POWER SYSTEMS

MODIFICATIONS TABLE

REV PREPARED CHECKED APPROVED DATE MODIFICATIONS STAT.

A AM MP/AK KS 17/05/12 FIRST ISSUE GFR

REVISED AS PER CLIENT COMMENTS

B K. SUTHAR R. MURUGAN D. SHAH 31/12/13

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 2/B

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Table of Content

1. PURPOSE .................................................................................................................................................................... 4

2. REFERENCE DOCUMENT .............................................................................................................................................. 4

3. GENERAL .................................................................................................................................................................... 5

3.1 ENVIRONMENTAL CONDITIONS ............................................................................................................................... 5

3.2 WATER ANALYSIS .................................................................................................................................................... 5

4. PAINTING & PRESERVATION ........................................................................................................................................ 6

4.1 PAINTING PROCEDURE FOR CARBON STEEL PIPES & FITTINGS ................................................................................. 6

4.2 GALVANIZING.......................................................................................................................................................... 6

5. DESIGN PRESSURE & MATERIAL SELECTION ................................................................................................................. 7

6. INSULATION FOR PIPING ............................................................................................................................................. 7

7. TECHNICAL PARTICULARS ............................................................................................................................................ 9

8. BRANCH TABLE ......................................................................................................................................................... 16

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 3/B

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1. PURPOSE

The purpose of this specification is to define the technical requirements for design, fabrication, and factory
inspections for Pipes & Pipe Fittings of the following systems of TASHIDING Hydro Electric Project:

Cooling Water System

Drainage & Dewatering System
Compressed Air System
Fire Protection System
Oil Handling System
Turbine related pipes
Generator related pipes

2. REFERENCE DOCUMENT

Particular Technical Specification Volume 3A

General Technical Specification Volume 3B
Following codes, regulations and standards:

Codes Description
IS 3589 : 2001 Steel Pipes for Water and Sewage (168.3 to 2540 mm Outside
Diameter)
IS 1239 : 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings - Specification
ASTM A 53 : 2002 Standard Specification for Pipe, Steel, Black and Hot Dipped, Zinc
Coated, Welded & Seamless
ASTM A 105 : 2003 Specification for carbon steel forgings for piping application.
ASTM A 106 : 2004 Standard Specification for Seamless Carbon Steel Pipe for High
Temperature Service
ASTM A 182 : 2004 Standard Specification for Forged or Rolled Alloy and Stainless Steel
Pipe Flanges, Forged Fittings, and Valves and Parts for High-
Temperature Service
ASTM A 213 : 1999 Standard Specification for seamless Ferritic & Austenitic Alloy-steel
Boiler, Superheater, & Heat-Exchanger Tubes.
ASTM A 234 : 2001 Specification for Piping Fittings of Wrought Carbon Steel and Alloy
Steel for Moderate and High Temperature Service
ASTM A 312 : 2004 Standard Specification for Seamless, Welded, and Heavily Cold
Worked Austenitic Stainless Steel Pipes
ASTM A 403 : 2007 Standard specification for Wrought Austenitic Stainless Steel Piping
Fittings
ISO 898 Part-1 : 2009 Mechanical properties of fasteners made of carbon steel and alloy
steel -- Part 1: Bolts, screws and studs
ISO 898 Part-2 : 1992 Mechanical Properties of Fasteners - Part 2: Nuts with Specified Proof
Load Values - Coarse Thread
ISO 3506 Part-1 : Mechanical properties of corrosion-resistant stainless steel fasteners -
2010 - Part 1: Bolts, screws and studs

