(m)

P = Density ofsoi"(Kg/mJ
2.3
is
0..
I
Dead load (Wd) or Back fill load in Kg/cm2 is obtained by
Total load in Kg/cm2 is obtained by

Wtd (for deflection consideration)
;/2 W1 + Wd
Wts (for strength consideration
W1
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a.
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reduction factor of ii is applied on W1 ).

/
of)
3.0
e~o
QJ
Percentage deflection in vertical direction' is given by
% defln
a.
0
a.
QJ
:S
~
C
QJ
E
:J
U
0
'0
<II
E
f-
+ Wd
(Note: Traffic loads or transient loads have less effect in deflecting a flexible
pipe than do permanent soil load, hence when considering deflection only a
c:
OJ
II
10 Wtd
---A--+---
Where A = Resistance of pipe due to its mean diameter (d), thickness (t) and
modules (E in Kg/cm2 ) and is given by
'
2F.
( JOI..\'
) ( d)
-'
ENGINEERING
ES
STANDARD
6!J18
ISSUE:JAN.'98
UNDERGROUND
PDIL
PIPING
SHEET14 OF 15
is
Cl.
'0
c
0
Vi
(fJ
And B = 120 Es (Es being modules of elasticity of soil in Kg/cm2 at overburden

pressure as determined in a triaxial test). Here soil pressure acting externally
on the pipe surface shall resist Wtd. The enveloping forces are acting radially
and the pipe ring is a confined arch under compression.
::
t
a.
"
:;
I
I
I
.
':;
Es = 4 TO 10 X 103 Kg/cm2in good ground above water table according to

compaction.
(fJ
Es = 2 to S-x 103 Kgicm2 in poor ground or in good ground beiow water table.
..:;
:::;
I ~~
I
I
g;
[l
3.1
When there is no soil pressure on the pipe surface. B = 0 and when soil
pressure is acting radially over pipe surface. A is negligible in comparison to B
and hence A = O.
3.2
Percentage deflection thus obtained should not be more than 2%.
4.0
Strength consideration.
4.1
Emparical formula for Bursting strength is
~
.9
c
3
0
.c
(fJ
a
"0
<lJ
U
:J
"0
0
0.
"':J
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6.
0
u
Wts
15
.9
s:;
jfEsx(/x(j)xiO-6
"..,
-'
is
4.7
Emperical formula for bending strain is given by
Cl.
5 x % deflection
~
~
x (-~-)
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c
~
6.
0
0;
>
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""
5.0
Design consideration
5.1
In burried pipe at any depth
a) % deflection < 2% (Calculated as per CL.-3.0)
(fJ
<lJ
6"
a:
b) Bursting strength (Wts) < value obtained as per Clause 4.1
'0
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0.
<lJ
5
.!!!
C
<lJ
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c) Bending strain shall be less than 0.35% for non-pressure pipe and 0.2% for
pressure pipe. (Calculated as per CL. - 4.2)
For safe burried pipe. above three conditions (under Clause 5.1) should be
satisfied.
Reference - Hand book of valves, piping and pipelines (book) by RH. Warring
(Gulf Publishing Campa my,Book Divn.)
-.
,..
--
ENGINEERING
PDIL
FINAL
CL
'0
c:
UNDERGROUND
ACCEPTANCE
OWNER'S
a
Vi
ISSUE: JAN.'98
--------
.J
0
ES 6018
STANDARD
PIPING
CERTIFICATE
SHEET 15 OF 15
FOR U.G.PIPING
(COOLING
WATER)
NAME
VI
WORK
Q;
0.
c:
ORDER
NO.
DATE
CONTRACTING
1)
FIRM
-5
:;
CONTRACTOR'S
a
-5
REF. :
SUB U.G.COOLING
VI
I
I
I
I
I
ro
i)
a.
'2
5
Check of layout as per piping arrangement
i i)
Check of special supports/Anchor

and standard supports
'='
i ii)
Check system as per P&I Drg.No.
"a
iv)
Acceptance of X-Ray examinaUon
v)
Acceptance of D.P. Inspection

joint (Root run only)
of trend)
vi)
Accpetance
(if any)
vii)
Hydrotesting
c:
VI
ill
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a.
'='
1)
6.
a
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1)
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D
.s
viii)
a;
E
of Heat Treatment
of the system
--
Pressure
--
Duration
--
Remarks
Installation
Blocks
on (date)
--
ix)
--
--
---
---
of valves
,
--
Total Number
a.
a
Qj
>
ill
0
PIPING
drawing
-a
;;
a
J:::
WATER
Making
of valve
-- Total
chamber
Water
VI
--
No.
--
Proofing
U
ill
15
0::
x)
Check supply of items in scope of Contractor

and its test certificate.
xi)
Special
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>-
t:ill
a.
a
a.
ill
-5
!!!
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ill
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CONTRACTOR
--
Remarks
POlL
OWNER
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WELD\END DETAIL
WALLTHICKNESS
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PIPE SUPPORTS
STANDARD TYPES AND APPLICATIONS
PDIL
ISSUE: FEB. '99

SHEET
1 OF 13
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GENERAL
1.1
This standard lays "down guidelines for the selection and application of pipe
supports and covers standard types and installation. The modification of the
standard types of piping supports described in this standard may be made only in
exceptional cases.
2.0
2.1
The supporting systems shall provide for and control the free or intended
movement of the piping including its movement in relation to that of connected
equipment. Vibration in the pipe shall be taken care of while deciding supports.
2.2
A careful study shall be made of the piping layout in relation to the surrounding
structure, adjacent piping and equipment before selecting the type of support to
be used at each supporting point. Maximum utilisation of the existing structurees
shall be made for supports.
2.3
Supports shall be selected to withstand all static and dynamic condition of loading
to which the piping and associated equipment may be subjected.
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Load calculations where required shall give consideration to the following:
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Weight of pipe, valves, flanges, fittings, insulating materials, suspended

hanger components and normal fluid contents.
(b)
Weight of hydrostatic test fluid or cleaning fluid if normal operating fluid

content is lighter.
(c)
Additional loading that may occur during erection.-
(d)
Intentional use of restraint against thermal expansion.
(e)
Reaction forces due to operation of safety and relief valves.
(f)
Wind loadings on outdoor piping.
(g)
Lateral friction force on the trestles due to expansion of pipe.
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Seismic Load
The criteria for calculating maximum spacing for horizontal pipes shall be as
indicated in Tables 1 & 2.
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Support spacing calculated on the basis of these criterian are tabulated in PS04.
3.0
MATERIAL
3.1
Materials of supports shall be as per individual supports standards and shall be

used within the temperature limitations mentioned therein.
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Pipe supporting elements subject to coirosion Oi electrolysis shall be suitably
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Hangers and supports shall be dimensionally compatible with the outside diameter
of pipe or if specified the outside diameter of the insulation.
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Hangers for the suspension of NPS 2// and larger pipe shall be capable of
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DETAILS OF TYPES OF SUPPORTS AND APPLICATION
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The selection of hangers and supports shall be made to provide the piping system
with the degree of control that its operating and design' characteristics require.
The simplest assembly of components that fulfills this requirement shall be most
desirable.
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Maximum Overload
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PIPE SUPPORTS
STANDARDTYPES ANDAPPLICATIONS
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650,000 kg/cm2for aluminium pipes
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Supports
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NPS 1" --24"
Resting
May be used
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guides,
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supports
Guide
TO be used
for horizontal pipes only. where the lateral
movement
of the
pipe is to be prevented.
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Maxm.Guide spacing
NPS 1""'2"-6m,2
1/2"",5"-9m,6"",10"-12m,12"",14"-15m,
18'~ 24" -18m.
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0
When the pipe is hung,the load of the' pipe to be supported

by the clomp shall not exceed the following:-
Ci
~
(;
guide
for NPS ,.:...24" (PS 11. 1)Also can
for
NPS::;2" (PS 11.1 a)
ii~'
NPS
PS 1110~Z'
Kgs
"0
Q)
'0.
0
u
2"-3"
700
,.' - 1 1/2"
500
4"-6"
1300
8"-20"
2000
Q)
.D
.8
'0
c:
~PS
NPS "'--24"
113
NPS s.2 1/2"
"0
c:
0
-::::J
5.3
Support
for vertical
insulated/bore
pipe at temp.
<200.c
when vibration
is not present.
C5
~"0
0
"0
c:
Q)
E
a.
0
a:;
>
Application
Type
PS
12.1&12.3
PSi2.1a&12.3a
PS12.2&12.2al
ON100-800
Limit of load:-
If)
5.4
Supports
Q)
'0'
PS 13.1
Resting
'0
DN25-600
...
11.
1:-
va.
0
...
a.
Q)
:5
,!!!
CQ)
E
:J
U
0
"0
If)
:c
I-
for horizontal
cold insulated
250-350
100-200
ON
;
Kg
[f'19
I
Q)
0
~
.
.
.
TO be used only when material of the pipe permits welding.
Can be used as resting,guide and anchor.
3000
1500
pipe in the absence
..
600-800
4500
6000
of vibrations.
PS 13.4
Hanger
PS 13.3
Anchor
PS 13.
Guide
400-500
NPS 1"-
12"
L=150forDN ~ 50
200forNPS > 2:'
PS 13.1a
Resting
'NPS 1/2:'-14"
NPS 'j'- -
ISSUED
Anchor
I
ill
FOR jMPLEMENTATION
P.YRPl>~
",) ;'
'
PS 13.3
PS 13.2a
Guide
NOS
~ c".
PS 13.4a
Hanqer
'
Engg.Comm.
,YB,~PA~EQ
REVIE~E~
FILE
APPROVED
NAME :PS 01SH4DWG.
1,..,,\, ..(
01
PDS:PS
PIPE SUPPORTS
PDIL
ISSUE:
STANDARDTYPES AND APPLICATIONS
-'
cs
Co
FEB., 99.
SHEET
OF
13
"0
c:
0
'in
<II
5,5
Supports
or insulated
pipes.
with the pipe is not permitted.(as
'E
~
a.
c:
for bore
is more
Support
in the
welded
case
with clamps
are to be used
only when welding
of alloy steel and where the pipe temperature-
than '350.c)
Type with clamps
Type to be directy
shown
to the
Application
direct
pipe
without
welding to the pipe
Q)
:5
:;
0
:5
'i
<II
1!
(;
a.
.8
PS141
Resting
;~
'
",,
".
Temperature
(;
'0
Q)
u
:;)
'0
0
:s.
~
for horizontal
.8
'0
c:
'0
c:
0
PS14.2
ON25-600
ON25-200
Guide
-t-
E{B+
Temperature
TO be used where
$.500.c
lateral
deflection
af the
pipe is to be prevented,
Maximum
PS14.5
ON150- 600
NPS
spacing
1"-3"
spacing
(m)
16"-24"
12
8"-14"
9
4"-6"
6
-~x
(m):-
-::J
CS
Co
'=0
~
'c
0
'6
S
ON150-600
PS15.3
"~
1
",
ON25-600
ON25-600
ON25-600
'
'
"
"
'"
,,'
<.~,
--
~FW
,
PS14.6
ON50-125
E
a.
0
,','
"'","
"
Anchor
To be used where
'::';~
,,
Temp.
limit <500.c
linear
movement
RBI
and
'.
rotation
of the pipe is to be completely
prevented.
Position of anchors
BID
.
Q)
to be decided
PS15.6
ON50-125
by flexibility calculation.
.',
f18i
I':'~"
'
--1'0
v>
Q)
0
PS 14.4
ON150-600
Resting
support
Temperature
upto
i
for vertical
PS15.4
ON150-600
pipe.
400.c
<II
U
Q)
'0'
a:
"0
0....
a.
0
max.
PS14.3
ON25-600
::~
a.
PS15.5
~- max,
,,,
ON25-600
$.500.c
'0
Q)
.D
PS15.2
ON25-600
pipe.
~N25-600
(;
Q)
'5.
0
u
ON25-600
a
a
'0
~
'is
..;
support
PS 15. 1
1-~ max.~-mO'2~O"9
Avoid where the length of pipe supported

is > 15m. Where there is possibility of
lifting off the support due movement and
transfer of load to other supports, use
spring supports.
1- ~max.
m"2~"9
Q)
:5
.!!!
cQ)
E
:;)
u
0
'0
Guide
To be used where pipe is crossing
wall or slob. Temp. limit 50gc.
<II
"
I-
ISSUED
FOR IMPLEMENTATION
PURPOSE
Engg.Comm.
PREPARED
APPROVED
,
r
FILE NAME:PSO1SH5.DWG
./
,4-
PDS:PS
PIPE SUPPORTS
PDIL
STANDARDTYPES AND APPLICATIONS
.J
0
a.
01
ISSUE: FEB., 99.

SHEET
OF
13
'0
c
0
'iij
VI
'E
...
v
a.
Type 15.9 is recommended

to 14.9 in all cases.
PS 14.9
DN 25-600
Hanger to be used where there is no vertical

movement of the pipe,where there is horizontal
movement hanger components
sholl be selected
to allow for swing and in no case the vertical
angle of the hanger rod should be greater
than 4',
temp. limit 500'c.
~
'c
~
v
:S
OJ
0
:S
.~
VI
in preference
PS 15,9
DN 25-600
PS 15,10
PS 14.10
DN 50-600
DN 50-600
:e
0
a.
Hanger
rod types
'P
PS 16,1 PS 16.2
.8
PS 16,3
"0
Application
'.0
"
0
g~g:1 Kg IPipeDN l~nJl Max

12 515125-50
140012000
16
"0
V
U
OJ
"0
0
825165-125 I 50012000
~
~
...
0
"0
V
'0..
0
u
v
.0
.8
5,6
Special
support.
"0
C
0
Type
Applic'?tion'
PS 17
-::J
0
a.
':Q
2
'c
,~-&it
FiJ'
0
:0
.E
cv
E
a.
0
v>
To be used for horizontal insulated pipes at high temperatures

as a guide where horizontal thermal expansion along the axis
of the pipe is appreciable and frictidnal resistance
to the
movement
of the pipe is to be. reduced. However performance
of the support will depend upon its regular maintanance.
(See PDS:PS 17)
T
I
T
I
Constant
v
0
VI
U
v
'0'
a':
:?:Q;
a.
0...
a.
v
:S
supports.
Sholl be used for critical high temperature

lines where high
vertical movement is involved and deviation in supporting
force must be limited to 6% of the load.
Variable spring supports,
These supports corry the exact load of the piping only in
operating
condition and is to be used for non critical lines
expanding vertically,
.;g
'0
spring
PS 18
To be used
lfi\
reciprocating
for vibrating
pump
pipes as compressor
discharge
or
piping.
,!!!
cv
E
OJ
u
0
"0
VI
:c
>-
ISSUED
DATE
.. ,I:
FOR IMPLEMENTATION
PURPOSE
Engg.Comm.
PREPARED
APPROVED I
FilE NAME:PSOISH6,DWG~c .'
~
~j
PDIL I
I
'-!....---/
..J
15
a..
'0
BRACKETS FOR HORIZONTAL PIPES I

INDEX AND LOAD CAPACITY
Indication of
Designation
Representation of support and

indicating the point of reference
in the piping plan & elevation
Type
0
'in
III
'e
Q;
Co
c
'
cu
:5
PS20A.
PS208.
1+
EL
I I PS20D.v=
Co
Section
JAN.
SHEET
EL
.8
PS21A.
1:1
- EL
OF
13
Max. Max.nom. I
Load dia. of
sheet
I See
kg.
pipe
L65X65X8
300
200 I
100
L65X65X8
450
120
50
L65X65X8
600
90
50
For details see PDS:PS20

ISMC 100 300
600
150
ISMC 100
450
500
150
ISMC 100
600
400
100
ISMC 100
ISMC 150
750
300
300
1200
ISMC 150
ISMC 150
450
600
1200
900
ISMC 150
750
7501
600
100
ISMC 150 900
L65X65X8
300
L65X65X8
450
L65X65X8
PS21 8.
)(
Q)
5
1:1
cu
u
:J
1:1
0
E+-
a.
V
(;
PS21D,v= w=
1:1
cu
'0.
PS228,
u
cu
.0
.8
PS22D.v=
w=
"0
c
II
see
50
150
2X200
600
For details.
2X120
50
2X90
50
"
150
ISMC 100
450.. 2X500
150
ISMC 100
600
;2X400
100
ISMC 100
750
2X300
ISMC 150
300,
?X120C
ISMC 150
450
bx 120(
ISMC 150
600
2X900
,;;
E
Co
ISMC
750
2X750
150
900
2X600
100
':J
EL
PS238.
-ci
::i
EL
-
PS23D.v=
'5c
OJ
>
cu
Od
w=
ISMC 150
For details
EL
(II
U
cu
150
a':
PS24A.
EL
Q;
Co
0
PS248.
a.
cu
:5
.!!1
'-0
50
Q)
>
.....
u
Q)
a.
en
Q)
.....
..!::
ISMC 150
600
ISMC 150
750
1800
>.
en
1800
Q)'--
'0
"0
PDS:PS23
1800
'0'
ISMC 150
see
:J
.D
.;:
]?
2X600
1:1
c
0
.....
PDS:PS22
300
100
ISMC 100
15
99.
w=
"E
:.c
PS20E.
C=
(II
:.0
S.No.
ISSUE:
EL
:;0
:5
'j;
I PDS:PS 01
PIPE SUPPORT
900
ISMC
1050
1800
300
ISMC 150
1200
1800
300
ISMC 150
1500
1400
150
150
Q)
""'
en
ccu
E
EL
u0:J
1:1
III
w=
>'Q)"C
O..c 00
E-:.o..c
0>-"'"
application
of
wall
bracket PS-24 with the
be checked
>" c
the
Q)ooo
requires to
with the calcu-
DATE
PURPOSE
EDCMH
PREPARED
'-
3:o.D
en Q)
tfl.9
V1
R

.....
o.2=SE
..c
lotion done by civil.
:.c
I-
Q; .S ..... Q)
The
load indicated
PS24D.v=
0"'"
..c(jc
.....
..c
E en..c0
Q).....
.Doa::en
Note:-
III
.....Q)
PQ:.
REVIEWED APPROVED'
FILE NAME: PS01 SH7
/'
f
j\
PDIL
'-..!.---/
.J
is
a.
I BRACKETS
FOR HORIZONTAL PIPES I ISSUE:

I SHEET
Indication of
Designation
Type
Representation
of support and
indicating the point of reference
'0
c
0
'in
1/1
Co
EL
,
.,
==
Section
S.No.
'E
I PDS:PS 01
PIPE SUPPORT
PS25A. h=
L65X65X8
Max.nom.
dia. of
pipe
Max.
Load
kg.
200
50
50
L65X65X8
450
L65X65X8
600
90
OF
13
sheet
See
II
100
300
120
99.
JAN.
"'5
0
==
'i
EL
1/1
PS25D.
h=
h= 1200max.
For
Co
"E
details
500
ISMC 100
ISMC 100
600
400
750
300
ISMC 150
600
500
150
ISMC
150
750
500
150
ISMC 150
900
500
100
ISMC
1050
500
100
ISMC 100
ISMC 100
3
4
"0
EL
PS26A,
"0
15
x
.,
h=
u
:J
.,
"0
0
a.
EL
PS26D.
5
"0
.,
'a.
0
u
.,
h=
w=
0c
c
0
..c
EL
PS27A.
h=
PS27D,
h=
w=
600
150
150
100
50
h= 1200max.
For
"0
150
L>
0
PDS:PS25
300
450
1
2
.8
see
details
see
PDS:PS26
L65X65X8
300
2X200
100
L65X65X8
450
L65X65X8
600
2X120
2X90
50
50
-:::;
is
'ci
::;
0
'6
E
.;
E
Co
0
BJ
EL
I .
Qj
>
.,
h= 1200max,
For details
O!!
I.
1/1
u.,
'0
a:
'0
::-
+EL
Co
a.
LJ
.I
i
PS28A. h=
,-
.,
==
ISMC 100
ISMC 100
450
2x500
150
ISMC 100
600
2x400
100
ISMC 100 750
2x300
50
5
6
ISMC 150
600
ISMC 150
750
2x500
2x500
150
150
ISMC 150
900
2x500
.!!!
1/1
see PDS:PS27
2x600
150
300
ISMC150 1050 2x500
100
100
c:
.,
E
:J
U
0
EL
.I
PS28D.
"0
1/1
:c
I-
h=
w=
h= 1200max.
1912.'c,
ISSUED
FOR
IMPLEMENTATION
EDCMH
-PC<.
DATE
PURPOSE
PREPARED
REVIEWED
I APPROVED I \.
FILE NAME: PSO1SH8
PDIL
~
C5
Q.
'0
c
0
'iii
II)
'E
PIPE SUPPORT
BRACKETSFOR HORIZONTALPIPES
PDS:PS
SHEET
Representation of support and

indicating the paint of reference
,8
Indication of
Designation
Type
PS30A.
03
EL
~
.~
IT+'!
<U
:5
:;
0
:5
'i
II)
PS32A. h=
(;
..c
Co
"E
.8
IEL
-------
"0
..c
:g
PS32D. h=
v=
w=
99.
OF
13
Max. Max.nom.
See
Load dia. of
kg.
pipe
sheet II
Section
ISMC 100
600
1300
150
ISMC 100
750
1300
150
ISMC 100
900
1300
ISMC 100
1050
1300
150
150
ISMC 100
1200
1300
150
100
h=
PS30D. h=
v=
w=
ISSUE: JAN.
8,
~
Co
C
S.No.
01
ISMC 100
1500
1000
ISMC 150
600
2700
ISMC 150
750
2700
9
10
ISMC 150
ISMC 150
900
1050
2700
2700
11
ISMC 150
1200
2700
300
12
ISMC 150
1500
2200
300
X

<U
0
.id
II)
<U
'0
d:
'0
?:~
Co
0
5<U
:5
.!!!
~-
0
0
"0
II)
:E
I-
L65X65X8
600
600
100
2
3
L65X65X8
L65X65X8
750
900
500
400
50
50
PS33D. h=
PS34C. h=
PS34E. h=
-ffi
h= 1200 max.
r~
EL
EL
Jl-
---~
max.
j
I
L~
ISMC 100
600
1300
150
ISMC 100
750
1300
150
ISMC 100
900
1300
150
4
5
6
ISMC 100
ISMC 100
ISMC 100
1050
1200
1500
1300
1300
150
150
1000
100
7
9
ISMC 150 600

ISMC 150 750
ISMC 150 900
2700
2700
2700
see ADS:
10
ISMC 150
1050
2700
PS35,
11
ISMC 150
1200
QJ
~'9<2'0 ~
DATE
PS35A. h =;
PS35D. h=
~ -~
h= 1200
jJ_EL g
Jl-
PS34A. h =
LJ
II)
C
<U
E
:J
PS33A. h =
EL
'0
c
"0
C
0
8,
11=
is
"0
<U
'0.
0
0
For details see PDS:PS30.32
max.
PS36A. h=
I~
PS36C. h=
12
ISMC 150
1500
For detail
PS36.
2700
2200
300
L~

,
PURPOSE
EDCMH
PREPARED
APPROVED
"
FILE NAME: PSO1SH9
. .8
PDS:PS
PIPE SUPPORTS
PDIL
STANDARDTYPES AND APPLICATIaNS
~r;i1
01
ISSUE: FEB., 99.

SHEET
10
OF
13
'0
c
0
'iij
fI)
'E
'QI
0..
C
'c
~
Representation
III
J::.
:;0
:5
'j
and
indicating
reference
the
in the
height
Designation
point of
SNo I Vertical
Type
plan & elev.
h
metre
Horizontal
Max.
Section
Indication of
of support
1500
I2500
13500
Max.load kg,
fI)
:e
0
0..
ISHB150 IISMC150
-< 3
1000, -
ISHB150
ISMC150
~ 4
2200
1300,-
ISHB 150
ISMC150
2200
1300
ISHB150
ISMC225
3000
3000
2100
ISHB200
ISMC225
>4~6
<4
>4<6
3000
3000
2 100
1000
~ 4
>4~6
2200
1300'-
2200
1300
~4.
3000
3000
21 00
>4~6
3000
3000
21 00
"0
'-
PS37 A
~3
.B
"0
,....
'q
(
III
PS37B
'0
"0
III
U
:J
"0
0
1=
h =
0.
QI
'-
(;
"0
III
'1i
0
u
PS37D 1=
h =
V=
W=
III
.D
.B
"0
c
[~~
"0
C
0
-::J
i5
D..
':Q
EE
EL
l3
0
0
N
. ~
FOR DETAILS SEE PDS:PS37,
ISHB150 IISMC150
ISHB150
ISMC150
PS38A hI == 3
ISHB200
ISMC150
ISHB200
ISMC225
ISHB200
ISMC225
:.0
..s
91
PS38B
III
1=
h =
Lwr-I
~ I ~
dd
ISMC150
ISMC225
ELI PS39B
PS39D
'0
I =
,-
FOR DETAILSSEE PDS:PS38
0..
0
V
>
QI
0
-<
=
=
W =
I
V
ISMC100
1000'
2200
1300
3000
3000
21 00
FOR S.NO.1 ,Max dia of pipe= 100
0..
0'-
0..
QI
:5
FOR DETAILSSEE PDS:PS39
riS40C
PS40A
.!!!
IfEL
III
:J
u
0
"0
fI)
:c
I-
, ..
I~qq
,DATE
PS40A
tSMC100
ISMC150
.--
ISMC150
1.5
ISMC150
450
1000
1000 800
1
1 =
h =
FOR DETAILS SEE PDS:PS40
ISSUED FOR JMPLEMENTATION
Engg.Comm.
PURPOSE
PREPARED
PS40C
il3
APPROVED
fiLE
NMlE:PSOI
SH 1O.DVlG
"r"
"
"'.h.,.Jj
',
PDS:PS
PIPE SUPPORTS
PDIL
. ~ [j:iJ
"
'0
c
0
'in
II>
'f
'
a.
c
Representation
indicating
in' the
of support
the
Indicotion
and

rr
.J::
SNo
Type
h
Section
Designation
point of reference
plan & elev.
~
.~
of
EL
PS41A.h=
:J
0
:5
'i
h=300 Imax.
II>
EL
SHEET
11
Max,
Max.Nam.
load
dia,af
kg
pipe 'f'
L65x65x8
450
400
100
L65x65x8
600
400
100
3
4
L65x65x8
L65x65x8
750
900
400
400
50
50
PS41B.h=
(;
~,
bEL
- ---JF--
--I-&-!- -je-
v=
W=

.0
.JP- - -j\;;
EL
-kH-
--*I
PS41E.h=
EL
FOR DETAILS SEE PDS:PS41
f---
Ib-
v
'i5
..s
PS42A.h=
I--
tc
:J
EL
old
I I
I I
I I
II>

'0'
(J
Z
(/)
a
-I
ci
W
I~
W
V1
W
:r:
a.
a.
::>
(/)
-I
::!;
~
I
I~
W
(J
~
I
I-
(/)
I-
- W
a.
;: a.
O1.!w
~ ~
0 u
~ ~
I
600
1200
100
ISMC 100
750
1200
100
3
4
ISMC 100
ISMC 100
900
1050
1200
1200
100
100
I- - .
a'0
I- 0~
ISMC 100
1200
1200
100
a.
PS428.h=
::>
(/) x
W
a. ::!;
CL :
:J
,
0...
a.
>z
-I
-I ::E
::>
-I
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~ u
a
z ~
I

:ft- - ~
EL
-*+-
-je-
Ia
z
I I
1'1
I I

:J
U
0
"0
II>
:.c:
(/)
ISMC 100
?::~
a.
.~

:5
W
CD
-I
~ :5
is
a.
-:0
2
'c
'0
(J
Z
0
':::J
0:
"0
C
0

0
PS41D.h=
0
u
E
a.
0
Qj
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W ~
U
...
"0
c
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~
>
I
-I
-I
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U
:J
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0
'1i
I
(/)
W
I
I-
=4-
..;
"0

z
;:
a
-I
a
-I I
"0
13
I- :.::
u
(/) w
:5
2
'.0
OF
,~
ISSUE: FEB., 99.
I--
:e
0
a.
01
:1!--~
I-
I~,DATE.
2..' C\l1
~
,
rs-42D.h=
v=
I
ISSUED
W=
FOR IMPLEMENTATION
,
PURPOSE
FOR
DETAILS
SEE PDS:PS42
Engg.Camm.
PREPARED
AP~ROVED
"
tiLE NAME:PSOtSHt 1.0WG

"",
"J
J... .. ,
.J
C
Q.
0
c
,2
UI
,!!!
ISSUE: FEB. '99
POlL
SHEET
12 OF 13
Representation of supports on drawings :-
1.
E
Q)
Co
C
Q)
pes: PS 01
PIPE SUPPORTS
Schematic supporting arrangement as support symbols as shown below shall be

marked on individual pipelines in piping plans. A letter'S' followed by a number
indicating serial number of support shall be marked on the drawing.
Q)
;
'S
UI
Q)
:e
CII
Co
'E
FIl
;
'
;S
.s
c
:t
0
.t::
UI
0
"C
f!
=>
"C
0
Ci
0
"C
,
Co
0
0
Q)
J=>
SYMBOLS FOR PIPE SUPPORTS
SI.No.
Support type
1.
Resting
.s
15
c
"C
C
CII
:J
e:.
Symbolic
representation
Applicable standards
PDS:PS
10,12.1,13.1,13.1a,14.1,14.4,
11,12.2,13.2,13.2a,14.2,14.5,
14.7,14.8,15.2,15.5,15.7,15.8,17
Remarks
15.1,15.4,18,92,93
2.
Guide
3.
Clamp
><
11.2,11,3,19
4.
Rigid hanger
13.4,13:4a,14.9,14.10,14.11,
15.9,15.10,16
(i) Spring hanger
(ii) Spring resting
503,510
503
;
"C
Q)
E
:.:i
CII
:0
.E
'E
Q)
E
Co
0
Qj
>
Q)
C
GIS
5.
UI
Q)
'2'
Q.
6.
Anchor
11.1,12.3,13.3,13.3a,14.3,14.6,
15.3,15.6
Q)
Co
e
Co
0::
;
.!!!
....
N
'E
Q)
q
0
0
0
0
Q)
NOTE:- These symbols should be marked on the pipe centreline.
=>
0
0
"C
.!!!
.t::
I-
0::
W
en
,,-'
==
Z
==
0::
...
DKM\DA
J~
..'.
~...{'~
..
~..~
A
,
- ,
~
-
PDS : PS 01
PIPE SUPPORTS
ISSUE: FEB. '99
PDIL
SHEET 13 OF 13
.J
15
a.
0
c
0
:1
c
QI
::::
2. Types and details of supporting structures as well as pipe support attachment shall be
entered in a tabular form as shown below.
'~
QI
SLNo. of Supporting
structure
support
:5
:;0
:5
'~
CI)
QI
S1
t:
co
a.
'E
PS 37A.1
L = 1500
H = 4500
Support Attachment
2
1
NPS 3" -PS 10.1
NPS 4" -PS 11.3
Foundation
Remarks
Type
NPS 1%"-PS 12,2
:
.E
c
::
0
. J::.
CI)
Exact designation as specified in PDS should be mentioned. Variable dimensions like

length of the supporting member which are not mentioned in the PDS should be
indicated.
'0
Q)
0
OJ
'0
0
a.
!!
a 3. In case the piping support assembly is not covered by the PDS, detailed sketch shall be
made on a separate sheet and the sketch numbers referred in the above table.
0
0
QI
.a
.E
15
c
'0
c
co
:::;
15
e:'0
2
'E
:.:i
co
U
..E
C
QI
E
a.
0
Qj
>
QI
0
c/S
CI)
U
QI
'e-
-o.0
0
>
W
D::
N
LL
....
N
0
'T
0
0
0
'T
N
0
;
.'.""..
D::
W
IX)
" .,
, ,..
,:'
r(
~"~!
.0..",
a.
QI
:5
.!!!
C
QI
E
::I
0
0
'0
CI)
:c
I-
:!:
-,
,.~
:>.
t
QI
a.
0
:!:
D::
0
LL
"
H\PDSPSO1 F2B.LWP
'{
~~
pth
a
0
PDS:PS 10
PIPE SUPPORT
PDII,
4.7.9A
ISSUE JAN..99
RESTING, GUIDE & AXIAL STOP
SHEET I or
RESTING & GUIDE NPS 1" - 24"

C
Insert ate, oxbx12 thk

(Note - 2)
0
I
Foundation, cxe
0a
V
Resting on structure
PS 10.1
Resting on concrete foundotion
PS 10.1a
V
S
V
0
Dor
0
ISA 65 x8
For NPS 10- - 2
17-1)fr
in. 6
5=1.5 for NPS
=2 for UPS
r-
C
21
50X10 thk. Doi for NPS 1" -
Material - 15:2062
Guide welded with support

a
F
Exomple of designation:
Resting NPS 1" - PS 10.1
Guide NPS 1- PS 10.2
PS 10.2
C
NPS
SLL DN
.15
2 1/7
1 1/2- 2-
4"
C
150
25
40
50
65
80
100
33.7
48.3
60.3
76.1
88.9
114.3
60
65
80
40
60X100
cxe
100X100
200
10'
12-
IC
IC
I8"
20'
24'
250
300
350
400
450
500
600
168.3 219.1 273

105
130
160
323.9 355.6 406.4 457.2 508
609.6
285
335
185
200
225
760
50X200
300X200
500X700
200X200
400X200
600X200
a
NOTES:
For opplicotion refer P501

Fixing orrongement of insert plote to be decided. by I oundat ion designer.
3 Height of foundation In he indiented by piping designer.
79-1-99.
DATE
PURPOSE
INGG COMM
PREPARED
REVIEWED
APPROVED
Fit UWE' PS IM OWC
PDS:PS 10
PIPE SUPPORT
ISSUE: JAN .99

SHEET 2 OF 6
RESTING/GUIDE FOR BARE PIPE NPS 26" TO 36"

RESTING
I
\
1
/
-7C
400
WRAPPER PLATE MATERIAL &

(TO 8E WELDED WITH THICKNESS SAME AS PIPE
WRAPPER PLATE)
P1PE
NPS
2C
283032
3C
SIZE
ON
650
700
750
800
900
DEVELOPED
LENGTH
L
330
356
381
406
525
560
600
640
715
457
GUIDE
GUIDE 93
150X50% / 6 1hk
SITE WELD
400
WRAPPER PLATE MATERIAL &
ISA 100X65X8
PIPE
(TO 13E WELDED WITH THICKNESS
WRAPPER PLATE)
GUIDE PLATES
MATERIAL - IS:2062
NOlt : IN CASE SLIDING I MCC IS REOUIPED 10 DC LESS. NO. OF
RODS (2-3) ARE TO DC WELDED ON THE SUPPORTING
STRUCTURE BELOW IHE PIRL.
DATE

PURPOSE
ENGG. COMM
PRE PARED
PIPE
NPS
26
2EC
30it
SIZE
DU
650
700
750
1300
36' 900
DEVELOPED
LENGTH
330
525
560
600
640
715
356
381
406
457
201.
APPROVED
REVIEWED
I
PIMA PS I 00 DWG
PD1L
t?
0.
0
C
0
PDS:PS 10
PIPE SUPPORT
ISSUE: JAN.,99.
SHEET 3 OF 6
AXIAL STOP FOR BARE PIPE NPS 7 TO 36"
R
LOPM NT
SEE TABLE
1-6 0 VENT HOLE
0
0
SHAPE AS PER TABLE
WRAPPER PLATE MATERIAL AND
THICKNESS SAME AS PIPE
PS 10.5W NTH WRAPPER PLATE) ONLY USED 10 I

ALLOY STEEL & S.S. PIPES.
PS 10.5
(WITHOUT WRAPPER PLATE)
SIZE
ON
50
so
100
125
H=150 UP TO 14PS 8 &

300 ABOVE NPS 8
R
30
45
SHAPE
5 "Pee
IOW.
SCH0/6:1239
50/.40/15:1239
80 #1.8. P1PE
SCH.40M . 1239 HEAVY.
PLATE
DEV.
WID1H
80
I 50
57
70
150 84
200 110
810" 250 136
12- 300 162
14" 350 173
16" 400 203
ISMO 100
ISMB 100
ISMB 150
ISMB 150
I5M8 150
19.113 200
ISMB 200
15M8 200
300
1e- 450 228
15M8 200
ISMB 250
19.18 250
ISMB 250
ISMB 250
ISMS 250
ISMB 250
ISMO 250
ISMB 250
ISMB 250
300
300
350
350
400
400
400
400
450
500
S
C
20"
22
24
PIPE
NPS
2"
s
500
550
600
2C
650
700
28
30" 750
32- 800
3e 850
38 950
254
282
305
330
356
381
406
432
457
150
180
200
200
200
250
.300
L=WIDTH OF BEAM (EXISTING)

TO BE MEASURED FROM SITE
29- I -99
DAIL
ISSUED FOR ImPi ELIE NIATiON

PURPOSE
ENGG. COMM
PREPARED
ritr
ze,'
REVIEWED 1
APPROVED
HIS HAUL . PS I OC.DWt.
PDS:PS I 0
PIPE SUPPORT
PDII,
psi
ISSUE: JAN..99.
SHEET 4 Or 6
AXIAL STOP FOR INSULATED PIPE

PS 1 0.6W (WITH WRAPPER PLATE)
A Ti-H
FOR PIPE NPS 2" TO 5"

0
SEE TABLE
0 VENT
I
HOLE
FOR SHOE DETAIL

REF. PS 14.1
70 f
SHAPE AS PER TABLE
EXISTING STRUCTURE
SECTION AA
V
I'S 10.6
(WITHOUT WRAPPER PLATE)
FOR PIPE NPS 6" 10 24"

A -gad
0
0
/
I
1
I
PIPE SIZE
NPS
ON
FOR SHOE D . REF. PS 14.1

I
I 70
0
ti
0
a
0
>
Er
SHAPE AS
PER TABU
SECTION AA
SHAPE
5 22' Pr(IfJON
SC11.40/6:12)9
80
7'
50
30
S'
so
45 SOLI0/15.1215
" NIL "P IOW
100
6W
150
700
57
84
110
10
16'
250
300
350
400
18'
70'
72"
74"
450
500
550
600
12'
Te
150
136
162
178
203
15140 100
15148 150
ISMB ISO
15148 150
:SKI 200
15148 200
ISMS 200
150
200
200
200
250
300
300
228
254
280
305
15M8 200
15118 250
15148 250
15148 250
300
300
350
350
EXISTING STRUCTURE
1 WRAPPER PLATE IS ONLY USED FOR ALLOY STEEL AND
MATERIAL & THICKNESS IS
STAINLESS STEEL PIPES.
SAME AS PIPE.
2 L.-WIDTH 01- EXISTING SIRUC I URI 10 OF MEASURED AT SITE.
w4, DIVE LOP/ D WIDTH OF WRAPPER FIAT E.
29-1-99
DATE

PURPOSE
(HOC. COMM
PREPARED
Pa ,,,a)
REVIEWED/
APPROVE()
01. kW(' PSI OD.DWG
PIPE SUPPORT
RESTING, GUIDE & AXIAL. STOP
PIML
pad
PDS:PS 10
ISSUE: JAN.,99.
SHEET 5 OF 6
PS 10.7
o.
RESTING SUPPORT
PIPING SYSTEM RUNNING HORIZONTALLY ABOVE GROUND LEVEL.o

PIPES WITH NEGLIGIBLE EXPANSION (Maximum temperature 80 C.)
NPS ?. 16"
7\
I
4?,
I
/
1
\"<
1P0
100
i
/
760
REF. POSTS 03
Min.
tr-1
r t
_ J
r!
0
E
NOTES
LOimensions or masonary base must be Fixed with respect to the
0v
-ts
II
numbers and nominal diameter of pipes as height and distance

between support to suit the toad. the pipes shalt be in intimate
contact with the entire surface of the support and corners of
the saddle plate shalt be rounded.
0
0
29 - 1 - 99
DATE

PURPOSE
cucc. COMM.
PREPARED
REVIEWED
APPROVED
rtntE: PS I OE Not
-f
I DIL
PS 10.8
PDS:PS I ()
PIPE SUPPORT
ISSUE: JAN.,99.
SHEET 6 OF 6
RESTING SUPPORT
F
PIPING SYSTEM RUNNING HORI7ONIALLY ABOVE GROUND LEVEL.
PIPES SUBJECTED TO SLIGHT EXPANSION (Max. temp. 100 C.)
NPS >7 16"
EN
/
I
EN
/ X%/
I
I"
.-e
1.--7.,
/ I
--e----,
.-
500 Min.
12
. i
7-y-rI
1
X 170
11
111
t__31sejec
80x80x220
0
;Th
F
fig
0
V
1.3
C.
0.
0.
V
C
"z
.2
C
C
4C,
0
NOTES
1 .DimENSIONS Of MASONARY BASE MUST BE FIXED WITH RESPECT TO THE NUMBERS AND
NOMINAL DIAMETER or PIPES AS WELL AS HEIGHT AND DISTANCE BETWEEN SUPPORTS TO
SUIT THE THE LOAD. THE CORNERS or THE SADDLE PLATE (8 THK SITAR BE ROUNDED.
0
0
CS
29-1-99.
DATE

PURPOSE
ENGG. COMM
PRE f 'ARE 0
REVIEWED
APPROVED
C' I rauc . P5101 TAG
r ,,f---.
PDS:PS1 I
PIPE SUPPORT
CLAMP
PDII,
ISSUE: JAN.,99.
1 SHEET
I OF 3
Guide
NPS 1/2"-24"
U--Bolt clomp ,
PS11.1
a
c
I
- - Malefic:I-IS:2062 Cr. A
tlr
Cl
oo
2
Oa
0
-
km
-Nut-IS:1363
When thickness exceeds 16mm.
dimensions h & h 1 to be
increased Proportionally
11
la
Threads & tolerances

os per 1S:1362 Coarse
t'0
E
Hole d;ameter=d1+
V
.)
PSI 1.1a
Anchor
U Bolt clomp ,
NPS 1/2"-2"
Le
'Ma
Example of designation
U-Doff clomp NP$ 1' -PSI 1.1
IIII
I I
if
tA
iv
tn NPS 1/2tu
a PIPE
DN
E
0
0
24-
2"
600
15
609.6
273 323.9355.6406.4 457.2
21.3
35
40
a8
62
76
94
105
135
160
192
248
302
352
402
452
497
554
648
82
88
95
109
125
140
155
190 215
245
306
360
411
460
515
570
620
720
10
dl
For 5.6. Pipes.use o pocking of 2mm.thk.

bituminised cord board between pipe
ond supporting structure/clump
IA
1410
M12
hi
65
70
WT. of
U bolt 0. 10 0.11 0.12 0.15 0.25 0.79
.:tomp.Ko
20
25
14 16
6
1.120
L124
05
90
105
16
12
0.84
0.92 2.81
2.15 2.54 4.0
4.47
4.92 5.41
6.31
NO1E. / . I. or appl tool ion.rel er PS01.
29-1-99
DATE

PURPOSE
ENGG. COMM.
PREPARED
REVIEwE0
APPROVED
PIPE SUPPORTS
TRUNNION DETAILS
PDIL
ad
PDS:PS 12
ISSUE: JAN..99.
SHEET I OF 6
a
0
is
/20
A)
o
0
FIG.1
0
V
NOTES:
Application of Trunnions has been shown in 1;9.1
Load capacity of trunions con be increased by providing
reinforcement pod(motl.& thickness some os pipe) and using higher
schedule trunnions according to Fig.3.
Trunnion welding procedure shall confirm to Engg. Std. ES:6004
(CS & AS PIPING), ES:6005(SS Piping) and welding detail os per fig.2 & 3.
For thin S.S. Pipes(Sch.10S or less) o wrapper plate of some moil, and
thickness shall be used (irrespective of trunnion material) in order to
reinforce the main piping in accordance with fig.4.
-j
0
V
E
3,
4.
a
Ca'
S.
MATERIALS:
A. CARBON STEEL & LOW TEMPERATURE CARBON SWF( PIPINGTRUNNION
Same as that of pip.;
S.S. PIPINC- First 100 mm shall he some os o f pipe

and remaining os per CS piping except os follows Entire Ts unniun material some as pipe if length is uplo 600 mm.
For SS PIPING. CS Ti minion couy be used it a wrapper plate of
material and thicknetS Some OS pipe I ; P e avidcd wrVI,Pri plait
may be mode from scrap stainless steel main pipe.
0. LOW ALLOY STEEL &

ft.
to
E
Ea
00
29-1-99.
DATE
PURPOSE
ENGG. COMM
PREPARED
24=1
REMEWE
da
APPROVED
III BANE :PS I 2A DAG
t3/4. -.1.?
i'
o
00,
-I-.
ra
..
!:
-:
PIPE SUPPORTS
W PM'
V S1
TRUNNION WELDED TO ELBOW/PIPE`
\-__
PDS:PS12
ISSUE: JAN..9 9.
SHEET 2 OF 6
INSULATED/BARE PIPE ...0 200' C WHEN VIBRATION IS NOT PRESENT

PS 12.18 Resting
PS 12.1 Resting
NPS 2"-32"
NPS 2"-32"
Elbow R r. 1.5 times 0 i ON
unless specified otherwise
- --1-- -----
I)
-5
co
o
9
0
--I
I
ott
vu
0It0
--.
o
c
0
o
tv
i
0
6
U
C
7
..-
6
(Min.)
i'
Al
ni
00
0
Bose Plo e
Moll. IS:2062
Dimensions some
r=iLl
i_J t_
___,
---11...-2?
Vi
Moth IS:2062 CrA.
NPS 4-,PS:12.1,L900
1 _,
-- L 20
---1
Jr
Ov
00
ir
a.
0
PS 12.3 or
PS 12.3a 1
Anchor
T.'d 7-os ps 12.1/ps12.10
Suf ix 'o' denotes trunnion

on stroight ton of pipe
NPS
I) -
PS 12.2 or
PS 12.2a *
Guide
XI
Bose Plo e
Mot I. IS:276
6
o
-.
c
lz
<
.1
Ll
r,
MarMill
Z3
0.
t7t
w
a.
_a-
diametrically opposite----,
\I\
1,1
0
0
MATL. SAME AS PIPE
......_
-,
o6
o-
1/2
4"
8'
70
10-
HL..
16
14 -
16'
_.,...I
12'
18" 20-
24' 28- .32-
80 100 125 150 200 250 300 350 400 450 500 600 700 800
Supporting pipe
NPS2-Sch.40/ UPS 4- Sch.410/ NPS 8 (Seh 40) UPS 10(S 640) NPS 14(Sch.40)
5:1239 Heavy 15:1239 Heavy
300
150
200
250
400
350
260
200
0
-33
2/
18
22
1
M30
0 of bolt(nnrhnr)
M24
MI6
1)20
hill
620
length of oinc/Itil bolt
380
160
Anchor Raft type
TYPE 0
TYPE C
of POS:ST -211
_
liat, ' a
29- I -99.
IENGG. COMM.
OATE
Pipe ON
50 65
PURPOSE
PREPARED
REVIEWED
APPROVED
RI NAM PSI 2e NYC
pth J
PI PE
ORTS
RUNN1ON WELDED TO ELBOW/PIPE'
PM L
ms:PS i 2
ISSUE: JAN.,99.
SHEET 3 OF 6
Low Temperature Service
f.'
,..
PS 12.4
...
S
-30
c
..
g
r)
Zi
a
2
"
'xi
2-Notches diametrically opposite
DN2
aw
12.4a
PS
z
Z,
0
m
. ti
LL)_
o
o
zna.
t
Z.,
a
y
LI
o
t
st)
n
ta
r4
j,
ON2-
(1.4
g
....
I IL
in
b
.-
,
;
_, m0
O
'Ai
i
IF
,,
,k
mi
'M.
NNE MINI
C,,
,;
J--
0N2
I
b2
Seasoned Vermin
proof Hardwood
all
NPS 4"-PS 12.4c -L700
V
0
N
6,
4,
a
0
1la
a_
NIPS
2- 2 I/7- 3'
ON
50
ON2
NPS 2- Sch.40/
15:1239 HEAVY
ra'
K
E
b2
29-1-99.
DATE
65
52
80
600
700
14"
100 125 150 200 250
300
350 400 450 500
NPS 4 "Sch.40/
HEAVY
NPS /1" San 40
102
201
18"
28"
12-
16"
20" 2e
10-
5-
NPS 10"Seh.40 HP514.'50.40
18: 1 2.39
200
PURPOSE
260
ENDO. COMM.
PREPARED
252
331
350
400
It? 2411
REVIEWED
APPROVED
CAI NMAC: PS I 2C .DAG
PDII
PDS:PS 12
PIPE SUPPORTS
TRUNNION WELDED TO ELBOW/PIPE
ISSUE: JAN.,99.
SHEET 4 OF 6
0
C
PS 12.6
PS 12.7
. Elevations of pipe and

800 1474t runnion ore of woys the some
_
-3:1(0
A
Trunnion support at
I iorizontol/Verticol Elbow
Trunnion support at
Horizontal/Vertical Pipe
Trunnion
V0
r verticoi g.
Stiffening Bar
10 X 25
* Shims ---
V
0
Support
12.5 Max. (Typ.)

DETAIL - A
VC
Note:4: Sufficient shims or wedges shall be provided

by the field to uniformly distribute the trunnion
load on the support.
0
V
Example of designation:
NPS
-PS12.6-t 501.1
0
n
In
o.
S
NPS
ON
TRUNNION
2'
2 I/2-
5U
Ni no 2
65
5BO
Sch 10/
IS:1239 Heovy
100
125 150
200
10-
12
250
00 350
14-
78-
32
400 450 500 600 1700
800
16--
NPS 4 Scl .40/ NPS 6-Soh.4C UPS 101S:1239 I 'toy), 15:1239 Hew., Sch .40
18-
20-
NIPS
24'
- St.:11.41.1
7
V
O
29-1-99.
DATE
ISSUED FOR IMPLt.MENTATION

PURPOSE
[NCO. COMM
PREPARED
REVIEWED
APPROVED
rat NNAL. PS120.0%t
--.
8,
PIPE SUPPORTS
ADJUSTABLE TRUNNION
PDIL
peUij
'
PDS:PS12
I ISSUE: JAN.,99.
SHEET 5 OF 6
PS: 12.8
Trim to suit
in field
is
`
s
r.ss
;
o
-it
e fl
Tr union .
:I 1.
Plate 1,' Squore
et
.7'.i
PO
Field shim
i c13
anti
IA,
3 ' Vent hole

3-19 Jock screws
with nut and locknut
a;
38 Adjustment
Y
_a
13 Cap
a
'el
s'i
1.5b
.r2
I P 0 C Fire
BASE PLATE DETAIL
Isui
PS: 12.9
8
0
Trim to suit
in field
..30
.-
'
8dine indent.
,- - ,
v
a
o
o
N10
2
'
;'
hole in pipe
.Line indent. Elev.
it
/ Do not cut
. F. ;
E in _,
n
ipe
rN
r) I
--
L 0h
ti
BASE PLATE DETAIL
Field tockweld otter

adjusting
EI
Straight pipe thd.pipe A
Elev.
_ _ _
Locknut
El
Do not Cut
hole in pipe
Tow notches diametrically

, _.-------r opposite
Suore Plate
4 Anchor Bolts t e 'C'
POS: ST 211
Example of designation: UPS

PIPE SIZE
Supp. line
NPS
Size (DU)
6C
Ea
if
,10"
29-1-99.
DATE
PS 12.9 1=
NPS 1 Sch.80/ NPS11/2- Sch.80/

15:1239 Heavy IS:1239 Heavy
NPS11/2Sch.00/ UPS r Sch.40/
80
15:1239 Heavy
IS:1239 HI!OvY
UPS 2- Sch.40/ UPS S Sch.40/
100
1S:1239 Heavy
IS:1239 Heavy
NPS
S Sch.40/ NPS 4' Sch.40/
150
IS:1239 Heavy
15:1239 Heavy
UPS 4' Sch.40/ IN c Sch.40/
200
1$:1239 Heavy
IS:1239 Heavy
NPS C Sch.40/ UPS C Sch.40/
IS:1239 Heavy
a250 IS:1239 Heavy
50

PURPOSE
Anchor
Dio.
Anchor
Length
150
200
18
16
380
150
150
700
18
Id
lb
380
200
18
LI 16
380
200 260
77
20
460
200
260
22
IA
20
460
200
260
22
Al 20
460
ENGG. COMM.
PREPARED
Ikt:. 29/1
REVIEWED!
it
APPROVED
NAM
PIPE SUPPORTS
TRUNNION WELDED TO PIPE
PDII,
1)1.)S:PS12
ISSUE: JAN.,99
SHEET U OF G
Pod Width.W
pipe Pod Width
(W).rnm.
Size
1/r to r
50
8- to 16-75
18" to 32-100
Nom.
C,
Pipc wall shall

not be burned
through or cut
0
Pipe wall sholinot be burned
through or Cut
.7 r(3.2 Attachment without Reinforcing pod
FIG.3- Altochmenl with Reinforcing pod.
5
0
7.1
1.
C.
0
V
Wropper Thole
S.S.)
>IV
11(3.4 Wropper Plate Detail
O
O
79-1-99.
OAT(

PURPOSE
ENGG. COMM. M 4C 7,0)

APPROVED
REVIEWED
PREPARED
Ft tom(
rst owC
PDII
To
Dimensions in mm.
. 0-
,,e,0
ISSUE: JAN . 99.
PIPE CLAMP FOR REFRIGERATION SERVICE
.-
O
a
I'DS:PS 13
PIPE SUPPORTS
TYPE PS13
NPS
SHEET
Hord
wood
10
r..
ti
0
c
-
ltaio
8R
_..
i 4 Appp
..
Ina
8
0
..
-24"
E
a
'5
OF
I 10
gi...
.......
11 le"
5r)
?
:
MATERIAL
Hot
Bolts
0
0
&
Nuts
55
IS:2062 Gr.A
IS:1363
EXAMPLE OF DESIGNATION:
Clomp NPS 1",d1=180,PS13 (Designation only for clamp)
0
0
Resting clomp NPS 1 ,d1 = 160,PS13.1(Designotion for clamp with resting base)
DIMENSIONS:
PIPE NPS
d= OD of pipe
33.7
48.3 60.3 76.1 88.9 114 3 139.7 168.3 219.1
d1= max.
230
250
0
0
0
CC
11/2 2-
2 1/2
3-
290 310 320 370 400 430
0
0
0
a:.
0
273 323.9 355.6 406.4 457
508
622
790
840
955
570
740
685
650
100
b=Length of wooden block
150
200
250
Flat
100x10
150x10
200x10
M20X80,22
Wt. of clomp&bolt
kg.
c.,
100
.V
0L
of
hole.
I
200
150
Ce cn
Wt.
150
support,kg.
NOTES:Internal diameter of clam
p (d1) shall be
values given in table-1 Corresponding

to the
FOR
C
0
300
200
Pipe NPS
obtained by subtracting from d1 -mox.the

a
C
2C
16-
70
L
./f
20-
14 -
it
60
Bolt&hole dio.
570
le
10"
insulation thickness.
application refer PS 01.
i /2"
T-S
4--68" - 10"
Insulation thickness
65
75
100 115 130
100 70
50
100 80
30
50
130
12"
2- 43 '/'
DATE
99

PURPOSE
--
165
-
160 130
110
60
30
170
150
100
70
40
200
180
130
100
70
30
0
O
150
TABLE- 1
E=v,
Engg.Comm. A4ww R-c )4 -1134)--wik 11 -1.1
REVIEWED
APPROVED'
PREPARED
PDS:PS13
Aj.
fr.
o
,
i'15
0
0
PIPE SUPPORTS
r(3,=-4 PD11_,
.
ISSUE: JAN.
PIPE CLAMP FOR REFRIGERATION SERVICE
p811 j
OF
SHEET
99.
4
Dimensions in mm. TYPE PS13.1 to PS13.3 resting on metallic surface.
TYPE PS13.1
For dimension
of I&L refer
table of sh.1
NPS
-24"
I7
UPS 1-2"
"
Resting
__
":,
0
o
(.1
w
10
10
r
...
L.
1j -1--
TYPE PS13.2 . NPS r - r

Dimensions
Ua
on
2a
...
,
-ac:
_
n
0
V
o
.0
-6
..,
c.
&
1.1 d
IM
-.
.
rme)
11..
IW
si
Lo__,J Lea
II
r...,
10 1/
__YU
.."
--3--I I-- ---I I-
Apply graphite /grease on bose before placing on structure.
TYPE PS13.3
Anchor
4-1
NPS 1"-2"
Cuidc moll. 15226
I
_ill
.
101
No
material some as type PS 13.1
t
,
0
I-
NPS 2 1/2" -24"
Guide
0
I__
_, ...
255
.--J
L.J,...1
-..L
Apply graphite/grease on bose before placing on structure.
10 thk. plate
Mott. IS:226
NPS 2 1/2" -24"
7 1 T-
Dimensions & material some os type P513.1
,
i
10
^10V
___I
Support
2-m12x40 for 1--22-M16X50 for 1 1 /2" -5"

4-M20-60 for 6" - 17
Support to be fixed by bolts to 1S1363
- to be positioned on OSSOMbly.
to be fixed by welding
or
TYPE
PS13.4
UPS 1" -24"
Hanger
'
For hanger rod & clip

refer PS16
10
IMPLEMENTATION
ISSUED
29' I gFOR
I
DATE
fliRPOSE
Engg.Comm.
PULPARLO
/ga, Q cT--c.
FU
VIF.Wit)
APPROVED
FILE NNAE:RPO4
I DII ,
_i0
0
1
ali
PDSTS13
PIPE SUPPORTS
ISSUE: JAN. 99.
FOR REFRIGERATION SERVICE
&Li
SHEET
OF
Dimensions in mm.
NPS 1"-14"
TYPE PS13.10
Resting
c
...)
IL
.r...
mow IS:226
d
Asbestos pocking I
IS:1363
a
ION
'50
c
-i
MI
n (1:7
00
5
13 )
-Hord wood
O
7
:
li
go
r.31
ON of pipe
c i
o
"
32
28
33 40
49
270 280 280 290
110
120
125
f
h
10
12
14"
175
480
225
570
279
620
330
700
362
740
370
430
520
570
690
155
191
255
305
200
245
315
400
359
440
650
410
2 1/2
55 67
300 340
82
360
95
370
121
420
290
127
310
320
142
140 170
150
185
105
99
130
8"
1 1/2 2"
240 250
0
0
1/2" 3/4 -
220 230 230

78 83 90
E
0
Mot1.1S226
Resting,DN25,PS 13.10
C0
aOV
._
0
o.
0
?
4_
0
0
0
V
0
Pr,2/
3"
120 123
127
130
333
349
200
140
100
1171
495
442
525
151
159
166
193
266
220
292
dl
12
16
20
M12
260 270 275 320
M16
M20
690
250 255
335
350
405
460
550
610
720
Wt. of block
including nutkg.
NOTES:
1. For opplicotion,refcr
PS 01
0
0
O
2 9' / i q
DATE

PURPOSE
Engg.Comm.
PREPARED
n..C_
REVIEWED
APPROVED
Pll11,
-J
PIPE SUPPORTS
FOR REFRIGERATION SERVICE
P DS: PS 13
ISSUE: JAN.99.
SHEET 4 OF 4
TYPE PS13.20
ON 15-350
Guide
Dimensio and material some os P513.10
a
44
aO
' Guide
11- Mall. IS:226
It:
0
0
0
`53-f
201-- 113
11 70
TYPE PS13.3o
ON 15-350
Anchor
Dimensio and material some as PS13.10
0
C
0
0
O
L.
TYPE PS13.40
r Tanger
Dimension and
material some as
Type PS 13.1a
ON 15-350

refer PS 16
_Mot!. IS:2062 Gr.A
a
0
4)
0
0
IMPLLMLN TAT ION
DATE
PURPOSE
ingg.Cornm
PREPARED
t, 1./,(;',`
REVIEWED
IAPPROVED
ALE ti/v4E:PS I 39i 4
"I
PD1L
o
For insulated le uninsulotcd

pipe of temp.<500'c
NPS 1.-24-
..
(4
i
in i
".
01
a
5
Apply graphite/grease on bole

before placing on structure
except oxygen lines
ON 25
r 29.7
pipe
i.,
L 1-
LIJ
;:o.
Temp.
<300*c
Material of shoe
15.2062
65
80
100
125 150
200
250 300 35C 400 450 500 600
48.3
60.3
76.1
88.9
114.3
139.7 1683
219.1
273 323.5 355.6 476.4 457.2 508 622
150
TYPE PS 14.2 Guide

NPS 1.-24./
Dimensions 6c motEsome as type P514.1 /
NPS 1"-5"
_..1
tilde
N..
"t7
IT
-3JL__JEw3
Apply grophite/greose on base
before placing on structure except
oxygen
300
200
350
300
200
>300tC400t 100(500)
15:2002 Cr.2A lor1/2Mo
50
100
-..,..,
:5 8_
40
SI 8'
--. -
c> 51,
a
- _
N.
NPS 6- -24-
ISNT/Plate
\ iii
IIII
0
tOthk.ptote
For SS.orolloy st.
in c)
pipe.5 thk.wrapper
plate of same mow _ ...I In I 25
ose plate
I
os that of pipe shall ottIS:226
I
be welded (For detail
see sheet 5)
1,42
O`%
-
09 8
el ra
NPS r-s-
in
I`
SHEET 1 OF 5
/ -- --
Resting
TYPE PS 14.1
ISSUE: JAN. 99.
SUPPORT WELDED WITH PIPE
Dimensions in mm
r>
PDS:PS 14
PIPE SUPPORT
NPS 6"--24'
\ 41).
II
I
Ill.
._,_1_3 _...1Li.
El_
Guide:
MottIS:2062
I
1j
._
in
in
NI'
He 711_ I al,
L.
lines
TYPE PS 14.3 Anchor

NPS
-24 Dimensions drrnotl.some os type PS14.1
UPS 6'-24"
NPS 1.-5
/
/
__L _
1111
151-Cr
Support to be fixed by welding

Or
Support to be fixed by bolts to 15:1363

NOTE: Foropplicotion.refer P501
21 1 qC
DATE
PURPOSE
II
2-M12 X 40 lui Ws 1"-2'

2-M16 X 50 for NPS 2 1/2.-52-6120 X 60 for NPS 6'--24to be positioned on assembly
EDCMIT
PREPARED
1w11ecan1 ItC-Tsva
-1.
REVIEWED ) APPROVED
NAME PS I 4A
PD1L
ISSUE: JAN. 99
TYPE PS 14.4
SHEET 2 OF 5
TYPE PS 14.5
Pestle-5A support for verticol pipe,NPS 6" - 24"
At
PDS:PS 14
PIPE SUPPORT
Guide for verticol pipe.NPS

At temp.<500*c
ambient ternp.(s Vic)

Mox.21)00 kg
r2
10 thk.plote
Mote riol some
os sheet I
For SS.or alloy steel pipe I

5 Thk.wrapper plate
to be used(( or
detail see shee 5)
ISMC 150
ISNT/Plote(shoe)
materiot range
as type PS14 I
0
5
ISMC 150
, ISA 65X65X6
to be fixed finally
ISMC 150
600r-flax.
d4 100
7
r.)
ISA 65X65X6
to be ixed finally
3
3
Guide
refer sheet 1
3
01
T--
0
V
a0
14,
o
UPS
2-
40
6- - 1 cr
17" -16"
18" - 24"
c
.0 0
0
0
t!
600max.
d+100
ISMC 150
K = d+220 for shoe hieghl 100

= d+320 for shoe hieght 150
= d+430 for shoe hieghl 200
50
100
150
200
TYPE PS 14.6
Anchor for vertical pipe,NPS 2"-5"

150
'PS
a
1
10thik.plote
Motl.some os sheet
M16X50 bo r ts(hole 130.to be

positioned on ossembly) to IS:/ 363
2
0
V
L10
Existing structure
2 ci I.
0Al
ISSIWO FOR IMPI FMFNTATION
F.
runno,4-
F OCMH
0-1(c''')f^c.2
Rivicwio
APPROVED
Fil F NAML PS1413
PDS:PS 14
PIPE SUPPORT
ISSUE: JAN. 99
SHEET 3 OF 5

6
a
0
r,
TYPE PS 14.7 Guide
NPS -24"
For pipe crossing wall
1 OThk.plote
Material:some os sheet 1
10Thk, plate
Material: IS:2062
a0
p.
10Min.
L..
200Min.
TYPE PS 14.11 Hanger
TYPE PS 14.8 Guide

0
For
pipe crossing R.C.C.sl b

70
(fair-
NPS 4 - -245%
0
0
For elbow(R--t. 1 to SON)

MPS r -1r
c............,.....i
detail :ref er PS16
...",
Material some
os sheet 1
0
lN
Ld+300
d +400 f
;too 400
450
- 600
a
0
10 Thk.plote
Materiall some
as sheet 1
10 Thk.plote
Mo eriol: IS:2052
0
a
a
TYPE PS 14.10 Hanger
1YPE PS 14.9 Hanger
r horizontal pipc : NPS 1"

/' For hanger rod
& clip detail.
refer PSI 6
- Material some
os sheet 1
For vertical pipe.NPS r -24"

For hanger rod
& clip detail,
--refer PS16
DATE

PURPOSE
COCMI I
PREPARED
.4/141(1'14:)
C4 24
REVIEWED APPROVED
F ILE NAME - PS14C
PD11,1
a.
1 POS:PS 14
PIPE SUPPORT
ISSUE: JAN. 99.
SHEET 4 or 5
Welding detoils
0
0
Material:
Except where indicated otherwise.steel of the some composition os that of the
pipe shall be used for the pipe support attochmentilectrode should be
co mpat ible with pipe and support material.
2. Preparation of base metal:
The ends shall be prepared by flame cutbng,mochining or grinding.Flome cut

surfaces shall be reasonably smooth and I ree from oxtdes.low Alloy Steels
shall be preheated to o minimum temperature of 100'c before thermal cutting.
The edges to be welded should be free from scole.dust.

oxide. oiLdirt or other foreign matter.
Method of welding:
Weld shall be mode by manual shielded metal are welding.
The fillet weld shall bl,nd smoothly,the pipe with no undercutting
at the edge.
(c) The throat dimension - o- shall be 0.71 of the thickness of the pipe
or support attachment whichever is smaller.
CN
(d). The fillet weld requirement for pipe support attachment shall be os
indicated below.
O
Pipe
12
Pipe
attachment
Et;
>su
a
0
ISSUED
()ATE
FOR IMPLEMENTATION
EDCMil
tkviewED
API'ROVil)
FILE NAME: PS140
i_PDS:PS 14
PIPE SUPPORT
PD11,1
ISSUE: JAN. 99.
fied
SHEET 5 OF 5
Dimensions in nun.
WRAPPER PLATE
NB'S
1,
....
E
;
f.
=
r
t0
15
I
.
.1
I F,Aahaahasi,,.w-
41r1
'l
25
'o
so
25
1-6o Tell tole hole .1
Material of wrapper plate sholl be some os thot of pipe
vD
u
NPS 6" -24"
1
I
3.5
--A
I 60 Vent hole
25
25
Resting.DN 150.17 514.1
ON
25
32
023e
33.7
117
40
65
BO
42.4
48.3 60.3 76.1
88.9
121
124 130 138 145 151
50
90
100 110 125 150 175 200 225 250 300 350 400 450 500 600
101.6 114.3 127
1121=219.1 244.5
350
NOTES:
1.
For other dimension
refer
sheet

DATE
PURPOSE
422
197 210 222 237 262 278 303 329 351 411 ,
1
157 164 170 184
250
11
273 323.9 355.6406.4 457.2 508
FOCkin
PREPARED
4.441
4?;:
4-44
REVIEWED
APPROVED
FILE NAME 'S14E
PDS:PS 15
PIPE SUPPORT
SUPPORT CLAMP
ISSUE: JAN. 99.
(FOR MODERATE LOADS)
SHEET 5 OF 9
TYPE PS 15.9(11)
TYPE PS 15.9(1)
vd
Pipe spacer
CJ I L,
d+6mm
d4-6mm
(For suspension of
uninsuloted lines)
Clomp NPS 1",PS 15.9(1).NPS/ON is nominal
1'
a
O
a
v
.....
a
2
(For suspension of
hot insulated lines)
Pipe/clomp size
NPS.in ()N,mm
pipe/clomp size (or uninsuloted/insuloted pipe.
A
mm
dxL
mm
El X T
mm
/I
mm
h
mm
K1
mm
K2
mm
Load
kg
I /2"
15
21.5
M8 X 30
25 X 6
40
120
200
3/4
20
27
M8 X 30
25 X 6
45
130
200
25
34
1412 X 55
35 X 6
50
150
730
570
40
49
1412 X 55
35 X 6
60
160
240
570
50
61
1412 X 55
35 X 6
65
175
250
570
M12 X55
35 X 6
75
210
315
570
M16 X 70
35 X 6
85
230
330
570
M16 X 75
65 X 10
95
255
355
1180
M16 X 75
65 X 10
110
285
385
1180
6"
M16 X 75
65 X 10
130
325
425
1180
8-
M20 X 90
65 X 10
160
385
485
1180
1 0"
1420 X 90
65 X 10
190
450
580
1180
12-
1420 X 90
65 X 10
215
500
630
1180
I4"
M24 X 100
65 X 10
230
550
680
1180
16"
1424 X 110
100 X 16
255
585
710
2360
1 8"
1424 X 110
100 X 16
285
650
800
2360
20-
M30 X 130
100 X 16
310
705
855
2360
1430 X 130
100 X 16
360
805
960
2360 1
1 1/2
22 1/2"
3"
24"
600
622
75
100
125
150
Mated I some Ps sheet I.