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 4/B

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Codes Description
ISO 3506 Part-2 : Mechanical properties of corrosion-resistant stainless steel fasteners -
1998 - Part 2: Nuts
ISO 4014 : 2011 Dimensional standard for Hexagonal head bolts, Product Grade A & B
ISO 4032 : 1999 Dimensional standard for Hexagonal nuts, Product Grade A & B
ISO : 7089 : 2000 Plain Washer Normal Series Product Grade A
ISO 1461 : 2009 Hot dip galvanized coating on fabricated iron and steel articles -
specifications and test methods
ISO 8501 : 1994 Preparation of steel substrates before application of paints and related
products
ASME B 16.5 : 1996 Steel Pipe Flanges and Flanged Fittings.
ASME B 16.9 : 2003 Factory-made wrought Butt-Welding Fittings
ASME B 16.11 : 2001 Forged Steel Fittings, Socket Welding and Threaded.
ASME B 16.20 : 2000 Metallic Gaskets for pipe flanges : Ring Joint, Spiral-Wound and
Jacketed
ASME B 16.21 : 2005 Non-metallic Flat Gaskets for Pipe Flanges
ASME B 31.1 : 2001 Power Piping (Code for pressure piping)
ASME B 36.10 : 2004 Dimensional standard for welded & seamless wrought steel pipe
ASME B 36.19 : 2004 Dimensional Standard for Stainless steel Pipe
MSS-SP-83 : 2001 Class 3000# steel pipe unions socket welding and threaded
DIN 975 :2003 Threaded rod / stud bolts

3. GENERAL
3.1 ENVIRONMENTAL CONDITIONS

1. Maximum ambient temperature 40 C

2. Minimum ambient temperature 2 C
3. Maximum Relative Humidity 98%
4. Minimum Relative Humidity 40%
5. Maximum raw water temperature 25 C
6. Minimum raw water temperature 2 C

3.2 WATER ANALYSIS

Parameter Value
PH 7.2
Alkalinity as CaCO3 (mg/l) 50
Total Hardness CaCO3 (mg/l) 120
Calcium as Ca (mg/l) 42
Chloride as Cl (mg/l) 22
Sodium as Na (mg/l) 3

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 5/B

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4. PAINTING & PRESERVATION

4.1 PAINTING PROCEDURE FOR CARBON STEEL PIPES & FITTINGS

DFT Min.
Procedure Product description Shade
(m)
Surface
Preparation Sa 2 to Sa 3 as per ISO 8501
(Blasting)
Primer coat 2 component Epoxy based Red
(Done at Manuf. Oxide primer with anticorrosive 50 m Red / Grey
End) Zinc Phosphate pigment
2 component Epoxy based paint
Intermediate coat Grey /
with Micaceous Iron Oxide 120 m
(Done at Site) Brown
pigment.
Final coat 2 component Epoxy based finish As per
60 m
(Done at Site) paint with high gloss Clause no. 5
TOTAL 230 m

Note:
All Pipes & Fittings (Embedded or Overground) - Surface preparation & Primer coat shall be done.
Painting is not required on Galvanized and Stainless Steel pipes.
Same procedure is applicable for pipe spools.

4.2 GALVANIZING

Hot dip galvanizing shall be carried out as per ISO 1461.

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 6/B

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5. DESIGN PRESSURE & MATERIAL SELECTION

Design
System Pressure Material Colour Code
KG/CM2
Cooling water system 10 Carbon Steel RAL 6029 (Mint Green)
Drainage & Dewatering System 10 Carbon Steel RAL 6029 (Mint Green)
Fire Fighting System 16 Carbon steel RAL 3000 (Flame Red)
LP Compressed Air System 10.5 Carbon steel RAL 5012 (Light Blue)
Oil Handling System 10 Carbon steel RAL 2000 (Yellow Orange)
TURBINE PIPES
Penstock drain pipe 42 Carbon steel RAL 6029 (Mint Green)
Spiral case drain pipe 42 Carbon steel RAL 6029 (Mint Green)
Pit drain pipe 10 Carbon steel RAL 6029 (Mint Green)
Shaft seal leakage pipe 10 Carbon steel RAL 6029 (Mint Green)
Head cover pump drain pipe 10 Carbon steel RAL 6029 (Mint Green)
Balancing pipe 42 Carbon steel RAL 6029 (Mint Green)
Pressure Taps 42 Stainless steel -
Bottom ring drain pipe 10 Carbon steel RAL 6029 (Mint Green)
Shaft seal circuit after fine filters 10 Stainless steel -
GENERATOR PIPES
Oil mist system 10 Carbon steel RAL 2000 (Yellow Orange)
Lower bearing cooler oil piping 10 Carbon steel RAL 2000 (Yellow Orange)
Upper bearing cooler oil piping 10 Carbon steel RAL 2000 (Yellow Orange)
Braking system 40 Stainless steel -
Jacking system 220 Stainless steel -
HP Oil Injection 150 Stainless steel -

6. INSULATION FOR PIPING

Suitable insulation with vapour proof cover (if required) to prevent condensation shall be provided as per below
guidelines:

Cooling Water System: Piping inside generator barrel and pipes running above electrical installation such
as panels.
Drainage & Dewatering System and Fire Fighting System: Pipes running above electrical installation such
as panels.

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 7/B

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7. THICKNESS CALCULATION B

The overall formula used by ASME B31.1 for pressure Solution has been used:

tm= PDo / 2(SE + Py) + A

Where,
tm= Minimum required wall thickness of pipe, mm
P = Design pressure, Kg/cm2
Do = Outside diameter of the pipe, mm
S = Allowable stress, Kg/cm2
E = Weld joint efficiency or quality factor (1.0 for seamless and 0.85 for ERW pipes)
y = Dimensionless constant which varies with temperature, in this case it is 0.4
A= Corrosion Allowance, 1.5mm

A mill tolerance of 12.5% has been considered during thickness calculation.

The details of thickness selection have been elaborated in the respective Tables.

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 8/B

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TECHNICAL PARTICULARS FOR CS PIPES, PIPE FITTINGS & HARDWARES

2
For Fire Fighting System - Design pressure - 16 kg/cm B
For LP Compressed Air System - Design pressure 10.5 kg/cm2
DIMENSIONAL
SIZE (NB) RATING / THK (mm) JOINT DESCRIPTION TYPE MATERIAL
STANDARD
From To PIPES
15 40 Sch. 40 SW Seamless pipes, Plain End - ASTM A 106 GR B ASME B 36.10M
50 80 Sch. 40 BW Seamless pipes, Bevelled End - ASTM A 106 GR B ASME B 36.10M
100 150 HEAVY BW ERW pipes, Bevelled End - IS 1239 (Part I) IS 1239 (Part I)
200 250 6.3 mm thk BW ERW pipes, Bevelled End - IS 3589 (Fe 330) IS 3589
FITTINGS
Elbows, half & full coupling, ASME B 16.11/
15 40 2000 #/3000 # SW Forged ASTM A 105
Tees, Reducers, Caps, Unions MSS-SP-83
Sch. 40/
Elbows, Branching, Tees,
50 150 As per Thk of BW Formed ASTM A234 WPB ASME B 16.9
Reducers, Caps
connecting pipe
As per Thk of Elbows, Branching, Tees,
200 250 BW Formed ASTM A234 WPB ASME B 16.9
connecting pipe Reducers, Caps
SLIP ON FLANGES/BLIND FLANGES

50 250 Class 150 # - Raised face Forged ASTM A 105 ASME B 16.5

BOLTS / STUDS
Hexagonal Head Bolts / ISO-4014 CL8.8 A2C
M10 M36 - - - ISO-898 Part-I
Stud Bolts /DIN 975 CL. 8.8 A2C
NUTS
M10 M36 - - Nuts - ISO-898 Part-2 ISO 4032 CL-8 A2C
WASHERS
M10 M36 - - Plain Washer - Mild Steel ISO 7089-200 HV A2C
GASKETS
Non asbestos
compressed gasket
ALL SIZES 1 mm to 3 mm - Gasket - (UNIKLINGER Cl- ASME B 16.21
18 / CHAMPION
AF120)

Note: Downstream piping of deluge valve system (For Fire Fighting System) shall be Galvanized Carbon Steel.

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 11/B

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Note:
End connection of all pipes & pipe fittings for instruments shall be of screwed/threaded (BSPP).
All pipe fittings shall be of seamless type.
The selected pipe thickness and schedule is the minimum required size, if the selected size & thickness is not
available, next higher size will be used.
Other pipes/ fittings, which are not specified in the specification, will be decided as per supplier
proposal/standard practices.
ABBREVIATIONS:
BW : Butt Weld
SW : Socket Weld
ERW : Electric Resistance Welded
PE : Plain End
SCH : Schedule
BSPP : British Standard Parallel Pipe threads
NBR : Nitrile Butadiene Rubber