1
ISSLI FOR IMPLEMENTATION

CO
DATE
PURPOSE
EOCMH
PREPARED
REVIEWED APPROVED
FILE NAME: P5151
PDS:PS 16
PIPE SUPPORT
PDIL
Pad
i
Dimensions in mm.
0.0TYPE
PS
15
TYPE PS 16.1
<
ISSUE: JAN. 99.
A
Normal
- e-nII
MN
:--v
..
MN
,,i
ER
sumo
il
OF
TYPE OF CLIP
16.2
.".:2,
SHEET
4!
la
II
__.J
fO 0
05
8-Forr
insulated
All
pipe
IF
.1.,
0
a
7) .-
/7
.2-
al
-----\____.
,
/,
Is
5,
V
C-For
uninsuloted
elbow
"I
I1
la
IF
.n
e
?
4:, - To be welded
JO
el
V
v
0V
SnV
after assembly
(See note 2)
d
3c
EMI
co
.7
5
..
)
i:
.
:,
1r
7)
D-For
insulated
elbow
\\
t
ill
rr
I
I
Example of designation;
!longer rod d=12,L=
P516.1
To be bent and
welded after
assembly
o
d
12
16
20
25
32
36
b
60
60
80
100
120
130
b1
f1
h1
120 20
150 25
200 30
230 35
250 40
250 45
14
18
22
26
33
39
110
145
180
215
250
250
95
125
155
185
210
210
M12 30
M16 40
M20 50
M24 60
M30 80
M36 90
_4,___.
S
6
10
16
16
16
20
L min .
L max.
400-2000
500-2000
600-2000
700-2000
800-2000
900-2000
x.record
loud kg. Pipe NPS
2"
515
1
1/2"-5"
825
6"
- 24"
1230
6" - 247
2260
6"-24"
3640
6"-24"
5300
MO
NOTES:
Material: Hanger rod-IS:2062 Gr.A Nut -IS:1363,Clip-Some os that of pipe.

For cosy assembly of site,moke hanger rod with overlap welding as shown in
type PS 16.2.
For welding refer PS 14,sheet 4.
For application, refer PS 01.
2-9' r eln._,_.$4.
c
ISSUED FOR IMPLEMENTM
312-44) lec :licesl`ii 9
DATE
REVIEWED APPROVED
PREPARED
PURPOSE
PDII,
PDS:PS 16
PIPE SUPPORT
ISSUE: JAN. 99.
HANGER ROD
SHEET 2 OF 2
Dimensions in mm.
TYPE PS 16.3(1) TYPE PS 16.3(11) TYPE PS 16.3(111)
TYPE PS 16.3(W)
0
E
a
V
5O
a
a
O
0
e
0
0
03
a
O
V
For clomp
a
0
refer
PDS:PSI 5,f or beom attachment PS94,ond for turnbuckle PS94.
o
0
0
Specify wether right hand

or left hand thread
Welded eye
6
a
151
Threads os per IS:1362-coorse

Example of designation: Hanger rod M12,PS16.3(1)
E0
Nom.
rod size
Mox.recommended
Lood
kg.
12
100
M12
515
21
16
100
100
A116
M20
825
20
1230
21
21
25
32
150
150
M24
M30
2260
3640
31
42
36
45
48
150
200
200
M36
1145
1148
5300
6300
10000
42
Preferred lengths of the hanger rods shol be 300.350.400-100 -1400.1800 and 2000.
Material:- IS:2062 Gr.A

OA I F
PuRPOS1.
EDCM Ii
1 4 R L PAHL()
iti4"
WLVILWLU
APPROVED
nl I NAME: 14S16b1
7:Eir;(*.;-.C7
PDII
BRACKETS FOR IIORIZONTAL PIPES
Pad
SHEET 1
T ype PS 20A
PDS:PS 20
PS 21
ISSUE:APRIL,
PIPE SUPPORTS
99
OF
Type PS 20E3
100
I a
1
.C\
*7:
Weld to existing structure
type PS 21A
5591
Type PS 210
1 EE
--Weld to existing structure
Type PS 210
Weld
IL
(1
11
70
70
Li
Tie rod M16
Tie rod PS WA
PS 50A
o.
65 x 8
I. 65 x 8
1
C
o
0
0
type PS 20E
Concrete
0
c.:
N
(A
a
0
0
SI.No,
x8
65 x 8
300
x8
450
65
600
11
f1
Tie Rod
300
150
22
M20
450
150
22
M20
600
22
22
M20
M20
27
M24
750
150
150
300
200
150
450
200
27
M24
150
150
600
750
200
200
27
27
M24
150
150
900
1050
200
700
27
M24
27
m24
r,
0
a
4
o.
Chorine! Size
ISMC
W=.... ..
100
100
100
100
150
0
V
65
Example of designation - Brooke PS20A.1

for bracket PS200/71D Indicate V=
72
V
Angle Size
SI.No.
8
9
10
19' 61,1
PURPOSE
I:
o.
0. ti
tr
0
c
0
"..";
0 0'
c
aa ci'1,3
M24
Fogg:Comm
PREPARC 0
o
S.
2_,Nizi
ArPnovE0
REVIEWED
Ir
UAL(C
.PC
I Dw
Pll.11
PIPE SUPPORT
BRACKETS FOR HORIZONTAL PIPES
PDS:PS 24
ISSUE:APRIL .99
SHEET I OF
Type PS 24A
Type PS 248
O
O
z
a
Existing Structure
V
O
V
O
V
0
O
Z.3
\ Herod
Example of designation Bracket PS24A 1

INDICATE v=
w=
M24 PS 50 A
for
bracket PS 240
07
Section
SLUG.
r.
Horizontal
ISMC
Bracing
Angle
150
65 x 8
600
t,
150
65 x 8
750
3
4
150
150
65 x 8
65 x 8
900
1050
150
65 x 8
1200
65 x 8
1500
150
F or opplicntion refer PS 01
For welding delakrefer P590

POHPOSF
Engg.Comml
PREPARED
Fcc priv._
REVIEWED
EH F NNAE. :PS2 4 ONG
APPROVUT
PDS:1)533
PIPE SUPPORT
SUPPORT FOR HORIZONTAL PIPES
SHEET 1 OF I
Type PS 33
Existing structure
Weld
V
C
EL
J 1,0
Existing structure
Type
PS 330
0
0
0
0
Tie rod M16 PS 50.6
0
V
0
_J
Weld
xi
Example of designation Support PS33A.1,h=
0
4,
PS330.1,h=
sa,
SI.No.
0.
0
0
Angle
65 x 8
600
65 x 8
750
65 x 8
900
For application refer PS 01

For welding detail,refer PS90
0
2-0 (l'ePl
DATE
ISSUED TOR IMPLEMENTATION

PURPOSE
Eagg.Comrh.
PREPARED
{-GC ^..o/
REVIEWED
Cu C niniC DC I
ttscrx-cd-t
APPROVED
nwr
PIPE SUPPORT
PDIL,
PDS:P535
ISSUE.AP1211, ,99
SHEET 1 OF 1
Existing structure
Type PS 35 A
E
et
.0
Weld
Existing structure
Type PS 35 0
22
rod M16 PS 502

Weld
of designation Support PS35A.1.h=

PS35D.1.h =
SI.No.
4S
2
3
4
5
6
7
8
9
10
11
12
4.
0
0
II
ISMC
Channel
size
20'9'99
DATE
100
100
100
100
100
100
150
150
150
150
150
150
600
750
900
1050
1200
1500
600
750
900
1050
1200
1500
120
120
120
120
120
120
160
160
160
160
160
160

PURPOSE
For opplicotion refer PS 01

For welding detoiLrefer PS90
Engg.Comm.
PREPARED
n-
REVIEWE
FILE NAME :PS33.D VC:
APPROVED
PDIL
PIPE SUPPORT
PDS:PS36
1SSUE:APRIL.,99.
SHEET 1 op
-Co
.t?
Type PS 36 A
I1
EL
s_
.c
Existing structure
V
0
Type PS 36 C with hold down bolts
-Weld
Existing structure
100
Exomple of designation Support PS36A. .11=

P5360.1.h=
Hold down bolts

Chonnel
size
ISMC
I1
100
600
120
150
100
750
120
150
3
4
100
V
F
SI.No
100
250
200
16
18
100
250
200
16
18
120
150
100
250
200
16
18
120
150
100
250
200
16
18
1200
120
150
100
250
200
16
18
1500
120
150
100
250
200
16
18
150
600
140
200
140
300
240
20
22
8
9
150
150
750
140
200
140
300
240
20
22
140
200
140
300
240
20
22
10
11
150
150
900
1050
140
200
140
300
240
20
22
1200
140
200
140
300
240
20
22
12
150
1500
140
200
140
300
240
20
22
6
7
0
is
900
1050
bl
100
100
100
01
Bolts
IS:1363
Concrete
POS:ST71 I
(C)
M16 x 50
MI 6 x 380
M20 x 60
M20 x 470
For opplicotion refer PS 01

E
For welding detoil.refer P590
00
Cy
DAT E

PURPOSE
Engg.Corrim
PREPARED
7.0/y
RE VICWCE)
FILE NAME :PS36.0WC;
a-P---
ArrRovco
PIPE SUPPORT
PDS:P840
ISSUE.APRII...99
SHEET 1 OF 1
0
F
lype PS 40 A
Type PS 40 C
with welding to existing structure
with hold down bolts
0
1
EE
EE
0
0
Weld
0V
0
a
O
a
0
Weld
0
4
0
Dose plate os per

MS 07
6
a
Example of designotion Support PS 40A.1,1=
h=
a0
Channel section 15/AC
Designation
Vertical
Transverse
-PS4OC .1
100
50
PS 40A.2-PS40C.2
150
50
PS
For /application refer PS 01

For welding deloii.refer P590
tt. 'Cr
DATE
ISSUED MR IMPLEMENTATION
PURPOSE
F..nyg.Cuumn
PREPARED
o it I117-r'
Rrv1cwE6 J APPROVED
NAMI .PS40 OWG
PDII,
c?
a
0
C
PDS: PS 65
PIPE SUPPORT
ISSUE: APRIL 99
TRESTLE FOR OVERHEAD PIPES
Dimension in mm.
For welding.see PS 90
SHEET I OF I
Type PS 50.A
a
V
_C
O
V
O
As per PS 07
As per PS 08
V
O
9
0
C
V
C
V
O
C
AS
a:
0
Trestle PS 65.1 h=
1=
Designation
PS 65.1
.c
PS 65.2
PS 65.3
PS 65.4
E3
Section
()Transverse
Verticol
ISMB 100
ISMB 150
ISMB 150
ISMB 200
ISMB 200
ISMB 250
ISMB 250
ISMB 300
Note:
1. For opplication.refer PS 06

/
NAkI
I O.F.A.
P. O. I. L. I
r,TF WI TRAP
DRAIN P in
VENT
M A Y-SP)
ASSEMBLIES
PDS : P -123
SINDRI
SHEET
FOR HEADER N P S Vi T O I I/2 " ;

VENT SIZE i,/2"
G AS AND
STEAM
FOR HEADER N PS 7i 2" ,

VENT SIZE 3/4"
0
"------ISEENOTEN0-11
cip
s
.- - (
FOR PRESSURE
GAS AND
RATING :LI 900
CLASS
STEAM
FOR PROCESS
CONSIDERATION
OR
.._
0 0
3
FOR PRESSURE
RATINGS 3 900
CLASS
.
*
RATING >900
CLASS
/ 'CD
( INCWDING
PIPING TEST )
Ornims...
ASSEMBLY NO. A 005
HA
4-
DATE
1 0KO. BY :(
ASSEMBLY NO A 004
.0
0 .. 0
ASSEMBLY NO. A 003
FOR PRESSURE
ASSEMBLY NO A 002
ASSEMBLY NO. A 001
WIN. BY: 5,R sHAR
0.. EENOTEN0-11
" IlL
FOR PIPING
TEST ONLY
ALL CASES
1 OFi
VENTS
A
MEDIUM
LIQUID .
0
FOR PRESSURE
RATINGS .->9011)
CLASS
)
-0
ASSEMBLY NC. A 006
il APPD. BY :
kAA---"--r-.6
IMECH
.
i
P. D. I. L.
VENT, DRAIN AND
FOS :P-12 3
STEAM TRAP ASSEMBLIES
SINDRI
SHEET_ .2 OF 10
DRAINS
FOR HEADER
NP 5 yi
MEDIUM
DRAIN SIZE In s
TO 11/2"
FOR HEADER NI PS 7 2" .2.

GRAIN SIZE 3/4'
GAS
FOR PIPING
J 0
TEST ONLY
[SEENO fli/Cn-----0
);EE NOTE NOASSEMBLY
NO
A 101
ASSEMBLY
CONSIDERATION
OR
RATING 4 SOO
CLASS
ASSEMBLY
FOR PRESSURE
,-(13D
FOR PRESSURE to
RATING A- 900
GLASS
0
NO A 103
5
.
,-7
FOR PRESSURE
CD -
RATING 7 500
CLASS
FOR PRESSURE (-9M,

RATING '7' 900 \---2
FOP
DATE
c,. E4-0
.-
1
1
o ETA'L
CKD. BY
NO A 104
. CO
ii....
Pre
CLASS
ASSEMBLY NO A 106
ASSE M GLY NO A 105
STEAM
ASSEMBLY
ALL CASES
( INCLOUNG PIPI NC.
TEST)
URN. RY: s.R SHARMA
102
GAS
FOR PROCESS
LIQUID
NO A
REFER SHEET
. I
(t-1
NO
3454.66
APPD. BY :
MECH
P. D. I. L.
PDS:P - 123
VENT, DRAIN AND STEAM TRAP ASSEMBLIES
SINDR1
.3
SHEET ,
OF
C, STEAM TRAP ASSEMBLIES:

HEADER
F Ok HEADER SIZE 1/2 " lo '12

PRESSURE RATING 5 900 CLASs
ASSEMBLY NO A
107
FOR HEADER SIZE, V2 " 10 11/?:

PRESSURE dATING .1-900 C'.ASS.
ASSEMBLY NO
DRN BY: S.R.SW.RMA
DATE
A 108
APPD. BY :
I mEcH
10
I L.
P. D.
VENT , OR4. I N
AND :,-TrAm
TR,
PDS. P- 123
A5SEMBLIES
SINORI
SHEET. I. .OF 1.0
COMMON FOR PRESSURE RATING ^900

cu\se.-)
41
il)
cf,
. 57 4'
al
CN
23
.
A
V)
1.-9
Z
-
Q
m
w
cc
ST
Boo
I
ti -97 r 4 -71ct
C.
SEE NOTE- 2 2 1 f (1, 314P
1
1, - -2 2)
-/
1
sEEN
Tho-4-20i-'
'
EC4_7_t
ti)
J>
n_
roil HEADER
col
.
83
SIZE 7-17."
_ _
FOR HEADER SIZE UP TO 10
A 109
.1-- -- r
74
;---i
35
0._-;
z
"
Fa-,
_.(39
z 2. '2 9)-- 12
x.
0- rujc_i 35
-- ....., 5^, 4'2
ASSEMBLY NO A Ho
LAI
26
--11
13 8:
3; '_NB1Z
17
COMMON FOR PRESSURE RATING ,- 900

v.
cif
.)
0
<
U
0
VI
10
0
CI
Z
/-
w
=
C
ASSEMBLY NO. A III
CC
i --ra --/
2 6"! Nr" , 38
,..
190 ..- ,
Z
Lo
S
U1
20 11!'
in
"11 - 42
SEE NOTE
33 go .......,.._
0
ll-
.E.-.
I
FOR HEADER SIZE r T 0 10"
lie
3/AMr..
<
,.,.. SEE NCIE -V21 ,
- ---- ' ' s i. 2-2-
"-I SEE
e
r.t 0,NC1 -. 5
D
2
u)
3?
FOR HEADER
(;)
r-- ST
800 _
r
\...
t
t
FOR HEADER SIZE UPT010
-C)
"I
@3
URN. BY: &)(1,...;1.,-.
36
ST
ASSEMBLY 0.
07 .--..,
boo
DATE
40
A II2
I
49
SIZE 7., ein
CLASS.
ID
_._
, 3,4'
:^_
, FOR HEADER SIZENB12'
) C..
I CKD. BY: II) j:C_
4 (:;, S2I I
',..-1
(11\p? APPD. BY :
HEcm
r7.11'...7.7.71r7-:''.7.,:
rtgagegMr1,5
/01'
P. D. I. L.
SINDRI
PDS:P 4;
SHEET. . 5
n STEAM TRAP ASSEMBLIES:-
_ .0F. IQ.
(f)rSCHARCONQ 10 COW)ENSKIE. HEADER)
HEADER
FOR HE AOER SIZE 1/2 II/2;

PRESSURE RATING Ca ROO cLA.sS
Boo
LY NO
ASSEMB
A 120
FOR HEADER SILL V2.11.0

PRESSURE ?ATING 900 CLASS.
ASSEMBLY NO
DEM.
: S.ft S H.e.11.MA
A 121
I
VENT ORL,I N
POS . P- 123
AND tTiAM TIR;;;- ASSEMBLIES
H EET 4 OF 10
COMMON FOR PRESSURE RATING c900

ASS
3/4
fg
1115; \25)
1/42.1
3
- _ - --
'-
b LC
2 2;
.ii. :. ": .
OR HEADER S:ZE
L1/4.1
cc S E 1'...?2..4
._
ct)
L7;
+
40
1.
col
22
I .f
.7,
3,,;
(3
'\,---\--/
6.-2A -14
- ,---R32)
" N........___ . ...
S e E t :2'
35) C1/4
I
r 1
C1/4
.
ri
!1/4?,
3__ )
:
67")
; .:3
Er
0
LL
31)
3G '
'
aa
--.
soo
c)
39 -73 SEE NOIE.411
:
m \ (If
1:
cn;
55 ..42, ,, - .)---\
:_I
A's .L____,
33 .
__,.L-A Cf
4.55. F:0 61.N 7.0 . 1.., 123
37J
FOR HEADER SIZE >12
.1
t (Th.
3
_,
COMMON FOR PRESSURE RATING 900

CL ASS
cr
4
0
/N.
FOR_tlf.ADS.
tf:
uJ
C_
li
'1"
ill NO/F.7472Q
cl FOR HEADER SIZE UPTO 13
r G)
ED
ED
-re
;21
tit_E
Lei
SIZE _ ? 0 rt
) /71)
c.a./
P 24
ASSEMBLY
----
FOR HEADER SIZE 7
--rgit
. ;
o
z
u;
39,
'
1_1324
35
""\
i 40
j
I
I
SEENOTE1 33
ASSEMDL Y NO
IIRN. (1Y, A A,'41_,,)
(-4?
(
r,
A 125
F OR HEADER SRE 1 2
.DATEm
Ft
CKO. Gti :
APPD..
P. D. I. L.
P DS: P- 123
SINDRI
SHEET 7 OF. P
DESCRIPTIONS
0 1/2 THREADED CAP (RATING AS PER SERVICE CLASS)
1/2 1 BRANCH CONNECTION AS PER STD.
Vi e
1/2
CSEE NcTE NC-2)
HAL F
NIPPLE , AS PER PDS: P- 145, L=100
PIP E.
LENG TH 100-m4THK.AS PER STD.)
S W GLOBE VALVE (TAG NO AS PEh S T D.)
3/4 THREADED CAP (RATING AS PER SERVICE CLASS)
0
0
3/ BRANCH CONNECTION AS PER STD

3/4/ HALF
NIPPLE ,
AS PER PDS: P- 145 ; 7."
3/4 PIPE, LENGTH 100 T"'" ( THK AS PER STD)
3/4 S.W GLOBE VALVE (TAG NO. AS PER STD. )

1k EQUAL TEE ( S.W
0
0 I
0
0
I/2 PIPE LENGTH 10" ( THK. AS PER STD.)

if
F L AN G E (2 NG ONE CONNECTION WITH GASKET, BOLTS , NUTS AS PER STD)
14
SW GLOBE VALVE ( TAG NO. AS PER STD. )

-3)
STEAM TRAP WITH BUILT-IN STRAINER (

2 DRAIN FUNNEL TYPE 3
AS PER PDS: P- 125
2 1t PIPE, LENGTH 5Th k THK. AS PER STD.)
3/4 EQUAL TEE

EQUAL TEE OF MAIN LINE SIZE
CAP OF BRANCH LINE SIZE (
SEE NOTE Nal-
BRANCH CONNECTION AS PER STD.SIZE AS PER TABLE
(SEE NOTE NO-
3/4 " HALF COUPLING ( RATING AS PER SERVICE CLASS )

3/4
PIPE LENGTH 10n1 ( THK AS PER STD. )

..
C HALF NIPPLE , As PER pr)s
ORN. BY:
kkkan%
DATE
4 s 88 I
CKO. BY: -04L

-9:-
100
-trkti/ I
APPO BY :
l_pt!c
14
P. D. I. L.
SINORI
POS F-123
.
SHEET 8
DESCRIPTIONS
?7
28
29
30
31
32
(.13)
-
51
66-)\
3.
ES)
,-jag)
"Th
1)
El?)
EID
1
3/4 FL AN G E :2 NO ONE CONNECTION WITH GAsKET.BOLTS, NUTS AS PER STO

3/4 SITE BENDS, 10 NOS.
3/4 HALF COUPLING (PATING AS PER SERVICE CLASS )

SITE BENDS, 10 NOS
CHECK VALVE (TAG NO AS PER STD )
3/4 CHECK VALVE ( TAG NO AS PER STD
HEADER
W GATE VALVE
I /2 S W GATE VALVE
I" THREADED CAP
11/21 THREADED CAP
i - FLANGE (2 NO. ONE CONNECTION WITH GASKET, BOLTS , NUTS AS PER S TO.)
1 SITE BENDS 10 NOS
I" HALF COUPLING :RATING AS PER SERVICE CLASS )
i / 2 HALF COUPLING ( RATING AS PEP SERVICE CLASS )
I" PIPE LENGTH 10 : THK AS PEP STD I
I" CHECK VALVE
P-14-5 ,1-=l00
1%2
NIPPLE . A "lc
EQUAL TEE
11
Th
E133
()RN BY
PTD5
DATE
598
CKO BY
APPO. BY
or_1.9
P. D. I. L.
SINDRI
PDS P -123
SHEET.."...0E.1
NOTE S:
I. TO BE SEAL WELDED AF TER HY D TEST.

2- BRANCH CONNECTION TO BE FED TO COMPUTER
AS A SEPARATE REQUIREMENT AGAINST MAIN LINE - BRANCH
SIZE TO BE TAKEN FROM TABLE -1 BELOW
IN CASE THE TRAP SIZE IS DIFFERENT FROM rHE INLET
PIPE SIZE, THE REQUIRED REDUCER WILL BE SUPPLIED BY
TRAP MANUFACTURER.
CAP OF BRANCH LINE SIZE TO BE FED TO COMPUTER AS A
SEPARATE REQUIREMENT AGAINST MAIN LINE. BRANCH
SIZE TO BE TAKEN FROM TABLE -I BELOW.
DRN. BY:
S.R.SHARMA I 4 .DATE
epaia
CKD. BY
APPD. BY :
MECH
PDS: P : 12
.S.
DRIP LEG ON STEAM HEADER
P. D. I. L.
SINDRI
SHEET4.9....OPAQ.
HEADER
--i
t
t\.-.-).cf
_-
. 1I
n ck
1 1
DC)
--)
TO TRAP
ret
DRIP LEG
HEADER SIZE T
(DH)
.
BRANCH SIZE
2
( DL)
TENGTH BET.C.L
OF HEADER AND 300
WE LD OF DRIP
3'
r"-"' 6"
8"
10"
3"
4" i 6"
6"
8"
8"
350
350
400
400
12" I. 14"
16"
18"
20"
24"
10"
12"
12"
12-
12"
450
500
525
550
600
300
LEG c L )
300
I
TABLEI
DRN. BY
:ty:.
,..
I
I '. 5 ea I
DATE
cro Ps (
L.
'1
APPD. RV
m
EC
IN
NSTALLATIO
ON OF LPG MOUNDED
D BULLETS
AT NRL,A
ASSAM
CON
NSTRUCTIO
ON/ERECTIO
ON, PRE-CO
OMM, COMM
M163-E-601
EM
DOC. NO.
REV
Page 1 off 51
PART II: TECHN

NICAL
C
CONSTR
RUCTION
N/ERECTION, PRE-COM
MMISSIO
ONING,
MISSION
NING
COMM
0
P1
P
RE
EV.
15.09.15
29.07.15
REV DATE
D
--EFF
FDATE
FORM
M NO: 02-0000-00
021F1 REV4
ISSUED FOR ENQUIRY

R
PU
URPOSE
JKY
JKY
P
PREPD
DILIP
DILIP
REVWD
GC
GC
APPD
All rights
r
reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 2 of 51
CO
ONTENTS
S NO.
Sl.
1
2
DE
ESCRIPTION
N
REMARKS
S
General Scope of W
Works and Se
ervices
Construcction / Erectiion
General Scope of W
Works and Se
ervices
mmissioning
Pre-com
Basic Pla
an for Temp
porary Servicces
Mechaniical completion
Commissioning
LIST OF
F ANNEXU
URES
ANN
NEXURE
NU
UMBER
DE
ESCRIPTION
N
ANNEXURE-1
Contracttors Work D
Definition
ANNEXURE-2
Detail Te
echnical Sco
ope
ANNEXURE-3
Quality Control
C
Proccedures and Inspection
Requirem
ment
ANNEXURE-4
Evaluatio
on and Prog
gress Reportting
ANNEXURE-5
General Notes
ANNEXURE-6
General Guidelines for Installatio

on of LPG
Mounded Bullets.
FORM NO: 02-0

0000-0021 F2 RE
EV3
REMARKS
S
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 3 of 51
CONSTRUC
C
CTION / ER
RECTION A
AND PRE COMMISSIO
C
ONING
1.0
G
General
sco
ope of Work
k and servic
ces - Constrruction/Erec
ction
CONTRACT
C
TOR shall be
e responsib
ble for safe transportattion, constrruction and erection
o the prefa
of
abricated Mo
ounded Bullets/Unit in
ncluding rolling of plattes, shot bllasting &
e
edge
preparration in co
ontractor sh
hop, rolling
g of plates at site is not permitted & also
b not limitted to the fo
but
ollowing:
1.1
Construction and erection of Mounde

C
ed Bullets/Unit and perfo
orm all otherr activities re
equired to
b performed
be
d for implem
mentation of the WORK including Assembly, Fa
abrication, in
nspection,
te
esting, locall PWHT, hyd
dro testing, localized
l
coa
ating/paintin
ng of field we
eld joints and internal
s
surface
coating on moun
nd.
1.2
Provide and supply in due course

P
e all constru
uction Equip
pment and Materials,
M
to
ools, and
te
emporary fa
acilities nece
essary for implementation of the WO
ORK.
1.3
1.4
Establish an
E
nd operate adequate m
material con
ntrol system
m in site for receipt, unloading,
u
in
nspection, maintenance
m
e, handling, storage an
nd utilization
n to ensure
e all Equipm
ment and
M
Materials
arre preserved and available as necessary fo
or completio
on of the Mounded
B
Bullets/Unit.
P
Provide
and supply all sttaff, tradesm
men and labo
ours for implementation of the WOR
RK.
1.5
E
Establishme
nt of overall construction
n policy and procedures for the Mou
unded Bullets/Unit.
1.6
Provision off overall ma

P
anagement and contro
ol of constrruction phasse of the Mounded
B
Bullets/Unit.
1.7
Ensuring tha
E
at all parts of
o the Moun
nded Bulletss/Unit are cconstructed and tested strictly in
a
accordance
with the sp
pecifications and applica
able codes and standa
ards asked ffor in the
p
project
documents.
1.8
E
Ensuring
tha
at constructio
on is accomp
plished in acccordance with
w the Time
e/Job schedu
ules.
1.9
Provide tran
P
nsportation of
o all Equip
pment and Materials to
o be provid
ded and sup
pplied by
C
CONTRACT
TOR under th
he CONTRA
ACT either fro
om inside orr outside to Site.
S
1.10
Construct, op
C
perate and maintain
m
all temporary fa
acilities requ
uired for its personnel
p
in
nvolved in
the WORK.
1.11
Provide transsportation in
P
n the area of
o the Site and between Site and te
emporary faccilities for
a its perso
all
onnel involv
ved in the implementation of the WORK, including field
d labour,
a
administrativ
ve staff, etc.
1.12
Recruit field and organizze, manage

R
e and supervvise its Sub Contractorss and field labour for
the WORK.
1.13
Provide liaisson with OW

P
WNER, Contractors, and
a
Vendorss to ensure
e that the Mounded
B
Bullets/Unit
is constructed in accorrdance with the respecttive standard
d and specifications,
s forth in th
set
he CONTRA
ACT.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 4 of 51
1.14
Establish with OWNER adequate procedures,, control an

E
nd reporting systems to
o provide
c
close
controll of the progress of the W
WORK.
1.15
Provision of labour and facilities for loading, unloading and transportation of the Equipment
P
w
within
the site area.
1.16
Performance
P
e and/or provvision of all other workss and/or servvices require
ed for perforrmance of
the WORK.
1.17
Execution off the whole

E
e civil, strucctural and building
b
works of the Mounded
M
Bu
ullets/Unit
a
and/or
utilitie
es and off-sitte facilities.
1.18
P
Prefabricatio
on of piping spools
s
in a sshop on the Site.
1.19
Erection and installatio

E
on of EQUIPMENT an
nd auxiliaryy facilities associated
a
with the
M
Mounded
Bu
ullets/Unit.
1.20
Installation of
o pipe work including fie
eld fabrication at site.
1.21
Installation and
a
testing of all instrrumentation network and equipme
ent of the Mounded
B
Bullets/Unit.
1.22
Installation and
a testing of
o electrical ssystem and equipment
e
o the Mound
of
ded Bullets/U
Unit.
1.23
Maintenance
M
e of construcction equipm
ment, vehicle
es and tackles of the Mounded
M
Bullets/Unit,
d
during
construction and erection perriod.
1.24
P
Pre-commiss
sioning, Com
mmissioning of the Moun
nded Bulletss/Unit.
1.25
C
Carrying
out Mechanical Completion
n.
1.26
P
Perform
all material
m
iden
ntification as per applicattion codes a
and standard
ds.
1.27
P
Provide
draw
wings and do
ocuments ass required.
1.28
C
Contractor
sh
hall ensure and
a shall be
e solely respo
onsible for ssafety in all activities.
a
2.0
G
General
sco
ope of WOR
RK and Serv
vices- Pre-commission
ning
CONTRACT
C
TOR shall be responsib
ble for the pre-commisssioning pha
ase of the Mounded
B
Bullets/Unit.
CONTRACT
C
TOR shall prrovide at SIT
TE an adequ
uate numbe
er of qualified pre-comm
missioning
e
engineers
to direct and control
c
pre-ccommissionin
ng activities.
CONTRACT
C
TOR shall als
so ensure th
hat all specia
al tools and test equipm
ment required
d for prec
commissioni
ng are availa
able at its ow
wn cost.
CONTRACT
C
TOR shall provide ad
dequate con
nstruction labour, con
nstruction to
ools and
e
equipment
fo
or pre-comm
missioning.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 5 of 51
Pre-commis
P
ssioning wh
hich shall be
e performed
d by CONTRACTOR sh
hall include
e, but not
limited to, th
he following
g:
2.1
Cleaning, flu
C
ushing, drain
ning and re
emoval of te
emporary bliinds and the replaceme
ent of all
p
permanent
ittems remove
ed while the WORK is in
n progress.
2.2
Cleaning
C
of any other parts,
p
which
h have corro
oded to an extent, which, will detrrimentally
affect
a
Mounded Bullets
s/Unit/Mound
ded Bullets//Unit perforrmance or run length for such
reasons
r
as in
ncreased fou
uling due to rust.
2.3
Checking, Te
C
esting, calibration simula
ation test an
nd adjustmen
nt of instrum
ments, equipment and
s
systems
inclu
uding contro
ol valves and
d safety devices, and insstallation and checking of
o orifices
p
plates
and otther sensor devices in sso far as this
s can be don
ne before acctual operation of the
ittem concern
ns of comple
ete system a
and loops.
2.4
Function tesst and checking out of electrical sy

F
ystems inclu
uding substtations, transsformers,
c
cables
and switchgear,
s
c
checking
of all interlockks and setting of all relayys. This sha
all include
d
drying
out op
perations, filttering of oil if
i required.
2.5
For motor drriven equipm

F
ment, ampera
age checking of motors and remova
al of tempora
ary safety
s
screens.
2.6
For
F all piping
g systems, installation a
and removall of tempora
ary blinds ass required, ccirculation
and
a commiss
sioning of syystems inclu
uding processs systems, services, effluent and drainage,
d
utilities
u
distrib
bution, relieff and blow d
down and interconnecting lines.
2.7
All
A such furth
her works which
w
CONT
TRACTOR ju
udges to be necessary or in the re
easonable
opinion
o
of OWNER
O
is ne
ecessary to bring the Mounded
M
Bu
ullets/Unit to a state of readiness
r
fo
or the intro
oduction off feedstock into Proce
ess Mound
ded Bullets//Unit for prrocessing
requirements
r
s and for saffe commenccement of op
peration.
3.0
B
Basic
Plan for
f Tempora
ary Service
es
3.1
C
Constructio
on Power:
F fabricatio
For
on/constructtion works a
at site, Consttruction Pow
wer, 3-Phase
e, 4-Wire, 415 Volt
AC, 50 Hz will
A
w be availab
ble at two po
oints for Con
ntractor on frree of cost basis.
b
Contractor shall
C
s
have to
o arrange fu
urther distrib
bution which
h shall includ
de adequate
ely rated
d
distribution
and
a
sub distribution boards/feede
er pillars, po
ower supplyy cables an
nd other
a
associated
m
materials
for feeding loa
ads to carry out construcction and fab
brication acttivities at
h own cos
his
st. Contracto
or is require
ed to obtain all statutory
ry approvalss/License fro
om State
G
Govt.
C
Contractor
shall
s
arrang
ge for nece
essary elecctrical equip
pments, cab
bles etc. fo
or further
d
distribution
s
suiting
to his
s requiremen
nt at his own
n cost. The C
Contractor shall
s
engage
e licensed
e
electrician
fo
or this purpo
ose. Suitable power dis
stribution centre of inco
oming breaker feeder
a outgoing
and
g breakers & MCCB feed
ders shall be
e arranged b
by the Contra
actor.
For consume
F
ers who are
e more than
n 100m awa
ay, intermediate feeder pillar boxess shall be
in
nstalled from
m where pow
wer shall be tapped as per
p requirem
ment. Each feeder
f
pillar box shall
b outdoor type cubicle
be
e and comp
prising one incomer MC
CCB bus-ba
ar and few outgoing
M
MCCBs.
FORM NO: 02-0
0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 6 of 51
3.2
Adequate no
A
os. of interconnecting e
earth pits forr connecting
g electrical equipment
e
s
should
be
c
constructed.
3.3
All interconn
A
necting cable
es shall be multicore, stranded
s
cop
pper conduc
ctor PVC ca
ables and
these shall be
b buried dire
ectly under soil.
s
3.4
Contractor shall
C
s
arrange
e all necesssary require
ements for developing
d
fabrication yyard with
b
barricading
n
nearby
the plant.
p
3.5
Water for co
W
onstruction shall be used
d from existiing net workk of water su
upply insted--of taking
the undergro
ound water. One
O point frree cost of water
w
supply shall be pro
ovided by NR
RL for the
s
same
and alll further distributions sha
all be laid byy CONTRAC
CTOR.
3.6
S
Sewage
& Refuse
R
Disp
posal
A temporarry building liike site officce, canteen etc. shall be

All
e provided with
w individu
ual septic
ta
anks and so
oak pits for treatment an
nd disposal of
o sanitary sewers. Consstruction site
e shall be
p
provided
with
h a network of temporary
ry drain for disposal of ra
ain water.
4.0
4
M
Mechanical
Completion
n
Mechanical
M
C
Completion
means the time when all construction, erectio
on & installation work
as
a per finallyy approved P&ID after HAZOP sttudy and p
pre-commisssioning relate
ed to the
Mounded
M
Bullets/Unit
B
ordance with the Pro
oject drawings and
is completted in acco
s, and all mechanical
specification
s
m
a
and
pressurre tests, inccluding but not limited to hydrote
esting, non-operating ad
djustments, cold alignment checks, final cleanu
up, field calib
bration of
safety
s
valves
s, calibration
n of all instru
uments, instrrument loop checking an
nd testing, m
monitoring
/ control / sa
afety system
ms checking and testing
g, and all prre-commissioning activitties have
been
b
comple
eted, all inco
oming & outg
going service
es and utilities have bee
en connected to each
Mounded
M
Bu
ullets/Unit. In
nterconnections of proce
ess lines an
nd interconne
ection are completed
c
and
a the Mou
unded Bulletts/Unit is rea
ady in everyy respect forr commissio
oning and fo
or the first
in
ntroduction of
o feed mate
erials.
Itt means that for Mechanical Com
mpletion, CONTRACTO
OR shall pe
erform all necessary
n
works,
w
tests and checks of all discipllines.
When
W
OWNER is satisffied that Me
echanical Completion of
o the Mounded Bullets//Unit has
b
been
achievved, the OWNER
O
sh
hall issue certificate of Mechan
nical Comp
pletion to
C
CONTRACT
TOR in accorrdance with tthe CONTRACT.
5.0
C
COMMISSIO
ONING
5.1
S
Schedule
fo
or Commiss
sioning
CONTRACT
C
TOR shall prepare a scchedule for commission
ning, start-u
up, and perfformance
te
esting and initial operattion in conjunction with OWNER. Th
his shall be issued at le
east three
m
months
before pre comm
missioning off the first fac
cility.
This schedule shall inclu
T
ude all activvities as deta
ailed herein and any oth
her special activities,
w
which
require
e to be perfo
ormed during
g commissio
oning.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
5.2
EM163-E-601
DOC. NO
O.
REV
V
Sheet 7 of 51
C
Commission
ning
CONTRACT
C
TOR shall be respon
nsible to perform
p
com
mmissioning
g of the Mounded
B
Bullets/Units
s and to pro
ovide necesssary facilitiies during ccommissioniing of the Mounded
B
Bullets/Unit
i
including
the
e Performan
nce Tests. CONTRACT
C
OR shall pro
ovide comm
missioning
e
engineers
an
nd supporting staff and adequate
a
co
ommissioning
g labour.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 8 of 51
AN
NNEXURE--1
CON
NTRACTOR
RS WORK DEFINITIO
ON
C
CONTRACT
TOR shall pe
erform/prov
vide the following activ
vities but no
ot limited to
o:
1.
CONTRACT
C
TOR scope of work shall
s
broadlly be conssist of consstruction / erection,
pre-commisssioning, co
r
refurbishing,
ommissioning
g and Start Up of the Mounded
M
Bu
ullets/Unit
u
under
the management
m
t of commisssioning team
m it include
es but not liimited to civvil works,
fa
abrication & erection off structural steelwork,
s
field assemb
bly, mechaniical erection
n and / or
a
assembly
an
nd installatio
on of all equ
uipment and
d machineryy, piping, ele
ectrical systtems and
n
network,
insttrumentation
n, insulation, painting, etc.,
e
except in
i so far as "Contract" otherwise
o
p
provides,
the
e provision of all temporary facilities, staff, tra
adesmen, la
ab our, tools, tackle,
equipment and materia
c
construction
als, insurancce, consuma
ables and everything
e
w
whether
of
te
emporary or permanentt nature neccessary and
d required in
n and for the
e work, so ffar as the
n
necessity
forr providing th
he same is sspecified or reasonably
r
i
inferred
in or from the co
ontract.
2.
Perform all piping

P
p
fabriccation and erection
e
work
ks as per Annex-2A, titled piping fa
abrication
a erection work.
and
3.
P
Perform
all equipment
e
errection workks as per Annex-2B, titled equipment erection work.
w
4.
4
P
Perform
all electrical
e
worrks as per A
Annex-2C, titled
5.
P
Perform
all in
nstrumentatiion works ass per Annex--2D, titled instrumentatio
on works.
6.
P
Perform
all in
nsulation wo
orks as per A
Annex-2E, tittled insulatio
on works.
7.
P
Perform
all painting
p
workks as per An
nnex-2F, title
ed painting work.
w
electriical work.
Supply the materials in order to

S
o execute WORK
W
as per CONT
TRACT & Technical
T
elsewhere in
s
specification
i tender documents.
8.
CONTRACT
C
TOR shall be
e responsible
e for providin
ng services and materia
als for construction of
a temporary
all
y facilities, which
w
are essential
e
forr successful completion
n of construcction and
e
erection.
The CONTR
T
RACTOR sha
all establish, operate an
nd maintain all tempora
ary facilities, such as,
b not limitss to:
but
a Labour camp/officers
a)
c
s camps.
b Fabricatio
b)
on shops/ya
ard.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 9 of 51
c Worksho
c)
op for mainte
enance of co
onstruction/te
esting equipment.
d Field drawing office.
d)
e Tempora
e)
ary warehous
ses, includin
ng open storage yards.
f)
Construcction offices (including fa

acilities for photocopying
g, drawing re
eproduction, etc.)
g First aid along

g)
a
with ambulance.
a
h Lab facilities, includin
h)
ng NDT, for testing calib
bration, etc.
i))
All temporary or ap
pproach roa
ads for carrrying out th
he WORK including te
emporary
approach
h roads for access
a
to CO
ONTRACTO
ORS site offfice/worksho
op/camp, etcc. ground
preparation for heavy lifts includ
ding approacches to cran
nes for heavy lifts. OWN
NER does
not take any
a responssibility for ma
aking temporary roads.
j))
Canteen & catering facilities

f
for a
all CONTRA
ACTORS wo
ork force.
k All drain
k)
nage around the facilities create
ed for his WORK, an
nd sewage disposal
arrangem
ments for lab
bour camps/o
officers cam
mps, site officces, etc.
l))
All winterrization requ

uirements forr personnel/materials & equipment.
m Necessary transporrt for move

m)
ement of itss personne
el, constructtion Equipm
ment and
Materials
s, consumab
bles, etc.
n Watering of roads thrrough water tankers for dust
n)
d
suppresssion.
o All tempo
o)
orary lighting
g for working
g during nigh
ht.
p All tempo
p)
orary hutme
ents, sanitaryy & potable water and domestic
d
sew
werage requ
uirements
of Contra
actors work force.
9.
Supply to OW
S
WNER comp
plete surveyy report within three (3) working day
ys after completion of
a survey.
any
10.
All excess soil shall be disposed off by CONTR

A
RACTOR ou
utside the prremises in a location
d
designated
by
b OWNER representativ
r
ve.
11.
P
Perform
all nondestructiv
n
ve, hydrosta
atic and pre commissioni
c
ing testing required.
12.
Supply to OWNER com

S
mplete test records within three (3) days after completion of actual
te
esting.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 10
0 of 51
13.
P
Perform
all welding
w
inclu
uding radiogrraphy requirred.
14.
P
Provide
draw
wings and do
ocuments ass required.
15.
Provide mob
P
bilization and
d demobiliza
ation, tempo
orary material and
u
utilities
required executin
ng work.
FORM NO: 02-0

0000-0021 F2 RE
EV3
tem
mporary facilities and
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 11
1 of 51
AN
NNEXURE-2
2
D
DETAIL
TE
ECHNICAL
L SCOPE
See accomp
panying by discipline:
d
Annexure-2A
A
A
Pipe prefabriccation and Erection
B
Annexure-2
A
Eq
quipment errection
Annexure-2C
A
C
Ellectrical worrk (Refer doccument EM163-TS08

801attached
d in Tender)
Annexure-2
A
D
In
nstrumentatio
on work (Refer documen
nt EM163PNIN-7901-00
0 attached in
n Tender)
Annexure-2
A
E
In
nsulation worrk
Annexure-2
A
F
Pa
ainting workk
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 12
2 of 51
ANN
NEXURE-2A
PIPE PREFABRIC
P
CATION AN
ND ERECT
TION
1.0
P
PIPING
1.1
M
Magnitude
of
o Piping
CONTRACT
C
TOR shall pre
efabricate, install and te
est all piping
g as shown on
o the plan drawings
a isometric
and
cs.
2.0
P
PIPING
FAB
BRICATION AND EREC
CTION
2.1
Piping systems and pipe supports shall be designed, fabrricated, insp

P
pected, and tested in
a
accordance
with
w rules, codes,
c
speciffications and
d drawings.
2.2
Miscellaneou
M
us piping ma
aterials for vvents, drainss, instrumentt connection
ns, etc. on equipment
s
shall
be insta
alled using P & ID'S and
d equipment drawings.
2.3
The fabricattion and erection

T
e
of piping includes field welds. It is CONTRA
ACTOR'S
r
responsibility
y to choose the num
mber and lo
ocation of field
f
welds to ensure efficient
transportation and hand
dling during erection. Fu
urthermore CONTRACT
TOR shall lo
ocate the
field welds in
n such a wayy that final adjustment fo
or fit-up purp
poses will be
e possible.
2.4
CONTRACT
C
TOR will furn
nish OWNER
R with a marrked up set of isometrics
s identifying
g all spool
p
pieces,
and weld numb
bers. All piping spools shall be cle
early identified, per isom
metric by
m
means
of sta
ainless steel tags affixed
d with wire.
2.5
CONTRACT
C
TOR is respo
onsible for tthe fabrication and erecction of pipe
e supports, hangers,
a
anchors
and guides, as required
r
by the drawings
s and speciffications.
Spring pots and spring hangers, which
S
w
shall be provided
d by CONT
TRACTOR as
a will be
installed, ad
a
assembled,
djusted and unlocked byy CONTRAC
CTOR after hydrostatic testing of
the line. The required an
ngle iron will be decided in the field a
and supplied
d by CONTR
RACTOR.
2.6
CONTRACT
C
TOR shall be
b responsib
ble for the fabrication, installation and disma
antling of
te
emporary sp
pool pieces and blinds required for control va
alves, safety
y valves and
d in - line
in
nstruments during testting and cleaning. Requirements for these shall be m
minimized.
R
Requirement
ts for these will
w be presccribed by OW
WNER.
2.7
CONTRACT
C
TOR is resp
ponsible for the installa
ation and te
esting of all piping and steam,
e
electrical
tra
acing and all materials including all items neccessary to completely
c
cclose the
s
systems
in strict
s
accordance with th
he established test systtem procedu
ures and priorities as
d
directed
by OWNER.
O
2.8
F
Flushing
an
nd Cleaning of Piping S
Systems
i))
Sections fabricated in CONTRAC

CTOR'S worrkshop shall be fitted witth plastic end caps to
e ends, and jointing
j
surfa
aces shall be
e suitably prrotected.
seal pipe
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 13
3 of 51
These ca
aps shall not be remo
oved until se
ections are in the course of erection after
delivery at
a SITE and then shall b
be removed for
f refuse.
iii) During fa
abrication an
nd erection th
he sections shall be insp
pected or intternal cleanliness.
abricated pip
ping shall be
e cleaned att the comple
etion of fabrication. Care
e shall be
iiii) All field fa
taken to see that all burrs, weld
ding icicles, and weld sp
patter and re
emoved by reaming,
ement, morta
ar, sand,
chipping,, filling or her to meanss. All foreign materials such as ce
heavy oiil film & loo
ose scale sshall be rem
moved from the interiorr of pipe th
horoughly
flushing with
w water.
ivv) The wate
er which will be used for testing and
a
flushing
g of the pip
ping system shall be
recollecte
ed per instru
uction given by OWNER
R.
v)
v Piping sy
ystems shalll be flushed
d with suitab
ble water ass supplied by
b Contracto
or unless
designate
ed for nitrog
gen or air ttesting. OW
WNER'S approval is required before
e start of
flushing.
v CONTRA
vi)
ACTOR shalll supply all e
equipment, pumps,
p
gaug
ges, etc. req
quired for
flushing and
a
testing
g of the pipin
ng systems.
v For hydro
vii)
o testing and
d flushing the piping CO
ONTRACTOR
R shall weld and caps an
nd
install drain plugs, remove end caps after successful hyydro test.
3.0
H
HYDRO
TES
STING
3.1
Inspection an
nd hydro tessting of the p
piping systems shall be in accordan
nce with the drawings
and specifica
a
ations and in
n strict witne
ess by OWNE
ER represen
ntatives.
3.2
A
Atmospheric
c pressure systems
s
shalll be:
-
Visually inspected that all joints a

are properly made.
eakage test under atmosspheric cond
ditions.
Filled with water for a 24 hours le
akage occurs
s in the systtem during te
esting, repaiirs must be made
m
withou
ut
If any lea
extra cossts to OWNE
ER.
3.3
CONTRACT
C
TOR shall tes
st all piping systems as
s per the pro
oject test dia
agrams. Tessting is to
b witnesse
be
ed and approved by OWNER and where applicable
e by the appointed
a
(independent inspection authority) ffiled inspecttor. A test schedule by test system
m shall be
p
prepared
by CONTRACT
TOR and shall be submitted to OWN
NER for App
proval.
3.4
T
Testing
and completion shall
s
be in a
accordance with
w project system
s
priorrities.
3.5
All equipme
A
ent, pumps, gauges, pressure rec
corders tem
mporary pipin
ng and fittings, test
g
gaskets
and bolting, required for tessting of the piping
p
system
ms and part of CONTRA
ACTOR'S
s
supply.
Before testing CO
ONTRACTO
OR shall calibrate its testting equipme
ent.
3.6
CONTRACT
C
TOR shall su
upply and insstall blind fla
anges when required to enable testiing of the
liines.
3.7
Inexpensive temporary gaskets su

upplied by CONTRACT
TOR, shall be used in
nstead of
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 14
4 of 51
permanent gaskets
p
g
whe
ere test blin
nds are loca
ated for hyd
drostatic tessting. On successful
c
completion
o a test the permanent
of
p
g
gasket
shall be installed when the blinds are rem
moved.
3.8
Piping system
P
ms shall be tested with suitable watter. Extreme
e care shall be
b taken tha
at suitable
w
water
is used
d for stainlesss steel systtems. For sttainless stee
el the water must
m
be app
proved by
O
OWNER
and
d shall have a content off chlorides 50 mg/L
3.9
T Testing Equipment (including

The
(
te
esting water)) will also be furnished by
b CONTRAC
CTOR.
3.10
CONTRACT
C
TOR is to pe
erform the testing in a sequence so
s as to allo
ow sufficientt time for
in
nsulation an
nd/or painting
g to complette within the time frame of the projecct schedule.
3.11
A formal sysstem of docu

umentation will be deve
eloped by CONTRACTO
C
OR and app
proved by
O
OWNER
for use by CON
NTRACTOR
R to certify th
his testing phase of the piping erecction. This
s
system
will also
a
include a section forr supplying OWNER'S
O
"B
But list" com
mments.
3.12
Erected pipin
E
ng shall be hydrostatica
ally tested in test syste
ems, but nott through eq
quipment,
c
control
valve
es etc. excep
pt where pipiing is welded
d to equipment.
3.13
CONTRACT
C
TOR remainss responsible
e for ensurin
ng that no ittem of equip
pment, or insstrument,
iss damaged by the test pressure
p
or the test fluid
d. Suitability of test fluid to be appro
oved prior
to
o testing by the OWNER
R.
3.14
When lines are

W
a pressure
e tested, vallves at the end
e of the lines must be
e covered with
w a test
b
blank
for sa
afety reason
ns. A record
d, preferablly on the te
est diagram
ms, shall be
e kept by
C
CONTRACT
TOR indicatin
ng which secctions have been comple
eted.
N
Note:
Testing
g against clo
osed valves in not allowe
ed (spades tto be used)
3.15
After testing the piping systems,

A
s
the
ey shall be completely
c
flushed and drained.
d
OW
WNER will
a
approve
whe
en a line is considered
c
flushed and drained
d
by C
CONTRACTO
OR.
3.16
When each section or circuit

W
c
has been pressurre tested an
nd passed, a certificate prepared
b CONTRA
by
ACTOR on CONTRACTO
C
OR'S furnish
hed forms sh
howing detaiils must be signed
s
by
C
CONTRACT
TOR and OW
WNER, when
n the test ha
as been com
mpleted and
d the system
m drained,
te
est blanks must
m
be remo
oved by CONTRACTOR
R.
3.17
Records shalll be maintain

ned for each
h piping systtem after tessting. These records sha
all contain
the following information:
a Date of Te
a)
est.
b Identificattion of Piping
b)
g Tested.
c Test Fluid.
c)
d Approved by Owner/C
d)
Consultant/R
Representativves.
3.18
The following
T
g activities by
b CONTRA
ACTOR are included
i
for the reinstattement of pip
ping after
h
hydro
testing
g:
- CONTRA
ACTOR insta
alled temporrary testing blinds
b
to be pulled.
-
Tempora
ary spool pieces taken out.
Gaskets renewed, te
emporary rep
placed with permanent.
p
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 15
5 of 51
Flange co
onnection bo
olts tightene
ed.
Post hydro punch listt items corre

ected.
ary strainers installed.

Tempora
Chemica
al cleaning pe
erformed.
Supportss and hangers checked ifi in final possition.
Rotating equipment cold

c
alignme
ent checked.
ation of control
c
and safety va
alves and in - line instrumentts which
Reinstalla
CONTRA
ACTOR has removed for hydro-testing.
3.19
Nondestructiive testing of welds and

N
a
systems
s is to be performed in accorda
ance with
s
standards,
co
odes and sp
pecifications prior to perfform any hyd
dro-test.
4.0
4
P
PIPING
MAT
TERIAL IDE
ENTIFICATIO
ON AND PA
AINTING
4.1
4
All piping materials are supplied by

A
b CONTRA
ACTOR and shall be prroperly stam
mped and
to ensure that
c
color-coded
t
the corrrect materia
als are used as requirred by the drawings,
d
s
specification
s, codes and
d regulationss.
4.2
4
All materialss will be ade

A
equately marked as to its specificattions. CONT
TRACTOR should
s
be
r
required
to cut
c same orr otherwise render piecce(s) to have
e no markin
ng, CONTRA
ACTOR'S
transfer or re
eplacement of
o proper ide
entification marking
m
to th
he pieces invvolved, mustt be done
a
according
to
o approved stamping m
method and to be countter stamped by CONTR
RACTOR.
P
Paint
alone is unaccepta
able.
4.3
4
The governin
T
ng principle shall be tha
at in the insta
alled piping systems, all components can be
id
dentified and their origin and comp
plete specificcations can be determined. The method for
id
dentification and stamp
ping or tagging of the various
v
com
mponents of the system shall be
w
worked
out in
n coordinatio
on with OWN
NER and only be implem
mented afterr approval.
CONTRACT
C
TOR shall be
e held responsible for this requireme
ent as a min
nimum, and any
a other
r
requirements
s of local codes
c
and regulations as to identification an
nd documen
ntation of
m
materials.
4.4
4
Surface prep
S
paration and
d paint appliccation of pip
ping system by CONTRA
ACTOR, sha
all be per
p
paint
specific
cation.
4.5
4
CONTRACT
C
TOR shall asssure that no
o welds are covered by prime coatss prior to accceptance
o hydro test.
of
4.6
4
CONTRACT
C
TOR must ensure
e
that all stamping
g such as code stamp
ps, registratiion spool
id
dentification, charge num
mbers etc. shall
s
be visib
ble after pain
nt work.
5.0
W
WELDING
5.1
A welding shall
All
s
be carried out according to codes and speccifications.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 16
6 of 51
5.2
W
Welder's
qua
alification.
5.2.1
All welders including th

A
hose with vvalid qualifications will be require
ed to subm
mit a test
c
conducted
by
y OWNER prior
p
to start of welding.
Welders thatt have a cerrtificate whicch is still valiid for the typ
W
pe of materia
al and in acccordance
w ASME IX
with
X will not be
e tested by O
OWNER.
5.2.2
A current lisst of qualifie

ed welders must be maintained
m
b
by CONTRA
ACTOR and
d a copy
furnished to OWNER each time a revision is ma
ade.
5.3
Welders ide
W
entification stamps
s
shall be provide
ed by CONT
TRACTOR. Each weld shall be
c
clearly
stamped with welders
w
iden
ntification. All
A welding iincluding tack welding shall be
c
carried
out by qualified
d welders. U
Unstamped welds shalll be-removed and rep
placed at
C
CONTRACT
TOR'S expen
nse.
5.4
J SITE fab
Job
brication sha
all be carried
d out under cover
c
where possible.
5.5
W
Weld
spatterr shall be kno
ocked off around all welds leaving a smooth cle
ean surface.
5.6
Where openings for bran

W
nches are cu
ut in run of pipe,
p
all matterial, which may drop in
nside the
p
pipe,
shall be
e completelyy removed before the bra
anch line is welded in pllace.
5.7
T interior welds
The
w
of orifice flanges sshall be grou
und smooth.
5.8
E
Electrodes,
Rods, Wire
es and Fluxe
es
Electrodes shall be store
E
ed in the ma
akers airtight containerss until require
ed for use. E
Electrode
h
heaters
shalll be used on
n Job SITE, ffor low hydro
ogen types of
o electrodess.
5.9
O
Open
Air We
elding
Where welding in the open
W
o
air is unavoidable
e, WORK must
m
be disccontinued w
where the
q
quality
of the weld mayy be impaire
ed by weath
her conditio
ons. Includin
ng but not limited to
a
airborne
moisture, sand
d or high wiinds. After rain
r
the metal surfaces
s shall be dried. For
m
metal
temperature below
w 5 0C joints to be preheated.
5.10
W
Welding
Pro
ocedure Qualification
5.11
CONTRACT
C
TOR shall supply we
elding proce
edure speccifications and
a
qualificcation in
a
accordance
with
w the rule
es as set by OWNER.
F
Fees
for ins
spection required for we
elding proce
edure and w
welders qua
alifications, supply
s
of
e
equipment
required for the qualificcation test of
o welders a
and welding proceduress are for
a
account
of CONTRACTO
C
OR.
5.12
Inspection and
a Testing
g
5.12.1
Inspection of
o welds sha
all be in acccordance with
w
the insttructions of OWNER and/or the
r
requirements
s of codes and standard
ds.
5.12.2
C
CONTRACT
TOR shall be
e responsiblle for the re
epair of faultty welds and
d for all the
e required
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 17
7 of 51
extra radiogrraphy and in

e
nspection off the faulty welding
w
workk. In case off a faulty we
eld, 100%
r
radiography,
on CONTR
RACTOR'S account, sh
hall be done
e on the we
eld performe
ed as per
c
code.
OWNER sha
O
all have absolute discretion in the selection
s
of tthe welds, which
w
are to
o be radio
g
graphed.
5.12.3
C
CONTRACT
TOR shall pro
ovide NDE sservice, acce
eptable to OWNER.
NDT inspection shall be carried out in accordance with code
N
es for all line
es as indicatted in the
p
piping
speciffication.
6.0
S
STRESS
RE
ELIEVING
6.1
CONTRACT
C
TOR shall prrovide stresss-relieving service accep
ptable to OW
WNER. Spo
ool pieces
s
shall
be stre
ess relived in an apprroved furnacce equipped
d with therm
mostatic control and
te
emperature recorder. Field
F
welds to be stresss relieved w
with electricc resistance heaters.
T
Temperature
e cycles to be monitored
d with portab
ble temperatu
ure recorderr.
6.2
Stress relievved welds shall

S
s
be harrdness teste
ed by appro
oved proced
dure and mu
ust meet
c
criteria
spelle
ed out in spe
ecifications.
7.0
T
TRANSPOR
RTATION
The following various ca
T
ategories off transportattion of pipe,, pipe fitting
gs and preffabricated
p
pipe
spools will be pe
erformed byy CONTRAC
CTOR. All categories include load
ding and
u
unloading
ma
aterials. Cattegories will consist of but not limited
d to:
-
Instrumen
nt connectio
ons (up to an
nd including the first blocck valve).
From CO
ONTRACTOR
R'S warehou
use to CONT
TRACTOR'S
S pipe prefab
b shop.
From CO
ONTRACTOR
R'S pipe pre
efab shop to CONTRACT
TOR'S paintting shop.
From CO
ONTRACTOR'S pipe pre
efab or painting shop to
o CONTRAC
CTOR'S storrage area
or workin
ng area locatted on site o
or any other location on SITE.
S
All transsportation re
equired perrforming no
ondestructive
e testing off prefabrica
ated pipe
spools.
8.0
L
LIFTING,
LIF
FTING EQUIPMENT AN
ND GEAR
8.1
Rigging and
R
d hoisting shall be exxecuted as per consttruction spe
ecification and
a
local
r
requirements
s and safetyy rules, as manufacturers instruction
ns. If there are
a stringent one shall
p
prevail.
8.2
T
Testing
And
d Certificatio
on
All CONTRA
A
ACTOR furn
nished crane
es, lifting ap
ppliances an
nd lifting ge
ear must be properly
te
ested, exam
mined and/orr inspected b
before being used on SIT
TE, and at the intervals specified
in
n the applica
able regulatiions. Copiess of the relev
vant certifica
ates must alw
ways be ava
ailable on
S
SITE
for insp
pection on re
equest by OW
WNER or otther authoritiies.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 18
8 of 51
8.3
O
Operation
8.3.1
CONTRACT
C
TOR shall no
ot permit a lifting appliance to be
e operated otherwise
o
th
han by a
p
person
traine
ed and comp
petent to do so.
8.3.2
CONTRACT
C
TOR shall take
t
expresss steps to ensure that all personnel employed by
C
CONTRACT
TOR are com
mpetent and experienced
d for their asssigned tackss.
9.0
D
DRAWINGS
AND DOCU
UMENTS
C
CONTRACT
TOR shall fill in checklistss as required
d by OWNER.
10.0
M
MISCELLAN
NEOUS
10.1
CONTRACT
C
TOR shall furrnish all field
d engineering surveying layout, and checking to
o properly
in
nstall all abo
ove ground piping to m
meet all requ
uirements off the drawings and specification.
O
OWNER
is authorized
a
to
o reject any W
WORK alrea
ady installed
d, which is no
ot in accorda
ance with
d
drawing
and specifications and of ad
dequate qua
ality.
10.2
All costs invvolved in de

A
emolition, removal and replacement of rejected
d works sha
all be the
r
responsibility
y of CONTR
RACTOR. A
All materials
s equipmentt or auxiliaries not acccepted by
O
OWNER
sha
all be remove
ed immediattely from SIT
TE.
10.3
Underground
U
d service lin
nes are marrked at their installation
n limits to above
a
groun
nd piping,
in
ndicating line size, service and line number.
10.4
During stora
D
age, fabricattion and ere
ection, care must be ta
aken to ensu
ure that san
nd, scrap
m
materials,
we
elding rods, items of clo
othing and other
o
foreign
n bodies are not allowed
d to enter
p
piping.
10.5
All connectio
A
ons which are left open
n by CONTR
RACTOR shall be well protected,
p
so that no
s
sand,
dirt or any foreign objects com
me into the syystem.
10.6
In certain in
nstances sp
pecial bolting torques might be re
equired on critical con
nnections.
CONTRACT
C
TOR will arra
ange WORK in accordan
nce with thesse requireme
ents.
10.7
Flanged pipiing connections to Mou

F
unded Bulletts/Equipmen
nt shall be aligned
a
and
d shall be
p
properly
fitte
ed before bo
olting up. Pip
ping may be
e heated to bring
b
it into alignment only
o
when
a
approved
byy OWNER. Extreme ccare should be exercissed to avoid
d damage. Heating,
w
welding
and flame cutting on equipm
ment will not be permitted
d.
10.8
No cold springing or pre

N
e- stressing of piping will be allowe
ed other than
n indicated on piping
d
drawings,
iso
ometrics and
d manufacturer's instructions (e.g. fo
or expansion
n joints).
10.9
Flange facess shall be cle

F
ean and free
e from foreig
gn matter be
efore assemb
bly. Damaged flange
fa
aces may be
e dressed with
w a medium
m cut file only if th
he damage does
d
not req
quire new
fa
acing. This shall
s
be decided by OW
WNER.
10.10
During erection care sha

D
all be taken to remove all
a dirt, sealss, sand and foreign mattters from
in
nside the pip
pe.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 19
9 of 51
10.11
Since CONT
S
TRACTOR is
s responsiblle for both the prefabriccation and th
he erection of all the
p
piping,
it is CONTRACT
C
TOR'S sole rresponsibility
y to ensure that all pipin
ng to be insstalled fits
p
properly
prio
or to lifting. CONTRAC
CTOR is to check all Mounded
M
Bu
ullets/Equipm
ment and
p
piping
to be piped to, for
f proper lo
ocation and orientation.. OWNER will
w not ente
ertain any
c
claims
for exxtra work.
10.12
In all cases, all designate

ed support and
a hangerss should be iin unlocked I cold positio
on before
ent. CONTRA
ACTOR will be expected
d to expedite
e this in criticcal phase.
final alignme
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 20
0 of 51
ANN
NEXEURE-2
2B
EQUIPM
MENT (MOU
UNDED BU
ULLETS/DR
RAIN VESS
SEL) EREC
CTION
1.0
S
SURVEYING
G
1.1
Baseline and
B
d base elevvation will be
e furnished to the CON
NTRACTOR. CONTRAC
CTOR will
furnish all su
urveying from
m this baselin
ation.
ne and eleva
1.2
OWNER sha
O
all have the authority at any time to
o determine in accordance with the drawings
o written directives, the correctnesss or complete
or
eness of the
e lines in use
e by CONTR
RACTOR.
1.3
Any erroneo
A
ous WORK shall be co
orrected to OWNER'S
O
ssatisfaction at CONTRA
ACTOR'S
e
expense.
2.0
R
RIGGING
ST
TUDIES AND PLANS
2.1
C
CONTRACT
TOR shall supply rigging studies and
d plans as sp
pecified.
3.0
E
EQUIPMENT
T HANDLING
3.1
The handling of all Mo

T
ounded Bulllets/Drain Vessel
V
shall include, bu
ut not limite
ed to the
fo
ollowing activities by CO
ONTRACTOR.
3.1.1
Submittal to OWNER off detailed rig

S
gging studie
es and planss for lifting, transporting
g and
s
setting
of Mo
ounded Bulle
ets/Unit 4 weeks
w
in advvance of worrk for OWNE
ER to review
w and
a
approval.
Co
omplicated liffts shall be sstarted in the
e morning an
nd complete
ed the same day.
T transporrtation plans
The
s are to include as a minimum:
T
Type
of equipment to be
e used to tran
nsport each piece.
T planned route of the
The
e movement.
T estimate
The
ed duration of
o the movem
ment.
T obstructtions to the route
The
r
to be te
emporarily re
emoved.
3.1.2
Receive, inspect, store, protect and

R
d perform pre
eventative m
maintenance
e on all equipment in
with the specification
a
accordance
ns and dra
awings and
d/or equipm
ment manuffacturers
in
nstructions.
3.1.3
Plumb level and align eq

P
quipment witth coordinate
es in accord
dance with th
he specificattions and
d
drawings.
3.1.3.1
G
GENERAL
All of the Mo
A
ounded Bullets/ Drain Vessel
V
mustt be plumbe
ed, leveled and aligned
d with the
c
coordinates
n plan and elevation an
nd to the to
olerances
specified on the drawiings both in
c
called
out in the speccifications, sspecific ma
anufacturerss instruction
ns or recom
mmended
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 21
1 of 51
m
manufacture
's practices.
-
ACTOR will be required to verify fielld conditionss and will be

e responsible
e for final
CONTRA
alignmen
nt of mechanical items for this projject. CONT
TRACTOR will
w check th
he anchor
bolt locattions against the Mound
ded Bullets/e
equipment. A
Any deviation
n must be re
eported to
OWNER in writing.
ACTOR will be required

d to supply and install shims required for all Mounded
CONTRA
Bullets/eq
quipment errection. All cinch ancho
ors required for equipme
ent and sup
pports will
be suppliied and ereccted by CON
NTRACTOR..
Prior to the
t placement of the equipment on a foundation, the surfac
ces of the fo
oundation
shall be cleaned off oil, grease
e, excess concrete
c
and
fore
eign
matte
ers
by
CONTRA
ACTOR.
Prior to setting
s
the equipment
e
on the founda
ations, the u
underside off the equipm
ment base
plate or supports will
w be clean
ned free of oil, grease
e and otherr loose matterials by
ACTOR.
CONTRA
Mounded
d Bullets/equ
uipment sha
all be set tru
ue to line. att correct ele
evation and in proper
orientatio
on as shown
n and noted o
on the drawiings.
Maximum
m allowable setting tollerances sh
hall be in a
accordance with manufacturers
requirements or with the specificcations, whic
chever is mo
ore stringent..
The Mou
unded Bulle
ets/equipment shall be set, levele
ed, aligned and inspeccted with
precision
n tools (ste
eel straight edge, gra
aduated ma
achinist levvels, dial in
ndicators,
theodolite
es, water levvel instrume
ents, turbine levels, etc.)). Setting, le
eveling and alignment
a
shall be according
a
to
o manufacturrer's recomm
mended tolerrances and specification
s
ns.
CONTRA
ACTOR shalll remove all temporary shipping
s
sup
pports or ere
ection materials.
CONTRA
ACTOR shall do surfacce preparatio
on for, and apply coating and wra
apping on
buried ve
essels before
e installation
n.
For Moun
nded Bulletss/equipmentt with sliding
g type suppo
orts, CONTR
RACTOR will remove
dirt, grea
ase or othe
er foreign m
matter and will
w coat with graphite grease sup
pplied by
CONTRA
ACTOR on th
he support.
4.0
4
M
MATERIAL
HANDLING SYSTEM
4.1
4
E
ERECTION
& COMMISS
SIONING
4.1.1
4
The complete material handling ssystem inclu

T
uding its all Mounded Bullets/Dra
ain
V
Vessel
shalll be erected
d at site an
nd commisssioned in acccordance with
w
the be
est
e
engineering
practice.
4.1.2
4
Packing, forrwarding, trransportation

P
n, unloading
g and stora
age at site
e, safety an
nd
p
protection
off various com
mponents att site, insura
ance etc. sha
all be the responsibility of
the Contracto
or / supplier.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 22
2 of 51
4.1.3
4
All men, matterial and to

A
ools required
d shall be arrranged by tthe Contracttor at his ow
wn
c
cost.
The Co
ontractor sha
all also arran
nge for the safe
s
handling
g, storage, protection
p
an
nd
s
security
of hiis good at site.
4.1.4
4
The purchas
T
ser shall be responsible
r
for supplying
g his part off material on
nly as covere
ed
b the clausse pertaining to the wo
by
ork to be excluded
e
from Contracto
ors scope of
s
supply.
4.1.5
4
After erectio
A
on at site, related
r
Mou
unded Bulle
ets/Drain Ve
essel shall be
b tested fo
or
s
satisfactory
o
operation
for mechanica
al completion and full-lo
oad performa
ance run. Th
he
C
Contractor
shall carry ou
ut performance test as per mutually agreed prrocedure. Th
he
d
details
of th
he procedurre shall be
e submitted by the Co
ontractor forr purchaserrs
a
approval.
4.2
4
M
MECHANICA
AL COMPLE
ETION
4.2.1
4
Mechanical completion shall be cconsidered as achieve

M
ed when th
he system is
m
mechanically
y complete along
a
with the pre-comm
missioning a
activities and
d is ready fo
or
fe
eeding. Thiss shall includ
de but not lim
mited to the following:
f
The installation as per FINAL PROP
T
POSAL is complete in alll respects in accordance
e
w the draw
with
wings, specifications inccluding any approved
a
changes there
eto and in
with all applicable codess and laws.
a
accordance
Temporary construction
T
c
facilities are
e removed to
t the extentt necessary to permit th
he
M
Mounded
Bu
ullets/Unit sta
art-up and commissionin
ng.
4.2.2
4
The OWNER
T
R shall inspect and ccertify that the
t
Contracctor execute
ed the job in
a
accordance
with
w drawing
gs and speciifications.
4.2.3
4
Omissions / rectifications
O
s of minor ite
ems, if any, not affecting
g commissio
oning shall not
w
withhold
MECHANICAL COMPLETION as long as the Contractor agrees to supplyy /
r
rectify
the sa
ame within the
t specified
d period. Th
he decision of
o the OWN
NER is final in
this regard.
4.3
4
C
COMMISSIO
ONING AND
D GUARANT
TEE TEST
4.3.1
4
After issue of Mechan

A
nical comple
etion certific
cates by Owner,
O
CON
NTRACTOR
R&
O
OWNER
sh
hall mutuallyy decide the
t
date of
o commissioning of the Mounde
ed
B
Bullets/equip
pment.
5.0
P
PREPARE
E
EQUIPMENT
T FOR OPER
RATION
5.1
Immediately prior to turnover, CONTRACTOR

R will make
e all the Mo
ounded Bulllets/Drain
Vessel ready
V
y for operatio
on. This includes, but is not limited tto such activvities as:
5.1.1
R
Removal
of preservative
p
es and rust p
preventatives
s.
5.1.2
Installation of
o seals or re
emoval of ste
eel covers.
5.1.3
R
Removal
of moisture
m
abs
sorbing mate
erials.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 23
3 of 51
5.1.4
D
Draining
of oil
o reservoirss and the flusshing and filling of the in
nitial charge.
5.1.5
r's represe
Assisting eq
A
quipment manufacture
m
entatives byy final che
eckout of Mounded
B
Bullets/equip
pment
.
5.1.6
Remove all temporary supports, b

R
bracing, or other
o
foreign
n objects th
hat were insstalled in
M
Mounded
Bullets/equipm
ment or otther equipm
ment to pre
event damage during shipping,
s
storage,
tran
nsport and errection.
5.1.7
C
Conduct
all flushing,
f
blow
wing and chemical clean
ning required
d by the spe
ecifications.
6.0
Scaffolding sufficient
S
s
am
mount of sccaffolding required for good
g
perform
mance of th
he WORK
s
shall
be supp
plied by CON
NTRACTOR
R.
7.0
D
DRAWINGS
AND DOCU
UMENTS
7.1
CONTRACT
C
TOR will carry out all construction
n and any required prrocurement activities
d
directly
from
m the AFC construction
c
n drawings and specificcations and forming pa
art of the
C
CONTRACT
T. No additional design w
work or deve
elopment e.g
g. completio
on of drawing
gs will be
r
required
from
m CONTRAC
CTOR.
H
However,
the
e plan type drawings ca
alled out to be supplied
d by CONTR
RACTOR in previous
of this sectio
s
subsections
on are includ
ded in CONT
TRACTOR'S
S scope of WORK.
W
7.2
All of CONTR
A
RACTOR'S drawings, ca
alculations, documents, test reports
s, and test ce
ertificates
a
are
to be submitted to OWNE
ER for app
proval in 6-fold.After receiving approval
C
CONTRACT
TOR to subm
mit for final approval alll of the abo
ove and one
e (1) soft co
opy in CF
fo
ormat. CON
NTRACTOR drawings re
eceiving "Ap
pproved as Noted"
N
stamp may be worked
w
on
p
provided
all notes are incorporated
d. It is und
derstood tha
at OWNER'S
S approval shall not
r
relieve
CON
NTRACTOR from his obligations to
o timely com
mplete the WORK according to
a
approved
pro
oject schedu
ule by OWNE
ER.
7.3
CONTRACT
C
TOR'S drawin
ngs shall be
e clearly marrked with titlles, equipme
ent numberss or other
ittem identificcation.
7.4
Approval of drawings
A
d
an
nd calculation
ns by OWNE
ER in no wa
ay absolves CONTRACT
TOR from
itts responsib
bility for the accuracy orr for the des
sign, constru
uction and timely perform
mance of
the WORK.
7.5
C
CONTRACT
TOR shall pro
omptly subm
mit reports off each and every
e
test or inspection.
7.6
CONTRACT
C
TOR shall submit
s
quality records of the mate
erials, as specified
s
in previous
s
sections
and
d the applicable engineering specificcations.
7.7
CONTRACT
C
TOR shall furnish an equ
uipment insttallation reco
ord indicatin
ng date of in
nstallation
a tag number of each piece of equ
and
uipment.
7.8
CONTRACT
C
TOR shall furrnish an equ
uipment maiintenance re
ecord indicatting date an
nd type or
m
maintenance
e of each pie
ece of equipm
ment during the CONTR
RACTOR period.
7.9
C
CONTRACT
TOR shall fill out checklissts as require
ed by OWNE
ER.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 24
4 of 51
8.0
L
LIFTING,
LIF
FTING EQUIPMENT AN
ND GEAR
8.1
Rigging and hoisting shall be execu

R
uted in acco
ordance with
h constructio
on specifica
ation local
a
and
governm
mental requ
uirements and
a
safety manuals, as
a well as specific equipment
m
manufacture
r's instructio
ons. If there are
a conflicts
s the more sttringent shalll prevail.
8.2
CONTRACT
C
TOR shall on
nly perform the lifts and
d movemen
nts in accord
dance with approved
a
C
CONTRACT
TOR submitte
ed rigging sttudies and plans.
p
8.3
Preferably, Mounded
P
M
Bullets/equipm
B
ment will be lifted in a
accordance with manufacturer's
in
nstructions, if include, using
u
lifting trunnions, liftting lugs if p
provided, or by slings atttached to
o around the
or
t
equipme
ent, with adequate prrotective me
easures to prevent da
amage to
e
equipment.
N temporarry lifting lugss shall be use
No
ed without th
he written ap
pproval of OWNER.
O
8.4
No nozzles or
N
o other app
purtenancess not intende
ed for lifting shall be ussed for attacchment of
s
slings.
8.5
Mounded Bu
M
ullets/equipm
ment shall be
e handled with
w sufficientt care to pre
event damag
ge. Slings
s
shall
have adequate protection
p
to
o prevent marring
m
the surface off equipment. Where
n
necessary,
s
sling
spread
ders shall b
be used to prevent cru
ushing or other
o
damag
ge to the
e
equipment.
8.6
T
Testing
And
d Certificatio
on
All CONTRA
A
ACTOR furn
nished crane
es, lifting ap
ppliances an
nd lifting ge
ear must be properly
te
ested, exam
mined and /o
or inspected before bein
ng used on ssite and at th
he intervals specified
in
n the applica
able regulatiions. Copiess of the relev
vant certifica
ates must alw
ways be ava
ailable on
s for inspe
site
ection on req
quest by OW
WNER or proper authoritiies.
8.7
O
Operation
8.7.1
CONTRACT
C
TOR shall not permit a lifting appliance to be
e operated otherwise
o
th
han by a
p
person
traine
ed and comp
petent to do so.
8.7.2
CONTRACT
C
TOR shall take
t
expresss steps to
o ensure th
hat all pers
sonnel employed by
C
CONTRACT
TOR are com
mpetent and experienced
d for their asssigned taskss.
9.0
WELDING
W
W
Welding
of or on equipm
ment shall only be permitted with the approval of OWNER.
10.0
M
MOUNDED
BULLETS/E
EQUIPMENT
T PAINTING
G TOUCH
Equipment to
E
t be erecte
ed by CONT
TRACTOR will be delivvered to SITE finished painted.
C
CONTRACT
TOR is respo
onsible to apply
a
remedial I touch u
mages to
up painting for any dam
p
paint,
or protective coatings on equ
uipment handled by it in
n connection
n. With any aspect of
this operations such as unloading
u
tra
ansport, han
ndling and errection.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 25
5 of 51
ANN
NEXURE-2C
C
ELECT
TRICAL WO
ORK
1.0
S
SCOPE:
ELE
ECTRICAL WORK COV
VERS
1.1
Installation and
a
erection
n of the follo
owing equipm
ment (itemss) consists of
o the prepa
aration for
in
nstallation, connection,
c
testing and pre-commis
ssioning etc. as per speccifications an
nd as per
d
drawings.
A Electrical activities ca
All
arried out at site shall be
e as per rele
evant IS, Ind
dian electricitty rules &
IE ACT with latest amen
ndment. Anyy other job which
w
is nott mentioned in this anne
exure but
n
necessary
fo
or the fulfillment of the prroject shall be
b carried ou
ut by the con
ntractor inva
ariably.
NOTE-REFE
N
ER DOCUM
MENT EM16
63-TS-0801 ATTACHED
D IN TENDER FOR
S
SCOPE
OF WORK
W
& SP
PEC.
FORM NO: 02-0

0000-0021 F2 RE
EV3
DETAIL
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 26
6 of 51
ANN
NEXURE-2D
INSTRUME
ENTATION
N WORK
1.0
G
GENERAL
1.1
Instrumentattion symbolss and identifiication of fun

nctions shall be based on
o the current edition
of ISA S5.1.
o
1.2
Specification
S
ns for instrum
ments and ittems of control equipme
ent are show
wn on data sheets to
b issued ass they becom
be
me available.
1.3
All materials
A
s and conne
ections for co
ontrol valves, relief valvves, level co
ontrollers an
nd similar
e
equipment
shall comply with applica
able requirem
ments for va
alves and fitttings as notted in the
p
piping
speciffication.
1.4
CONTRACT
C
TOR shall in
nstall all sh
him plates, fixing material such as but not limited to
a
anchors,
red heads, etc.
1.5
C
CONTRACT
TOR shall insstall all instru
ument equip
pment tag pla
ates.
NOTE-REFE
N
ER DOCUME
ENT-EM163
3-PNIN-7901
1-00 ATTAC
CHED IN TE
ENDER FOR
R DETAIL
S
SCOPE
OF WORK
W
& SP
PEC.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 27
7 of 51
ANN
NEXURE-2E
INSUL
LATION WO
ORK
1.0
Fabrication
F
a
and
installattion of insulation and weatherproo
w
ofing with (m
mastic) and//or metal
with specificcation, drawiings & line b
ja
acketing in accordance
a
bills schedule
es for:
-
1.1
Piping
Instruments.
Insulation ma
aterials.
CONTRACT
C
TOR shall furrnish all insu
ulation materrials of the tyype and qua
ality as speciified.
P
Painting
Spe
ecifications and
a Codes o
of Owner/PM
MC.
S
Substitute
materials mayy not be used without prior written A
Approval from
m OWNER.
Insulation ma
aterials shalll be properlyy stored in a dry place and
a shall be dry when a
applied by
CONTRACT
C
TOR.
Insulating ma
aterials (co
ompounds off mastics), which
w
can de
ecompose or polymerize
e in hot or
ccold climates
s shall be sto
ored in an aiir - condition
ned or heate
ed warehouse.
Insulating materials with
h a limited self
s
life or pot
p life shalll be marked
d with manu
ufacturers
rrecommende
ed ultimate using
u
date.
1.2
P
Piping
shall not
n be insula
ated until OW
WNER has accepted
a
or piping is rea
ady for insula
ation.
Piping which
P
h will be hyd
drostatically tested shall not be insu
ulated until such
s
tests ha
ave been
s
successfully
completed and
a accepte
ed by OWNE
ER.
2.0
D
DRAWINGS
AND DOCU
UMENTS
2.1
CONTRACT
C
TOR will carry out all insulation insttallation, we
eatherproofin
ng directly from
f
AFC
drawings/ and
c
construction
a project sspecificationss.
2.2
All of CONTRACTOR'S test reports and test ce

A
ertificates are
e to be subm
mitted to OW
WNER for
A
Approval
in 33 fold.
2.3
C
CONTRACT
TOR shall pro
omptly subm
mit reports off each and every
e
test or inspection.
2.4
CONTRACT
C
TOR shall su
ubmit qualityy records off the materials, if appliccable as specified in
p
previous
secctions and the applicable
e engineering
g specifications.
3.0
MISCELLAN
M
NEOUS
Insulation insstallation and
d weatherprroofing shall be in accord
dance with project
p
speciifications.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 28
8 of 51
ANNE
EXURE-2F
F
PAINT
TING WORK
K
PO
OLYURETHA
ANE BULLE
ET PROTECTIVE COAT
TING
The
e minimum requiremen
nts for the coating ma
aterials, equ
uipment, application, in
nspection,
rep
pair, handling
g & other asspects of exxternal (surfa
ace) corrosio
on protection
n of mounde
ed bullets
(cylindrical unfired Pressurre vessels) a
are covered under these
e technical sp
pecificationss.
1.0
SC
COPE OF WO
ORK
This specification governs the minimum
m requireme
ents for mate
erials (coatin
ng as well as surface
eparation prior to coating
g), equipme
ent, coating application, inspection, repair, hand
dling and
pre
all other aspeccts of extern
nal corrosion
n protection of Mounded
d Bullets for bulk storage of the
uefiable (haz
zardous) gas
ses under prressure.
liqu
d that the Polyurethane
P
e coating (1
100% solidss, high build
d, elastomerric)on the
It iss envisaged
external surfac
ce of the mo
ounded bulle
ets shall prov
vide a hard, tough, high
h electrical re
esistance
(forr corrosion prevention in conjuncction with Cathodic protection syystem) surfface with
outtstanding ad
dhesion and impact resisstance to prrotect againsst damage during
d
the process of
mounding (com
mpaction of graded
g
sand
d followed by
b earth cover). The coa
ating system
m shall be
suittable for serrvice temperratures betw
ween minimu
um -55 C and ambien
nt + 55 C (although
these temperatures may not
n be norm
mally achieve
ed/ encounttered) in serrvice. Also vvery high
leve
els of chlorid
des & sulphates, particu
ularly in coastal installattions, should
d be withstoo
od by the
coa
ating during entire design life span.
m
bu
ullets, with internal presssures the unfired
u
shell areas widen more than
n the ring
In mounded
stifffened region
n. The coatin
ng system sshall withstan
nd, without d
damage durring the entirre service
life span, the co
onstraint developed thus producing bending mo
oments in the mounded bullets in
longitudinal dire
ection, the maximum
m
off which occu
ur/ are likely to occur in the plane of
o the ring
stifffener.
The
e work to in
nclude furniishing all la
abour (skille
ed & unskilled), materia
als, tools & tackles,
equ
uipment & performance
p
of all operrations and incidentals necessary for
f coating handling,
storring and tran
nsporting of coated bulle
ets or part thereof. The ccoating operrations will have to be
carrried out in narrow spa
ace around the mound
ded bullet p
prior to grad
ded sand fiilling and
com
mpaction aro
ound the fabrricated bulle
et.
The
e steel surfa
ace prepara
ation prior tto actual co
ommenceme
ent of coating shall co
onform to
STE
EEL STRUC
CTURE PA
AINTING CO
OUNCIL-SUR
RFACE PR
REPARATION SPECIFICATION:
SSP
PC-SP10.
Rem
moval of all equipment and excesss materials from site, following co
ompletion off Coating
ope
erations is included in the
e scope of work.
w
or approval from ownerr / consultant shall be obtained byy the coatin
ng applicato
or for any
Prio
dev
viations from the requirem
ments of thiss specificatio
on and/ or th
he standards
s referred therein.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
2.0
DOC. NO
O.
REV
V
Sheet 29
9 of 51
REF
FERENCE DOCUMENT
D
TS:
STIP3 (STEEL BULLET INSTITUTE ,

USA
A)
NAC
CE 6H 284 (NATIONAL
(
ASS
SOCIATION
N OF
CORROSION ENGINEERS
E
S)
SSP
PC- SP1
SSP
PC- SP10
SIS
S 055900
NAC
CE TM-01-7
7
NAC
CE TM-01-7
75
3.0
EM163-E-601
CORR
ROSION CO
ONTROL SYS
STEMS OF
STEEL BULLETS
URET
THANE TOP COATS FO
OR
ATOM
MOSPHERIC
C
APPLIICAITON (TECHNICAL COMMITTE
EE
REPO
ORT)
STRUCTURAL ST
TEEL PAINT
TING COUN
NCIL:
NING
SOLVENT CLEAN
STRUCTURAL ST
TEEL PAINT
TING COUN
NCIL:
NEAR
R WHITE BLA
AST CLEAN
NING
PICTO
ORIAL SURF
FACE PREP
PARATION
STANDARD FOR
R PAINTING OF STEEL
STRUCTURES
VISUA
AL STANDA
ARD FOR SU
URFACE & N
NEW
STEEL AIR BLAS
ST CLEANED
D SAND
ABRA
ASIVES
VISUA
AL STANDA
ARD FOR SU
URFACE & N
NEW
STEEL CENTRIFU
UGALLY BL
LAST CLEAN
NED
WITH STEEL GRIIT 7 SHOT
GEN
NERAL REQ
QUIREMENT
TS:
The applicator shall submiit for ownerr / consulta
ants approvval, coating procedure including
uality contro
ol (QC) meth
hodology, prrior to comm
mencement o
of coating
quality assurancce (QA) & qu
of th
he bullets. Only
O
duly ap
pproved metthodology shall be follo
owed in coa
ating applica
ation. The
applicator shall provide
p
stan
ndard equipm
ment for coa
ating works; no improvissed equipme
ent will be
acce
epted/ allowe
ed.
The applicator shall supply all
a coating m
materials req
quired as per this specification & pro
ovide test
om standard
d laboratorie
es. The applicator shall also carry out tests on
n applied
data// reports fro
coating for adhe
esion, film th
hickness and pinhole/ holiday
h
dete
ection. The results
r
of these tests
onsultant app
proved laboratory.
shalll be through a owner/ co
Conssidering logistical and te
echnical aspects, coating
g of bullets sshall be carrried out in th
he mound
(prio
or to grade sa
and filling & compaction
n) after post weld
w
heat tre
eatment and
d hydrostaticc testing.
All manpower
m
(s
skilled, unskilled) shall be applicators responsib
bility and only
y personnel skilled in
the coating
c
appllication shall be deploye
ed by the ap
pplicator. Th
he coating shall
s
be insp
pected by
qualified inspec
ctors. The qualification
q
of inspecto
ors shall be
e verified/ approved
a
by owner/
cons
sultant.
The applicator shall provide access duriing all phase
es of work to
o the owner//consultants and their
inspe
ectors. Any expenses incurred byy the applicator due to
o owner/ consultants in
nspectors
stopping the coa
ating work because
b
it iss not being carried
c
out a
as per these
e specificatio
ons, shall
be borne by the applicator.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 30
0 of 51
All equipment
e
sh
hall be subject to owne
er/ consultan
nts approval and should
d be of good quality,
main
ntained in good
g
operatiing condition and suita
able for use
e to apply materials
m
ass per this
spec
cification.
All cleaning,
c
priming, coatin
ng machine
es shall be preferably equipped
e
wiith rubber o
or wheels
overlaid with harrd fiber to prrevent marking or denting the extern
nal surface of
o the bullet.
ating schedu
ules & engin
neering inforrmation inclu
uding drawin
ngs when
The owner shall provide coa
nsions, obstrructions and
d access to tthe surface area to be coated
c
as
availlable, showing all dimen
well as the calcu
ulations of arrea to be sprrayed.
Befo
ore, bid subm
mission, the applicators are advised
d to acclimattize themselves with site
e working
cond
ditions and owner
o
will pe
ermit such visits by applicators.
Durin
ng surface preparation
n, any acce
eptable mettal defects detected shall be imm
mediately
brought to the no
otice of owner/ consultant and the applicator sha
all hold
the work
w
on such
h steel piece
e till such tim
me as cleared for further action by th
he owner/con
nsultant.
Onlyy plural com
mponent air less spray system sha
all be used as per reccommendatio
on of the
manufacturer of Primer Polyyurethane.
4.0
4
SAFE PRACTIC
CES:
High
h performancce spray applied coating
gs may contain potentia
ally toxic ing
gredients an
nd require
all (local, state, central) saffety regulatiions to be observed
o
du
uring coating
g operationss. Proper
safetty precautions must be observed ag
gainst recog
gnized safetyy hazards evven during sstorage of
primer & coating
g materials at
a site. Appliicable (statu
utory, state, local) regula
ations goverrning safe
hand
dling practice
es shall be enforced.
e
5.0
PRIM
MER
The type of primer used sha
all be as per coating man
nufacturers specification
ns.
a) Fo
or areas not to be cathodically prote
ected: Polyvinyl Butyl (wa
ash) type
b) Fo
or areas to be
b cathodica
ally protected
d: Aluminum
m filled moisture cured
Urethane Prime
er or two (2
2) compone
ent chemica
al cured Urrethane Prim
mer Single package
sture-cured Urethane
U
prrimers conta
aining non-le
eafing Aluminum pigmen
nted, are fasst curing,
mois
chem
mical & corrrosion resisstant and e
eliminate the
e mixing & pot life lim
mitation of two
t
pack
mate
erials.
6.0
SUR
RFACE PREPARATION:
Altho
ough, Elasto
omeric 100%
% solids Polyyurethane coating
c
mate
erial has exc
cellent Corro
osion and
Erossion resistan
nt properties
s, it must h
however, be considered
d part of an
n engineered
d system
whicch includes adequate/
a
appropriate
a
ssurface prep
paration. It iss axiomatic in protective
e coating
work
k that the performance
p
of most ap
ppropriately chosen coa
ating will be
e no better than the
surfa
ace preparattion. Accordingly, the su
urface shall be
b blast clea
aned as follo
ows:
The external surface of bullets
b
(or part thereoff) shall be blast cleaned to SSPC-SP10
cification nea
ar white blas
st cleaning w
with 2-3 Mil anchor
a
profiile (or else conform
c
to SIS
S Gr Sa
spec
2-1/2
2 Specificatio
ons).
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 31
1 of 51
Nearr white blastt cleaned su

urface finish
h is defined as one from
m which all Oil , grease
e, dirt mill
scale
e, rust, corrrosion produ
ucts, oxides, paints or other foreig
gn matter ha
ave been co
ompletely
remo
oved from th
he surface. The
T abrasive
e shall not be
b reused ass this could be detrimen
ntal to the
surfa
ace.
Dry sand
s
blastin
ng using com
mpressed airr blast nozzlles and dry sand of a maximum
m
parrticle size
not la
arger than th
hat passing through a 16
6 mesh scre
een US Sieve
e Series sha
all only be ussed.
all be using
g compresse
ed air blast nozzles & crushed grit made of cast
c
iron,
Grit blasting sha
malle
eable iron, steel
s
or syntthetic agentss other than
n sand of a m
maximum pa
article size no
n longer
than passing through a 16 mesh scree
en US Sievve Series. T
The largest commercial
c
grade of
meta
al grit permittted by this specification
s
is SAE No. G-25 abrasive material..
Clossed re-circula
ating nozzle
e blasting ussing compre
essed air, va
acuum and any
a of the p
preceding
abra
asive may be
e used.
with clean brushes
b
mad
de of hair, bristle
b
or fibe
er or else
The blasted surfface shall be brushed w
wn off with compressed
c
d air (from w
which detrim
mental oil & water have
e been rem
moved) or
blow
clean
ned by vacu
uum for the purpose of removing an
ny traces orr blast produ
ucts from the
e surface
and also for rem
moval of abra
asives from p
pockets & co
orners.
all be done in such a manner that no
n damage is
i done to partially or
Blast cleaning operation sha
ed portions of
o the bullet..
entirely complete
If an
ny rust is forrmed on Bullet (externa
al surface) after
a
Blast Cleaning, the
e surface shall be reblastt cleaned be
efore painting
g.
ned surface shall be exxamined forr any tracess of oil, gre
ease or smudges. If
The blast clean
oved as outliined in SSPC
C-SP1-63 sp
pecification.
present, these shall be remo
e Anchor pa
attern producct on the su
urface shall be 50 micrrons. The
The height of profile of the
or pattern to be determiined by an Elcometer 1
123 or equivvalent surfacce profile
height of Ancho
ge. The averrage reading
g from ten (10) randomlyy selected arreas shall co
onstitute the height of
gaug
the profile.
p
The profile meassurement to be done on flat (withoutt curvature) areas only.
The blast cleane
ed surface should
s
be fu
urther treated or primed preferably within 24 ho
ours after
blastt cleaning bu
ut in any eve
ent before an
ny visible or detrimental rusting occu
urs.
All above operattions shall be
e witnessed by & certifie
ed by owner// consultants inspector.
7.0
PRIM
MING
SYCHROME
ETER) to en
nsure Dew Point is at least
l
3 C below
b
the
Measure humidiity (using PS
er controlled
d conditions,, heating ste
eel surface may be ressorted, to
ambient temperature. Unde
ndensation problems.
p
elimiinate the con
Two component chemicals cure
c
urethan
ne primer sh
hall be sprayyed onto the cleaned surface in a
fog coat
c
as thinly as possible (approxim
mately 1 Mil)) so as to tin
nt but not mask the colo
our of the
subs
strate. The primer
p
on application sha
all be free fro
om runs & drips. The priimed surface
e shall be
prote
ected so that it will not come
c
in conttact with rain
n, Mist, Dust or other foreign substan
nces until
comp
pletely harde
ened & the Urethane
U
top
p coat has been
b
applied
d. The Urethane top coa
at shall be
applied before th
he Prime Co
oat has completely cured not less th
han two (2) hours,
h
nor more
m
than
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 32
2 of 51
five (5) days aftter the prime coat has been applie
ed. Howeverr, the Prime
e Coat at the time of
Urethane applica
ation should be hard and
d not tacky.
8.0
COA
ATING
Equipment for sp
pray application shall be
e plural comp
ponent Airless spray sysstem
ndard instrucctions from the Manufacturer shall be followed
d for Spray, material ha
andling &
Stan
stora
age. Always,, dry nitrogen (gas) blanket over ma
aterial shall b
be maintaine
ed.
minal thickne
ess of 100% solids elastomeric uretthane shall be 40 Mils (1,000 micro
o) unless
Nom
otherwise specified. The fiinished polyyurethane shall be gen
nerally smoo
oth & free of sharp
protu
uberances. A minor amount
a
of sags,
s
dimplling & curtaining, whicch otherwisse meets
spec
cifications requirement shall
s
howeve
er be not con
nsidered as ccause for rejjection.
ore actual co
oating application on the
e bullet surfa
ace, a test pa
atch shall be
e applied & inspected
Befo
for Runs,
R
drips & Gel time as
a well as T
Tack free tim
me. In case of doubt, Ad
dhesion testt shall be
carried out.
Mou
unded Bullets/Unit Repeat Area iss calculated along with the Materia
al volume in
n counter
numbers (countters are atta
ached on th
he Mounded
d Bullets/Units that mea
asure the volume
v
of
erials dispensed), apprroximate sp
peed and number
n
of passes.
p
Sprays apply requisite
mate
thickkness in mu
ultiple passe
es in single
e application
n keeping sspray gun perpendicula
p
ar to the
subs
strate. If the surface is la
arge enough
h to require more than one
o day for coating,
c
the edges of
the coated
c
area
a shall be fe
eathered and
d roughened
d with a grin
nding tool fo
or over spra
aying and
primed.
d with 100% solids Elasttomer Uretha
ane hand
Skips, if any, holidays, deteccted should be repaired
k or equiva
alent after the
e edges are roughened..
mix kit
9.0
INSP
PECTION
All work
w
under this speciffication shalll be subjecct to Inspecction by the
e owner/con
nsultants
Inspe
ector. All pa
art of the work
w
shall b
be accessiblle to the ow
wner/consulttants inspecctor. The
applicator shall correct
c
any defective
d
wo
ork indicated
d by the Insp
pector.
n to steel sh
hall be meassured using Elecometerr adhesion te
ester as per ASTM D
Pull off Adhesion
1 using a Aluminum do
olly attached
d to the coa
ating & a pe
erpendicular force applie
ed to the
4541
dollyy. Average reading
r
from
m three (3) randomly selected
s
spo
ots shall be at least 8 N/sqmm.
Adhe
esion test sh
hall be carriied out on ffully cured coating
c
(7 da
ays at 25 C) & on flatt (without
curva
ature) test area.
a
Applicator shall supply certtificate from the coating
g manufactu
urer that the
e material ussed (with
batch numbers) are free fro
om manufactturing defec
cts & will me
eet all perforrmance crite
eria when
prop
perly applied as given in this specificcations.
All above test sh
hall be witnessed & certified by owne
er/ consultan
nts inspecto
or.
Inspe
ection and Testing.
T
All painting
p
materials includ
ding primerss and thinne
ers for appliccation shall be procured directly
from manufacturers as perr specificatio
ons and sha
all be accom
mpanied by
y manufacturers test
certifficates. Pain
nt formulation
ns without ccertificates arre not appliccable.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
10.
EM163-E-601
DOC. NO
O.
REV
V
Sheet 33
3 of 51
QUA
ALITY ASSU
URANCE
The contractor shall
s
guaranttee that the chemical an
nd physical properties
p
off paint materrials used
i accordance with the specifications contained herein/to be provided
d during exe
ecution of
are in
work
k.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 34
4 of 51
AN
NNEXURE-3
3
Q
QUALITY
C
CONTROL
PROCEDU
URE AND IN
NSPECTIO
ON REQUIR
REMENTS
1.0
C
CONTRACT
TOR'S QUAL
LITY CONTR
ROL
1.1
CONTRACT
C
TOR shall provide a qu
uality contro
ol program manual incllude specific WORK
m
methods
and
d inspections
s, which asssure quality.
This quality control prog
T
gram manual must be submitted to
t OWNER for Approvval before
s
starting
the construction
c
activities.
A installation WORK mu
All
ust be in striict accordance with this approved manual.
m
1.2
T quality control
The
c
progrram shall incclude as a minimum
m
the following:
-
2.0
Methods use to con

ntrol drawing
gs; specifica
ations and CONTRACT
T correspon
ndence to
assure th
hat only the latest
l
revisio
ons are being used in the field.
Inspectio
on personal name,
n
organ
nization.
Inspectio
on methods and docum
mentation of inspection ((or tests) fo
or shop fabrrication, if
required, and installa
ation.
m SITE receivving point, th
hrough "ove
er, short and
d damage
Material control procedures from
on" through storage
s
and through insttallation.
inspectio
Positive material
m
iden
ntification Prrocedures fo
or:
Electrical cable pullin
ng and testin
ng.
Asphalt placement
p
in
nspection.
Handling and storage
e methods to
o prevent da
amage.
on and testiing procedu
ures and reports for ciivil, structural, piping, e
electrical,
Inspectio
instrument, equipment and all insstallation WO
ORK.
Repair.
nd reject.
Scrap an
Grouting.
Welding.
q
Welder qualification.
Receiving
g all perman
nent Mounde
ed Bullets/Unit material & equipmen
nt.
Rigging.
Welder's tests.
Nondestrructive exam
minations to be used.
Positive material
m
iden
ntification ettc.
Identifica
ation of CON
NTRACTOR
RS and ensu
uring their compliance
c
with
w
the ma
anual and
WORK re
equired.
Material certification
c
verification methods.
Calibratio
on procedure
es for measurements an
nd test equip
pment.
Marking and
a identificcation of com
mponents in process and
d complete assemblies.
a
Shop fabrica
S
ation and fie
eld installatio
on inspection OWNERS
S REPRESE
ENTATIVE to
t ensure
s
specification
s in the follo
owing areass will be perrformed by full adheren
nce to Receiving and
in
nspection.
-
on of test ins
spection equ
uipment.
Calibratio
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
-
EM163-E-601
DOC. NO
O.
REV
V
Sheet 35
5 of 51
Preventivve maintenance and storage protecttion.

Internal cleanliness.
c
Proper material
m
use and
a control.
Nondestrructive testin
ng and its results.
Workman
nship.
3.0
OWNER'S REPRESENT
O
R
TATIVE or others as authorized
a
b
by OWNER are to be permitted
a
access
to CONTRACT
C
TOR'S workk areas forr the purpo
ose of inspection of material,
e
equipment,
documentattion and other areas as require
ed in CONTRACTOR'S
S quality
a
assurance
I quality
q
contrrol program.
4.0
4
N concrete will be place

No
ed by CONT
TRACTOR without
w
an OW
WNER "Pou
ur Release F
Form.
5.0
OWNER'S construction
O
c
inspections will not relieve. CONT
TRACTOR of
o inspection
n or other
es.
r
responsibiliti
6.0
For piping all welders tesst pieces shall be suppliied by CONT

F
TRACTOR and
a fully pre
epared for
w
welding
by CONTRACTO
C
OR.
7.0
CONTRACT
C
TOR shall evidence
e
its familiarity and experie
ence with the executio
on of the
in
nstallation of
o WORK to
o the requirrements of the applicab
ble codes and
a
shall pe
erform its
W
WORK
in acccordance to
o these requirements and
a
to insttructions isssued by O
OWNER'S
R
REPRESEN
TATIVE in th
his regard.
8.0
C
CHECK
ON QUALITY OF
O WORK
8.1
OWNER'S REPRESENT
O
R
TATIVE'S in
nspector sha
all have free
e access to the place where
w
the
W
WORK
is performed at all
a times, in order
o
to checck the qualityy of WORK.
8.2
Iff during insp

pection I che
eck reveals unsatisfactor
u
ry WORK, CONTRACTO
C
OR shall imm
mediately
at CONTRAC
a
CTOR'S exp
pense take ssuch correctiive measure
es as deeme
ed required.
9.0
C
CONTROL
S
SYSTEMS
C
CONTRACT
TOR shall inittiate and ma
aintain the fo
ollowing conttrol systems
s.
9.1
Backfilling
-
9.2
Compacttion tests.
C
Concrete
-
Design mix
m and apprroval record((s).
Batch Mo
ounded Bulle
ets/Unit insp
pection recorrd.
Slump te
est record.
Compres
ssive test reccord.
Pour rele
ease record.
Grouting release record.
n records.
Placement inspection
e curing reco
ords.
Concrete
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
9.3
DOC. NO
O.
REV
V
Sheet 36
6 of 51
Design mix
m and apprroval recordss.
Batch pla
an inspection
n records.
Placeme
ent inspectio
on records.
P
Piping
-
9.5
A
Asphalt
-
9.4
EM163-E-601
Weld x-ra
ay file.
Pipe and fitting certifficate file.PM
MI
Isometric
c weld contro
ol sheet.
Hydrostatic test recorrds.
G
Grounding
E
Earth
resista
ance test rec
cords.
9.6
E
Electrical
Ca
able and Ins
strument ca
able
-
Insulation
n resistance test recordss.
Continuitty test record
ds.
9.7
M
Material
cerrtification filles
9.8
M
Mounded
Bu
ullets/Equip
pment
-
ay file.
Weld x-ra
Material certificate
c
files.
Mounded
d Bullets/Equ
uipment insttallation reco
ords.
Equipme
ent maintena
ance record.
Hydrosta
atic test records.
Grouting release records.
Alignmen
nt records.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 37
7 of 51
AN
NNEXURE-4
4
SCHEDULE
S
E, PROGRE
ESS EVALUATION AND
A
PROGRESS REP
PORTING
1.0
G
GENERAL
1.1
WORK shall start and be completted in the field

W
f
as indicated on the approved project
c
construction
schedule.
CONTRACT
C
TOR shall follow the sequence of construction in
n executing the
t WORK as
a shown
in
n the schedu
ule or as mo
odified by OW
WNER.
The detailed scheduling of WORK w
T
will be supplied by the C
CONTRACT
TOR. WORK
K shall be
c
conducted
in
n such a man
nner that oth
her construc
ction activities are not afffected.
Once detaile
O
ed schedule, established and appro
oved by OW
WNER, CON
NTRACTOR commits
ittself to follow
w the schedu
ule in detail.
2.0
D
DETAILED
& SCHEDUL
LE
2.1
Detailed con
D
nstruction sc
chedule musst cover all construction work, from
m lowest levvel up to
h
highest
level.
2.2
Activities sho
A
own by means of a bar chart must include as a minimum th
he activitiess listed in
4
4.
3.0
P
PROGRESS
S REPORTIN
NG
CONTRACT
C
TOR shall is
ssue a reporting proce
edure and a representative samp
ple of all
p
progress
rep
ports.
F
Following
schedules and
d reports mu
ust be issued
d by CONTR
RACTOR to OWNER:
O
Construction
C
n schedule. (Preliminary
(
and detailed
d)
M
Monthly
statu
us report.
W
Weekly
progress report.
M
Monthly
consstruction guide schedule
e.
D
Daily
manpower reports..
A except de
All
etailed consttruction sche
edule based on approved project construction scchedule.
4.0
4
C
CONSTRUC
CTION SCHE
EDULE
As Mutually
A
y agreed bettween NRL & PDIL, aftter that CON
NTRACTOR
R will issue separate
g
graphical
"S
S" curves fo
or the follow
wing work activities
a
off total CONT
TRACT.
5.0
INTRODUCT
TION
The introducction to the monthly
T
m
stattus report sh
hall include CONTRACT
TOR'S comm
ments on
the overall construction schedule wiith a status update line as attachme
ent, and sha
all consist
o the following items:
of
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
6.0
EM163-E-601
DOC. NO
O.
REV
V
Sheet 38
8 of 51
Goals ac
chieved last month.
m
Goals forr next month
h.
Reason for
f delay, if any.
a
Reason
n for deviatio
on of original schedule.
Average manpower by
b craft, including management and
d indirect staff.
ACTOR'S co
omments to g
general situa
ation.
CONTRA
C
CONSTRUC
CTION ACTIV
VITIES STA
ATUS
T
This
section consists of scheduled
s
vversus actual progress curves.
T progresss curves are
The
e to be comm
mented upon
n by CONTR
RACTOR.
T basis for reporting shall
The
s
be the construction
c
schedule:
T monthly status shall be reported
The
d as a percentage of the
e total WORK
K per type off WORK.
7.0
M
MANPOWER
R AVAILAB
BILITY I REQ
QUIREMENT
TS FOR THE
E MONTH COMING
C
CONTRACT
C
TOR shall submit its man
npower availlability requirements for the next mo
onth. This
s
section
conssists also of the
t schedule
ed versus the actual manpower curvves.
T
These
manpower curvves
8.0
are a
accompanied
d by CONT
TRACTOR'S comments hereon.
MAIN CONSTRUCTION
M
N EQUIPMENT AVAILABILITY I REQUIRE
EMENTS FO
OR THE
M
MONTH
COMING
CONTRACT
C
TOR shall su
ubmit its main construction equipme
ent availability / requirem
ments for
the next mo
onth. This section
s
conssists also off the sched
duled versuss actual con
nstruction
e
equipment
re
equirement curves.
c
Thesse by CONT
TRACTOR'S comments hereon.
9.0
W
WEEKLY
PR
ROGRESS REPORT
R
Progress rep
P
porting will be
b done on a weekly bassis by the acctually comp
pleted work based on
d
details
of work such ass quantitiess or piece of
o equipmen
nt as a perrcentage of the total
a
anticipated
w
work
per worrk activities a
as defined in
n item 4.
9.1
Progress will only be re

P
eported on tthe basis of completed activities ass per the pe
ercentage
b
breakdown
of
o the major steps as folllows:
P
Progress
Me
easurement Parameterrs
Actual physic
A
cal progresss in the field shall be me
easured bassed upon sta
andard perce
entage of
c
completion
o progress stages, that, they are
of
e to be pre
epared by CONTRACT
TOR and
A
Approved
by
y OWNER to
o calculate a
actual physiccal progresss of the WORK, the exa
act weight
v
value
of eac
ch activity fro
om lowest le
evel up to highest
h
levell in each ca
ategory of th
he WORK
s
shall
be speccified by CO
ONTRACTOR
R and supplied to OWNE
ER.
After OWNER'S Approva
A
al this weigh
ht value can be used forr calculation of actual prrogress of
the WORK.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
10.0
W
WEEKLY
PR
ROGRESS MEETING
M
10.1
W
Weekly
Worrk List
EM163-E-601
DOC. NO
O.
REV
V
Sheet 39
9 of 51
In the weekly
y progress review
r
meetting CONTR
RACTOR sha
all forecast the
t WORK itt plans to
p
perform
durin
ng the weekk by means of a weekly WORK list including itss manpower resource
a
allocation
ass per the activities listed in 4 and 6.
T
This
weekly program sha
all be in acco
ordance with
h the constru
uction guide
e schedules.
10.2
W
Work
Front
CONTRACT
C
TOR shall submit monthly and weekly a total reccapitulation of
o the total w
work front
a
available
witth estimated
d manpower requiremen
nts, materials and equip
pment which
h shall be
s
supplied
by CONTRACT
C
TOR.
11.0
M
MONTHLY
C
CONSTRUC
CTION GUID
DE SCHEDU
ULE
Based on ap
B
pproved ove
erall constru
uction sched
dule, CONTRACTOR must
m
issue a monthly
c
construction
guide sched
dule covering a two (2) months
m
perio
od, for each individual activity.
Progress updating of co
P
onstruction g
guide sched
dules must b
be weekly and
a
presented in the
w
weekly
progrress review meeting at ssite.
h individual activity:
T updated
The
d issue will show for each
-
12.0
Percent complete.
c
Weight fa
actor comple
ete.
D
DAILY
MANPOWER RE
EPORTS
C
CONTRACT
TOR shall be
e furnished d
daily manpow
wer report ass per agreed
d format.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 40
0 of 51
AN
NNEXURE-5
GEN
NERAL NOTES
1.0
D
DRAWING
AND
A
DOCUM
MENTS
1.1
CONTRACT
C
TORS drawin
ngs shall be
e on standard
d size sheetts to be mutually agreed
d upon by
b
both
parties during kick-o
off meeting.
1.2
CONTRACT
C
TORS draw
wing shall be
b clearly marked
m
with
h titles, num
mbers of otther item
id
dentification.
1.3
Approval off drawings and deta

A
ail calculatio
ons by OW
WNER, in no way absolves
C
CONTRACT
TOR from itss responsibillity for the accuracy
a
or for the desiign, construcction and
timely performance of WORK.
W
1.4
A Built dra
As
awings.
1.5
As built co
A
omments willl be marked up by CON
NTRACTOR on a maste
er copy
o these dra
of
awings, desiignated for this purpose, These ch
hanges are to be
a
approved
by OWNER.
1.6
Near the end of the WORK, the re

N
elevant draw
wing origina
als will be handed
o
over
to CON
NTRACTOR
R, for transfe
erring of the collected
c
ap
pproved com
mments
b CONTRA
by
ACTOR to the
ese originalss by high quality draftsm
man ship.
2.0
S
SAFETY
2.1
CONTRACT
C
TOR shall sttrictly comply with India
an safety & regulations. An OWNE
ER safety
o
officer
is inccluded in the
e OWNER site
s manage
ement organisation. His instructionss shall be
fo
ollowed and
d regular saffety meeting
gs shall be attended
a
by C
CONTRACT
TORS Forem
men. The
s
safety
meetin
ngs shall be chaired by tthe OWNER
RS safety offficer.
2.2
CONTRACT
C
TOR shall be
b responsib
ble for the safety of a
all OWNER supplied pe
ermanent
e
equipment
and materialss under custtody, and sh
hall rectify/re
eplace any damage or lo
oss taking
p
place
free off cost to OW
WNER.
C
CONTRACT
TOR is responsible for the safety of
o all its pe
ersonnel, an
nd shall arra
ange and
p
provide
all sa
afety applian
nces to his personnel,
p
such as bootss, goggles, safety
s
belts, helmets,
s
safety
lamps
s, etc. CONTRACTOR shall be als
so responsib
ble for safetty of all Con
nstruction
E
Equipment
and
a
Materials, all materials included
d in CONTR
RACTORS scope
s
of supply, and
a Temporarry Facilities.
all
CONTRACT
C
TOR shall prrovide for su
ufficient num
mber of fire e
extinguisherss during con
nstruction
e
erection
period.
CONTRACT
C
TORS organ
nization shalll have a sa
afety officer to supervise
e heavy liftss, work in
h
high
elevatio
ons, critical locations, work during
g nights, and constanttly be ensu
uring that
w
working
pers
sonnel strictly follow the safety requiirements.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 41
1 of 51
Such CONTRACTORS nominated safety office

S
er shall be ssubject to OW
WNERS accceptance
a
and
CONTR
RACTOR sha
all not change the safety officer du
uring entire execution of
o WORK,
w
without
OWN
NERS appro
oval.
2.3
CONTRACT
C
TOR shall fen
nce the nece
essary areas
s whenever it is the requ
uirement forr safety of
the personn
nel, equipm
ment & materials,
m
and shall p
provide guarded entrry points
C
CONTRACT
TOR shall also provide necesssary fencin
ng around areas und
der preng to segreg
c
commissioni
gate them co
onstruction areas.
a
2.4
S
Safety
Guidelines
2.4.1
G
General
CONTRACT
C
TOR shall ad
dhere to safe
e constructio
on practice a
and guard ag
gainst hazarrdous and
u
unsafe
workiing condition
n and shall ccomply with safety
s
rules of OWNER as set forth herein.
2.4.2
F
First
Aid and Industriall Injuries
2.4.2.1
CONTRACT
C
TOR shall maintain
m
firrst aid facilities for itss personne
el and thosse of its
s
subcontracto
ors.
2.4.2.2
CONTRACT
C
TOR shall make
m
for am
mbulance service
s
and for the tre
eatment of industrial
in
njuries.
Names of th
N
hose providiing these se
ervices shall be furnish
hed to OWN
NER prior to
o start of
c
construction
and their telephone
t
n
numbers sha
all prominen
ntly posted in CONTRA
ACTORS
field office.
2.4.2.3
All critical industrial shall

A
s
be re
eported pro
omptly to tthe OWNE
ER and a copy of
C
CONTRACT
TORS reportt covering e
each personal injury req
quiring the attention
a
of physician
s
shall
be furbished to the OWNER.
2.4.3
G
General
Rulles
Smoking with
S
hin the batte
ery area, tan
nk farm is sttrictly prohib
bited. Violato
ors of the no
o smoking
r
rules
shall be
e discharged
d immediate
ely.
2.4.4
C
Contractors
s Barricade
es
2.4.4.1
CONTRACT
C
TOR shall erect
e
and m
maintain ba
arricades re
equired in connection with his
o
operation
to guard or pro
otect:
a Excavatio
a)
ons
b Hoisting Areas
b)
c Areas ad
c)
djudged haza
ardous by CONTRACTO
ORS or OWNERS inspe
ectors
d OWNERS existing property
d)
p
subjject to dama
age by CONT
TRACTORS
S operationss.
e Road unlloading spotts.
e)
2.4.4.2
CONTRACT
C
TORS perso
onnel and tho
ose of his su
ubcontractorrs shall beco
ome acquain
nted with
b
barricading
p
practice
of th
he OWNER and shall res
spect the provision there
eof.
2.4.4.3
Barricades and
B
a hazardous areas ad
djacent to bu
ut not located
d in normal routes of tra
avel shall
b marked by red flasher lanterns att nights.
be
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 42
2 of 51
2.4.5
S
Scaffolding
2.4.5.1
Suitable sca
S
affoldings sh
hould be pro
ovided to workmen for all works th
hat cannot safety
s
be
d
done
from th
he ground or
o from solid
d constructio
on except su
uch short pe
eriod work as
a can be
d
done
safely from
f
ladderss.
2.4.5.2
Scaffolding or
S
o staging more
m
than 4 meters abo
ove the grou
und or floor, swing or su
uspended
from and ov
verhead sup
pport or ere
ected with stationary ssupport shall have a guard
g
rail
p
properly
atta
ached, bolte
ed, breached
d and otherrwise secured. Such sccaffolding or
o staging
s
shall
be so prevent
p
it from
m swaying ffrom the building or struccture.
2.4.5.3
Working plattform, gangw

W
ways and sttairways sho
ould be so constructed
c
that they sh
hould not
s unduly or
sag
o unequallyy and if the h
height of the
e platform of the gangw
way or the sttairway is
m
more
than 4 meters ab
bove ground
d level the
ey should be closely bo
oarded, sho
ould have
a
adequate
wid
dth and shou
uld be suitab
bly fastened as describe
ed in 2.4.5.2 above.
2.4.5.4
Every operating on a working platfo

E
orm shall be
e provided w
with suitable
e fencing or railing to
p
prevent
the fall
f of person
ns or materia
als.
2.4.5.5
Safe-means of access shall be proviided to all working platfo

S
orms and oth
her working places.
A
Adequate
pre
ecautions sh
hall be taken
n to prevent danger from
m electrical equipment.
e
No materials
N
s on any of the sites of work shall be
b so stacke
ed or placed
d to cause danger
d
or
in
nconveniencce to any pe
erson or publlic.
The CONTR
T
RACTOR sh
hall also pro
ovide all ne
ecessary fencing and lights to prrotect the
w
workers
and staff from accidents,
a
a
and shall be
e bound to b
bear the exp
penses of de
efence of
e
every
suit, action
a
or other proceeding of law th
hat may be brought by any person for injury
s
sustained
ow
wing to neglect of the CONTRACT
C
OR and payy any damages and cossts which
m
may
be aw
warded in any such su
uit or action
n or which may with the consen
nt of the
C
CONTRACT
TOR be paid to comprom
mise any claim by any su
uch person.
2.4.6
D
Demolition/G
General Saffety
2.4.6.1
Before any demolition

B
d
w
work
is comm
menced and also during the progres
ss of the dem
molishing
w
work:
a All roads
a)
s and open areas adjaccent to the work site shall either be
b closed or suitably
protected
d.
b No electrric cable or apparatus, which is lia
b)
able to be a source of danger, sha
all remain
electrically charged.
c All practical steps sh
c)
hall be taken
n to prevent danger to pe
ersons employed from risk
r
of fire
o explosion or flooding.
or
2.4.6.2
All necessarry personal safety

A
s
equip
pment as co
onsidered ne
ecessary by the OWNE
ER should
b kept ava
be
ailable for th
he use of the
t
personss employed on the site
e and main
ntained in
c
condition
suitable for imm
mediate use
e, and the CO
ONTRACTO
OR should take adequate
e steps to
e
ensure
prope
er use of equ
uipment by these
t
conce
erned.
a Workmen
a)
n engaged in
i welding a
and cutting works
w
shall be provided
d with protecctive face
and eye-shields, han
nd gloves, ettc.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 43
3 of 51
b During le
b)
ead painting,, the followin
ng precaution
ns should be
e taken.
-
No paint containing lead or lead produ

uct shall be used exceptt in the form
m of paste
r
or ready-made
paint.
m
shou
uld be supp
plied for use
e by the wo
orkers when
n paint is
Suitable face masks
plied in the
e form of spray
s
or a surface havving lead pa
aint dry rub
bbed and
app
scra
apped.
eralls shall be
b supplied by the CONTRACTOR
R to the worrkmen and adequate
Ove
faciilities shall be
b provided to enable the
t working painters to wash themsselves on
cesssation of WO
ORK.
2.4.6.3
When the WORK

W
W
is done near anyy place whe
ere there is risk of drow
wning, all necessary
n
s
safety
equipment should
d be provide
ed and kept ready for usse and all ne
ecessary ste
eps taken
fo
or prompt rescue
r
of an
ny person in
n danger an
nd adequate
e provision should be made for
p
prompt
first aid treatme
ent of all injuries likely to be susttained durin
ng the coursse of the
W
WORK.
2.4.6.4
Use of hosting machines and tackle

U
es including their attach
hments, anchorage and supports
s
shall
conform
m to the follo
owing standa
ards or conditions:
a These sh
a)
hall be of go
ood mechaniical construc
ction sound materials an
nd adequate
e strength
and free from potent defects and
d shall be kept in good working
w
order.
b Every cra
b)
ane driver of
o hoisting orr lowering materials
m
or a
as means of
o suspension shall of
durable quality
q
and adequate
a
strrength and frree form potent defects.
c Every cra
c)
ane driver orr hoisting ap
ppliance operator shall be
b properly qualified.
q
d In case of
d)
o every hoisting machine and of every
e
chain ring neck, shackle, sw
wivel, and
pulley blo
ock used in hoisting or lowering orr as means of suspension, the safe
e working
load sha
all be ascerttained by ad
dequate me
eans. Every hoisting ma
achine and all gears
referred to
t above sha
all be marke
ed with the safe working load of the conditions
c
under
which it is
s applicable.
No parts of any
N
a machine
e or any gear shall be loaded
l
beyo
ond safe wo
orking load except
e
for
the purpose of testing.
2.4.6.5
Motors, gears, transmisssion lines, electric wirring and oth