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 15/B

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B
9. BRANCH TABLE

CARBON STEEL MATERIAL

8 1/4'' T
15 1/2'' RT T
20 3/4'' RT RT T
25 1'' RT RT RT T
32 1.1/4'' RT RT RT RT T
40 1.1/2'' RT RT RT RT RT T
Z E

50 2'' RT T
65 2.1/2''
I

80 3''
S

100 4''
125 5''
R U N

150 6'' T
200 8'' HC RT T
250 10'' RT T
300 12'' D RT T
350 14'' RT T
400 16'' RT T
450 18'' RT T
500 20'' RT T
550 22'' RT T
600 24'' RT T
1/4'' 1/2'' 3/4'' 1'' 1.1/4'' 1.1/2'' 2'' 2.1/2'' 3'' 4'' 5'' 6'' 8'' 10'' 12'' 14'' 16'' 18'' 20'' 22'' 24''
8 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 550 600
B R A N C H S I Z E

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 16/B

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STAINLESS STEEL MATERIAL B

8 1/4'' T
15 1/2'' RT T
20 3/4'' RT RT T
25 1'' RT RT RT T
32 1.1/4'' RT RT RT RT T
40 1.1/2'' RT RT RT RT RT T
E

50 2'' RT T
Z
I

80 3'' D T
S

100 4'' HC D RT T
R U N

150 6'' D D D T
200 8'' D D D RT T
1/4'' 1/2'' 3/4'' 1'' 1.1/4'' 1.1/2'' 2'' 3'' 4'' 6'' 8''
8 15 20 25 32 40 50 80 100 150 200
B R A N C H S I Z E

LEGEND:
T - Equal Tee,
RT - Reducing Tee,
HC - Half Coupling,
D - Direct Connection.

H-6746000CA00001EC PIPES & PIPE FITTINGS-TECHNICAL SPECIFICATION 17/B

 Table of Content

1. PURPOSE .......................................................................................................................................................................................... 3

2. PAINTING PROCEDURE FOR CARBON STEEL PIPES, PIPE SUPPORTS, CLAMPS AND FITTINGS ..................................................... 3

3. PAINTING PROCEDURE ON WELDING AREA AFTER ERECTION AT SITE FOR PIPE, CLAMP AND FITTINGS..................................... 4

4. PAINT MANUFACTURER BRAND NAME & DESIGNATION ................................................................................................................ 5

5. PAINTING PROCEDURE ON WELDING AREA OF HOT DIP GALVANIZED PIPES & FITTINGS AT SITE ............................................... 5

HSJCPA01-000 000 000 EC Page 2

 1. PURPOSE

The purpose of Painting specification is to define painting procedure for carbon steel pipe , pipe
fittings, pipe supports & clamps, which are to be used for Alstom hydro project at site as well as work
D shop.
This specification is not applicable for pipes, fittings used for bracing and temporary support.

2. PAINTING PROCEDURE FOR CARBON STEEL PIPES, PIPE SUPPORTS, CLAMPS AND FITTINGS

Procedure Product description DFT Shade Volume INSPECTION

Min. solid REQUIREMENTS
(m) (Min.)

Surface
Sa 2 to Sa 3 as per Visual / Roughness
Preparation
ISO 8501 measurement
(Blasting)
2 component Epoxy
Primer coat based Red Oxide
(Done at primer with 50 m Red / Grey 45% Thickness & Adhesion
Manuf. End) anticorrosive Zinc
Phosphate pigment
Intermediate 2 component Epoxy
coat based paint with
120 m Grey / Brown 75% Thickness & Adhesion
(Done at Micaceous Iron
Site) Oxide pigment.
Final coat * 2 component Epoxy As per
(Done at based finish paint 60 m contract / 50% Thickness & Adhesion
Site) with high glossy specification
TOTAL 230 m

* Final coat for Pipes and pipe fittings exposed to sunlight shall be applied with 2 components
acrylic based polyurethane topcoat cured with aliphatic Isocyanate
Notes :
1. All Pipes & Fittings (Embedded or Overground) - Surface preparation & Primer coat shall be
done from supplier/ manufacturer's end before dispatch to site.
2. Painting is not required on Galvanized pipes.
3. Paint approved brands : Akzo Nobel, Jotun paints, Berger, Hempel paint, Asian paint and
Sigma paint. Do not mix two brands in single system.
D 4. Rust prevention treatment on inside surface of process pipes and pipe fittings is not
required. Site shall take care for removal of the same during erection/commissioning.
5. All process pipes/pipe spool used in the product / system shall be closed tightly from the ends
with Plastic/PVC labirinth type end caps by supplier before dispatch. The condition of cap
shall be check by site every quarterly and if required same shall be replaced