M
her dangero
ous parts off hoisting
a
appliances
s
should
be pro
ovided with e
efficient safe
eguards.
Hoisting app
H
pliances sho
ould be provvided with such
s
meanss as to reduce to minimum the
a
accidental
descent of th
he load, ad
dequate preccautions should be tak
ken to reducce to the
m
minimum
the
e risk of anyy parts of a ssuspended load becomiing accidenttally displace
ed. When
w
workers
are employed on electrica
al installation
ns, which are already energized,
e
iinsulating
m
mats,
wearin
ng apparel, such
s
as glovves, sleevess and boots as may be necessary sshould be
p
provided.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
TION OF LP
PG MOUNDE
ED BULLET
TS
INSTALLAT
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
2.4.6.6
2.4.6.7
EM163-E-601
DOC. NO
O.
REV
V
Sheet 44
4 of 51
All scaffolds
A
s, ladders and
a
other sa
afety device
es mentione
ed or descriibed herein shall be
m
maintain
in safe condittions and n
no scaffolds, ladder or equipment shall be altered
a
or
r
removed
while it is in use
e.
T
These
safety
y provisions should be b
brought to th
he notice of all concerne
ed by displaying on a
n
notice
board at a promin
nent place at
a the work-sstop. The pe
erson respon
nsible for co
ompliance
o the safety code shall be
of
b named th
herein by the
e CONTRAC
CTOR.
2.4.6.8
To ensure efffective enfo

T
orcement of the rules an
nd regulation
ns relating to safety pre
ecautions,
the arrangem
ments made by the CON
NTRACTOR shall be ope
en to inspecttion by OWN
NER.
2.4.6.9
The WORK throughout

T
t
i
including
an
ny temporaryy work shall be carried out
o in such a manner
a not to inte
as
erfere in anyy way with tthe traffic on
n any roads or footpaths
s at the site or in the
v
vicinity
there
eto or any exxisting workss whether th
he property o
of the Admin
nistration or of a third
p
party.
2.4.6.10
Notwithstand
N
ding the above guide
elines, there in nothing gin the
ese to exe
empt the
C
CONTRACT
TOR from following all sta
atutory safetty rules, Reg
gulations or Acts in force
e in India
2.4.6.11
S cleaning
Site
g should be done
d
by CONTRACTOR
R every day.
The above safety guid
T
delines do not, in an
ny way, relieve CONT
TRACTOR from his
r
responsibility
y of safety of his perssonnel and his obligatio
on to take all necessa
ary safety
p
precautions
ures and to follow safe
e constructio
on practice during exe
ecution of
and measu
W
WORK.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 45
5 of 51
AN
NNEXURE-6
6
GEN
NERAL GU
UIDELINES
S FOR INST
TALLATION
N OF LPG MOUNDED
D BULLETS
S
Sl. NO.
1.
2.
3.
4.
5.
6.
7.
8.
DES
SCRIPTION
N
REMAR
RKS.
Introducction
Referen
nce
Pre Lift Information
Responsibility
Delegattion of Respo
onsibilities
Lifting Methodology
M
y
General Safety Plan
n
Minimum
m Requirem
ment of Equip
pments & Ea
arth
Moving Equipmentss for construction
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
EM163-E-601
DOC. NO
O.
REV
V
Sheet 46
6 of 51
1. Introduc
ction
The Purpose of this doccument is to
o provide guiidelines for the
t safe and
d efficient exxecution of the
t heavy
lift operation
n of LPG Mo
ounded Bulle
ets to verify that all nece
essary consiiderations ha
ave been ad
ddressed.
This docume
ent has been originated by PDIL forr the guidanc
ce of the Co
ontractor. Co
ontractor sha
all ensure
and submit the
t Lifting Plan for Owne
er/PDIL review and approval.
In general the procedu
ure details the Installattion method
dology, tech
hnical clarificcations and General
Safety Plan to be follow
wed during th
he Heavy Liftt Operation.
2. Referenc
ce:
This docume
ent follows PDIL
P
Genera
al Specificattions of the Erection
E
of L
LPG Mounde
ed Bullets.
3. Prelift in
nformation:
Item
m to be lifted
d : LPG Mou
unded Bulletss.
Wt.
: Approx 450
4 Mt. (Mounded Bulle
et in 6 Piece
es or more as per suita
ability of
Cranes, of
o each parrt =75 Mt.)
Dime
ensions
: 7000 I.D.X
X 52000L(m
mm)
Earth Moving Equipments
E
Proposed for
f Erection
n:
Main
n crane : Capacity
C
100
0 MT
Tailing crane: Capacity
C
75
5 MT
Hydra
: Capacity
C
10 MT
Fork
klift
: Capacity
C
10 MT
4.
4 Respons
sibility:
Contractor is responsible for the following:
Obta
aining permitts to work re
equired for th
he Installatio
on of Mounde
ed Bullets.
Unde
ertake prepa
aration, Insta
allation and clean the arrea immediattely after com
mpleting the
e job.
Barricade the en
ntire lift area
a. Unauthorizzed personn
nel are strictly not allowe
ed to enter inside the
barricaded area..
Insta
all proper sig
gn board to prevent
p
unau
uthorized pe
ersonnels en
ntry.
Ensu
ure that the crane,
c
tools and tackles used are ce
ertified and h
have their va
alid test certificates.
Ensu
ure that all riigging gearss are used in
n safe manne
ers.
Ensu
ure that the ground und
der both the crane is levveled and min
m 95 % co
ompacted an
nd survey
crew
ws verify leve
eling & comp
paction stren
ngth.
The Installation Engineer an
nd Rigging Foreman
F
sha
all ensure th
hat the perso
onnel involvved in this
operration fully un
nderstand th
heir scope off work through this proce
edure.
Ensu
ures compettency of the riggers, ope
erators and foreman.
f
Ensu
ure all the pe
ersonnel involve in lifting
g has adequate PPEs.
Ensu
ure barrier frree commun
nication betw
ween the liftin
ng crew and personnel involved.
Obta
aining founda
ation clearan
nce from PD
DIL/Client priior to erectio
on.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 47
7 of 51
5. Delegatio
on of Respo
onsibilities
CONSTRUC
CTION HEA
AD shall be re
esponsible ffor the implementation of
o
Proccedure and ensure

e
the required
r
qua
ality and HS
SE standard and practices are main
ntained at
each
h stage of the installation
n of Mounde
ed Bullets.
Ensu
ure the work
ks carried ou
ut meeting the
t project quality
q
requiirements, sa
afety and pro
ogress of
the work.
w
All sa
afety measu
ures are imp
plemented ass per HSE plan
p
planning
g and coordination of rig
gging and
erection activities.
Erecction scheme
e of Mounde
ed Bullets.
Ensu
ure safety prractices are maintained at each stag
ge of the insttallation of Mounded
M
Bullets.
TPI of
o tools & tackles, crane
e and also arrrange of req
quired PPE.
Com
mmunication the procedu
ure down the
e line with ha
azards involvved & mitiga
ation measurres.
CONTRACT
TOR RIGGIN
NG SUPER
RVISOR shall work in fu
ull compliancce with Safe
ety for the movement
m
and lifting op
peration of main
m
crane and
a signal to
o main crane
e operator an
nd tailing rigging Forema
an.
with safety for the Rig
CONTRACT
TOR RIGGING FOREM
MAN shall w
work in full compliance
c
gging and
movement of
o main/tailin
ng crane.
SAFETY OF
FFICER sha
all monitor that
t
All the
t
Equipm
ment, Tools and Tackles are ce
ertified In a
accordance with the site
s
HSE
Requ
uirement.
All manpower,
m
directly or ind
directly involvved in this activity
a
has b
been informe
ed of the hazzards and
risk factor
f
by the
e activity in charge.
c
All re
egular Safety Equipments (PPE) sshall be use
ed like helme
et, goggles, work glove
es, safety
harness etc.
Stop
p unauthorize
ed entry in lifting zone.
Shall stop the liffting operatio
on if there iss any immine
ent danger to
t any perso
on/s life or da
amage to
the Mounded
M
Bu
ullets.
RIGGER sh
hall work in full complia
ance with Safety,
S
are competent,
c
c
certified
for the lifting operation,
o
correct sling
ging methodss, signals etc.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 48
8 of 51
6. Lifting Methodolog
M
gy (Mound
ded Bullets
s)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
LP
PG Bullets shall
s
be fab
bricated in 6 sections or
o more as the length shell piece shall be
de
ecided to suiit transportation & erecttion and eacch duly teste
ed,inspected
d,trial assembled only
forr connecting
g ends, matcch marked a
and stress re
elieved at sh
hop/fabricate
ed yard & tra
ansported
to site.
i proposed that hemisp
pherical end
ds will be used for these
e bullets. Ho
owever the contractor
c
It is
ma
ay wish to im
mport pre-fab
bricated hem
mispherical ends.
e
Exxternal coatin
ng of bullet sections
s
will be done priior to installing the same
e on the sand bed.
En
nsure both th
he cranes ha
ave been checked as pe
er daily checck list by the operator.
Ph
hysically che
eck each shackle
s
for any damage, check th
he slings fo
or any breakages or
da
amage. Chec
ck the shackkle for prope
er pin insertio
on and orien
ntation.
Co
onnect lifting
g tools tackle
es to the cra
anes hook block
b
as perr the tackles
s arrangeme
ent shown
in Rigging Plan.
En
nsure both crane
c
standing area & marching lo
ocation has been marke
ed on the ground for
refference of th
he lifting crew
w/Operator.
Ma
ake sure the
e mats are la
aid as per th
he lifting plan
n and march
hing route off the 100t cra
ane. Also
pla
ates 25mm being
b
laid att 75t crane lo
ocation as per the lifting plan.
To
otal weight of
o the each Mounded Bullet
B
is app
prox 450 Mtt, which nee
eds to be erected
e
at
po
osition in six equal piece
es or more a
as per suitab
bility of cranes of each part
p
having weight of
75
5 Mt.
Co
ontractor sha
all insure tha
at the positio
on of main crane
c
with m
main boom le
ength & swing radius
forr the lifting of
o Mounded Bullet
B
piecess.
Ch
heck the initial position of
o the suppo
ort crane from the lifting point of the
e Mounded Bullets
B
as
pe
er the riggin
ng plan. Sub
bsequently determine the
t
path (steel plates layout) of th
he tailing
cra
ane.
Co
onnect the tools tackless as per the rigging plan
n. Attach taglines as re
equired to co
ontrol the
loa
ad and remo
oval of slingss upon safe installation.
Th
he sections for each bullet
b
shall than be lifted and trransported to
t the sand
d bed in
acccordance with the overa
all approved Lift Plan as submitted b
by contractor.
Th
he first bullett section to be laid on the prepared
d, template and
a leveled sand bed w
will be the
se
ection adjace
ent to the R.C
C.C. Wall.
Th
he other sec
ction will be installed in ssequence an
nd each secttion aligned with
w adjacen
nt section
witthin tolerancce limits and
d tack-welded
d in place.
Th
he Contracto
or shall ensure that prior to commenccement of fin
nal circ. weld
ding, bullet ssections
tha
at are tack-w
welded togetther are dimensionally in
nspected to ensure the alignment
a
an
nd other
dimensional re
equirementss have been met.
En
nsure that all
a the temporary suppo
orts/ rollers and devices used to secure
s
the Mounded
Bu
ullet Parts du
uring the res
sting positio
on have been removed and
a the Mou
unded Bulle
et Parts is
fre
ee to be lifted
d.
Th
he 100t cran
ne will be ho
oisting until the Mounde
ed Bullet Pa
arts is almost free of th
he resting
rolller assy.
On
nce load is clear
c
from th
he Roller (~2
200mm), Th
he Hydra will remove the
e resting Ro
oller assy.
be
eneath.
No
ow the 100t crane will boom
b
down whereas the
e 75t crane will swing th
he load maintains as
de
esired radiuss. If required
d the crane has to marc
ch 1~2m to maintain sm
mooth swing
g for 100t
cra
ane.
Th
he load on th
he 100t crane (Safe Load Indicator) will be checcked.
Ho
oist down, re
emove the ta
ackles and d
demobilize th
he crane.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 49
9 of 51
7. General Safety Pla

an
All liifting tackles used, will have a sa

afe working load in exxcess of the
e required weight
w
of
comp
ponents bein
ng lifted and
d displayed o
or visibly ma
arked.
The crane will be
e set up carrefully to takke into consid
deration possitioning so as
a to take advantage
of the minimum radius princciple. This wiill allow for a greater saffety margins
s. The set up
p position
for th
he crane willl be such ass to minimize
e obstruction
n to general site
s activitiess.
The exact radiuss for the crane will be ca
alculated and the maxim
mum capacities for each lift at the
required radius will
w also be included.
All activities
a
of lifting tackle
e will be ca
arried out by
y experienced Rigging Superintend
dent with
previous experie
ence in simiilar lifting op
peration und
der the supe
ervision of Heavy
H
lift Errection In
s, slings, shackles,
s
e
etc.
will be
e checked by the experienced
e
charge. Chains
Rigging
Supe
erintendent / Erection En
ngineer.
An experienced
e
rigger will act, as Ban
nks Man ass required b
but the ultim
mate responssibility for
each
h lift will res
st with the Crane
C
Opera
ator. Approp
priate hand signals will be used to facilitate
communication of the exactt precision movements
m
e equipment. Any lift
required to position the
shalll not procee
ed until all aspects arre to the sa
atisfaction o
of the Crane Operator// Rigging
Supe
erintendent and
a Erection
n Engineer.
Durin
ng the lift op
peration, acc
cess to the lift area and
d entire area
a immediate
ely adjacent to the lift
will be cordone
ed off with tape and ssigns. Perso
onnel will be
e appointed
d to prevent anyone
vertently enttering beyon
nd the cordoned area.
inadv
All personnel
p
will have and
d wear Helm
mets, Safety Footwear, Safety Glas
sses, Harnesses and
high visibility vessts.
All personnel
p
wo
orking directtly shall be ffamiliar with the presentt procedure and with the
e general
site safety
s
rules. The safety tool box talkk shall be he
eld prior to ea
ach lifting op
peration.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
CO
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
EM163-E-601
DOC. NO
O.
REV
V
Sheet 50
0 of 51
8. Minimum
m requirem
ment of Eq
quipments and Earth
h Moving Equipments
E
s to be deployed
by the contractor
c
as and wh
hen require
ed.
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Descripttion
CRANE- 100 MT(CRA

AWLER OR T
TYRE MOUNTED)
CRANE- 75MT
HYDRA WITH
W
AUDIO--VISUAL SIG
GNALLING DEVICES &
LIMIT SWIITCHES(10--18 MT)
JCB WITH
H REVERSE HORN AND
D REAR LIG
GHT/MIRROR
R
DUMPER((6M3)
TRACTOR
R WITH TRA
AILER
MINI BATC
CHING PLAN
NT/RMC SU
UPPLIER
MIXTURE MACHINE WITH
W
WEIG
GH BATCHER(FOR BRIC
CK
P
WORK & PLASTER)
NEEDLE VIBRATORS
V
S
WATER TA
ANKERS
THREODO
OLITE/TOTA
AL STATION
N (1 SEC)
DUMPY/AUTO LEVEL
L
DG SET(S
SILENT TYPE) (25-65 KV
VA)
PLATE CO
OMPACTOR
R
DEWATER
RING PUMP
PS (5 HP)
WELDING MACHINES
S
TIG WELD
DING MACHINES
GRINDING
G M/C
GAS CUTT
TING SET
GAMA X-R
RAY SOURC
CE FOR RAD
DIOGRAPHY
X-RAY SO
OURCE FOR
R RADIOGRA
APHY(250 AMP)
A
DPT KIT(S
SET)
MPT KIT(S
SET)
S.R. MACH
HINES WITH
H RECORDER
HARDNES
SS TESTER DIGITAL
PORTABL
LE ALLOY ANALYSER
AIR COMP
PRESSOR(2
250 CFM)
BLAST CL
LEANING EQ
QPT.
SPARY PA
AINTING MA
ACHINE(AIR
R LESS)
WATER FIILLING PUM
MP
HYDROTE
EST PUMP(M
MOTORISED)(0-250KG
G/CM SQ)
HYDROTE
EST PUMP(M
MOTORISED)(0-50KG/C
CM SQ)
TOOLS & TACKLES FOR
F
TAPE C
COATING
HOLIDAY DETECTOR
R
TOOLS & TACKLES FOR
F
ANCHO
OR FASTNE
ER
PORTABL
LE DRILLING
G M/C & HOLE CUTTER
R
POWER HACKSAW
H
JACK HAM
MMER
PIPE BENDING M/C
BOLT TEN
NSIONER FO
OR ALL SIZES AS PER
R SOQ
TORQUE WRENCH
W
F
FOR
BOLT TIGHTENING
T
G OF FLANG
GES
FORM NO: 02-0

0000-0021 F2 RE
EV3
Minimum
Re
equirement
Du
uring Constn.
01
01
03
01
01
02
01
01
04
01
01
01
AS
S REQUIRED.
01
01
15
08
10
05
01
01
AS
S REQUIRE
ED.
AS
S REQUIRE
ED.
02
02
01
01
01
02
02
01
01
AS
S REQUIRED.
02
01SET
01SET
01
02SET
AS
S REQUIRED.
01
01SET
All rights reserved
INSTALLAT
TION OF LP
PG MOUNDE
ED BULLET
TS
AT NRL
L,ASSAM
ONSTRUCT
TION/ERECT
TION, PRE--COMM, CO
OMM
CO
42.
43.
44.
45.
46.
47.
48.
49.
EM163-E-601
DOC. NO
O.
REV
V
Sheet 51
1 of 51
TOOLS & TACKEL FO

OR INSULAT
TION(ALL SIZES)
MOTHER ELECTROD
DE OVEN
PORTABL
LE ELECTRO
ODE OVEN
TOOLS & TACKLE FO
OR CALIBRA
ATION OF SAFETY
S
VAL
LVES
AS PER SOQ
TOOLS & TACKEL FO
OR CHEMIC
CAL
CLEANING
G/PASSIVAT
TION AS PE
ER SOQ
LABORAT
TORY EQPTS.
ELCOMET
TER
24 VOLT POWER
P
SOURCE
AS
S REQUIRED.
01
15
AS
S REQUIRE
ED.
AS
S REQUIRE
ED.
AS
S REQUIRED.
02
04
Notes:
1 Any othe
1.
er equipmen
nt required ffor completion of work but not spe
ecifically me
entioned
here, sha
all be deployyed by Contrractor withou
ut any additio
onal cost.
2 The deta
2.
ails of minim
mum critical equipments in good wo
orking condition, require
ed to be
mobilized
d by the co
ontractor, to complete the
t
work within the sc
chedule. The
e actual
deployme
ent schedule of constru
uction equip
pments shall be approvved by Engineer-incharge. Contractor
C
s
shall
augmen
nt the above
e list with ad
dditional num
mbers/categ
gories of
equipments, tools & tackles, as required
d and direccted by Eng
gineer-in-charge to
complete
e the work within
w
the com
mpletion time
e schedule and
a quoted price.
p
3 Contracto
3.
or to confirm
m that the a
above minim
mum equipm
ments are avvailable with
h him in
good worrking condition and shall be timely mobilized
m
on
n his project site. Contracctor has
the option to hire som
me of these equipments from equipm
ment-hiring agencies
a
alsso.
4 Owner/PDIL reserve
4.
es the right to physically check & verify the availability
a
o
of these
equipments prior to award
a
of work.
5 Contracto
5.
or shall repllace any de
efective/damaged equipm
ment promp
ptly to comp
plete the
work with
hout any time & cost imp
plication to th
he Owner/PDIL.
6 Instruments (as app
6.
plicable) to be made available
a
witth valid caliibration certtificates,
issued by
y NABL accrredited laborratory.
FORM NO: 02-0

0000-0021 F2 RE
EV3
All rights reserved
PROJECT EXECUTION PLAN
EM163-PNPM-003
INSTALLATION OF MOUNDED BULLET AT NRL,

ASSAM.
Document No.
Rev.
Sheet 1 of 46
PROJECT EXECUTION PLAN,

PLANNING, SCHEDULE, MONITORING,
CONTROL & INSPECTION
Form No.: 02-0000-0021F2 Rev1
All rights reserved
1.0
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 2 of 46
PROJECT EXECUTION PLAN, PLANNING & SCHEDULE, INSPECTION

The following section deals with the project execution plan philosophy for the Mounded
Bullet Job on Lumpsum Turnkey package concept. Brief and detailed scope of work of
respective disciplines is defined in this Tender Document. The project execution plan
describes the various methodologies to be adopted for various activities required to be
carried out for the successful completion of the subject package. The project
implementation philosophy for the contract performance shall be followed by the agencies
keeping in view the parameters defined in the various sections of the project execution
plan. However, these are not limited to the project and construction management
procedures and techniques as enumerated in various sections under Project Execution
Plan but would favour an adoption of constructive and affirmative approach to the whole
action plan by adopting the conceptual and professional skill to achieve project
completion in sequential and phased manner within the defined project schedule. The
agencies shall firm up their action plans and develop various information, depending upon
the requirement of project implementation philosophy to be adopted to achieve the
stipulated completion of the project as per time schedule under the contract provisions.
The Mounded Bullet is located in the refinery area with well defined battery limits as
shown in overall plot plan. It is envisaged that major activities of the Contractor would be
confined within the units battery limit.
1.1
Scope and Responsibilities
1.1.1
General
This Lumpsum Turnkey package has been prepared as a Bidding Package to the extent
enumerated in various sections and documents enclosed. The Contractors scope
comprises of detailed engineering, total procurement of all equipment and items including
construction materials, construction and installation, insulation, testing, painting,
commissioning, guarantees of supplies and works. Detail scope of work and disciplinewise technical requirements are provided in respective sections of this Tender Document.
The Contractor will execute the project on Lumpsum Turnkey basis, in accordance with
tender document. To achieve this goal and requirements of the Owner/Consultant,
Contractor will establish his project organization giving due consideration to the following
aspects:
x Effective execution and timely completion of each phase of the project.
x Maintaining high quality in each phase of the project.
x Good relation and coordination between the Owner/Consultant and the other
Contractors.
x Assignment of experienced resources and personnel for immediate and smooth
launching of the project.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 3 of 46
x Maximum indigenisation of the supplies of services.

1.1.2
Engineering
Contractors scope of work includes detailed engineering including preparation of
engineering drawings and datasheets, making use of standard specifications, standards,
design guides and technical documents enclosed in this Tender Document. Technical
requirements, technical documents, standard specifications, Consultant standards and
guides to be followed for different type of works shall be as provided in this Tender
document.
Contractor to carry out the detailed engineering defined above. Engineering required to
be done by the Contractor may arise singularly or in combination due to manufacturing,
fabrication, purchased items, construction, commissioning, statutory requirements,
Government regulations, safety requirements, site conditions, resultant total procurement
and construction, installation and testing, insulation, painting and commissioning, etc.
1.1.3
Procurement
Contractors scope includes ordering, all import formalities, fabrication/purchase of
equipment and materials, port clearance, packaging and transportation to site, stores
management which includes preservation and storage of equipment and materials,
uncovered storage, air-conditioned storage and open storage.
Vendor manuals relating to installation, operation and maintenance and test certificates
should be necessarily sent along with equipment. Please also refer Final Documentation
Submission requirement spelt out in this Tender Document, in this regard.
Before ordering, clearances for technical portion would be taken from Consultant in
respect of the critical equipments (special equipments) comprising of mechanical static,
electrical and instrumentation items. For instrumentation items, other equipment and
materials can be ordered without referring to Consultant as long as ordering is in
accordance with datasheets, drawings, standards, specifications. Any ordered items
which do not confirm to the contractual requirement identified at any stage of the project
shall be rejected. Replacement/modification and project delay arising out of this shall be
to the Contractors account.
Whenever clearances are to be taken, it would be necessary to submit details of
technically acceptable offer.
Procurement of spares for two years operation as per spare part philosophy detailed in
the scope of supply. Commissioning spares are also in the Contractors scope.
Coding system for stores management to be given by Owner/Consultant after the award
of the contract is to be adhered to by Contractor; suitable procedure based on the same
shall be developed by the Contractor for execution.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
1.1.4
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 4 of 46
Construction and Installation

Contractors scope covers detail engineering, construction, installation and
commissioning of the unit as per P&Is, datasheets, drawings, standards, specifications,
codes, statutory and state regulation. Supply of construction materials, labour, labour
supervision, tools, tackles, consumable materials and accessories not specifically
mentioned herein but nevertheless necessary, as per the Consultant for the construction,
installation, testing and commissioning of the complete system including cranes or any
other material handling equipment is also part of Contractors scope.
1.1.5
Quality Assurance
The desired quality is to be met for different activities at various stages of the project. The
quality checks by Owner and Consultant could be of audit type/involvement at all stages
of project execution by the Contractor and details of the quality plans will be furnished.
Contractor is required to submit detailed Quality Control (QC) measures to be adopted by
him for all stages/types of activities. A notice period of six weeks is to be given for
imported items and one week for indigenous items for association with respect to witness
QC steps by Owner/Consultant. Detailed methodology is enclosed in Tender Document
for compliance. Facilities at shops/site/engineering office for carrying out quality checks
by Owner/Consultant shall be provided/ organised by Contractor.
1.1.6
Project Management
The project management services will include planning, scheduling, monitoring, progress
reporting, quality assurance and quality control and overall project management
functions. Contractor shall nominate a Project Manager who will be responsible for the
total scope of work under this contract and shall respond to Owner and Consultants
Project Managers on all matters relating to this contract.
The Contractor is expected to execute the work/services under this contract on Task
Force concept with a dedicated team of specialists who will be responsible and respond
to the Project Manager. The Task Force shall be so organized as to give effective
management and control of various services to the Project Manager.
1.1.7
Organization
The organisation upto working level including period envisaged for different phases of the
project engineering, ordering, follow up for manufacture of equipment, clearances,
transportation, inspection of equipment and materials, warehousing, safety, construction,
commissioning and project management will be submitted along with the bid. Bio-data of
key personnel will also be submitted with the offer.
1.1.8
Sequence for Decisions
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 5 of 46
Along with bid submission, it is necessary for the Contractors to bring out variation, if any,
in related data sheets, drawings, specifications, standards, codes, scope, any other
contractual clauses and seek clarifications from Consultant/Owner. The decision of the
Consultant shall be final and binding on the bidder in such cases. For those such items,
which arise during execution of the project, the stringent specification/standards will be
applicable, and shall be binding on the Contractor. However, the decision of the
Consultant/Owner shall be final and binding on the Contractor.
1.1.9
Vendor List
All items required for project are to be purchased through approved vendors of Owner/
Consultant. Wherever such details are not available, vendor list to be proposed by
Contractor and clearance to be obtained from Owner/Consultant before initiating the
ordering process.
1.1.10 Waste Disposal/Scrap, etc.

All waste generated which could be surplus earth after use and or surplus construction
materials will be disposed off from time to time as directed by Owner/Consultant.
1.1.11 Environmental Management System
Bidders should comply with the latest relevant elements of the International Standard for
environmental protection, as applicable to their scope of work.
1.2
Project Management and Execution
1.2.1
Project Management
Overall plot plan, unit plot plan, detailed technical requirements along with the detailed
scope of work and overall proposed implementation schedule is issued by Consultant.
These will form the basis for formulation of the overall project schedule of the plant by
Contractor. The Contractor is required to organise his services in a systematic manner to
ensure execution and completion of the unit as per the schedule. The bidder is required
to submit along with his bid the methodology/procedure proposed by him for this unit
together with the organisational set up proposed and bio-data of key personnel.
In order to achieve uniformity in execution of various activities of Mounded Bullet,
Consultant
has
developed
engineering
design
basis
and
project
procedures/methodologies to be adopted by the executing agency. The Contractor is
required to carry out detailed engineering, procurement, tendering, construction
supervision and management, planning scheduling, monitoring, reviewing, reporting, and
overall project management activities. All activities to be performed and services to be
rendered by the Contractor under this contract shall be monitored by Consultant and will
be subject to periodic reviews by Consultant. The Contractor shall facilitate such
reviews/monitoring by Consultant.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 6 of 46
Immediately after the award of job, a kick-off meeting will be held to finalise and establish
the modalities and procedures to be adopted for execution of the contract based on the
enquiry document, commitments made by Contractor and subsequent agreements
reached between Owner/Consultant and Contractor during negotiations. The kick-off
meeting will be attended by key members of Owner/Consultant and Contractor. This will
address all necessary details and arrangement between Owner/Consultant and the
Contractor.
The Contractors service for engineering, procurement, tendering, construction,
supervision and management, planning, scheduling, monitoring, reporting, and overall
project management shall meet the requirements given in this section.
English language and Metric Units shall be used in all documents, drawings, reports,
correspondences etc. under this contract.
1.2.2
Supply of Detailed Engineering

The Contractor shall provide the detailed engineering services for Mounded Bullet as
mentioned in this bid document furnished by the Owner/Consultant. The services shall
cover the detailed engineering required for execution and completion of the Mounded
Bullet.
Obtaining approvals of the detail engineering documents shall be the responsibility of the
Contractor and the same is included in his scope of work. Such review and approval by
Owner/Consultant shall, however, not relieve the Contractor of his responsibilities.
For achieving the project schedule, it may be necessary in some cases to prepare the
drawings in stages and release it for construction so as to take up simultaneous
execution of detail engineering and construction. Any revision involved for the above is
included in the scope of work of the Contractor. Also any change required to meet site
conditions/statutory requirements shall have to be carried by Contractor at no extra cost.
The Contractor is required to organise a Task Force of dedicated specialists from each
discipline under a Project Engineering Manager who will be assisted by engineering
Coordinator. An engineering schedule will be prepared and submitted to
Owner/Consultant for approval. This approved schedule shall be used for all engineering
activities. The engineering coordinator shall coordinate all design and engineering
activities and interact with purchase, inspection, expediting, C&T, tendering, planning,
construction and project groups. His responsibilities shall include.
(a) Engineering coordination for procurement involving:
y Preparation of Material Requisitions (MRs).
y Technical evaluation of offers received (which may involve technical discussions
with vendors and concerned specialists may have to be deputed to vendors works
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 7 of 46
or to Owner/Consultants offices as per requirements) and preparation of

recommendations.
y Preparation of Technical Purchase Requisition (PRs) on selection of vendor.
y Review/approval of vendor drawings/documents. (This may call for arranging
specialist visits to vendors works for timely approvals of critical items.)
(b) Engineering coordination for sub-contractors involving:
y Preparation of schedule of quantities and specifications for various contracts.
y Technical evaluation and recommendation of offers received. This may involve
arranging technical discussions with Tenderers at Owner/Consultants office if
called for due to job requirements.
y Preparation of technical-agreed variations for incorporation in contracts for the
selected Contractor.
In any case, Contractor has to take owner approval for sub-contractors list prior to
scrutiny and award.
(c) Engineering coordination for construction involving:
y Timely issue of approved construction drawings including drawings duty approved
by Owner/Consultant as per requirements. Some of the drawings will need
licensors approval.
y Providing/arranging clarification on drawings and specifications wherever called for
including specialists visits to site.
y Making regular periodic visits to project site for review of site requirements in
respect of engineering activities.
(d) Monitoring progress of engineering activities and advising Project Manager on

shortfalls and corrective actions needed. He will also attend the review meetings.
Plant design, detailed engineering and construction shall be based on sound engineering
practices. List of applicable codes, standards and mandatory rules to be used in design is
also mentioned in bid document.
Drawings/Documents/MRs etc., which are to be generated by Contractor shall be
numbered as per the Documents Numbering Procedure of Owner/Consultant.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 8 of 46
Head Office engineering support of Contractor shall be provided to site during

construction including deployment of engineering specialists for field engineering as and
when required by Contractor.
1.2.3
Procurement
The procurement services to be provided by the Contractor shall cover the purchasing,
inspection, expediting, custom clearance and transportation activities
(a)
Purchase
The purchase activities will cover all equipments and materials as per the scope of work.
The purchase group shall consist of adequate number of experienced and qualified
Purchase Officers commensurate with the number of material requisitions to be handled
and the time schedule for ordering. A procurement schedule will be prepared and
submitted to Owner/Consultant for approval. This approved schedule will be followed for
all procurement activities.
Purchasing activities shall be coordinated by an experienced purchase coordinator who
shall be responsible for:
(b)
Coordinating with engineering group regarding preparation of material requisitions

(MRs), evaluation and clarifications on offers of vendors, technical discussions,
negotiations with vendors, technical recommendations preparation of purchase
requisitions to form part of purchase requisitions selected vendors purchase order.
Coordination for processing of change orders as required during execution of the

project on account of additions/modifications as well as transit losses/damages.
Before ordering, clearance for technical portion for rotating, instrumentation and
electrical items as indicated in technical details would be taken from Consultant.
Preparation and issue of status reports on purchasing activities.
Attending review meetings with Owner/Consultant on all purchase activities.
Inspection and Expediting

The Contractor is required to organise a proper inspection and expediting system so as to
ensure timely delivery of all the items/equipment meeting the specified quality criteria.
This function has to be carried out by appropriate deployment of qualified personnel who
have wide experience in their respective fields. Owner/Consultant will reserve the right to
inspect items deemed necessary by them without any additional cost to Contractor/subcontractor/vendor /third party.
Expediting is one of the vital activity of successful and efficient procurement system which
enables timely execution on the project. Such expediting has to be carried out by
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 9 of 46
deployment of expediting coordinator located at Contractors Head Office who would be

assisted by expediters located in various regional offices. To enable this function to be
very effective and fruitful, following functions are to be carried out as a minimum.
Expediting Coordinator
Expediting Coordinator located at the Contractors HO will liaison with various
departments such as purchase, projects, engineering, transportation etc. on one hand
and regional inspection/expediting offices and vendors on the other. The basic functions
of such expediting coordinator would be:
y
Maintain effective communication link between various departments of the Contractor

including his regional offices and vendors on whom the orders are placed.
Status maintenance of all the orders.
Analyzing the order status in detail after identifying the critical order and initiation of
suitable remedial measures.
Acting as an effective instrument in final delivery of the item within CDD.
Preparation of order close out reports of each order.
Expediting coordinator shall be a person who is highly communicative and has sound
technical knowledge; he must be highly analytical, alert, quick in gathering up-to-date
information of the various orders.
Responsibility of Expediting Coordinator

y
Attending periodical review meetings with Contractors project department and

Owner/Consultant.
Distribution of Fax of Intent/Letter of Intent and status maintenance.
Liaison with regional offices to obtain order generate acknowledgement of Fax of

Intent/Letter of Intent.
Intimate Owner/Consultant of reservations (if any) from the vendor in purchase order
acceptance.
Distribution of POs / PRs to vendors and regions.
Expediting of vendors drawings and other related documents.
Expediting of approval of drawing by respective engineering department and timely

return of the same to the vendor.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 10 of 46
Ensure receipt of periodical expediting reports and preparation of monthly status

report against each order as per the requirement of IOCL/Consultant.
Identification of critical orders/issues and initiate of remedial action.
Expediting of decision on deviation sought by the vendor.
Follow up actions with various concerned departments regarding all the issues
discussed in the review meetings.
Prompt despatch of material after inspection with the assistance of transportation

department.
Follow up of despatch particulars after despatch.
Ensure preparation of order close out report for each order giving complete details of
the order including ordered quality, contractual delivery date (CDD).
Date of completion, delay, if any and reasons for delay, status of final documents etc.
Ensure receipt/distribution of vendor documents including final documents as per PR.
Preparation of final procurement closing report. The order close out reports shall be
accompanied with two sets of complete documents in respect of each order
bound/put together in a folder comprising of: purchase order, purchase requisition,
change orders (if any), inspection certificates, material test certificates, final vendor
drawings (if applicable), operation/maintenance manuals, any other document as
specified in PR.
Expeditor
Expeditors responsibility commences from the time he receives the intimation of
placement of TOI/LOI/order on vendor located in his region till the time he furnishes the
despatch particulars of the item under a particular PO. During this process expeditor shall
monitor and maintain all activities of the vendors such as:
y
Vendors understanding of the order.
Submission of design drawing documents for approval.
Sub-ordering, planning and scheduling.
Manufacturing testing and despatch.
Delays, power cuts, strike lock out etc.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 11 of 46
Submission of final documents as per PR.
Above functions may be possible only by frequent visits to vendors office and shops
including their sub-vendors establishments as the case may be. Expeditor shall be able
to visualise the problems in advance and suggest timely corrective measure. In nutshell,
expeditor is not a mere progress reporter but a vital catalyst for successful completion of
the job. Expeditors responsibilities are as below:
(c)
Ensure order acknowledgement from the vendor.
Communicate the person concerned the reason for vendors inability to accept the
order (if so).
Progress reporting of various orders located in the region.
Communication with the vendors whenever he finds lack of efforts on their part.
Raise alarm report at an appropriate time on possible serious delay or vendors

inability in meeting with scheduled date of delivery and also to suggest action plan.
Liaise with inspection department for timely inspection, including third party
inspection/statutory inspection as specified/required.
Liaise with engineering department for approval of drawing, acceptance of deviation

etc. through the expediting coordinator.
Liaise with transportation department for sound and quick despatch of material.
Inspection Quality Assurance System

The objective of the quality assurance scheme of the Contractor shall be to ensure the
conformity of equipment, material, site construction to various standards, specifications,
drawings and technical requirements that are being mutually agreed between the
Contractor and Owner/Consultant. Quality Assurance System should clearly indicate the
organisational approach for quality control and quality assurance of the various
equipment/construction activities and also provide a verifiable evidence of the Contractor
having carried out all the activities laid down in the bid document and the procedure.
Such conformity to quality level shall be ensured by controlling the quality level of
purchased items at vendors/sub-vendors shop/site and shall cover from source
surveillance to final inspection. The Contractor to submit a detailed inspection and testing
plan for various shop/site activities as a part of his Procurement Manual which shall be
duly approved by Owner/Consultant. The Procurement Manual shall as a minimum
include:
In house Inspection Programs
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 12 of 46
Inspection procedures consistent with mandatory codes.
Procedures for material identification and transportation.
Certification of non-destructive testing.
Inspection responsibility shall include but not be limited to the following:

y
Single or multiple visits to the vendors shop/site as per the requirement.
Pre-inspection liaison meeting with the vendor for vendors correct understanding of
the inspection requirements.
Approval of quality assurance/quality control plan procedure clearly indicating stages

of inspection with specific reference to witness and review.
Ensure submission of quality control procedure and approval of the same for critical
sub-orders.
Inspection of various equipment/items as per relevant codes, specifications/drawings

including witnessing of final acceptance test at vendors works/site.
Maintenance of inspection reports periodically highlighting hold, deviation etc.
As indicated for expediting coordinator, Contractor should nominate an inspection

coordinator with similar responsibility who will liaise various inspection offices/vendors for
proper coordination.
Inspection for Foreign supply items through an Approved Third Party Inspection Agency
Inspection requirements shall be fulfilled through Owner/Consultant approved Third Party
Inspection Agency. The payments to be made to the Third Party Inspection Agency shall
be the responsibility of the Contractor. Further, the responsibility for inspection/testing as
per specification approved documents and agreed Quality Assurance procedure and
plans shall be that of the Contractor. Inspection activities of the Third Party Inspection
Agency shall be coordinated by the Inspection Coordinator of Contractor.
(d)
Customs Clearance and Transportation

The Contractor is required to organise a custom clearance and transportation (C&T)
system to ensure prompt clearance of imported equipments from customs and
transportation of equipments/materials to project site from ports/vendors works. This
function shall be carried out by deployment of qualified and experienced personnel. C&T
functions shall include, but not be limited to the following:
Appointment of Contractors
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Clearing forwarding of imported equipments/materials.
Collection and transportation of bulk materials by road from vendors works.
Transportation of consignments from port to site by road.
Handling of consignments at project site.
Transportation of general cargo and over dimensioned consignments by road/rail

Clearing and handling of air consignments, if applicable.
Any other contracts relating to C&T services.
Supervision of Contractors
Supervision, monitoring and coordination of above contracts for import clearance and
transportation as detailed below by Contractor.
Import Clearances
y
Monitoring and coordination with clearing agents, customs, ports, steamer agents,
airlines, railways and transport agencies for clearance of imported consignments.
Registration of contracts with custom under project imports.
Control of payment of import duty to customs, payment of port dues, etc.
Conducting surveys with various agencies for imported consignments landed in

damaged condition and corrective action for timely replacement of items.
Despatch of Indigenous Project Goods
(e)
Coordination with inspection/expediting group and all indigenous suppliers for

expeditious despatch of consignments.
Monitoring movement of consignments from vendors works to project sites.
Collection, transportation and delivery of bulk-material to project site.
Monitoring Movement of Consignments

Total monitoring of movement of all consignments dispatched to project site from various
points of despatch. A chaser has to be deployed from Contractor, for transportation of all
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ODC Consignments as well as important consignments (imported and indigenous) as and

when advised by Owner/Consultant.
(f)
Reporting
Preparing and issuing weekly, fortnightly and monthly status reports on clearance of
imported equipments/materials and movement of equipments/materials from various
despatch points to project site.
Monthly reports on Over/Short Rejected/Damaged (OSRD) items. It shall be Contractors
responsibility to arrange for timely replacement of OSRD items.
(g)
Tendering
Tendering activities of the Contractor shall be properly organised to ensure award of
various contracts in line with the project schedule. The tendering group shall consist of
sufficient number of contract engineers/officers who are having adequate professional
experience and qualifications.
Contractor shall prepare a Tender schedule for carrying out different works such as civil
and structural equipment erection, piping, electrical, instrumentation, painting etc. All
tendering activities shall be carried out in accordance with this approved tender schedule.
The Contractor shall deploy a contract coordinator for coordination of tendering activities.
The contract coordinator shall be responsible for:
y
Coordinating with the Resident Construction Manager during execution of the

contracts regarding clarifications on contract terms and conditions as required.
Preparation and issue of status reports on contracting activities.
Attending review meeting with Owner/Consultant on all contracting activities.
Preparation of tender documents, issue of enquiry to approved Contractors through

receipt of bids, techno-commercial evaluation of offers for award of contract will be
carried out by Contractor.
All major tenders will be handled by the Contractor from his Head Office. However,
tenders for certain minor construction will be handled by Contractors site office.
1.3
Project Planning, Scheduling & Monitoring System

The Contractor is required to institute and maintain a proper planning, scheduling and
monitoring system and employ professionally qualified and experienced planning
engineers for the project. The system shall have latest state of the art technique. To this
effect, Contractor shall implement this system through the Prima Vera Project Planner.
The system developed should be capable to support and enforce proper control
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mechanism in the project. It should be based on hierarchical breakdown of works with

elaborate level of detailing and control. The levels of controls should be such that it
supports and foster controls at activity level, function level and management level with
greater emphasis on target, scope and commitment at various stages of contract for
accountability and action planning. Such multi-level/multi-tier system of planning,
scheduling and monitoring, supports, effective information generation, assimilation,
summarisation and reporting in proper and adequate manner. The system shall be
predictive type and should constitute pre-warning mechanism to diagnose and anticipate
the problem well in advance and provide preventive features/measures. It is required that
work breakdown structure should consist of details of systems, work packages, functions,
work items and activities from monitoring point of view at micro level and summarisation
at higher levels. It is expected that the work breakdown structure coding system or
methodology to be followed shall be informed/discussed with the successful bidder during
the kick-off meeting.
Following schedules, documents, reports shall be prepared and submitted by the
Contractor for Owners/Consultants review/approval at various stages of the project:
1.3.1
Kick-Off Meeting
On award of job, the Contractor is required to submit the following documents which will
be discussed during the kick-off meeting to establish planning requirements, inputs and
outputs for overall schedule, monitoring and progress reporting.
y
List of work package/areas.
List of critical drawings.
Breakdown of work packages to work items level.
Input requirements of each work item/activity.
Schedule start and finish dates of all milestone/activities in line with overall schedule
of the project.
Overall system-wise, discipline-wise weightages for each item/activity.
Three month front-end schedule within a week of award.
In this kick-off meeting, it will be endeavoured to reach complete understanding with

Contractor on activities, inputs and logic to establish planning documents for monitoring.
Venue of the kick-off meeting to be held between the successful Bidder, Consultant and
the Owner, shall be either at Consultant Office or Owner Office.
1.3.2
Early Planning Document/Look Ahead Schedule
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Immediately after the award of contract and pending finalisation of overall project
schedule, detailed activity chart/network, functional schedules etc., the Contractor in
consultation with Consultant shall prepare a look ahead schedule as a guideline for the
activities to be performed during the relevant periods.
1.3.3
Overall Project Schedule

The Contractor shall submit within 30 days of Fax of Intent, the work breakdown
structure showing project work load, that is, preparation of tenders, material requisitions,
construction drawings equipments etc. alongwith a sufficiently detailed overall project
schedule in the activity network form, clearly indicating the major milestones, inter
relationship/interdependencies between various activities such as process, engineering,
procurement tendering, manufacture, delivery, construction etc. together with computer
analysis of critical path and floats as well as quantum of work for major activities.
The schedule will be reviewed and approved by Owner/Consultant and the comments if
any shall be incorporated in the network issued for implementation within two weeks
from receipt of comments. The network thus finalised shall form part of the Contract and
will become the basis for developing further detailed activity network. This schedule shall
not be revised without the prior permission from the Owner/Consultant during the entire
period of contract. The changes made during revision of the contract shall be approved
by Owner/Consultant.
1.3.4
Detailed Activity Network

The Contractor should develop detailed activity networks for various systems/plant/ unit of
the project, based on approved overall project schedule within two months of Fax of
Intent. Such networks would be computerised for further monitoring and reporting.
1.3.5
Functional Schedules
The Contractor should prepare resource-based detailed functional schedules in line with
detailed activity networks for functional monitoring, scheduling and control. This should
clearly reflect strategies and philosophy of execution. Owner/Consultant reserves the
right to check the functional schedule and status of activities at anytime and at any
location of performance/execution. Further, the functional schedules shall be submitted
by the Contractor on demand by the Owner/Consultant.
1.3.6
Progress Measurement Methodology

The Contractor is required to submit during the kick-off meeting, the detail methodology of
progress measurement of engineering, procurement, manufacturing, delivery,
computation of total service/physical progress at the unit-wise level and on the overall
basis. The progress basis shall be physical realisation of work such as in terms of
deliverables and construction quantity/volume accomplished. The amalgamation of such
output across the project to compute overall progress shall be suitably established with
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proper rational and norms and maintained throughout the project. Owner/Consultant
reserves the right to modify the methodology in part or in full.
1.3.7
Vendor Scheduling and Monitoring

The Contractor shall establish schedules for pre-ordering and post ordering for follow up.
The vendor monitoring preferably should be on logical networks and commitments at
least on critical items in order to monitor them on regular basis for effective control.
Owner/Consultant may demand such follow up procedure and logical networks for
various critical equipment at any time during the course of order execution. The
manufacturing schedule shall be established and agreed with the vendors and
acceptance shall be brought to the notice of Owner/Consultant in time.
1.3.8
Construction Network
The Contractor shall prepare and submit a detailed construction network with full
consideration of logistics, construction studies and method for Owner/Consultant
approval. The Contractor shall describe the resources required and special construction
equipments, Tools and tackles to be mobilized. The network shall be developed
subsequent of substantial progress of engineering and ordering with fairly known
construction workload and quantities.
1.3.9
Construction Worksheets
The Contractor shall further detail out the construction network into area-wise details in
terms of work, quantity and schedule, to firm up basis for area control. The construction
schedule should be worked out based on work front generation criteria which will call for
availability of input like drawings, materials and access for each/group of activity to be
performed. It may be in the form of resource loaded bar chart with S curve.
Owner/Consultant reserves the right to access the same.
1.3.10 Construction Contractor Schedule

The Contractor shall agree upon the construction schedules with sub-contractors for
proper mobilisation, monitoring and control. Owner/Consultant reserves the right to ask
for such programme and status of any time as may be required.
1.3.11 Computerisation
Contractor should follow proper computerised control for the following project modules:
y
Activity network
Engineering (Residual)
Purchasing, delivery and expediting
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Construction planning and control
Materials control at head office.
Material allocation and control at field office
Proper warehousing control
Project documents and construction drawings
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The above distinct but integrated components of project should be monitored as

deliverable and quantum level. To perform such elaborate level of input-output control at
each deliverable, the packages used should forecast resources based on recovery plan in
dynamic manner for adequate control.
As indicated earlier, project schedules as above shall be developed/evolved using the
latest version of the Prima Vera Project Planner Software Package.
1.3.12 Project Review Meetings
Contractor shall present programme and status at various review meetings as required.
Monthly Review Meeting
Level of participation
Owner, Consultant and Contractor
Agenda
Monthly programme v/s progress status/statistics

Major hold ups/slippage
Completion outlook
Assistance required
Areas of concern and critical issue
Recovery action plan
Venue
Owner/Consultant office
Level of participation
Contractor/Consultants
engineers
Agenda
Weekly programme v/s actual achieved in week

Programme for next week
Purchase requisition status report
Recovery actions and hold up analysis
Weekly Review Meeting
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Site office
1.3.13 Progress Reporting

The Contractor shall submit the following progress reports on a regular basis for
Owner/Consultant information/review.
Monthly Progress Report
This report shall be submitted on a monthly basis within seven calendar days from cut-off
date, or as agreed upon, covering overall scenario of the project. The report shall include,
but not limited, to the following:
y
Executive summary or summary of major events/activities.
Schedule v/s actual percentage progress and progress curves for engineering,
ordering, manufacturing, delivery, contracting, construction, commissioning, overall.
Areas of concern/problem/hold-ups, impact; recovery action plans/catch-up plans.
Activities executed achievements during months and targets for the following month.
Analysis of critical activities and impact on overall completion.
Chronological achievements of key events indicating schedules and actual date.
Annexure giving status summary for drawings material requisitions, equipment and
materials delivery, contracting and construction.
Resource requirement deployment status.
Change order status.
Invoice status.
Construction photographs ( color).
Weekly Reports
This report will be prepared for Head Office and construction site in summarized fashion
and submitted on every Tuesday taking status as of Sunday by the Contractor on weekly
basis and will cover following items:
y
Activities completed (engineering, procurement, contracting, construction. etc.)
Programme for subsequent week.
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Resource deployed man and machine.
Quantities and productivity achieved in key areas of work.
Progress on procurement activities including material requisition status reports.
Constraints, if any.
The report/information may be transmitted preferably through fax to Owner/Consultant

HO.
Daily Reports
y
Important activities for the day at site.
Material/equipments receipts for the day.
Labour deployment report.
Requirement of Copies for Submission of Schedule & Reports

SN
Name of Document
Number of Copies
Owner
Consultant
HO
Site
Overall project schedule
Detailed activity network
Functional schedule
Construction network
Monthly progress report
Weekly progress report
Daily report
Copies shall be forwarded through Consultant. Above requirement is indicative and shall
be reconfirmed during kick-off meeting.
1.3.14 Material Control
It is essential that the Contractor follow an integrated material control system for the
project. In the system, material identification in the drawing office, procurement and
allocation, are all channelized and controlled in an orderly manner. The Contractor should
follow a system for material identification, and should give construction orientation to
material control. The Contractor, right from the beginning, at the drawing office stage will
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start identifying materials system-wise or area-wise. The system will be based upon
backing of material from the material take off stage through material requisitioning,
placement of purchase order, manufacturing at vendors shop upto receipt at site for
making the material available for performing planned and sequential construction work.
At the construction site, the Contractor will develop and implement a system of
inspection, receipt and effective utilisation of materials received by re-examining the work
front availability and priority between and amongst various systems and areas.
In the case of multiple agencies carrying out construction at site, the Contractor must
adopt methodology of allocation and de-allocation and timely issue of the materials
thereby preventing possible idle storage of items at the Contractors level. Contractor
must follow proper warehousing procedure at project store to maintain various planned
and unplanned issues and dynamic stock status records. Through periodic reviews, the
Contractor will have a system of generating hold up reports well in advance to identify
exception on material availability and to track such material by the expeditery through a
systematic follow up procedure from the vendors.
Owner/Consultant may introduce checkpoints at procurement, allocation and construction
stages to know the development, status and behaviour of the system and the Contractor
shall submit the following reports on monthly basis: bulk material status report, and
material hold up/shortage report.
1.4
Project Time Control Methodology
1.4.1
The time for completion of the complete scope of work shall be strictly as per the time
schedule given in the tender document.
1.4.2
The tenderer shall furnish the following documents along with the bid:
(a) An overall schedule in the form of network, clearly indicating all important milestones
in design, engineering, fabrication, procurement construction, testing,
commissioning, etc. for the plant commensurate with the overall time schedule.
(b) Resource deployment schedule indicating mobilisation of all critical resources
including manpower and machinery for the smooth execution of the job at
engineering offices, fabrication shops and construction site. The resource schedule
shall also contain various construction aids envisaged to be deployed for execution.
(c) Organisation structure for effective project management and control, clearly
indicating the responsibility centre as well as bio-data of the key personnel, who are
permanent employees of the Contractor.
1.4.3
Within 30 days of issue of fax/letter of intent, the Contractor shall finalise the following as
detailed earlier:
(a) Overall Project Schedule
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Overall project schedule in line with the agreed milestone and detailed to adequate
work breakdown structure level covering all phases of the work such as detailed
engineering, procurement, manufacturing, shipment, tendering and field erection. This
schedule shall also include the interface activities to be provided by the
Owner/Engineer-in-Charge and the dates by which such facilities are needed.
Contractor shall get the scheduled submitted and reviewed by Owner/Engineer-inCharge and the agreed schedule shall form part of the Contract monitoring document
based on which performance would be reported and evaluated. This document shall
be signed by both the parties. The Owner/Engineer-in-Charge shall also review the
weightage allotted to various activities and method of reporting to be adopted by the
Contractor. During the progress of the contract if in the opinion of Owner/Engineer-inCharge, desired progress as physically/sequentially is not maintained, it would be
obligatory on the Contractor to re-programme the work schedule in order to
accommodate the backlog and/or provide work front to other agency, without any
obligation to the Owner/Consultant.
(b) Functional Schedules
y Engineering Schedule
This shall indicate list of drawings, specification and sketches to be prepared
discipline wise for each plant and scheduled date of issue of each document.
y Ordering, Manufacturing & Delivery Schedule
This will be in the form of bar chart and shall indicate item-wise all the major activities
regarding ordering, shop fabrication/manufacturing and delivery of materials.
y Construction Schedule
This will be in the form of a detailed bar chart showing all the construction activities
(civil, structural, piping, equipment erection, electrical, instrumentation, insulation,
painting, etc.) at site with their durations and workload and highlighting the inputs
namely drawings, materials availability, etc., compatible with the related functional
schedule. The Contractor shall provide on request key construction net work of any
work module for critical review and control.
y Resource Deployment Schedule
A detailed deployment schedule indicating manpower, machinery, construction,
equipment in line with the overall project schedule.
y Precommissioning and Commissioning Schedule
Contractor shall develop this schedule in the form of a bar chart and submit the same
to Consultant for review.
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y Any other document required for monitoring.

1.4.4
In line with the construction schedule, the Contractor shall submit a monthly programme
for site activities and the target set in shall be strictly adhered to. In all matters concerning
the extent of targets set out in the monthly programme and the degree of achievement,
the decision of Consultant/Owner shall be final and binding. The monthly programme
shall be further broken into weekly programmes. At the end of each week, a report shall
be submitted by the Contractor indicating the achievement during the week against the
targets, reason for shortfall if any and the construction programme for the following week.
Contractor shall also attend weekly/monthly review meeting conducted by Consultant or
by his representative to review project status.
1.4.5
The Contractor shall regularly submit a detailed progress report in respect of:
y
Release of drawings
Sub-ordering of materials
Manufacturing
Delivery of equipment/material status report
Construction
Other features like mobilisation, safety etc.
Report indicating the critical activities governing the timely completion of the project
and actions to overcome the same to be submitted every month.
This report will be issued every month on an agreed cut off date and shall include the
following brief description of the progress achieved during the month. Reason for short
fall if any and action plan to make up short-fall.
1.4.6
Scheduled and actual percentage progress discipline-wise/system-wise as well as

overall physical progress.
Job completion trend in the form of updated overall schedule.
Progress photograph (Colour) highlighting major achievement.
The Contractor at any point of time of operating would be permitted to revise the
accepted schedule/control documents with the Owner/Engineer-in-Charge without
changing the contractual completion date.
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1.4.7
The review of the performance of work would be made at different levels of management
and Contractor is expected to ensure proper participation for effective reviewing and
action plan.
1.4.8
The Contractor should ensure availability of professionally qualified planning engineer

both at HO and site deemed adequate by the Owner/Engineer-in-Charge.
1.4.9
The Contractor at his own cost should maintain a control room at site highlighting all the
features, schedule and achievements of the project.
1.4.10 Weighted percentage of each discipline/group of work shall be mutually agreed to

between the Contractor and Owner/Engineer-in-Charge after the award of contract to
facilitate compilation of progress.
1.5
Construction, Construction Supervision and Management

Construction
1.5.1
1.5.2
The Contractor will carry out the construction works in accordance with all relevant codes,
standards, specifications, his documents and drawings, and based on the most efficient
use of local resources. The Contractor will act as principal employer on the labor
employed for construction activities and will follow Indian Labor Act, and all statutory
regulations in this regard. The Contractor will have total responsibilities for the following:
y
Construction, erection and installation of all equipment, machinery, piping and

materials supplied by the Contractor.
Complete civil and structural works
Site supervision, planning and coordination at site.
The Contractor is required to organise and mobilise construction management services in

a systematic and sequential manner to ensure that the plant installation is carried out in
accordance with the approved engineering drawings, specifications, standards, QA/QC
procedures etc. and its mechanical completion is achieved within targeted time schedule.
For this purpose, the Contractor shall deploy a construction management team headed
by a Resident Construction Manager (RCM) at site. The construction management team
shall include engineers/specialists in QA/QC, project control (planning, scheduling,
monitoring), , safety, warehousing, etc.
Construction supervision, coordination and management activities shall be carried out by
Contractor in accordance with the approved construction procedures by Consultant.
Contractor will prepare construction schedules based on the overall project schedule of
the plant and submit to Owner/Consultant for approval. Monitoring and control of the
construction activities will be carried out as per the approved construction schedule and
procedure.
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A construction management team headed by a Resident Construction Manager will be

deployed at site by Contractor. The Contractor shall ensure delegation of adequate and
sufficient power to his RCM for effective and smooth functioning of the field management.
HO support shall be provided to the RCM at site during construction as and when
required on all matters of project execution including the following:
y
Field engineering
Vendor specialists required during construction
Rectification/replacement of defective supplies, if any, noticed during construction
Inspection/expediting of replacement orders/field purchase order for ordered items

placed by field purchase
Expediting replacement of imported items found short/damaged.
1.5.3
The Contractor shall establish and maintain a material testing laboratory for carrying on
field tests during execution of contracts under different disciplines by Sub-contractors, at
no extra cost to owner. Also, all material handling equipment shall be subjected by the
Contractor to required load test initially and then periodically to ensure safe/stable
operation including witnessing and maintaining records of such tests.
1.5.4
The construction organisation will include the following for effective execution, monitoring
and control: planning, scheduling, monitoring reporting, construction supervision, quality
assurance and quality control, warehouse management and material control, field
engineering/purchase, safety personnel administration.
(a) Quality Assurance and Quality Control (QA/QC): QA/QC personnel will be responsible
for ensuring quality of construction carried out by different Sub-contractors in
accordance with the approved QA/QC procedures and management of material
testing laboratory.
(b) Warehouse Management and Material Control: This discipline will be responsible for
carrying out the warehouse management and material control in accordance with the
warehousing procedure and material control procedure. The material control plan and
warehousing procedure shall be submitted by Contractor for Owner/Consultants
review/approval. The activities of the contractor will include:
y
Transport Liaison, filing of insurance claims and follow up.
Receipt, handling, identification, inspection, and acceptance of materials including

free issue materials to be supplied by owner.
Documentation for control and accounting of materials.
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Materials control and issue
Inventory checks
Field requisition and purchase
Spare and tools
Material appropriation and handing over
Security
Taking with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
Intimating HO regarding short, lost, damaged items and taking up with suppliers
and taking replacement action when applicable.
Perform material reconciliation and identification of surplus material and its

handing over to the Owner after certification by the Consultant.
Contractor will generate and issue following reports: fortnightly statement of

consignments in transit; daily report of material received; report on over, short,
reject, and damage receipts against each consignment on receipt at warehouse;
weekly status of consignments, material receipt report; monthly status of field
purchase; monthly status of excess, shortage rejected and damage settlement.
(c) Field Engineering: This discipline will be responsible for controlling and issue of
technical drawings and documents, preparation of field sketches, field modifications,
checking/preparation of as-built drawings, technical assistance for field purchase and
field tendering etc. Specialist engineers from Vendor HO will also be deployed at site
as per requirements.
(d) Safety: It is the responsibility of the Contractor to ensure that safe construction
procedures are complied with. They will also ensure that adequate first aid medical
facilities are available for emergency purpose and that safety procedures as per the
approved safety procedure are followed by the different Contractors. To assist in the
development of an effective safety programme, a safety checklist for various jobs
shall be developed and the same shall be reviewed by the Contractors Site Incharge.
The responsibilities will include the following: coordination and supervision of the
details of the job safety programme; initiation and supervision of the use of accident
report and investigation form; preparation of periodic accident summaries; tallying
safety inspection of the job site and submission of summary inspection report to site
Consultant in charge.
1.5.5
Quality Assurance/Quality Control
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All work/services to be performed by the Contractor under this contract shall be of

specified/approved quality and Contractor shall have a quality assurance/quality control
(QA/QC) system during the performance of various activities such as engineering,
procurement, tendering, construction etc. Review/approval of activities by
Owner/Consultant shall not however dilute the responsibility of Contractor for maintaining
quality.
(a) QA/QC Procedure: Contractor shall submit the QA/QC procedure to be adopted for
engineering procurement and construction activities of plant for review and approval
to Owner/Consultant. The QA/QC procedure shall cover all activities to be performed
by Contractor. Some important activities and procedures to be evolved are listed
below:
y
General: Document control, coordination, non-conformance report of Subcontractors, output identification and traceability, QA system review
Procurement/Inspection: Incoming material control, welding qualification and

repair, manufacturing or fabrication process control, applicable non-destructive
examination, coating/lining, preservation, post-weld heat treatment wherever
applicable, packaging and despatch control, transportation, inspection/test plans
for all specific and mandatory tests (as per drawings and codes) with clear
indication of witness, verification and hold points.
Construction: Pre-construction activities, job construction, welding qualification

and repair, inspection/test plans for all specified tests (as per drawing and codes)
with clear indication of witness, verification and hold points. Contractor shall
prepare construction QA plans for review of the Owner/Consultant and the same
shall cover as minimum the areas as under, and shall confirm their compliance to
approved codes/standards/specifications, etc.
Site Preparation: Incorporation of all witness tests/hold points of construction

work, clean-up testing, instrumentation installation and construction.
(b) As a part of Construction and Quality Assurance, the Contractor shall also comply
with the following activities:
y
Stage-wise inspection of quality of work as per approved QA plan and contract

specifications.
Develop welding procedures and welders qualification procedures for their work.
Ensure compliance of various statutory rules, regulations and safety measures

and to arrange and co-ordinate site inspection, testing etc. as required under local
statutory rules and regulations prevalent in India.
Take all necessary precautions to protect construction work and material from
damage by climate, outside elements and construction activities.
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Ensure that materials used are in accordance with drawings/project specification.
Review safety procedures prepared by the Contractor for compliance with

applicable codes, regulations and Owner requirements.
Prepare schemes for heavy/critical equipment's erection/lifts/rigging before and

submit the same for Consultant review/approval.
Perform housekeeping activities, which include maintaining sanitary facilities,

sweeping clean up, removal of excess materials/temporary facilities, scaffolding,
as necessary.
Conduct periodic quality/technical audits for ensuring quality and conformance

with the contract.
To take immediate appropriate corrective actions as and when such discrepancy

arises to fulfil quality, safety obligations.
(c) QA/QC procedure shall also include quality plans, mostly in tabular formats defining
the specific quality practices and flow of every identifiable activity of a discipline. All
disciplines concerned with the performance of work are to be covered. These quality
plans should indicate the following:
y
For Design and Engineering: Activity description; preparation, checking, review

and approval requirements; code of conformance (applicable standard
specification number); applicable procedure number; QA data/records produced.
For Procurement and Construction: Activity description; procedure number,

inspection and test plan number, conformance code, testing and inspection code
(d) QA/QC procedure and quality plans will be discussed during kick-off meeting. Hold,
witness and verification points and Owner/Consultant/audit requirements will be
finalised between Contractor and Owner/Consultant.
(e) During the performance of the contract, the Contractor shall:
y
Implement approved quality assurance programme including but not limited to:
(i) Performance of internal quality audits, preparation of audit reports and
submission for review of Consultant. Contractor shall evolve a comprehensive
system of planned and documented audit to verify whether various performed
activities comply with detailed procedures, specifications, guidelines etc. and
to determine the effectiveness of quality system. Scope of such internal audits
shall be furnished to Consultant for review. Verification documents shall be
generated during audit and submitted periodically to Consultant for review.
Throughout all stages of the scope of contract, the Contractors procedures,
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documents, activities, products and services and those of his Sub-contractor's

shall be subject to Owner/Consultant review/approval. Such surveillance and
audit are optional and shall not relieve the Contractor of his contractual
obligations and liabilities.
(ii) Generation of QA records (mostly inspection and test plans) as per quality
plan and submission for review by Owner/Consultant. The Contractor shall
submit all quality records (generated during activity execution) and audit
results on well laid formats/performance for Owner/Consultant review. The
rights of such review are reserved by Owner/Consultant. Owner/Consultant
may review it in full, parts or selectively. However, complete correctness of
the QA records shall be the sole responsibility of the Contractor irrespective
of its review by Owner/Consultant.
y
Facilitate Owner/Consultant in the quality audit at works.
Certify QA Programme documents of Contractors and submit to Owner/Consultant

for review.
Carry out audits/inspection at Contractors works as per approved QA programme

and submit the reports for review by Owner/Consultant
Get similar QA system implemented at his Sub-contractors works/office. QA

records from the Contractor shall be reviewed and certified for compliance by the
Contractor before submitting to Owner/Consultant for information.
Carry out audits at Contractors' office/works and submit the report to

Owner/Consultant for information.
Ensure that all personnel shall be assigned tasks commensurate with their
qualification. Specialized workmen shall be qualified and certified.
Handle non-conformance brought out by internal and external sources as follows:

(i) Non-conformance brought out by Contractor's own review/audit shall be
resolved by Contractor himself. One level higher than those responsible to
carry-out the activity shall resolve the non-conformance. Such resolution shall
be in full knowledge of Departmental Manager. Corrective action shall be
initiated at the earliest. Report of such resolution shall be submitted to
Owner/Consultant for information.
(ii) Non-conformance brought out by Owner/Consultant through any of the
following shall be resolved by the Contractor. Such corrective actions shall be
submitted to Owner/Consultant for review. However, corrective action shall be
initiated at the earliest: technical reviews, QA review and surveillance,
inspection, external audit (Owner/Consultant)
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Glossary of Terms used in the Section
1.5.6
Hold Point: A point designed by Owner/Consultant in the approved quality plan

submitted by Contractor in the kick-off meeting which requires inspection/verification
and acceptance by Owner/Consultant before any further processing is permitted. The
Contractor shall not process the activity/item beyond a hold point without written
approval by Owner/Consultant except where prior writer permission for further
processing is available.
Witness Point: An activity designated by Owner/Consultant/Licensor which requires

witnessing by Owner/Consultant/Licensor as the activity is performed. After proper
notification has been provided (notification modalities and period shall be finalised in
kick-off meeting), the Contractor is not obliged to hold further processing if
Owner/Consultant is not available to witness the activity or does not provide
comments before the date notified. Basis of acceptance shall be as per relevant
technical specification.
Verification Point: A point where Owner/Consultant Plans to audit, monitor or witness

in-process activity. The Contractor is not obliged to provide any advance written
notification of these points. Basis of acceptance shall be as per relevant technical
specification.
Quality Surveillance: Monitoring or making observations to verify whether or not

material/items or services conform to specified requirements. Surveillance activities
may include audit, inspections, witness of testing, review of quality documentation,
personnel qualifications etc.
QA Records: Documents which demonstrate achievement of required quality and

verify effective operation of quality system, viz.
inspection reports, test
data/Inspection and test plans, qualifications reports, validation reports, audit report,
material review reports, calibration data.
Quality Audit: A systematic examination of the acts and decisions by people with
respect to quality in order to independently verify or evaluate and report degree of
compliance to the operational requirement of the quality programme, or the
specifications or contract requirements of the product or service.
Construction Equipment
The Contractor is required to organize and mobilize the construction equipment and other
tools tackles in a sequential manner to ensure that plant installation is carried out in a
mechanized manner and its mechanical completion is achieved within targeted time
schedule. The Contractor shall without prejudice to his responsibility to execute and
complete the work strictly as per the specifications and other laid down procedures by
mechanizing the construction activities to the maximum extent by deploying all necessary
construction equipment/machinery of adequate capacities and numbers. For this purpose,
the Contractor shall deploy a rigging team headed by a rigging foreman reporting to Area
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Engineer responsible for equipment erection. Area Engineer should be well conversant
with various erection techniques and shall be responsible for preparing erection schemes
in accordance with the approved procedures and based on crane manuals suiting to plan
layout. Area Engineer will have to foresee various other constructive activities in the
surroundings while planning erection schedules including safety aspects of man and
machinery also.
Contractor will prepare erection schedule based on the overall project schedule of the
plant in phased manner with erection schemes of various equipments, vessels and
submit to Owner/Consultant for approval, monitoring and control of erection schedule.
Erection activities will be carried out as per the approved construction procedures.
For efficient working and maintenance of construction aids, Contractor shall establish and
maintain crane yard/workshop equipped with regular maintenance facility for various
construction aids for carrying out routine field maintenance during performance for the
contract. Temporary approach road, wherever required for the movement of the crane
and other vehicles for equipment erection and transportation of material shall be properly
planned and be made by the Contractor for quick mobilisation of the transportation
system. The proper padding for the crane movement shall be done to avoid any delays of
erection schedule. Weekly/fortnightly maintenances shall be planned in such a way that it
should not hamper the erection schedule.
Contractor shall ensure the timely augmentation of the plant, equipment and machinery
depend upon the exigencies of the requirement to meet the overall project schedule.
During performances of the work, Contractor must ensure that structures, materials or
equipments are adequately braced by guys, struts or otherwise approved means which
shall be supplied and installed by the Contractor as required till the erection works is
satisfactorily completed. Such guys, shoring, bracing, strutting, planking supports etc.
shall not interfere with the work of other agencies and shall not damage or cause
distortion to other works executed by him or other agencies. Contractor to submit the
construction equipment schedule.
1.5.7
Construction Manpower
The Contractor is required to organise and mobilise construction staff in a sequential
manner to ensure that plant installation is carried out in accordance with the S curve
defined with other chapter of the Bid package. Mobilisation of construction staff should be
such that S curve based on the time schedule and progress achieved in the phased
manner should match with the overall project time schedule. For this purpose, the
Contractor shall clearly indicate in his construction methodology that work shall be done
departmentally or by engaging such Sub-contractor or the combination of both.
Contractor will prepare detailed methodology for the work to be carried out departmental
as well as by Sub-contractor clearly defining the scope and responsibility of main
Contractor and Sub-contractor.
During the execution of works at site, if the principal Contractor engages Sub-contractors
for execution of works at site as per approval obtained from Owner/Consultant in line with
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contract provisions and in the event Sub-contractor complains in writing to the Owner with
regard to the non-payment of their dues from the principal contractor for the works
executed by them and site (excluding final payments and payments due after termination
of Sub-contractors' services by the main contractor), Owner reserves their right to make
such payment to the Sub-contractors based on approved measurement with due notice to
the principal Contractor. Owner shall release such payments to Sub-contractor at the cost
and risk of the main Contractor in order to ensure smart execution of work at site. The
above such payment made by Owner to the Sub-contractor shall be adjusted in the
running account bills or any other payment due to the concerned principal contractor.
Contractor to submit the construction manpower schedule.
All Sub-contractors will be managed by the main Contractor construction staff who will
perform the duties of construction management and will administer, coordinate, and
inspect the work of the Sub-contractor and be responsible for the quality. The contractor
will establish the prerequisite for successful construction of sub-contractor work.
However, by deploying the Sub-contractors as approved by Owner/Consultant for any
discipline, does not absolve the principal Contractor for his total responsibility under the
subject contract.
The Contractor to ensure that in case of Sub-contract failure to execute the works as per
standards/specifications/drawings and negligence and disobedience in carrying out any
order or instruction of Owner/Consultant will be viewed very seriously and dealt with
appropriately in accordance with provisions of the contract. Contractor to submit the
construction manpower schedule alongwith the bid.
1.6
QA System/Inspection Requirements for Bought Out Items & During Construction
1.6.1
Contractors are required to follow a well-documented quality assurance and quality

control system covering all phases of project viz. engineering, procurement, installation,
testing and commissioning. Similarly, Contractors are required to develop their own
resources for inspection of all bought-out items supported by third party inspection
services for specific cases.
1.6.2
Specification for Turn-Key Bidder's Quality Assurance System
(a)
Introduction
This specification establishes the quality assurance requirements to be met by the
turnkey bidder during execution of contracted services. in case of any conflict between
the requirements of this specification and other documents such as technical
specifications, contract conditions etc., the contractor shall notify Owner/Consultant of all
such conflicts for final resolution.
(b)
Scope of Work by Contractor

Prior to the award of contract, the following documents shall be submitted along with the
bid for evaluation:
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Quality policy
Quality objective
Company quality manual
Project quality plans
Copy of certificate of approval of quality management system
After the award of contract, within four weeks after the award of the contract, the
Contractor shall participate in the pre-start meeting with Owner/Consultant to finalize
Project Quality Plans as regards to the following:
y
Standard practices specified by the Contractor
Hold, witness and verification point
Owner/Consultants review/audit requirements
During job execution, implement approved project quality plan including but not limited to:
y
Performance of internal quality audits, preparation of audit reports and submission for
Owner/Consultant's review.
Generation of QA records as per quality plan and submission for Owner/Consultant's

review.
Records of management review of quality system
Contract review records
Design review, verification and validators records
Assessment records of acceptable vendors/sub-vendors
Records of nonconformity
Records of external quality audit
Records of training
Inspection reports
Test data/inspection and test plans
Qualification reports
Material review reports
Calibration data
Quality cost report
Schedule control and progress reports
Facilitate Owner/Consultant in the quality audit at his works.
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Certify QA Programme documents of sub-contractor and submission for review to

Owner/Consultant.
Carry out audits/inspection at sub-contractor's works as per approved QA programme

and submit the reports for Owner/Consultant's review.
Quality Assurance System Requirement

y
Requirements stipulated in this specification shall be fulfilled by the Contractor/Subcontractor. All other features of QA System shall be as per Contractors standards.
The Contractor shall ensure that the quality system is clearly understood and faithfully
implemented at all levels in his organisation.
The Contractor shall develop quality consciousness among all personnel working for
the contract.
Non-conformances brought out by Contractors/Sub-contractors own internal

review/audit shall be resolved by Contractors'/Sub-contractors, themselves. One level
higher than those responsible to carry out the activity shall resolve the nonconformances. Such resolution shall be in full knowledge of Departmental Manager.
Corrective action shall be initiated at the earliest. Report of such resolution shall be
submitted to Owner/Consultant for information.
Non-conformances brought out by Owner/Consultant through any of the following:

technical reviews, QA reviews and surveillance, inspection, external audit
(Owner/Consultant), post construction quality audit (by Owner/Consultant) to be
carried out immediately after declaration of mechanical completion by the Contractor.
Non-conformances brought out due to the above, shall be resolved by the
Contractor/Sub-contractor. Such corrective actions shall be submitted to
Owner/Consultant for review. However, corrective action shall be initiated at the
earliest.
The Contractor shall evolve a comprehensive system of planned and documented

audit to verify whether various performed activities comply with detailed procedures,
specifications, guidelines etc. and to determine the effectiveness of quality system.
Scope of such internal audits shall be furnished to Owner/Consultant for review.
Verifiable documents shall be generated during audit and submitted periodically to
Owner/Consultant for review. Audits shall be carried out by independent engineers
not responsible for execution of the activity to be audited.
Throughout all stages of the scope of contract, the Contractor's procedures,

documents, activities, products and services and those of his Sub-contractors' shall
be subjected to quality surveillance and audit by Owner/Consultant. Such surveillance
and audit are optional and shall not relieve the Contractor of his contractual
obligations and liabilities.
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The Contractor shall submit all quality records (generated during activity execution)
and audit results on well laid formats/proforma for Owner/Consultant's review. The
rights of such review are reserved by Owner/Consultant. Owner/Consultant may
review it in full, parts or selectively. However, completes correctness of the QA
records shall be the sole responsibility of the Contractor irrespective of its review by
Owner/Consultant.
The Contractor shall get similar QA system implemented at his Subcontractors

works/office. QA records from the Subcontractor shall be reviewed and certified for
compliance by the Contractor before submitting to Owner/Consultant for information.
Contractor shall carry out audits at Subcontractors, office/works and shall submit the
report to Owner/Consultant for information.
All personnel shall be assigned tasks commensurate with their qualification.

Specialized operators shall be qualified and certified. The Contractor shall have a
system for identifying personnel training needs in line with the latest ISO guidelines.
Immediately after submitting written declaration of mechanical completion by the

Contractor, Owner/Consultant will carry out post-construction quality audit. Contractor
shall extend all help and cooperation to carry out this audit including providing all
necessary resources to Owner/Consultant and shall implement all corrective
measures, based on the post-construction quality audit findings and observations at
no cost to the Owner/Consultant.
1.7
Inspection Coordination Methodology
1.7.1
All equipment and materials are to be procured from vendors listed in the approved
Vendor List enclosed in this Bid, or from other reputed vendors after obtaining specific
approval of the Owner/Consultant. In this regard, no difference is made between the
equipment and materials purchased by the contractor directly or by his contracted
agencies.
1.7.2
After finalisation of purchase order, a detailed QA/QC plan shall be developed by the
vendor, duly reviewed by the Contractor and shall be submitted for approval of the
Owner/Consultant. It is envisaged that QA/QC plans for the critical Items shall be
reviewed/approved by the Owner/Consultant and for the balance items QA/QC plans
shall be submitted for records. The management of quality control system is to be
developed generally based on the categorisation of various equipment and materials.
Preliminary categorisation of various items involved is enclosed. For items not included
here, categorisation shall be decided during detailed engineering and Owner/Consultant
may change inspection category based on final information and quantities. For
indigenous items, consultant shall carry out inspection as deemed necessary. For
imported items, contractor should engage Owner/Consultant approved Third Party
Inspector (TPI). Each stage of inspection by the TPI, must define whether it is a hold
point, witness point, verification point or internal inspection point by the vendor.
Contractor shall make independent QA Plans through the approved Third Party Agency
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which shall be having a confirmation of meeting the minimum inspection requirements

spelt out. All inspection stages where Owner/Consultant desires to participate (which
shall be preferably only for critical items) shall be marked on the QA/QC plan and these
stages must necessarily be attended by the Contractor in addition to the other stages
being attended by him. In case the QA/QC plans are not submitted in sufficient detail, the
Contractor may be asked to re-submit the plans.
1.7.3
The personnel to be deployed by the third party inspection agency must have adequate
qualification and experience for the type of work involved and the owner may ask for
approval of the personnel employed for the job and his replacement, if required.
1.7.4
The Contractor shall submit a detailed vendor's inspection schedule for the coming two
months at the beginning of each month as well as notify owner's involvement at the
appropriate inspection stage, giving a clear notice period of 15 days. The contractor shall
submit monthly inspection and expediting reports of the inspection agency regularly to the
Owner/Consultant.
1.7.5
Consultants inspector shall witness the test on a mutually agreed the date according to
contractor's inspection notification, wherever applicable.
1.7.6
Submission of category-wise inspection plan by Contractor at Consultant HO for review. It

is envisaged that the QA/QC plans shall be submitted to the Consultant in accordance
with the clauses as defined above.
1.7.7
After finalisation of the vendor, the copy of PO or technical specification for sub-ordered
items along with QAP will be submitted by Contractor to Consultant covering the location
where the sub-ordered items are manufactured. The QAP is to be duly approved by the
Consultant.
1.7.8
Contractor will be totally responsible for furnishing the complete and correct technical
document/specifications to his sub-vendor. It is responsibility of the contractor to ensure
that relevant specifications indicated in the tender documents are incorporated in the suborder/sub-order specification. Each PO shall categorically indicate involvement of various
agencies for inspection.
1.7.9
Contractor shall forward the approved copy of relevant drawings/documents to the TPI
before giving inspection call. The final inspection will he done by the TPI, based upon
drawings/documents reviewed by TPI/Consultant in Code AP (Approved) wherever
applicable.
1.7.10 Contractor will ensure presence of their inspection engineer at sub-vendor's works during
inspection by TPI or Owner/Consultant inspection engineer (wherever applicable).
1.7.11 Contractor shall expedite to ensure delivery of all the materials as per CDD.
1.7.12 All correspondence by contractor to the Consultant for submission of documents and
inspection calls shall also be intimated to Owner.
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1.7.13 A list of items generally covered in a tendered package is enclosed. The list has been
generally categorised as A, B, C, D and S.
Category A
Stage-wise and final inspection with document review
Category B
Final inspection and document review
Category C
Document review only
Category D
Direct despatch to site with test certificates
Category S
Selective inspection for package
Scope of inspection (indicative) by Owner/Consultant for various items shall generally be

as per the above category. Categorisation shall however be finalized during the execution
phase of the Project/s. QAP documents for the categories, once finalized shall be
submitted for Owner/Consultant review/approval/records.
1.7.14 The minimum involvement of Contractor's inspection for indigenous equipment will be:
y For item wherever category of inspection indicated by Consultant as A, Contractor's
inspection shall also be Category A.
y Wherever inspection of Consultant is under Category B, inspection by contractor will
be Category A.
y For items where inspection of Consultant is under Category C and D, the category of
inspection by the contractor will be category B and C respectively.
After completion of all stages of inspection as per approved Inspection Test Plans (ITP),
the TPIA (Third Party Inspection Agency) shall prepare an inspection release note.
Alongwith the inspection release note, test certificate and record will be provided to the
Contractor and the Consultant. Methodology of routing of the inspection release notes
and related inspection documents for endorsement by Consultant if required for critical
documents will be spelt out during the kickoff meeting with the successful bidder.
It shall be contractor's responsibility to ensure availability of following documents at
location of inspection to Third Party Inspection prior to his inspection:
y Consultants approved /reviewed drawing/data sheet
y Test certificates and test records of vendor
1.8
Typical Inspection Requirement During Construction for a Turnkey Package
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Management of construction quality control system is divided into following categories:

y Procurement of Materials Required for Construction Works: A sample list of materials
defining the categories is enclosed as Table-1. Visual inspection and review of test
records/certificates, release notes of contractor to be submitted to Consultant site by
Contractor for acceptance as per Table-2. List of such materials will be submitted to
Owner/Consultant for categorisation after award of sub-contract against each type of
work, viz. civil/structural, mechanical, electrical, instrumentation etc. is given in Table
3 to 6.
y Execution of Works: It is foreseen that the contractor shall get the works executed by
employing sub-contractors. Before starting the work, all procedures/documents
concerning the quality plans shall be frozen after approval of Owner/Consultant. For
drawing up the Inspection Test Plans (ITP) for various works at site, these shall also
be categorised (sample categorisation is enclosed as, Table-7).
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Table-1: List of Materials to be Procured at Site for Civil Works

SN Description of construction
process/job
Category on
basis of
criticality
Cement
Coarse aggregate
Fine aggregate
Stone aggregate for road work
Filling soil
Murrum/sand etc.
Water
Bricks and tile brick
Reinforcement steel
10
Structural steel
11
Asphalt for road work
12
Paint
13
Sanitary wares
14
Sanitary fittings
15
Chemical for anti-termite treatment
16
Acid resistant tile and mortar
17
AC/GI/Color-coated sheets
18
Steel doors
20
Aluminium doors
21
Marble and marble chips
22
Metallic hardener for flooring
23
Grouting compound
24
Wood for doors windows, ventilator
25
Flush door
26
Panelled door
27
Particle board
36
Roof insulation material
37
Gratings/chequered plates
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Remarks
C/C/B
Cement/epoxy grouts
B/B
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Legend
A Critical sampling by contractor in presence of Consultant, verification of records by
contractor and review of records by Consultant.
B Major sampling and verification of records by contractor; visual inspection and review
of records by Consultant.
C Minor sampling and verification of records by contractors; visual inspection and
review of material receipt and inspection report of contractor by Consultant.
(Records mean manufacturer's test certificate; any outside laboratory/field laboratory test
report; material receipt report submitted by contractor; inspection report of contractor).
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Table-2: Scope of Consultant/Owner Review for Materials Procured at Site
SN
1.
Description of Activity
Sampling for tests
Category
Remark
Contractor
Contractor
Contractor
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
2.
Visual inspection
3.
Verification of Records
a.
Manufacturer's test
certificate
Contractor
Contractor
Contractor
b.
Laboratory test
Contractor
Contractor
Contractor
c.
Material receipt report
Contractor
Contractor
Contractor
d.
Inspection report of
contractor
Contractor
Contractor
Contractor
Review of Records
a.
Manufacturer's test
certificate
Consultant
/Owner
Consultant
/Owner
b.
Laboratory test
Consultant
/Owner
Consultant
/Owner
c.
Material receipt report
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
d.
Inspection report of
contractor
Consultant
/Owner
Owner
Note:
Consultant
/Owner
As per contract, all approvals shall be done by Consultant/Owner.

For categorization of materials refer Table-1.
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Table-3: Categorization of Constructional Activities/Jobs

Discipline: Civil Works
SN
Description of construction activity/job
1.
2.
3.
4.
a.
b.
5.
Excavation in all types of strata

Back-filling
Site-grading/micro-grading/site cleaning
Layout
Initial (grid filter and BM)
Further internal layout
PCC below foundation
6.
RCC in foundation including piles
7.
RCC in super-structure
8.
Roofing CGI/AC sheets
9.
Painting (building works)
10.
Steel doors/window/ventilators
11.
12.
13.
14.
Water proofing/roof insulation

Hand rails/toe guards/gratings
WBM works for road work
Structural fabrication and erection
Category on
basis of criticality
C
B
C for cutting
Remarks
A
C
C for cutting area
B for filled-up area
A for equipment
B for buildings
C for balance works
A for equipment
B for buildings
C for balance works
B for main buildings
C for balance sheds
B for main plant buildings
C for balance works
B for main plant buildings
C for balance works
B for all buildings
B for all works
B for all works
B for all works
Legend
A Stage-wise inspection as per ITP by Owner/Consultant in addition to Contractor.
B Stage-wise inspection by contractor as per ITP and final inspection by
Owner/Consultant along with review of records maintained by contractor during
erection/execution.
C Review of contractor's stage-wise inspection records by Owner/Consultant.
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Discipline: Mechanical Works
SN
Description of construction activity/job
Category on
basis of
criticality
1.
Static Equipment (Shop-fabricated)
a.
Mounded Bullet/ Drain vessels
2.
Static Equipment (Site-fabricated)
a.
Mounded Bullet
b.
Miscellaneous
3.
Welding, heat treatment and NDT
4.
Painting and insulation
Remarks
Legend
erection/execution.
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Discipline: Electrical Works
SN Description of construction activity/job
Category on
basis of
criticality
1.
Cable trays
2.
Cable Laying
a.
LT & controls
3.
CP System
4.
Earthing
Remarks
Legend
erection/execution.
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Discipline: Instrumentation Works
SN Description of construction activity/job
1.
2.
a.
b.
d.
e.
f.
g.
h.
i.
j.
k.
m.
n.
p.
r.
3.
a.
b.
c.
d.
e.
f.
Receipt of material at site contractor's

scope
Field Instrumentation Works
Underground cable trench
Cable tray erection
Inst. Stanchion fabrication/erection
Calibration of instruments
Instrument installation
Junction box installation
Cable laying, glanding, termination &
clamping
Impulse tubing/piping
Pressure/hydrotesting of impulse
tubing/piping
Back filling of cable trench
Pneumatic tubing
Pressure test/leak test of air/pneumatic
tubing
Earthing
Loop testing
Existing Control Room Works Related with
DCS(TFMS & NRMT)
Interfacing of equipments with each other
Internal loop testing
Loop testing
Interlock checking
Site acceptance test
Emergency shutdown check
Category on
basis of
criticality
Remarks
B
B
B
C
A
B
B
B
B
A
B
B
A
A
A
B
A
A
A
A
A
Legend
erection/execution.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
EM163-PNPM-003

ASSAM.
Document No.
Rev.
Sheet 46 of 46
Table-7: Scope of Consultant/Owner Review for Construction Activities/Jobs

SN Description of Activity
1.
2.
Category
Remarks
Stage-wise inspection
Contractor,
Contractor
Contractor
as per ITP
Consultant
/Owner
Final inspection
Contractor,
Contractor
Contractor
Contractor
Contractor
Contractor
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner
Consultant
/Owner/
3.
Gen./verification of
stagewise inspection records
Review of stage-wise
inspection records
Note: As per contract, all approvals shall be done by Consultant/Owner.

For categorization of construction activities/jobs refer Table-3 to 6.
Form No.: 02-0000-0021F2 Rev1
All rights reserved
PROJEC
CTS & DEV
VELOPMEN
NT INDIA LTD
L
EM163-MB-ANNEX
X-HSE
DO
OCUMENT NO.
RE
EV
GENERAL
L GUIDE
ELINES
FOR
HEAL
LTH, SAFETY AND ENV
VIRONMENT (HS
SE)
AT
LIGARH REFINE
ERY, AS
SSAM
NUMAL
Abbreviations:
AERB
ANSI
BARC
BS
PDIL
ELCB
EPC
EPCC
ESI
GCC
GM
GTAW
HOD
HSE
HV
IS
IE
JSA
LOTO
LPG
LSTK
MV
PPE
RCM
ROW
SCC
SLI
TBM
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Atomic Energy Regulatory Board

American National Standards Institute
Bhabha Atomic Research Centre
British Standard
Projects & development India Limited
Earth Leakage Circuit Breaker
Engineering, Procurement and Construction
Engineering, Procurement, Construction and Commissioning
Employee State Insurance
General Conditions of Contract
General Manager
Gas Tungsten Arc Welding
Head of Department
Health, Safety & Environment
High Voltage
Indian Standard
Indian Electricity
Job Safety Analysis
Lock Out & Tag Out
Liquefied Petroleum Gas
Lump Sum Turn Key
Medium Voltage
Personal Protective Equipment
Resident Construction Manager or Site-in-Charge, as applicable
Right of Way
Special Conditions of Contract
Safe Load Indicator
Tool Box Talks
Construction Standards Committee

Convenor :
Sh.
Members :
Sh.
Sh.
Sh
Sh.
Sh.
Sh.
CONTENTS
CLAUSE
TITLE
PAGE NO.
1.0
2.0
Scope
References
5
5
3.0
Requirement of Health, Safety and Environment (HSE) Management

System to be complied by Bidders
3.1
Management Responsibility
3.1.1
HSE Policy & Objective
3.1.2
Management System
3.2
3.3
5
5
5
3.1.3
Indemnification
3.1.4
3.1.5
Deployment & Qualification of Safety

Personnel
Implementation, Inspection & Monitoring
3.1.6
Behavior Based Safety
3.1.7
3.1.8
Awareness
Fire prevention & First-Aid
9
9
3.1.9
3.1.10
3.1.11
Documentation
Audit
Meetings
9
10
10
3.1.12
Intoxicating drinks & drugs and smoking
11
3.1.13
Penalty
11
3.1.14
Accident/Incident investigation
14
House Keeping
HSE Measures
3.3.1
Construction Hazards
3.3.2
Accessibility
14
15
15
16
3.3.3
Personal Protective Equipments (PPEs)
16
3.3.4
Working at height
17
3.3.5
Scaffoldings
18
3.3.6
Electrical installations
19
3.3.7
Welding/Gas cutting
21
3.3.8
Ergonomics and tools & tackles
22
3.3.9
3.3.10
Occupational Health
Hazardous substances
22
23
3.3.11
Slips, trips & falls
23
3.3.12
3.3.13
3.3.14
3.3.15
3.3.16
3.3.17
3.3.18
Radiation exposure
Explosives/Blasting operations
Demolition/Dismantling
Road Safety
Welfare measures
Environment Protection
Rules & Regulations
23
24
24
24
25
25
26
Contd to page 4
CONTENTS (contd. from page 3)
4.0
3.3.19
Weather Protection
3.3.20
Communication
3.3.21
Confined Space Entry
3.3.22
Heavy Lifts
3.3.23
Key performance indicators
3.3.24
Unsuitable Land Conditions
3.3.25
Under Water Inspection
3.3.26
Excavation
3.4
Tool Box talks
3.5
Training & Induction Programme
3.6
Additional safety requirements for working Inside a running
3.7
Self Assessment and Enhancement
3.8
HSE Promotion
3.9
LOTO for isolation of energy source
Details of HSE Management System by Contractor
4.1
On Award of Contract
4.2
During Job Execution
4.3
During short listing of the sub-contractors
Records
5.0
Appendices
1.
Standards/Codes on HSE
2.
Details of First AID Box
3.
Types of Fire Extinguishers & their Appln.
4.
Indicative List of statutory Acts & Rules
5.
Construction Hazards and their mitigation
6.
Training subjects / topics
7.
Construction Power Board ( typ)
8.
List of HSE procedures
Attachments (Reporting Formats)
I.
Safety Walk through Report
II.
Accident/Incident Report
III.
Suppl. Accident/Incident Investigation Report
Near Miss Incident Report/Dangerous occurrence
IV.
V.
Monthly HSE Report
VI.
Permit for Working at height
VII.
Permit for Working in Confined Space
VIII.
Permit for Radiation work
IX.
Permit for Demolishing/ Dismantling
X
Daily Safety Checklist
XI
Housekeeping assessment & compliance
XII
Inspection of temporary electrical booth / installation
XIII
Inspection for scaffolding
XIV
Permit for erection / modification & dismantling of
scaffolding
XV
Permit for heavy lift/critical erection
XVI
Permit Energy Isolation & De-Isolation
XVI
Permit for Excavation
Appendix-A
Appendix-B
Appendix-C
Appendix-D
Appendix-E
Appendix-F
Appendix-G
Appendix-H
HSE-1 Rev.0
HSE-2 Rev.0
HSE-3 Rev.0
HSE-4 Rev.0
HSE-5 Rev.0
HSE-6 Rev.0
HSE-7 Rev.0
HSE-8 Rev.0
HSE-9 Rev.0
HSE-10 Rev.0
HSE-11 Rev.0
HSE-12 Rev.0
HSE-13 Rev.0
HSE-14 Rev.0
HSE-15 Rev.0
HSE-16 Rev 0
HSE-17 Rev 0
26
26
27
27
27
28
28
28
29
30
31
32
32
32
33
33
34
35
STANDARD SPECIFICATION FOR

HEALTH, SAFETY &
ENVIRONMENT MANAGEMENT
AT CONSTRUCTION SITES
1.0
SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/Vendors including their sub-contractors/sub vendors
during construction.
This specification is not intended to replace the necessary professional judgment needed to
design & implement an effective HSE system for construction activities and the contractor is
expected to fulfill HSE requirements in this specification as a minimum. It is expected that
contractor shall implement best HSE practices beyond whatever are mentioned in this
specification.
Requirements stipulated in this specification shall supplement the requirements of HSE
Management given in relevant Act(s)/legislations, General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job (Technical) Specifications.
Where different
documents stipulate different requirements, the most stringent shall apply.
2.0
REFERENCES
The document should be read in conjunction with following:
-
General Conditions of Contract (GCC)

Special Conditions of Contract (SCC)
Building and other construction workers Act,
Indian Factories Act
Job (Technical) specifications
Relevant International / National Codes (refer Appendix-A for standards/codes on HSE)
Relevant State & National Statutory requirements.
Operating Manuals Recommendation of Manufacturer of various construction Machineries
3.0
REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT

SYSTEM TO BE COMPLIED BY BIDDERS
3.1
Management Responsibility
3.1.1
HSE Policy & Objectives

The Contractor should have a documented HSE policy duly & objectives to demonstrate
commitment of their organization to ensure health, safety and environment aspects in their line
of operations.
HSE Policy of the contractor shall be made available to Owner / PDIL at the place of execution of
specific contract works, as a valid document.
3.1.2
Management System
The HSE management system of the Contractor shall cover the HSE requirements &
commitments to fulfill them, including but not limited to what are specified under clause 1.0
and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan from PDIL /
Owner prior to commencement of any site works. Corporate as well as Site management of the
Contractor shall ensure compliance of their HSE Plan at work sites in its entirety & in true
spirit.

HEALTH, SAFETY &
3.1.3
Indemnification
Contractor shall indemnify & hold harmless, Owner/PDIL & their representatives, free from any
and all liabilities arising out of non-fulfillment of HSE requirements or its consequences.
3.1.4
Deployment & qualifications of Safety personnel

The Contractor shall designate/deploy various categories of HSE personnel at site as indicated
below in sufficient number. In no case, deployment of safety Supervisor / Safety Steward shall
substitute deployment of Safety Officer / Safety Engr what is indicated in relevant statute of
BOCW Act i.e deployment of safety officer/Safety Engineer is compulsory at project site. The
Safety supervisors, Safety stewards etc. would facilitate the HSE tasks at grass root level for
construction sites and shall assist Safety Officer / Engineers.
a)
Safety Steward
For every 250 workmen, one safety steward shall be deployed.
As a minimum, he shall preferably possess School leaving Certificate (of Class XII with
Physics & Chemistry etc.) and trained in fire-fighting as well as in safety/occupational
health related subjects, with minimum two year of practical experience in construction
work environment and preferably have adequate knowledge of the language spoken by
majority of the workers at the construction site.
b)
Safety Supervisor
For every 500workmen, one safety Supervisor shall be deployed.
As a minimum, he shall possess a recognized Degree in Science (with Physics &
Chemistry) or a diploma in Engg. or Tech. with minimum Two years of practical
experience in construction work environment and should possess requisite skills
with construction safety & fire related day-to-day issues.
c)
to deal
Safety Officer / Safety Engineer

One for every 1000 workers or part thereof shall be deployed.
Safety officer/Engineer Should Possess following Qualification & Experience :
(i)
Recognized degree in any branch of Engg. or Tech. or Architecture with practical

experience of working in a building or other construction work in supervisory
capacity for a period of not less than two years, or possessing recognized diploma in
any branch of Engg. or Tech with practical experience of building or other
construction work in supervisory capacity for a period of not less than five years.
(ii)
Recognized degree or diploma in Industrial safety with one paper in Construction

Safety
(iii)
Preferably have adequate knowledge of the language spoken by majority of the

workers at the construction site.
Alternately
(i)
Person possessing Graduation Degree in Science with Physics & Chemistry

and
degree or diploma in Industrial Safety (from any Indian institutes recognized by

HEALTH, SAFETY &
AICTE or State Council of Tech. Education of any Indian State) with practical
experience of working in a building, plant or other construction works (as Safety
Officer, in line with Indian Factories Act, 1958) for a period of not less than five
years, may be considered as Safety Officer, in case Owner/Client of the project
agrees for /approves the same.
d)
HSE In-Charge
In case there is more than one Safety Officer at any project construction site, one of them,
who is senior most by experience (in HSE discipline), may be designated as HSE InCharge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of Client and contractors.
In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like
the Building and Other Construction Workers Regulation of Employment and Conditions
of Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same shall be
followed.
Contractors shall ensure physical availability of safety personnel at the place of specific
work location, where Hot Work Permit is required / granted. No work shall be started at
any of the project sites until above safety personnel & concerned Site Engineer of
Contractor are physically deployed at site. The Contractor shall submit a HSE organogram
clearly indicating the lines of responsibility and reporting system and elaborate the
responsibilities of safety personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and furnish
Bio-Data/ Resume/ Curriculum Vitae of the safety personnel as above for PDIL/Owners
approval, at least 1 month before the mobilization. The Contractor, whenever required,
shall arrange submission of original testimonials/certificates of their Safety personnel, to
PDIL/Owner (for verification/scrutiny, etc.)
Imposition / Realization of penalty shall not absolve the Contractor from his/her
responsibility of deploying competent safety officer at site.
Adequate planning and deployment of safety personnel shall be ensured by the Contractor
so that field activities do not get affected because of non-deployment of competent &
qualified safety people in appropriate numbers.
3.1.5
Implementation, Inspection/Monitoring
x
The Contractor shall be fully responsible for planning, reporting, implementing and
x monitoring all HSE requirements and compliance of all laws & statutory requirements.
The Contractor shall also ensure that the HSE requirements are clearly understood &
x implemented conscientiously by their site personnel at all levels at site.
The Contractor shall ensure physical presence of their field engineers / supervisors, during
the continuation of their contract works / site activities including all material transportation
activities. Physical absence of experienced field engineers / supervisors of Contractor at
critical work spot during the course of work, may invite severe penalization as per the
x discretion of EIC, including halting / stoppage of work.
Contractor shall furnish their annual Inspection Plan, with regard to project issues /subjects,
x frequency and performers to PDIL/Owner.
The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.

HEALTH, SAFETY &
3.1.6
The Contractor shall ensure important safety checks right from beginning of works at every
work site locations and to this effect format No: HSE-10 Daily Safety Check List shall
be prepared by field engineer & duly checked by safety personnel for conformance.
The Contractor shall carry out inspection to identify various unsafe conditions of work
sites/machinery/equipments as well as unsafe acts on the part of
workmen/supervisor/engineer while carrying out different project related works.
Adequate records for all inspections shall be maintained by the Contractor and the same
shall be furnished to PDIL/Owner, whenever sought.
The Contractor shall not carry-out work by engaging single worker anywhere without any
supervisor anytime during day or night.
To demonstrate involvement/commitment of site management of Contractor, at least one
Safety Walk through in a month shall be carried out by Contractors head of site (along
with his area manager/field engineers) and a report shall be furnished to PDIL/Owner as per
format No: HSE-1 Safety walk through report followed by compliance for unsatisfactory
remarks.
As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected,
tested and examined by competent people (approved by concerned State authorities) before
being used at site and also at periodical interval (e.g. during replacement,extension,
modification, elongation/reduction of machine/parts, etc.) as per relevant statutes. Hydra,
cranes, lifting machinery, mobile equipments / machinery / vehicles, etc. shall be inspected
regularly by only competent / experienced personnel at site and requisite records for such
inspections shall be maintained by every contractor. Contractor shall also maintain records
of maintenance of all other site machinery (e.g. generators, rectifiers, compressors, cutters,
etc.) & portable tools/equipments being used at project related works (e.g. drills, abrasive
wheels, punches, chisels, spanners, etc.). The Contractor shall not make use of arbitrarily
fabricated derricks at project site for lifting / lowering of construction materials.
Site facilities /temporary. installations, e.g. batching plant, cement godown, DG-room,
temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc.
and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motor
cycle/bicycle-shed, site washing facilities, First-aid centers, urinals/toilets, etc. should be
periodically inspected by Contractor (preferably utilizing HR/Admn. personnel to inspect
site welfare facilities) and records to be maintained.
Behaviour Based Safety

x
x
The contractor shall develop a system to implement Behaviour-Based Safety (BBS)

through which work groups can identify, measure and change the behaviours of employees
and workers
The BBS process shall include the following:
Identify the behaviours critical to obtaining required safety performance.
Communicate the behaviours and how they are performed correctly to all
Observe the work force and record safe/at risk behaviours. Intervene with workers
to give positive reinforcement when safe behaviours are observed. Provide
coaching/correction when at risk behaviours are observed
Collect and record observation data
Summarize and analyze observation data
Communicate observation data and analysis results to all employees
Provide recognition or celebrate when safe behaviour improvements occur
Change behaviours to be observed or change activators or change consequences as
appropriate.
Communicate any changes to workforce
Contractor through its own HSE committee shall implement the above process.
The necessary procedures and reporting formats shall be developed by the contractor for
approval by PDIL/Owner.

HEALTH, SAFETY &
3.1.7
The HSE committee of contractor shall observe individuals behavior for safe practices
adapted for utilization/execution of work for following as a minimum:PPE
Tools & equipment
Hazard Identification & control
House keeping
Confined space entry
Hot works
Excavation
Loading & unloading
Work At height
Stacking & storage
Ergonomics
Procedures
Awareness and Motivation

x
3.1.8
The Contractor shall promote and develop awareness on Health, Safety and Environment
protection among all personnel working for the Contractor.
Regular awareness programs and fabrication shop / work site meetings at least on monthly
x
basis shall be arranged on HSE activities to cover hazards/risks involved in various
operations during construction.
x
Contractor to motivate & encourage the workmen & supervisory staff by issuing /
awarding them with tokens/ gifts/ mementos/ monetary incentives / certificates, etc.
x Contractor shall assess & recognize the behavioral change of its site engineers / supervisors
periodically and constantly motivate / encourage them to implement HSE practices at
project works
Fire prevention & First-Aid
x
x
x
x
x
3.1.9
The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer
Appendix-B for details), trained personnel/nurse (male) to administer First Aid, stand-by
Ambulance vehicle and
fire protection measures such as adequate
The Contractor shall arrange installation of
number of steel buckets with sand & water and adequate number of appropriate portable
fire extinguishers (Refer Appendix-C for details) to the satisfaction of PDIL/Owner.
The Contractor shall deploy trained supervisory personnel / field engineers to cater to any
emergency situation.
In case the number of workers exceeds 500, the Contractor shall position an Ambulance /
vehicle and nurse on round the clock basis very close to the worksite.
The Contractor shall arrange FIRE DRILL at each site at least once in three months,
involving site workmen and site supervisory personnel & engineers. The Contractor shall
maintain adequate record of such fire drills at project site
Documentation
The Contractor shall evolve a comprehensive, planned and documented system covering the
following as a minimum for implementation and monitoring of the HSE requirements and the
same shall be submitted for approval by owner/PDIL.
HSE Organogram
Site specific HSE Plan
Safety Procedures, forms and Checklist. Indicative list of HSE procedures is attached as
Appendix :H
Inspections and Test Plan
Risk Assessment & Job Safety Analysis for critical works.

HEALTH, SAFETY &
The monitoring for implementation shall be done by regular inspections and compliance of
the observations thereof. The Contractor shall get similar HSE requirements implemented
at his sub-contractor(s) work site/office. However, compliance of HSE requirements shall
be the responsibility of the Contractor.
Any review/approval by PDIL/Owner shall not
absolve contractor of his responsibility/liability in relation to fulfilling all HSE
requirements.
3.1.10 Audit
The Contractor shall submit an Audit Plan to PDIL/Owner indicating the type of audits and
covering following as minimum:
x
Internal HSE audits regularly at least on quarterly basis by engaging internal

qualified
auditors (viz safety officers/Construction personnel having 5 years experience in
construction safety and Lead Auditor Course :OSHA 18001certification).
External HSE audits regularly at least on every six months by engaging qualified external
auditors (viz safety officers/Construction personnel having 10 years experience in
construction safety and Lead Auditor Course :OSHA 18001certification).
All HSE shortfalls/ non-conformances on HSE matters brought out during review/audit, shall be
resolved forthwith ( generally within a week) by Contractor & compliance report shall be
submitted to PDIL/Owner.
In addition to above audits by contractor, the contractors work shall be subjected to HSE audit
by PDIL/Owner at any point of time during the pendency of contract. The CONTRACTOR shall
take all actions required to comply with the findings of the Audit Report and issue regular
Compliance Reports for the same to OWNER/ PDIL till all the findings of the Audit Report are
fully complied.
Failure to carry-out HSE Audits & its compliance (internal & external) by Contractor, shall
invite penalization.
3.1.11 Meetings
x
The Contractor shall ensure participation of his top most executive at site (viz. Resident
Construction Manager / Resident Engineer / Project Manager / Site-in-Charge) in Safety
Committee / HSE Committee meetings arranged by PDIL/Owner usually on monthly basis
or as and when called for.
In case Contractors top most executive at site is not in a
position to attend such meeting, he shall inform PDIL/Owner in writing before the
commencement of such meeting indicating reasons of his absence and nominate his
representative failure to do so may invite very stringent penalization against the specific
Contractor, as deemed fit in Contract. The obligation of compliance of any observations
during the meeting shall be always time bound.
The Contractor shall always assist
PDIL/Owner to achieve the targets set by them on HSE management during the project
implementation.
In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most
executive at site on weekly basis and maintain records. Such internal HSE meetings shall
essentially be attended by field engineers / supervisors (& not by safety personnel only) of
the Contractor and its associates. Records of such internal HSE meetings shall be
maintained by the Contractor for review by PDIL/Owner or for any HSE Audits.
Agenda of internal HSE meeting should broadly cover: -

HEALTH, SAFETY &
a)
b)
c)
d)
e)
f)
g)
h)
i)
Confirmation of record notes / minutes of previous meeting

Discussion on outstanding subjects of previous points / subjects, if any
Incidents / Accidents (of all types) at project site, if any
Current topics related to site activities / subjects of discussion
House keeping
Behavioral Safety
Information / views / deliberations of members / site sub Contractors
Report from Owner / Client
Status of Safety awareness, Induction programs & Training programs
The time frame for such HSE meeting shall be religiously maintained by one and all.
3.1.12 Intoxicating drinks & drugs and Smoking
x
x
The Contractor shall ensure that his staff members & workers (permanent as well casual)
shall not be in a state of intoxication during working hours and shall abide by any law
relating to consumption & possession of intoxicating drinks or drugs in force.
The Contractor shall not allow any workman to commence any work at any locations of
project activity who is/are influenced / effected with the intake of alcohol, drugs or any
other intoxicating items being consumed prior to start of work or working day.
Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
The Contractor shall ensure that all personnel working for him comply with No-Smoking
requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition
tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be
allowed inside the project / plant complex.
Smoking shall be permitted only inside smoking booths exclusively designated &
authorized by the Owner/PDIL.
3.1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of noncompliances and also for repeated failure in implementation of any of the HSE provisions,
PDIL/Owner may impose stoppage of work without any cost & time implication to the Owner
and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative
limit of
2.0% (Two percent) of the contract value for Item Rate or Composite contracts with an overall
cPDILing of 1, 00, 00, 000 (Rupees One crore)
0.5% (Zero decimal five percent) of the contract value for LSTK, OBE, EPC, EPCC or Package
contracts with an overall cPDILing of 10, 00.00.000 (Rupees ten crores)
This penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
PDIL/Owner. The same shall be binding on the Contractor. Imposition of penalty does not make
the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations is
specified below:

HEALTH, SAFETY &
Sl.
No.
1.
2.
3
4.
Violation of HSE norms
Penalty Amount
Rs 500/- per day/ Item / Person.

For not using personal protective equipment
(Helmet, Shoes, Goggles, Gloves, Full body harness,
Face shield, Boiler suit, etc.)
Working without Work Permit/Clearance
Rs 20000/- per occasion
Execution of work without deployment of requisite Rs. 5000/- per violation per day
field engineer / supervisor at work spot
Rs 10000/- per item per day.
Unsafe electrical practices (not installing ELCB,
using poor joints of cables, using naked wire without
top plug into socket, laying wire/cables on the roads,
electrical jobs by incompetent person, etc.)
5.
Working at height without full body harness, using Rs. 10000/- per case per day.
non-standard/ rejected scaffolding and not arranging
fall protection arrangement as required, like handrails, life-lines, Safety Nets etc.
6.
Rs 500/- per item per day.

Unsafe handling of compressed gas cylinders (No
trolley, jubilee clips double gauge regulator, and not
keeping cylinders vertical during storage/handling,
not using safety cap of cylinder).
Use of domestic LPG for cutting purpose / not using Rs. 3000/- per occasion.
flash back arresters on both the hoses/tubes on both
ends.
No fencing/barricading of excavated areas /
Rs. 3000/- per occasion.
trenches.
Not providing shoring/strutting/proper slope and not Rs.5, 000/- per occasion.
keeping the excavated earth at least 1.5M away from
excavated area.
Non display of scaffold tags, caution boards, list of Rs.1000/- per occasion per day
hospitals, emergency services available at work
locations.
Rs. 2000/- per occasion per day
Traffic rules violations like over speeding of
vehicles, rash driving, talking on mobile phones
during vehicle driving, wrong parking, not using seat
belts, vehicles not fitted with reverse horn / warning
alarms / flicker lamps during foggy weather.
Rs10000/- per meeting.
Absence of Contractors RCM/SIC or his
nominated representative (prior approval must be
taken for each meeting for nomination) from site
HSE meetings whenever called by PDIL/Owner &
failure to nominate his immediate deputy (in the siteorganogram) for such HSE meetings.
Rs 10000/- per month.
Failure to maintain HSE records by Contractor
Safety personnel, in line with approved HSE
Plan/Procedures/Contract specifications..
Failure to conduct daily site safety inspection (by
Rs.10000/- per occasion.
Contractors safety engineers/safety officers),
internal HSE meeting, internal HSE
Awareness/Motivation Program, Site HSE Training
and HSE audit at predefined frequencies (as
approved in HSE Plan).
7.
8.
9.
10.
11.
12.
13.
14.

HEALTH, SAFETY &
Sl.
No.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Violation of HSE norms
Penalty Amount
th
Failure to submit the monthly HSE report by 5 of Rs. 10000/- per occasion and Rs.
subsequent month to Projects Engineer-in-Charge / 1000/- per day of further delay.
Owner
Poor House Keeping
Rs. 5000/- per occasion per subject
Failure to report & follow up accident (including
Near Miss) reporting system within specific timeframe.
Degradation of environment (not confining toxic
spills, spilling oil/lubricants onto ground)
Rs. 20000/- per occasion
Rs10000/- per occasion
Rs 5000/- per occasion per worker

Not medically examining the workers before
allowing them to work at height / to work in
confined space / to work in shot-blasting / to work
for painting / to work in bitumen or asphalt works,
not providing ear muffs while allowing them to work
in noise polluted areas, made them to work in air
polluted areas without respiratory protective devices,
etc.
Violation of any other safety condition as per job
Rs. 5000/- per occasion
HSE plan / work permit and HSE conditions of
contract (e.g. using crowbar on cable trenches,
improper welding booth, not keeping fire
extinguisher ready at hot work site, unsafe rigging
practices, non-availability of First-Aid box at site,
not using hood with respiratory devices by blaster
for shot//grit blasting, etc.)
Failure to carry-out Safety audit in time (internal & Rs. 20,000/- per occasion
external), close-out of identified shortfalls of
Observations of Safety Aspects(OSA),etc
Carrying out sand blasting instead of grit/shot
Rs. 50,000/- per day
blasting
Failure to deploy adequately qualified and
Rs. 10000/- per day per Officer
competent Safety Officer
Rs 25,000/- per occasion
Utilization of hydra/ back-hoe loader for material
shifting or any other unauthorized /unsafe lifting
works
Any incident / accident at project site has been
Rs 10,00,000/-per occasion
caused because of willful negligence or gross
violation of safety measures / provisions on the part
of the Contractor or any of its sub-agencies
Any violation not covered above
To be decided by PDIL/Owner.
x
The Contractor shall make his field engineers/supervisors fully aware of the fact that they
keep track with the site workmen for their behavior and compliance of various HSE
requirements. Safety lapses / defects of project construction site shall be attributable to the
concerned job supervisor / engineer of the Contractor, (who remains directly responsible
for safely executing field works). For repeated HSE violations, concerned job supervisor /
engineer shall be reprimanded or appropriate action, as deemed fit, shall be initiated (with
an information to PDIL & Owner) by the concerned Contractor.

HEALTH, SAFETY &
Contractor shall initiate verbal warning shall be given to the worker/employee during his first
HSE violation. A written warning shall be issued on second violation and specific training shall
be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on
the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall
call for his forthright debar from the specific construction site. A record of warnings for each
worker/employee shall be maintained by the Contractor, like by punching their cards / Gate
passes or by displaying their names at the Project entry gate. Warnings, penalizations,
appreciations etc. shall be discussed in HSE Committee meetings by site Head of the
Contractor.
3.1.14 Accident/ Incident investigation
All accidents / incidents shall be informed to PDIL/Owner at least telephonically by Contractor
immediately and in writing within 24 hours on Format No. HSE-2 as applicable , by Contractor.
Thereafter, a Supplementary Accident / Incident investigation Report on Format No. HSE-3
shall be submitted to PDIL/Ownerwithin 72 hours. Near Miss incident(s),Dangerous
accidents/incident shall also be reported on Format No. HSE-4 within 24 hours. The accident/
incident shall be investigated by a team of Contractors senior Site personnel (involving Site-inCharge or at least by his deputy) for establishing root-cause and recommending corrective &
preventive actions.
Findings shall be documented and suitable actions taken to avoid
recurrences shall be communicated to PDIL/Owner.
Owner/PDIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help
and cooperation in this regard. PDIL/Owner shall have the right to share the content of this report
with the outside world.
3.2
House Keeping
The Contractor shall ensure that a high degree of house keeping is maintained and shall ensure
inter alia; the followings:
a)
All surplus earth and debris are removed/disposed off from the working areas to designated
location(s).
b) Unused/surplus cables, steel items and steel scrap lying scattered at different places within
the working areas are removed to identify location(s).
c) All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
d) Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and
bricks etc shall not be allowed on the roads to obstruct free movement of men &
machineries.
e) Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.
f) Water logging on roads shall not be allowed.
g) No parking of trucks/trolleys, cranes and trailers etc shall be allowed on roads, which may
obstruct the traffic movement.
h) Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working
areas.
i) Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
within the plant area/ or these materials shall be transported with top surface wet.
j) The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing.
k) At least two exits for any unit area shall be assured at all times same arrangement is
preferable for digging pits / trench excavation / elevated work platforms / confined spaces
etc.
l) Welding cables and the power cable must be segregated and properly stored and used .The
same shall be laid away from the area of movement and shall be free from obstruction.
m) Schedule for upkeep/cleaning of site to be firmed up and implemented on regular basis

HEALTH, SAFETY &
The Contractor shall carry-out regular checks (minimum one per fortnight) as per format No:
HSE-11 for maintaining high standard of housekeeping and maintain records for the same.
3.3
HSE Measures
3.3.1
Construction Hazards
The Contractor shall ensure identification of all Occupational Health, Safety & Environmental
hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor
shall carry out Job Safety Analysis (JSA)/Risk Analysis specifically for high risk jobs/crtical
jobs like
a)
Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation
etc.) & hot works.
b) Work in confined space,
c) Deep excavations & trench cutting (depth > 2.0 mts.)
d) Operation & Maintenance of Batching Plant.
e) Shuttering / concreting (in single or multiple pour) for columns, parapets & roofs.
f) Erection & maintenance of Tower Crane.
g) Erection of structural steel members / roof-trusses / pipes at height more than 2.0 Mts. with
or without crane.
h) Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
of 100T capacity.
i) All lifts using 100T Crane plus mechanical pulling.
j) All lifts using two cranes in unison (Tandem Lifting).
k) Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
l) Laying of pipes (isolated or fabricated) in deep narrow trenches manually or
mechanically.
m) Maintenance of crane / extension or reduction of crane-boom on roads or in yards.
n) Erection of any item at >2.0 Mts. height using 100T crane or of higher capacity
o) Hydrostatic test of pipes, vessels & columns and water-flushing.
p) Radiography jobs (in-plant & open field)
q) Work in Live Electrical installations / circuits
r) Handling of explosives & Blasting operations
s) Demolishing / dismantling activities
t) Welding / gas cutting jobs at height (+2.0 Mts.)
u) Lifting / placing roof-girders at height (+2.0 Mts.)
v) Lifting & laying of metallic / non-metallic sheet over roof/structures.
w) Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with & without using
cranes
x) Calibration of equipment, instruments and functional tests at yards / work-sites.
y) Operability test of Pump, Motors (after coupling) & Compressors.
z) Cold or Hot works inside Confined Space.
aa) Transportation & shifting of ODC consignments into project areas.
bb) Working in charged/Live elect. Panels
cc) Stress Relieving works (Electrically or by Gas-burners).
dd) Pneumatic Tests
ee) Card board blasting
ff) Chemical cleaning
and take feedback from PDIL/Owner. The necessary HSE measures devised shall be put in to
place, prior to start of an activity & also shall be maintained during the course of works, by the
Contractor. Copies of such JSAs shall be kept available at work sites by the Contractor to enable
all concerned carrying out checks / verification.

HEALTH, SAFETY &
A list of typical construction hazards along with their effects & preventive measures is given in
Appendix-E.
3.3.2
Accessibility
x
The Contractor shall provide safe means of access(in sufficient numbers) & efficient exit to
any working place including provisions of suitable and sufficient scaffolding at various
stages during all operations of the work for the safety of his workmen and PDIL/Owner.
x
The Contractor shall implement use of all measures including use of life line, fallarresters, retractable fall arresters , safety nets etc. during the course of using all safe
accesses & exits, so that in no case any individual remains at risk of slip & fall during their
travel.
3.3.3
The access to operating plant / project complex shall be strictly regulated. Any person or
vehicle entering such complex shall undergo identification check, as per the procedures in
force / requirement of PDIL/Owner.
Accessibility to confined space shall be governed by specific system / regulation, as
established at project site.
Personal Protective Equipments (PPEs)

x
The Contractor shall ensure that all their staff, workers and visitors including their subcontractor(s) have been issued (records to be kept) & wear appropriate PPEs like nape strap
type safety helmets preferably with head & sweat band with cotton chin strap
(made of industrial HDPE), safety shoes with steel toe cap and antiskid sole, full body
harness (C marked and conforming to EN361), protective goggles, gloves, ear muffs,
respiratory protective devices, etc.
All these gadgets shall conform to applicable IS
Specifications/CE or other applicable international standards. The Contractor shall
implement a regular regime of inspecting physical conditions of the PPEs being issued /
used by the workmen of their own & also its sub-agencies and the damaged / unserviceable
PPEs shall be replaced forthwith.
x
Owner/PDIL may issue a comprehensive color scheme for helmets to be used by various
agencies. The Contractor shall follow the scheme issued by the owner/PDIL and shall choose
any colour other than white (for Owner) or blue (for PDIL) All HSE personnel shall
preferably wear dark green band on their helmet so that workmen can approach them for
guidance during emergencies. HSE personnel shall preferably wear such dresses with
fluorescent stripes, which are noticeable during night, when light falls on them.
x
For shot blasting, the usage of protective face shield and helmets, gauntlet and protective
clothing is mandatory. Such protective clothing should conform relevant IS Specification.
x
For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to PDIL &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at all time.
x
An indicative list of HSE standards/codes is given under Appendix-A.
x
Contractor shall ensure procurement & usage of following safety equipments/ accessories
(conforming to applicable IS mark / CE standard) by their staff, workmen & visitors
including their subcontractors all through the span of project construction / precommissioning/ Commissioning:-

HEALTH, SAFETY &
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
3.3.4
PPEs (Helmet, Spectacle, Ear-muff, Face shield, Hand gloves, Safety Shoes, Gum
boot)
Barricading tape / warning signs
Rechargeable Safety torch (flame-proof)
Safety nets (with tie-chords)
Fall arresters
Portable ladders (varying lengths)
Life-lines (steel wire-rope, dia not less than 8.0 mm)
Full body harness (double lanyard)
Lanyard
Karabiner
Retractable fall arresters (various length)
Portable fire extinguishers (DCP type) 5 kg capacity
Portable Multi Gas detector
Sound level meter
Digital Lux meter
Fire hoses & flow nozzles
Fire blankets / Fire retardant cloth (with eyelets)
Working at height
x
The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints as specified in the attached permit (Format No. HSE-6).
He
shall also undertake to ensure compliance to the conditions of the permit during the
currency of the permit including adherence of personal protective equipments. Contractors
Safety Officer shall verify compliance status of the items of permit document after
implementation of action is completed by Contractors execution / field engineers at work
site. Job Safety Analysis (JSA) for specific works at height duly commented by
PDIL/Owner, shall be kept attached with particular Permit for Work (PFW) at site for ready
reference & follow-up.
x
Such PFW shall be initially issued for one single shift or expected duration of normal work
and extended further for balance duration, if required. PDIL/Owner can devise block-permit
system at any specific area, in consultation with project specific HSE Committee to specify
the time-period of validity of such PFW or its renewal. This permit shall be applicable in
areas where specific clearance from Owners operation Deptt. /Safety Deptt. is not
required. PDIL / Owners field Engineers/Safety Officers/Area Coordinators may verify and
counter sign this permit (as an evidence of verification) during the execution of the job.
x
All personnel shall be medically examined & certified by registered doctor, confirming
their medical fitness for working at height. The fitness examination shall be done once in
six months.
x
In case work is undertaken without taking sufficient precautions as given in the permit, PDIL
/Owner Engineers may exercise their authority to cancel such permit and stop the work till
satisfactory compliance/rectification is arranged made. Contractors are expected to
maintain a register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.
x
The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his
workers. Fall arresters are to be used while climbing/descending tall structures or vessels /
columns etc. These arresters should lock automatically against the anchorage line,
restricting free fall of the user. The device is to be provided with a double security opening
system to ensure safe attachment or release of the user at any point of rope. In order to

HEALTH, SAFETY &
avoid shock, the system should be capable of keeping the person in vertical position in case
of a fall.
x
The Contractor shall ensure that Full body harnesses conforming EN361 and having
authorized C marking is used by all personnel while working at height. The lanyards and
life lines should have enough tensile strength to take the load of the worker in case of a fall.
One end of the lanyard shall be firmly tied with the harnesses and the other end with life
line. The harness should be capable of keeping the workman vertical in case of a fall,
enabling him to rescue himself.
x
The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping
roofs in order to reduce the chances of slippages and falls.
x
The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of
fall from height is present.
The safety net, preferably a knotted one with mesh ropes
conforming to IS 5175/ ISO 1140 shall have a border rope & tie cord of minimum 12mm
dia. The Safety Net shall be located not more than 6.0 meters below the working surface
extending on either side up to sufficient margin to arrest fall of persons working at different
heights.
x
In case of accidental fall of person on such Safety Net, the bottom most portion of Safety
Net should not touch any structure, object or ground.
x
The Contractor shall ensure positive isolation while working at different levels like in the
pipe rack areas. The working platforms with toe boards & hand rails shall be sufficiently
strong & shall have sufficient space to hold the workmen and tools & tackles including the
equipments required for executing the job. Such working platforms shall have mid-rails, to
enable people work safely in sitting posture.
3.3.5
Scaffoldings & Barricading

x
Suitable scaffoldings shall be provided to workmen for all works that cannot be safely done
from the ground or from solid construction except such short period work that can be safely
rd
done using ladders or certified (by 3 party competent person) man-basket. When a ladder
is used, an extra workman shall always be engaged for holding the ladder.
x
The Contractor shall ensure that the scaffolds used during construction activities shall be
strong enough to take the designed load. Main Contractor shall always furnish duly
approved construction-design details of scaffold & SWL (from competent designers) free
of charge, before they are being installed / constructed at site. Owner/PDIL reserves the right
to ask the Contractor to submit certification and or design calculations from his Head office
/ Design/ Engineering expert regarding load carrying capacity of the scaffoldings.
All scaffolds shall be inspected by a competent Scaffolding Inspector of the Contractor. He

shall paste a GREEN tag (duly signed by competent Scaffolding Inspector) on each
scaffold found safe and a RED tag (duly signed by competent Scaffolding Inspector) on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be permitted to be used
and Scaffolds with RED ones shall immediately be made inaccessible. Work being found
continuing on scaffolds with RED tag shall be considered unauthorized work by Contractor
2
3
and may invite penalization from PDIL/Owner. For every 120-125 m /m area / volume or
its parts thereof minimum one TAG shall be provided.
The Contractor shall ensure positive barricading (indicative as well as protective) of the
excavated, radiography, heavy lift, high pressure hydrostatic & pneumatic testing and other
such areas. Sufficient warning signs shall be displayed along the barricading areas.