HSJCPA01-000 000 000 EC Page 3

 6. Pipe fittings shall be supplied without end caps.
7. Fittings Includes: Elbows, Bends, Tee, Reducer, Flanges, Couplings, unions, etc.
8. In case of pipe spools supplied from manufacturer, same procedure is applicable.

3. PAINTING PROCEDURE ON WELDING AREA AFTER ERECTION AT SITE FOR PIPE, CLAMP AND
FITTINGS

DFT Volume
INSPECTION
Procedure Product description Min. Shade solid
REQUIREMENTS
(m) (Min.)
Surface
Manual Cleaning - Visual
Preparation
Rough grinding & ( For surface
(Done at
solvent cleaning. roughness)
site)
2 component
Primer coat modified epoxy high
(Done at solid mastic / 80 m Red / Grey 75% Thickness & Adhesion
site) surface tolerant
paint/ self-priming.
Intermediate 2 component Epoxy
coat based paint with
120 m Grey 75% Thickness & Adhesion
(Done at Micaceous Iron
Site) Oxide pigment.
Final coat 2 component Epoxy As per
(Done at based finish paint 60 m contract / 50% Thickness & Adhesion
Site) with high glossy specification
TOTAL 260 m

Notes :
1. Paint approved brands : Akzo Nobel, Jotun paints, Hempel paint, Berger paint, Asian paint
and Sigma paint. Do not mix two brands in single system.
2. Solvent cleaning means all types of organic solvent like Kerosene, Xylene and all paints
thinner.
3. For any damage in the primer coat during transportation, the above painting procedure shall
be followed.

HSJCPA01-000 000 000 EC Page 4

 4. PAINT MANUFACTURER BRAND NAME & DESIGNATION

Sr. No. MFG. Name Primer coat Intermediate coat Final coat
1 Akzo Nobel Interguard 269 red Interguard 475 HS MIO Interthane 990
2 Jotun paints Penguard primer red Penguard Express MIO Hardtop XP PU
Berger thane finish -
Product code 682
3 Berger paints Epilux 610 primer Epilux 155 HB MIO
(Mixing ration 4 : 1 -
Base : Hardener)

Notes : For final colour shade (i.e RAL No.), please refer respective project piping specification.

5. PAINTING PROCEDURE ON WELDING AREA OF HOT DIP GALVANIZED PIPES & FITTINGS AT SITE

DFT Volume
INSPECTION
Procedure Product description Min. Shade solid
REQUIREMENTS
(m) (Min.)
Clean by manually
Surface
with wire brush /
Preparation
solvent cleaning/ Visual
(Done at
degreasing/ sand
site)
paper.
Primer coat Cold Galvanizing
(Done at spray as per ASTM 30 m Silver Grey Thickness
site) A-780
Final coat Cold Galvanizing
(Done at spray as per ASTM 30 m Silver Grey Thickness
Site) A-780

TOTAL 60 m

Notes :
1. Approved material - Any brand Cold galvanizing material complying to ASTM A-780.
2. Incase of pipe spools supplied from manufacturer, same procedure is applicable.

The above mentioned painting procedures/ thickness of paint/ colour shade is the minimum
requirement. However for any project specific requirement, respective piping specification shall be
referred.

HSJCPA01-000 000 000 EC Page 5

 Caution:
1. Before applying Intermediate coat on pipe & pipe fittings at site oil stains if any shall be
removed with solvent cleaning/ emery paper.
2. For flanges, the machined surface where the gasket will be fixed (Raised face incase of SORF
flange & flat face incase of SOFF flange) shall be prevented from rust by applying tectyl 506.
D Except machined surface all other surface (including bolt holes) shall be applied with primary
coat at supplier end.
3. Grease shall be applied on threads of pipe & pipe fittings & no tectyl should be applied on
threads of pipe & pipe fittings.

HSJCPA01-000 000 000 EC Page 6