HEALTH, SAFETY &
x
Scaffolding shall be constructed using foot seals or base plates only.
3.3.6
Electrical installations
x
All electrical installations/ connections shall be carried out as per the provisions of latest
revision of following codes/standards, in addition to the requirements of Statutory
Authorities and IE/applicable international rules & regulations:
-
OISD STD 173

SP 30 (BIS)
: Fire prevention & protection system for electrical installations

: National Electric Code
x
All electrical installations shall be approved by the concerned statutory authorities.
x
All temporary electrical installations / facilities shall be regularly
checked by the
licensed/competent electricians of the Contractor and appropriate records shall be
maintained in format no: HSE-12 Inspection of temporary electrical booth/installation at
project construction site. Such inspection records are to be made available to PDIL/Owner,
whenever asked for.
3.3.6.1 The Contractor shall meet the following requirements:
a.
Shall make Single Line Diagram (SLD) for providing connection to each equipments &
machinery and the same (duly approved by PDIL/Owner) shall be pasted on the front face of
DBs (distribution boards) or JBs (Junction boxes) at every site. ( A typical Switch Board
Sketch is attached as Appendix -G )
b.
Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per provisions
of the latest revision of the Indian Electrical/ applicable international regulations.
c.
Shall deploy qualified & licensed electricians for proper & safe installation and for regular
inspection of construction power distribution system/points including their earthing. A
copy of the license shall be submitted to PDIL / Owner for records. Availability of at least
one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be
ensured at site round the clock to attend to the normal/emergency jobs.
d.
All switchboards / welding machines shall be kept in well-ventilated & covered shed/ with
rain shed protection. The shed shall be elevated from the existing ground level to avoid
water logging inside the shed . Installation of electrical switch board must be done taking
care of the prevention of shock and safety of machine.
e.
No flammable materials shall be used for constructing the shed. Also flammable materials
shall not be stored in and around electrical equipment / switchboard. Adequate clearances
and operational space shall be provided around the equipment.
f.
Fire extinguishers and insulating mats shall be provided in all power distribution centers.
g.
Temporary electrical equipment shall not be employed in hazardous area without obtaining
safety permit.
h.
Proper housekeeping shall be done around the electrical installations.
i.
All temporary installations shall be tested before energizing, to ensure proper earthing,
bonding, suitability of protection system, adequacy of feeders/cables etc.

HEALTH, SAFETY &
j.
All welders shall use hand gloves irrespective of holder voltage.
k.
Multilingual (Hindi, English and local language) caution boards, shock treatment charts and
instruction plate containing location of isolation point for incoming supply, name &
telephone No. of contact person in emergency shall be provided in substations and near all
distribution boards / local panels.
l.
Operation of earth leakage device shall be checked regularly by temporarily connecting

series test lamp (2 bulbs of equal rating connected in series) between phase and earth.
ELCB tester /test meter shall be used for testing ELCBs
m. Regular inspection of all installations at least once in a month. (Ref. Format HSE-12).
3.3.6.2 The following features shall also be ensured for all electrical installations during construction
phase by the contractor:
x
Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch shall not
exceed 1.5 M. The main switch shall be connected to the point of supply by means of
armoured cable.
x
The outgoing feeders shall be double or triple pole switches with fuses / MCBs. Loads in a
three phase circuit shall be balanced as far as possible and load on neutral should not
exceed 20% of load in the phase.
x
The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type.
Use of rewirable fuses shall be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.
x
All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.
x
All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be
provided with socket caps.
x
Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5
2
mm copper shall be used for all single phase hand tools.
x
Only metallic distribution boxes with double earthing shall be used at site.
No wooden
boxes shall be used.
x
All power cables shall be terminated with compression type cable glands. Tinned copper
lugs shall be used for multi-strand wires / cables.
x
Cables shall be free from any insulation damage.
x
Minimum depth of cable trench shall be 750 mm for MV & control cables and 900 mm for
HV cables. These cables shall be laid over a sand layer and covered with sand, brick & soil
for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of buried trench route.
When laid above ground, cables shall be properly cleated or supported on rigid poles of at
least 2.1 M high. Minimum head clearance of 6 meters shall be provided at road crossings.

HEALTH, SAFETY &
x
Under ground road crossings for cables shall be avoided to the extent feasible. In any case
no under ground power cable shall be allowed to cross the roads without pipe sleeve.
x
All cable joints shall be done with proper jointing kit. No taped/ temporary joints shall be
used.
x
An independent earthing facility should preferably be established within the temporary
installation premises. All appliances and equipment shall be adequately earthed. In case of
armoured cables, the armour shall be bonded to the earthing system.
x
All cables and wire rope used for earth connections shall be terminated through tinned
copper lugs.
x
In case of local earthing, earth electrodes shall be buried near the supply point and earth
continuity wire shall be connected to local earth plate for further distribution to various
appliances. All insulated wires for earth connection shall have insulation of green colour.
x
Separate core shall be provided for neutral. Earth / Structures shall not be used as a neutral
in any case.
x
ON/OFF position of all switches shall be clearly designated / painted for easy isolation in
emergency.
3.3.7
Welding/ Gas cutting

x
Contractor shall ensure that flash back arrestors conforming to BS: 6158 or equivalent are
x installed on all gas cylinders as well as at the torch end of the gas hose, while in use.
All cylinders shall be mounted on trolleys and provided with a closing key. Empty &
filled-up gas cylinders shall be stored separately with TAG, protecting them from direct
sun or rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be
maintained at the gas cylinder stores. Stacking & storing of compressed gas cylinders shall
x be arranged away from DG set, hot works, Elect. Panels / Elec. boards, etc
The burner and the hose placed downstream of pressure reducer shall be equipped with
x Flash Back Arrester/Non Return Valve device.
The hoses for acetylene and oxygen cylinders must be of different colours. Their
x connections to cylinders and burners shall be made with a safety collar.
x At end of work, the cylinders in use shall be closed and hoses depressurized.
Cutting of metals using gases, other than oxygen & acetylene, shall require written
x concurrence from Owner.
x All welding machines shall have effective earthing at least at distinctly isolated two points.
In order to help maintain good housekeeping, and to reduce fire hazard, live electrode bits
x shall be contained safely and shall not be thrown directly on the ground.
The hoses of Acetylene and Oxygen shall be kept free from entanglement & away from
common pathways / walkways and preferably be hanged overhead in such a manner which
x can avoid contact with cranes, hydra or other mobile construction machinery.
Hot spatters shall be contained / restricted appropriately (by making use of effective fireretardant cloth/fabric) and their flying-off as well as chance of contact with near-by
x flammable materials shall be stopped.
The Contractor shall arrange adequate systems & practices for accumulation / collection of
metal & other scraps and remnant electrodes and their safe disposal at regular interval so as
x to maintain the fabrication and other areas satisfactorily clean & tidy.
All gas cylinders must have a cylinder cap on at all times when not in use.

HEALTH, SAFETY &
3.3.8
Ergonomics and tools & tackles

x
The Contractor shall assign to his workmen, tasks commensurate with their qualification,
x experience and state of health.
All lifting tools, tackles, equipment, accessories including cranes shall be tested
periodically by statutory/competent authority for their condition and load carrying capacity.
Valid test & fitness certificates from the applicable authority shall be submitted to
Owner/PDIL for their review/acceptance before the
lifting tools, tackles, equipment,
x accessories and cranes are used.
The contractor shall not be allowed to use defective equipment or tools not adhering to
x safety norms.
Contractor shall arrange non-sparking tools for project construction works in operating
x plant areas / hydrocarbon prone areas.
Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or
Aerial Work Platforms (mobile or stationary) to avoid ergonomical risks and workmen
shall be debarred to board such elevated platform during the course of their shifting /
x transportation.
Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use)
to minimize overloading risk.
SLI shall have capability to continuously monitor and
display the load on the hook, and automatically compare it with the rated crane capacity at
the operating condition of the crane. The system shall also provide visual and audible
x warnings at set capacity levels to alert the operator in case of violations.
The contractor shall be responsible for safe operations of different equipments mobilized
and used by him at the workplace like transport vehicles, engines, cranes, mobile ladders,
x scaffoldings, work tools, etc.
The Contractor shall arrange periodical training for the operators of hydra, crane,
excavator, mobile machinery, etc. at site by utilizing services from renowned
manufacturers
3.3.9
Occupational Health
x
The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
x
For surface cleaning operations, sand blasting shall not be permitted even if not explicitly
stated elsewhere in the contract.
x
To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
shall not contain Thorium.
x
Appropriate respiratory protective devices(hood with respiratory devices) shall be used to
protect workmen from inhalation of air borne contaminants like silica, asbestos, gases,
fumes, etc.
x
Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulling
of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting
equipments.
x
For jobs like drilling/demolishing/dismantling where noise pollution exceeds the specified
limit of 85 decibels, ear muffs shall be provided to the workers.
x
To avoid work related upper limb disorders (WRULD) and backaches, Display Screen
Equipments' workplace stations shall be carefully designed & used with proper sitting
postures. Power driven hand-held tools shall be maintained in good working condition to

HEALTH, SAFETY &
minimize their vibrating effects and personnel using these tools shall be taught how to
operate them safely & how to maintain good blood circulation in hands.
x
The Contractor shall arrange health check up (by registered medical practitioner) for all the
workers at the time of induction. Health check may have to be repeated if the nature of duty
assigned to him is changed necessitating health check or doubt arises about his wellness.
PDIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding, Radiography,
Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-ups shall be
conducted by registered Medical practitioner and records are to be maintained by the
Contractor.
x
The Contractor shall ensure vaccination of all the workers including their families, during
the course of entire project span.
3.3.10 Hazardous substances
x
Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, antitermite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good ventilated
area. These containers shall be labeled with the name of the materials highlighting the
hazards associated with its use and necessary precautions to be taken. Respective MSDS
(Material Safety Data Sheet) shall be made available at site & may be referred whenever
problem arises.
x
Where contact or exposure of hazardous materials are likely to exceed the specified limit or
otherwise have harmful effects, appropriate personal protective equipments such as gloves,
goggles/face-shields, aprons, chemical resistant clothing, respirator, etc. shall be used.
x
The work place shall be checked prior to start of activities to identify the location, type and
condition of any asbestos materials which could be disturbed during the work. In case
asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured
and the matter shall be reported immediately to PDIL/ Owner.
3.3.11 Slips, trips & falls
The contractor shall establish a regular cleaning and basic housekeeping programme that covers
all aspects of the workplace to help minimize the risk of slips, trips & falls. The contractor shall
take positive measures like keeping the work area tidy, storing waste in suitable containers &
harmful items separately, keeping passages, stairways, entrances & exits especially emergency
ones clear, cleaning up spillages immediately and replacing damaged carpet/ floor tiles, mats &
rugs at once to avoid slips, trips & falls.
3.3.12 Radiation exposure
x
All personnel exposed to physical agents such as ionizing & non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with adequate
shielding or protection commensurate with the type of exposure involved.
x
For Open Field Radiography works , requirements of Bhabha Atomic Research Centre
(BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
x
The Contractor shall implement an effective system of control (as described in the AERB
regulations) at site for handling radiography-sources & for avoiding its misuse & theft.

HEALTH, SAFETY &
x
The contractor shall generate the Format No: HSE-8 Permit for radiation work before
start of work.
x
In case the radiography work has to be carried out at day time, suitable methodology to be
used so that other works, people are not affected.
3.3.13 Explosives/Blasting operations
x
Blasting operations shall be carried out as per latest Explosive Rules (Indian / International)
with prior permission. The Contractor shall obtain license from Chief Controller of
Explosives (CCoE) for collection, transportation, storage of explosives as well as for
x carrying out blasting operations.
The Contractor shall prepare exclusive method statement (in cognizance with statutory
requirements) for diffusing unfired explosives, if any, at project site before carrying out
actual task. Nowhere blasting shall be carried out by the Contractor or its agency without
the involvement of competent supervisor and licensed blaster / shot blaster.
3.3.14 Demolition/ Dismantling
x
The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work
x to guard against unsafe working practices.
The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, if required as directed by
x PDIL/ Owner at no extra cost.
Before carrying out any demolition/ dismantling work, the contractor shall take prior
approval of PDIL/Owner and generate theFormat No.HSE-9. For revamp jobs in operating
plants where location of underground utilities is not known with certainty, the contractor
shall depute an experienced engineer for supervision and shall make adequate arrangements
x for Fire fighting & First-Aid during the execution of these activities.
The Contractor shall arrange approved Job Safety Analysis (JSA) / Method Statement for
the specific demolition / dismantling task and corresponding action plan commensurate
with hazards / risks associated therein. In no case any activity related to demolition /
dismantling shall be carried out by the Contractor without engaging own supervision / field
engineer.
3.3.15 Road Safety
x
x The Contractor shall ensure adequately planned road transport safety management system.
The vehicles shall be fitted with reverse warning alarms & flashing lights / fog-lights and
x usage of seat belts shall be ensured.
The Contractor shall also ensure a separate pedestrian route for safety of the workers and
comply with all traffic rules & regulations, including maintaining speed limit of 20 kmph
or indicated by owner for all types of vehicles / mobile machinery. The maximum
x allowable speed shall be adhered to.
In case of an alert or emergency, the Contractor must arrange clearance of all the routes,
roads, access. The Contractor shall deploy sufficient number of traffic controllers at project
site routes / roads/ accesses, to alert reversing movement of vehicles & machinery as well
as pedestrians.
x
Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also
to & from the labour colony to & from project sites.
x
Hydras shall only be allowed for handling the materials at fabrication/ storage yards and in
no case shall be allowed to transport the materials over project / plant roads.

HEALTH, SAFETY &
x
The Contractor shall not deploy any such mobile machinery / equipments, which do not
have competent operator and / or experienced banks-man / signal-man. Such machinery /
equipments shall have effective limit-switches, reverse-alarm, front & rear-end lights etc.
and shall be maintained in good working order.
x
The Contractor shall not carry-out maintenance of vehicles / mobile machinery occupying
space on project / plant roads and shall always arrange close supervision for such works.
x
For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
loading / unloading of pipes, movement of side booms, movement of vehicles on the ROW,
etc.
x
Contractors shall arrange /install visible road signs, diversion boards, caution boards, etc
on project roads for safe movement of men and machinery.
3.3.16 Welfare measures
Contractor shall, at the minimum, ensure the following facilities at work sites:
x
A crche at site where 10 or more female workers are having children below the age of 6
x years.
x Adequately ventilated / illuminated rooms at labour camps & its hygienic up-keeping.
Reasonable canteen facilities at site and in labour camps at appropriate location depending
upon site conditions. Contractor shall make use of industrial variety of LPG cylinder &
satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of
wastes from canteens & urinals /toilets shall also be made and regular review shall be made
to maintain the ambience satisfactorily hygienic & shall also comply with all applicable
x statutory requirements.
Adequately lighted & ventilated Rest rooms at site (separate for male workers and female
x workers).
Urinals, Toilets, drinking water, washing facilities, adequate lighting at site and labour
camps, commensurate with applicable Laws / Legislation.
3.3.17 Environment Protection
Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment.
Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste materials,
such as metals, plastics, glass, paper, oil & solvents. The waste that cannot be minimized,
reused or recovered shall be stored and disposed of safely. In no way, toxic spills shall be
allowed to percolate into the ground. The contractor shall not use the empty areas for dumping
the wastes.
The contractor shall strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases,
harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need
arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other
waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A
discharge plan suggesting the methods of treating the waste before discharging shall be
submitted to PDIL/Owner for approval.

HEALTH, SAFETY &
For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This
fertile soil shall be placed back on top after backfilling.
For offshore construction barges, arrangements shall be made for safe disposal of human, food
& other wastes and applicable laws in this regard shall be followed.
3.3.18 Rules & Regulations
All persons deployed at site shall be knowledgeable of and comply with the environmental laws,
rules & regulations relating to the hazardous materials, substances and wastes. Contractor shall
not dump, release or otherwise discharge or disposes off any such materials without the express
authorization of PDIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is
given under Appendix-D.
3.3.19 Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, rain, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun
screen lotions, respirators, dust masks, etc. and rearranging/ planning the construction activities
to suit the weather conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle in the form
of temporary shelter shall be made at site.
3.3.20 Communication
All persons deployed at the work site shall have access to effective means of communication so
that any untoward incident can be reported immediately and assistance sought by them.
All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
For information to all, typical subjects that should be communicated are: Inside the company (Top to down)
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Quality Policy
HSE Policy contents
Environment Policy
HSE Objectives
Safety Cardinal Rules
HSE Target reached or missed
Praises & Warnings to personnel for HSE Management
Safety Walk Through Reports and safety defects / shortfalls (by management)
HSE Audit results
Revised Statutory Health & Safety provisions, if any
H & S publicity
Suggestions
Inside the Company (Bottom to up)

a.
b.
c.
d.
e.
Complaints
Compliances on safety defects / shortfalls
Suggestions
Proposals for changes & improvements
HSE Reports (including near-miss reports)

HEALTH, SAFETY &
3.3.21 Confined Space Entry

The contractor shall generate a work permit (Format No. HSE -7) before entering a confined
space. People, who are permitted to enter into confined space, must be medically examined &
certified by registered doctor, confirming their medical fitness for working in confined space.
All necessary precautions mentioned therein shall be adhered to. An attendant shall be
positioned outside a confined space for extending help during an emergency. All appropriate
PPEs and air quality parameters shall be checked before entering a confined space. It shall be
ensured that the piping of the equipment which has to be opened is pressure- free by checking
that blinds are in place, vents are open and volume is drained. Inside confined space works, only
electrical facilities / installations of 24V shall be permitted. Contactor shall ensure usage of safe
& suitable arrangement of oxygen supply for individual workmen (during the course of work in
confined space), if oxygen concentration is found to be less than 19.5% (v/v) there.
3.3.22 Heavy Lifts
x
The contractor shall submit detailed rigging studies plan for PDIL/ Owner approval prior to
lifting equipment which cannot be erected with a crane of approx. 100 MT capacity due to
x constraints of its dimensions, location of foundation height, approach & weight.
Contractor shall generate the format no:HSE-15 Permit for heavy lift/critical erection
x
Prior to actual lifting activities, contractor shall check the validity of the crane inspection
certificate issued by statutory/ competent authority. This requirement shall also apply to all
rigging equipments utilized for the job.
x
The contractor shall, at all times, be responsible for all rigging activities.
x
The Contractor shall ensure medical fitness of all workmen who are engaged / involved in
erection of equipments, vessels etc. and such fitness checks shall be carried-out every six
months interval with the help of a registered medical practitioner & record shall be
maintained
x
Adequate safety measures such as positive barricading, usage of appropriate PPEs, permit
to work, etc. shall be taken during all heavy or critical lifts.
x
For lifting any material (irrespective of shape, size or volume), at any height, it is always
advisable to prepare a Plan of Erection (PoE) taking into consideration hazards & risks
associated therein this can enable people to put their own experiences of various natures
& side-by-side establish a practical method for risk-free erection / lifts. The contractor shall
prepare PoE & shall document the same, when risks are identified as medium or high
and the same shall be approved by its competent / qualified engineer.
3.3.23 Key Performance Indicators
The contractor shall measure an activity in both leading & trailing indicators for statistical and
performance measurement. The activities pertaining to key performance indicators are covered
in Monthly HSE Report (Format No. HSE-5). The contractor shall try to achieve a statistically
fair record and strive for its continual improvement.
Leading Indicators viz:-:
-
Number of Safety Inductions carried-out at site (for workmen & staff members)
Number of HSE inspections carried out
Number of Safety Walk Through carried-out by site-head.

HEALTH, SAFETY &
Number of HSE shortfalls / lapses identified per contractor & closed-out in time.
Number of Safety Meetings conducted (in-house / with contractors)
Number of HSE Audits made (internal & external) vis--vis non conformances raised
Number of HSE Awareness / Motivational program conducted by contractors
Number of HSE Trainings conducted at site for supervisors & workmen
Study of Near miss case reported
Encouragements / Awards / Recognitions to workmen, job supervisors & field engineers.
Suggestions for improvement
Trailing Indicators viz:-:

-
Calculation of HSE statistics viz frequency rate, severity rate, LTA free manhours,etc
Analysis of incidents / accidents (nature, severity, types etc.)
Study of Incident / Accident with respect to :
Variety
Period of the year / project span

Timings of the incident / accident
Age profile of victims
Body parts involved
Penalty levied for causing incident / accident
3.3.24 Unsuitable Land Conditions

Contractor shall take appropriate measures and necessary work permits/clearances if work is to
be done in or around marshy areas, river crossings, mountains, monuments, etc. The Contractor
shall make right assessment and take all necessary action for developing work areas to make
them safe & suitable for crane operations or other vehicular movement before carrying out any
project related activity / operation. Contractor shall take all necessary actions to make the
surroundings of its site establishments (site office, stores, lay-down area etc.) work-worthy
safe and secure.
3.3.25 Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection arrangements
and shall posses communication facilities like cellular phones, wireless, walkie-talkie.
All
divers used for seabed surveys, underwater inspections shall have required authorized license,
suitable life saving kit. Number of hours of work by divers shall be limited as per regulations.
PDIL/ Owner shall have the right to inspect the boat and scrutinize documents in this regard.
3.3.26 Excavation
The Contractor shall obtain permission from competent authorities prior to excavation wherever
required.
The Contractor shall locate the position of buried utilities (water line, cable route, etc.) by
referring to project / plant drawing / in consultation with PDIL/Owner. The Contractor shall start
digging manually to locate the exact position of buried utilities & thereafter use mechanical
means.
The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance equal to depth
of pit (whichever is more)

HEALTH, SAFETY &
The Contractor shall maintain sufficient angle of repose during excavation shall also
provide slope or suitable bench as decided by PDIL / Owner.
The Contractor shall arrange battering or benching wherever required for preventing
collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth
collapse due to heavy rain / influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid underpinning / under-cutting to prevent collapse of chunk of earth
during excavation
The Contractor shall use stoppers to prevent over-run of vehicle wheels at the edge of
excavated pits / trenches.
The Contractor shall arrange strengthening of shoring & strutting proactively to avoid
collapse of earth / edges due to vehicular movement in close proximity of excavated areas / pits
/ trenches, etc.
3.4
Tool Box Talks (TBT)

Contractor shall conduct daily TBT with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBT is to be conducted
by the immediate supervisor of the workers
The Contractor shall conduct TBT before start of every morning or evening shift or night shift
activities, for alerting the workers on specific hazards and their appropriate dos & donts. The
Contractor shall provide sufficient rests to the site workmen and their foremen to avert fatigue
& thereby endangering their lives during the course of site works.
TOOL BOX TALK RECORDING SHEET
Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name
Signature
Section
Remarks, in any
The topics during TBT shall include

-
Hazards related to work assigned on that day and precautions to be taken.

Any forthcoming HSE hazards/events/instruction/orders, etc.
The above record can be kept in local language, which workers can read. These records shall be
made available to PDIL/ Owner whenever demanded.

HEALTH, SAFETY &
3.5
Training & Induction Programme

x
Initial induction of workers into Construction oriented activities and appraising them about
the methodology of works and how to carry-out safely and the same should not be inter
mixed with Tool Box Talks or HSE Training. In this regard careful action should be made
& maintained for imparting HSE induction to every individual, irrespective of his
task/designation/level of employment, whereas, HSE Training should be imparted to
specific person/group of people who are to carry-out that specific task more than once for
example, Riggers must be trained for working at heights, welders must be trained for work
in confined space, fitters/carpenters, mesons must be trained for work at heights, etc.
x
Contractor shall conduct Safety induction programme on HSE for all his workers and
maintain records. The Gate Pass shall be issued only to those workers who successfully
qualify the Safety induction programme.
x
The Contractor shall brief the visitors about the HSE precautions which are required to be
taken before their proceeding to site and make necessary arrangements to issue appropriate
PPEs like Aprons, hard hats, ear-plugs, goggles & safety shoes etc., to his visitors. The
Contractor shall always maintain relevant acknowledgement from visitor on providing him
brief information on HSE actions.
x
Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about
-
Potential hazards to which they may be exposed at their workplace

Measures available for prevention and elimination of these hazards
The topics during training shall cover, at the minimum: -
Why safety should be considered during work - explanation

Education about hazards and precautions required
Employees duties & responsibilities
Emergency and evacuation plan
HSE requirements during project activities
Fire fighting and First-Aid
Use of PPEs
Occupational health issues dos & donts
Local laws on intoxicating drinks, drugs, smoking in force
Common environmental subjects lighting, ventilation, vibration, smoke/fumes etc.
x
Records of the training shall be kept and submitted to PDIL/ Owner.
x
The Contractor shall make regular program for conducting Safety Training on various
topics related to various activities & their safe-guarding utilizing experienced persons /
outside agency / faculty. A program for Safety Training (indicative list as per Appendix F)
shall be furnished by the Contractor in its HSE Plan .
x
For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner/PDIL.

HEALTH, SAFETY &
3.6
ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING

PLANT
As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant:
a)
Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined Space
from Owner in the prescribed format.
b)
The contractor shall monitor record and compile list of his workers entering the operational
plant/unit each day and ensure & record their return after completing the job.
c)
Contractors workers and staff members shall use designated entrances and proceed by
designated routes to work areas only assigned to them. The workers shall not be allowed to
enter units' area, tanks area, pump rooms, etc. without work authorization permit.
d)
Work activities shall be planned in such a way so as to minimize the disruption of other
activities being carried out in an operational plant/unit and activities of other contractors.
e)
The contractor shall submit a list of all chemicals/toxic substances that are intended to be
used at site and shall take prior approval of the Owner.
f)
Specific training on working in a hydrocarbon plant shall be imparted to the work force and
mock drills shall be carried out for Rescue operations/First-Aid measures.
g)
Proper barricading/cordoning of the operational units/plants shall be done before starting

the construction activities. No unauthorized person shall be allowed to trespass. The height
and overall design of the barricading structure shall be finalized in consultation with the
Owner and shall be got approved from the Owner.
h)
Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i)
Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of critical
activities.
j)
Emergency evacuation plan shall be worked out and all workmen shall be apprised about
evacuation routes. Mock drill operations may also be conducted.
k)
Flammable gas test shall be conducted prior to any hot work using appropriate measuring
instruments. Sewers, drains, vents or any other gas escaping points shall be covered with
flame retardant tarpaulin.
l)
Respiratory devices shall be kept handy while working in confined zones where there is a
danger of inhalation of poisonous gases. Constant monitoring of presence of Gas/
Hydrocarbon shall be done.
m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on live
lines and work on corroded tank roof.
n)
Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be done.

Closing of valve will not be considered sufficient for isolation.

HEALTH, SAFETY &
3.7
o)
Welding spatters shall be contained properly and in no case shall be allowed to fall on the
ground containing oil. Similar care shall be taken during cutting operations.
p)
The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe
and got it approved from Safety Department of the Owner.
q)
Plant air should not be used to clean any part of the body or clothing or use to blow off dirt
on the floor.
r)
Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's
plant operation personnel.
s)
Experienced full time safety personnel shall be exclusively deployed to monitor safety
aspects in running plants.
Self Assessment And Enhancement

The contractor shall develop a method of check & balance through self assessment &
enhancement techniques and shall explore the opportunities for continual improvement in the
HSE system.
3.8
HSE Promotion
The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops/seminars/training programmes, celebrating HSE awareness weeks &
National Safety Day, conducting quizzes & essay competitions, distributing pamphlets, posters
& material on HSE, providing incentives for maintaining good HSE practices and granting
incentives / bonus for completing the job without any lost time accident.
3.9
Lock Out and Tag Out (LOTO) for isolation of energy source
x
Contractor shall follow the LOTO/Isolation procedure of owner for all energy source
x isolations installed/under purview by /of owner ie. Brown field
For all the other energy source (not under purview of client/owner) i.e Green field
Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel,
electrical panels from the energy source covering following as minimum:-
x
x
Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic,

chemical, thermal, gravitational, radiation and other forms of stored
or kinetic
energy.
Establishing the energy isolation devices viz: manually operated electrical circuit
breakers, disconnection switches, blind flanges, etc
Installation of Lock Out devices for preventing the inadvertent release of stored
energy and Tag Out devices ( Danger, Do Not operate or Do not Remove tags)
to indicate that testing, maintenance or servicing is underway and the device cannot
be operated until the tag out device is removed.
Lock Out and Tag out log book
Permit for isolation and de-isolation of energy source as per format NO: HSE-16
Availability of competent persons like experienced operators at substations, pump
house, units, etc, ; supervisors,etc.
Contractor shall ensure that all the sources are locked out and tagged properly before giving
clearance to start the job.
After the completion of job, contractor shall ensure all tools and tackles are removed
and nobody is present in the working area and signing on LOTO log book.

HEALTH, SAFETY &
x
Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person carrying out
the task shall himself carry the key for the lock in /Lock out.
4.0
DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
4.1
On Award Of Contract
The Contractor shall submit a comprehensive Health, Safety and Environment Plan or
programme for approval by PDIL/Owner prior to start of work. The Contractor shall participate in
the pre-start meeting with PDIL/Owner to finalize HSE Plans which shall including the
following:
-
4.2
HSE policy & Objectives

Job procedure to be followed by the Contractor for construction activities including
handling of equipments, scaffolding, electric installations, etc. describing the risks
involved, actions to be taken and methodology for monitoring each activity. Indicative list
of procedures is enclosed as Annexure-H
PDIL/Owner review/audit requirement.
Organization structure along with responsibility and authority, on HSE activities.
Administrative & disciplinary steps involving implementation of HSE requirements
Emergency evacuation plan/ procedures for site and labour camps
Job Safety Analysis for high risk jobs
Procedures for reporting & investigation of accidents and near misses.
HSE Inspection
HSE Training programmes at project site
HSE Awareness programmes, at project site
Reference to Rules, Regulations and statutory requirements.
HSE documentation viz reporting, analysis & record keeping.
During Job Execution

Contractor shall implement approved Health, Safety and Environment management programme
including but not limited to as brought out under para 3.0. Contractor shall also ensure:
x
to arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act, etc, as applicable.
to arrange all HSE permits before start of activities (as applicable), like permits for hot
work, working at heights (Refer Format No. HSE-6), confined space (Refer Format No.
HSE-7), Radiation Work Permit (Refer Format No. HSE-8), Demolishing/ Dismantling
Work Permit (Refer Format No. HSE-9),Permit for erection/modification & dismantling of
scaffolding(Refer Format No:HSE-14), Permit for heavy lift/critical erection (Refer Format
No:HSE-15) ,Permit for energy Isolation & De-isolation (HSE-16) ,storage of chemical /
explosive materials & its use and implement all precautions mentioned therein.
In this
regard, requirements of Oil industry Safety Directorate Standard No. Std -105 "Work
Permit Systems shall be complied with while working in existing Oil or Gas processing
plants. List of the persons involved shall be maintained as annexure to the work permit
issued for a particular activity.
to submit, timely, the completed checklist on HSE activities in Format No.HSE-1, Monthly
HSE report in Format No.HSE-5 (use of web based package (www.PDIL.co.in/conthse) is
compulsory wherever the facility is available else a hard copy is to be submitted), accident/
incident reports, investigation reports etc. as per PDIL/Owner requirements. Compliance of
instructions on HSE shall be done by Contractor and informed urgently to PDIL/Owner.

HEALTH, SAFETY &
4.3
that his top most executive at site attends all the Safety Committee/HSE meetings arranged
by PDIL/Owner and carries out safety walk through regularly. Only in case of his absence
from site that a second senior most person shall be nominated by him, in advance, and
communicated to PDIL/Owner for performing the above tasks.
display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various dos & donts, etc.
provide posters, banners for safe working to promote safety consciousness.
identify, assess, analyze & mitigate the construction hazards & incorporate relevant control
measures before actually executing site works. (HIRAC = Hazard Identification, Risk
Analysis and Control).
arrange testing, examination, inspection of own as well as borrowed construction

equipments / machinery (stationary & mobile) before being used at site and also at
rd
periodical interval, through own resources and also by 3 party competent agencies (as
deemed fit in statutes). Records of such test, examination etc. shall be maintained & shall
be submitted to PDIL/Owner as & when asked for.
carryout audits/inspection (internal & external) at his works as well as sub contractor works
as per approved HSE plan/procedure/programme & submit the compliance reports of
identified shortfalls for PDIL/Owner review.
arranging HSE training for site workmen (of his own & sub contractors) through internal or
external faculty at periodical intervals.
assistance & cooperate during HSE audits by PDIL/Owner or any other 3 party and submit
compliance report.
generate & submit of HSE records/report as per this specification.
apprise PDIL/Owner on HSE activities at site regularly.
carry-out all dismantling activities safely, with prior approval of PDIL/Owner representative.
The Contractor shall ensure that Hot works and painting works do not continue at the
same place / location at project site for which chance or probability
of fire incident
exists.
rd
During Short Listing Of The Sub-Contractors

The contractor shall review the HSE management system of the sub-contractors in line with the
requirements given in this specification. The contractor shall be held responsible for the
shortcomings observed in the HSE management system of the sub-contractor(s) during
execution of the job.

HEALTH, SAFETY &
5.0
RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following reporting
formats/:
Safety Walk Through Report
Accident/ Incident Report
Supplementary Accident/ Incident Investigation report
Near Miss Incident Report
Monthly HSE Report
Permit for working at height
Permit for working in confined space
Permit for radiation work
Permit for demolishing/ dismantling
Daily Safety checklist
House keeping Assessment & compliance
Inspection of temporary electrical booth/installation
Inspection for scaffolding
Permit for erection/modification &dismantling of scaffolding
Permit for heavy lift/critical erection.
Permit for Energy isolation and de-isolation.
Permit for Excavation
Inspection reports of Equipment/tools/tackles
Report of Toolbox talks
PPE issue report/register
Site inspection reports
Training records
(*) The formats shall be developed in consultation with PDIL/Owner
HSE-1
HSE-2
HSE-3
HSE-4
HSE-5
HSE-5
HSE-7
HSE-8
HSE-9
HSE-10
HSE-11
HSE-12
HSE-13
HSE-14
HSE-15
HSE-16
HSE-17
*
As indicated in
specification
*
*
*

HEALTH, SAFETY &
APPENDIX-A
(Sheet 1 of 2)
A.
IS CODES ON HSE
SP: 53
Safety code for the use, Care and protection of hand operated tools.
IS: 838
Code of practice for safety & health requirements in electric and gas welding
and cutting operations
IS: 1179
Eye & Face precautions during welding, equipment etc.
IS: 1860
Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 1989 (Pt -II)Leather safety boots and shoes

IS: 2925
Industrial Safety Helmets
IS: 3016
Code of practice for fire safety precautions in welding & cutting operation.
IS: 3043
Code of practice for earthing
IS: 3764
Code of safety for excavation work
IS: 3786
Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents
IS: 3696
Safety Code of scaffolds and ladders
IS: 4083
Recommendations on stacking and storage of construction materials and

components at site
IS: 4770
Rubber gloves for electrical purposes
IS: 5121
Safety code for piling and other deep foundations
IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557
Industrial and Safety rubber lined boots
IS: 5983
Eye protectors
IS: 6519
Selection, care and repair of Safety footwear
IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293
Safety Code for working with construction Machinery
IS: 8519
Guide for selection of industrial safety equipment for body protection
IS: 9167
Ear protectors
IS: 11006
Flash back arrestor (Flame arrestor)
IS: 11016
General and safety requirements for machine tools and their operation
IS: 11057
Specification for Industrial safety nets
IS: 11226
Leather safety footwear having direct moulded rubber sole
IS: 11972
Code of practice for safety precaution to be taken when entering a sewerage

system
IS: 13367
Code of practice-safe use of cranes
IS: 13416
Recommendations for preventive measures against hazards at working place

HEALTH, SAFETY &
APPENDIX-A
(Sheet 2 of 2)
B.
Safety Glasses
INTERNATIONAL STANDARDS ON HSE
ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092,

BS 1542, BS 679, DIN 4646/ 58311
Safety Shoes
ANSI Z 41.1, AS 2210, EN 345
Hand Gloves
BS 1651
Ear Muffs
BS 6344, ANSI S 31.9
Hard Hat
ANSI Z 89.1/89.2, AS 1808 , BS 5240, DIN 4840
Goggles
ANSI Z 87.1
Face Shield
ANSI Z 89.1
Breathing Apparatus
BS 4667, NIOSH
Welding & Cutting
ANSI Z 49.1
Safe handling of compressed: P-1
(Compressed Gas Association Gases in cylinders 1235

Jefferson Davis Highway,
Arlington VA 22202 - USA)
Full body harness
EN-361
Lanyard
EN-354
Karabiner
EN-362 and EN-12275

HEALTH, SAFETY &
APPENDIX-B
DETAILS OF FIRST AID BOX
-----------------------------------------------------------------------------------------------------------------------SL.
DESCRIPTION
QUANTITY
NO.
-----------------------------------------------------------------------------------------------------------------------1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Small size Roller Bandages, 1 Inch Wide

(Finger Dressing small)
6 Pcs.
Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing)
6 Pcs.
Large size Roller Bandages, 4 Inches Wide
(Body Dressing Large)
6 Pcs.
Large size Burn Dressing
(Burn Dressing Large)
4 Pkts.
Cotton Wool
(20 gms packing)
4 Pkts.
Antiseptic Solution Dettol (100 ml.) or Savlon
1 Bottle
Mercurochrome Solution (100 ml.) 2% in water
1 Bottle
Ammonia Solution (20 ml.)
1 Bottle
A Pair of Scissors
1 Piece
Adhesive Plaster (1.25 cm X 5 m)
1 Spool
Eye pads in Separate Sealed Pkt.
4 pcs.
Tourniqut
1 No.
Safety Pins
1 Dozen
Tinc. Iodine/ Betadin (100 ml.)
1 Bottle
Polythene Wash cup for washing eyes
1 No.
Potassium Permanganate (20 gms.)
1 Pkt.
Tinc. Benzoine (100 ml.)
1 Bottle
Triangular Bandages
2 Nos.
Band Aid Dressing
5 Pcs.
Iodex/Moov (25 gms.)
1 Bottle
Tongue Depressor
1 No.
Boric Acid Powder (20 gms.)
2 Pkt.
Sodium Bicarbonate (20 gms.)
1 Pkt.
Dressing Powder (Nebasulf) (10 gms.)
1 Bottle
Medicinal Glass
1 No.
Duster
1 No.
Booklet (English & Local Language)
1 No. each
Soap
1 No.
Toothache Solution
1 No.
Vicks (22 gms.)
1 Bottle
Forceps
1 No.
Note Book
1 No.
Splints
4 Nos.
Lock
1 Piece
Life Saving/Emergency/Over-the counter Drugs
As decided at site
----------------------------------------------------------------------------------------------------------------Box size: 14" x 12" x 4"

----------------------------------------------------------------------------------------------------------------Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.

HEALTH, SAFETY &
APPENDIX-C
TYPE OF FIRES VIS--VIS FIRE EXTINGUISHERS
Fire
Extinguisher
Fire
Water
Originated
from
paper, clothes, wood
Inflammable liquids
like alcohol, diesel,
petrol, edible oils,
bitumen
from
Originated
gases like LPG,
CNG, H2
Foam
CO2
Dry Powder
can control
minor surface
fires
can control
minor surface
fires
Multi purpose
(ABC)
Electrical fires
D
LEGEND :
: CAN BE USED
: NOT TO BE USED
Note: Fire extinguishing equipment must be checked at least once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next inspection date is
given. Type of extinguisher shall clearly be marked on it.

HEALTH, SAFETY &
APPENDIX-D
List of Statutory Acts & Rules Relating to HSE
-
The Indian Explosives Act and Rules
The Motor Vehicle Act and Central Motor Vehicle Rules
The Factories Act and concerned Factory Rules
The Petroleum Act and Petroleum Rules
The Workmen Compensation Act
The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
The Indian Electricity Act and Rules
The Indian Boiler Act and Regulations
The Water (Prevention & Control & Pollution) Act
The Water (Prevention & Control of Pollution) Cess Act
The Mines & Minerals (Regulation & Development) Act
The Air (Prevention & Control of Pollution) Act
The Atomic Energy Act
The Radiation Protection Rules
The Indian Fisheries Act
The Indian Forest Act
The Wild Life (Protection) Act
The Environment (Protection) Act and Rules
The Hazardous Wastes (Management & Handling) Rules
The Manufacturing, Storage & import of Hazardous Chemicals Rules
The Public Liability Act
The Building and Other Construction Workers (Regulation of Employment and Condition of service)
Act
Other statutory acts Like EPF, ESIS, Minimum Wage Act.

HEALTH, SAFETY &
APPENDIX-E (Sheet 1 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES
ACTIVITY
(A)
EXCAVATION
Pit Excavation
upto 3.0m
TYPE OF
HAZARD
Falling into pit
EFFECT OF
HAZARD
Personal injury
Earth Collapse
Suffocation/
Breathlessness
Buried
Contact with
buried electric
cables
Gas/ Oil
Electrocution
Explosion
Pipelines
Pit Excavation
beyond 3.0m
Same as above
plus
Flooding due to
excessive rain/
underground
water
Digging in the
vicinity of
existing Building/
Structure
Movement of
vehicles/
equipments close
to the edge of cut.
Can cause
drowning situation
Building/Structure
may collapse
Loss of health &
wealth
May cause cave-in
or slides.
Persons may get
buried.
PREVENTIVE MEASURES
Provide guard rails/ barricade with warning
signal
Provide at least two entries/ exits.
Provide escape ladders.
Provide suitable size of shoring and strutting, if
required.
Keep soil heaps away from the edge equivalent to
1.5m or depth of pit whichever is more.
Don't allow vehicles to operate too close to
excavated areas. Maintain at least 2m distance
from edge of cut.
Maintain sufficient angle of repose. Provide
slope not less than 1:1 and suitable bench of 0.5m
width at every 1.5m depth of excavation in all
soils except hard rock.
Battering/benching the sides.
Obtain permission from competent authorities,
prior to excavation, if required.
Locate the position of buried utilities by referring
to plant drawings.
Start digging manually to locate the exact
position of buried utilities and thereafter use
mechanical means.
Prevent ingress of water
Provide ring buoys
Identify and provide suitable size dewatering
pump or well point system
Obtain prior approval of excavation method from

local authorities.
Use under-pining method
Construct retaining wall side by side.
Barricade the excavated area with proper lighting
arrangements
Maintain at least 2m distance from edge of cut
and use stop blocks to prevent over-run
Strengthen shoring and strutting

HEALTH, SAFETY &
APPENDIX-E: (Sheet 2 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (Contd.)
ACTIVITY
Narrow deep
excavations for
pipelines, etc.
Rock by
excavation
blasting
TYPE OF
HAZARD
Same as above
plus
Frequent cave-in
or slides
Flooding due to
Hydro- static
testing
Improper
handling of
explosives
Uncontrolled
explosion
Rock excavation
by blasting
(Contd)
Scattering of
stone pieces in
atmosphere
Entrapping of
persons/ animals.
Misfire
Piling Work
Failure of piledriving
equipment
Noise pollution
Extruding
rods/casing
Working in the
vicinity of 'LiveElectricity'
(B)
CONCRETING
EFFECT OF
HAZARD
May cause severe
injuries or prove
fatal
PREVENTIVE MEASURES
Battering/benching of sides
Provide escape ladders
May arise drowning Same as above plus

situation
Bail out accumulated water
Maintain adequate ventilation.
May prove fatal
Ensure proper storage, handling & carrying of
explosives by trained personnel.
Comply with the applicable explosive acts &
rules.
May cause severe
Allow only authorized persons to perform
injuries or prove
blasting operations.
fatal
Smoking and open flames are to be strictly
prohibited
Can hurt people
Use PPE like goggles, face mask, helmets etc.
May cause severe

injuries or prove
fatal
May explode
suddenly
Can hurt people
Can cause deafness

and psychological
imbalance.
Can hurt people
Can cause
electrocution/
Asphyxiation
Air pollution by
cement
Handling of
ingredients
May affect
Respiratory System
Hands may get
injured
Protruding
reinforcement
rods.
Feet may get

injured
Barricade the area with red flags and blow siren

before blasting.
Do not return to site for at least 20 minutes or
unless announced safe by designated person.
Inspect Piling rigs and pulley blocks before the
beginning of each shift.
Use personal protective equipments like ear
plugs, muffs, etc.
Barricade the area and install sign boards
Provide first-aid
Keep sufficient distance from Live-Electricity as
per IS code.
Shut off the supply, if possible
Provide artificial/rescue breathing to the injured
Wear respirators or cover mouth and nose with
wet cloth.
Use gloves & other PPE.
Use Provide platform above reinforcement for
movement of workers.

HEALTH, SAFETY &
APPENDIX-E : (Sheet 3 of 12)

ACTIVITY
Super-structure
(C)
REINFORCEMENT
TYPE OF
HAZARD
Earthing of
electrical
mixers,
vibrators, etc.
not done.
Falling of
materials from
height
EFFECT OF
HAZARD
Can cause
electrocution/
asphyxiation
Continuous
pouring by same
gang
Revolving of
concrete mixer/
vibrators
Same as above
plus
Deflection in
props or
shuttering
material
Passage to work
place
Cause tiredness of
workers and may
lead to accident.
Parts of body or
clothes may get
entrapped.
Shuttering/props
may collapse and
prove fatal
Curtailment and
binding of rods
Carrying of rods
for short
distances/at
heights
Checking of
clear distance/
cover with hands
Hitting projected
rods and
standing on
cantilever rods.
Persons may get

injured
Improperly tied and

designed
props/planks may
collapse
Persons may get
injured
Workers may get
injured their hands
and shoulders.
PREVENTIVE MEASURES
Ensure earthing of equipments and proper
functioning of electrical circuit before
commencement of work.
Use hard hats

Remove surplus material immediately from work
place.
Ensure lighting arrangements during night hours
Insist on shift pattern
Provide adequate rest to workers between
subsequent pours.
Allow only mixers with hopper
Provide safety cages around moving motors
Ensure proper mechanical locking of vibrator
Avoid excessive stacking on shuttering material
Check the design and strength of shuttering
material before commencement of work
Rectify immediately the deflection noted during
concreting.
Ensure the stability and strength of passage
before commencement of work.
Do not overload and stand under the passage.
Rods may cut or

injure the fingers
Use PPE like gloves, shoes, helmets, etc.

Avoid usage of shift tools
Provide suitable pads on shoulders and use safety
gloves.
Tie up rods in easily liftable bundles
Ensure proper staging.
Use measuring devices like tape, measuring rods,
etc.
Persons may get

injured and fell
down
Use safety shoes and avoid standing

unnecessarily on cantilever rods
Avoid wearing of loose clothes

HEALTH, SAFETY &

ACTIVITY
(D)WELDING
AND GAS
CUTTING
TYPE OF
EFFECT OF
HAZARD
HAZARD
Falling of material May prove fatal
from height
Transportation of
rods by trucks/
trailers
Protruded rods may

hit the persons
Welding radiates
invisible
ultraviolet and
infra-red rays
Improper
placement of
oxygen and
acetylene cylinders
Radiation can
damage eyes and
skin.
Leakage/ cuts in
hoses
Opening-up of
cylinder
Welding of tanks,
container or pipes
storing flammable
liquids
PREVENTIVE MEASURES
Use helmets
Provide safety nets
Use red flags/lights at the ends
Do not protrude the rods in front of or by the side
of driver's cabin.
rd
Do not extend the rods 1/3 of deck length or
1.5m whichever is less
Use specified shielding devices and other PPE of
correct specifications.
Avoid thoriated tungsten electrodes for GTAW
Explosion may occur Move out any leaking cylinder

Keep cylinders in vertical position
Use trolley for transportation of cylinders and
chain them
Use flashback arrestors
May cause fire
Purge regulators immediately and then turn off
Never use grease or oil on oxygen line
connections and copper fittings on acetylene lines
Inspect regularly gas carrying hoses
Always use red hose for acetylene & other
fuel gases and black for oxygen
Cylinder may burst
Always stand back from the regulator while
opening the cylinder
Turn valve slowly to avoid bursting
Cover the lug terminals to prevent short
circuiting
Explosion may occur Empty & purge them before welding
Never attach the ground cable to tanks, container
or pipe storing flammable liquids
Never use LPG for gas cutting

HEALTH, SAFETY &

ACTIVITY
(E)
RADIOGRAPHY
TYPE OF
HAZARD
Ionizing
radiation
Transpor-tation
and Storage of
Radiog-raphy
source
(F) ELECTRICAL
INSTALLATION
AND USAGE
(*)
Loss of Radio
isotope
Short circuiting
EFFECT OF
HAZARD
Radiations may react
with the skin and can
cause cancer, skin
irritation, dermatitis,
etc.
PREVENTIVE MEASURES
Ensure Safety regulations as per BARC/AERB

before commencement of job.
Cordon off the area and install Radiation warning
symbols
Restrict the entry of unauthorized persons
Wear appropriate PPE and film badges issued by
BARC/AERB
Never touch or handle radiography source with
Same as above
hands
Store radiography source inside a pit in an
exclusive isolated storage room with lock and
key arrangement. The pit should be approved by
BARC/AERB.
Radiography source should never be carried
either in passenger bus or in a passenger
compartment of trains.
BARC/AERB has to be informed before source
movement.
Permission from Director General of Civil
Aviation is required for booking radio isotopes
with airlines.
Same as above
Try to locate with the help of Survey Meter.
Inform BARC/AERB (*)
Can cause
Use rubberized hand gloves and other PPE
Electrocution or Fire Don't lay wires under carpets, mats or door ways.
Allow only licensed electricians to perform on
electrical facilities
Use one socket for one appliance
Ensure usage of only fully insulated wires or
cables
Don't place bare wire ends in a socket
Ensure earthing of machineries and equipments
Do not use damaged cords and avoid temporary
connections
Use spark-proof/flame proof type field
distribution boxes.
Atomic Energy Regulatory Board (AERB),

Bhabha Atomic Research Centre (BARC)
Anushaktinagar, Mumbai 400 094

HEALTH, SAFETY &

ACTIVITY
(G) FIRE
PREVENTION
AND
PROTECTION
TYPE OF
HAZARD
EFFECT OF
HAZARD
Overloading of
Electrical
System
Bursting of system
can occur which
leads to fire
Improper laying
of overhead and
underground
transmission
lines/cables
Can cause
electrocution and
prove fatal
Cause burn injuries

Small fires can
become big ones and may prove fatal
and may spread
to the
surrounding
areas
PREVENTIVE MEASURES
Do not allow open/bare connections
Provide all connections through ELCB
Protect electrical cables/equipment's from water
and naked flames
Check all connections before energizing
Display voltage and current ratings prominently
with 'Danger' signs.
Ensure approved cable size, voltage grade and
type
Switch off the electrical utilities when not in use
Do not allow unauthorized connections.
Ensure proper grid wise distribution of Power
Do not lay unarmoured cable directly on ground,
wall, roof of trees
Maintain at least 3m distance from HT cables
All temporary cables should be laid at least 750
mm below ground on 100 mm fine sand
overlying by brick soling
Provide proper sleeves at crossings/ intersections
Provide cable route markers indicating the type
and depth of cables at intervals not exceeding
30m and at the diversions/termination
In case a fire breaks out, press fire alarm system
and shout "Fire, Fire"
Keep buckets full of sand & water/ fire
extinguishing equipment near hazardous
locations
Confine smoking to 'Smoking Zones' only.
Train people for using specific type of fire
fighting equipments under different classes of fire
Keep fire doors/shutters, passages and exit doors
unobstructed
Maintain good housekeeping and first-aid boxes
(for details refer Appendix-B)
Don't obstruct assess to Fire extinguishers.
Do not use elevators for evacuation during fire.
Maintain lightening arrestors for elevated
structures
Stop all electrical motors with internal
combustion

HEALTH, SAFETY &

ACTIVITY
TYPE OF
HAZARD
Improper
selection of Fire
extinguisher
EFFECT OF
HAZARD
It may not
extinguish the fire
Improper storage Same as above

of highly
inflammable
substances
(H)
VEHICULAR
MOVEMENT
Short circuiting
of electrical
system
Same as above
Can cause
Electrocution
Crossing the
Speed Limits
(Rash driving)
Personal injury
Adverse weather Same as Above

condition
PREVENTIVE MEASURES
Move the vehicles from dangerous locations
Remove the load hanging from the crane booms
Remain out of the danger areas.
Ensure usage of correct fire extinguisher meant
for the specified fire (for details refer AppendixC).
Do not attempt to extinguish Oil and electric
fires with water. Use foam cylinders/CO2/sand
or earth.
Maintain safe distance of flammable substances
from source of ignition
Restrict the distribution of flammable materials
to only min. necessary amount
Construct specifically designed fuel storage
facilities
Keep chemicals in cool and dry place away from
heat. Ensure adequate ventilation
Before welding operation, remove or shield the
flammable material properly
Store flammable materials in stable racks,
correctly labeled preferably with catchment
trays.
Wipe off the spills immediately
Don't lay wires under carpets, mats or door ways
Use one socket for one appliance.
Use only fully insulated wires or cables
Do not allow open/bare connections
Provide all connections through ELCB
Ensure earthing of machineries and equipments
Obey speed limits and traffic rules strictly
Always expect the unexpected and be a
defensive driver
Use seat belts/helmets
Blow horn at intersections and during
overtaking operations.
Maintain the vehicle in good condition
Do not overtake on curves, bridges and slopes
Read the road ahead and ride to the left
Keep the wind screen and lights clean
Do not turn at speed.
Recognize the hazard, understand the defense
and act correctly in time.

HEALTH, SAFETY &

ACTIVITY
(I)
PROOF
TESTING
(HYDROSTATI
C /PNEUMATIC
TESTING)
TYPE OF
HAZARD
Consuming
alcohol before
and during the
driving
operation
EFFECT OF
HAZARD
Same as above
Falling objects/
Mechanical
failure
May prove fatal
Bursting of
piping
Collapse of
tanks
Tanks flying off
May cause injury

and prove fatal
PREVENTIVE MEASURES
Alcohol and driving do not mix well. Either
choose alcohol or driving.
If you have a choice between hitting a fixed
object or an on-coming vehicle, hit the fixed
object
Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
Do not force the driver to drive fast and round the
clock.
Do not day dream while driving
Ensure effective braking system, adequate
visibility for the drives, reverse warning alarm..
Proper maintenance of the vehicle as per
manufacturer instructions
Prepare test procedure & obtain PDIL/owner's
approval
Provide separate gauge for pressurizing pump
and piping/equipment
Check the calibration status of all pressure
gauges, dead weight testers and temperature
recorders
Take dial readings at suitable defined intervals
and ensure most of them fall between 40-60% of
the gauge scale range
Provide safety relief valve (set at pressure
slightly higher than test pressure) while testing
with air/ nitrogen
Ensure necessary precautions, stepwise increase
in pressure, tightening of bolts/nuts, grouting, etc.
before and during testing
Keep the vents open before opening any valve
while draining out of water used for hydro-testing
of tanks.
Pneumatic testing involves the hazard of released
energy stored in compressed gas. Specific care
must therefore be taken to minimize the chance
of brittle failure during a pneumatic leak test.
Test temperature is important in this regard and
must be considered when the designer chooses
the material of construction.

HEALTH, SAFETY &

ACTIVITY
(J)
WORKING AT
HEIGHTS
TYPE OF
HAZARD
Person can fall

down
Material can fall

down
(K) CONFINED
SPACES
Suffocation/
drowning
EFFECT OF
HAZARD
May sustain severe

injuries or prove
fatal
May hit the

scrap/material
stacked at the
ground or in
between
May hit the workers
working at lower
levels and prove
fatal
Unconsciousness,
death
PREVENTIVE MEASURES
A pressure relief device shall be provided, having
a set pressure not higher than the test pressure
plus the lesser of 345 KPa (50 psi) or 10% of the
test pressure.
The gas used as test fluid, if not air, shall be
nonflammable and nontoxic.
Provide guard rails/barricade at the work place
Use PPE like full body harness, life line, helmets,
safety shoes, etc.
Obtain a permit before starting the work at height
above 3 meters
Fall arrest and safety nets, etc. must be installed
Provide adequate working space (min. 0.6 m)
Tie/weld working platform with fixed support
Use roof top walk ladder while working on a
slopping roofs
Avoid movement on beams
Keep the work place neat and clean
Remove the scrap immediately
Same as above plus

Do not throw or drop materials or equipment
from height. I.e. do not bomb materials
All tools to be carried in a tool-kit
Bag or on working uniform
Remove scrap from the planks
Ensure wearing of helmet by the workers
working at lower levels
Use respiratory devices, if reqd.
Avoid over crowding inside a confined space
Provide Exhaust fans for ventilation
Do not wear loose clothes, neck ties, etc
Fulfill conditions of the permit

HEALTH, SAFETY &

ACTIVITY
TYPE OF
HAZARD
EFFECT OF
HAZARD
PREVENTIVE MEASURES
Check for presence of hydrocarbons, O2 level
Obtain work permit before entering a confined
space
Ensure that the connected piping of the
equipment which is to be opened is pressure
free, fluid has been drained, vents are open and
piping is positively isolated by a blind flange
Presence of
foul smell and
toxic
substances
Ignition/ flame
can cause fire
(L)
HANDLING
AND
LIFTING
EQUIPMENTS
Failure of load
lifting and
moving
equipments
Inhalation can pose

threat to life
Same as above plus

Check for hydrocarbon and Aromatic compounds
before entering a confined space
Depute one person outside the confined space for
continuous monitoring and for extending help in
case of an emergency
Person may sustain
Keep fire extinguishers at a hand distance
burn injuries or
Remove surplus material and scrap immediately
explosion may occur Do not smoke inside a confined space
Do not allow gas cylinders inside a confined
space
Use low voltage (24V) lamps for lighting
Use tools with air motors or electric tools with
max. voltage of 24V
Remove all equipments at the end of the day
Can cause accident
Avoid standing under the lifted load and within
and prove fatal
the operating radius of cranes
Check periodically oil, brakes, gears, horns and
tyre pressure of all moving machinery
Check quality, size and condition of all chain
pulley blocks, slings, U-clamps, D-shackles, wire
ropes, etc.
Allow crane to move only on hard, firm and
leveled ground.
Allow lifting slings as short as possible and
check gunny packings at the friction points
Do not allow crane to tilt its boom while moving
Install Safe Load Indicator
Ensure certification by applicable authority

HEALTH, SAFETY &

ACTIVITY
(M)
SCAFFOLDI
NG,
FORMWOR
K
AND
LADDERS
TYPE OF
HAZARD
Overloading of
lifting
equipments
EFFECT OF
HAZARD
Same as above
Overhead
electrical wires
Can cause
electrocution and
fire
Person can fall

down
Person May sustain

severe injuries and
prove fatal
Failure of
scaffolding
material
Same as above
Material can
fall down
Persons working at
lower level gets
injured
PREVENTIVE MEASURES
Safe lifting capacity of derricks and winches
written on them shall be got verified
The max. safe working load shall be marked on
all lifting equipments
Check the weight of columns and other heavy
items painted on them and accordingly decide
about the crane capacity, boom and angle of
erection
Allow only trained operators and riggers during
crane operation.
Do not allow boom or other parts of crane to
come within 3m reach of overhead HT cables
Hook and load being lifted shall preferably
remain in full visibility of crane operators.
Provide guard rails for working at height
Face ladder while climbing and use both hands.
Ladders shall extend about 1m above landing for
easy access and tying up purpose
Do not place ladders against movable objects and
maintain base at 1/4 unit of the working length of
the ladder.
Suspended scaffolds shall not be less than 500
mm wide and tied properly with ropes
No loose planks shall be allowed
Use PPE, like helmets, safety shoes,etc
Inspect visually all scaffolding materials for
stability and anchoring with permanent
structures.
Design scaffolding for max. load carrying
capacity.
Scaffolding planks shall not be less than 50X250
mm full thickness lumber or equivalent. These
shall be cleated or secured and must extend over
the end supports by at least 150mm and not more
than 300mm
Don't overload the scaffolds
Do not splice short ladders to make a longer one.
Vertical ladders shall not exceed 6m.
Remove excess material and scrap immediately
Carry the tools in a tool-kit bag only
Provide safety nets

HEALTH, SAFETY &

TYPE OF
HAZARD
Personal
(N)
STRUCTUR negligence and
AL WORKS danger of fall
ACTIVITY
(O)
PIPELINE
WORKS
(P)
GRIT
BLASTING
EFFECT OF
HAZARD
Can cause injury or
casualty
Lifting/ slipping
of material
Same as above
Erection/
lowering failure
Can cause injury
Other
Same as above
Pollution in
neighboring
area, hit by grits
and high
pressure air
Can cause personal

injury
PREVENTIVE MEASURES
Do not take rest inside rooms built for welding
machines or electrical distribution system.
Avoid walking on beams at height
Wear helmet with chin strap and full body
harness while working at height.
Use hand gloves and goggles during grinding
operations
Cover or mark the sharp and projected edges
Do not stand within the operating radius of
cranes
Do not stand under the lifted load
Stack properly all the materials. Avoid slippage
during handling
Control longer pieces lifted up by cranes from
both ends
Remove loose materials from height
Ensure tightening of all nuts & bolts
Do not stand under the lifted load
Do not allow any person to come within the
radii of the side boom handling pipes
Check the load carrying capacity of the lifting
tools & tackles
Use safe Load Indicators
Use appropriate PPEs
Wear gum boots in marshy areas
Allow only one person to perform signaling
operations while lowering of pipes
Provide night caps on pipes
Provide end covers on pipes for stoppage of pigs
while testing/ cleaning operations
Ensure the blasting is done in enclosed shed.
Keep safe distance while blasting operations.
Wear positive pressure blast hood or helmet
with view window, ear-muff/plug, gloves,
overall or leather coat /apron, rubber shoes.

HEALTH, SAFETY &
APPENDIX-F
TRAINING SUBJECTS / TOPICS
(For contractors personnel)

1.
The Law & Safety Statutory Requirement / Applicable statutes / Duties of employer / employee
2.
Policy & Administration Why HSE? / Duties & Responsibilities of Safety

site / Effect of incentive on accident prevention
3.
HSE & Supervision Duties of Supervisor / HSE integrated supervision /

responsible for site accidents?
4.
Safety Budget / Cost of Accidents Direct costs / Indirect costs
5.
Hazard Identification / Type of hazards / HIRAC
6.
Behavioural Safety & Motivation
7.
Housekeeping Storage / Stacking / Handling of materials / Hydra handling
8.
Occupational Health in Construction sector
9.
Personal Protective Equipments Respiratory & Non- respiratory
10.
Electricity & Safety ELCB / Fuse / Powered tools / Project illumination
11.
Handling of Compressed Gas Transportation / Storage / FBAs / Fire prevention
12.
Machine Safety Machine guarding / Maintenance
13.
Transportation Hazards & risks in transp. of materials / ODC consignments
14.
Cranes & Other Lifting machinery Legal requirements vis--vis essential safety requirements.
15.
Communication HSE Induction / TBTs / Safety Committee / Safety meeting /

propaganda / Publicity.
16.
Excavation Risks & Dangers / Safety measures
17.
Working at Heights Use of ladder / Work on roofs / Scaffolds / Double harness

line / Fall arrester / Safety Nets / Floor openings
18.
Hazards in Welding & important safety precautions
19.
Gas Cutting Hazards & safety measures
20.
Fire prevention & fire protection
Personnel at project
Who should be held
Safety
lanyards / Life-

HEALTH, SAFETY &
APPENDIX - G
CONSTRUCTION POWER BOARD( typ)

HEALTH, SAFETY &
APPENDIX-H
LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:A.
HSE Management Procedures:

x
x HSE Risk Management (including JSA/HIRA)
x HSE Legal Compliance and Other Requirements
x HSE Objectives & Performance
x HSE Training and Competence (including Induction)
x HSE Motivation & Award Scheme
x HSE Audits
x HSE Meetings
x HSE Sub Contractor Management
x HSE Emergency Management
x HSE Incidents Reporting and Management
x HSE Reports
x HSE Management System Review
x HSE Change Management
x HSE procedure for Behaviour based Safety
x First Aid & Management
Roles, Responsibility, accountabilities and Authorities
B.
Job procedures/Safe Operating procedures

x
x Setting Up Site & Signages
x Handling of Electrical Appliances
x Working at Height
x
Confined Space Entry
x Permit to Work (including hot works)
x Housekeeping
x Lifting Operations
x Transportation of materials including Manual Handling
x Compressed Air Tools and Units
x Earthmoving Operations & excavation
x Scaffolding
x Fire Prevention/Protection
x
Hazardous Substance handling & Storage
x Radiation Hazard
Personal Protective Equipment

HEALTH, SAFETY &
FORMAT NO.
HSE-1 REV 0
(Sheet 1 of 6)
SAFETY WALK-THROUGH REPORT
(Name & signature of walk through performer to be inserted at the bottom of each page)
Project
: _____________
Report no.
: ___________
Date
: _____________
Contractor
: ___________
Inspection by
:_____________
Owner
: ___________
Frequency
: Monthly
Job no.
: ___________
Note : Write NA wherever the item is not applicable

SL.
NO.
ITEM
1.
a)
HOUSEKEEPING
Waste containers provided and used
b)
Sanitary facilities adequate and Clean
c)
Passageways and Walkways Clear
d)
General neatness of working areas
e)
Other
2.
PERSONNEL PROTECTIVE EQUIPMENT
a)
b)
Goggles; Shields
Face protection
Satisafctory
/ Yes
Non
satisfactory/
No
Remarks
Action
Hearing protection
Foot protection
e)
Hand protection
f)
Respiratory Masks etc.
g)
Full body harness conforming to C , EN 361
h)
Hard hat (HDPE)
i)
Other
3.
EXCAVATIONS/OPENINGS
a)
b)
Openings properly covered or barricaded

Excavations shored
c)
Excavations barricaded
d)
Overnight lighting provided
e)
Other
Safety walk-through performer (Name & Signature)..

HEALTH, SAFETY &
FORMAT NO.
HSE-1 REV 0
(Sheet 2 of 6)
SL.
NO.
ITEM
4.
WELDING & GAS CUTTING
a)
Gas cylinders chained upright
b)
Cables and hoses not obstructing
c)
Screens or shields used
d)
Flammable materials protected
e)
Live electrode bits contained properly
f)
Fire extinguisher (s) accessible
g)
Other
5.
SCAFFOLDING & BARRICADING
a)
Fully decked platforms
b)
Guard and intermediate rails in place
c)
Toe boards in place
d)
Adequate shoring
e)
Adequate access
f)
Positive barricading for critical activities
g)
Installation of warning signs
h)
Other
6.
LADDERS
a)
Extension side rails 1 m above
b)
Top of landing
c)
Properly secured
d)
Angle + 70 from horizontal
e)
Other
Satisafctory
/ Yes
Non
satisfactory/
No
Remarks
Action
Safety walk-through performer (Name & Signature)..

HEALTH, SAFETY &
FORMAT NO.
HSE-1 REV 0
(Sheet 3 of 6)
SL.
NO.
ITEM
7.
HOISTS, CRANES AND DERRICKS
a)
Condition of cables and sheaves OK
b)
Condition of slings, chains, hooks and eyes

O.K.
Inspection and maintenance log-books
maintained
Outriggers used
c)
d)
e)
f)
Reverse horn installed / active / coupled with

gear
Signs/barricades provided
g)
Signals observed and understood
h)
Qualified operators
i)
Other
8.
MACHINERY, TOOLS AND EQUIPMENT
a)
Proper instruction
b)
Safety devices
c)
Proper cords
d)
Inspection and maintenance
e)
Other
9.
VEHICLE AND TRAFFIC
a)
Rules and regulations observed
b)
Inspection and maintenance
c)
Licensed drivers
d)
Other
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Safety walk-through performer (Name & Signature)
Action

HEALTH, SAFETY &
FORMAT NO.
HSE-1 REV 0
(Sheet 4 of 6)
SL.
NO.
ITEM
10.
TEMPORARY FACILITIES
a)
Emergency instructions posted
b)
Fire extinguishers provided
c)
Fire-aid equipment available
d)
Secured against storm damage
e)
General neatness
f)
In accordance with electrical requirements
g)
Other
11.
FIRE PREVENTION
a)
c)
Personnel trained & instructed to make use

of facility
Fire extinguishers checked periodically &
record maintained
No smoking in Prohibited areas.
d)
Fire Hydrants not obstructed Clear
e)
Other Regular fire drill conducted
12.
ELECTRICAL
a)
Use of 3-core armored cables everywhere
b)
Usage of 'All insulated' or 'double-insulated'

electrical tools
All electrical connection are routed through
ELCB
Natural Earthing at the source of power
(Main DB)
Continuity and tightness of earth conductor
b)
c)
d)
e)
f)
g)
Effective covering of junction boxes, panels

and other energized wiring places
Ground fault circuit interrupters provided
h)
Prevention of tripping hazards maintained
f)
DCP extinguishers arranged & licensed

electrician engaged at site
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Action

HEALTH, SAFETY &
FORMAT NO.
HSE-1 REV 0
(Sheet 5 of 6)
SL.
NO.
14.
a)
b)
c)
15.
a)
b)
c)
d)
16.
a)
b)
c)
d)
e)
17.
a)
b)
c)
d)
e)
f)
g)
18.
a)
b)
ITEM
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
HANDLING AND STORAGE OF

MATERIALS
Safely stored or stacked
Passageways clear / free from obstructions
Fire fighting facility in place
FLAMMABLE GASES AND LIQUIDS
Containers clearly identified / protected from
fire
Safe storage & transportation arrangement
made
Fire extinguishers positioned nearby
Facilities kept away from electric spark, hot
spatters & ignition source.
WORKING AT HEIGHT
Approved Erection plan and work permit in
place
Safe access, Safe work platform & Safety
nets provided
Life lines, Fall arrester, Full body harness
and with double lanyards used;
Health Check record available for workers
going up?
Protective handrails arranged around floor
openings
CONFINED SPACE
Work Permit obtained from requisite
authority
Test for toxic gas and sufficient availability
of oxygen conducted & status
Supervisor present at site & at least one
person outside the confined space for
monitoring deputed
Availability of safe means of entry, exit and
ventilation (register for entry & exit
maintained)
Fire extinguisher and first-aid facility
ensured
Lighting provision made by using 24V Lamp
Proper usage of PPEs ensured
RADIOGRAPHY
Proper storage and handling of source as per
BARC/ AERB guidelines (authorized
radiographer available)
Work permit obtained
Action

HEALTH, SAFETY &
FORMAT NO.
HSE-1 REV 0
(Sheet 6 of 6)
SL.
NO.
ITEM
c)
Cordoning of the area done
d)
Use of appropriate PPE's ensured
e)
f)
HSE training to workers/supervisors

imparted during the fortnight (indicate topic)
Minimum occupancy of workplace ensured
19.
HEALTH CHECKS
a)
All Workers medically examined and found

be fit for working at heights (slinging,
rigging, painting etc.)
in confined space
in excavation / trenching
in shot blasting
Availability of First Aid box with contents
b)
c)
d)
e)
f)
g)
h)
20.
a)
b)
c)
d)
e)
f)
g)
Satisafctory
/ Yes
Non
satisfactory
/No
Remarks
Proper sanitation at site, office and labour

camps
Arrangement of medical facilities.
Measures for dealing with illness at site &
labour camps.
Availability of Potable drinking water for
workmen & staff.
Provision of crches for children.
Stand by vehicle / ambulance available for
evacuation of injured
ENVIRONMENT
Chemical and Other Effluents properly
disposed
Cleaning liquid of pipes disposed off
properly
Seawater used for hydro-testing disposed off
as per agreed procedure
Lubricant Waste/Engine oils properly
disposed
Waste from Canteen, offices, sanitation etc
disposed properly
Disposal of surplus earth, stripping materials,
Oily rags and combustible materials done
properly
Green belt protection
Action

HEALTH, SAFETY &
FORMAT NO.
HSE-2 REV 0
(Sheet 1 of 3)
ACCIDENT / INCIDENT REPORT
(To be submitted by Contractor after every Incident / Accident within 24 hours to PDIL/ Owner)
Report No.: ____________________________
Date: ______________________
Project site: ____________________________ Name of work: _______________________

Contractors name: ________________
Non-disabling injury (NonLTA)
Disabling injury (other LTA)
Fatal (LTA):
First Aid case (non LTA)
Contractors Job Engineer (name) ________
Hospitalized but resumed duty before end of 48 hrs

Hospitalized & failed to resume duty within next 48 hrs
Death / Expiry
Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractors Name: .
Gate Pass No.:.. Age: _____Yrs. Victims medical fitness exam. (Pre-empl.) date: - ______
Date & time of Accident / Incident: _______________________________________________
Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender
Carpenter
Meson
Fitter
Helper
Gas cutter
Grinder
Welder
Electrician
Driver
Rigger
M/c.operator
Engineer
Manager
Other/specify
No formal education
Non-Matriculate
Matriculate
Graduate
Post- grad
Other/specify
NIL
Less than 2 yrs
2-5 yrs
5-10 yrs
11-15 yrs
15 years and above
Qualification
Job Experience
Location where the incident happened: ___________________________________________

______________________________________________________________________________

HEALTH, SAFETY &
FORMAT NO.
HSE-2 REV 0
(Sheet 2 of 3)
Activity / Works that was continuing during incident / accident: Excavation
Demolition
Concrete carrying
Concrete pouring
Transportation of materials
Transportation
(manually)
materials (mechanically)
Work on or adjacent to water
Work at height (+2.0 mts)
Scaffold preparation
Scaffold dismantling
Piling works
Welding
Grinding
Gas-cutting
Pipe fit-ups & fabrication
Structural fabrications
Machine works
Hydro-testing works
Electrical works
Erection activities
Other/specify
of
What exactly the victim was doing just before the incident / accident? ....................................
.
.
Nature of injury:
Bruise or Contusion
Abrasion (superficial wound)
Sprains or strains
Cut or Laceration
Puncture or Open wound
Burn
Inhalation of toxic or
Poisonous fumes or gases
Fracture
Absorption
Amputation
Other/specify
Parts of body involved in incident / accident

Face
Head
Eyes
Throat
Arm (above wrist)
Hand (including wrist)
Fingers
Truck (Abdomen / Back /
Throat
Chest / Shoulder)
Leg (above ankle)
Foot (incl. ankle)
Multiple
Toes
Other/specify
Accident type:
Struck against
Struck by
Fall from Elevation
Fall on same level
caught in
caught under
caught in between
Rubbed or abraded
Contact with (Electricity)
Contact with chemicals or

oils
Vehicle accident
Contact
with
extremes)
Other/specify
(Temp./

HEALTH, SAFETY &
FORMAT NO.
HSE-2 REV 0
(Sheet 3 of 3)
Medical Aid provided: - (indicate specific aids / treatment etc.).

..
------------------------------------------------------------------------------------------------------------------------Actions taken to prevent recurrence of similar incident / accident:
.
.
.
.
...
_____________________________________________________________________________
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ..
Safety Officer
Site Head / Resident Construction Manager
(Signature and Name)

Stamp of Contractor
To
:
:
Owner
RCM/Site-in-charge PDIL (3 copies)
Divisional Head (Constn) through RCM
Project Manager, PDIL, through RCM

HEALTH, SAFETY &
FORMAT NO.
HSE-3 REV 0
(Sheet 1 of 5)
SUPPLEMENTARY INCIDENT / ACCIDENT INVESTIGATION REPORT

TICK THE APPROPRIATE ONE AS APPLICABLE (furnish within 72 hours)
Supplementary to Incident / Accident Report No: ______ (Copy enclosed)
Date: ______________________
Report No.: ____________________________
Project site: ____________________________ Name of work: _______________________
Contractors name: ________________
Non-disabling injury (NonLTA)
Disabling injury (other LTA)
Fatal (LTA):
First Aid case (non LTA)
Contractors Job Engineer (name) ________
Hospitalized but resumed duty before end of 48 hrs

Hospitalized & failed to resume duty within next 48 hrs
Death / Expiry
Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractors Name: .
Gate Pass No.:.. Age: _____Yrs. Victims medical fitness exam. (Pre-empl.) date: - ______
Date & time of Accident / Incident: _______________________________________________
Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender
Carpenter
Meson
Fitter
Helper
Gas cutter
Grinder
Welder
Electrician
Driver
Rigger
M/c.operator
Engineer
Manager
Other/specify
No formal education
Non-Matriculate
Matriculate
Graduate
Post- grad
Other/specify
NIL
Less than 2 yrs
2-5 yrs
5-10 yrs
11-15 yrs
15 years and above
Qualification
Job Experience
Location where the incident happened: ___________________________________________

______________________________________________________________________________

HEALTH, SAFETY &
FORMAT NO.
HSE-3 REV 0
(Sheet 2 of 5)
Activity / Works that was continuing during incident / accident: Excavation
Demolition
Concrete carrying
Concrete pouring
Transportation of materials
Transportation
(manually)
materials (mechanically)
Work on or adjacent to water
Work at height (+2.0 mts)
Scaffold preparation
Scaffold dismantling
Piling works
Welding
Grinding
Gas-cutting
Pipe fit-ups & fabrication
Structural fabrications
Machine works
Hydro-testing works
Electrical works
Erection activities
Other/specify
of
What exactly the victim was doing just before the incident / accident? ....................................
.
.
Particular of tools & tackles being used and condition of the same after incident/accident:
.........................................
was
caused):
(How
the
incident
Description
of
Incident/Accident
.
Nature of injury:
Bruise or Contusion
Abrasion (superficial wound)
Sprains or strains
Cut or Laceration
Puncture or Open wound
Burn
Inhalation of toxic or
Poisonous fumes or gases
Fracture
Absorption
Amputation
Other/specify
Parts of body involved in incident / accident

Head
Face
Eyes
Throat
Arm (above wrist)
Hand (including wrist)
Fingers
Truck (Abdomen / Back /
Throat
Chest / Shoulder)
Leg (above ankle)
Multiple
Foot (incl. ankle)
Toes
Other/specify

HEALTH, SAFETY &
FORMAT NO.
HSE-3 REV 0
(Sheet 3 of 5)
Accident type:
Struck against
Struck by
Fall from Elevation
Fall on same level
caught in
caught under
caught in between
Rubbed or abraded
Contact with (Electricity)
Contact with chemicals or

oils
Vehicle accident
Contact
with
extremes)
Other/specify
(Temp./
Name & Designation of person who provided First-Aid to the victim: ---------------------------------------
Name & Telephone number of Hospital where the victim was treated_________________________
Mode of transport used for transporting victim Ambulance / Private car / Tempo / Truck / Others
How much time taken to shift the injured person to Hospital________________________________
In case of FATAL incident, indicate clearly the BOCW Registration No. of the victim
/Company
Comments of Medical Practitioner, who treated / attended the victim/injured (attached / described
here)_____________________________________________________________________
What actions are taken for investigation of the incident, please indicate clearly (Video film /
Photography / Measurements taken etc..)
Immediate cause (Please tick the right applicable)

Hazardous
methods
or
procedures
inadequately
guarded
Environmental
hazards
(excess
noise/
space
constraint/
inadequate
ventilation
Poor housekeeping
Inadequate or improper
PPE
improper
illumination/Moving on oval
surface
Working on dangerous
equipment

HEALTH, SAFETY &
FORMAT NO.
HSE-3 REV 0
(Sheet 4 of 5)
Failure to secure
Horse-play
Failure to use PPE
Inattention to surroundings
Improper use of hands &

body-parts
Bypassing
standard
procedures
Improper use of equipment
or tools & tackles
Others(specify)
By-passing safety devices
Over confidence
Impulsiveness
over-exertion
Faulty judgement or poor

understanding
Fatigue
Failing to keep attention

constantly
Defective vision
Nervousness & Fear
Slow reaction
Others(specify)
Unsafe mixing or placement

of tools & tackles
Operating without authority
excessive haste
Failure in communication
drug
or
influence
alcoholic
Basic cause
Ill health or sickness
Root cause
Inadequate Engg
Improper Design
Inadequate knowledge
Inadequate skill
Inadequate supervision
Improper work procedure
Substandard performance
Inadequate maintenance
Inadequate Planning &

organization
Inadequate training
Inadequate compliance
with standard
Improper inspection
Others(specify)
Loss of man days and impact on site works, (if any)
Remarks from Contractors Safety Officer / Engineer

Was the victim performing relevant tasks for which he was engaged /employed?
Yes / No
Was the Supervisor present on work-site during the incident?
Yes / No
Have the causes of incident rightly identified?
Yes / No
Cause of Accident was_____________________________________________________________

HEALTH, SAFETY &
FORMAT NO.
HSE-3 REV 0
(Sheet 5 of 5)
Remedial measures recommended by Safety Officer of Contractor for avoiding similar incident in
future
:
.
.
.
.
...
Intimation to local authorities (Dist Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ..
_____________________________________________________________________________
Safety Officer
Site Head / Resident Construction Manager

Stamp of Contractor
To :
:
Owner
RCM// Site-in-charge of PDIL (3 copies)
_
Project Manager PDIL, through RCM

HEALTH, SAFETY &
FORMAT NO.
HSE-4 REV 0
NEAR MISS INCIDENT/ DANGEROUS OCCURRENCE SUGGESTED PROFORMA

(to be submitted within 24 hours)
x
Near Miss : Human injury escaped & no damage to property, equipment
x or interruption to work.
Dangerous Occurrence: Damage to property, equipment or interruption of work, but not
resulting in personal injury/illness, e.g. Fire incident, collapse of structure, crane failure,
etc
Report No.: _________________
Name of Site: _________________________
Date: ______________________
Name of work: __________________________
Contractor: __________________
__________________________________________________________________________________
Incident reported by
Date & Time of Incident
Location
__________________________________________________________________________________
Brief description of incident
__________________________________________________________________________________
Probable cause of incident
__________________________________________________________________________________
Suggested corrective action
__________________________________________________________________________________
Steps taken to avoid recurrence
To
:
:
Yes
Owner
RCM/Site-in-charge PDIL (3 copies)
Project Manager PDIL, through RCM
No

HEALTH, SAFETY &
FORMAT NO.
:
HSE-5 REV 0
MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by each Contractor)
Actual work start Date: _______________

For the Month of: __________________
Project: ____________________________
Report No: ________________________
Name of the Contractor: ______________
Status as on : ______________________
Name of Work : _____________________
Job No : __________________________
(Contractor in consultation with PDIL shall generate the reports through web based
package(www.PDIL.co.in/conthse) only.
UPTO
PREVIOUS
MONTH
ITEM
THIS
MONTH
CUMULATIVE
1) Average number of Staff & Workmen

(average daily headcount, not man days)
2) Man-hours worked
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
Fatal
7) Number of Lost Time Accidents (LTA)
Other LTA
Fatalities
8) Number of Loss Time Injuries (LTI)
Other LTI
9) Number of Non-Loss Time Accidents
10) Number of First Aid Cases
11) Number of Near Miss Incidents
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to accidents
15) LTA Free man-hours i.e. LTA free man-hours counted from the
Last LTA (enter date: .)
16) Frequency Rate (No. of LTA per 2 lacs man-hours worked)
17) Severity Rate (No. of man days lost per 2 lacs man-hours
worked)
18) Loss Time Injury Frequency (No. of LTI per 2 lacs man-hours
worked)
19) No. of activities for which Job Safety Analysis (JSA) completed
20) No. of incentives/ awards given
21) No. of occasions on which penalty imposed by PDIL/ Owner
22) No. of Audits conducted
23) No. of pending NCs in above Audits
24) Compensation cases raised with Insurance
25) Compensation cases resolved and paid to workmen
26) Whether workmen compensation policy taken
27) Whether workmen compensation policy is valid
28) Whether workmen registered under ESI Act, as applicable
Remarks, if any
Date:
Prepared by Safety Officer
To : - OWNER
- RCM PDIL (2 copies)
Yes
Yes
Yes
No
No
No
Approved by Site Head / Resident Construction Manager


HEALTH, SAFETY &
FORMAT NO.
:
HSE-6 REV 0
PERMIT FOR WORKING AT HEIGHTS (ABOVE 2.0 METER)
(In duplicate to be issued daily for site and for office)
Permit No..
Name of Main Contractor
Name of work executing agency / sub agency / vendor:...
Date
Exact Location of work
Nature of work ..Duration of work (from) (to) .......
Number of workers covered within this permit
(List enclosed with name & gate pass numbers.)
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Status of compliance
(Yes / No)
Items / Subjects
Work areas / Equipments inspected
Work area cordoned off
Adequate lighting is provided
Precautions against public traffic taken
Concerned persons in & around have been alerted & cautioned
Hazards / risks involved in routine / non-routine task assessed and control
measures have been implemented at specific task
ELCB provided for electrical connection & found working
Ladder safely attached / fixed
Scaffoldings are checked and TAGs are found used correctly
Working platforms are provided and are found sound /safe for use
Safe access & egress arrangements (e.g. ladders, fall arresters, life-lines etc.)
are satisfactorily incorporated
a.
Openings on platform / floors are effectively cordoned / covered
b.
Safety Nets are provided wherever required
Use of following safety gadgets by people working at area under this permit, is
checked and found satisfactory Safety helmet
Safety harness (full body) with double lanyard
Safety Shoes
Safety gloves
Safety goggles
Housekeeping of work area found satisfactorily tidy / clean & clear
Adequate measures have been taken for works being continued at the ground
level, when simultaneous works are permitted overhead at that very location.
Materials are not thrown from heights on to ground
Medical examination of workers are made & found satisfactory
Responsible job engineer / supervisor found physically present at work spot for
overall administration of work as well as safety of people.
Above items have been checked & compliance has been found in place. Hence work is permitted to
start / continue at the above-mentioned location. Work shall not start till identified lapses are rectified.
Additional Precautions, if any .
..
Work Permit issued by
Contractor Engineer/RCM
Verification By
Contractor Safety Officer
AT THE END OF THE DAY/WORK:

All works at height are completed & workmen have returned safely from work location at
(time).. (date)
(Sig. Contractor Engineer)

HEALTH, SAFETY &
FORMAT NO.
HSE-7 REV 0
CONFINED SPACE ENTRY PERMIT

Sr.No. _________________________
Project site ___________________________
Name of the work ______________________
Date ___________________________
Name of Contractor ____________________
Nature of work ___________________
Exact location of work _____________
Safety Requirements POSITIVE ISOLATION OF THE VESSEL IS MANDATORY
(A) Has the equipment been ?
Y
NR
Isolated
from
power/steam/air
isolated from liquid or
gases
depressurized
&/or
drained
blanked/
blinded/
disconnected
(B)
Expected Residual Hazards
lack of O2
corrosive chemicals
heat/ steam / frost

(C)
Protection Measures
gloves
protective clothing
grounded air duct/blower
/AC
Fire fighting arrangements
Y
NR
Y
NR
water
flushed
&/or
steamed
Man ways open &
ventilated
cont. inert gas flow
arranged
adequately cooled
combustible gas/ liquid

pyrophoric iron / scales
high humidity
ear plug / muff
dust / gas / air line mask

attendant with SCBA/air
mask
safety harness & lifeline
radiation
removed
proper
provided
sources
lighting
H2S / toxic gases

electricity / static
ionizing radiation
goggles / face shield

personal gas alarm
rescue
equipment/team
communication
equipment
Authorization / Renewal (It is safe to enter the confined space)

No.
of
persons
Name of persons allowed
allowed
Signature
Contractor's
Supervisor
Contractor's
Safety Officer
Time
From
Permit Closure :
was closed
stopped
will continue on ...
(A) Entry
Site left in a safe condition

Housekeeping done
(B)
removed
key transferred
(C) Multilock
Ensured all men have come out
Man-ways barricaded
Remarks, if any:
To
Signature
Workman

HEALTH, SAFETY &
FORMAT NO.
HSE-8 REV 0
RADIATION WORK PERMIT
:
Project
Name of the work
:
Name of site contractor :
Location of work
Source strength
Sr.No. :
Date :
Job No.:
Cordoned distance (m) :

Name of Radiography agency :
No. of workers engaged
Approved by Owner/PDIL
The following items have been checked &compliance shall be ensured during currency of the
permit:
S. No.
Item description
Safety regulations as per BARC/AERB ensured while source in use/in transit & during
storage
Area cordoned off / safe working platform provided
Lighting arrangements for working during nights ensured
Warning signs/ flash lights installed
Cold work permit taken (if applicable)
PPEs like film badges, dosimeters used
Done
Additional precautions, if any ______________________________________________________

(Radiography Agencys BARC/AERB authorized Supervisor)
Permission is granted.
Permit is valid from ___________ AM/PM ____________ Date to ___________ AM/PM _________
Date
(Signature of permit issuing authority of site contractor)
Name
Permit renewal:
:Designation:
Permit extended up to
Date
Additional precautions required, if any
Date:
Sign of issuing authority with
date (of site contractor)
Time
Work completed/ stopped/ area cleared at ________ Hrs of Date ______________

(Sign. of permit issuing authority)
Name & Signature of site contractor:

HEALTH, SAFETY &
FORMAT NO.
Project
Name of the work
Name of contractor
:
HSE-9 REV 0
DEMOLISHING/DISMANTLING WORK PERMIT
:
Sr.No. :
:
Date :
:
Job No. :
Name of sub-contractor :
No. of workers to be engaged:

Line No./ Equipment No./ Structure to be dismantled

Location details of dismantling/ demolition with sketch : (clearly indicate the area)
The following items have been checked &compliance shall be ensured during currency of the
permit:
S.
No.
Item description
Done
Not
Applicable
Services like power, gas supply, water, etc. disconnected

Dismantling/ Demolishing method reviewed & approved
Usage of appropriate PPEs ensured
Precautions taken for neighbouring structures
First-Aid arrangements made
Fire fighting arrangements ensured
Precautions taken for blasting
(Contractors Supervisor)
(Contractors Safety Officer)
Permission is granted.
(Permit issuing authority)
Name
Date
:
:
Completion report :
Dismantling/ Demolishing is completed on _____________ Date at ____________ Hrs.
Materials/ debris transported to identified location
Services like power, gas supply, water, etc. restored
(Permit issuing authority)
CONTRACTORs NAME
Tagging completed (as applicable)

HEALTH, SAFETY &
FORMAT NO.
HSE-10 REV 0
DAILY SAFETY CHECKLIST
(To make use of before start of days work)
Project
Name of the work
Name of contractor
:
:
:
Sr.No. :
Date :
Job No. :
Description of Job decided to perform : x

Use of PPE / Safety Gadgets
Sl.
No
1
2
3
4
Safety Helmets
Safety Shoes
Hand Gloves
Dust Musk
Sl.
No
6
7
8
9
Safety Goggles
10
PPEs
Compliance
(Yes / No)
PPEs
Compliance (Yes
/ No)
Face Shield
Full body harness
Fall Arrest System
Safety net
Horizontal life-line made
of steel wire, (dia not
less than 8.0 mm.)
(Serial No. 1 & 2 are compulsory for everyone. Specify & ensure use of other safety gadgets as required for the job)
x
Identify following important unsafe conditions: -
Sl. No
Conditions
1
Access to work site / emergency escape clear
2
Soil / Loose earth kept away from excavated pit / slope / ladder provided
Electrical wire / welding lead lying entangled on ground / welding m/c. booth
3
accessible
4
Elevated work platform / open ends are protected
Ground area cordoned off before lifting works or erection at height / ground
5
area checked & cordoned-off before start of height works
Structural members / erected pipes / wooden boards/pieces etc. are safely
6
anchored at heights and are not likely to fall down on people when working
beneath
Rope ladders tied-up on tall steel structures, long before are removed to get
7
rid of their use
8x
Any Other
Yes / No
Indicate actions taken, if status of any of the above items is found No
.
x
Specific Safety guidelines / precautions, if any (communicated thro TBT)
x
Above conditions and PPE compliances are checked by undersigned and correct status are indicated after
verification
Inspected by
Contractor Engineer
Verification By

HEALTH, SAFETY &
FORMAT NO.
HSE-11 REV 0
(Sheet 1 of 2)
HOUSEKEEPING ASSESSMENT & COMPLIANCE

Project
Name of the work
Name of contractor
Name of contractor
Sl
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
:
:
:
: Fortnightly
Subjects of Review
Cleanliness at the Main entry / access of site

Ground condition / floor areas free from waterlogging / oil spillage
Ground & elevated floors free from rubbish /
wastes / accumulated debris / scraps.
Manholes / openings are covered / fenced
Trenches are barricaded / walkways are in place
Drains are cleaned / not choked / not occupied
by dumped materials
Sufficient CAUTION boards / instructions
displayed
Construction machinery are maintained &
parked in orderly manner.
Movement of site people are not obstructed
because of dumping / storing of construction
materials
Access / egress to Electrical Distribution Boards
/ Panels clear from wires / cables / earth-strips
etc.
Electrical panel rooms / sheds / MCC / Control
rooms / Substations etc. are clean & tidy and not
used for storing dress / clothes, tiffin-box or
bicycles.
Passage behind Elec. panels are free for access
Fire extinguishers / fire-buckets are accessible
without any difficulty.
Stair-steps, platforms & landings are clear & tidy
Sheds / rooms & work areas have got sufficient
illumination as well as ventilation
Cables / Wires / welding leads are routed /
hanged appropriately & are not creating unsafe
condition.
Stacking / storing of insulation materials or their
packing.
Removal or cleanliness of left-over sand,
concrete, brick-bats, insulation-materials, excess
earth, wastes etc.
Storing / stacking of sand, metal chips, re-bars,
steel pipes, valves, fittings etc.
One escape route at ground & minimum two
escape routes at elevation available,
Sr.No. :
Date :
Job No. :
Satisafctory/
Non
Yes
satisfactory/No
Remarks
Action

HEALTH, SAFETY &
FORMAT NO.
HSE-11 REV 0
(Sheet 2 of 2)
Sl
No.
Subjects of Review
Satisafctory/
Non
Yes
satisfactory/No
Remarks
Action
21. Captions / Posters / Slogans on various safety

instructions are displayed legibly in local
language
22. Cable trenches are water-free or regular
arrangement for taking out accumulated water
exists.
23. Windows of rooms / offices are regularly
cleaned
24. Facilities for cycle sheds, drinking water,
washing, rest-rooms etc. are maintained in tidy
manner.
25. Toilet, Urinals, Canteen / kitchen / pantry etc.
are maintained & free from obnoxious smell.
26. Construction tools / tackles are stored
systematically - the items are tagged / tested /
certified by competent third party.
27. Sufficient numbers of Dust-bins / Waste-bins
found at site and are regularly emptied.
Additional remarks, if any
Inspected by
Contractor Engineer
Verification By

HEALTH, SAFETY &
FORMAT NO.
HSE-12 REV 0
INSPECTION OF TEMPORARY ELECTRICAL BOOTH / INSTALLATION

Project
:
Name of the work
:
Name of contractor
:
Sub Station No:/Booth No
SL
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
SUBJECTS
Sr.No. :
Date :
Job No. :
Location:
OBSERVATION (YES /NO)
ACTION TAKEN
Switchboards installed properly are in order and

protected from rain & water-logging.
Adequate illumination provided for switchboard
operation during night hours & the lamps are protected
from direct human contact.
Voltage ratings, DANGER signs, Shock-TreatmentChart displayed in the installation / booth
Fire extinguisher (DCP or CO )2 & Sand Bucket kept in
close vicinity of Switchboards
Valid License & Competent Electrician / Wireman
available & name/ license no. displayed at booth /
installation.
General housekeeping in & around booth / installation
found in order.
Cable-route-markers for U/G cables provided.
Monthly inspection report of Electrical hand tools
available in booth / installation.
Insulated Mat provided in front of Elec. Panels.
Rubber hand gloves available/ used by Electricians
Availability of CAUTION boards for shutdown & / or
repairing works.
All incoming & outgoing feeders have proper MCCB /
HRC fuses / Switches.
Switchboards earthed at two distinctly isolated
locations.
Switchboards have adequate operating space at the front
face & at the rear face too.
All connections provided through 30mA ELCB.
Testing records of all ELCBs available at site
Only industrial type plugs & sockets are used.
Temporary connections are 3-core double insulated &
rd
core is earthed at both
free from cuts & joints and 3
ends
Socket boards are properly mounted on stand &
protected from water ingress.
Electrical equipments operating above 250V have two
earthing / double earthing.
All incoming / outgoing cables are properly glanded &
terminated with lugs.
Switch-boards are of industrial variety / type.
Sketch for installation / connection (SLD) made &
pasted & other safety labels/display boards
Labeling of incoming / outgoing feeders made.
All hand lamps are protected from direct contact.
All electrical cable / joints are in safe condition
Inspected by
Contractor Engineer
Verification By

HEALTH, SAFETY &
FORMAT NO.
HSE-13 REV 0
(Sheet 1 of 2)
INSPECTION FOR SCAFFOLDING
Project
Name of the work
Name of contractor
:
:
:
Sr.No. :
Date :
Job No. :
Sl.
Description
Yes
No
1 Whether work permit is obtained to take up work at height above 1.5 Mts?
Whether atmospheric condition is stormy or raining and works at
2
heights have been permitted?
3 Whether steel pipes scaffoldings are used for units /off-site areas?
Whether scaffolding has been erected on rigid/firm/leveled surfaces /
4 ground? Whether foot-seals or base-plates are used beneath the uprights (vertical steel pipes)
Whether scaffold construction is as per IS specification with toe-board and
5
hand-rails (top-rail as well as mid-rail)?
Whether distance between two successive up-rights are less than 2.5 Mts
6 (height of scaffold & load carrying capacity governs the distance between
two uprights)
Whether all uprights are extended at least 900 mm above the top most
7
working platform (to enable fitting of handrails)?
Whether vertical distance of two successive ledgers is satisfactory?
8
(varying between 1.3 Mts. To 2.1 Mts)
Whether the peripheral areas of working at height are cordoned-off? (for
9
avoiding accident to people arising out of dropped / deflected materials)
10 Whether platform is provided? Is it safely approachable?
Whether end of scaffold platform / board are extended beyond transoms?
11
(125mm to 150 mm)
Whether CE / IS approved quality and worthy conditioned full-body safety
12 harness (with double lanyard & karabiners) are used while working at
heights?
Whether life-line of safety harness is anchored to an independent secured
13
support capable of withstanding load of a falling person?
Whether the area around the scaffold is cordoned off to prohibit the entry of
14
unauthorized person / vehicle?
Whether clamps used are of good condition, of adequate strength and free
15
from defects?
16 Whether ladder is placed at secured and leveled surface?
17 Whether water-pass and oil-spills are avoided around the scaffold structure?
18 Whether ladder is extended 1.5mts. above the landing point at height?
19 Whether more than one access/egress provided to the scaffold?
Whether ladder used are of adequate length and overlapping of short
20
ladders avoided?
Whether metallic ladders are placed much away from near-by electrical
21
transmission line?
22 Whether rungs of ladder are inspected and found in good order?
23 Whether fall-arresters provided on both the access/egress routes?
Whether diagonal (cross) bracings are provided at regular interval on the
24
scaffold?
Whether working platform on the scaffold has been made free from jolt
25
or gap?
Whether tools or materials are removed after completion of the days job at
26
heights?
Whether a valid Permit for Work (PFW) is obtained before taking up work
27
over asbestos or fragile roof?
28 Whether sufficient precaution is taken while working on fragile roof?
No
N.A
Actions
taken

HEALTH, SAFETY &
FORMAT NO.
HSE-14 REV 0
(sheet 1 of 2)
PERMIT FOR ERECTION / MODIFICATION & DISMANTLING OF SCAFFOLDING
Project
:
Sr.No. :
Name of the work
:
Date :
Name of contractor
:
Job No. :
Duration: FromTo
Nature of activities
:
SL.
No.
1
2
3
4
5
6
9
10
11
12
13
14
15
16
17
18
x
x
x
x
x
SUBJECTS / ITEMS
DONE
NOT
DONE
Specific task of Erection / Modification / Dismantling of scaffolds,

identified & TAGGED accordingly (before as well as after carryingout jobs).
People engaged in doing the job are identified & are certified by Job
Engineer of Main Contractor as experienced / trained.
Concerned persons are alerted by the Job Engineer of Main Contractor
in connection with possible hazards & what the workmen MUST do /
MUST not do.
Verification by Job Engineer of Main Contractor made for confirming
that all persons permitted to carry-out the jobs are making use of
Helmet, Safety Shoes, Goggles, Gloves & Double lanyard safety
harness and other relevant PPEs.
Area of work is effectively cordoned-off / barricaded / illuminated.
For taking-up / lowering down Scaffolding members / clamps /
couplings etc. appropriate ropes / pulleys/ chains etc. have been
arranged for use (not to throw any item) & the same have been
verified as fit for purpose.
Items / members of scaffold, being lowered are removed from the area
& stacked correctly.
Ropes, chains, pulley blocks etc. being used for lifting or lowering
scaffold items, are inspected by the Job Engineer & their certifications
as well as physical conditions have been found O.K, before signing
this PERMIT.
Safety Net / Life-line / Fall Arresters etc. are arranged in position and
Job Engineer has found working conditions favourable for activities to
start.
Scaffold erection or dismantling tasksare being supervised by
Experienced Engineer / Competent person.
Only competent & experienced people have been selected / engaged in
Scaffolding erection, modification or dismantling tasks.
Adequate & effective actions for traffic and movement of people
around the cordoned-off area taken to avoid inadvertent incident
Working platforms are protected with handrails & toe-boards.
Access & Exit (for reach & escape) are safe for use by people.
Tools, tackles to be used for above jobs are verified by job Engineers
of Main contractor as genuinely good and tied-up at height (to prevent
their fall).
Site important Telephone Nos. are made known to everyone
SOP (Safe Operating Procedure) for the specific task is made &
followed too.
Emergency vehicle has been arranged at work locations.
REMARKS
Names to be
noted
This permit for work shall be available at specific work location all the time.
After completion of work, permit shall be returned to safety cell of main contractor, without fail.
This Permit shall be issued maximum upto (Monday to Sunday).
Additional Precautions, if any
ACCORD OF PERMISSION (to be ticked) - YES ( ) / NO (

)
Inspected by
Contractor Engineer
Verification By
Contractor Safety Officer]

HEALTH, SAFETY &
FORMAT NO.
HSE-14 REV 0
(sheet 2of 2)
Everyday Site working conditions & performance of workmen shall be assessed / checked by Contractor
Site Engr. and Safety Officer shall verify the same .
Name / Sign.
Site
Engr.
Safety
Off.
MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
SUNDAY
FORMAT NO.
HSE-15 REV 0
PERMIT FOR HEAVY LIFT/CRITCAL ERECTION

Project
Name of the work
Name of contractor
Nature of activities
:
:
:
:
Location of work
:
Equipment/Structure to be erected:
SL.
NO.
1)
Sr.No. :
Date :
Job No. :
Duration: FromTo
Name /Type of crane
:
Wt. of equipment/ structure to be erected :
Description of Item
Yes
8)
Is the crane type suitable for lift or as per erection

procedure?
Is the crane have the correct number of counterweights
fitted?
Availability of Load Certification of crane from
authorized agency.
Is the load chart of crane available in carne cabin/or with
Crane operator?
Is the device to check the Wind speed in crane is working?
Is the safety features in crane are working?
Availability of Load certification of slings and other
accessories from authorized agency
Availability of Licensee/certificate for crane operator from
authorized agency.
Availability of approved JSA for the subject activities.
9)
Availability of approved erection/rigging procedures.
10)
Availability of temporary gratings/ platforms for critical

lifting(as applicable)
Tool Box conducted before erection?
Has the area been cordoned off?
Are the authorized persons during erection are identified?
Does each person identified for erection understand their
roles and responsibilities?
Is the ground on which crane will rest or outrigger support
are correct?
2)
3)
4)
5)
6)
7)
11)
12)
13)
14)
15)
16)
Is hard stand requirement (if any) complied?
17)
Is the communication system (viz walkie talkies,etc are

working properly?
If more than one crane is lifting the load, is an
Intermediate rigger will supervise the lift?
If there is other obstruction within the operating radius of
the crane, have correct precautions been taken to prevent
collision?
18)
19)
20)
COMPLIANCE STATUS
No
Not applicable
Remarks
All the persons are wearing the requisite PPE?
Inspected & Issued by

Contractor Engineer/RCM
Verification By
FORMAT NO.
HSE-16 REV 0
PERMIT FOR ENERGY ISOLATION & DE-ISOLATION

Project
Name of the work
Name of contractor
x
x
x
x
:
:
:
Sr.No. :
Date :
Job No. :
ENERGY ISOLATION PERMIT

Clearance required from:..Hrs Date
To . ..Hrs .Date
Name of equipment/ energy source etc
.
Nature of job to be done: .
Area.Location:..
PERMIT VALIDATION
I hereby authorize the ..personnel(performer)
to isolate the above equipment/energy source from all
sources of power and handover the equipment/energy
source for maintenance/repair.
Issuing authority
Area Incharge/RCM
Signature:
Name:
Signature:
Name:
Date:
Date:
SAFETY PRECAUTIONS FOR CLEARANCE

1. Notify workers of intent to de- energize
2. Obtain lock,tag or locking/tagging devices
3. Shut down ,de energize, dissipate any
residual energies.
4. Apply lock ,tag and locking and/or tagging
devices
5. *Any other job specific precautions
6. Verify effectiveness of lockout by
attempting to restart.
7. Proper PPE is ensured
I certify that the energy source mentioned above is
isolated from all sources and is safe to start the work.
Tag No:
PERFORMING AUTHORITY
The work and precautions will be carried out under my
overall responsibility.(Testing/execution engineer)
NORMALISING AFTER CLEARANCE

1. Notify workers of intent to re- energize
2. Conduct visual inspection to confirm that the
danger zone is clear of workers
3. Conduct visual inspection to confirm that tools
,equipments danger zone is clear of workers
4. Reposition the safety devices(interlocks,
valves, guards, covers ,sensors, as applicable, etc)
5. *Any other job specific normalizing details
6. Remove lock, tag and locking and/or tagging
devices.
7. Re energize.
8. Confirm system is operating properly& safely
I certify that the energy source mentioned above is
isolated from all sources and is safe to start the work.
Lock No:.
Tag No:
Lock No:.
Issuing authority
Issuing authority
Area Incharge/RCM
Area Incharge/RCM
Signature:
Date:
Signature:
Date:
Name:
Name:
(*to be included by contractor in consultation with
(*to be included by contractor in consultation with
PDIL/owner)
PDIL/owner)
ENERGY DE-ISOLATION PERMIT
PERMIT VALIDATION
PERFORMING AUTHORITY
I hereby authorize the ..personnel(performer)
I herby certify that the equipment/energy source
to de- isolate the above equipment/energy source from mentioned above has been de-isolated and is ready for
all sources of power and handover the equipment/energy normal operation.(Testing/execution engineer)
source for normal operation..
Issuing authority
Area Incharge/RCM
Signature:
Name:
Signature:
Name:
Date:
Date:
Countersigned by Issuing authority
FORMAT NO.
HSE-17 REV 0
PERMIT FOR EXCAVATION
(depth 2m and above)

(Sheet 1of 2)
Project
Name of the work
Name of contractor
:
:
:
Sr.No. :
Date :
Job No. :
Job Description
Size of excavation
:
:
Location:
COMPLIANCE STATUS
Yes
No
Not
applicable
SL.
Description of Item
NO.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
Suitable and sufficient risk assessments and method statements

has been carried to ensure that the work shall be undertaken in
accordance with specification and standard.
Are plans/details of underground services available and the
same has been reviewed?
Has survey done to locate the services/obstacles, etc.
Has the live services (electrical, water line, air line, telephone
line,etc) has been disabled for carrying out the job.
Is adequate barriers/fences to protect the excavation are in
place?
Is Adequate warning signs are in place?
Is Assessment of ground conditions done and remedial action (if
any) taken?
Safe access / egress (e.g. ramp / steps / ladders etc.) provided for
site workmen & supervisors.
Is the excavation work being undertaken in proximity of
structure, etc ? If Yes, its effect is considered?
Availability of competent person for supervising the excavation
work?
Adequate safe arrangement to prevent collapse of edges (e.g.
shoring / strutting / benching / sloping etc.) made at site.
Hard barricades (at least 1.0M away from edge & for excavation
near site access roads) with warning signs/caution boards are
provided
Accumulation / passage-ways of water at periphery of
excavation / trench stopped/ restricted.
Is the equipment being used for excavation has been checked for
adequacy and is in good working condition having all the safety
features?
Age & fitness of workmen ensured by medical test before
engagement in job ?
Arrangement of Monitoring of possible oxygen deficiency or
obnoxious gases done & action taken?
PERMIT GRANTED -
Yes /
No
Name & Signature of Site Engr

Contractor (Initiator)
Name & Signature of Safety Officer

Contractor
(Issuing authority)
Remarks
FORMAT NO.
HSE-17 REV 0
PERMIT FOR EXCAVATION
(Sheet 2of 2)
NOTES: -
1. Slopes or benches for excavation beyond 2.0M depth shall be designed & approved by Contractors site
head.
Excavated earth to be kept at least 1.5M away from edges
Safety helmets, Safety shoes or gum-boots, gloves, goggles, Face shield, Safety Harness shall be essential
PPEs.
Permit shall be made in duplicate and original shall be available at site of work.
Permit shall be issued for maximum one week only (Monday to Sunday)
After completion of works, permit shall be closed & preserved for record purpose
2.
3.
4.
5.
6.
GRANT OF PERMIT AND EXTENSIONS
Sl.
No.
Validity period
From ____To ____
Working Time
From _____To _____
1.
2.
3.
4.
5.
6.
7.
Additional safety instructions if any: 1.

2.
3.
Initiator (site
Engr. of Main
Contractor)
Issuing authority
(Safety Officer
of Main
Contractor)
Review by PDIL /
Owner (Remarks
with date
Installation of LPG
G Mounded Bullets at
N
NRL
VEND
DOR LIST
0
D
DOCUMENT
T NO
REV
V
SHEET 1 OF 30
VE
ENDOR
R LIST
Installatio
on of LP
PG Mou
unded Bullets
B
a
at NRL
P
REV
V
01.06.201
15
REV DATE
E
EFF DA
ATE
FORM NO: 02
2-0000-0021F1 REV2
R
FOR REVIEW
PURP
POSE
HK
PREPD
RA
R
SKT
REVWD
R
APPD
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M
d Bulletts at NR
RL
P
D
DOCUMENT
T NO
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REV
V
SHEET 2 OF 30
HODIC PR
ROTECTIO
ON VENDO
OR LIST
1.0 CATH
Sr. No.
N
VEN
NDORS
M/s Raychem
R
R
RPG
Ltd
M/s Consultech
C
h
M/s Afcons
A
Corrrosion pro
otection Pvt Ltd (Form
merly SSS Electricals
s (I) Pvt
Ltd.)
M/s Corrosion
C
C
Control
Services (Bombay) Pvt Ltd
M/s Corrtech,
C
A
Ahmedabad
d
M/s CTS
C
Private Limited
M/s Corrtech
C
In
nternationa
al Pvt Ltd
dor list for materials

s for civil works
w
are as under
2.0 Vend
2.1
F
FOR
CEMENT (OPC
C 43 grade
e) :1
2
3
4
5
6
7
2.2
F
FOR
REIN
NFORCEMENT STEE
EL (Fe 500
0D Grade)) :1
2
3
2.3
ADIT
TYA
CEMENT CORPORATION OF INDIA LTD.
GUJR
RAT AMBU
UJA
J K CEMENT(L
C
LAXMI CEM
MENT)
LARS
SEN & TUB
BRO CEMENT
THE ASSOCIATED CEMENT COM
MPANIES LIMITED
L
SHRE
EE CEMEN
NT
STEE
EL AUTHO
ORITY OF INDIA LTD
D.
TATA
A IRON & STEEL
S
CO
O. LTD.
RAST
TRIYA ISP
PAT NIGAM
M LIMITED
D (Vishakha
apattanam
m).
F
FOR
STRU
UCTURAL
L STEEL (F
Fy 250 Mp
pa as per IS-2062) :--
1
2
3
STEE
EL AUTHO
ORITY OF INDIA LTD
D.
TATA
A IRON & STEEL
S
CO
O. LTD.
RAST
TRIYA ISP
PAT NIGAM
M LIMITED
D (Vishakha
apattanam
m).
2-0000-0021 F2 REV2
FORM NO: 02
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M
d Bulletts at NR
RL
VEND
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SHEET 3 OF 30
3.0 INSTRUMENTA
ATION
Sl.No
V
Vendors
Name
N
Gas An
nalysers (IR, Therma
al Conduc
ctivity, Parramagnetiic)
1.
ABB Ltd (BU Ana
alytical &Ad
dv)
2.
Chemtro
ols Industrie
es Limited (Maihak Make)
M
3.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
4.
Endress+
+ Hauser (India)
(
pvt. Ltd.
5
MaihakA
Aktiengesellschraft
6
Siemenss AG
7
Emerson
n Process Manageme
ent Singap
pore Ltd
8.
AmetekIn
nc
9.
M.S.A In
nternationa
al
pH, con
nductivity & ORP An
nalyser
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
2.
Endress+
+ Hauser (India)
(
pvt. Ltd. (Liquid Analyse
er)
3
ABB Indiia Limited
4
Forbes polymetron
p
n Pvt. Ltd.
5
Zellwege
er SA
6
Yokogaw
wa Electric Corporatio
on
7.
Emerson
n Process Manageme
ent Singap
pore Ltd
8
Foxbaro Far East Pte
P Ltd
9
ABB Pro
ocess Analyytics
10
Hach com
mpany
Trace Analyser/
A
I
Ion
Selecttive
1.
Forbes Polymetron
P
nPvt. Ltd
2
ABB Indiia Limited
3
Zellwege
er SA
4
Bran &Lu
uebbe Ltd
5
Hach com
mpany
SOX/ NO
OX Analyser
1.
ABB Indiia Ltd.
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
3.
Sick AG
4.
Siemenss AG
5.
Horiba Ltd.
6.
Yokogaw
on
7.
Emerson
n Process Manageme
ent Singap
pore Ltd
8.
Lear Siegler Meas.. Controls Corp.
9.
M.S.A In
nternationa
al
10.
Thermo Environme
ent Instrum
ments Inc
Mass Spectrome
S
eter
1.
VG Gas Analysis Systems
S
2.
Orbital Science
S
Co
orporation
3
ABB Indiia Limited
Gas Ch
hromatogrraph
1.
Applied Automation
A
n Inc
2-0000-0021 F2 REV2
FORM NO: 02
Country
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Singapore
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
France
Ja
apan
Singapore
Singapore
U.K
U
U.S.A
U
In
ndia
In
ndia
France
U.K
U
U.S.A
U
In
ndia
In
ndia
Germany
G
Germany
G
Ja
apan
Ja
apan
Singapore
U.S.A
U
U.S.A
U
U.S.A
U
U.K
U
U.S.A
U
In
ndia
Singapore
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M
d Bulletts at NR
RL
VEND
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2.
Foxbaro Far East Pte
P Ltd
3
ABB Indiia Limited
4
Emerson
n Process Manageme
ent (I) Pvtt. Ltd.
5.
ABB Pro
ocess Analyytics
Flue Ga
as Analyse
er (ZrO2 ty
ype)
1.
ABB Ltd (BU Ana
alytical &Ad
dv)
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
3.
Ametek Inc
4.
GE Pana
ametrics
H2S/ To
otal Sulphu
ur Analyse
ers
1.
Barton In
nstrument Systems Limited
L
4.
ABB Indiia Ltd.
System
m House Analysers
A
1.
ABB Ltd (BU Ana
alytical &Ad
dv)
2.
Chemtro
ols Industrie
es Limited
3.
Emerson
n Process Manageme
ent (I) Pvt. Ltd
4.
Intech
5.
Adage Automation
A
Pvt Ltd.
Density
y Analyserrs
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd (coriolis type)
2.
Bopp & Reuther
R
MesstechnikkGmbh (co
oriolis type))
3.
Solartron
nMobrey
Moisturre Analyse
ers
1.
GE Pana
ametrics
2.
AmetekIn
nc
Gas & Fire
F Detec
ction Syste
em
1.
Andrew Yule
Y
& Company Ltd
d. (Fire)
2.
Honeywe
ell Automa
ation India Limited (G
Gas)
3.
J B Boda
a And Brotthers Pvt. Ltd. (Gas Make-Inte
ernational S
Sensor
Technolo
ogy)
4.
Pollution
n Protection
n System Mumbai
M
Pv
vt Ltd (Gass)
5.
Teledyne
e Fluid Sysstems (Gass)
6.
General Monitors (Gas)
(
Air Qua
ality Monittoring Sys
stem
1
Chemtro
ol industriess Ltd.
Flow Ellement: Orifice/ Ven
nturi/ Flow
w Nozzle
1.
Baliga Liighting Equ
uipments Limited
L
(On
nly Orifice))
2.
General Instruments Consorttium (Only Orifice)
3.
Instrume
entation Ltd
d, Palakkad
d
4.
Micro Precision Pro
oducts Privvate Ltd.
5.
Eureca Industrial Eqipments
E
Pvt Ltd.
6.
Unicontrols Instrum
ments Pvt. Ltd.
7.
Bopp & Reuther
R
MesstechnikkGmbh
8.
Technom
matic Spa
9.
ISA Conttrols Limite
ed
10.
Daniel Measureme
M
ent & Contrrol
11
Flowtech
h Instruments service
es (Orifice//Venturi)
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
Singapore
In
ndia
In
ndia
U.K
U
In
ndia
In
ndia
U.S.A
U
Ireland
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
Ita
aly
In
ndia
In
ndia
Germany
G
U.K
U
Ita
aly
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
Thailand
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ita
aly
U.K
U
U.S.A
U
In
ndia
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M
d Bulletts at NR
RL
VEND
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T NO
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12
Chemtro
ol Industriess Ltd
Pitot Tu
ube/ Annu
ubar
1.
Control Engineers
E
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
3.
Micro Precision Pro
4
ABB Indiia Limited
5.
Unicontrols Instrum
ments Pvt. Ltd.
6.
Technom
matic Spa
7.
ISA Conttrols Limite
ed
8
Daniel Measureme
M
ent & Contrrol
Rotame
eters
1.
Instrume
entation En
ngineers Pvvt. Ltd.
2.
Krohne Marshall
M
Pvt. Ltd.
3.
Placka In
nstrumentss & Controls Pvt. Ltd. (Purge Rotameter O
Only)
4.
Rota Insttrumentatio
on
5.
Eureca Industrial Eqipments
E
Pvt Ltd.
6.
ABB Indiia Ltd.
7
Krohne
8
Rota Yokkogawa Gm
mbh& Co. Kg
9
Tokyo Ke
eiso Co. Lttd.
10.
Yamatakke Corpora
ation
11
Emerson
n Process Mgt
12
Flowtech
es
13
Chemtro
ol Industriess Ltd
Mass Flow Meterr (Coriolis Type)
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2
SIEMEN
NS Ltd.
3.
ABB Indiia Limited
4
Bopp & Reuther
R
MesstechnikkGmbh
5
Endress + Hauser Gmbh& Co.
6.
Krohne
7.
Schlumb
berger Ressource Man
nagement Ltd.
8.
Chemtro
ol Industriess Ltd
Turbine
e Flowmetter
1.
FmcSanmar Ltd.
2.
ABB Indiia Ltd.
3.
Bopp & Reuther
R
MesstechnikkGmbh
4.
Instrome
et Internatio
onal N.V
5.
Itochu Corporation (Rep.KubotaCorpn.))
6.
Yamatakke Corpora
ation
7.
Oval Ase
ea Pacific Pte
P Ltd
8.
Barton In
L
9.
Emerson
n Process Mgt
10.
Emerson
n Process Mgt
11.
Rockwell Internatio
onal Corpn
n.
12.
Chemtro
ol Industriess Ltd
Vortex meter
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Ita
aly
U.K
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Ja
apan
Ja
apan
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Germany
G
U.S.A
U
In
ndia
In
ndia
In
ndia
Germany
G
Holland
H
Ja
apan
Ja
apan
Singapore
U.K
U
U.K
U
U.S.A
U
U.S.A
U
In
ndia
All rights reserved

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M
d Bulletts at NR
RL
VEND
DOR LIST
1.
Krohne Marshall
M
Pvt. Ltd.
2.
Yokogaw
wa Limited
3.
Siemenss Ltd.
4
ABB Indiia Ltd.
5.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
6
Bopp & Reuther
R
MesstechnikkGmbh
7.
Endress + Hauser Gmbh& Co.,
8.
Krohne
9
10
Schlumb
nagement Ltd.
PD Meter
1.
Rockwin Flow Mete
ers (I) Pvt. Ltd.
2.
Bopp & Reuther
R
MesstechnikkGmbh
3.
Oval Ase
ea Pacific Pte
P Ltd
4.
Emerson
n Process Mgt
5.
Schlumb
nagement Ltd.
6.
Chemtro
ol Industriess Ltd
Magnettic Flow meter
m
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2.
ABB Indiia Ltd.
3.
Endress + Hauser (India) Pvtt. Ltd.
4.
Krohne Marshall
M
Pvt. Ltd.
5.
Siemenss Ltd.
6
Bopp & Reuther
R
MesstechnikkGmbh
7
Krohne
8
Yamatakke Corpora
ation
9.
Chemtro
ol Industriess Ltd
Insertio
on Type Fllow Meter
1
Siemenss Ltd.
Ultraso
onic Flow Meter
M
1
2.
Siemenss Ltd.
3.
Chemtro
ol Industriess Ltd
Orifice Meter
1
Chemtro
ol Industriess Ltd
Meterin
ng Skid
1
Chemtro
ol Industriess Ltd (for liiquid & Ga
as)
Pressure Gauges
s
1.
A N Instrruments Pvvt. Ltd.
2.
General Instruments Consorttium,
3.
H.Guru Industries
4.
Manome
eter (India) Pvt. Ltd
5.
PeejeeEngg. Workks
6.
Precision
n Industries Ltd. (stan
ndard norm
mal type)
7.
Premium
m Inst. & Co
ontrols Ltd
d.
8.
Walchan
ndnagar Ind
dustries Lttd.
9.
Ashcroft India(P) Ltd.
L (standa
ard normal type)
2-0000-0021 F2 REV2
FORM NO: 02
P
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T NO
REV
V
SHEET 6 OF 30
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Germany
G
Ja
apan
U.S.A
U
In
ndia
Germany
G
Singapore
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Germany
G
Ja
apan
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
All rights reserved
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LPG Mounded
M
d Bulletts at NR
RL
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10.
11.
12.
13.
14.
P
D
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T NO
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Dresser Europe S.A

A
WikaAlexxenderWie
egardGmbh
h& Co.
Spriano Spa
Nagano Keiki Seisa
akusho
Rueger SA
S
15.
Budenbe
erg Gauge Co. Ltd
Vol. Sea
al Pr. Gau
uges
1.
A N Instrruments Pvvt. Ltd. (=<
<600# Exce
ept Urea Service)
S
2.
Dresser Europe S.A
A.
3.
WikaAlexxenderWie
egandGmb
bh& Co.
4.
Spriano Spa
5.
Nagano Keiki Seisa
akusho
6.
Rueger Sa
S
7.
Budenbe
erg Gauge Co. Ltd.
Local D/P
D Indicattors
1.
Switzer Instrumentt Co.
2.
Barton In
L
3.
Delta Co
ontrols Ltd.
Pressure & D/P Transmitte
T
ers
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2.
Honeywe
ell Automa
ation India Limited
3.
Yokogaw
wa Limited
4.
Siemenss Ltd.
5
Endress + Hauser (India) Pvtt.Ltd.
6.
Siemenss Ag, Germ
many
7
Yamatakke Corpora
ation
8
Yokogaw
on
9
Emerson
n Process Mgt Singapore Ltd
10.
SmarSin
ngaporePte
e. Ltd.
11
Honeywe
ell Inc.
12.
Moore Products Co
ompany
Vol. Sea
al Pr./Dp Transmitte
T
er
1.
Honeywe
ell Automa
ation India Limited
2.
Yokogaw
wa Limited
3.
Siemenss Ltd.
4.
ABB Indiia Limited
5.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
6.
Endress+
+ Hauser (India)
(
Pvt.. Ltd.
7.
Fuji Elecctric System
ms Co., Ltd
d. (Except Urea Servvice)
8
Yamatakke Corpora
ation
9.
Yokogaw
on
10
Emerson
11
Moore Products Co
ompany
Pressure & D/P Switches
S
Including Vol. Seal
1.
Indfos In
ndustries Lttd. (Exceptt Vol.Seal))
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
Germany
G
Germany
G
Ita
aly
Ja
apan
Switzerlan
d
U.K
U
In
ndia
Germany
G
Germany
G
Ita
aly
Ja
apan
Switzerlan
d
U.K
U
In
ndia
U.K
U
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ja
apan
Ja
apan
Singapore
Singapore
U.S.A
U
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Ja
apan
Ja
apan
Ja
apan
Singapore
U.S.A
U
In
ndia
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M
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RL
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3.
P
D
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Switzer Instrumentt Co., (Exce

ept Vol.Se
eal)
Kaustubh
ha Udyog
g (pressurre switch & D/P switches
s
except
volumetrric seal)
4.
Endress + Hauser(( India ) Pvvt. Ltd.
5
Nagano Keiki Seisa
akusho
6
Yamatakke Corpora
ation
7
Delta Co
ontrols Ltd.
8.
Sor Inc.
9.
United Electric
E
Con
ntrols Co.
Vol. Sea
al Pressurre.&Dp Sw
witches (U
Urea Servic
ce)
1.
Spriano Spa
2.
Delta Co
ontrols Ltd.
3
Endress + Hauser(( India ) Pvvt. Ltd.
4..
Sor Inc.
Transpa
arent/ Refflex / Bicolor Mag.Le
evel Gaug
ges
1.
Chemtro
ols Samil(In
ndia) Pvt Ltd.
2.
Pune TechtrolPvt.L
Ltd. (<=300
0# Rating Only)
O
3.
Tecnoma
atic (India)) Pvt. Ltd.
4.
V-Autom
mat & Inst. (P)
( Ltd., (U
Upto 300#)
5.
Nisan Sccientific Pro
ocess Equ
uipments Pvt. Ltd.
6
ABB Indiia Ltd.
7.
Bliss Ana
and Private
e Ltd.
8
Richard Klinger Ag
g
9.
CesareB
Bonetti
10
Technom
matic Spa
11
Nihon Klingage Co
o. Ltd.
12
Clark-Re
eliance Corrp.
13
Jerguson
n Gauge & Valve Co.
14
Tyco Inte
ernational Inc.
15.
Flowtech
es
Level Switches
S
(F
Float & Diisplacer Type)
1.
Chemtro
ols Enginee
ering Limite
ed
2.
V-Autom
mat & Inst. (P)
( Ltd., (U
Upto 300# , Non-Critical Service
e)
3.
ABB Indiia Ltd.
4.
Bliss Ana
and Private
e Ltd.
5.
Siemenss Ltd. ( ultra
asonic,vibrrating,capa
acitance,pa
addle)
6
Magnetro
ol Internatiional N.V.
7.
Isa Controls Limite
ed
8.
KdgMobrey Ltd.
9
Sor Inc.
Capacittance Lev
vel Switch
1
Vega Grieshaber KG
K
RadarL
Level Switc
ch
1
Vega Grieshaber KG
K
Displac
cer Type Level
L
Transmitters
1.
Chemtro
ols Industrie
es Limited (Eckdart Make
M
Electtronics)
2.
Dresser Valve India
a Pvt Ltd (Rating <= 600#)
2-0000-0021 F2 REV2
FORM NO: 02
REV
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apan
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ndia
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ndia
Austria
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aly
Ita
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apan
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In
ndia
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ndia
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ndia
In
ndia
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3.
Magnetro
ol Internatiional N.V. (Lvdt)
4.
Dresser Masoneila
an
5.
Foxboro EckardtGm
mbh
6.
Parcol Spa (Pneum
matic Transsmission Only)
O
Nucleonic Level Transmittter
1.
Berthold Technolog
gies Gmbh
h&Co.Kg
2.
3.
Kay Rayy
4.
Vega Grieshaber KG
K
Capacittance Typ
pe Level Trransmitterr
1.
Magnetro
ol Internatiional N.V
2
3
Siemenss Ltd.
4
5
Krohne
6
KdgMobrey Ltd
7.
Vega Grieshaber KG
K
Tank Le
evel Instru
uments
1.
Endress + Hauser Gmbh& Co., (Non-C
Contact & Servo)
S
2.
Krohne (Non-Conta
(
act Type)
3.
ABB Indiia Limited
4.
Emerson
n Process Manageme
ent (i) Pvt. Ltd.
5.
Siemenss Ltd. (Radar level Trransmitter, guided wa
ave Radar))
6
Tokyo Ke
eiso Co. Lttd.
7
EnrafSin
ngaporePte
e. Ltd.
8
L & J Technologiess
Resitive
e Electrod
de Type Le
evel Instru
ument
1.
Clark-Re
eliance Corrp
2.
Schlumb
nagement Ltd.
Speciall Level Sw
witches (Viibration Fo
ork/Rf Admittance)
1.
2.
ABB Indiia Limited
3.
Protocon
ntrol Instrruments (I) Pvt. Ltd. (Fo
or non critical
applicatio
ons)
4.
Sor Inc.
5.
Vega Grieshaber KG
K
Ultraso
onic Level Transmittter
1.
Siemenss Ltd.
2.
Vega Grieshaber KG
K
Tank Fa
arm Management
1.
Endress + Hauser ( India) Pvvt. Ltd. (Servo,Radar))
Guided wave Rda
ar
1.
Endress + Hauser ( India) Pvvt. Ltd
Temperrature Elements (Th
hermocouple, Rtd)
1.
Altop Ind
dustries Ltd
d. (Only No
ormal Type
e (Mi))
2.
ABB Indiia Limited
3.
Detriv Instrumentattion & Elecctronics Ltd
d (Only No
ormal Type
e)
2-0000-0021 F2 REV2
FORM NO: 02
REV
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France
Germany
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Ita
aly
Germany
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Germany
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U
Germany
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In
ndia
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Germany
G
Germany
G
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U
Germany
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Germany
G
Germany
G
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ndia
In
ndia
In
ndia
Ja
apan
Singapore
U.S.A
U
U.S.A
U
U.S.A
U
Germany
G
In
ndia
In
ndia
U.S.A
U
Germany
G
In
ndia
Germany
G
In
ndia
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ndia
In
ndia
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ndia
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ndia
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Pyro Electric Insstruments Goa Pvt.. Ltd. (A. Thermocouple

assemblies with//without thermowellss; B.RT
TD asse
emblies
with/with
hout thermo
owells)
5.
Tempsen
ns Instruments (I) Pvvt. Ltd.
6.
Unicontrols Instrum
ments Pvt. Ltd.
7..
Electrica
al & Electro
onics Ltd. (Only Norm
mal Type)
8.
Eliend Engineering
g Pvt. Ltd. (Only
(
Norm
mal Type)
9.
General Instruments Consorttium
10..
Industria
al Instrumentation, (O
Only Norma
al Type)
11.
12
Sensyco
on ( M/S De
egussa Ag
g)
13
W.C. HeraeusGmb
bh
14.
Thermo Electric Co
o. Ltd.
15.
Okazaki Manufactu
uring Co.
16.
Yamatakke Corpora
ation
17.
Goa Insttruments In
ndustries Ltd
L
Bimetallic Therm
mometer
1.
2.
General Instruments Consorttium
3.
H.Guru Industries
4.
Krohne Marshall
M
Pvt. Ltd.
5.
Waaree Instruments Ltd
6.
L
7.
Technom
matic Spa
8.
Nagano Keiki Seisa
akusho
9.
Rueger Sa
S
In
ndia
In
ndia
In
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In
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In
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In
ndia
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Germany
G
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G
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H
Ja
apan
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apan
In
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In
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In
ndia
Ita
aly
Ja
apan
Switzerlan
d
U.S.A
U
In
ndia
10.
Trend Instrument Inc.
11.
Goa Insttruments In
ndustries Ltd
L
Dial The
ermomete
er (Hg In Steel/Glass
S
s)
1.
In
ndia
2.
In
ndia
3.
H.Guru Industries
In
ndia
4.
PeejeeEngg. Workks
In
ndia
5.
Waaree Instruments Ltd
In
ndia
6.
Walchan
ndnagar Ind
dustries Lttd.
In
ndia
7
L
In
ndia
8.
Goa Insttruments In
ndustries Ltd(Liquid
L
filled,
f
Gas filled Merccury in In
ndia
steel)
Radiatio
on Pyrom
meter
1.
Siemenss Ag, Germ
many
Germany
G
2
Tempsen
ns Instruments (I) Pvvt. Ltd.
In
ndia
3.
C.C.R. Technico
T
Ita
aly
4
ChinoCo
orpn.
Ja
apan
5.
Land Infrrared
U.K
U
6.
Wahl Insstruments
U.S.A
U
Temperrature Transmitters
2-0000-0021 F2 REV2
FORM NO: 02
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VEND
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1.
ABB Indiia Limited
2.
Endress+
+ Hauser (India)
(
Pvt.. Ltd.
3.
Siemenss Ltd.
4.
Siemenss Ag, Germ
many
5
M-System
m
Temperrature Swiitches
1.
Goa Insttruments In
ndustries Ltd
L
Gate/Plug Valves
s
1.
Audco In
ndia Limited(L&T Valvves Divn.)
2.
BHEL(Va
alves Divission)
3.
Chemtro
ols Enginee
ering Limite
ed (Plug Valves)
V
4.
Ksb Pum
mps Limited
d (Valves Divn)
D
5.
Flowservve India Co
ontrol Pvt. Ltd.(Plug Valve
V
upto
o 12300# u
upto
6 600#)
6.
Velan Incc.
7.
Malbranq
queS.A.
8.
CesareB
Bonetti
9.
Fasani S.P.A.
S
10.
Petrol Va
alves S.R.L
L
11.
Matsura H. P Mach
hine Workss Co.Ltd.
12.
Bel Valve
es
Globe / Angle Va
alves
In
ndia
In
ndia
In
ndia
Germany
G
Ja
apan
1.
In
ndia
In
ndia
In
ndia
2.
3.
4.
5.
6.
7.
8.
9
10.
11
12.
13
14
15.
16
Dresser Valve India

a Pvt Ltd (Rating <= 600# , Sizze 3/4 To 6
6)
Emerson
n Process Manageme
ent India Ltd
L
Instrume
entation Ltd
d. (Palakka
ad) (=<250
00#,Exceptt
Slurry,No
oise,Cavita
atation)
Mil Contrrols Limited (=<600#
#,Except Sllurry,Noise
e,Cavitation
n)
R K Controls Instru
uments Pvtt Ltd(=<600#,Except
Slurry,No
oise,Cavita
ation)
Samson Control Pvvt Ltd(upto
o 6 &=<60
00#)
Circor flo
ow technologies india
a pvt. Ltd. ( globe 2 to
t 16 300#
#
angle 12
2 2500#)
Flowservve india co
ontrol pvt. Ltd.
L ( globe
e valve uptto 30 600#
# upto
24 900#
#, upto 16 2500# uptto 4 4500#
#)
Koso fluiids controlss pvt. Ltd. ( globe valves: upto 8 2500# 1
10 to
18 300#
# angle valves upto 8
8 300# )
Severn glocon
g
(i) pvt.
p Ltd. ( 1 to 8 ratin
ng 2500# ( except slurry
,noise , cavitation);
c
; 1 to 12 rating
r
600#
# (except slurry
s
,noisse
cavitation
n)
Tecnik valves pvt. Ltd. ( globe valve (up
pto 4-150#
# ,air & wa
ate
service) )
Dresser Masoneila
an (=<2500
0#,Urea Se
ervice Also
o)
Arca-Reg
glerGmbh (=< 2500#
#)
Parcol Spa (=<250
00#,Urea Service
S
Also)
Nippon Fisher
F
Co. Ltd. (=<25
500#)
Yamatakke Corpora
ation (=<25
500#)
Fisher Xomox (=< 2500#)
2-0000-0021 F2 REV2
FORM NO: 02
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Canada
C
France
Ita
aly
Ita
aly
Ita
aly
Ja
apan
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
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Singapore
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Flowservve (=<2500
0#)
EMET Control
C
Pvtt Ltd (Glo
obe upto 4
4 300#, Angle
A
upto
o 11/2
2500#)
19.
Chemtro
ol Industriess Ltd. (for water
w
& ste
eam)
Ball Valves
1.
Tyco Vallves & Con
ntrols (I) Lttd (=< 150 #)
2.
Virgo En
ngineers Ltd. (=<600#
# With Mac
ccair Actua
ators)
3.
Anand Teknow
T
Aids engine
eering India Limited
d (upto 6,, 600#
(ON-OFF
F))
4.
Flowservve India co
ontrols Pvt. Ltd. ( upto
o 16 600#
#)
5.
Koso Flu
uid Controls pvt. Ltd. ( upto 8 ,2500# ,10
0 to 18 90
00# )
6
Rotex Manufacture
M
ers & Eng
gineers Prrivate Limited ( Shu
utdown
Valves Pdil
P approvved make , upto 6 60
00#, 6 to 10
1 150# )
7.
Velan Inc. ( ball va
alves on/o
off size: to 6 (ratting upto 2
2500#)
size 8to
o 16 ( ratin
ng upto 900
0# ) size 18 to 30 (rating
(
upto
o 300#
)
8
Perrin Gmbh ( SIZE
E TO 12 & Ratin
ng 150# to 2500# , size 14
to 18 & rating 150# to 1500
0# size 20
0 to 24 , rating 15
50 # &
300# )
9
Metso Au
utomation (=<2500#))
10.
Petrol Va
alves S.R.L
L
11.
Pibiviessse S.P.A. (Rating Uptto 2500 #)
12.
GTC Italia
13.
Metso Au
utomation (=<2500#))
14.
Orbit Vallves (=<25
500#)
15
M/s Brayy Control Pvt
P Ltd (uptto 4 300#))
16
EMET Control Pvt Ltd (upto 8
8 150#, fo
or air servicce)
Butterflly Valves
1.
Instrume
entation Ltd
d. (Palakka
ad) (=< 300
0#)
2.
Tyco Vallves & Con
ntrols (I) Lttd (=< 150 #)
3.
Virgo En
ngineers Ltd. (=<300#
#)
4.
Flowservve india co
ontrol pvt. Ltd.
L ( upto 30,300# upto
u
12 60
00#)
5.
Koso fluiid controls (pvt.) ltd. (=<
( 150#)
6.
Korea Un
nicom valvves co. Ltd.( for rating
g =< 300#))
7
Parcol Spa (=< 250
00# Urea Service
S
Als
so)
8
Orton s.rr.l (Upto 25
500#)
9
Bray Con
ntrols(=< 300#)
3
10
Keystone
e (Upto 25
500#)
11
Metso Au
utomation (Upto 2500#)
12
Leeds Va
alve Ltd
13
EMET Control
C
Pvt Ltd (upto 4
4 900#, 6 150# to 16
1 150#, d
double
eccentricc)
Saunde
ers (Pinch) Valves
1
Weir BDK VALVES
S( a unit off weir india pvt. Ltd. ) upto 1500
0#
Solenoid Valves
1.
Asco (Ind
dia) Limite
ed
2.
Rotex Au
utomation Limited
3.
IMI Norg
gren-Herion
nFluidtronicGmbh&C
Co.
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
U.S.A
U
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ndia
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ndia
ca
anada
Germany
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Ita
aly
Ita
aly
Ita
aly
Ita
aly
Singapore
Singapore
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Korea
K
Ita
aly
Ita
aly
U.S.A
U
Singapore
Singapore
U.K
U
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
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4.
Alexende
er Controlss Ltd.
5.
Asco Jou
ucomatic Ltd.
L
Prds& Spray
S
Nozzzle,Vent Valves
V
Up
pto 2500#
1.
Cci Valve
e Technolo
ogy Ab
2.
ABB
3.
Control Componen
C
nts Inc.
4.
Spx Valvves & Conttrols (Cope
es-Vulcan Ltd)
L
5.
ARCA(Forbes Marrshal)(mech
h spray no
ozzle type desuperhe
d
eater )
6.
Control Componen
C
nts Inc.
7.
Circor Flow Techn
nologies In
ndia Pvt. Ltd.
L
(1 to 20 upto 150#,
1to 10 upto 1500#
#, 1 to 8 upto 2500
0# )
8.
Chemtro
ol Industriess Ltd ( PRD
DS Combine & Split))
Electric
c Actuatorr
1.
Rotork Control
C
(De
eutschland)) Gmbh
2.
Biffi Italia
a S.R.L
3.
Limitorqu
ue, U.S.A
4.
Marsh Automation (for safe area)
a
Air Filte
er Regulattor
1.
Asea Bro
own Boverri Ltd.
2.
Divya Co
ontrol Elem
ments Pvt. Ltd.
3.
Mil Contrrols Limited
4.
Placka In
nstrumentss & Controls Pvt. Ltd.
5.
Shavo Norgren(Ind
N
dia) Pvt Ltd
d.
6.
ABB Indiia Limited
Pressure Regulator
Chemtro
ol Industriess Ltd
1
Limit/Proximity Switches
S
1.
Osna Ele
ectronics Pvt.
P Ltd. (In
ntrinsically Safe Proxximity Switcches)
2.
Pepperl + Fuch
3.
EL-O Ma
atic India Pvt
P Ltd(for non
n critical apps)
4.
Rotex Manufacture
ers & Engin
neers Pvt Ltd(for
L
non
n critical ap
pps)
5.
Protocon
ntrol Instruments (I) Pvt.
P Ltd. ( for
f non crittical applica
ations)
6
Pepperl + Fuch
7.
Pepperl + Fuchs Pte Ltd.
8.
Honeywe
ell Inc.
Valve actuator
a
(P
Pneumatic
c/ Rotary)
1.
EL-O-Ma
atic India private
p
limitted ( for no
on- critical application
ns)
2.
Rotex Manufacture
ers & Engin
neers Priva
ate Limited
d
3.
Bray Con
ntrol Pvt Lttd.
Self acttuated pre
essure con
ntrol valve
e
1
Nirmal In
ndustrial co
ontrols privvate limited
d ( size to 6 & rrating :
< =300# )
Slam Shut off valve
1.
Nirmal In
ndustrial co
ontrols privvate limited
d ( size to 6 & rrating :
< =300# )
Electroneumatic Positione
er
1.
Siemenss Limited
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
U.K
U
U.K
U
Sweden
U.K
U
In
ndia
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ita
aly
U.S.A
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Singapore
U.S.A
U
In
ndia
In
ndia
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ndia
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Turbine
e Bypass valves
v
1.
Circor Flow Techno
ologies Ind
dia Pvt. Ltd
d. ( 2 to 24 upto 2500# )
Desupe
erheater
1.
Cicor Flo
ow technologies India Pvt. Ltd
d ( upto 24
4 300# up
pto 28
1500 # Multi
M
nozzle
e 3 to 4 upto
u
2500#
#)
2.
EMET Control Pvt Ltd (1 600#
6
X 3 2500#)
Pressure reducin
ng station
1.
Cicor Flo
ow technollogies India
a Pvt. Ltd. (1 to 20 upto 1500
0#, 1 to
10 upto 1500 # 1tto 8 upto 2500#)
Safety Valves
V
& Thermal
T
R
Relief
Valv
ves Upto 2500#
2
1.
FaingerL
Leser Valve
es (P) Ltd. (Upto 600
0#, To 6)
6
2..
Instrume
entation Ltd
d. (Palakka
ad)
3.
Tyco San
nmar Ltd.
4.
Bliss ana
and private
e limited (8
( * 10 300#,
3
6 * 8 600# ,4 * 6
1500#)
5.
Mekaster engg. Ltd
d ( upto 60
00# safety 4* 6 , th
h relief * 1)
6.
Dresser Valve & Controls
7.
Parcol Spa (For Urrea Service
e Also)
8.
Tai Milan
no S.P.A (F
For Urea Service
S
Als
so)
9.
10.
Crossby Valve &En
ngg. Comp
pany Ltd.
11.
Farris
12
Dresser Industries Incorporatted
13.
Teledyne
e fluid Systtem
14.
Sapag GEC
G
Alstho
om
15.
BOPP & Reuther Messtechn
M
ic GMBH
Vaccum
m Breakers
s
1.
Braunsch
hweigerFla
ammenfilte
erGmbh
2.
Parcol Spa
3.
Tai Milan
no S.P.A
4.
Itochu Corporation
5.
Safety Systems Ukk Ltd.
6.
Whessoe
eVarec Lim
mited
Rupture
e Discs
1.
Bs&B Sa
afety Syste
ems (India)) Limited
2.
Fike Europe
3.
SapagGe
ecAlsthom
m
4.
Teledyne
e Fluid Sysstems
5.
Continen
ntal Contro
ols Inc.
Pilot relief valves
s
1.
Bliss Ana
and Private
e Limited (Size
(
1* 2 2500#)
Controll Panel
1.
Asea Bro
own Boverri Ltd.
2.
Electroniics Corporration Of In
ndia Ltd
3.
Industria
al Control Appliances
A
(P) Ltd.,
4.
Jaisun&H
Hutchisun Controls Ltd.,
L
5.
Pyrotech
h Electroniccs Pvt.Ltd.
2-0000-0021 F2 REV2
FORM NO: 02
REV
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ndia
In
ndia
In
ndia
In
ndia
In
ndia
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ndia
In
ndia
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ndia
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ndia
Canada
C
Ita
aly
Ita
aly
Ja
apan
U.K
U
U.K
U
U.S.A
U
Thailand
France
Germany
G
Germany
G
Ita
aly
Ita
aly
Ja
apan
U.K
U
U.K
U
In
ndia
Belgium
France
Thailand
U.S.A
U
In
ndia
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ndia
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ndia
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M
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P
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T NO
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6
United Electric
E
Co. (Delhi) Pvvt. Ltd. (Up
pto 10 Mtrss.)
7
Yokogaw
wa Limited
8
Instrome
et Internatio
onal N.V
9.
Prima au
utomation (India)
(
PVT
T. LTD. ( fo
or package
e equipments)
10.
TAN SW
WA technolo
ogies Inc
Panel Access.
A
( Relay,Swit
R
tch,Lamp,,Terminal,,Push Buttton)
1
Larsen & Toubro Ltd.(Contro
L
l& Automa
ation (Lamp
p, Push Bu
utton)
2
Rockwell Automation India Lttd. (Relays
s)
3.
Econix Hi-TECH
H
C
Componen
ts Pvt. LTD. (For Te
erminal Blo
ocks &
accessorries Only)
4.
Elmex co
ontros pvt. Ltd.
5.
Jyoti Lim
mited (Relay)
6.
Digitable
eThielenGm
mbh& Co
7
Phoenix Contact Gmbh&
G
Co..
8.
Siemenss Ag, Germ
many (Lamp
p,Pushbuttton,Contacctors)
9
Stahl-Un
nd Apparatebau Hanss LefferGm
mbh (Lamp
p,Pushbutto
on)
10
WagoKo
ontakltechn
nikGmbh
11
Weidmulller Ltd.
12
Omron Corporation
C
n (Relay)
13.
Pepperl + Fuchs Pte Ltd. (Sw
witch)
14.
Phoenix contact (in
ndia) pvt. Ltd.
L (for terrminal bloccks)
15
M/s Pow
wercam Ele
ectricals Pvvt Ltd (Pilott lamp, Pussh button)
Program
mable Log
gic Contro
oller
1.
Ge Fanu
uc Systemss Prvitate Limited
L
2.
Honeywe
ell Automa
ation India Limited (Safety Syste
em)
3.
Larsen & Toubro Ltd.(Contro
L
l& Automa
ation (Non Failsafe)
4.
Moore Controls
C
Ltd
d. (Failsafe
e)
5.
Rockwell Automation India Lttd. (Non Fa
ailsafe)
6
Siemenss Ltd., (Non
n Failsafe)
7.
ABB Indiia Limited
8.
Emerson
n Process Managem
ment (I) Pvt. Ltd. ( Delta V SIS
S ESID
system)
9.
Rockwell automatio
on India Pvt.
P Ltd. (N
Non failsafe
e & Failsaffe (ICS
Triplex TMR,
T
DMR
R)
10.
Siemenss Ltd. (ESD
D- Siemattic S7-400FH/PLC-Simatic S-3
300,s7400 (fmr//dmr)
11
Hima Pa
aul Hildebra
andt Gmbh
h + Co Kg (Failsafe)
12.
Marconi Italiana (N
Non Failsaffe)
13
Omron Corporation
C
n (Non Failsafe)
14.
Triconexx (Fault Tollerant Tmr)
15.
Ge Fanu
uc Automattion North America, Inc. (Fault Tolerant T
Tmr)
Distribu
uted Control System
m
1.
Honeywe
ell Automa
ation India Limited
2.
Yokogaw
wa Limited
3.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
4.
ABB Indiia Limited
2-0000-0021 F2 REV2
FORM NO: 02
REV
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Holland
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ndia
Germany
G
Germany
G
Germany
G
Germany
G
Germany
G
Germany
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apan
Singapore
In
ndia
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In
ndia
In
ndia
Germany
G
Ita
aly
Ja
apan
Singapore
U.S.A
U
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5
Siemenss Ltd. (Sima
atic Pcs7
7)
6.
Siemenss Ag, Germ
many
7
Invensyss
8
Yokogaw
on
9
Emerson
10.
Bailey Controls Co
ompany
11.
Honeywe
ell Inc.
Multiple
exer / Rem
mote I/O
1.
Mtl Instru
ument Limited
2.
Pepperl + Fuch
3.
Pepperl + Fuch
4.
Stahl-Un
mbh
5.
6.
M.T.L., U.K.
U
7.
M.system
m Co. Ltd. ( Remote I/O; Modell No.R3)
Receive
er Instrum
ments (Indicator,Con
ntroller,Re
ecorder)
1.
Chino-La
axsons (Ind
dia) Limited (Only Re
ecorder)
2.
Eurotherrm Del Indiia Limited
3.
Honeywe
ell Automa
ation India Limited
4.
Moore Controls
C
Ltd
d.
5.
Yokogaw
wa Limited
6.
Masibus Automation & Instrumena
ation Pvtt.Ltd. (Re
eceiver
Instrume
ents exceptt recorder))
7.
ABB Indiia Limited
8
Siemenss Ag, Germ
many
9.
ChinoCo
orpn.
10.
Yokogaw
on
11
Heraeus Electro-Nite Internattional N.V..
12
Honeywe
ell Inc.
Alarm Annunciat
A
tor
1.
Industria
al Instruments & Conttrols
2.
Shree Ellectronics
3.
M.T.L., U.K.
U
4.
Rocheste
er Instrume
ent System
ms Ltd.
5.
Riley Panalarm
6.
Ronan Engg.
E
Co.
Barrier//Isolator/T
Trip Amplifier
1.
MTL Insttrument Lim
mited
2.
Pepperl + Fuch
3.
Digitable
eThielenGm
mbh& Co
4.
Foxboro EckardtGm
mbh
5.
Pepperl + Fuch
6.
Stahl-Un
mbh
7.
Yokogaw
on
8.
M. Systtem Co. Ltd. (Sig
gnal Isola
ators Fittin
ngs:Model Nos.
M2VS;M
M5VS;W2VS
S;W5VS)
9.
2-0000-0021 F2 REV2
FORM NO: 02
REV
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ndia
Germany
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Holland
H
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apan
Singapore
U.S.A
U
U.S.A
U
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ndia
In
ndia
Germany
G
Germany
G
Singapore
U.K
U
Ja
apan
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Ja
apan
Ja
apan
Ja
apan
U.S.A
U
In
ndia
In
ndia
U.K
U
U.K
U
U.S.A
U
U.S.A
U
In
ndia
In
ndia
Germany
G
Germany
G
Germany
G
Germany
G
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apan
Ja
apan
Singapore
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LPG Mounded
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RL
VEND
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10.
Camille Bauer
B
Ag
11
M.T.L., U.K.
U
12..
Honeywe
ell Inc.
Temperrature Sca
anner
1.
Industria
al Instrumentation
2.
Protocon
ntrol Instruments (I) Pvt.
P Ltd.
Cctv / Access
A
Sy
ystem
1.
Honeywe
ell Automa
ation India Limited
2.
Yokogaw
wa Limited
Miscelle
enous Item
ms (Rtu / ScadaEtc)
S
)
1
ABB Indiia Limited
2.
Rockwell Automation India Pvt. Ltd.
3.
Siemenss Ltd. (Sima
atic WINccc)
Energy meter
1.
M.system
m co. Ltd.( Model No. 53U)
Surge Protection
P
n Devices
1.
Phoenix Contact (India) Pvt. Ltd.
Wiring Ducts
1.
Trinity to
ouch Pvt.Lttd.
DIN Raiil
1.
Trinity to
ouch Pvt.Lttd.
Interfac
ce Module
e
1.
Trinity to
ouch Pvt.Lttd.
Cable connector
c
r
1.
Phoenix contact (In
ndia) Pvt. Ltd.
L
Machine Monitorring System
1.
Bruel&KjjaerGmbh
2.
Skf Cond
dition Monitoring Inc.
3.
Bentley NevedaLlc
N
c
Speed Indicator
I
1.
Pepperl + Fuch
2.
Shinkaw
wa Electric Co.
C
3.
4.
Jacquet
5.
Bentley NevedaLlc
N
c
Anti Su
urge Contrroller
1.
Compresssor Contro
ol Corpora
ation
2.
Invensyss Triconex
3.
Dresser Rand Co
o.
Burner Managem
ment Syste
em
1.
DuragInd
dustrieElekktronikGmb
bh& Co Kg
g
2.
Siemenss Ag, Germ
many
3.
Mitsubish
hi Heavy In
ndustries Ltd.
L
4.
Omron Corporation
C
n
5.
Yamatakke Corpora
ation
6.
Honeywe
ell Inc.
2-0000-0021 F2 REV2
FORM NO: 02
P
D
DOCUMENT
T NO
REV
V
SHEET 17 OF 30
Switzerlan
d
U.K
U
U.S.A
U
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ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
Germany
G
Singapore
U.S.A
U
Ge
ermany
Ja
apan
Sin
ngapore
Sw
witzerland
U.S.A
Singapore
Singapore
Singapore
In
ndia
Germany
G
Ja
apan
Ja
apan
Ja
apan
U.S.A
U
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M
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RL
VEND
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T NO
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Furnace
e Camera, Heater, Thermal
T
Im
mager
1.
Tempsen
ns instruments (I) Pvvt. Ltd.
Termina
al Automa
ation Systtem
1.
Asea Bro
own Boverri Ltd.
2.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
3.
Honeywe
ell Automa
ation India Limited
4.
Chemtro
ol Industriess Ltd
I/P Converter
1.
Emerson
n Process Manageme
ent (I) Pvt. Ltd.
2.
Invensyss (Foxboro)
3
Yokogaw
wa Limited
4.
Yokogaw
on
5.
Emerson
n Process Manageme
ent Ltd
6.
Moore Products Co
ompany
Instrum
ment Powe
er & Contrrol Cables
1.
Associatted Cabless Ltd.
2.
Associatted Flexible
es & Wiress Pvt. Ltd.
3.
Cords Ca
able Indusstries Ltd.
4.
Delton Cables
C
Ltd
5.
Insucon Cables & Conducto
ors (P) Ltd. (For Sma
aller Non-C
Critical
Projects))
6.
J K Cables Limited
d
7.
Kei Indusstries Limitted
8.
Paramou
unt Cable Corporatio
C
n
9.
T C Com
mmunicatio
ons Pvt Ltd
10.
Thermo Cables Lim
mited
11.
Toshniwal Cables
12.
Udey Pyyro Cables Pvt Ltd
Extensiion & Com
mpensating Cables
1.
Associatted Cabless Ltd.
2.
Associatted Flexible
es & Wiress Pvt. Ltd.
3.
Cords Ca
able Indusstries Ltd.
4.
Delton Cables
C
Ltd
5.
6.
J K Cables Limited
d
7.
Kei Indusstries Limitted
8.
Paramou
unt Cable Corporatio
C
n
9.
Thermop
padsPvt. Lttd.
10.
Toshniwal Cables
Cable Trays
T
& Ac
ccessories
s (Al./Gi)
1.
Globe Ellectrical Ind
dustries
2.
Indiana Engg
E
Workks Pvt Ltd
3.
Metalite Industries,,
4.
Parekh Engineerin
E
g Compan
ny
5.
Sadhana
a Engineerring Corporration
6.
Steelite Engineerin
E
ng Limited
Multi Trransit Inle
et System
2-0000-0021 F2 REV2
FORM NO: 02
REV
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In
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In
ndia
In
ndia
In
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ndia
Ja
apan
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U
U.S.A.
U
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
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ndia
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1.
MctBrattbergAktieb
bolag
2.
RoxtecA
Ab
3.
Hawke In
nternationa
al
Junctio
on Box & Cable
C
Glan
nd
1.
Baliga Liighting Equ
uipments Limited
L
2.
Ceag Fla
ameproof Control
C
Ge
ears Pvt.Ltd
d.
3.
Flamepro
oof Equipm
mentsPvt. Ltd.
L
4.
Flexpro Electicals
E
P Ltd.
Pvt.
5.
Trinity To
ouch Pvt. Ltd.
L (Only cable Glan
nds upto size 25M)
6.
Stahl-Un
mbh
7.
TAN SW
WA technolo
ogies Inc (JJunction Box)
B
CS Sea
amless Pip
pes
1.
Indian Tu
ube Co(Ta
ata Div. Of Tubes &Pipes)
2.
Ismt Limited
3.
Maharasshtra Seam
mless Ltd.
4.
EtsTrouvvay&Cauvin
5.
Phoceen
nne
6.
Horst Ku
urversGmb
bh
7.
Mannesm
mann Hand
del Ag
8.
Dalmine Spa
9.
Ibf Seam
mless Pipess Spa
10.
Maruben
ni Itochu Stteel
11.
Nippon Steel
S
Corpo
oration
12.
Nissho Iw
wai Corporration
13.
Okura & Co. Ltd.
14.
Sojitz Co
orporation CS Seamless Pipes
15.
Sumitom
mo Metal In
ndustries Lttd.
16.
Hyundai Corporatio
on
17.
Vomal In
nternationa
al Limited
SS Seamless Pip
pes
1.
Choksi Tube
T
Comp
pany Ltd.
2.
Nuclear Fuel Comp
plex
3.
Rajendra
a Mechaniccal Industrries Ltd.
4.
Ratnama
ani Metals & Tubes Limited
L
5.
Matix Tu
ubes Comp
pany Pvt. Ltd.
L
6.
Phoceen
nne
7.
Tps-Tech
hnitubeRohrenwerke
eGmbh
8.
Dalmine Spa
9.
T.T.I- Tu
ubacex Tub
bos Inoxida
ables,SA(1
1/2 NB SS
S pipe)
SS Tub
bes
1.
Choksi Tube
T
Comp
pany Ltd.
2.
Nuclear Fuel Comp
plex
3.
Ratnama
ani Metals & Tubes Limited
L
4.
Matix Tu
ubes Comp
pany Pvt. Ltd.
L
5.
6
Nishitanii& Co. Ltd.
7..
Sumitom
mo Metal In
ndustries Lttd.
2-0000-0021 F2 REV2
FORM NO: 02
REV
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Sweden
U.K
U
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In
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ndia
Germany
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ndia
In
ndia
In
ndia
In
ndia
France
France
Germany
G
Germany
G
Ita
aly
Ita
aly
Ja
apan
Ja
apan
Ja
apan
Ja
apan
Ja
apan
Ja
apan
Korea
K
U.K
U
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ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
Germany
G
Ita
aly
Spain
In
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apan
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apan
Ja
apan
All rights reserved
r
LPG Mounded
M
d Bulletts at NR
RL
VEND
DOR LIST
Pipe Fitttings
1.
Eby Indu
ustries
2.
Excel Hyydro-Pneum
matics Pvt Ltd,
3.
Micro Precision Pro
4.
Precision
n Engineerring Industtries
5.
Tecnoma
6.
Wesmecc Engineerss Pvt. Ltd.
7.
CellierS.A.
8.
Siemenss Ag Pgi
9.
Thyssen-Krupp Sta
ahlunionGm
mbh
10
CesareB
Bonetti
11
Technom
matic Spa
12.
Sumitom
mo Metal In
ndustries Lttd.
13.
Dewrancce& Co. Ltd
d.
14.
Hopkinso
ons Limited
d
15.
Thompso
on Valves Ltd.
16.
Velan En
ngineering Co. Limite
ed
17.
Anderson Greenwo
ood & Co.
18.
Crane Company In
ntl. Sales
Compre
ession Fitttings
1.
Aura Inc
2.
Baldota Valve
V
& Fitting Co.Pvvt.Ltd.
3.
Excel Hyydro-Pneum
matics Pvt Ltd,
4.
Excelsior Engg Wo
orks
5.
Panam Engineers
E
6.
Precision
n Engineerring Industtries
7.
Reliance
e Engg. & Electrical
E
C
Corpn.
8.
Vikas Ind
dustrial Pro
oducts
9.
Arya Cra
afts & Engineering Pvvt Ltd.
10.
Fluid Controls Pvt Ltd
11
Wesmecc Engineerss Pvt. Ltd.
12.
Parker Hannifin
H
Sin
ngaporePte. Ltd.
13.
Swagelo
ock Compa
any/Crexim
mco
Instrum
ment Minia
ature Valve
es
1.
Audco In
ndia Limited(L&T Valvves Divn.)
2.
Aura Inc
3.
BHEL (V
Valves Divission)
4.
Chemtro
ol Industriess Ltd
5.
Excel Hyydro-Pneum
matics Pvt Ltd,
6.
Chemtro
ols Samil(In
ndia) Pvt Ltd
7.
Hyd- Air Engineerin
ng works Lonavla
L
8.
Excelsior Engg Wo
orks
9.
Ksb Pum
mps Limited
d (Valves Divn)
D
10.
Panam Engineers
E
11.
Tecnoma
12.
Wesmecc Engineerss Pvt. Ltd
13.
CellierS.A.
2-0000-0021 F2 REV2
FORM NO: 02
P
DOCUMENT
D
T NO
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V
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apan
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U
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U
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U
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U
U.S.A
U
U.S.A
U
In
ndia
In
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In
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In
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In
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In
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In
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In
ndia
In
ndia
Singapore
U.S.A
U
In
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In
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In
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In
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14.
BfeBonn
ney Forge Valve
V
Licensee
15.
Euromisu
ure Cremo
ona
16
Technom
matic Spa
17
Kosei Sa
angyo Ltd
18
Sumitom
mo Metal In
ndustries Lttd.
19.
Dewrancce& Co. Ltd
d.
20.
Hopkinso
ons Limited
d
21.
Velan En
ngineering Co. Limite
ed
22.
Anderson Greenwo
ood & Co.
23.
Crane Company In
ntl. Sales
24.
Swagelo
ock Compa
any/Crexim
mco
Purge Rotameter
R
r
1.
Instrume
entation En
ngineers Pvvt. Ltd.
2.
Placka In
nstrumentss & Controls Pvt. Ltd.
3.
Eureca Industrial Equipments
E
s Pvt Ltd
Self Actuated Pre
essure Co
ontrol Valv
ves
1.
Nirmal In
ndustries Control
C
Pvtt Ltd (1/2 to
t 6 &<30
00#)
Slam Shut Off Va
alve
1.
Nirmal In
ndustries Control
C
Pvtt Ltd (1/2 to
t 6 &<30
00#)
AIR HEA
ADER/AD
DPOT
1
Wesmecc engineering pvt. Ltd
d.
Conden
nsate pot
1
d.
Valve manifolds
m
1
d.
Calibration equip
pment & services
1
Tempsen
ns instruments (i) pvtt. Ltd.
Enclosu
ures
1
Trinity to
ouch pvt. Lttd. (weathe
erproof siz
ze 80 * 80 mm)
m
Instrum
ment contrractor for inst. Cons
struction /erection
/
w
works
1
ANI insttrument ( upto
u
0.5 cro
ores
2.
Instrocon
n engineerrs and conttrols (I) Pvt. Ltd ( uptto 0.5 crore
es)
3.
Jasubhai engineering pvt. Ltd
d.
4.
Koso ind
dia pvt. Ltd. ( kent inttrol controll valve divn
n.)
5.
L&T ( construction contracts Divn.)
6.
Miraj insttrumentatio
on service (upto 0.5 crores)
7.
Narayan engineering (< Rs. 5 lacs (sma
all project)))
8.
Pace pro
ocess control pvt. Ltd
d.
9.
Peron en
ngg. Consttruction ltd.
10.
Protect control
c
pvt.. Ltd.
11
Technim
mont ICB ltd
d.
12.
M/s Godrej & Boycce mfg. co. ltd
2-0000-0021 F2 REV2
FORM NO: 02
REV
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apan
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apan
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22 OF 30
PIP
PING:
Ven
ndors Nam
me
Sl.No
CS Weld
ded Pipes To
T API 5L Spiral
S
Long
g. Welded (SAW/EFSW)
1.
HEAVY METAL
M
PIPE CENTRE
E (Upto 24" (Upto SCHX
XXS)
2
Jindal Pip
pes Ltd.
3
JOTINDR
RA STEEL & TUBES LTD.
L
(" to 14")
4
KALPESH
H TUBE(INDIA), (TRADER)
5
Lalit Profiles & Steel Inds. Ltd.
6.
Mann Ind
dustries
7.
Mukat Pip
pes Tarapur
8
PRATIBH
HA INDUST
TRIES NB LTD.,
L
(16" to
o 24" NB, Wall
W Thickne
ess: 6
mm to 20
0 mm)
9.
P.K.Forge
e & Fitting Industries
I
10.
Ratnamani Metals & Tubes Ltd.
11
SAIL
12
SAGAR STEEL
S
COR
RPORATIO
ON (TRADER
13
Saw Pipe
es
14
Surinder Engg. Co. Pvt.
P Ltd
15.
Surya Ro
oshini Ltd
16
THE BEN
NGAL MILL STORES SUPPLY
S
CO
O.(TRADER
R)
17
Welspun Gujarat Sta
ahl Rohren Limited (Fo
or Anjar and
d Dahej Plan
nts)
18
Phoceenne
19
ETS Trou
uvay & Cauvin
20
Mannesm
mann Hande
el AG
21
Thyssen--Krupp Stah
hlunion Gmb
bH
22
Dalmine SPA
S
23
Raccortubi SRL
24
Kosei Sangyo Ltd
25
Marubeni Itochu Ste
eel
26
Mitsubish
hi Corporatio
on
27
Nippon Kokan
K
28
Nippon Steel
S
Corporration
29
Nishitani & Co. Ltd.
30
Nissho Iw
wai Corpora
ation
31
Okura & Co.
C Ltd.
32
Sojitz Corporation
33
Sumitomo
o Metal Industries Ltd.
34
Hyundai Corporation
C
n
35
British Steel Corpora
ation
36
Corus Tu
ubes Limited
d
37
SAW pipe
es USA, Incc
CS/AS LT
L Seamles
ss Pipes
1.
BHEL
2
Indian Tu
ube Co.
3
ISMT Lim
mited
4
Jay Lakshmi steel & engineering co.
5
Jindal Sa
aw Ltd.
6.
Maharash
htra Seamle
ess Ltd.
7.
P.K.Forge
I
8
Phoceenne
2-0000-0021 F2 REV2
FORM NO: 02
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9.
ETS Trou
uvay & Cauvin
10.
Mannesm
mann Hande
el AG
11
Horst Kurrvers GmbH
H
12
Dalmine SPA
S
13
Gam Racccordi S.P.A
A
14
IBF Seam
mless Pipess SPA
15.
Raccortubi SRL
16
Marubeni Itochu Ste
eel
17
Mitsubish
hi Corporatio
on
18
Nippon Steel
S
Corporration
19
Nishitani & Co. LTD..
20
Nissho Iw
wai Corpora
ation
21
Okura & Co.
C Ltd.
22
Sojitz Corporation
23
Sumitomo
24
Hyundai Corporation
C
n
25
AB Sandvvik Steel
26
Vomal Intternational Limited
27
Corus Tu
ubes Limited
d
28
ation
SS Seam
mless/ Welded Pipes
1.
Anil Meta
al Corporatio
on
2
Apex Tub
bes
3
BHANDA
ARI FOILS & TUBES LIMITED
L
(Seamless Up
pto 4" (Sch. 80)
& Welded
d Upto 20" (Thk.
(
<= 8
4
Choksi Tube Compa
any Ltd.
5
HEAVY METAL
M
& TUBES (Upto
o 8" (thickness upto 18
8.26 mm))
6.
HEAVY METAL
M
PIP
PE CENTR
RE (Upto 8"
8 ( Upto SCH80S)
S
(P
PDIL
approved
d Manufactu
urer's Make only))
7.
Jaylakshm
mi Steel & Engg.
E
Co
8
Jindal Sa
aw Ltd.
9.
KRYSTAL STEEL MANUFACT
M
TURING PV
VT. LTD. (U
Upto 2" (Matterial
de SS 321))
upto Grad
10.
Mardale Pipes
P
Plus Ltd
11
MODERN
N TUBE IN
NDUSTRIES
S LIMITED (Upto 2" (U
Upto SS G
Grade
321))
12
Nuclear Fuel
F
Comple
ex
13
P.K.Forge
I
14
Prakash Steelage Limited(0.5
L
to 20 we
elded & 0.25 to 8 smls
(upto sch
h 40s))
15.
QUALITY
Y STAINLES
SS PVT. LT
TD. ( Seam
mless: Upto
o 6" (SCH40
0S ),
Welded: Upto 20" (S
SCH40S)
16
Rajendra
a Mechanica
al Industriess Ltd.
17
18
SANDVIK
K ASIA PVT
T. LTD. (" to 2" (Thk: upto 8.74 mm))
m
19
SANGHV
VI METALS (TRADER))
20
SCOROD
DITE STAIN
NLESS (IND
DIA) PVT. LTD. (Upto 2"
2 (Upto SS
S Grade
321))
21
Shubhlaxxmi Metals & Tubes Pvvt. Ltd
22
Suraj Sta
ainless Limitted
23
THE BEN
S
CO
O.(TRADER
R)
24
ETS Trou
uvay & Cauvin
2-0000-0021 F2 REV2
FORM NO: 02
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F
Germany
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Germany
G
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Ittaly
Ittaly
Ittaly
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Japan
Japan
Japan
Japan
Japan
Japan
Japan
Korea
K
Sweden
S
U.K.
U
U.K.
U
U.K.
U
In
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In
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In
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In
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In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
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In
ndia
In
ndia
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In
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France
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26
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T NO
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Phoceenne
H. BUTTIING GmbH & CO. (Sea
amless : Up
pto 30" (upto
o 16mm thkk) &
Welded: Upto 72" (u
upto 64mm )
27
Horst Kurrvers GmbH
H
28
Mannesm
mann Hande
el AG
29
Thyssen--Krupp Stah
hlunion Gmb
bH
30
Dalmine SPA
S
31
Gam Racccordi S.P.A
A
32
IBF Seam
mless Pipess SPA
33
Raccortubi SRL
34
Marubeni Itochu Ste
eel
35
Mitsubish
hi Corporatio
on
36
Nippon Steel
S
Corporration
37
Nishitani & CO. LTD
D.
38
Nissho Iw
wai Corpora
ation
39
Okura & Co.
C LTD.
40
Sojitz Corporation
41
Sumitomo
o Metal Industries LTD
D.
42
Ab Sandvvik Steel
43
T.T.I. Tubacex
T
Tub
bos Inoxida
ables, S.A.
44
SOSTA BV
B (Upto 72
2" ( thicknesss upto 25.4
4 mm))
45
46
Corus Tu
ubes Limited
d
47
ation
48
Hyundai Corporation
C
n
SS Seam
mless Tube
es
1.
Anil Meta
al Corporatio
on
2
APEX TU
UBES PVT. LIMITED (U
Upto 50.8 mm
m OD (Thiickness Uptto 4.00
mm))
3
BHANDA
ARI FOILS & TUBES LIMITED (Up
pto 50 mm OD)
O
4
HEAVY METAL
M
& TUBES (Upto
o 8" (thickness upto 18
8.26 mm))
5
KRYSTAL STEEL MANUFACT
M
TURING PVT. LTD. (Up
pto 50.8 OD
D
(Material upto Grade
e SS 321))
6.
MODERN
N TUBE IND
DUSTRIES LIMITED (U
Upto 50.80 OD (Upto S
SS
Grade 32
21))
7.
8
Prakash Steelage
S
Limited (0.25
5" to 4" (upto
o 5mm thickness))
9.
10.
SANDVIK
K ASIA PVT
T. LTD. (OD
D upto 60.33
3 (Thk: upto
o 8.74 mm)))
11
SCOROD
DITE STAIN
NLESS (IND
DIA) PVT.LT
TD. (Upto 50.80 OD (U
Upto SS
Grade 32
21))
12
Suraj Sta
ainless Limitted
13
T.T.I.-Tub
bacex Tubo
os Inoxidab
bles, S.A.(O
OD 15.8 mm
m to 250.0 mm,
wall thk.1.0 mm)
Fittings: CS/AS/SS
S Seamless
s & Forged
d
1.
Amforge industries
2
Anil Meta
al Corporatio
on
3
COMMER
RCIAL SUP
PPLYING AG
GENCY
2-0000-0021 F2 REV2
FORM NO: 02
REV
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France
F
Germany
G
Germany
G
Germany
G
Germany
G
Ittaly
Ittaly
Ittaly
Ittaly
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Sweden
S
Spain
S
Netherland
N
U.K.
U
U.K.
U
U.K.
U
Korea
K
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VEND
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5
6.
7.
8
9.
10.
11
12
13
14
15.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
P
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T NO
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25 OF 30
CSA FITT
TINGS (Forrged: " to 2" (Upto 90
000#) & Sea
amless: 2" tto 8"
(Upto SC
CH XXS))
EBY Fastteners
EBY Indu
ustries
FIT-TECH
H INDUSTR
RIES (CS (F
Forged) Elb
bow and Tee
e " NB to 1 "
NB, Ratin
ng 3000#, 6000#,
6
9000
0#
Flash Forrge(P) Ltd.
Gujarat In
nfrapipes Pvt. Ltd.
IISCO Ltd
d.
Jay Lakshmi Steel & Engineerin
ng Co.
KALPESH
H TUBE(INDIA),(TRAD
DER) (upto a max orde
er value Rs..25.0
lakh)
M.S Fittin
ngs Manufacturing Co. Pvt Ltd.
Mardale Pipes
P
Plus Ltd
National Org
O Chemiccal India Ltd
d
Navkar Forgings & Fittings
F
Pvt. Ltd
NL HAZR
RA
P.K Forge
e & Fitting industries
Parmar Techno
T
Forg
ge
Perfect Marketing
M
(P
P) Ltd,
PETROC
CHEM INDU
USTRIES (Seamless:
(
upto 16" (all Fittings) &
upto 36" (Only Capss) Sch : XXS
S/
RAJENDRA FORGE
E INDUSTR
RIES (CS: Upto
U
12" Sch
h 40 & SS: 6" Sch
40S)
SAGAR STEEL
S
COR
RPORATIO
ON (TRADER)
SANGHV
VI METALS (TRADER))
Sawan Engineers
Shivanan
nda Pipe Fitttings Ltd.,
Surya Ro
oshni Ltd
S & G En
ngineers (P)) Ltd.
STEWAR
RTS AND LL
LOYDS OF INDIA LIMITED
Teekay Tubes
T
Private Limited
THE BEN
S
CO
O.(TRADER
R)
Topaz Piping Industries
Tube Ben
nd
Tube Pro
oducts Incorrporate(CS fitting Only))
Visvesara
aya iron & steel
s
Ltd.
Zoloto Ind
dustries
BHDT GM
MBH
Phoceenne
ETS Trou
uvay & Cauvin
Vallourecc
Seikmann
n Anlagen-T
Technik GM
MBH.
TPS-Technitube Roh
hrenwerke GMBH
G
Mannesm
mann Hande
el AG
Horst Kurrvers GmbH
H
Dalmine SPA
S
Gam Racccordi S.P.A
A
IBF Seam
mless Pipess SPA
IND Mecccanica Basssi Luigi & C.
C SPA
Mantovan
ni SpA
Raccortubi Srl
2-0000-0021 F2 REV2
FORM NO: 02
REV
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In
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In
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In
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In
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In
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In
ndia
In
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In
ndia
In
ndia
In
ndia
In
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In
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In
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In
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Austria
A
France
F
France
F
France
F
Germany
G
Germany
G
Germany
G
Germany
G
Ittaly
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Ittaly
Ittaly
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51
Techno Forge
F
SPA
52
Marubeni Itochu Ste
eel
53
Nippon Kokan
K
54
Nishitani & co. Ltd.
55
Nissho Iw
wai Corpora
ation
56
Okura & co.
c Ltd.
57
Sojitz Corporation
58
Sumitomo
59
Avesta Candvite
C
Tub
be AD
60
Helens Energy
61
Haitima Corporation
C
62
Corus Tu
ubes Limited
d
63
ation
64
Eurotube
e Limited
65
66
Bonney Forge
F
Forged Flanges
1.
Ajay Forg
ging Pvt. Ltd
d
2
Amforge Industries
3
Anandma
ayee Forgin
ngs PVT. LT
TD.
4
C D Engineering
5
Chaudha
ary Hammerr Works (P) LTD.
6.
Echjay In
ndustries Ltd
d
7.
Ferrous Alloys
A
Forging Pvt. Ltd
8
Golden Irron & Steel Works
9.
GOOD LU
UCK ENGIN
NEERING CO.
C ("-12"" (Upto 2500#), 14"-16
6" (Upto
900#), 18
8"-32" (Upto
o 600#),
10.
J.K Forgings
11
Kunj Forg
gings Pvt. Ltd.(Materia
L
l CS/SS/AS
S)
12
MAHESH
H INDUSTR
RIES (Upto 8"
8 (150#, Material: AST
TM A105 on
nly))
13
Perfect Marketing
M
(P
P) Ltd
14
Punjab Steel
15.
RAJENDRA FORGE
E INDUSTR
RIES (CS & SS : Upto 12",
1 300#)
16
R D Forge (A Unit Of
O R D Chem
micals Pvt Ltd)
L
17
Sanghvi Forgings
F
& Engineering Ltd
18
Sawan Engineers
19
S & G EN
NGINEERS (P) LTD.
20
TECHNO
O FORGE LTD. (Upto 42"
4 (upto 30
00#), upto 24"
2 (600#), u
upto
20" (900#
#), upto 16" (1500#),
21
Tube Ben
nd (Calcutta
a) Pvt Ltd
22
Viraj, Tarrapur
23
Phoceenne
24
ETS Trou
uvay & Cauvin
25
Horst Kurrvers GmbH
H
26
I.S. Intern
national
27
Mantovan
ni spa
28
Officine Nicola
N
Galpe
erti & Figlio
o S.P.A
29
Raccortubi Srl
30
Nichinan Sangyo CO
O. Ltd.,
31
Nishitani & CO. Ltd.
32
Sojitz Corporation
2-0000-0021 F2 REV2
FORM NO: 02
REV
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Japan
Japan
Japan
Japan
Japan
Japan
Japan
Sweden
S
Sweden
S
Sweden
S
U.K.
U
U.K.
U
U.K.
U
U.K.
U
U.S.A.
U
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In
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In
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In
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In
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In
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In
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In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
France
F
France
F
Germany
G
Ittaly
Ittaly
Ittaly
Ittaly
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Japan
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Gate/ Globe/ Chec
ck Valves CS/SS/AS
C
<
<900
Lbs
1.
AV VALV
VES LTD. (ccast upto 42
2 ,150#) 28
8 300#, 24 (600#) & fforge
upto 2 (8
800#)
2.
Advance Valves
3.
ASSOCIATEDTOOLING
GS(I)PVT.LTTD
4.
Audco Ind
dia Limited (L&T Valve
es Divn.)
5.
Auto cap industries ( to 2 , 800#
8
(only CS & SS)
6.
Bell- O Seal valves ltd.( For zerro leakage , hazardouss fluids.)
7.
Bhel ( vallves division
n)
8.
Brightech
h Valves an
nd control pvt. Ltd. ( Up
pto 8 X 300# for Cs, A
As &
SS Matl )
9.
Chemtech industrial valves pvt. Ltd.
10.
Crawley & Ray ( Fou
under & Eng
gineers ) Pv
vt. Ltd.
11.
Datre corrporation ltd
d.
12.
Dewrance
e Macneill & co. Ltd.
13.
Econo va
alves pvt. Lttd.
14.
Expert en
ngineering enterprises.
e
.
15.
Flocon Syystems Pvt. Ltd. ( CS upto
u
6 150#)
16.
Flovel valves pvt. Ltd.( single disc , dula plate & nozzzle check va
alves
only : uptto 48 (150#
#) & 24 (uptto 600#)
17.
Fluidtech equipmentt Pvt. LTD. ( cast # CS
S & SS 2 to
o 12 150# & 2
to 8 300 # and forge
ed (CS and SS ) to 2 (800#)
18.
Forward alloys
a
& casstings ( upto
o 14)
19
Guru indu
ustrial valve
es PVt. LTD
D.( cast cs : only upto 24 (150#), 20
(300#)
20
Hawa Engineers ltd.
21
Hawa vallves India pvt.
p Ltd. ( CS
S upto, 6, 150#)
1
22
Hi-tech Valves
V
pvt. Ltd.
L (CS,<=8
800 #, size -2<=300#
# for size 2--6)
23
Intervalve
e India Ltd.. (cast upto
o 24 (upto 300#) & Upto
U
12 60
00# ,
forged up
pto 2 (800))
24
JC Valves & Controls India Pvt.. Ltd.
25
KSB Pum
mps Limited (Valves Divvn)
26
Larsen & Toubro Lim
mited (1/2" to
t 2")
27
Kirloskar brothers ltd
d.( Cs upto 12 , 300#)
28
Leader va
alves ltd.
29
M.H. valvves ltd.
30
Micon engineers (hu
ubli) [pvt. Ltd
d.(Cast upto
o 12 150# &300#, 6 6
600#
31
Microfinissh Valves ltd
d.
32
NSSL ltd.( Upto 80 ( 150#), 56 Upto 600#
# & forged upto
u
800 #)
33
Niton valvves industries pvt. Ltd.
34
Oswal ind
d. Ltd
35
S&M ind. Valves pvtt. Ltd.
36
Shreeraj Industries
37
Shalimar valves
38
Steel stro
ong
39
Venus pu
ump & engin
neering worrks.
40
Viba Fluid
d control
41
Weir BDK
K Valves
42
ZED valvves Co. Pvt. LTD.
43
Zoloto Ind
dustries. ( 40
4 mm to 20
00 mm( only
y cs &ss)))
44.
Velan Incc. ( upto 48 , 600#)
2-0000-0021 F2 REV2
FORM NO: 02
REV
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U.K.
U
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In
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In
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In
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In
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In
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In
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In
ndia
In
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In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
In
ndia
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ndia
Canada
C
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LPG Mounded
M
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RL
VEND
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45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
P
D
DOCUMENT
T NO
SHEET 2
28 OF 30
FRIULCO
O SPA (Upto
o 32" (900#
#); 24" (1500
0#); 14" (25
500#))
Valvitalia SPA
BFE Bonney Forge Valve
V
Licen
nsee
Cesare Bonetti
B
Fasani S.P.A.
GTC Italia
a, S.R.L.
OMB S.P
P.A.
Petrol vallves S.R.L
Matsura H.
H P Machin
ne Works Co.Ltd.
C
NishitanI & Co. Ltd.
Sojitz Corporation
Redpoint Alloys BV
POYAMVA
ALVES,(AMP
POS.COOP.))
Walthan & Weir
Babcock Borsig Esp
pana , S.A
Sufa ltd.
BEL Valvves
Boteli valve group Co.
C Ltd.
Zhejianng
g Jihua valvve Co. Ltd.
Ball valv
ves (Metal Seated)
1.
AIRA EU
URO AUTO
OMATION PVT.
P
LTD. (Upto 6", Rating:
R
150
0# &
300#)
2
Brightech
h Valves An
nd Controls Pvt. Ltd. (4
4" x 150# fo
or CS, AS & SS
Material)
3
Delval Flo
ow Controlss Private Lim
mited
4
Guru Indu
ustrial Valve
es Pvt. Ltd.
5
JC valvess & Controlss India Pvt. Ltd.
6.
Microfinissh Valves (P
P) Ltd.
7.
NSSL Lim
mited (2" NB
B to 12" NB
B, Ratings:150# & 300#
# (Material: Cast
CS/AS/SS
S))
8
OSWAL INDUSTRIE
I
ES LTD. (Upto 24" (150
0#, 300#, & 600#))
9.
VIRGO ENGINEERS
E
S LTD. (Uptto16" (Upto
o 600#))
10.
WEIR BD
DK VALVES
S (A UNIT OF
O WEIR IN
NDIA PVT. LTD.)
L
(Cast: Upto
30" (150#
# & 300#); 20"
2 NB
11
VELAN IN
NC. (Size upto 16" (Ra
ating upto 600#))
12
Alfa Valvo
ole SRL
13
CESARE
E BONETTI SPA (Upto 24" (150#) & 4" (Upto 1500#) Tru
unnion
Mounted only)
14
GE powe
er (Nuovo Pignone SPA
A)
15.
GTC Italia
a, S.R.L.
16
Petrol Va
alves S.R.L
17
Valvitalia Spa
18
Red point alloys Bv
19
Metso Au
utomation
20
Orbit Valvves PLC
Gaskets
s
1.
Ferrolite Joinings
J
(P) Ltd.
2
Gaskets (India) Pvt. Ltd
3
Goodrich gasket pvt. Ltd. (upto 24")
4
Hindustan Asbestos & Allied Prroducts
5
Hindustan Compositte Ltd.
2-0000-0021 F2 REV2
FORM NO: 02
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Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
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Japan
Japan
Netherland
Spain
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Spain
S
Spain
S
UAE
U
U.K
U
China
C
China
C
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Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Ittaly
Netherland
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Singapore
S
Singapore
S
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6.
HINDUST
TAN FERREDO LTD.
7.
IGP Engineers Limited
8
Madras In
ndustrial Prroducts(upto
o 48")
9.
Mechaniccal Packing Industries Ltd.,
10.
Packingss & Jointingss (P) Ltd.
11
PRASHA
ANT ENGG STORES
12
Perfect Marketing
M
(P
P) Ltd,
13
Reinz Talbros Privatte Limited
14
Spiraseal gaskets pvvt. Ltd. (CAF & Teflon)
15.
Starflex sealing
s
india
a Pvt. Ltd.
16
THE BEN
S
CO
O.(TRADER
R)
17
UNIQUE INDUSTRIA
AL PACKIN
NGS PVT. LTD.
L
Spirally Wound Ga
askets
1.
Gaskets (India) Pvt. Ltd
2
Goodrich gasket Pvtt. Ltd.
3
IGP Engineers Limited
4
Madras In
ndustrial Prroducts
5
Packingss & Jointingss Pvt. Ltd
6.
Perfect marketing
m
(P
P) Ltd,
7.
Prashant Engg Store
es
8
Spiraseal gaskets pvvt. Ltd.
9.
Starflex sealing
s
india
a pvt. Ltd.
10.
Uniklinge
er Gaskets, Pune
11
Garlock Sealing
S
systtems Ltd., Pune
P
12
TEADIT gaskets,
g
Mu
umbai
13
THE BEN
S
CO
O.(TRADER
R)
14
UNIQUE INDUSTRIA
AL PACKIN
NGS PVT.LT
TD. (Upto 42"(600#)
4
& Upto
24" (2500
0#))
STRAIN
NERS (PERMANENT IN
NCLUDING
G Y-TYPE)
1.
CHEMTE
ECH INDUS
STRIAL VAL
LVES PVT. LTD
2
FLAIR ST
TRAINERS & FILTERS
S (Size upto
o 42" (Ratin
ng upto 1500
0#))
3
GRAND PRIX
P
ENGINEERING PVT. LTD. (upto 60" pipeline, upto ANSI
1500#)
4
GREAVE
ES LIMITED
D
5
GUJARA
AT OTOFILT
T
6.
KWIKFLO
O FILTERS PVT. LTD.
7.
LEADER VALVES LIMITED
L
(up
pto 300# & upto 12"sizze)
8
MOD FAB
BRICATOR
RS
9.
MULTITE
EX FILTERA
ATION ENG
GINEERS LTD
L
10.
ZOLOTO
O INDUSTRIES (15mm to 100mm))
11
BOTELI VALVE
V
GRO
OUP CO. LTD.
L
(Y - Ty
ype only: 14
4" (150#) & 3"
(300# & 600#))
6
SPRING
G SUPPORT
TS
1.
MYRICS PIPING SY
YSTEM PVT
T.LTD.
2
PIPE SU
UPPORTS INDIA PVT. LTD.
3
PIPING & ENERGY PRODUCT
TS (P) LTD..
4
SARATH
HI ENGG. ENTERPRIS
E
SES PVT. LTD.
L
5
SPRING SUPPORT
TS MFG. CO
O.
6.
FLEXIDE
ER S.P.A.
2-0000-0021 F2 REV2
FORM NO: 02
REV
V
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In
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In
ndia
China
C
In
ndia
In
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In
ndia
In
ndia
In
ndia
Ittaly
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LPG Mounded
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FASTEN
NERS
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AEP COM
MPANY
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CAPITAL
L INDUSTRIES
3
CONSOL
LE ENGG. & FASTNER
RS INDUST
TRIES
4
EBY FAS
STNERS
5
FIT TIGH
HT NUTS & BOLTS LTD.
6
FIX FIT FASTENER
F
RS MFG. PV
VT. LTD.
7
INDUSTR
RIAL ENGIN
NEERING CORPORAT
C
TION (Size upto 4" (M100))
8
MEGA EN
NGINEERIN
NG PRIVAT
TE LIMITED
D (" to 3" Material:
M
CS/AS/SS
S)
9
METRO MECHANIC
M
CAL PVT.LT
TD.
10
NAGBHU
USHANAM INDUSTRIE
ES
11
NIREKA ENGG. CO
O. PVT. LTD
D.
12
PACIFIC FORGING & FASTEN
NERS PVT. LTD. (M 10
0 to M125)
13
PERFEC
CT MARKET
TING (P) LT
TD,
14
PIONEER
R NUTS & BOLTS
B
PVT
T. LTD.
15
PRECISION AUTO ENGINEER
RS
16
PRECISION ENGINEERING IN
NDUSTRIES
S
17
PTD FAS
STNERS PV
VT. LTD.
18
SANGHV
VI METALS (TRADER))
19
SUNDAR
RAM FASTE
ENERS LIM
MITED
20
UDHERA
A FASTENE
ERS
5.0 CS STEEL PLA

ATES (A51
16 Gr.60)
Sr. No.
N
VEN
NDORS
SAIL
ESSA
AR
TATA
A
JINDA
AL
RASH
HTRIYA IS
SPAT NIGA
AM LTD. (V
Vizag Plan
nt)
WELS
SPUN
JSW ISPAT STEEL

S
2-0000-0021 F2 REV2
FORM NO: 02
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PROJECTS & DEVELOPMENT INDIA LTD

TECHNICAL SPECIFICATION FOR LPG MOUNDED

INSTALLATION OF LPG MOUNDED BULLETS AT NRL

ISSUED FOR ENQUIRY

PROJECTS & DEVELOPMENT INDIA LTD

ISSUED FOR ENQUIRY

PROJECTS & DEVELOPMENT INDIA LTD

Numaligarh Refinery Limited, (NRL) presently operates a 3 MMTPA refinery at

: Numaligarh, Golaghat District

Nearest Railway Station

Nearest Sea Port

Nearest National Highway

BRIEF SCOPE OF WORK

This document includes design & detailed engineering, preparation of

Scope also covers obtaining statutory approval on engineering drawings,

PROJECTS & DEVELOPMENT INDIA LTD

PROJECTS & DEVELOPMENT INDIA LTD

NUMALIGARH REFINERY LIMITED

ISSUED FOR ENQUIRY

FORM NO:02-0000-0021F1 REV3

All rights reserved

PROJECTS & DEVELOPMENT INDIA LTD

Project Execution Plan

General Guidelines For HSE

FORM NO: 02-0000-0021F2 REV2

All rights reserved

PROJECTS & DEVELOPMENT INDIA LTD

Detailed Index of various Sections are as follows:

Drg. / Doc. No.

Drg. / Doc. No.

Civil scope drawing for mound

Pile Layout for Mound Tentative

Drg. / Doc. No.

Specification for mounded Bullets

Specification for drain vessel

FORM NO: 02-0000-0021F2 REV2

All rights reserved

PROJECTS & DEVELOPMENT INDIA LTD

Document No. & Rev.

PART - A : General Documents

PART - A, Front Sheet

Technical Scope of Supply & Work for

Design Philosophy of Instrumentation

PART - B : Specifications for Supply of Field Instruments

PART - B, Front Sheet

Technical Enquiry Specification for Safety

Technical Enquiry Specification for

Technical Enquiry Specification for

FORM NO: 02-0000-0021F2 REV2

All rights reserved

PROJECTS & DEVELOPMENT INDIA LTD

PART - C : Specifications for Erection Materials

PART - C, Front Sheet

ENGINEERING SPECIFICATION FOR

ENGINEERING SPECIFICATION FOR

ENGINEERING SPECIFICATION FOR

ENGINEERING SPECIFICATION FOR

ENGINEERING SPECIFICATION FOR

ENGINEERING SPECIFICATION FOR

ENGINEERING SPECIFICATION FOR

PART - D, Front Sheet

BILL OF QUANTITY FOR SUPPLY OF

FORM NO: 02-0000-0021F2 REV2